Haas 96-0012 Service And Operation Manual
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Haas 96-0012 Service And Operation Manual

Haas 96-0012 Service And Operation Manual

Automatic pallet changer
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Haas Technical Publications
HAAS SERVICE AND OPERATOR MANUAL ARCHIVE
Automatic Pallet Changer Operators Manual 96-0012 RevC English June 2001
•
This content is for illustrative purposes.
•
Historic machine Service Manuals are posted here to provide information for Haas machine owners.
•
Publications are intended for use only with machines built at the time of original publication.
•
As machine designs change the content of these publications can become obsolete.
•
You should not do mechanical or electrical machine repairs or service procedures unless you are qualified
and knowledgeable about the processes.
•
Only authorized personnel with the proper training and certification should do many repair procedures.
WARNING: Some mechanical and electrical service procedures can be
extremely dangerous or life-threatening.
Know your skill level and abilities.
All information herein is provided as a courtesy for Haas machine owners
for reference and illustrative purposes only. Haas Automation cannot be held
responsible for repairs you perform. Only those services and repairs that are
provided by authorized Haas Factory Outlet distributors are guaranteed.
Only an authorized Haas Factory Outlet distributor should service or repair a
Haas machine that is protected by the original factory warranty. Servicing by
any other party automatically voids the factory warranty.
Manual_Archive_Cover_Page Rev A
June 6, 2013

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  • Page 1 Automatic Pallet Changer Operators Manual 96-0012 RevC English June 2001 • This content is for illustrative purposes. • Historic machine Service Manuals are posted here to provide information for Haas machine owners. • Publications are intended for use only with machines built at the time of original publication. •...
  • Page 2 Manual_Archive_Safety_Pages Rev A Haas Technical Publications June 6, 2013...

  • Page 3: Read Before Operating

    Manual_Archive_Safety_Pages Rev A Haas Technical Publications June 6, 2013 EFORE PERATING ACHINE ♦ Only authorized personnel should work on this machine. Untrained personnel present a hazard to themselves and the machine, and improper operation will void the warranty. ♦ Use appropriate eye and ear protection while operating the machine. ANSI approved impact safety goggles and OSHA approved ear protection are recommended to reduce the risks of sight damage and hearing loss. ♦ Do not operate the machine unless the doors are closed and the door interlocks are functioning properly. Rotating cut- ting tools can cause severe injury. When a program is running, the mill table and spindle head can move rapidly at any time in any direction. ♦ The Emergency Stop button is the large, circular red switch located on the Control Panel. Pressing the Emergency Stop button will instantly stop all motion of the machine, the servo motors, the tool changer, and the coolant pump. Use the Emergency Stop button only in emergencies to avoid crashing the machine. ♦ The electrical panel should be closed and the key and latches on the control cabinet should be secured at all times except during installation and service. At those times, only qualified electricians should have access to the panel. When the main circuit breaker is on, there is high voltage throughout the electrical panel (including the circuit boards and logic circuits) and some components operate at high temperatures. Therefore, extreme caution is required. Once the ma- chine is installed, the control cabinet must be locked and the key available only to qualified service personnel. ♦ Consult your local safety codes and regulations before operating the machine. Contact you dealer anytime safety is- sues need to be addressed. ♦ DO NOT modify or alter this equipment in any way. If modifications are necessary, all such requests must be handled by Haas Automation, Inc. Any modification or alteration of any Haas Milling or Turning Center could lead to personal injury and/or mechanical damage and will void your warranty. ♦ It is the shop owner’s responsibility to make sure that everyone who is involved in installing and operating the machine is thoroughly acquainted with the installation, operation, and safety instructions provided with the machine BEFORE they perform any actual work. The ultimate responsibility for safety rests with the shop owner and the individuals who...

  • Page 4: Modifications To The Machine

    Manual_Archive_Safety_Pages Rev A Haas Technical Publications June 6, 2013 ♦ Follow these guidelines while performing jobs on the machine: Normal operation - Keep the door closed and guards in place, while machine is operating. Part loading and unloading – An operator opens the door or guard, completes task, closes door or guard before press- ing cycle start (starting automatic motion). Tool loading or unloading – A machinist enters the machining area to load or unload tools. Exit the area completely before automatic movement is commanded (for example, next tool, ATC/Turret FWD/REV). Machining job set-up – Press emergency stop before adding or removing machine fixtures. Maintenance / Machine Cleaner– Press emergency stop or power off the machine before entering enclosure. Do not enter the machining area anytime the machine is in motion; severe injury or death may result. Unattended Operation Fully enclosed Haas CNC machines are designed to operate unattended; however, your machining process may not be safe to operate unmonitored. As it is the shop owner’s responsibility to set up the machines safely and use best practice machining techniques, it is also their responsibility to manage the progress of these methods. The machining process must be monitored to pre- vent damage if a hazardous condition occurs. For example, if there is the risk of fire due to the material machined, then an appropriate fire suppression system must be installed to reduce the risk of harm to personnel, equipment and the building. A suitable specialist must be contacted to install monitoring tools before machines are allowed to run unattended. It is especially important to select monitoring equipment that can immediately perform an appropriate action without human intervention to prevent an accident, should a problem be detected. MODIFICATIONS TO THE MACHINE DO NOT modify or alter this equipment in any way. If modifications are necessary, all such requests must be handled by Haas Automation, Inc. Any modification or alteration of any Haas machining center could lead to personal injury and/or mechanical damage and will void your warranty.

