The RPL is compatible on the following machines:

• VF-2/SS/YT built after 1/1/17
• VF-3/4/SS/YT built after 1/1/18
• VF-5/SS/XT built after 1/1/20

Note: For a list of options that are not compatible with the RPL, refer to the Specifications and Compatibility tab in the Introduction chapter.

This procedure shows how to install the Robot Pallet Loader (RPL) option. The RPL option also requires the following options for the machine:

• Auto Window option (field install kit dependent on machine) Refer to the VMC - Auto Window - Installation
• 93-1001314 - Single Zero Point Ready Kit (available for VF- 1-5, VM-2/3)
• 93-1001318 or 93-1001319 - RPL-25KG Ready Kit VF-SML/MED
• Safety Device (light curtains or fence with interlock)
• 100.24.000.1111 Software Version or later

Note: For Existing machines that need 100.24.000.1111 software, contact Haas Service for access.

This procedure is for the following kits:

• 93-1001040 - Pallet System Install Kit Non-CE
• 93-1001124 - Pallet System Install Kit VF-1/2 CE
• 93-1001125 - Pallet System Install Kit VF-3/4 CE
• 93-1001126 - Pallet System Install Kit VF-5 CE
• 93-1001128 - RPL Fence Field Install Kit

Note: Refer to Chapter 4 of this manual for instructions on installing the zero point ready on VMC and UMC machines.

The RPL pallet [1] needs to be removed from the shipping pallet [2].

Only pick up the RPL pallet with a forklift through the slots for the forks [3].

Note: Keep the shipping brackets installed while moving the RPL pallet off of the shipping pallet.

The RPL is blocked by several shipping brackets. 

The robot shipping bracket [1] is fastened to the base of the pallet [2].

The load station [3] is secured with the wooden brace [4].

The pallet shelf [5] is secured to the load station brace by the stringers [6].

Remove the wood from the pallet shelf first. Then remove the wooden brace from the load station.

Note: The robot shipping bracket is easiest to remove by jogging the robot away from the shipping bracket. Wait to remove this shipping bracket until after the robot is setup and activated.

The pallet comes with the following components installed on it:

1. Operator Load Station
2. Pallet Shelf
3. HRP-2 Robot
4. HRP Control Box

Verify that the electrical connector [5] is oriented as shown in the image.

Warning: Due to the range that robot joints can move, the robot can't maneuver through the area aligned with the electrical connector. The orientation shown in the image is needed for the robot to navigate the operator station, and the pallet shelf effectively.

Lift the RPL from the side where there is the pallet jack slots and move it into the place next to the machine. See the next step for exact placement measurements.

Important: Make sure the pallet jack used has forks that are at least the same length of the RPL pallet to ensure safe lifting.

The pallet needs to be positioned on the right side of the machine, located next to the auto window that is installed.

Use a forklift to move the pallet into the correct position.

Place the pallet with the operator station facing the same direction as the front of the machine [1]. Make sure that the left edge of the pallet [5] is parallel to the right edge of the machine [4].

Position the pallet so that:

On VF-2:

• The front side of the pallet [2] is [3] (18" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On VF-3:

• The front side of the pallet [2] is [3] (17" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On VF-5:

• The front side of the pallet [2] is [3] (13" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

If the pallet is sitting on an uneven surface, use the 4 leveling feet [1] to raise the pallet off the ground. 

Use a level to make sure that the pallet is roughly level after raising it of the ground.

Lock the leveling feet in position by tightening the nuts [2] on each foot.

Note: If the pallet is stable just sitting on the surface, lower the leveling feet until they make contact with the pucks. The pallet only needs to be leveled with the feet if there is noticeable rocking or shaking when the robot moves around.

Install the anchors [1] from the installation kit after the RPL has been placed in its final position. Use the provided template in the kit  to mark each individual anchor drilling location.

Note: The kit comes with four anchors, but only three are required for installation [2]. The fourth anchor [3] is recommended but not required for anchoring down the RPL.

Follow the link below on how to install the anchors. 

Fasten the sheet metal brackets [1] and [2] together using the FBHCS [3].

Install the magnetic cups onto the sheet metal [4]. This sheet metal will connect the machine to the load station [5] with the magnets.

Note: In this image the machine is not shown so that the magnetic cups can clearly be seen. These magnets connect to both the load station and the machine.

Important: For CE Kits use the self-tapping screws instead of the magnet cups.

Cut the zip-tie to take the E-stop/work light button holder [1] off the load station. Rotate the holder [1] and use the bolts provided to mount the holder onto the load station. 

Assemble the number plates and mounting hardware as shown [1]. Lightly tighten t-nuts onto first 1-2 threads of bolts.  

Slip t-nuts into the top slot of the top shelf  [2] and tighten bolts. Number plates A1- A5 should be placed on the top shelf, B1 - B5 on the second shelf, and so on.

Name plates should be installed on the side of the shelf facing the robot arm.

For 93-1001040 Non-CE Install Kit:

Install the light curtains and mirrors as shown in the image.

Place the emitter [1] behind the pallet shelf.

Place the two mirrors [2] on the side opposite the machine.

Place the receiver [3] next to the E-stop of the load station.

For All CE Install Kit:

Use the 4 self-tapping screws [2] to fasten the top mating panel [1] to the other load station to machine mating panels [3] installed in the previous step.

For 93-1001124 CE Install Kit (VF-Small Kit):

Fasten the sheet metal that mates the machine to the fence assembly.

Fasten the top panel [5] to the other sheet metal. Use the self tapping screws [6] on all locations that don't have pem nuts to hold them in place. If there are pem nuts use the BHCS.

Connect the panel angled top panel [1] and angled bottom panel [2] to the back of the machine.

Use the T-nuts [3] to fasten the panels to the pallet shelf [4].

Note: Use the second T-slot from the inside to fasten the panel to the shelf. The slot to the left of the this will be used for another panel.

