Instruction manual ENG - LNS North America · 2019-05-18 · the bar feed system, as well as the CNC lathe, must be strictly observed. Non-qualified personnel, children, and persons

LNS SA 2534 Orvin/Switzerlandwww.LNS-group.com

Instruction manual ENG

9.ECO.01

ECOLOAD S2

V4.1

TABLE OF CONTENTS

CHAPTER 1: BASIC NOTIONS ............................................................... 1-1 1. STRUCTURE ......................................................................................................................... 1-2

2. RIGHTS ................................................................................................................................. 1-3

3. DECLARATION OF COMPLIANCE ..................................................................................... 1-4

4. SAFETY INSTRUCTIONS ..................................................................................................... 1-5

5. SAFETY DEVICES ................................................................................................................ 1-6

6. SECURITY ANALYSIS FOR THE CORRECT INCORPORATION ...................................... 1-6

CHAPTER 2: TECHNICAL DATA ........................................................... 2-1 1. CHARACTERISTICS............................................................................................................. 2-2

2. FLOOR PLANS ..................................................................................................................... 2-2

3. LAYOUT OF THE ELEMENTS ............................................................................................. 2-6

CHAPTER 3: SETTING INTO OPERATION ............................................ 3-1 1. TRANSPORTATION ............................................................................................................. 3-2

2. LIFTING ................................................................................................................................. 3-3

3. MOUNTING OF THE RETRACTION SYSTEM (optional) ................................................... 3-4

4. POSITIONING ....................................................................................................................... 3-6

5. LEVELING ............................................................................................................................. 3-7

6. ALIGNMENT ........................................................................................................................ 3-10

7. MOUNTING OF THE MAGAZINE ....................................................................................... 3-12

8. ANCHORING ....................................................................................................................... 3-16

9. CONNECTION ..................................................................................................................... 3-17

CHAPTER 4: ELECTRICS ....................................................................... 4-1 1. ELECTRICAL EQUIPMENT .................................................................................................. 4-2

2. ELECTRICAL CABINET ....................................................................................................... 4-3

3. POWER SUPPLY .................................................................................................................. 4-4

4. DIAGRAMS ........................................................................................................................... 4-6

5. PLC (Programmable logic controller) ................................................................................ 4-8

6. PCB (Printed Circuit Board) .............................................................................................. 4-12

7. INTERFACE ........................................................................................................................ 4-13

8. SAFETY SWITCHES ........................................................................................................... 4-17

CHAPTER 5: PNEUMATICS ................................................................... 5-1 1. PNEUMATICAL EQUIPMENT .............................................................................................. 5-2

2. PNEUMATIC CIRCUIT DIAGRAM ........................................................................................ 5-3

3. F.R.L. COMBINATION UNIT (Filtering-Regulation-Lubrication) ...................................... 5-4

4. SOLENOID VALVE MANIFOLD ........................................................................................... 5-5

5. RODLESS CYLINDER FORMATION AND MAINTENANCE ............................................... 5-6

6. MAINTENANCE .................................................................................................................... 5-7

ECOLOAD S2

CHAPTER 6: GENERAL DESCRIPTION ................................................ 6-1 1. LOADING SYSTEM ............................................................................................................... 6-2

2. FEEDING SYSTEM ................................................................................................................ 6-4

3. TRANSMISSION .................................................................................................................... 6-5

4. PUSHER ................................................................................................................................ 6-6

5. CHANNEL SET .................................................................................................................... 6-10

6. SPINDLE LINER .................................................................................................................. 6-13

CHAPTER 7: OPERATION ...................................................................... 7-1 1. REMOTE CONTROL ............................................................................................................. 7-2

2. HMI (Human Machine Interface) .......................................................................................... 7-4

3. POWERING AND EMERGENCY STOP ............................................................................... 7-6

4. AUTOMATIC / MANUAL SEQUENCE .................................................................................. 7-8

5. OPERATION PARAMETERS .............................................................................................. 7-11

6. SERVICE PARAMETERS ................................................................................................... 7-16

CHAPTER 8: TROUBLESHOOTING GUIDE .......................................... 8-1 1. ALARMS ................................................................................................................................ 8-2

CHAPTER 9: APPENDICES .................................................................... 9-1 1. ORDERING FORM ................................................................................................................ 9-2

2. PROGRAMMING EXAMPLE ................................................................................................. 9-3

3. LNS ADDRESSES & CONTACTS ........................................................................................ 9-4

CHAPTER 1: BASIC NOTIONS 1-1

ECOLOAD S2

CHAPTER 1: BASIC NOTIONS

1-2 CHAPTER 1: BASIC NOTIONS

ECOLOAD S2

1. STRUCTURE This manual consists of various chapters, each containing several points, paragraphs, etc. Lists may be contained in paragraphs.

The page number is indicated in the top outer corner of the page. The chapter number and title are indicated in the top inner corner of the page. The model of the bar feed system is indicated in the bottom right-hand corner of the page.

1.1. Cross-references Each chapter generally contains all of the information related to the description and settings of the devices and elements represented therein. Therefore, if a setting must be made while you are handling the system, please refer to the chapter on the device to be set, for example: (see chapter *) or (see point *).

1.2. Captions Whenever possible, the reference numbers contained in the instruction manual are shown with the LNS ordering number of the indicated element. To make it easier to place an order of supplies, a form has been included in the annex at the end of this manual.

1.3. Symbols and terminology

This sign recommends following the directions very closely avoiding causing an incident that could result in injury, damage to the equipment, or data loss.

This sign indicates that safety measures must be taken to avoid possible electrical shocks or mishaps.

The notes stress interesting points or comments, and provide useful advice for optimal system operation.

This sign serves to point out the portion mentioned on the description.

This sign points out an advice about environmental protection.


