3.1 UMC PP - 6 STATION

UMC PP - 6 Station Version 2 - Installation

Introduction

The following procedure will show you how to install a 6 station Pallet Pool on a the following machines:

  • UMC-1250/SS

The Next Generation software on the machine must be version 100.20.000.1110 or higher.

The Pallet Pool option is currently not field installable.

Important: To ensure that the Pallet Pool does not become mis-aligned, it is recommended that the machine and Pallet Pool be anchored. Refer to the following link: Anchoring Instructions.

The Pallet Pool option has a room for a total of 7 pallets that can be installed on a UMC-1250 with the 6 station Pallet Pool option.

The Pallet Pool has 2 servo axes. The PR axis rotates the Pallet Pool ram and the PS axis extends and retracts the Pallet Pool ram to load/unload the pallets.

The UMC-1250 must be level before the Pallet Pool can be installed. Refer to the installation procedures linked below:

  • UMC-1250 Installation

Push [POWER OFF].

Set the main circuit breaker to the OFF position.

Lock the main circuit breaker. Use an approved lock with an approved safety tag.

Caution: When you handle a PCB, you must wear an Electrostatic Discharge (ESD) strap.

To level the machine without the Pallet Pool connected to the machine, do the following: 

Make sure that there is a shorting block [1] installed on the top two pins of the P12 connector on the I/O PCB 

Make sure there is a jumper (P/N 33-0527) [2] connected to I/O PCB at P14.
 Note: These jumpers are needed to operate the machine without the Pallet Pool.

Disable the pallet pool, change setting 382 Disable Pallet Changer to Pallet Pool.


Note: The above step will disabled the Pallet Pool to allow you to zero return the machine so it can be leveled.

Leveling Screws Hardware

Note: The washers [1] and nuts [2] are installed during shipping and should be saved for installation and not be discarded.

Note: The washer orientation [3] is important.  The conical part of the washer should be against the casting,  see illustration.

Mating the Pallet Pool

   

1

Remove the loading station door blocking bolt [1].

Make sure to raise all of the pallet shelf supporting screws [2] before placing the pallet pool on the floor. 

2

Verify that the drip tray [1] is installed on the machine. Contact Haas service if it is not.

3

Remove the bolts [1] to remove the shipping brackets. There are two brackets, the first [2] that hold the forks to the loading station, and the bottom [3] that just holds the loading station. 

4

Install the alignment bars [1] onto the pallet pool base.

 NOTE: Use the CABCOOL as a height reference in relation to the pallet pool enclosure opening.

Move the pallet pool assembly so the alignment arms are 3 - 6” (76 - 152 mm) away from the alignment blocks [2]. 

Install the leveling pads under the pallet pool and lower the pallet pool. 

 NOTE: The image shown is for the UMC-500 and 16 station UMC pallet pool but the process is the same.

5

Use a long pallet jack or forklift to move the pallet pool close to the machine.

A decal has been placed on the rear of the machine to indicate where the pallet forks should lift the machine from.

NOTE: Have the pallet jack pick up the pallet pool from the opposite side of where the slide window would be.

6

Install the turnbuckles [3] with the provided hardware (SHCS, washer, and bushings [1]) onto the alignment arms [2] and the base casting [4].

NOTE: The side of the turnbuckle with the two bushings should be installed on the side of the pallet pool.

Evenly tighten the turnbuckles until the alignment arms are almost tight against the alignment bars, STOP once the alignment bars areapproximately 1-2" away from the alignment blocks.

Adjust the height of the pallet pool so that the height of the alignment bars are to the center of the blocks before tightening the turnbuckles flush to the alignment blocks. Raise or lower the pallet pool leveling screws evenly when doing so.

Continue to evenly tighten the turnbuckles until the alignment arms are tight against the alignment blocks.

Once the alignment bars and blocks are evenly flush to each other loosen up the turn buckles.

7

Install the HPU lift assist using the provided hardware.

The jam nut has been pre-adjusted so there is no need to adjust that any further. 

8

Turn [OFF] the main circuit breaker and wait until the Vector Drive High-Voltage light turns off.

 Note: The PR (Pallet Rotate) and PS (Pallet Slide) amps are already installed at the factory.

Knock out the pre-cut access panel [1].

Route the pallet pool cables [2] into the control cabinet as shown in the illustration.

Connect the PR motor encoder cable to Maincon PCB channel 15
Connect the PS motor encoder cable to Maincon PCB channel 16.

Connect the PR motor power cable to the amplifier labeled PR. Install the ferrite filter bead on the motor power cable.

Connect the PS motor power cable to the amplifier labeled PS. Install the ferrite filter bead on the motor power cable.

9

Connect the air gun hose [1] to the air line under the pallet pool [2]. 

