Last updated: 07/12/2019

Haas Automatic Parts Loader - Lathe - Installation


AD0448

Introduction

1

This document explains how to assemble and install the Haas Automatic Parts Loader (APL) for a Lathe.

NOTE: Before installing the APL make sure that the lathe is leveled and the distance from the floor to the casting is 3 inches.

Assemble the APL

1

Remove the table shipping brackets [1] on both sides of the APL table.

2

Attach the left and the right pillars [1] to the APL base using BHCS [2].

NOTE: Make sure that the flanges [3] on top of both pillars are facing forward.

3

Use the provided lifting brackets [1] to lift the AU/AW axes assembly [2] with the forklift or hoist.

Mount the AU/AW axes assembly to the flanges [3] on top of the pillars using sixteen SHCS [4] with the T-nuts. 

NOTE: Make sure that the tab on the cable tray [5] is inserted into the pillar to protect the cables from the sharp edges.

Make sure that the left side of the extrusion beam is flush with the side of the flange [6].

NOTE: Leave the lifting brackets on for the leveling process.

                          

4

Install the sheet metal panels as shown in the pictures.

5

Route the AU and AW axes cables with the air lines down through the pillar [1].

Connect the air lines to the solenoids in accordance with the decal.

Install the provided conduit tube over the air lines to protect it from damage.

Connect each solenoid cable to the corresponding connection on the manifold bracket under the solenoids.

6

ST-10/15.

Brake loose the bolts [1] that secure the right side hard stop block [2].

Position the hard stop block [2] 0.75 inches (19mm) away from the edge of the rack gear assembly [3].

Torque the hard stop mounting bolts to 25 ft-lbs (33.9 Nm).

Prepare The Lathe

1

Remove the auto door cover [4].

2

Use the provided drill guide [1] to drill the mounting holes for the DOOR FULLY OPEN status switch.

Align the right most hole on top of the drill guide that is marked with one slot [2] with the autodoor cover mounting hole to the left of the auto door motor and secure it with the BHCS.

ST-10/15:

  • Drill the two Ø 3/16" (4.7mm) mounting holes through the drill guide holes that are marked with one slots [3].

ST-20/25:

  • Drill the two Ø 3/16" (4.7mm) mounting holes through the drill guide holes that are marked with the slots on both sides [4].

Using the provided self tapping screws, install the DOOR FULLY OPEN switch assembly [5] and the DOOR FULLY OPEN trip flag [6].

3

ST-10/15:

  • Align the right most drill guide hole [1] that marked with three slots next to it with the existing pemnut on top of the roof panel and secure it with the BHCS.
  • Drill the four Ø 11/32" (8.7mm) mounting holes through the drill guide holes [2] that are also marked with the three slots.

ST-20/25:

  • Place the drill guide up against the cable cover [3] flange as shown in the picture.
  • Drill the four Ø 11/32" (8.7mm) mounting holes through the drill guide holes [4] that are marked with the three slots.

Install the support pillar [6] onto the machine (with the beam mounting flange [5] facing the front of the machine) using the BHCS and the nuts on the underside of the roof panel. 

 

4

Place the light curtain mount [1] flush with the right door opening edge [2].

Mark and drill seven Ø 3/16" (4.7mm) mounting holes [3].

Attach the light curtain mount to the machine using the self tapping screws. 

NOTE: You can route the light curtain cable at this point to avoid reinstalling the self tapping screws. Refer to the electrical installation section below. 

5

Remove the tooling tray bracket that is attached to the bottom of the pendant.

ST-10/15:

  • Place the drill guide [1] against the front panel, 8 inches (203mm) away from the right corner of the enclosure.

ST-20/25:

  • Place the drill guide [1] against the front panel, 17.75 inches (450mm) away from the right corner of the enclosure.

Drill the four Ø 3/16" (4.7mm) mounting holes through the drill guide holes [2] that are marked with two slots.

Remove the drill guide and attach the tooling tray [3] to the front panel using four self tapping screws [4].  

6

Make sure that the front edge of the APL and the front of the machine are parallel. [1]

Use the provided measurements between spindle motor cover [2] and the right APL pillar [3] to place the APL on the left side of the machine.

NOTE: Dimensions are in inches.

7

Turn the air supply OFF.

Inside the CALM cabinet, remove the NPT plug [1] from one of the CALM manifold ports and install the push to connect fitting.

Route the air line from the APL solenoid rack to the CALM cabinet and connect it to the fitting you installed earlier.