ECOLOAD S2

2. RIGHTS All rights reserved. Reproduction, recording or transmission of all, or any portion, of this manual, in any form or through any means whatsoever, whether mechanical, photographic, sound or other, without the express written authorization of LNS SA, is prohibited. LNS SA disclaims all responsibility for errors which may be contained in this manual and the problems which may result therefore. LNS SA and its subsidiaries cannot be made responsible for the debts, losses, expenses, or damage incurred, or suffered, by the buyer of this product, or a third party, following an accident, incorrect use, or misuse, or stemming from modifications, repairs, or transformations not authorized by LNS SA. LNS SA and its subsidiaries cannot be held responsible for damage and problems arising from the use of options and products other than LNS products, or products approved by LNS SA. The names of the products indicated in this manual are registered trademarks. The instructions found in this manual are only for information ; they are subject to change without notice.


ECOLOAD S2

3. DECLARATION OF COMPLIANCE Sample representation; the original document is always shipped with the unit.

EC DECLARATION OF CONFORMITY

According to annex II A of the directive 2006/42/EC

We declare that the following machinery complies with the next directives :

- Machinery Directive: 2006/42/EC - Low Voltage Directive: 2006/95/EC - EMC Directive : 2004/108/EC

Manufacturer : LNS SA Route de Frinvillier

CH- 2534 Orvin Suisse

Compiling relevant technical information : Plaseco Kurt De Pauw Chemin des Petits-Clos 12

CH- 1744 Chénens Suisse

Description of the machine : barfeed system

Type : ECOLOAD S2

Serial number : See official document

The following essential requirements of the machine directive 2006/42/EC are applied and fulfilled : 1.1.2, 1.1.3, 1.1.5, 1.1.6, 1.2.1, 1.2.2, 1.2.3, 1.2.4, 1.2.5, 1.2.6, 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.5, 1.3.6, 1.3.7, 1.3.8, 1.3.9, 1.4.1, 1.4.2, 1.4.3, 1.5.1, 1.5.3, 1.5.4, 1.5.8, 1.5.9, 1.6.2, 1.6.3, 1.7.1, 1.7.2, 1.7.3, 1.7.4.

The following transposed harmonised standards have been used : - Concerning the Machinery Directive : EN ISO 12100:2010 : Safety of machinery – Basic concepts & principles, EN ISO 14121-2:2013 : Safety of machinery – Risk assessment, EN ISO 13857:2008 : Safety of machinery – Safety distances to prevent hazard

zones being reached by upper and lower limbs, ISO 14120:2002 : Safety of machinery – Conception of movable guards, EN ISO 13850:2006 : Safety of machinery – Emergency stop equipment, EN ISO 13849-1:2008 : Safety of machinery – Safety-related parts of control systems, ISO 14118:2000 : Safety of machinery – Prevention of unexpected start-up, EN 60204-1:2005 : Safety of machinery – Electrical equipment of machines, EN ISO 14119:2013 : Safety of machinery – Interlocking devices, EN ISO 4414:2011 : Pneumatic Power – Rules and Safety requirements, CEI 60812:2006 : Safety of machinery – FMECA Analysis,

- Concerning the Low Voltage Directive : EN 61439-1/3:2013 : Low-voltage switchgear and control gear assemblies

- Concerning the EMC Directive : EN 61000-6-4 : Generic emissions standard, Industrial environment EN 61000-6-2 : Generic immunity standard, Industrial environment

Place and date : Seal and signature :

Orvin, April the 10th 2014 Mrs. Nadia Pellaton Manager Export department


ECOLOAD S2

4. SAFETY INSTRUCTIONS Only people who know the product and are sufficiently qualified, may install, put the spindle in use, maintain and, where necessary, repair. The customer must ensure that the provisions regarding internal monitoring, the indication prescribed events, organization of work, staff training is available with instructions for assembly.

All persons who perform work on this machine, must have read and understood the notice instructions. LNS disclaim all responsibility for possible accidents or property damage caused when safety instructions are not followed : Do not handle the equipment without having

knowledge of the safety instructions and the instructions for use. Safety instructions for the bar feed system, as well as the CNC lathe, must be strictly observed.

Non-qualified personnel, children, and

persons under the influence of alcohol or medication should not handle the equipment.

Loose garments, long hair and jewellery can

be dangerous. Do not remove any covers while the bar

feeder or the machine is under electrical power.

Do not conduct any maintenance operations

during the automatic cycle. Do not grasp moving or rotating objects, or

nearby elements. If certain safety shields or safety covers are

removed to conduct maintenance, they must be reinstalled as soon as the maintenance work is completed.

No servicing should be carried out on the

interface or inside the electrical cabinet while the bar feeder or the lathe is under electrical power.

It is strictly prohibited to jump wire or remove

circuit breakers, main switches, and especially safety switches.

To avoid any harm to persons, or damage to

components, use only the indicated points for lifting and moving the bar feeder system. No one should be near the hanging load, or within the operating range of the overhead hoist/crane, forklift, or any other means used for lifting and transportation. Do not knock the bar feeder while moving it as this could damage it.

Do not move the bar feeder while it is

electrically powered on.

Don’t hit the barfeed when moving it, this could result in damages.

The work area surrounding the bar feed

system should always be clear of objects and well lit. The presence of oil on the ground could cause falls; it is important to maintain the floor clean on a regular basis.

Do not place the machine in a damp area

and make sure that water or oil does not come into contact with the electrical equipment.

Do not open the clamping device (collet or

chuck) of the lathe manually when the bar feeder is in automatic mode (Interface).

Each time the diameter is changed, also

adapt spindle reduction tube. The use of spindle reduction tubes is highly recommended for machining bars with diameters smaller than the maximum capacity of the spindle.

Do not attempt to recharge the batteries of

the PLC. For the use and maintenance of the bar

feeder, use only parts provided by or recommended by LNS.

If it is necessary to move the bar feeder once

it has been originally installed, do not reinstall it before first contacting LNS or its local representative.

The rotating bar should never protrude the

rear of the lathe spindle. The maximum length (max. L) the bar feeder

system is allowed to load is given by the length of the lathe spindle. The bar should never extend more than 3 times its diameter beyond the lathe clamping device without support.

