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Haas Automatic Pallet Changer User Manual

Haas Automatic Pallet Changer
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96-0012 rev G
1
June 2003
OM
PERATOR’S ANUAL
Automatic
Autom a t i c
Automatic
Autom a t i c
Pallet Changer
Pallet Changer
INTRODUCTION
1.0 AUTOMATIC PALLET CHANGER (APC)
1.1 OVERVIEW
IMPORTANT!
Read this entire section before attempting to install or run the APC. Serious injury or dam-
age to the machine could result from not following these procedures.
The HAAS Automatic Pallet Changer (APC) is used to automatically load and unload pallets into a HAAS VF-3
or VF-4. The APC is controlled by the VMC control, and uses the same air and power supplies. A simple M
code (M50) is all that is required to change pallets.
The APC assembly consists of the base, which serves as the home position for the two pallets, and a receiver
assembly, which is bolted to the VMC table and holds the pallets in place during machining operations. The
VMC unit contains air lines for clamping pallets, and a special automatic door in the side of the VMC enclosure
allows for loading and unloading of pallets. The APC has its own operator's panel, which includes CYCLE
START, FEED HOLD, PALLET READY, and EMERGENCY STOP buttons.
The APC can be programmed to load a pallet or change pallets by calling an M50. When a pallet change is
programmed, the VMC table moves to the right and adjacent to the empty pallet position on the APC base. The
receiver assembly then unclamps the pallet. The automatic door opens, the table moves to the unload position,
and the pallet is pulled into its home position. The VMC table moves over to the other pallet position, the next
pallet is pushed onto the receiver, and the pallet is clamped into position. The table then returns to its pro-
grammed position and the door closes.
Pallet movement is accomplished through the use of a drive motor and chain. The drive motor has a nonadjust-
able slip clutch that prevents damage to the motor if the pallet change is physically blocked.
NOTE: The machine will beep during a pallet change. This is an audible warning
signal, and not an alarm.
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Haas Automatic Pallet Changer Specifications

General IconGeneral
BrandHaas
ModelAutomatic Pallet Changer
CategoryIndustrial Equipment
LanguageEnglish

Summary

1.0 AUTOMATIC PALLET CHANGER (APC)

1.1 OVERVIEW

Provides a general introduction to the Automatic Pallet Changer (APC) system.

1.2 APC WORKING DIMENSIONS

APC DIMENSIONS

Details the physical dimensions and clearances of the Automatic Pallet Changer (APC).

APC WORK ENVELOPES

Illustrates the work envelopes and key measurement points of the APC system.

APC PALLET CLEARANCES

Specifies clearances required for pallets within the APC and VMC for VF-3 and VF-4.

2.0 MAINTENANCE SCHEDULE

PERIODIC MAINTENANCE

Outlines the routine maintenance tasks required for the APC on a daily, weekly, and monthly basis.

3.0 INSTALLATION

TOOLS REQUIRED

Lists the necessary tools for the installation of the Automatic Pallet Changer (APC).

GENERAL REQUIREMENTS

Specifies the environmental and operational requirements for installing the APC.

3.1 VF/APC FOOTPRINT

Provides the dimensional footprint of the VF-3/VF-4 machine with the APC installed.

3.2 ROUGH LEVELING/ALIGNMENT

Details the initial steps for leveling and aligning the APC with the VMC.

Installing Door Air Cylinder

Instructions for connecting the automatic door air cylinder to the VMC.

Positioning the APC

Guidance on placing and centering the APC unit in its designated installation location.

Setting up the APC

Procedures for setting up the APC operator's panel and related components.

Coolant Tank Placement

Diagram showing the recommended placement of the coolant tank relative to the APC and milling center.

Side Doors for Export Machines

Information regarding the operation and security of side doors on export machine configurations.

3.3 FINE TUNING

SETTINGS

Details the VMC settings used for fine-tuning pallet loading and unloading positions.

ADDITIONAL SETTINGS FOR FMS

Lists additional settings specific to FMS applications for pallet management.

4.0 PROGRAMMING

4.1 PROGRAM COMMANDS

Explains M codes and operator panel buttons for programming APC functions.

PROGRAMMING FOR FMS

Details FMS programming, including pallet scheduling and program assignment.

Safe Distance Settings Table

Specifies safe X-axis distances for VF-3 and VF-4 during pallet loading/unloading.

4.2 M CODES

Lists and explains M codes specifically used for programming the APC.

FMS G CODES

Details G codes used in conjunction with FMS for pallet operations.