For 93-1001125 and 93-1001126 CE Install Kit (VF-Med Kit):

Use the T-nuts and SHCS and washers [1] to fasten the rear enclosure to the inside edge of the shelf post [2].

Once both the top piece [3] and bottom piece [4] are fixed to the shelf post, use the self tapping screws [5] to fasten the sheet metal to the right enclosure panel [6] of the machine.

Note: Since you are using self-tapping screws on the machine enclosure, it's recommended to mount the sheet metal to the shelf post first. This will help avoid having to remove and fasten the screws going into the enclosure multiple times.

For 93-1001125 and 93-1001126 CE Install Kit (VF-Med Kit):

Use the T-nuts and SHCS and washers [1] to fasten the shelf-to-fence enclosure panels [2] and [3] to the side of the shelf closest to the machine

Once mounted to the shelf, use the self-tapping screws [4] to secure the enclosure panels to to the fence post [5].

Note: The fence that would be connected to the post [6] in the image is omitted in order to show the location of the panels relative to the RPL pallet.

Use the BHCS [6] to install the enclosure piece [7] that connects the shelf-to-fence top piece [2] to the enclosure panel installed in the previous step.

Robot Interface Mounting Location

The Robot electrical interface box has magnetic mounts to attach to the machine sheet metal.

Mount the Robot electrical interface box [1] as shown in the picture.

Route the Robot interface electrical cables through the bottom of the electrical cabinet.

Follow the next section for where to install the cables coming from the interface box and the Remote Jog Handle (RJH).

Remove the bottom cable cover [1] from the control cabinet [2].

For machines purchased with the RPL option, cables will be coiled inside the cover. 

Note: RPL's being added to an existing machine will have to install these cables. These are included in the field install kit for the zero point ready.

Connect the cables to the load station cable bracket [3] which is located as shown in the image. 

The cables coming from the load station are connected to the bracket in the previous step [7], or routed all the way to the control cabinet. Make sure the following cables are connected:

1. 33-2565 - Connect to P12 on IOPCB.                              Note: Make sure to remove jumper from P12                           on the IOPCB before installing the cable.
2. 32-1303 - This is connected to P14 on the IOPCB. One end connects to the cable bracket at the Door Open label and the Station Locked label. The other end is connected to the cutout at the skirt of the machine where the foot pedal connects. If there is already a cable routed to this connector it needs to be replaced with the 32-1303 cable.
3. 32-1286 - Connects to the foot pedal assembly [8] and then also to the connector of the cable 32-1303.
4. 32-1304 - Connect to the cable bracket at the Door Open label
5. 33-1308 - Connect to the cable bracket at the Station Locked label
6. 33-1482 - Connect to P50 on the IOPCB (pallet alarm). 
7. 33-5838 - Connect work lights to splitter on top of load station. And then connect to work light power supply [9].

Note: The foot pedal assembly [8], cable 32-1286 [10] and the 32-1303 [2] cables are found in the Zero Point Installation kits.

Route the cables and hoses going to the load station and robot through the cable conduit [1] on the machine side of the pallet.

Close the air valve [1] at the bottom of the lube cabinet.

Bleed the remaining air out of the manifold by pulling on the air release [2]. Make sure the gauge on the manifold reads zero.

Use the included magnets to attach the Air Booster onto the back of the enclosure for small VFs [1] and onto the side of the lube cabinet for medium VFs [2].

Route the steel braided air lines [1] through the through the conduit spring holder [2].

Route the opposite ends of the air lines through the hole in the enclosure..

Note: The hole in the enclosure shown is for a VF-2. The enclosure hole for the VF-3 through 5 is on the right enclosure wall.

 Note: Both hoses coming from the work holding are steel braided. They are shown as green and red in the image to differentiate between them.

Attach the mounting bracket [1] to the sheet metal on the exterior side of the machine, around the enclosure hole. Use ¼-20 bolts [2].

Run each steel braided hose through a cable clamp [3] and bolt these to the mounting bracket. 

Route the hoses to the lube panel.

 Note: Both hoses coming from the work holding are steel braided. They are shown as green and red in the image to differentiate between the clamp (red) and unclamp (green) hoses.

Connect the green hose to the unclamp port [1] of the solenoid denoted with a green zip tie on it.

Connect the red hose to the clamp port [2] of the solenoid denoted with a red zip tie on it.

Connect the red air hose to the 90 degree fitting [1] underneath the load station.

Route the hose through the RPL conduit to the air booster assembly and connect it to the load station solenoid [2]. 

Connect the red high pressure air hose to the RPL gripper solenoid assembly in the RPL arm [1]. 

Route the airline through the conduit and connect it to the push-connect fitting between the two solenoids [2].

Connect the air booster to the manifold [1] using the included HOSE 1/4 OD PE RED HIGH PRESSURE.

Connect cable 33-1359 CBL AIR VISE PRESS SWS PP ROBOT 12FT  [1] to the pressure sensor as shown. 

Route the cable back to the I/O board and plug this into P13 using the adapter cable provided in the kit.

Note: The pressure sensor should be on the fitting where the red hose is connected. This sensor makes sure the zero point is clamped.

Connect cable 33-1355 CBL DUAL AIR VISE ROBOT LOAD STATION to P36 [5] on the IO PCB. Connect the coolant refill to the pigtail if needed.

Route the other end directly to the Air Booster.

Connect the V-1 end [1] to the solenoid going to the zero point in the machine [4].

Connect the V-2 end [2] to the solenoid going to the load station zero point [3].

Locate the Mode Switch on the Controller Operator Panel. The key should be set to Auto Mode[2].

Make sure the [E-STOP] button[3] is not pressed.

Turn on the Robot Control box by rotating the Breaker clockwise to On[1].

Turn on the Haas CNC.

Zero Return all Axes.

Insert Service USB key.  Go into Service mode.