LNS disclaim all responsibility for possible

accidents or property damage caused when safety instructions are not followed.


ECOLOAD S2

5. SAFETY DEVICES The ECOLOAD S2 bar feed system has been designed with a focus on maximum safety during its handling and complies with all EC requirements. Safety covers and devices make access to the moving parts of the bar feed system impossible. Safety switches keep the bar feed system from operating when these protections are open. By pressing the emergency stop button located on the remote control, the functions of the bar feed system and the lathe are immediately stopped.

The LNS company, or its local representative, may not be held responsible for possible accidents or property damage, whether caused directly or not, by any means whatsoever, if certain safety devices have not been included.

6. SECURITY ANALYSIS FOR THE CORRECT INCORPORATION Before considering assembling the machine, it is necessary to consider the following points:

Consider security strategies that reduce risks to an acceptable level;

Define the tasks required for applications to predict and assess the need of access and / or for the approach;

Identify sources of risks, including failures and failure modes associated with each task. Risks can come from:

o machine in which the device ECOLOAD S2 is integrated;

o its association with other equipment,

o People’s interaction with the machine.

Evaluate and assess the risks associated by using the machine ECOLOAD S2:

o programming risks

o operation risks

o risks of use

o maintenance risks

Choose methods of protection :

o the use of protective devices

o the introduction of signals

o compliance with safe work procedures


ECOLOAD S2

6.1. Layout of the safety elements on the bar feeder

Designation Description A Emergency stop button on remote control B Emergency stop button on electrical cabinet C Main access cover D Magazine cover

SQ10 Safety switch of the main access cover SQ11 Safety switch of the magazine cover SQ12 Safety switch of the retraction system

SQ10

SQ12

SQ12

A

B

C

D


ECOLOAD S2

CHAPTER 2: TECHNICAL DATA 2-1

ECOLOAD S2

CHAPTER 2: TECHNICAL DATA

2-2 CHAPTER 2: TECHNICAL DATA

ECOLOAD S2

1. CHARACTERISTICS Note : Depending on the country and the standards in effect, certain technical data, such as the power supply, may vary. Please see the technical card delivered with the device.

Ecoload S2

Bar diameter ¼” – 2-5/8” (5mm – 65mm)

Max. Bar length 12” – 49” (300 - 1250mm)

depends on lathe spindle length

Spindle height 34” – 49” (850 – 1250mm)

Weight 660 lb (300 kg)

Compressed air supply 6 kg/cm2

Air consumption 1.585 gal (6 liters) / per loading cycle

Power supply 200~480V AC – 0.4A – 50~60 Hz

Cycle time to change bars 10 seconds

Magazine capacity 25”

Max admissible weight on the magazine 705 lb (320 kg)

X-axis retraction displacement 12” (300mm)

Z-axis retraction displacement 23” (585mm)

2. FLOOR PLANS The following floor space plans indicate the most frequently used dimensions for placing the bar feed system. Details on the dimensions of other parts or elements of the bar feed system will be furnished upon request. All dimensions are in millimeters.


ECOLOAD S2

2.1. Without retraction system

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�

��

��

� ��

��

��

��

�


ECOLOAD S2

2.2. X-axis retraction system

��

��

��

��

��

��


ECOLOAD S2

2.3. Z-axis retraction system

��

��

��

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��

��

��


ECOLOAD S2

3. LAYOUT OF THE ELEMENTS

Designation Description

A Main access cover

B HMI

C Remote control

D Electrical cabinet

E Pusher

F Pusher carrier

G Loading channel

H Protection grate

I Magazine

J Magazine inclination adjustment

K Retraction system (optional)

L Front stand

M Rear stand

A

B

C

D

E

F

G H

I

J

K

M L

CHAPTER 3: SETTING INTO OPERATION 3-1

ECOLOAD S2

CHAPTER 3: SETTING INTO OPERATION

3-2 CHAPTER 3: SETTING INTO OPERATION

ECOLOAD S2

1. TRANSPORTATION Please read the safety precautions described at the beginning of this manual before handling the following devices.

1.1. Description Depending on its destination, the ECOLOAD S2 bar feed system may be delivered either on a pallet, or packed in a wooden crate. When sea or air transports it, the second solution is recommended.

1.2. Unpacking For practical and safety reasons, the bar feed system must be unpacked in a spacious, well-lit location.

Check to see that the lifting capacity of the hoisting crane, or lift truck, is adequate before proceeding with the handling of the merchandise. No one should be near the hanging load, or within the operating range of the overhead hoist/crane, forklift, or any other means used for lifting and transportation.

1) If the bar feed system is received in a crate, start by

unscrewing the top panel. 2) Remove the front.

3) Remove the side-walls.

From this point on, the bar feed system is unpacked in the same way as when delivered on a pallet. A pusher and guiding channel set is mounted in the bar feeder. Depending on the purchase order, other sets may be delivered in a separate box.

The interface plug/cable is tightened with remote control box. Interface diagram, operation manual, air tube and anchor bolts are placed inside the electrical cabinet.

1

2 3


ECOLOAD S2

2. LIFTING

For installing the bar feeder, it’s advisable to contact us or one of our branches, agents. We cannot be held responsible for any malfunction resulting from an incorrect installation in which we did not take part in.

2.1. Procedure 1. Insert two bars into the holes under the body, place the hoist vertically above central of the bar feeder.

2. Place the straps over the ends of the bars, and then attach them to the hoist. The loading capacity of both the hoist and straps must be larger than 1 ton.

3. Raise the hoist to tighten the straps.

4. Remove the screws for holding the bar feeder to the pallet during transportation.

5. Lift the bar feeder and remove the pallet. Ensure that the bar feeder is balanced.

6. Move the bar feeder, taking care that it remains horizontal and that no one is nearby or under the suspended load. Do not knock the bar feeder as you move it; this may damage it.

