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
• 93-1001032 - Zero Point Ready Kit (available for VF- 1-5, VM-2/3)
• 93-1001039 or 93-1001103 - 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.

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 - Connect to 32-1286 which will then connect to the foot pedal [8]. The other end of the cable will connect to IOPCB P14. The other end connects to the cable bracket at the Door Open label and the Station Locked label.
3. 32-1304 - Connect to the cable bracket at the Door Open label
4. 33-1308 - Connect to the cable bracket at the Station Locked label
5. 33-1482 - Connect to P50 on the IOPCB (pallet alarm). 
6. 33-5838 - Connect work lights to splitter on top of load station. And then connect to work light power supply [9].

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

For instructions on the air installation for the Zero point in the machine, refer to the previous chapter in the Zero Point Ready - Installation section.

There are two air regulators that can be used for setting the clamp force. The air booster [1] controls the clamp force of the zero point receiver inside the machine and the load station.

Before beginning any installation on the pneumatics, turn off the air and purge the remaining air so that there is no air left in the system. 

This will make installation of the solenoids and air hoses easier.

Install the air booster on the side of the lube cabinet using the magnets to attach.

In the lube panel connect the hoses to the solenoids installed in the previous section.

Connect the hose coming from the air manifold in the lube panel [1] to the incoming connector of the air booster [2].

Connect the output of the air booster [3] to the port on the solenoid [4].

Connect the clamp [5] and unclamp [6] hoses coming from the zero point on the machine to the solenoid as shown in the image.

Note: Both hoses going to the zero point are steel braided. They are shown as gray in the image.

Note: The pressure switch should be on the red clamp hose.

The clear hose [7] coming from the lower solenoid gets routed to the RPL load station.

Connect the clear air hose [1] to the 90 degree fitting [2] underneath the load station [3].

Route the hose through the RPL conduit to the lube cabinet and connect it to the fitting at the bottom solenoid [4] in the solenoid assembly.

Connect the fitting [1] to the main air manifold in the lube cabinet.

Connect the 3/8 in hose to the fitting, and route it to the robot gripper air port labeled AIR 1 [2].

The AIR 1 fitting is located at the base of the robot [3].

Turn the air back on in the machine.

Set air booster pressure to max pressure.

Locate the Mode Switch on the Controller Operator Panel. The keu 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.