Go to Parameters> Factory tab.  Change the following:

• 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
• 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1
• 2192 [:] Light Curtain Trigger Threshold to 0

Verify that the following  parameters are set to these values:

• 2128 [:] PALLET POOL TYPE to 4 Robot
• 2129 [:] PALLET LOADING SHELF to PP_SHELF_A

Go to Settings and change the following:

• 382 Disable Pallet Changer to None
• 372 Parts Loader Type to None
• 376 Light Curtain Enabled to On

Press [CURRENT COMMANDS].

Go to Devices>Robot>Jogging tab. Change the following:

• Maximum Jogging Speed to 7.9 in/sec (200 mm/sec).

Go to the Setup tab. Change the following:

• Max Robot Speed to 157 in/sec (3988 mm/sec). 
• Gripper Net Mass - Enter the Net Mass of the gripper. Refer to the HRP-2 Machine Layout Drawing to get the correct value for this setting.
  
  Warning: Setting this value incorrectly can cause the Robot Arm to not move correctly.
  
  
• Number of Grippers to the number of grippers.
• Raw Gripper Clamp Output to 1.
• Raw Gripper Unclamp Output to 2.
• Raw Gripper Clamp Delay to the clamp/unclamp duration in sec.
• Raw Gripper Clamp Type to OD/ID.

Press [CURRENT COMMANDS].

Go to Devices>Robot>Setup tab[1].

Press [E-Stop].

Press [F1] to connect the robot[2].

The first time connecting a robot to a machine, a Robot Activation window will pop-up. This pop-up shows the Software Version of the machine[3], the MAC address of the robot[4], and the Machine Generated Code[5] used for Machine Time Extension on the portal.

To activate the robot, enter the F Number[6] and Unlock Code[7].

The F Number is found on the robot ID tag that is on the control panel door or on the robot arm.

The Unlock Code is generated after completing the Robot Installation on the Haas Business Center.

 Note: The machine needs to be activated before the robot is activated. Follow the Machine Activation / Time Extension - NGC procedure.

For Service Activation. In Service Mode, Press [INSERT] to connect the robot. This will be disabled after a Cycle Power.

Note: This step can only be completed by a HFO Service Technician.

Note: The green button on the control box will light up.

Press the [HANDLE JOG] button. 

Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.

On the Remote Handle Jog Touch press the Joint button to go into the Joints Coordinates.

Jog the robot from its shipping position to a safe position.

Note: Press [Emergency Stop] before working on the robot.

Note: Turn off the machine air by turning the valve in the Air/Lube cabinet and pull the pressure relief valve to release the air in the system.

DCS Setup (Dual Safety Check)

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

Note: This is required for RPL's.

Refer to the procedure linked below for how to set up a Fanuc Dual Check Safety (DCS) zone.

Note: This is setup the same as it is on a normal HRP-2 machine.

Note: Make sure DCS is setup correctly at this point before continuing.

Once the robot is installed and operational, continue to setup the RPL system using the tabs in the CURRENT COMMANDS > DEVICES menu in the control.

Chapter 9 Pallet Loader Setup will show how to configure the shelf, setup the pallet holders, and set the needed positions for the robot.

The RPL is compatible on the following machines:

• UMC-500/SS built after 6/20/23
• UMC-750/SS built after 8/29/22
• UMC-1000/SS built after 3/29/23

Note: For a list of options that are not compatible with the RPL, refer to the Specifications and Compatibility tab in the Introduction chapter.

This procedure shows how to install the Robot Pallet Loader (RPL) option. The RPL option also requires the following options for the machine:

• Auto Window option (field install kit dependent on machine) Refer to UMC - Auto Window - Installation
• Single Zero Point Ready Kit (UMC-500/750/1000 machines)
• Safety Device (Light Curtain or Safety Fence)
• 100.24.000.1111 or later Software Version

Note: For Existing machines that need 100.24.000.1111 software, contact Haas Service for access.

This procedure is for the following kits:

• 93-1001040 - ROBOT-25 PALLET SYS INSTALL KIT
• 93-1001123 - PALLET SYS INSTALL KIT UMC CE
• 93-1001128 - FENCE INSTALL KIT RPL-25KG

Note: Refer to Section 4.2 of this manual for instructions on installing the zero point ready on VMC and UMC machines.

The pallet comes with the following components installed on it:

1. Operator Load Station
2. Pallet Shelf
3. HRP-2 Robot
4. HRP Control Box

Verify that the electrical connector [5] is oriented as shown in the image.

Warning: Due to the range that robot joints can move, the robot can't maneuver through the area aligned with the electrical connector. The orientation shown in the image is needed for the robot to navigate the operator station, and the pallet shelf effectively.

Lift the RPL from the side where there is the pallet jack slots and move it into the place next to the machine. See the next step for exact placement measurements.

Important: Make sure the pallet jack used has forks that are at least the same length of the RPL pallet to ensure safe lifting.

The pallet needs to be positioned on the right side of the machine, located next to the auto window that is installed.

Use a forklift to move the pallet into the correct position.

Place the pallet with the operator station facing the same direction as the front of the machine [1]. Make sure that the left edge of the pallet [5] is parellel to the right edge of the machine [4].

Position the pallet so that:

On UMC-500:

• The front side of the pallet [2] is [3] (20" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On UMC-750:

• The front side of the pallet [2] is [3] (17.5" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On UMC-1000:

• The front side of the pallet [2] is [3] (16" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

If the pallet is sitting on an uneven surface, use the 4 leveling feet [1] to raise the pallet off the ground. 

Use a level to make sure that the pallet is roughly level after raising it of the ground.

Lock the leveling feet in position by tightening the nuts [2] on each foot.

Install the anchors [1] from the installation kit after the RPL has been placed in its final position. Use the provided template in the kit  to mark each individual anchor drilling location.

Note: The kit comes with four anchors, but only three are required for installation [2]. The fourth anchor [3] is recommended but not required for anchoring down the RPL.

Follow the link below on how to install the anchors. 

Fasten the sheet metal brackets [1] and [2] together using the FBHCS [3].