7. Place the bar feeder behind the lathe, as close as possible and in approximate alignment with the lathe spindle. For the placement, the stationary and mobile space requirements for the lathe and the bar feeder should be taken into account.


ECOLOAD S2

3. MOUNTING OF THE RETRACTION SYSTEM (optional) The magazine slides with the bar feeder when the retraction is used. Before mounting the system, make sure the floor surface is flat and smooth.

The retraction system allows the bar feeder moving on certain distance so that there is some space behind the spindle for service.

The retraction system is an optional and integrated device. The user can order it along with the bar feeder or order it later upon requirement. If it is not equipped with your bar feeder, please skip this section.

3.1. Mounting of the X-axis retraction system The X-axis retraction system allows the bar feeder moves among the lateral direction. This movement gives more space on the longitudinal direction.

Please follow the steps below to install the retraction system. Lift the bar feeder according to the corresponding procedure in this

chapter. Remove the safety sensor protector and sensor by sequence. Screw the retraction system toward the bar feeder stand.

Notice the locking device must be placed toward the front of the bar feeder.

Move the bar feeder backward and forward couple times and confirm the retraction system was mounted properly.

Mount the safety sensor and sensor protector by sequence. Insert the cable into the electrical cabinet from the opening behind

the bar feeder. Make sure that the cable will not be clamped when the bar feeder is moving on the retraction system.

Insert wire 18 and 110 into contact 18 and 110 on terminal TB17. Move the jumper from contact 18 and 110 to the storage socket as shown.

Jumper storage socket

Jumper

Sensor

Sensor protection


ECOLOAD S2

3.2. Mounting of the Z-axis retraction system The Z-axis retraction system allows the bar feeder moves among the longitudinal direction. This movement gives more space on the lateral direction.

Please follow the steps below to install the retraction system. Lift the bar feeder according to the corresponding

procedure in this chapter. Remove the safety sensor protector and sensor by

sequence. Screw the retraction system toward the bar feeder stand.

Notice the locking device must be placed toward the front of the bar feeder.

Move the bar feeder backward and forward couple times and confirm the retraction system was mounted properly.

Mount the safety sensor and sensor protector by sequence. Insert the cable into the electrical cabinet from the opening

behind the bar feeder. Make sure that the cable will not be clamped when the bar feeder is moving on the retraction system.

Insert wire 18 and 110 into contact 18 and 110 on terminal TB17. Move the jumper from contact 18 and 110 to the storage socket as shown.

Sensor

Sensor protection

Jumper storage socket

Jumper


ECOLOAD S2

4. POSITIONING The bar feeder must be placed behind the lathe as closer as it could be. The maximum distance between the lathe and bar feeder should not exceed 100mm.

In the other words, the bar stock length should not exceed spindle length.

4.1. Bar feeder without retraction system

4.2. Bar feeder with retraction system If the bar feeder is equipped with retraction system, please position the bar feeder after the retraction is locked on the bar feeder.

100 mm Max.

Side view

100 mm Max.


ECOLOAD S2

5. LEVELING Before preceding this step, make sure that the lathe is leveled.

5.1. For bar feeders without retraction system Put the level on position C and D of bar feeder stand by sequence as shown. Loose 8 nuts A on the stand. Level the bar feeder by adjusting 8 screws B.

Turn the bolt clockwise until it touch against the ground and to lift the bar feeder or turn it counter-clockwise to drop the bar feeder.

Lock nuts A after the leveling is finished.

A

B

CD


ECOLOAD S2

5.2. For bar feeder with X-axis retraction system Put the level on position C and D of bar feeder stand by sequence as shown. Loose nuts A on the stand. Level the bar feeder by adjusting screws B and E on each stand.

Turn B clockwise until it touch against the plate under the stands to lift the bar feeder or turn it counter-clockwise to drop.

Lock all nuts A after the leveling is finished.

A

B

C

D

E


ECOLOAD S2

5.3. For bar feeder with Y-axis retraction system Put the level on position C and D of bar feeder stand by sequence as shown. Loose nuts A on the stand. Level the bar feeder by adjusting screw B on each stand.

Turn itclockwise until it touch against the plate under the stands to lift the bar feeder or turn it counter-clockwise to drop.

Do not adjust nuts and bolts remarked E.

Lock all nuts A after the leveling is finished.

B

C

D

A

E


ECOLOAD S2

6. ALIGNMENT

Open both stand covers. Make sure that nut B tightly contact to the plate C

Open the electrical cabinet. Loose nuts A on both sides (total 6 nuts).

Adjust the bar feeder height by turning nuts B on each stand. Note that nut D must be always locked and should not be adjusted.

After finishing all adjustments, lock A and close both stand covers.

A

B

D

C


ECOLOAD S2

6.1. Center adjustment Continuously adjust nuts B until the pusher is at central of the spindle on both front and rear sides. When the alignment is finished, lock all the nuts A.

A

B

CD

Spindle rear end Spindle front end

Pusher

Spindle


ECOLOAD S2

7. MOUNTING OF THE MAGAZINE The magazine was delivered without assembling. The user has to assemble it on the bar feeder before installation. Please follow the procedures below to install the magazine according to your bar feeder type.

7.1. Standard bar feeder (without retraction system) 1. Unlock the magazine brackets by loosing screws pointed.

Magazine kit for bar feeders without retraction system

Magazine kit for bar feeders with retraction system


ECOLOAD S2

2. Mount the magazine body A, magazine middle rod B and lock them with the brackets.

3. Mount the magazine stands C as shown.

4. Loose nut D. Tilt the magazine by adjusting nut E. Lock nut D after the adjustment is finished. Please note there is no firm value of this angle. It must be adjusted according to the bar stock diameter and surface condition.

5. Lock the magazine brackets by tightening screws pointed.

A

B

C

D

E

15°

Keep the stem straight.


