2.1 Mill - APL

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

Machine Requirements:

• VF-1/2 & VM-2 Built 4-1-2019 and later
• Haas Autodoor (See machine requirements for CAN Auto Door)
• Remote Jog Handle - Touch
• I/O board updated to 34-349xB or later
• I/O PCB HINGE DOOR. 93-1000297 I/O DOOR ASSY HINGED
• NGC/Software Version 100.19.000.1100 or greater
• SMTC 30 or 50 Pocket
• Check the Layout Drawing document for Machine Specifications

Note: The automatic vise is not included with the mill APL. It must be ordered as an additional option.

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

Complete the following on both sides of the door:

• Remove the autodoor motor cover [1]
• Remove the autodoor motor assembly [2]
• Install the new proximity switch bracket [3] to the existing proximity switch block [5]
• Install the door always open proximity switch [4] to the bracket [3]

• Install drill guide [2] for the door open flag [1]
• Drill and tap 2x 10-32 holes through the sheet metal of the door
  • Drill size: #21 or 5/32"
  • Tap 10-32 NF
• Remove the template and install the door open flag with 2x flat head cap screws
• Re-install the autodoor motor assembly, bracket, and cover
• Use provided shims to set the height between the proximity switch and the door open flag

• Move the Remote Jog Handle (RJH) to the opposite side of the control pendant

• Move the air gun hose mount [1] to the opposite side of the tool rack
• Drill holes in the tool rack for the 1/4"-20 screws
  • Use a  H (17/64") drill to make clearance holes 

• Bring the APL approximately 35 inches (89 centimeters) from the front of the machine - measure from the APL pillar to the seam between the sheet metal panels on the front of the machine
• Remove the back panel shipping bracket [1]
• Secure the back panel [2] to the support bracket [4]. Leave screws loose
• Maneuver the APL until you can attach panel [2] to [3]
• Tighten all screws

• 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

• 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 screws 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 [2] of the horizontal beam until it is leveled
• Tighten the bolts that secure the horizontal beam to the pillars

• 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]

• 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 amplifiers
• 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 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

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. 

Attach the APL E-Stop as shown and route the cable along the bottom so that it groups up with the other cables that route to the control cabinet.

Connect the APL E-Stop button wire to TB1 on the I/O Board.

Remove jumper from JP1 on the I/O PCB.

Change factory setting: 1278 [1278]: Robot Ready E-Stop Enabled to True

• Place the machine side light curtain mount flush with the bottom and side of the door opening as shown in the picture
• Mark off hole pattern
• Drill holes using a #14 drill (3/16")
• Install light curtain mount and self-tapping screws [1]

• Remove the tool tray plastic insert [1] to gain access to the screw to remove the tool tray
• Remove the tool tray [2]
• Place two screws into the bracket [3]
• Install 4x 40-1985 sheet metal screws [4] leave screws loose to aid with alignment of the APL. Tighten once APL is aligned.
• Re-install the tool tray in addition to the tool tray spacer included in the install kit

• Assemble the light curtain brackets [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 mill side
• Install the light curtain transmitter on the APL side on the bracket next to the pendant
• Make sure that the transmitter and the receiver are pointed at each other before tightening the mounting bolts

• Route the light curtain transmitter cable [1] using regular cable clamps and magnetic cable clamps under the sheet metal alongside the base of the APL, around the back of the APL, and up the cable pillar
• Include the cable into the main bundle [3] and route all cables around the autodoor cover and down the first cable channel across the top of the door
• Route the light curtain receiver cable [2] along the side of the door opening past the pendant
• Add this cable into the bundle and then route all of the cables through the second cable channel toward the back of the machine
• Use cable wrap around any exposed cables
  • Wrap the cables between the main APL cable channel and the autodoor motor cover
  • Wrap the cable between the second cable channel on the roof of the machine and the lube cabinet

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.

If plugs P5/6/7 are not available on the PSUP PCB. Remove a fan power cable from P5/6/7 and plug in 33-7180 CBL FAN ADAPTER TO DUAL FAN. Plug in the fan power cable and light curtain power cable into 33-7180.

• 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

• Mount an indicator base clamped to the gripper [1] 
• Jog the AU axis and measure the offset between the dowel pins [2] on the APL table to verify the table is in line with AU axis motion - NTE 0.060" (1.5mm).

• Jog the AU and AW axes to place the gripper [1] in front of the automatic vice [2]
• If necessary move the APL base [3]  front to back until the stock is aligned with the vice
• Note: Make sure the entire APL assembly stays perpendicular with machine when you move the base
  

• 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