2.3 EC PP - 6 + 1 Station

The following service video shows how to install the 6 station pallet pool on the EC-400.

Note: This service video is for reference only and does not replace the written procedure.

The following procedure will show you how to install a Pallet Pool on a EC-400 Horizontal Machining Center.

The Next Generation software on the machine must be version 100.19.000.1110 or higher.

Important: To ensure that the Pallet Pool does not become mis-aligned, it is recommended that the machine and Pallet Pool be anchored. Refer to the following link: Anchoring Instructions.

The Pallet Pool option has 6 pallet stations plus 1 pallet in the machine. A maximum of 7 pallets can be installed on a EC-400 with the Pallet Pool option.

The Pallet Pool has 2 servo axes. The PR axis rotates the Pallet Pool ram and the PS axis extends and retracts the Pallet Pool ram to load/unload the pallets.

The EC-400 must be leveled before the Pallet Pool can be installed. Refer to the EC-400 Installation procedure.

To level the machine without the Pallet Pool connected to the machine, do the following: 

Make sure that there is a shorting block [1] installed on the top two pins of the P12 connector on the I/O PCB 

Make sure there is a jumper (P/N 33-0527) [2] connected to I/O PCB at P14.
 Note: These jumpers are needed to operate the machine without the Pallet Pool.

 Disable the pallet pool, change setting 382 Disable Pallet Changer to Pallet Pool.

Note: The above step will disabled the Pallet Pool to allow you to zero return the machine so it can be leveled.

Refer to the EC-400 - Installation procedure.

Remove E-Stop [1] from panel.

Disconnect Pallet Alarm Cable (P/N 33-0428) at P50 [2] from the I/O NGC Board in the Control Cabinet. 

Disconnect cable at P12 [3] from the I/O NGC Board in the Control Cabinet.

Disconnect male pin cables from PC ELECT CONN BRKT [4] labeled:

• PROBE UP
• PROBE DOWN

Disconnect female pin cables from PC ELECT CONN BRKT [4] labeled:

• DOOR OPEN SW
• STD LCKD SW
   Note: APC Proximity switch will only be disconnected from the PC ELECT CONN BRKT [4] labeled STD LCKD SW and does not have to be removed from inside the APC casting.

Remove access panel [1].

Follow the cable [2] to remove E-Stop completely.

Cable should have already been disconnect from P50 in step 1. 

 NOTE: Store the E-Stop and their cables in a safe location, these will be used by the service personnel to install the Pallet Pool for machines built after 10/11/2023.

Remove the APC Door Interlock by following these steps in order:

• Close the airline [1].
• Release the remaining entrapped air by pulling the pin [2].
  
• Make sure the gauge reads 0 PSI [3].
• Remove the Solenoid [4].
• Install plug [5].
• Remove the hose from the fitting [6].
  Note: Once hose is removed from the fitting from the interlock, the hose may be left routed on the machine.

Remove APC Front Load Station Enclosure Panels in the following order:

• [1] ENCL PANL SKIRT FRONT 
• [2] ENCL PANL FRONT LOWER 
• [3] ENCL PANL PALLET LOAD DOOR & HEADER ASSEMBLY
• [4] ENCL PANL FRONT RIGHT 
• [5] ENCL PANL FRONT LEFT
• [6] ENCL PANL TOP FRONT LEFT 
• [7] ENCL PANL TOP FRONT RIGHT 

 Note: Use a stiff putty knife and a rubber mallet to help remove front apc enclosure panels.

Remove the ENCL DRAIN PAN UPPER CENTER [1].

Turn Pallet [1] 90 degrees counter clockwise so that the arrow on the PALLET [1] and the arrow on the APC LOAD STATION DISC [2] are pointing towards each other. 

Using a lifting apparatus and eyebolts, remove Pallet.

Note: Turn LOAD STATION DISC [2] 90 degrees clockwise using handle so that the arrow is back to the original position. This must be done to place the pallet back on to the H-frame.

Remove (3) bolts [1] to remove LOAD STATION LOCK PLATE [2].

Remove APC COVER [1] by removing (5) bolts.

Remove SPRING [2].

Remove LOCK NUT [3] using T-1357.  

Remove (6) bolts [4] to remove APC LOAD STATION DISC [5] and APC LOAD STATION SPINDLE [6].