ECOLOAD S2

7.2. Bar feeders with retraction system 1. Unlock the magazine brackets by loosing screws pointed.

2. Mount the magazine body and middle rod B and lock them with the brackets.

3. Mount the magazine basement C as shown.

4. Connect magazine stand D and fix as shown

A

B

C

D


ECOLOAD S2

5. Adjust nut E so that the plates F are parallel with the bar feeder stand plates.

6. Adjust nut G so that the magazine basement wheels J are able to contact with the ground. Then lock nuts H.

7. Loose nut C.

Tilt the magazine by adjusting nut L. Lock nut K after the adjustment is finished. Please note there is no firm value of this angle. It must be adjusted according to the bar stock diameter and surface condition.

8. Lock the brackets which loosed on step 1.

F

F

E

E

G

G

H H

H H

J J

15°

K

L


ECOLOAD S2

8. ANCHORING After the bar feeder is positioned, leveled, aligned and the magazine is mounted. The bar feeder must be anchored. Figures below offer the anchoring location for each model. Please refer to corresponding instruction and anchor your bar feeder accordingly.

8.1. Bar feeder without retraction system Anchor the bar feeder at location A of each stand and location B of the magazine stands (total 6 anchor spots).

8.2. Bar feeder with X-axis retraction system Anchor the bar feeder at location A of the retraction system guiding rail (total 4 anchor spots).

8.3. Bar feeder with Z-axis retraction system Anchor the bar feeder at location A of the retraction system guiding rail (total 4 anchor spots).

A

A A

A

A

A A

B

A

A

A

A


ECOLOAD S2

9. CONNECTION Once the bar feeder has been aligned and anchored to the ground, the bar feeder must be connected to the interface of the lathe and compressed air need to be connected.

For the electrical connection, please see Chapter 4, Electrics.

For the pneumatic connection, please see Chapter 5, Pneumatics.


ECOLOAD S2

CHAPTER 4: ELECTRICS 4-1

ECOLOAD S2

CHAPTER 4: ELECTRICS

4-2 CHAPTER 4: ELECTRICS

ECOLOAD S2

1. ELECTRICAL EQUIPMENT Please read the safety instructions provided at the beginning of this manual before handling the following devices. Particular attention should be given to the handling of electrical elements because of risks of electrocution. In case of possible electrical malfunctions, it is advisable to contact LNS or their local representative.

1.1. Description This chapter contains all of the elements regarding the electrical circuit of the bar feed system. The electrical parts, and groups, which may require a setting, at some time or other, are described herein in detail.

1.2. Layout of the elements


A Electrical cabinet

B Remote control

C Encoder

HMI Human Machine Interface

QS1 Main power switch

LS1 TOP CUT measuring sensor

SR1 Guiding channel in 0° position sensor

SR2 Guiding channel in 15° position sensor (not visible)

SR3 Pusher origin reference sensor

STP1 Emergency stop button on bar feeder

STP2 Emergency stop button on remote control

SQ10 Main access cover switch

SQ11 Magazine cover switch

SQ12 Retraction device safety switch

SQ11

STP1

LS1

SR3

SR1

SQ10

A

QS1

HMI B STP2

C

SQ12


ECOLOAD S2

2. ELECTRICAL CABINET


A Transformer

B Protective ground terminal

PCB Printed Circuit Board (PCB)

PLC Programmable Logic Controller (PLC)

QF2 24V DC power supply breaker

A QF2 PLC

PCB

B


ECOLOAD S2

3. POWER SUPPLY The main power is supplied by the interface cable. Before connecting the interface cable to the lathe, make sure the transformer wiring meet the power supply.

AC System DC System

AC 110V

PLC

+24 / M

Lathe

QS1

Transformer

AC 20V Bridge

Rectifier

P / -

3.1. Main power switch QS1

Make sure it is turned OFF before opening the electrical cabinet.

Power ON Power OFF

Direction of power supply


ECOLOAD S2

3.2. QF2 breaker Breaker QF2 protects the one phase 220V AC which powers PLC. If the one phase required power exceeds 4A, the breaker activates and terminates 2 phases.

After the problem is fixed, reset the breaker by flipping lever B up.

3.3. Transformers The transformer supplies 20V AC and 110V AC to the bar feeder. The incoming power must be connected to the Primary terminal block. Use the contacts corresponding to the supplied power (190V AC to 480V AC, see drawing below). There are 2 sets of independent power supply unit on the secondary terminal. Unit A supplies 110V AC. Unit B supplies couple alternatives output power but the wiring must ALWAYS connected to 0V/20V !

Never connect the unit B to 0V/24V.

3.4. 24V DC power supply The bridge rectifier converts the AC power from transformer and offer 24V DC to proximity switches, interface signals, remote control, solenoid valves and buzzer.


A Power poles input

B ON / OFF lever

C Power poles output

Secondary terminal block

Unit A Unit B

Primary terminal block

A

B

C


ECOLOAD S2

4. DIAGRAMS

4.1. Symbols

Index Symbol Description Designation

1

AS1 Pressure switch

2

C1 Capacity

3

CS1 Main disconnect switch

4

DE Bridge rectifier

5

F2 Fuse

6

LED0, LED13 Light-emitting diode

7

QF2 Circuit breaker

8

R1 ~ R5 Relay

9

S1~S7 Buttons

10

SR1, SR2, SR3 Proximity switch

11

STP1 / STP2 Emergency stop button

12

AS1 Pressure switch


ECOLOAD S2

4.2. Circuit diagram


ECOLOAD S2

5. PLC (Programmable logic controller)

5.1. Primary module The PLC processes the signals from the interface, sensors and remote control and sets the outputs according to the program logic. In addition, the PLC powers HMI with 24V DC.


A Input contacts. All connected wires are labeled.

B Input contacts notation.

C Input signals indication LED. Indicate the status of inputs X0 to X43.

D PLC status indication LED.

E Output signals indication LED. Indicate the status of outputs Y0 to Y27.

F Communication port.

G Output contacts notation.

H Output contacts. All connected wires are labeled.

