2.5 Mill - APL (Side Load)

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
• Remote Jog Handle - Touch
• I/O board updated to 34-349xB or later
• NGC/Software Version 100.24.000.1110 or higher
• 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.

Use a pallet jack to move the APL into the proper position. Adjust the APL to the measurements as shown:

Measure distances from the end of the AU axis arm to the machine:

• Measure 0.75" (19 mm) from the end of the arm to the sheet metal above the auto window  [1]
• Measure 11" (280 mm) from the side of the arm to the side of the side of the auto-window sheet metal [2]

Secure the sheet metal panels between the back of the APL and the back of the machine. Bolt one panel to the APL [1] and use magnets to attach the other panel to the machine [3]. Use bolts to secure the panels together [2]. 

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]. After leveling base, check that all four leveling screws contact 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 bottom of the VMC electrical control cabinet [1]. 

Feed all wires from conduit into the control cabinet except for the pneumatic line.

Verify that the push-connect fitting on the side of the APL manifold is connected securely to the pneumatic line [1]. 

Route the other end of pneumatic line through the bottom of the CALM cabinet [2]. 

Note: To prevent kinking, ensure that there are no hard bends in the hose.

Connect the other end of the hose to the CALM manifold to the air supply port labeled 'APL/Robot air supply port' [1] using the appropriate adaptor fitting. Reference the Air-Lubrication System decal on the door of the CALM cabinet. 

• 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 receiver end of the light curtain to the left side of the controller using the provided self-tapping 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 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 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. 

•  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 runout 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