  • Page 5: Safety Decals

    Manual_Archive_Safety_Pages Rev A Haas Technical Publications June 6, 2013 SAFETY DECALS To help ensure that CNC tool dangers are quickly communicated and understood, hazard symbol decals are placed on Haas Machines in locations where hazards exist. If decals become damaged or worn, or if additional decals are needed to emphasize a particular safety point, contact your dealer or the Haas factory. Never alter or remove any safety decal or symbol. Each hazard is defined and explained on the general safety decal, located at the front of the machine. Particular loca- tions of hazards are marked with warning symbols. Review and understand the four parts of each safety warning, explained below, and familiarize yourself with the symbols on the following pages. NEVER OPERATE THIS MACHINE WITH THE DOORS OPEN...
  • Page 6 Manual_Archive_Safety_Pages Rev A Haas Technical Publications June 6, 2013 MILL WARNING DECALS...
  • Page 7 Manual_Archive_Safety_Pages Rev A Haas Technical Publications June 6, 2013 LATHE WARNING DECALS...
  • Page 8 Manual_Archive_Safety_Pages Rev A Haas Technical Publications June 6, 2013 OTHER SAFETY DECALS Other decals may be found on your machine, depending on the model and options installed:...
  • Page 9 Read this entire section before attempting to install or run the APC. Serious injury or damage to the machine could result from not following these procedures. NOTE: The machine will beep during a pallet change. This is an audible warning signal, and not an alarm. 96-0012 rev C...
  • Page 10 (3.51 cm) PALLET ENCLOSURE USEABLE WORK SPACE 58” 46” (147.32 cm) (116.84 cm) MILL TABLE (AT HOME POSITION) SIZE: VF-3 48" x 18", (121.92 cm x 45.72 cm) TRAVEL: VF-3 40" x 20", (101.60 cm x 50.80 cm) 96-0012 rev C...
  • Page 11 A u t o m a t i c P a l l e t C h a n g e r P a l l e t C h a n g e r June 2001 INTRODUCTION PERATOR’S ANUAL APC P ALLET LEARANCES 96-0012 rev C...

  • Page 12: Maintenance Schedule

    P a l l e t C h a n g e r June 2001 MAINTENANCE PERATOR’S ANUAL 2.0 MAINTENANCE SCHEDULE ERIODIC AINTENANCE INTERVAL MAINTENANCE PERFORMED DAILY Do not over grease WARNING: Excessive chip buildup will require more frequent chip clean-up. WEEKLY INTERVAL MAINTENANCE PERFORMED MONTHLY 96-0012 rev C...

  • Page 13: Tools Required

    P a l l e t C h a n g e r June 2001 INSTALLATION PERATOR’S ANUAL 3.0 INSTALLATION TOOLS REQUIRED: · · · · Included - · · Included - ENERAL EQUIREMENTS VF/APC F OOTPRINT VF 3/4 WITH APC FOOTPRINT 96-0012 rev C...
  • Page 14 3.2 R OUGH EVELING LIGNMENT Remove pallet shipping bolts and install 1/2”-13 plugs. Use Loctite. Visually check to verify that plugs do not extend into roller channels. Figure 2.1 Removal of Shipping Bolts 96-0012 rev C...
  • Page 15 These wipers should overhang any temporary storage position. 2. Important! 5th Axis Port Figure 2.2 Fifth Axis port on the side of the Figure 2.3 Air cylinder installation. VMC control cabinet NOTE: M14 will move the table slowly in case a pallet is present. 96-0012 rev C...
  • Page 16 P a l l e t C h a n g e r June 2001 INSTALLATION PERATOR’S ANUAL Figure 2.4 Gaps A and B should be equal. Figure 2.5 The APC lip should be centered in the VMC drip trough. Figure 2.6 Installing the APC brace (VF-3 shown). 96-0012 rev C...
  • Page 17 Figure 2.7 APC roller alignment setup. If the rollers are not parallel, the APC must be moved. NOTE: If the rollers are parallel, but are not aligned, the adjustments will be made later in the "Fine Tuning" section. evenly 96-0012 rev C...
  • Page 18 P a l l e t C h a n g e r June 2001 INSTALLATION PERATOR’S ANUAL Figure 2.8 APC operator's panel cover. Important! Remember to remove the adjustment tool when finished. Figure 2.9 Chain drive roller positioning. Figure 2.10 Chain position adjustment tool placement. 96-0012 rev C...
  • Page 19 1/2“ - 13 Eyebolts Pallet Drip Pan Wiper Clamp Rail Drive Leg Pawl Pallet Drive Leg Figure 2.11 Lifting eyebolt locations. Figure 2.12 Pallet placement. Figure 2.13 View of APC base showing friction block and hard stop. 96-0012 rev C...
  • Page 20 P a l l e t C h a n g e r June 2001 INSTALLATION PERATOR’S ANUAL WARNING! This will cause the automatic door to fall. Keep hands clear. Figure 2.14 APC air hose connection to VMC air/lube cross fitting. 96-0012 rev C...

