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

Machine Requirements:

• NGC/Software Version 100.19.000.1100 or greater
• RJH-T
• Built after 1/1/19 or I/O board updated
• I/O PCB Hinge Door. 93-1000297 I/O DOOR ASSY HINGED
• Check the Layout Drawing document for Machine Specifications

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

Follow the wiring diagram  for the electrical components all of the wiring will make its way through the box under the control cabinet and to the I/O board.

If the machine does not come with a I/O HINDGED DOOR you will need to install it, follow the I/O HINGED DOOR PROCEDURE for instructions on how to install it.

A food pedal cable will also be routed from the front skirt [1] of the machine along the side skirt into the box under the control cabinet and connected to the I/O board as shown.

Please refer to the link to install the correct Workholding option.

Please refer to the link to install the correct Vise option.

• Use a pallet jack to move the APL [1] into the proper position.
• adjust APL to the measurements shown:
  • Measure distance of 0.5" (13mm) for the AU Axis of APL 
  • Measure distance of 1.25" (32mm)  for the AV Axis of APL

• Install the APL enclosure panel  to the electrical control cabinet.

• 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 and side to side [1]
• When done with leveling make sure that all four leveling scerws make contact with the floor
• Place the level on top of the horizontal beam [3]
• Loosen the bolts that secure the beam to the pillars
• Lift or lower the right side of the horizontal beam until it is leveled
• Tighten the bolts that secure the horizontal beam to the pillars
• Verify APL Arm Level [2]

• Remove the APL arm shipping bracket [1]

• Remove the table shipping brackets [1], [2]

• Remove the AW axes sheet metal shroud [2]
• Remove the AU and AW axes shipping brackets [1]

• Route the conduit from the apl to the UMC electrical control cabinet as shown.

• Inside this conduit are several wires and a pneumatic line from the APL manifold used to aupply air to the gripper solenoids
• Feed all wires from conduit into the control cabinet except for the pneumatic line.

• One end of the pneumatic line is connected to the APL manifold [1]
• The other end is routed through the manifold shown in the previous step but, instead of being fed into the electrical cabinet, is routed to the CALM cabinet [2]

• Verify the push-connect fitting on the side of the APL manifold is connected securely. 

• Connect the other end of the hose to the CALM manifold at the location shown using the appropriate adaptor fitting to do so.

• Bolt the transmitter end of the light curtain to the side of the APL enclosure using the provided hardware in the configuration shown.
• When installing the light curtains make sure that the end with the cable connection is on the bottom
• Run cable from bottom of transmitter under the pallet pool and through the wire conduit

• Bolt the reciever end of the light curtain to the left side of the controller using the provided hardware in the configuration shown.
• When installing the light curtains make sure that the end with the cable connection is on the bottom

• 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

 WARNING: Perform this step before connecting electrical APL components to the machine.

Note: The control needs to be in Service Mode to access the Factory Settings menu

• E-STOP the machine
• Change parameter 2191 LIGHT CURTAIN TYPE to LC_TYPE_1
• Set the setting 372 PARTS LOADER TYPE to TYPE 2 MILL APL
• Set the setting 375 APL GRIPPER TYPE to Dual Gripper
• Set the Setting 376 LIGHT CURTAIN ENABLE to ON
• Keep the E-STOP depressed and power the machine OFF

• 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

• 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

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

• 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 8
  • 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 8
  • 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

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.

If the machine has a Smart CAN auto door, plug cable 33-1518 into P15 on the SIO board. 

• 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

•  Note: APL's ship with the AW servo motor brake cable disconnected as a safety precaution.  This is to prevent the AW axis from dropping if the APL has not been enabled in the control.
  
• Connect the AW axis servo motor brake cable
• 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 are no active alarms associated with the AU, AV and AW axes
•  Warning:  If the APL is left disabled and the E-STOP is released the AW axis will fall
• Release the E-STOP and zero return the machine

• Set Grid Offsets for AU, AV, and AW axes:
• Zero Return AU, AV, and AW
• Go to the Diagnostics Tab> Parameters > Factory Settings
  • Press AU + F4
  • Press AV + F4
  • Press AW + F4

• Jog the C axis until vise is set to the position as shown
• Run indicator along entire length of 6" jaw until runnout is within tolerance (NTE +/- 0.001)
• Save this position under Factory Parameter 7.310 as your new C-Axis Pallet Offset. The C-Axis will rotate to this position for every part change.

• 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).

• 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)

 Warning: If you turn Setting 372 to None, the AW - axis will drop if not supported or disconnected. Do one of the following:

• Jog to a safe location
• Unplug all APL cables BERFORE releasing E-STOP
• Unplug AW brake BEFORE releasing E-STOP

To disable the APL to run the machine in stand-alone mode. Press [SETTING]. Change the following Settings:

• 372 Parts Loader Type to 0: None
• 376 Light Curtain Enabled to Off