 Note: The top bearing [7] and bottom bearing [8] will be reused in the new APC Load Station Spindle provided in the kit. Use a rubber mallet to help remove and install the bearings. The bottom bearing [8] might still be in place in the APC Bridge. If it falls out when removing the spindle, add grease and place it back into the APC Bridge. 

Remove Load Station parts:

[1] (4) Bolts

[2] APC LOAD STATION HANDLE     

[3] APC LOAD STATION PIN SLEEVE 

[4] APC LOAD STATION SHOT PIN 

Clean bore [1] and apply grease to the bore [1] and the bearings [4][5].

Add PIN [2] into APC LOAD STATION SPINDLE [3] provided in the kit. 

Slide TOP BEARING [2] into the APC LOAD STATION SPINDLE [3]

Slide BOTTOM BEARING [5] from underneath the body into the bore [1].
 Note: The bottom bearing [8] might still be in place in the APC Bridge. In case it fell out when removing the spindle, add grease and place it back into the APC Bridge. 

Install the APC LOAD STATION SPINDLE [3] and tighten the LOCKNUT [6].

Install APC LOAD STATION PIN 

Align the Disc [1] with the Pin on the Spindle and torque the (6) bolts [2].

Use Haas Fastener Torque Specifications.

Torque Lock Nut [1] using T-1357 to 100 lb-ft and use the (5) bolts to install the APC Cover [2]. 

Use Haas Fastener Torque Specifications.

Place APC Pallet [2] back on the H-frame using a lifting apparatus [1] and eyebolts so that it aligns with the (4) pins [3].

Add Black Foam Tape to panels [3], [4], [6], and [7].

Install panels in the following order:  

• [1] ENCL PNL TOP FRNT LT EC-400PP
• [2] ENCL PNL TOP FRNT RT EC-400PP
• [3] PP SKIRT LEFT UPPER
• [4] PP SKIRT RIGHT UPPER
• [5] PP SKIRT FRONT LEFT 
• [6] PP SKIRT FRONT LEFT
• [7] PP SKIRT FRONT RIGHT

Place a pallet on the machine load station. This pallet will be used in the leveling and alignment section.
NOTE: Do not place any of the pallets in the pallet pool at this time.

Remove the shipping brackets and all packing material from the Pallet Pool assembly. Remove the pallet pool guard panels [1].

Raise the Pallet Pool support feet [2] off the ground.

Pallet Pool Panel Alignment Arms Installation

Install the alignment arms [1] on to the pallet pool casting with the provided hardware.
NOTE: Zip-tie the cables and hoses to the pallet pool casting so you can move the pallet pool assembly into position without damage.

Use a pallet jack with long forks [2] to move the pallet pool assembly into position.

Move the pallet pool assembly so the alignment arms [1] are within 3 - 6” (76 - 152 mm) of the base casting locating tabs.
NOTE: If you don’t have a pallet jack with long forks. We recommend having the machine riggers place the Pallet Pool within the distance mentioned above.

Install the leveling pads [3] under the pallet pool and lower the pallet pool. 

Pallet Pool Turnbuckle Installation

Install the turnbuckles [3] with the provided hardware (SHCS, washer, and bushings [1]) onto the alignment arms [2] and the base casting [4].
Note: The side of the turnbuckle with the two bushings should be installed on the side of the pallet pool.

Evenly tighten the turnbuckles until the alignment arms are almost tight against the alignment bars, STOP once the alignment bars are approximately 1-2" away from the alignment blocks. 

Adjust the height of the pallet pool so that the height of the alignment bars are to the center of the blocks before tightening the turnbuckles flush to the alignment blocks. Raise or lower the pallet pool leveling screws evenly when doing so. During this time, lower or raise the pallet pool assembly so the pallet pool coolant drip pan [5] goes on top of the EC-400 coolant pan.
 NOTE: Be sure the drip edge of the EC-400 goes over the pallet pool sheet-metal.

Continue to evenly tighten the turnbuckles until the alignment arms are tight against the alignment blocks.

Once the alignment bars and blocks are evenly flush to each other, loosen the turn buckles 2 rotations.

Pallet Pool Coolant Drip Pan

To prevent coolant from running out of the machine apply sealant around the coolant drip pan.

Once both alignment arms are fully mated with the casting, loosen the turnbuckles about two turns.

Lifting Decal

The following decal is placed on the machine for safely moving the machine.