Install the magnetic cups onto the sheet metal [4]. This sheet metal will connect the machine to the load station [5] with the magnets.

Note: In this image the machine is not shown so that the magnetic cups can clearly be seen. These magnets connect to both the load station and the machine.

Note: For machines with the CE Install Kit, use the self tapping screws instead of the magnets to mate the sheet metal to the machine.

Cut the zip-tie to take the E-stop/work light button holder [1] off the load station. Rotate the holder [1] and use the bolts provided to mount the holder onto the load station. 

Assemble the number plates and mounting hardware as shown [1]. Lightly tighten t-nuts onto first 1-2 threads of bolts.  

Slip t-nuts into the top slot of the top shelf  [2] and tighten bolts. Number plates A1- A5 should be placed on the top shelf, B1 - B5 on the second shelf, and so on.

Name plates should be installed on the side of the shelf facing the robot arm.

For 93-1001040 Non-CE Install Kit:

Install the light curtains and mirrors as shown in the image.

Place the emitter [1] behind the pallet shelf.

Place the two mirrors [2] on the side opposite the machine.

Place the receiver [3] next to the E-stop of the load station.

For 93-1001123 CE Install Kit:

Install the rear fence mate panel [1] using the 2 self tapping screws [2].

Note: Do not fully tighten the screws at first. The mounting holes in the panel are slotted so that the position can be adjusted to mate to the fence. Have the fence and other sheet metal setup before fully fastening all the sheet metal in place.

The bottom screw should be mounted to the enclosure panel highlighted [3] in the image. 

For 93-1001123 CE Install Kit:

Install the fence [1] to enclose the RPL. Refer to Chapter 6 Fence Installation for more detail on installing the fence.

Use the self tapping screws [2] to mate the sheet metal [3] installed in the previous step.

Note: Fully tighten both sets of self tapping screws [4].

Robot Interface Mounting Location

The Robot electrical interface box has magnetic mounts to attach to the machine sheet metal.

Mount the Robot electrical interface box [1] as shown in the picture.

Route the Robot interface electrical cables through the bottom of the electrical cabinet.

Follow the next section for where to install the cables coming from the interface box and the Remote Jog Handle (RJH).

Remove the bottom cable cover [1] from the control cabinet [2].

For machines purchased with the RPL option, cables will be coiled inside the cover. 

Note: RPL's being added to an existing machine will have to install these cables. These are included in the field install kit for the zero point ready.

Connect the cables to the load station cable bracket [3] which is located as shown in the image. 

The cables coming from the load station are connected to the bracket in the previous step [7], or routed all the way to the control cabinet. Make sure the following cables are connected:

1. 33-2565 - Connect to P12 on IOPCB 
2. 32-1303 - This is connected to P14 on the IOPCB. One end connects to the cable bracket at the Door Open label and the Station Locked label. The other end is connected to the cutout at the skirt of the machine where the foot pedal connects. If there is already a cable routed to this connector it needs to be replaced with the 32-1303 cable.
3. 32-1286 - Connects to the foot pedal assembly [8] and then also to the connector of the cable 32-1303.
4. 32-1304 - Connect to the cable bracket at the Door Open label
5. 33-1308 - Connect to the cable bracket at the Station Locked label
6. 33-1482 - Connect to P50 on the IOPCB (pallet alarm). 
7. 33-5838 - Connect work lights to splitter on top of load station. And then connect to work light power supply [9].

Note: The foot pedal assembly [8], cable 32-1286 [10] and the 32-1303 [2] cables are found in the Zero Point Installation kits.

Route the cables and hoses going to the load station and robot through the cable conduit [1] on the machine side of the pallet.

Close the air valve [1] at the bottom of the lube cabinet.

Bleed the remaining air out of the manifold by pulling on the air release [2]. Make sure the gauge on the manifold reads zero.

Install the Air Booster on the back of the machine using the magnets to attach it.

Route the end of the zero point air lines [1] to the Air Booster. 

Note: Make sure the hoses for the zero point are high pressure hoses.

Connect the green hose to the unclamp port [1] of the solenoid denoted with a green zip tie on it.

Connect the red hose to the clamp port [2] of the solenoid denoted with a red zip tie on it.

Connect the air booster to the manifold [1] using the included HOSE 1/4 OD PE RED HIGH PRESSURE.

This step is for non-CAN lube panel machines only: 

Connect cable 33-1532 - Air Lube Solenoid cable to P35 on the IO PCB with the connector with the pigtail for Pallet Unclamp [16].

Route the cable to the lube panel to make the following connections to all the solenoid power cables. The color for each connector is listed:

[2] PulseJet Solenoid - White and Violet

[3] Auto Door  - Gray

[4] TRP Unclamp  - Yellow and Black

[5] Spindle Air - Violet

[6] Spindle Lube - White

[7] Min Lube Grease - White and Red

[8] Open Door Interlock - White and Brown

[9] Auto Air Gun (AAG) - Red

[10] TSC Purge - White and Orange and Yellow jumper to TAB Air [15]

[11] SMTC Pocket U/D - White and Black

[12] UMC Auto Window - White and Yellow

[13] Purge Solenoid - White and Gray

[14] Pallet Air Blast - White and Green

[15] Tool Air Blast Air (TAB) Yellow jumper from TSC Purge [10]

Connect the red air hose to the 90 degree fitting [1] underneath the load station.

Route the hose through the RPL conduit to the air booster assembly and connect it to the load station solenoid [2]. 

Connect the red high pressure air hose to the RPL gripper solenoid assembly in the RPL arm [1]. 

Route the airline through the conduit and connect it to the push-connect fitting between the two solenoids [2].

Connect cable 33-1307 CBL AIR VISE PRESS SWS PP ROBOT 21FT to the pressure sensor as shown. 

Route the cable back to the I/O board and plug this into P13 using the adapter cable provided in the kit.

Note: The pressure sensor should be on the fitting where the red hose is connected. This sensor makes sure the zero point is clamped.