Route the air hose from the pallet pool to line coming from the the lube cabinet [3].

Connect the air line from the pallet pool to the to the T-fitting [4] connecting the machine air gun line to the lube cabinet.

Follow the line from the lube cabinet [5] to help locate the T-fitting.

10

Connect the hydrualic lines to the bulkhead. The pallet clamp [1] is marked with a green zip tie and pallet unclamp [2] is marked with a red zip tie. The hydraulic lines should run through the conduit neatly.

NOTE: The bulkhead uses quick disconnects  for the hydraulic hoses. The clamp side has the male side quick disconnect [3] and the unclamp has the female side [4], this is to avoid switching the hoses.

Route the HPU oil level sensor cable 32-0423 from the HPU to the connector bracket [5].

NOTE: The image shows a machine without a 90 degree control cabinet, but the bulkhead will be attached to the bottom of the 90 degree control cabinet. 

11

Attach the lift and lower hoses from the HPU to the lift assist, these hoses are tee'd off and color coated.

The lower hose [1] will attach to the top fitting with the grey zip tie.

The lift hose [2] will attach to the lower fitting with the purple zip tie. 

12

Route the conduit [1] to the machine securing the conduit to the alignment arms [2] using the zip ties [3] included in the installation kit. 

13

Connect HPU UP/ DWN SOL [1] to P38.

Connect HPU THRML PROBE [2] to P46.

Connect HPU PALLET CLMP SOL  [3] to P35.

Connect HPU PRESSURE SNSR [4] to P48.

Remove the jumper connection from the P14 [5] connector on the I/O PCB.

Connect PP STATUS SWITCHES [6] to P14

Remove the shorting block from the P12 [7] connector on the I/O PCB

Connect PALLET CHNGR STATION [8] to P12

Connect PALLET ALRAM [9]  to P50.

Make sure all the Pallet Pool status bracket connectors are plugged into the correct location.

 NOTE: Store the Pallet Pool jumpers in a safe location, these will be used by the service personnel to move or service the machine.

14

Route the HPU PUMP PWR cable  to P1 on the TMD card located on the I/O PCB hinged door. 

The rest of the components in this image are already connected but this diagram can be used as reference. 

15

Set the main circuit breaker to the ON position.

Push [POWER ON].

Zero Return all the Axis'

Do the following to enable the pallet pool option.  

Important:  You will need to do this step if you perform a option 5 clean install option on a UMC with a pallet pool.

Set setting 382 Disable Pallet Changer to None.

Note: Machine may need to cycle power for pararmetes to display. 

Find the Haas Pallet Pool Parameters decal on the E-Stop on the Pallet Pool machine.  Write down the values.

Use the USB Service key to go into Service Mode.

Press [DIAGNOSTIC] Go to the PARAMETERS> Factory setting tab.

Set the following factory settings values:

  1. 2128 [:] Pallet Pool Type = HPU Assist
  2. 40.011 (HPU 1 Type ) = On Demand
  3. 15.019 [:] PR-Axis Invisible = False
  4. 16.019 [:] PS-Axis Invisible = False
  5. 15.004 [:] PR-Axis Disable = False
  6. 16.004 [16:3] PS-Axis Disabled = False
  7. Turn TMD card on
Set the Grid and TC offsets for PR and PS axis
 
  1. 15.078 PR-Axis Tool Change Offset = Use the decal value.
  2. 15.140 PR-Axis Grid Offset = Use the decal value.
  3. 16.078 PS-Axis Tool Change Offset = Use the decal value.
  4. 16.140 PS-Axis Grid Offset = Use the decal value.
  5. Zero Return after the grid offset is adjusted

 NOTE: If "No Pallet" message appears when selecting "Put away Load Station Pallet" and "Get highlighted Pallet", refer to the symptom table section in UMC/EC Pallet Pool - Troubleshooting Guide - NGC

Base Level Pallet Pool

1

Verify all outer supports legs are NOT touching the floor.

Make sure the pallet pool sit on 3 points, the leveling foot that is not touching the puck is the one closest to the machine control cabinet [1].

2

Move the ram to its home position if it is not already, place the bubble level on ram and rough level with respect to X & Y. 

NOTE: Rough level by adjusting the 3 leveling feet without adjusting the 4th in the air.

Assigning Missing Pallets on Scheduler

1

It is a possible to enter a condition where the shelves in the pallet scheduling page are not assigned [1]. This will not allow the PR and PS to zero return or recover the machine. 

This section will explain how to assign the missing shelves, if your machine is not in this condition please skip to the next section. 

First, press [CURRENT COMMANDS] and navigate to the Pallet Schedule Table tab.

2

Press [EMERGENCY STOP] [1] and highlight the shelf tab on pallet number one.