Turn [OFF] the main circuit breaker and wait until the Vector Drive High-Voltage light turns off.

Remove the operator side access panels [1].
Route the pallet pool cables [2] as shown in the illustration. The pallet pool work lights are routed among these cables. 

Connect the PR motor encoder cable to Main Control PCB channel 15 [4].

Connect the PS motor encoder cable to Main Control PCB channel 16 [3].

Connect the PR motor power cable to the amplifier labeled PR [5]. Install the ferrite filter bead on the motor power cable and secure the motor power cables using the 3/8" ID STEEL CLAMP to the bracket.

Connect the PS motor power cable to the amplifier labeled PS [6]. Install the ferrite filter bead on the motor power cable and secure the motor power cables using the 3/8" ID STEEL CLAMP to the bracket.

Important: Green ground PR & PS motor cables share the same terminal connection hole on the bracket. 

Important: This step only pertains to machines purchased before 11/10/2023 who ordered a Pallet Pool Ready Kit (P/N 93-1001011)

Important: If the machine was built before 11/10/2023, the aux panel cable (P/N 33-0528) will be found in the 93-3946 EC-400 E-STOP REPLACEMENT KIT and will need to be routed following the cables in the image. 

Install E-Stop [1] using (4) FHCS 4-40x1/4 and route the cables through the grommet [2].

Remove the access panel.

Find the existing cable aux front panel cable (P/N 33-0424) or (P/N 33-1424) that was disconnected from P12 and Probe Up and Probe Down on the PC Bracket when removing E-Stop. This is found in step 1 from the Pallet Pool Ready Pre-Installation. This cable should be removed and replaced by aux front panel cable (P/N 33-0528).

Route the aux front panel cable (P/N 33-0528) [3] so that it is connected to P12 [4] to the I/O PCB and the two male pin connectors to the Pallet Changer Bracket [5] Probe Up and Probe Down.
Note: Probe Up and Probe Down male pin connectors are placed in the PC Bracket and will later be used if the WIPS option is installed.

Route the aux front panel cable (P/N 33-0424A) [6] from the Pallet Pool E-Stop and connect it to the pig tail of cable (P/N 33-0528) [6].

Connect pallet alarm cable [7] (P/N 33-0482) to the I/O PCB at P50 [8].

Remove jumper (P/N 33-0527) [3] from I/O PCB at P14 and connect the pallet pool status cable (P/N 33-0427) [9] I/O PCB at P14 [10].

Make sure all the Pallet Pool status bracket connectors are plugged into the correct location.

The pallet pool work lights are connected to the LVPS on the bottom left corner of the cabinet to the proper terminals labeled on the cable.

Find the aux front panel cable (P/N 33-0528) inside the electrical cabinet and remove the jumper (P/N 33-0531) [1].

Route the aux front panel cable (P/N 33-0424A) [2] from the Pallet Pool and connect it to the pig tail of cable (P/N 33-0528).

Remove jumper (P/N 33-0527) [3] from I/O PCB at P14. Install the pallet pool status cable (P/N 33-0427) to the pallet pool bracket and route the cable and connect it to the I/O PCB at P14 [4].

Connect pallet alarm cable [5] (P/N 33-0482) to the I/O PCB at P50.
Make sure all the Pallet Pool status bracket connectors are plugged into the correct location.

NOTE: Store the Pallet Pool jumpers in a safe location, these will be used by the service personnel to move or service the machine.

The following procedure will show you how to connect the hydraulic hoses to the EC-400.

Remove the EC-400 hydraulic power unit access panel [1].

Locate the Hydraulic Power Unit (HPU) [2] pallet pool manifold. Remove the plugs.

The hydraulic hoses are labeled with colored zip ties. You will need to look at the hydraulic cylinder and connect them as shown in the illustration. Connect the clamp hydraulic hose [3] with the white ziptie to the HPU manifold labeled “CLAMP”.

Connect the Unclamp hydraulic hose [4] with the purple ziptie to the HPU manifold labeled “UNCLAMP/BRAKE ENGAGE”.

Power [ON] the machine and [RESET] all the alarms. This will turn on the HPU. Make sure there is no hydraulic fluid leaks around the hose fittings. If alarms occur after [RESET], power off the machine and verify the electrical connections.

It is possible to enter a condition where the shelves in the pallet scheduling page are not assigned [1]. This will not allow the PR and PS to zero return or recover the machine. 