SETTINGS

Defines APC pallet load/unload positions and safe X-axis settings (146-154).

4.3 SAMPLE PROGRAMS

Provides examples of programming sequences for pallet changes.

Example #1 (Basic)

Basic program using 'Pallet Ready' light for same part program on each pallet.

Example #2 (Part Tracking)

Program for tracking parts on each pallet with different machine operations.

FMS SAMPLE PROGRAMS

Sample FMS programs illustrating pallet scheduling and execution.

Example #1 (FMS Scheduling)

Sample FMS program loading next scheduled pallet and running correct part program.

Example #2 (FMS Conditional Jump)

FMS program tracking parts, using M46 for conditional jumps based on pallet presence.

SYSTEM VARIABLES

Lists system macro variables available for dual APC operation, including usage, priority, and status.

5.0 TROUBLESHOOTING

5.1 MACHINE SEQUENCE

Details the sequence of M codes executed during APC operations like pallet loading and unloading.

5.2 RECOVERY FROM POWER OUTAGE OR E-STOP

Flowchart and steps for recovering the APC after a power loss or E-STOP event.

6.0 ALARMS/FAULTS

630 APC Door SW Fault-Switch Not equal to Solenoid

Alarm for mismatch between APC door switch status and solenoid command.

631 APC-PALLET NOT CLAMPED OR HOME

Alarm indicating a pallet is not properly clamped or in the home position.

632 APC Unclamp Error

Alarm for failure of the pallet to unclamp within the allowed time.

633 APC Clamp Error

Alarm for failure of the pallet to clamp within the allowed time.

634 APC Mislocated Pallet

Alarm indicating a pallet is not in the correct position on the APC.

635 APC PAL num Conflict Rec and CH

Alarm for conflict between stored pallet number and actual pallet in use.

636 APC Unload Switch Missed PAL 1

Alarm for Pallet #1 failing to return from receiver to APC on time.

637 APC Unload Switch Missed PAL 2

Alarm for Pallet #2 failing to return from receiver to APC on time.

638 APC Door Not Open

Alarm for the automatic door failing to open or falling open.

639 APC Door Not Closed

Alarm for the automatic door failing to close.

640 APC Missing Pallet @ Receiver

Alarm when the receiver switch is not activated, indicating a missing or unclamped pallet.

641 APC Unknown Chain Location

Alarm when the chain position cannot be determined due to interrupted sequence.

642 APC Incorrect Chain Location

Alarm when the chain is not in the correct position for loading or unloading.

905 NO P Code In M14, M15, M36

Error code for missing P code in specific M codes.

906 Invalid P Code In M14, M15, M36

Error code for an invalid P code used with specific M codes.

907 APC Unload-Switch Missed PAL 3

Alarm for Pallet #3 failing to return from receiver to APC on time.

908 APC Unload-Switch Missed PAL 4

Alarm for Pallet #4 failing to return from receiver to APC on time.

909 APC-Program Not Listed

Alarm when a subprogram is not found in the Pallet Schedule Table.

910 APC Program Conflict

Alarm when a subprogram is not assigned to the loaded pallet in the PST.

911 APC PAL Load/Unload At Zero

Alarm indicating incomplete APC setup with zero load/unload positions.

912 APC No P Code Or Q Code For M46

Error for missing P or Q codes with M46.

Alarm 913 APC No P Code or Q Code For M49

Error for missing Q code with M49.

Alarm 914 APC Invalid P Code

Error for an invalid P code (program name) with M49.

Alarm 915 APC Illegal Nesting G188 or M48

Error for incorrect usage of G188 or M48.

Alarm 916 APC Negative PAL Priority Index

Software error indicating a negative pallet priority index.

Alarm 917 APC Number Of Pallets Is Zero

Alarm when the number of pallets in the FMS system is zero.

Alarm 918 APC Load Switch Missed PAL 1

Alarm for Pallet #1 failing to move to receiver on time.

Alarm 919 APC Load Switch Missed Pal 2

Alarm for Pallet #2 failing to move to receiver on time.

Alarm 920 APC Load Switch Missed PAL 3

Alarm for Pallet #3 failing to move to receiver on time.

Alarm 921 APC Load Switch Missed PAL 4

Alarm for Pallet #4 failing to move to receiver on time.

Alarm 922 APC Table Not Declared

Software error indicating invalid tables are being called.

PALLET SPECIFICATIONS

Weight

Specifies the weight of a single pallet.

Thickness

Specifies the thickness of a single pallet.

Bolt Holes

Details the spacing and type of bolt holes on the pallet.

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