A

E

F

B

C

D

H

G


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5.2. PLC I/O DIAGRAMS


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5.3. Input signals

Contact Indicator Description Contact to Remarks

L -- 1 phases 110V input Q2 breaker

PE -- Protective earth Lathe

N -- 1 phases 0V input Q2 breaker

S/S -- Common ground Power supply 0V

X00 0 Phase A Encoder Encoder signals

X01 1 Phase B Encoder

X02 2 Origin reference SR3(TB23) Sensor

X03 3 Channel in 0° position SR1 Sensor

X04 4 Channel in 15° position SR2 Sensor

X05 5 TOP CUT measuring sensor LS1 Sensor

X07 7 empty -- --

X10 10 Emergency stop circuit Emergency stop circuit

X11 11 Chuck signal A1

Interface signals X12 12 Lathe alarm A2

X13 13 M-function A3

X14 14 empty A4

X15 15 empty -- --

X16 16 Bar feeder in manual mode S1

Remote control buttons

X17 17 Bar feeder is ready for automatic mode

S2

X20 20 Bar feeder in automatic mode S3

X21 21 Manual pusher forward S4

X22 22 Manual pusher backward S5

X23 23 Swing the channel to 0° position S6

X24 24 Swing the channel to 15° position S7

X25 25 empty S2 --

X26 26 empty -- --

X27 27 empty -- --


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5.4. Output signals Contact Indicator Description Connect to Comment

24V -- 24V DC power output HMI

Independent DC power supply for HMI. 0V --

COM0 -- 24V DC input for terminal Y00 -- --

Y00 0 empty -- --

COM1 -- 24V DC input for terminal Y01 -- --

Y01 1 empty -- --

COM2 -- 24V DC input for terminals Y02, Y03 -- --

Y02 2 Bar feeder is in auto mode Remote control LED attributed to button

Y03 3 Pusher is behind FIRST FEED Remote control LED attributed to button

-- Void contact -- --

COM3 -- 24V DC input for terminals Y04, Y05, Y06, Y07

-- --

Y04 4 Bar feeder alarm Relay R1 Interface signal

Y05 5 START signal Relay R2 Interface signal

Y06 6 BAR END signal Relay R3 Interface signal

Y07 7 Bar feeder is in automatic mode Relay R4 Interface signal



-- --

Y10 10 Inching signal Relay R5 Interface signal

Y11 11 empty -- --

Y12 12 empty -- --

Y13 13 Pusher backward VAL1 Solenoid valve



-- --

Y14 14 Pusher forward VAL2 Solenoid valve

Y15 15 Swing the channel to 0° position VAL3 Solenoid valve

Y16 16 Swing the channel to 15° position VAL4 Solenoid valve

Y17 17 Buzzer -- Solenoid valve


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6. PCB (Printed Circuit Board) PCB is a board with circuit printed and electrical components welded on the surface. It offers sockets and terminals for electrical components like relays, cables and fuses. Refer to the table below for functions of each terminal.

Terminal block designation

Terminal designation Functions

TB1 5 unit of - terminals Negative common of the 24V DC supplied by bridge rectifier

TB2 017, 010, 007, 004, 006, 005, P, P, P Terminal for connecting buzzer and Interface signal R1 ~ R5 from PLC.

TB3 -, 017 Power supply terminal of buzzer. TB4 +24, +24, M, 002, 003 Power supply terminal of LED3 and LED13. TB5 114, 113, 112, 111 Interface signals from the lathe. TB6 -, P Power indicating light

TB7 102, +24, M (SR1) 103, +24, M (SR2) 104, +24, M (SR3)

Terminal for receiving proximity switches signals.

TB8 0, 20 Power supply terminal of the bridge rectifier. TB9 18, XT9 (AS1) 1. Terminal for connecting AS1 switch.

TB10 100, 101, 103, 102, 104, M Terminal for connecting encoder and switch SR1 ~ SR3

TB11 M, +24, 100, 101 Power supply terminal of encoder

TB12 120, 117, 122, 124, 123, 121, 116 Terminal for connecting remote control buttons S1 ~ S7

TB13 EM2, EM2, EM1, K, 5, +24 Terminal for connecting the STP1 emergency stop button.

TB14 105, +24, M Power supply terminal of LS1 switch.

TB15 M, +24, A4, A3, A2, A1, EM2, EM2, EM1, EM1, XT8, XT9

Terminal for connecting lathe interface signals.

TB16 007, 004, -, P, M, +24 1. Terminal for connecting PLC output contacts 004 and 007. 2. 2 sets of spare terminal of 24V DC.

TB17 18, 110 Terminal for connecting SQ12

TB18

R5 C, R5 NO, R5 NC, R4 C, R4 NO, R4 NC, R1 C, R1 NO, R1 NC, R3 C, R3 NO, R3 NC, R2 C, R2 NO, R2 NC

Terminal for connecting bar feeder interface signals

TB19 110, 106, 105 Terminal for connecting emergency stop circuit and PLC input contacts LS1

TB20 SQ10 : +24, 116, 16, 17 SQ11 : 116, +24, 17, 117

Terminal for connecting SQ10 and SQ12 switches.

TB21 +24, M Power supply terminal of HMI


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7. INTERFACE Before connecting, check to make sure that the voltage of the bar feed system corresponds to the one provided by the lathe. The voltage of the bar feed system is indicated on the identification plate. Only LNS (or certified) technician is authorized to modify the interface or parameter system.

7.1. Description The interface cable(s), between the bar feed system and the lathe is (are) provided by LNS. Interface presents all the signals exchanged between the bar feeder and the lathe. The male interface cable(s) which serves to transmit the interface signals is/are provided by bar feeder. The female side is supplied by the lathe manufacturer. There is a wide range of different interfaces available to meet the requirement of each lathe. A diagram of the installed interface can be found in the electrical cabinet. Before connecting the bar feeder, make sure the installed interface is suitable for your lathe. Contact us for any related questions.