Enable the APL

1

IMPORTANT:  Perform this step before connecting the APL to the machine. 

  • E-STOP the machine.
  • Change parameter 2191 LIGHT CURTAIN TYPE to 1 in the Factory Settings. 
  • Change parameter 2194 ENABLE FRONT DOOR FULLY OPEN SWITCH TO 1.
  • Set the setting 372 PARTS LOADER TYPE to TYPE 1.
  • Set the setting 375 APL GRIPPER TYPE to "APL GRIPPER".
  • Set the Setting 376 LIGHT CURTAIN ENABLE to ON.
  • Keep the E-STOP depressed and power the machine OFF.

NOTE: The control needs to be in service mode to access the Factory Settings menu.

Now you can connect the APL to the machine.

Electrical Installation

1

Install the AU, AV and AW axes amplifiers in the respect with the decal labels on the amplifier fan bracket .

NOTE: AU axis amplifier [1] shown on the picture.

2

NOTE: Skip this step if the machine has Live Tooling, Y axis or the Sub-Spindle option. Machines that were built with the  Live Tooling, Y axis and the Sub-Spindle  will have an additional ammplifier bank to the left of the Vector Drive and  will come with the dual lead DC BUS cable installed from the factory.

If the machine was built with the single lead DC buss cable (33-04901B) you will need to replace it with the dual lead DC BUS cable (33-0052C) provided with the kit.

Before working on this cable, power the machine OFF and allow the Vector Drive capacitors to discharge until the red light [1] on the Vector Drive is OFF.

Remove the old cable that supplies DC voltage from the Vector Drive terminals 2 and 3 to the alplifiers.

Install the new dual lead DC BUS cable (33-0052C) as follows:

  • Connect the end with the ring terminals [2] to the terminal 2 and 3 on the Vector Drive:
    • The white lead that is labeled TB2 "+" to the terminal 2
    • The black lead that is labeled TB3 "-" to the terminal 3
  • Route the longer cable through the fan bracket under the amplifiers and connect it to the "+" H.V. and the "-" H.V. terminals on the left most servo amplifier [3] as labeled.
  • Connect the remaining cable to the "+" H.V. and the "-" H.V. terminals on the right most servo amplifier [4] as labeled.

3

Route the AU, AV and AW axes power cables through the opening on the bottom of the control cabinet.

Connect the power cable leads to the high voltage terminals:

  • red to RED [1]
  • white to WHT [2]
  • black to BLK [3]

 NOTE: The AV axis power cable leads are labeled PH-A, PH-B and PH-C due to a different color scheme. Connect as follows:

  • PH-A to RED
  • PH-B to WHT
  • PH-C to BLK

Connect the ground wire [4] to the bracket for the amplifier fan.

Find the high-voltage terminals [5] on the nearest amplifier.

Find the high-voltage terminals [7] on the amplifier.

Install the jumpers [6] from the installation kit between these terminals.

Connect the black wire to -H.V. Connect the red wire to +H.V.

4

Connect the current command cables to the connector near the top of the each amplifier [1].

Connect the other ends of the cables to the AMPLIFIER COMMAND outputs on the NGC PCB [2] as follows:

  • AU axis to the output 13.
  • AV axis to the output 15.
  • AW axis to the output 16.

Route the U, V and W axes encoder cables through the opening on the bottom of the control cabinet and connect them to the ENCODER inputs on the NGC PCB [3] as follows:

  • AU axis to the input 13.
  • AV axis to the input 15.
  • AW axis to the input 16.

Route the AW axis brake cable into the control cabinet and connect it to P3/4/5 on the SIO.

5

Connect the DOOR FULLY OPEN switch as labeled:

  • COM to the top terminal [1].
  • NO to the middle terminal [2].

Route the cable into the control cabinet as shown on the picture.

 NOTE: Make sure to install the provided magnetic clip [3] and cable clamps [4] to keep the cable clear of the moving autodoor motor [5].

Connect the other end of the cable to the SIO P27 RRI Door Open input. 

Install the autodoor cover.

6

Assemble the light curtain mounting brackets as shown on the picture [1].

 NOTE: The light curtain kit contains the transmitter and the receiver. You can identify these by the sticker on the side of the housing. It is labeled "RECEIVER" [2] and "TRANSMITTER" [3]. 

When installing the light curtains make sure that the end with the cable connection is on the bottom.

Install the light curtain receiver [4] on the lathe side.

Install the light curtain transmitter [5] on the APL side.

Make sure that the transmitter and the receiver are pointed at each other before tightening the mounting bolts.