Connect cable 33-1306 to P36 [5] on the IO PCB. Connect the coolant refill to the pigtail if needed.

Route the other end directly to the Air Booster.

Connect the V-1 end [1] to the solenoid going to the zero point in the machine [4].

Connect the V-2 end [2] to the solenoid going to the load station zero point [3].

Locate the Mode Switch on the Controller Operator Panel. The key should be set to Auto Mode[2].

Make sure the [E-STOP] button[3] is not pressed.

Turn on the Robot Control box by rotating the Breaker clockwise to On[1].

Turn on the Haas CNC.

Zero Return all Axes.

Insert Service USB key.  Go into Service mode.

Go to Parameters> Factory tab.  Change the following:

• 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
• 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1
• 2192 [:] Light Curtain Trigger Threshold to 0

Verify that the following  parameters are set to these values:

• 2128 [:] PALLET POOL TYPE to 4 Robot
• 2129 [:] PALLET LOADING SHELF to PP_SHELF_A

Go to Settings and change the following:

• 382 Disable Pallet Changer to None
• 372 Parts Loader Type to None
• 376 Light Curtain Enabled to On

Press [CURRENT COMMANDS].

Go to Devices>Robot>Jogging tab. Change the following:

• Maximum Jogging Speed to 7.9 in/sec (200 mm/sec).

Go to the Setup tab. Change the following:

• Max Robot Speed to 157 in/sec (3988 mm/sec). 
• Gripper Net Mass - Enter the Net Mass of the gripper. Refer to the HRP-2 Machine Layout Drawing to get the correct value for this setting.
  
  Warning: Setting this value incorrectly can cause the Robot Arm to not move correctly.
  
  
• Number of Grippers to the number of grippers.
• Raw Gripper Clamp Output to 1.
• Raw Gripper Unclamp Output to 2.
• Raw Gripper Clamp Delay to the clamp/unclamp duration in sec.
• Raw Gripper Clamp Type to OD/ID.

Press [CURRENT COMMANDS].

Go to Devices>Robot>Setup tab[1].

Press [E-Stop].

Press [F1] to connect the robot[2].

The first time connecting a robot to a machine, a Robot Activation window will pop-up. This pop-up shows the Software Version of the machine[3], the MAC address of the robot[4], and the Machine Generated Code[5] used for Machine Time Extension on the portal.

To activate the robot, enter the F Number[6] and Unlock Code[7].

The F Number is found on the robot ID tag that is on the control panel door or on the robot arm.

The Unlock Code is generated after completing the Robot Installation on the Haas Business Center.

 Note: The machine needs to be activated before the robot is activated. Follow the Machine Activation / Time Extension - NGC procedure.

For Service Activation. In Service Mode, Press [INSERT] to connect the robot. This will be disabled after a Cycle Power.

Note: This step can only be completed by a HFO Service Technician.

Note: The green button on the control box will light up.

Press the [HANDLE JOG] button. 

Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.

On the Remote Handle Jog Touch press the Joint button to go into the Joints Coordinates.

Jog the robot from its shipping position to a safe position.

Note: Press [Emergency Stop] before working on the robot.

Note: Turn off the machine air by turning the valve in the Air/Lube cabinet and pull the pressure relief valve to release the air in the system.

DCS Setup (Dual Safety Check)

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

Note: This is required for RPL's.

Refer to the procedure linked below for how to set up a Fanuc Dual Check Safety (DCS) zone.

Note: This is setup the same as it is on a normal HRP-2 machine.

Note: Make sure DCS is setup correctly at this point before continuing.

Once the robot is installed and operational, continue to setup the RPL system using the tabs in the CURRENT COMMANDS > DEVICES menu in the control.

Chapter 9 Pallet Loader Setup will show how to configure the shelf, setup the pallet holders, and set the needed positions for the robot.

The pallet comes with the following components installed on it:

1. Operator Load Station
2. Pallet Shelf
3. HRP-2 Robot
4. HRP Control Box

Verify that the electrical connector [5] is oriented as shown in the image.

Note: Dual Rack RPL Requires 100.25.001.1100 or later Software Version

Warning: Due to the range that robot joints can move, the robot can't maneuver through the area aligned with the electrical connector. The orientation shown in the image is needed for the robot to navigate the operator station, and the pallet shelf effectively.

Note: The HRP Control Box [4] does not stay on the pallet as shown in the image. It will be placed next to the Haas machine electrical cabinet.

Lift the RPL from the side where there is the pallet jack slots and move it into the place next to the machine. See the next step for exact placement measurements.

Important: Make sure the pallet jack used has forks that are at least the same length of the RPL pallet to ensure safe lifting.

The pallet needs to be positioned on the right side of the machine, located next to the auto window that is installed.

Use a forklift to move the pallet into the correct position.

Place the pallet with the operator station facing the same direction as the front of the machine [1]. Make sure that the left edge of the pallet [5] is parellel to the right edge of the machine [4].

Position the pallet so that:

On UMC-500:

• The front side of the pallet [2] is [3] (20" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On UMC-750:

• The front side of the pallet [2] is [3] (17.5" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On UMC-1000:

• The front side of the pallet [2] is [3] (16" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

The pallet needs to be positioned on the right side of the machine, located next to the auto window that is installed.

Use a forklift to move the pallet into the correct position.

Place the pallet with the operator station facing the same direction as the front of the machine [1]. Make sure that the left edge of the pallet [5] is parallel to the right edge of the machine [4].

Position the pallet so that:

On VF-2:

• The front side of the pallet [2] is [3] (18" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On VF-3:

• The front side of the pallet [2] is [3] (17" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

On VF-5:

• The front side of the pallet [2] is [3] (13" or 50.8 cm) from the front of the machine [1]. 
• The left side of the pallet [5] is [6] (7" or 17.78 cm) from the left side of the machine [4].

If the pallet is sitting on an uneven surface, use the 4 leveling feet [1] to raise the pallet off the ground. 