A correct connection between lathe and bar feeder is critical for safe and reliable operation. It is recommended to request a trained technician to install the bar feeder. Should the interface instructions not be observed during the setting into operation, the damaged elements as well as the resulting damages are not covered by warranty.

7.2. Universal interface diagram The diagram shown below is called universal interface diagram. If the lathe type is not specified, an universal interface will be offered with the bar feeder. The universal interface diagram offers most of the signals which were connected to bar feeder interface terminals in advance. During connection, the wires should be connected / removed according to the interface supplied by the lathe. With this situation, we strongly recommend the user to contact us for technical support.


ECOLOAD S2

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7.3. Signals from the bar feeder to the lathe When a specific bar feeder signal is activated, the corresponding relay energizes therefore send signal to the lathe. The bar feeder interface offers wires of both NO and NC contacts. The user should connect the interface wires according to lathe signal logic. a) 24V DC power supply All the signals from the bar feeder were powered by the 24V DC from the lathe. When the corresponding relay energized at the bar feeder, the 24V DC travels through corresponding contact at bar feeder relay and return to lathe PLC. The lathe PLC hence receives bar feeder signals. b) R1 alarm relay When an alarm is activated in the bar feeder, the R1 relay is energized. The corresponding contact will be ON and signal will be sent / removed to the lathe according to the wiring logic. For safety reason, this signal should bring to a stop of the spindle. c) R2 START signal relay When the pusher is stopped based on servo encoder setup, it will energize Relay R2. Generally this signal is for confirming the bar stock hit the stopper during feeding so that the lathe chuck should be closed according. d) R3 BAR END (end of bar) relay When the pusher reaches BAR END position during feeding, relay R3 energizes. This signal is used to indicate that the rest bar stock length is not long enough to machine a complete part according to part length. Refer to operation parameter P06 and service parameter MODE 11, 12, 13 for further information. e) R4 bar feeder in auto relay This signal is present as soon as the bar feeder is switched into automatic mode (AUTO READY + AUTO START). f) R5 INCHING relay This relay energizes under circumstances below: Index Beginning End

1 The moment when the SHORT pusher leaves the origin reference for proceeding FIRST FEED.

The moment that SHORT pusher returns to the origin reference.

2 The moment when the LONG pusher leaves the origin reference for proceeding TOP CUT position.

The moment when the LONG pusher is stopped after arriving at TOP CUT position.

3 The moment when the lathe chuck opens during machining.

The moment when the LONG pusher is stopped after it has moved to the part length.

Refer to service parameter MODE 16 for more information.


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7.4. Signals from the lathe to the bar feeder The lathe interface signal logic can be configured with service parameters. Only trained personnel should change these settings.

a) 24V DC power supply All the signals from the lathe were powered by the 24V DC from the bar feeder. When the corresponding relay energized at the lathe, the 24V DC travels through corresponding contact and return to PLC. The PLC hence receives lathe signals. b) Emergency stop signals from the lathe This contacts XT8 and XT9 are part of the bar feeder emergency stop loop of the bar feeder. When the emergency circuit is open between XT8 and XT9, the bar feeder goes to EMERGENCY STOP MODE and arise an e01 alarm and energize relay R1. c) Lathe chuck signal (PLC input X11), terminal A1 Chuck signal is for confirming the status of lathe chuck (collet, clamping device). This signal initiates feeding and bar change process of bar feeder by itself as well as combination with other signals. The signal logic could be inverted by MODE 2 setup. d) Lathe alarm (PLC input X12), terminal A2 This signal indicates that a lathe alarm is arising. The signal logic could be inverted by MODE 3 setup. e) M function (PLC input X13), terminal A3 This signal serves as an auxiliary signal for confirming chuck status. To activate this function, please refer to MODE 7 for further information. The signal logic could be inverted by MODE 4 setup. f) Spare signal (PLC input X14), terminal A4 This signal is not connected in the universal interface.

7.5. Recapitulation of safety instructions related to the interface The lathe foot switch for opening the lathe clamping device should not be operational during the

automatic cycle of the lathe. The lathe pedal should not be operational as long as the feeding pusher feed command signal is

present.

Whenever possible, it is advisable to interlock lock the manual command for opening the lathe

clamping device while the feeding pusher command signal is on.

If the lathe is in the Emergency Stop mode, the bar feed system must also be under the

Emergency Stop mode, and vice-versa.

If the bar feed system generates an alarm, the lathe must go into alarm mode. The feeding

pusher feed command signal must go off, the spindle axis and rotation must stop.


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8. SAFETY SWITCHES

8.1. Main access cover safety sensor (SQ10) This sensor should be mounted on the bar feeder body and the latch mounted on the movable cover. When the main access cover is closed with the switch key plugged, wire 17 and 16 will be engaged but wire 116 and +24 will be disengaged so will not send signal to PLC input contact X16. The bar feeder hence is able to be switched to AUTOMATIC ready mode. When the main access cover is open, wire 17 and 16 will be disengaged but wire 116 and +24 will be engaged, sending signal to PLC input contact X16. The bar feeder will be switched to manual mode if it’s in automatic mode. Please follow the right picture for SQ10 wire connection in the switch. Check PLC I/O diagram for connecting to the PLC.

8.2. Magazine cover safety sensor (SQ11) This sensor should be bridged on the bar feeder body and the magazine cover. When the cover is closed with the switch key plugged, wire 117 and 17 will be engaged but wire 116 and +24 will be disengaged so will not send signal to PLC input contact X16. The bar feeder hence is able to be switched to AUTOMATIC mode. When the cover is open, wire 117 and 17 will be disengaged but wire 116 and +24 will engaged, sending signal to PLC input contact X16. The bar feeder will be switched to manual mode if it’s in automatic mode. Please follow the right picture for SQ11 wire connection in the switch. Check PLC I/O diagram for connecting to the PLC.

