2.4 Compact APL

This procedure outlines how to install the Compact APL on the following machines:

• VF-2/2SS/2YT/2SSYT
• VM-2
• DM-1/2
• DT-1/2
• UMC-350HD
• SMM/MM Reboot

Machine Requirements:

• Software Version 100.22.000.2000 or higher
• Machine must be ordered with the Auto Window Option.
• REMOTE JOG HANDLE - XL 93-1000610 REMOTE JOG HANDLE TOUCH LCD (RJH-XL)
• I/O board updated to 34-349xB or later
• I/O PCB HINGE DOOR. 93-1000297 I/O DOOR ASSY HINGED

Note: Workholding is not included with the C-APL. It must be ordered as an additional option.

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

The cylinder for the Auto Window will need to be raised from the shipping position.

Remove the cover [1] and its hardware [2] to expose the air cylinder [4] of the automatic window on the load station and raise the air cylinder [4] so that the brackets [3] and air cylinder are attached as shown.

 Note: Do this before placing the machine and compact APL together for easier access.

Use this step for C-APL machine with the style legs shown.

The front legs should be attached to the C-APL as shown in [1].

The back legs shown be attached to the C-APL as shown in [2].

Use this step for C-APL machine with the style legs shown.

For DT/DM & UMC-350HD Machines:

The legs of the Compact APL should look like the top image [1]. Make sure the bolts [2] on the all legs are in the bottom four (4) holes.

For VF/VM/SMM/MM Machines:

The legs of the Compact APL should look like the top image [2]. Make sure the bolts [5] on the all legs are in the bottom four (4) holes.

Use this step for C-APL machine with the style legs shown.

Attach the anchoring brackets to the Compact APL as shown.

 Note: The images show how the anchoring brackets will be attached on DM/DT & UMC-350HD machines, the bolts on the brackets will need to be shifted up for Compact APL's on VF & VM machines.

Use this step for C-APL machine with the style legs shown.

For UMC-350HD Machines:
For a standard 100mm Haas pneumatic vise, the bolts that control the height of the legs of the Compact APL should match the layout seen in the left image [1]. The front legs should have five (5) open holes above the bolts like the top of image [1] and the back legs should have six (6) open holes above the bolts like the bottom of image [1]. Refer to the table in the Level the C-APL section below for recommended heights of the C-APL.

For DM/DT Machines:
For a standard 100mm Haas pneumatic vise, the bolts that control the height of the legs of the Compact APL should match the layout seen in the middle image [2]. The front legs should have three (3) open holes above the bolts like the top of image [2] and the back legs should have four (4) open holes above the bolts like the bottom of image [2]. Refer to the table in the Level the C-APL section below for recommended heights of the C-APL.

For VF/VM/SMM/MM Machines:
For a standard 100mm Haas pneumatic vise, the bolts that control the height of the legs of the Compact APL should match the layout seen in the right image [3]. The front legs should have one (1) open hole above the bolts like the top of image [3] and the back legs should have two (2) open holes above the bolts like the bottom of image [3]. Refer to the table in the Level the C-APL section below for recommended heights of the C-APL

Use this step for C-APL machine with the style legs shown.

Attach the anchoring brackets to the Compact APL as shown.

Use this step if the C-APL is being installed on a UMC-350/350HD

Line up the Compact APL to the machine using the locating plate as shown.  The locating plate should be placed 3 inches [1] to the left of the window as shown.

Use this step if the C-APL is being installed on a DT/DM-1/2

Line up the Compact APL to the machine using the locating plate as shown.  The locating plate should be placed 1/4 inch [1] to the left of the window.

Use this step if the C-APL is being installed on a VF/VM-2

Line up the Compact APL to the machine using the locating plate as shown.  The locating plate should be placed 5 inches [1] to the right of the window edge.

Use this step if the C-APL is being installed on a SMM/MM

Line up the Compact APL to the machine using the locating plate [1] as shown.  The locating plate [1] should be lined up to the left of the window [2] as shown.

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 [2].

Route the air line from the C-APL solenoid rack to the CALM cabinet and connect it to the fitting

Adjust the leveling feet so that the c-apl table is the same height as top of the vise jaws [1]. Use the table below for height recommendations.

Note: Make sure the C-APL is not raised too high or it may crash into the top of the auto window.

Then use a bubble level to level the Compact APL from side-to-side [2] and front-to-back [3].

Once aligned and leveled, anchor the Compact APL. See the Anchoring Instructions (Drop-In Expansion) for anchoring information.

Remove the shipping brackets that are shown in red in the image.

Install the AU and AV 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 and AV 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

Route the U and V 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

Install New Bracket in Electrical Cabinet

Machines with a Wye/Delta [1] in the electrical cabinet will need to remove it before installing the new bracket [2] using the 10-32 screws [3] in the kit.

At this point if applicable, re-install the Wye/Delta [1] and then install the C-APL power supply and CAN board assembly [2] as shown next to the vector drive.

If the machine does not have an I/O hinge door already installed, install it at this time.

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

Remove the Jumper at P12 on the I/O board.

Connect the rotators cable 33-1176 [1] to P12 on the I/O board.

Connect the solenoids cable 33-1172 [2] to P3 on the SMTC board.

Connect cable 33-3333 [3] from P4 on the SMTC boards to P7 on the PSUP Board.

Connect cable 33-1518 [4] from P1 on the SMTC board to P15 on the I/O board.

Connect cable 33-1760A [5] from P2 on the SMTC board to P18 on the PSUP board.

Connect cable 33-1171 [6] from P5 on the PSUP to the C-APL power supply.

Connect the C-APL motor cable 33-1177 [7] to J6 of the C-APL CAN board.

Connect cable 33-5308 [8] from J1 on the C-APL CAN board to J2 on the I/O board.

Note: If the machine is powered by a single phase input, cable 33-7180 is needed to connect power to P5/P6/P7 on the PSUP board from P3 on the PSUP board.

Note: If this machine is equipped with other CAN systems, visit the CAN Systems Troubleshooting Guide for where the Compact APL falls in the CAN sequence.

Refer to this step if your machine has a light curtain or area scanner.

Install the relay bracket [1] to the LVPS bracket.

Install the safety relay [2] onto its bracket [1] as shown.

Important: If the machine is equiped with an Autodoor, the power supply and CAN board assembly will need to be removed to install the safety relay bracket.

Refer to this step if your machine has a light curtain or area scanner.

Connect the Area Scanner or Light Curtain Receiver Input cable to the safety relay connector [9].

If using the Light Curtain, connect the Light Curtain Emitter Input to the safety relay connector [10].

Refer to this step if your machine has a fence and uses an interlock.

The fence interlock cable 33-0734 [9] should be connected to P1 and P9 on the I/O board.

Light Curtain:

If the machine came equipped with the light curtain option, the light curtain needs to be installed. Follow the procedure below for installation: 

Robot Fence:

If the machine came equipped with the fence option, the robot fence and door interlock assembly need to be installed to machine. Follow the procedure below for installation:

Area Scanner:

If the machine came equipped with the area scanner option, the area scanner needs to be installed and configured to the space. Follow the procedure below for installation: 

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 and AV axes

Release the E-STOP and zero return the machine

Set Grid Offsets for AU and AV axes:

Zero Return AU and AV

Go to the Diagnostics Tab> Parameters > Factory Settings

• Press AU + F4
• Press AV + F4

Jog to a safe location

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

Change parameter 9015.001 CAN NODE 15 ENABLE to FALSE.