Use a level to make sure that the pallet is roughly level after raising it of the ground.

Lock the leveling feet in position by tightening the nuts [2] on each foot.

Install the anchors [1] from the installation kit after the RPL has been placed in its final position. Use the provided template in the kit  to mark each individual anchor drilling location.

Note: The kit comes with four anchors, but only three are required for installation [2]. The fourth anchor [3] is recommended but not required for anchoring down the RPL.

Follow the link below on how to install the anchors. 

Cut the zip-tie to take the E-stop/work light button holder [1] off the load station. Rotate the holder [1] and use the bolts provided to mount the holder onto the load station. 

Note: For dual rack RPL's, the HRP electrical box cannot be on the pallet. Move the electrical box behind rack 1 as shown in the image.

For example on a UMC the electrical box will be under or next the electrical cabinet of the machine.

Run the robot power cables coming from the electrical box underneath the machine so they are not coiled up. 

Note: Having the power cabled coiled up can cause electrical noise that could cause alarms coming from the robot control box. Make sure the power cables are not routed on top of eachother.

The 2nd rack comes in the shipping position where the 2nd rack is sitting on top of the base plate. The rack support legs needs to be extended out at installation.

Unfasten the 4 SHCS [1] holding the 2nd rack support legs [2] in position on the pallet.

Once the rack is free to pull out, prep getting the leveling pucks and studs so that they can be installed while pulling the rack out.

Pull the rack out away from the pallet as shown by the arrow.

Pull it out until you can see the tapped holes in the pallet for the 4 SHCS and washers [1] that were removed in the previous step. 

Start threading in the SHCS to hold the 2nd rack support legs in rough position. 

Run the leveling studs [2] down until they make contact with the pucks [3].

To align the rack, back off  the 4 SHCS that were installed from last step.

Move the rack so that the washers on the mounting screws [1] are centered in the cut outs in the guide channels [2] as shown in the image. 

Once the washers are centered, tighten down the SHCS bolts so that the rack holds its position.

Now that the rack has been extended, continue to the next steps which are to rough level the rack.

Note: The level does not need to be perfect. Imperfections in the level of the shelf can be corrected by changing the frame for the robot. Only rough level the rack.

Start leveling by using a bubble level on the vertical posts [1] of the rack.

Raise/lower the leveling screws [2] as needed to get each post vertical.

Continue adjusting the leveling screws until the level is in the middle for each post. 

Once the posts are vertical, move the level to the top shelf.

Place the level [2] on top of the pallet holders [1].

Adjust the leveling screws as needed.

Note: The rack just needs to be rough leveled. Prioritize this level over the previous step where the posts were made vertical.

Important: It's recommended to adjust the robot frame to match the shelf rather than attempt to adjust the level of the rack match the frame. Refer to the section below for creating a frame that matches the shelf.

For 93-1001040 Non-CE Install Kit:

Install the light curtains and mirrors as shown in the image.

Place the emitter [1] behind the pallet shelf.

Place the two mirrors [2] on the side opposite the machine.

Place the receiver [3] next to the E-stop of the load station.

Note: The image doesn't show the 2nd rack option. If the RPL has the 2nd rack have the light curtains cover the back side of the 2nd rack.

Close the air valve [1] at the bottom of the lube cabinet.

Bleed the remaining air out of the manifold by pulling on the air release [2]. Make sure the gauge on the manifold reads zero.

For UMCs:

Install the Air Booster on the back of the machine using the magnets to attach it.

For VF machines:

Use the included magnets to attach the Air Booster onto the back of the enclosure for small VFs [1] and onto the side of the lube cabinet for medium VFs [2].

For VF machines:

Route the steel braided air lines [1] through the through the conduit spring holder [2].

Route the opposite ends of the air lines through the hole in the enclosure..

Note: The hole in the enclosure shown is for a VF-2. The enclosure hole for the VF-3 through 5 is on the right enclosure wall.

 Note: Both hoses coming from the work holding are steel braided. They are shown as green and red in the image to differentiate between them.

For VF machines:

Attach the mounting bracket [1] to the sheet metal on the exterior side of the machine, around the enclosure hole. Use ¼-20 bolts [2].

Run each steel braided hose through a cable clamp [3] and bolt these to the mounting bracket. 

Route the hoses to the lube panel.

 Note: Both hoses coming from the work holding are steel braided. They are shown as green and red in the image to differentiate between the clamp (red) and unclamp (green) hoses.

For UMC machines:

Route the end of the zero point air lines [1] to the Air Booster. 

Note: Make sure the hoses for the zero point are high pressure hoses.

Connect the green hose to the unclamp port [1] of the solenoid denoted with a green zip tie on it.

Connect the red hose to the clamp port [2] of the solenoid denoted with a red zip tie on it.

Connect the air booster to the manifold [1] using the included HOSE 1/4 OD PE RED HIGH PRESSURE.

This step is for non-CAN lube panel machines only: 

Connect cable 33-1532 - Air Lube Solenoid cable to P35 on the IO PCB with the connector with the pigtail for Pallet Unclamp [16].

Route the cable to the lube panel to make the following connections to all the solenoid power cables. The color for each connector is listed:

[2] PulseJet Solenoid - White and Violet

[3] Auto Door  - Gray

[4] TRP Unclamp  - Yellow and Black

[5] Spindle Air - Violet

[6] Spindle Lube - White

[7] Min Lube Grease - White and Red

[8] Open Door Interlock - White and Brown

[9] Auto Air Gun (AAG) - Red

[10] TSC Purge - White and Orange and Yellow jumper to TAB Air [15]

[11] SMTC Pocket U/D - White and Black

[12] UMC Auto Window - White and Yellow

[13] Purge Solenoid - White and Gray

[14] Pallet Air Blast - White and Green

[15] Tool Air Blast Air (TAB) Yellow jumper from TSC Purge [10]

Connect the red air hose to the 90 degree fitting [1] underneath the load station.