With [EMERGENCY STOP] pressed, type the letter A and press [ENTER]. This will assign shelf A to pallet number 1 [2].

3

Repeat the previous step for the remaining pallet numbers in alphabetical number [1].

NOTE: The shelves can be re-assigned at any point  however the user chooses by repeating the same process (e.g. pallet number 3 can be assigned shelf B).

 

Align Pallet Drop Off Station

1

Insert the Service Key USB and put the machine in Service Mode.

Make sure there are no obstructions inside the machine or inside the pallet pool area. Pull out all the [E-STOPS] and [RESET] the alarms.

Press [ZERO RETURN] and then press [ALL]. The machine will zero return all the axes.

Once all the axis are zero returned press [RECOVER]. A pop up box will appear, select [2] for Pallet Changer Recovery.

2

The Pallet Changer Recovery screen shows the Pallet Pool Status. Make sure the Pallet Lifter is Down [1]. If not press [ALTER] to bring the Pallet Lifter down.

Press [H] and then the [DELETE] button. This will rotate the pallet lifter towards station H.

Press [F1] to open the auto window [3].

 

3

While still in the pallet recovery page press [H] then [DELETE] to rotate pallet pool to H position.

Open the window by pressing [F1] then press [+Z] to select Pallet slide Axis manually slide the RAM in the machine to the pickup location.

  NOTE: Jog the slide axis slownly and make sure the bottom of the forks clear the receiver casting. Raise the pallet pool evenly if they do not.

With the Pallet Pool in the down position, use the Gap Gauge [1] (0.134 in or 3.4 mm) to set the gap by adjusting the height of the Pallet Pool. Evenly raise or lower the pallet pool leveling screws in accordance to the gap gauge.

  NOTE: The pallet pool should still be only on 3 points while adjusting the gap.

4

Adjust the pallet pool RAM by jogging the PS or PR axis so the forks align correctly underneath the pallet.

Using the gap gauge [3] make sure the pallet forks are flush with the edge pallet [4]. If only one side is flush and there is a gap on the other side adjust the PR position by pressing [-Z] to select the Pallet Rotate Axis on the pallet recovery page.

 NOTE: You should be able to align the pallet pool by adjusting the PR and PS axis, if it becomes difficult to do so with only these two adjust the C-axis to a position that the pallet is flush with the edge of the forks. Then set Parameter 7.310 C-AXIS PALLET OFFSET to the current position. This is the position that the C-axis will rotate to during a pallet change operation.

Press [F2] to unclamp the pallet and press [ALTER] to lift and lower the pallet to make sure the pallet falls onto the pins smoothly. Continuously adjust the PR and PS axis to make sure the pins are aligned to the holes.

 WARNING: The air blast on the receiver makes a loud noise ear plugs are recommended.

Press [Recovery] to get out of pallet recovery and go to Factory Settings 2137 [:] Shelf H Slide Offset and 2147 [:] Shelf H Rotary Offset, and make sure the values match the PS and PR axis position, if they do not update the values.

Manually remove the pallet from the machine. 

Finally, drop the fourth leveling screw onto the puck.

5

Make sure there is a pallet in the machine and place a level on the pallet in the UMC receiver as shown in the image.

 

6

Place a puck under the lift assist leveling screw and make sure the puck and screw are in contact 

Unclamp the receiver and raise the pallet. 

NOTE: The hydraulic lift assist will not come with a leveling screw but a hex bolt.

7

With the pallet raised check the level on the pallet and adjust this using the leveling screw on the lift assist.

Confirm that the pallet is clear from the receiver at the pins and the locking clamp. 

8

Re-enter the pallet recovery page and make sure the pallet is unclamped before pressing [INSERT] to return the RAM to the pallet pool area.

Press [A] then [DELETE] to rotate the RAM to its home position.

Press [A] and [UNDO] to slide the RAM to its home position.

Verify that the level is still acceptable in the X & Y direction [1].

Once verified, zero return the PR and PS axis.

Setting Up Pallet Stations

1

Adjust the load station feet [1] so that it sounds smooth as it goes through a pick up and drop off cycle.

The load station for this machine will have leveling pucks rather than the typical feet seen on the other stations.

Lower all outer leveling feet [2] to the ground by hand then rotate each leveling foot by another 1/2 turn [3]. 

2

Please refer to the PALLET POOL OPERATORS MANUAL for how to load the pallets onto the machine using the Pallet Scheduling Table.

3

Place the provided tote under the Pallet Pool coolant discharge tray to catch the coolant and chips that drains from the pallets.

Empty the tote as needed. 

Test the pick up / drop off operation on the remaining stations by using the pallet pool recovery functions.  

Install the anchors.

Install the Pallet Pool guard panels.