  • Page 21: Fine Tuning

    # 506 # 507 NOTE: M14 will align the receiver with Pallet #1 (the pallet nearest the front of the VMC). M15 will align the receiver with Pallet #2 (the pallet nearest the rear of the VMC). 96-0012 rev C...
  • Page 22 VMC. See the Power Outage / E-Stop Recovery section of this manual. Under no circumstances attempt to operate the VMC until the pallet drive arm is disengaged from the pallet drive pin on the chain. Important! 96-0012 rev C...
  • Page 23 The machine will beep during a pallet change. This is an audible warning signal, and not an alarm. NOTE: Make sure to confirm the alignment at both pallet load positions. After confirmation the variables should be written down or saved to disk. 96-0012 rev C...

  • Page 24: Program Commands

    P a l l e t C h a n g e r June 2001 PROGRAMMING PERATOR’S ANUAL 4.0 PROGRAMMING 4.1 P ROGRAM OMMANDS These instructions are for hardcoded macro-programmed Automatic Pallet Changers. Figure 3.1 APC operator's control panel (top view). Important! 96-0012 rev C...

  • Page 25: Sample Programs

    ROGRAMS Example #1: Example #2: NOTE: M99 at the end of the program will cause continuous operation. M30 at the end of a program will cause the control to wait for the operator to press Cycle Start. 96-0012 rev C...

  • Page 26: Troubleshooting

    M17 - UNCLAMP PALLET AND OPEN AUTOMATIC DOOR (Used for machine installation only) M18 - CLAMP PALLET AND CLOSE AUTOMATIC DOOR (Used for machine installation only) M36 - HOLD UNTIL “PALLET READY” BUTTON IS PRESSED M50 - PERFORM PALLET CHANGE Prepare for Pallet Change: Read Switches: 96-0012 rev C...
  • Page 27 5.2 L IMIT WITCHES Door Open Switch - Receiver Clamp/Unclamp Proximity Sensor- Pallet Stop / Location Switches (2) Chain Stop / Location Switches (2) WARNING! Do not move the limit switches for any reason. 96-0012 rev C...
  • Page 28 P a l l e t C h a n g e r TROUBLESHOOTING June 2001 PERATOR’S ANUAL 5.3 R ECOVERY FROM OWER UTAGE OR Recovery from a power outage or an E-Stop initiated during a pallet change: 96-0012 rev C...
  • Page 29 Pallet Clamped switch. Pallet 2 is on the APC and engaging the Pallet Home Swtich under the control panel. Figure 2 Alignment Pin and Bushing alignment must be verified when manually positioning a pallet on the receiver. 96-0012 rev C...
  • Page 30 Press and hold the solenoid actuation buttons (small white buttons) to keep air pressure flowing to unclamp the receiver and hold the door open. If the buttons are released the door will close and the receiver will clamp. 96-0012 rev C...

  • Page 31: Alarms / Faults

    The following is a list of the alarms associated with the APC: NOTE: Machines with software version 10.02 or later will have corresponding Alarm numbers shown in parenthsis. Pallet Not Clamped (631) 1002 Unclamp Error (632) 1003 Clamp Error (633) 96-0012 rev C...
  • Page 32 Switch Missed Pal 1 (636) 1007 Switch Missed Pal 2 (637) 1008 Door Not Open (638) 1009 Door Not Closed (639) 1010 Missing Pallet @ Receiver (640) 1011 Unknown Chain Location (641) 1012 Incorrect Chain Location (642) 96-0012 rev C...

  • Page 33: Technical Reference

    Drilled holes in pallet should be less than 1" deep. Figure 6.1 Pallet bolt hole pattern and spacing. CAUTION! For pallet loads over 250 lbs, the load should be distributed evenly around the center of the pallet to avoid tipping the pallet during loading and unloading. 96-0012 rev C...

  • Page 34: Assembly Drawings

    P a l l e t C h a n g e r P a l l e t C h a n g e r ASSEMBLY DRAWINGS June 2001 PERATOR’S ANUAL 8.0 ASSEMBLY DRAWINGS APC Assembly 96-0012 rev C...
  • Page 35 A u t o m a t i c P a l l e t C h a n g e r P a l l e t C h a n g e r June 2001 ASSEMBLY DRAWINGS PERATOR’S ANUAL APC Assembly 96-0012 rev C...
  • Page 36 A u t o m a t i c P a l l e t C h a n g e r P a l l e t C h a n g e r June 2001 ASSEMBLY DRAWINGS PERATOR’S ANUAL APC Assembly 96-0012 rev C...

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