Route the hose through the RPL conduit to the air booster assembly and connect it to the load station solenoid [2]. 

Connect the red high pressure air hose to the RPL gripper solenoid assembly in the RPL arm [1]. 

Route the airline through the conduit and connect it to the push-connect fitting between the two solenoids [2].

Connect cable 33-1307 CBL AIR VISE PRESS SWS PP ROBOT 21FT to the pressure sensor as shown. 

Route the cable back to the I/O board and plug this into P13 using the adapter cable provided in the kit.

Note: The pressure sensor should be on the fitting where the red hose is connected. This sensor makes sure the zero point is clamped.

Connect cable 33-1306 to P36 [5] on the IO PCB. Connect the coolant refill to the pigtail if needed.

Route the other end directly to the Air Booster.

Connect the V-1 end [1] to the solenoid going to the zero point in the machine [4].

Connect the V-2 end [2] to the solenoid going to the load station zero point [3].

Robot Interface Mounting Location

The Robot electrical interface box has magnetic mounts to attach to the machine sheet metal.

Mount the Robot electrical interface box [1] as shown in the picture.

Route the Robot interface electrical cables through the bottom of the electrical cabinet.

Follow the next section for where to install the cables coming from the interface box and the Remote Jog Handle (RJH).

Remove the bottom cable cover [1] from the control cabinet [2].

For machines purchased with the RPL option, cables will be coiled inside the cover. 

Note: RPL's being added to an existing machine will have to install these cables. These are included in the field install kit for the zero point ready.

Connect the cables to the load station cable bracket [3] which is located as shown in the image. 

The cables coming from the load station are connected to the bracket in the previous step [7], or routed all the way to the control cabinet. Make sure the following cables are connected:

1. 33-2565 - Connect to P12 on IOPCB 
2. 32-1303 - This is connected to P14 on the IOPCB. One end connects to the cable bracket at the Door Open label and the Station Locked label. The other end is connected to the cutout at the skirt of the machine where the foot pedal connects. If there is already a cable routed to this connector it needs to be replaced with the 32-1303 cable.
3. 32-1286 - Connects to the foot pedal assembly [8] and then also to the connector of the cable 32-1303.
4. 32-1304 - Connect to the cable bracket at the Door Open label
5. 33-1308 - Connect to the cable bracket at the Station Locked label
6. 33-1482 - Connect to P50 on the IOPCB (pallet alarm). 
7. 33-5838 - Connect work lights to splitter on top of load station. And then connect to work light power supply [9].

Note: The foot pedal assembly [8], cable 32-1286 [10] and the 32-1303 [2] cables are found in the Zero Point Installation kits.

Route the cables and hoses going to the load station and robot through the cable conduit [1] on the machine side of the pallet.

Locate the Mode Switch on the Controller Operator Panel. The key should be set to Auto Mode[2].

Make sure the [E-STOP] button[3] is not pressed.

Turn on the Robot Control box by rotating the Breaker clockwise to On[1].

Turn on the Haas CNC.

Zero Return all Axes.

Insert Service USB key.  Go into Service mode.

Go to Parameters> Factory tab.  Change the following:

• 1278 [1278:] Robot Ready E-Stop Enabled to TRUE
• 2191 [694:] LIGHT CUTAIN TYPE to LC_TYPE_1
• 2192 [:] Light Curtain Trigger Threshold to 0

Verify that the following  parameters are set to these values:

• 2128 [:] PALLET POOL TYPE to 4 Robot
• 2129 [:] PALLET LOADING SHELF to PP_SHELF_A

Go to Settings and change the following:

• 382 Disable Pallet Changer to None
• 372 Parts Loader Type to None
• 376 Light Curtain Enabled to On

Press [CURRENT COMMANDS].

Go to Devices>Robot>Jogging tab. Change the following:

• Maximum Jogging Speed to 7.9 in/sec (200 mm/sec).

Go to the Setup tab. Change the following:

• Max Robot Speed to 157 in/sec (3988 mm/sec). 
• Gripper Net Mass - Enter the Net Mass of the gripper. Refer to the HRP-2 Machine Layout Drawing to get the correct value for this setting.
  
  Warning: Setting this value incorrectly can cause the Robot Arm to not move correctly.
  
  
• Number of Grippers to the number of grippers.
• Raw Gripper Clamp Output to 1.
• Raw Gripper Unclamp Output to 2.
• Raw Gripper Clamp Delay to the clamp/unclamp duration in sec.
• Raw Gripper Clamp Type to OD/ID.

Press [CURRENT COMMANDS].

Go to Devices>Robot>Setup tab[1].

Press [E-Stop].

Press [F1] to connect the robot[2].

The first time connecting a robot to a machine, a Robot Activation window will pop-up. This pop-up shows the Software Version of the machine[3], the MAC address of the robot[4], and the Machine Generated Code[5] used for Machine Time Extension on the portal.

To activate the robot, enter the F Number[6] and Unlock Code[7].

The F Number is found on the robot ID tag that is on the control panel door or on the robot arm.

The Unlock Code is generated after completing the Robot Installation on the Haas Business Center.

 Note: The machine needs to be activated before the robot is activated. Follow the Machine Activation / Time Extension - NGC procedure.

For Service Activation. In Service Mode, Press [INSERT] to connect the robot. This will be disabled after a Cycle Power.

Note: This step can only be completed by a HFO Service Technician.

Note: The green button on the control box will light up.

Press the [HANDLE JOG] button. 

Press the [CURRENT COMMANDS]  and go to Devices > Robot > Jogging tab.

On the Remote Handle Jog Touch press the Joint button to go into the Joints Coordinates.

Jog the robot from its shipping position to a safe position.

Note: Press [Emergency Stop] before working on the robot.

Note: Turn off the machine air by turning the valve in the Air/Lube cabinet and pull the pressure relief valve to release the air in the system.

DCS Setup (Dual Safety Check)

Each Haas Robot is provided with FANUC's DCS System. This allows the user to define speed and positional limits to the robot. If the robot goes outside of these limits, DCS will stop the robot and remove power to the motors.