This section will explain how to assign the missing shelves, if your machine is not in this condition please skip to the next section. 

First, press [CURRENT COMMANDS] and navigate to the Pallet Schedule Table tab.

NOTE: The VF-2SSYT 3 Station Pallet Pool was used to create the images, but the same process will apply for all pallet pool machines. 

Press [EMERGENCY STOP] [1] and highlight the shelf tab on pallet number one.

With [EMERGENCY STOP] pressed, type the letter A and press [ENTER]. This will assign shelf A to pallet number 1 [2].

Repeat the previous step for the remaining pallet numbers in alphabetical number [1].

 NOTE: The shelves can be re-assigned at any point however the user chooses by repeating the same process (e.g. pallet number 3 can be assigned shelf B).

Insert the Service Key USB and put the machine in Service Mode.

Make sure there are no obstructions inside the machine or inside the pallet pool area. Pull out all the [E-STOPS] and [RESET] the alarms.

Type [PS], press [ZERO RETURN] and press [SINGLE]. The machine will zero return PS-axis.

Type [PR], press [ZERO RETURN], and press [SINGLE]. The machine will zero return PR-axis.

Press [ZERO RETURN] and then press [ALL]. The machine will zero return all the axes.

Once all the axes are zero returned press [RECOVER]. A pop-up box will appear, select [2] for Pallet Changer Recovery.

The Pallet Changer Recovery screen shows the Pallet Pool Status. Make sure the Pallet Lifter is Down [1]. If not press [ALTER] to bring the Pallet Lifter down.

Press [G] and then the [DELETE] button. This will rotate the pallet lifter towards station G.

Set Pallet Gap

With pallet on the H-Frame and the Pallet Pool in the down position, extend the RAM and Forks under the pallet.  Use the Gap Gauge [1] 25-14354 to set the height of the Pallet Pool.  The Distance between the pins on the forks and the bottom of the Pallet surface should be the thickness of the Gap Gauge (.054") at all 4 pins.

Adjust the pallet pool slider by jogging the PS or PR axis so the forks align correctly underneath the pallet.  

NOTE: Machines built after October 2019 have four locating dowel pins on the Pallet Pool fork. The dowel pins must align with the locating holes underneath the pallet. 

Pallet Pool Side to Side Leveling

Place a precision level [1] parallel to the X-Axis on top of the load station pallet and record the machine level readings.

Loosen the left rear leveling screw [2] until it does not contact the pad.
 NOTE: The pallet pool may drift a small amount from the machine as you level it. Make sure the turnbuckles are loose about two turns to prevent the pallet pool assembly from binding.

Press [ALTER] to raise the pallet lifter.

Use the front leveling screws [3] to raise or lower the pallet pool until you match the side to side level of the pallet pool to the machine. Press [ALTER] to lower and raise the pallet lifter and make sure the bubble on the level remains the same.

Place the precision level [1] parallel to the Z-axis and record the machine level readings. Press [ALTER] to raise the pallet lifter and adjust the rear right screw until the bubble matches the level.

Use the rear right leveling screw [2] to raise or lower the pallet pool until you match the front to back level of the pallet pool to the machine. Press [ALTER] to lower and raise the pallet lifter and make sure the bubble on the level remains the same.

Once the level matches, lower the rear left leveling screw [3] until contacts the pad.

During the leveling process, the alignment arms may have shifted from the casting. Tighten the right and left turnbuckles until the alignment arms are fully mated with the casting.

Lower the supporting feet until they touch the ground.

Go to Factory Settings 2136 [:] Shelf G Slide Offset and 2146 [:] Shelf G Rotary Offset, and make sure the values match the PS and PR axis position, if not update the values

Press the [INSERT] button to return the slide home.

Press the letter [A] and then [DELETE] button. This will rotate the pallet lifter to the A station.

Select the pallet slide axis and use the RJH slowly to jog the PS axis towards the A station.

Verify that the pallet pool will pick up and drop off the pallet at the A station.

Test the pick-up / drop-off operation on the remaining stations by using the pallet pool recovery functions. Mechanically adjust each station tray by loosening the bolts and moving the tray to align to the pallet if necessary.

Install the anchors.

Install the Pallet Pool guard panels.

Set factory setting 2056 [:] HYDRAULIC POWER UNIT TYPE to 2 (On Demand).