Route the Transmitter cable [6] and the Receiver [7] cable into the control cabinet as shown.

 

7

Use the provided velcro patch to attach the 24VDC power supply to the right wall inside the control cabinet.

Interconnect the light curtain cables as shown on the diagram.

8

Install the SMTC PCB [1] onto the SIO door using the standoffs [2] and the screws [3].

Interconnect the SMTC PCB cables as shown on the diagram.

Remove Shipping Brackets

1

Make sure that the air supply is turned OFF and the pressure gauge in the CALM cabinet reads zero.

Remove the shipping brackets [1] from the rotator.

Reinstall the bolts.

 NOTE: The gripper assembly will rotate in position as soon as the air supply is turned back ON.

2

Remove the AU axis shipping brackets [1]  that are located on the back of the AW axis carriage.

Remove the AU axis servo motor cover to gain access to the W axis shipping brackets [3].

Remove the AW axis shipping brackets [3].

Reinstall the AU axis servo motor cover [2].

Level the APL

1

level the APL base with the bubble level on top of the APL table.

Use the leveling screws at the bottom of the APL base to level the APL front to back [1] and side to side [2].

When done with leveling make sure that all four leveling scerws make contact with the floor.

2

Place the bubble level [1] on top of the horizontal beam.

Loosen the bolts that secure the beam to the pillars.

Lift or lower the right side [2] of the horizontal beam until it leveled.

Tighten the bolts that secure the horizontal beam to the pillars.

Remove the lifting brackets. 

First Power-UP

1

Power Up the machine with the E-STOP depressed.

Before releasing the E-STOP, navigate to the CURRENT COMMANDS screen and make sure that the AUTOMATIC PART LOADER tab is visible. 

Navigate to the ALARMS AND MESSAGES and make sure that there is no active alarms associated with the AU, AV and AW axes.

 NOTE:  If the APL left disabled and the E-STOP released the AW axis will fall.

Release the E-STOP and zero return the machine.

Set the GRID offsets for the AU, AV and the AW axes. Refer to the Axis Grid Offset - NGC.

Align the Gripper to the Spindle

1

With an indicator base clamped to the gripper [1] Jog the AU axis and measure if the dowel pins [2] on the APL table is inline with the AU axis motion. NTE 0.02" (0.5mm).

2

Clamp the piece of round stock [1] in the APL gripper.

Jog AU and AW axes to place the gripper with the round stock in front of the spindle chuck [2].

Move the APL base [3] front to back with a pallet jack until the piece of round stock [1] align with the spindle.

 NOTE: When moving the APL base, make sure that the APL beam support [4] pillar moves the same amount and the front of the APL stays parallel to the front of the machine.

Once the APL grippers aligned with the spindle, tighten the bolts that secure the APL beam support to the roof panel [4].

3

Fine front-to-back adjustment of the gripper.

Remove the bolts that keep the rotator extrusion cover [1] in place.

Remove the rotator extrusion cover.

Break loose two bolts [2] that secure the rotator [3] to the bracket. This will allow you to move the gripper assembly front to back.

Once the gripper assembly is in desired position, torque the two mounting bolts [2] to 60 ft-lbs (81 Nm) and install the rotator extrusion cover.

Torque the four SHCS [4] to 20 ft-lbs (27 Nm) 

 

4

Set rotator limits. 

The rotator clockwise (CW) and counterclockwise (CCW) limits are set with the stop screws on top of the rotator unit. There is a stops crew for the CW limit [1] and the CCW limit [2]. 

To adjust the CW limit:

  • Break loose the jam nut [3].
  • Rotate the gripper assembly clockwise until it stops against the stop screw.
  • Turn the CW stop screw in or out to manipulate the CW limit position.
  • Once the rotator is in desired CW limit position, hold the CW stop screw with the wrench and tigten the jam nut [3].

Use the CCW stop screw [2] to set the CCW limit.

Anchoring Instructions

1

Use a pen [1] to put a mark on the floor at the location of each foot.

 Note: Turn the feet to the sides of the APL to avoid a tripping hazard.

Drill [2]  Ø 0.50" (13 mm) hole in each mark.

Drill the hole to a depth of 2.0" (51 mm).

2

Put the foot [3] over the hole [4].

Put an anchor [2] into the hole.

Use a hammer [1] to tap the anchor.

Tap the anchor until it is at the bottom of the hole.

Put a washer [6] and a nut [5] on the bolt.

Torque each nut to 55 ft-lb (75 Nm).