Note: This is required for RPL's.

Refer to the procedure linked below for how to set up a Fanuc Dual Check Safety (DCS) zone.

Note: This is setup the same as it is on a normal HRP-2 machine.

Note: Make sure DCS is setup correctly at this point before continuing.

Once the robot is installed and operational, continue to setup the RPL system using the tabs in the CURRENT COMMANDS > DEVICES menu in the control.

Chapter 9 Pallet Loader Setup will show how to configure the shelf, setup the pallet holders, and set the needed positions for the robot.

Note: Make sure that the DCS zone includes the 2nd rack in the DCS envelope. The DCS zone may need to be expanded if the 2nd rack is being field installed.

In order to setup the positions on Rack 2, start by navigating to the Pallet Pool and then Pallet Station Setup tab in current commands.

Change the value for the Rack Count to 2 [1]. 

This will populate the menu with more fields for the additional rack.

Check the rest of the fields in the template. Change the Total Pallets on Rack 2 [1] to 15 for the purposes of setup. 

Note: Even if you do not have 15 pallets its recommended to change it to 15 pallets for setup. This will be needed so that you can command the robot to move to any location on the rack.

In order to go through the Pallet Shelf Setup tab you need to assign all pallets to a shelf position.

Go to the Pallet Schedule Table and enter the shelf location for every pallet. Pallet designations on Dual Rack are specified by <Rack number>-<shelf position>. For example to assign pallet to shelf C5 on Rack 2 you would enter 2-C5 and press enter highlighting the shelf value for the pallet.

See the image for where to highlight when assigning shelf location [1].

Once all 15 spots on Rack 2 are assigned you can move on to setting/verifying the initial pickup location. This is detailed in next section.

The initial pickup location for Rack 2 will need to be set.

To set this position, start by clamping the red setup pallet in the gripper.

Use the Pallet Shelf Setup tab inside current commands. On this page press [F1] to switch between Rack 1 and Rack 2.

Highlight Position 2-A1 and press [F3] move to highlighted station. Don't let it go all the way to the position. Be ready to E-Stop the robot when you are close to the rack.

IMPORTANT: Run the robot slowly so that you can E-stop the robot in case it gets close to colliding with the rack.

When the setup pallet is extended above the rack, press E-Stop. You will jog the robot in cartesian motion to align the setup pallet to the 2-A1 pallet holder.

After pressing E-Stop, switch to the Robot Motions Setup tab.

Press [Handle Jog] so and select Cartesian mode on the RJH.

Jog the robot so that the red setup pallet lines up with the sides and back  of the pallet holder. Jog down so that the setup pallet is sitting flush or a few mm above the pallet holder.

Refer to the images for what good alignment looks like.

Once Aligned, highlight the Initial Pickup Position in the Rack 2 menu [3] and press [F2] to record the position.

Note: Make sure your Active Frame is set to Pallet Station R2 [4]. To change the frame press [F3].

Before testing the initial pickup position, check that the frame matches the shelf.

To test the frame, you will first need to recover the robot.

Once recovered, return to the Pallet Shelf Setup tab and clamp the setup pallet in the gripper.

Highlight station 2-A5 [1] and press [F3] [2] to move this pallet location. This will test if the frame matches the shelf, or if a new frame needs to be created.

Warning: Watch the robot carefully as it approaches the 2-A5 location. Its recommended to run the robot slowly to ensure it moves as expected. 

Note: If the robot alarms out moving across the shelf, recover the robot and then return to the ready location before going to the 2-A5 location. 

Note: If the frame is set correctly, the setup pallet will be just above the pallet holder. You should be able to slid the pallet holder underneath the setup pallet, with less than 1/4" gap.

If the setup pallet is way off as shown in the image, then the frame needs to be reset, as well as the initial pickup position.

Note: Refer to the section below for resetting the frame.

If the height of setup pallet is correct above the A5 location then the remaining pallet holders can be setup on the second rack.

Move to each of the pallet positions that will be used on the shelf.

Line up the pallet holders [1] underneath where the red setup pallet is located [2].

Once the pallet holder is aligned to the setup pallet, tighten the 4 SHCS [3] to secure the pallet holder in position.

If the frame needs to be reset for the 2nd rack, enter the Frames tab in Current commands and use the 3-point method option for the frame named "Shelf 2"

Use the following shelf areas to create the frame with the 3-point method. This will ensure your Z-direction is pointing the correct direction:

1. Location 2-C1 (use shelf post and pallet holder)
2. Location 2-C5 (use shelf post and pallet holder)
3. Location 2-A5 (use shelf post and pallet holder)

Clamp the red setup pallet in the robot gripper.

Use the pallet holders [1] and the inside edge of the rack post [2] to set each point in the 3-point method for the frame.

Start by jogging the robot down near rack station 2-C1 as shown (lower left corner).

Note: Image is shown from the backside of Rack 2. The setup pallet is closest to the 2-C1 pallet position in the image.

Press [F2] to record the first position. Then jog the robot to station 2-C5 (lower right corner) to set the second reference position.

Do the same process that was used to set reference position 1. Use the pallet holder [1] and inside edge of the shelf post [2] to align the setup pallet.

Once the setup pallet is aligned, press [F2] to record the current position as the second reference position. Then continue to setting the final reference position for the 3-point method.

Note: The image is from the backside of Rack2. The setup pallet is closest to the 2-C5 pallet position in the image.

Do the same process that was used to set the first two reference positions except this time using the shelf 2-A5 as the approximate location. Use the pallet holder [1] and inside edge of the shelf post [2] to align the setup pallet.

Once the setup pallet is aligned, press [F2] to record the current position as the final reference point.

Now the frame will be created. 

Important: Use this frame and reset your initial pickup location as outlined in the step above. If you need to adjust motion files, use this new frame as well. You could also direct entry this frame into the SHELF 2.