8.3. Retraction system safety sensor (SQ12) The sensor should be mounted on the bar feeder stand and the latch should be mounted on the retraction system. When the retraction system is locked with the switch key plugged, wire 3 and wire 4 will be engaged, keeping emergency top circuit closed. Please follow the right picture for SQ12 wire connection in the switch. Check circuit diagram for connecting to the PLC.

Swing arm

Switch key

Switch SQ10, SQ12

Switch SQ11

Wire 16

Wire +24

Wire 17

Wire 116

Wire 17

Wire +24

Wire 117

Wire 116

Wire 14

Wire 2

Wire 3

Wire 1


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CHAPTER 5: PNEUMATICS 5-1

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CHAPTER 5: PNEUMATICS

5-2 CHAPTER 5: PNEUMATICS

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1. PNEUMATICAL EQUIPMENT Please read the safety instructions provided at the beginning of this manual before handling the following devices.

1.1. Description This bar feeder is mainly driven by pneumatic elements. To guarantee an optimal operation of the bar feed system, a minimum pressure of 5 bars (75 psi), and a maximum pressure of 6 bars (90 psi) is mandatory.

1.2. Layout of the pneumatic elements


A Channel swinging / bar stock loading cylinder

B Channel lifting cylinder (not visible)

C Pusher driving cylinder

D Solenoid valves (generally covered and not visible)

E F.R.L. combination unit

F Pusher backward damping adjustment

G Pusher forward damping adjustment

H Pushing force adjustment

AS1 Air pressure switch (inside the electrical cabinet, not visible)

F

C

A G

H

D E


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2. PNEUMATIC CIRCUIT DIAGRAM


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3. F.R.L. COMBINATION UNIT (Filtering-Regulation-Lubrication)

3.1. Description The F.R.L. (Filtering-Regulation-Lubrication) combination unit serves to perform filtering, lubrication and regulation of the pressure before it is distributed into the pneumatic circuit of the bar feed system. The air must be furnished at a maximum pressure of 6 bar (90 psi), and whenever possible, clean and dry.


3.3. Connection For the pneumatic connections of the bar feeder, we provide a tube with pre-mounted quick acting coupler and probe.

Before connection, confirm the factory air pressure is not higher then 8 bar / 14 psi. Connect this tube on both F.R.L. unit and factory compressed air source.

3.4. Settings 1. Unlock the adjusting knob by pulling it upward.

2. To increase the pressure, turn it clockwise.

To decrease the pressure, turn it counter clockwise. The operational pressure should be set between 5 and 6 bar (75-90 psi).

3. When the settings are done, lock the adjuster by pushing it downward.


A Air inlet

B Pressure regulator

C Pressure gauge

D Condensate collector

E Lubricator

F Oil cup

G Regulated air outlet 8mm / G1/4 push-in fitting

H Oil refilling plug

I Soft start fitting

1

2

3

A

I

B

C

D

E

F

G

H


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4. SOLENOID VALVE MANIFOLD

4.1. Description The solenoid valve manifold serves to control the cylinders.



A 8mm (1/3 “) air inlet (from F.R.L. combination)

B Air outlet with silencer

VAL1 Move the pusher backward

VAL2 Move the pusher forward

VAL3 Raise the pusher to 0° position

VAL4 Lower the pusher to 15° position

4.3. Manual operation Directly controlled by the PLC, the electro-valves activate the pneumatic cylinders. By pressing button A, the pneumatic cylinders can be activated manually. This button could be kept at the activation position by pressing it down and turning 90° clockwise. To release the locking position, turn the knob 90° counter clockwise. This manoeuvre may prove to be useful during tests or maintenance. When the button is released, the pneumatic cylinder returns to its resting position (except for pneumatic cylinders activated by double-effect solenoid valve).

4.4. Air pressure switch To guarantee an optimal work of the bar feed system, the service pressure must be at least 5 bars (75 Psi). The pressure switch serves to confirm that this pressure is present and adequate. The pressure switch engages when the pressure is higher than 2 bar and close the emergency stop circuit.

When the air pressure drops below 0.5 bar, the switch disengages and interrupts the emergency stop circuit. An alarm arises.

A

B

VAL1

VAL2

B

A

A

VAL3

VAL4

A


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5. RODLESS CYLINDER FORMATION AND MAINTENANCE

The cylinder is assembled by the cylinder jar, the piston in it and also the sliding plate. The piston and the sliding plate are connected due to magnetism. The cylinder jar is a hollow tube with piston which apart from exhaust and induction side. When the air pressure is different, it makes the piston push to the smaller pressure side and the sliding plate will move to drive the pusher forward/backward. Please make sure there is enough lubricant between the cylinder jar and the sliding plate because it might lack of lubricant on account of times and again operation. Resistance will increase for cylinder to push the pusher if there is not enough lubricant or foreign matters like iron chippings adhering to it. As times of operation passing through, it will be unable to move on account of magnetism losing. According to the location where the bar feeder is placed, it is required to add solid grease from oil filler point periodically. Keep adding the grease until the dark oil evacuates and the clean oil drains away covering both side of the sliding plate. In addition, it is required to clean the surface of the cylinder regularly and smear some solid grease on it for isolating water impurities in order not to jam the sliding plate.

Oil Filler Point

Cylinder jar

Exhaust side

Induction side

Sliding plate


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6. MAINTENANCE The pneumatic system should be regularly maintained in order to ensure the system is powered by qualified compressed air. We recommend the user to check the F.R.L. combination as instructed below every week.

6.1. Check the condensate collector The condensate collector is a measure of quality of the compressed air. A qualified air should not produce any condensate inside the collector.

The F.R.L. combination should never be a replacement of air dryer!!!

The collector has an automatic drain plug. When there is no pressure inside the F.R.L. system, the drain plug is activated by the spring and the condensate released.

For users which always connect the compressed air, a manual draining is needed. Whenever the condensate is found inside the collector, drain the condensate by pushing the plug upward and check the humidity control system.

6.2. Check lubricator The oil consumption varies with the bar feeder applications. The oil height should not exceed half of the oil cup height. It is recommended to use oil ISO VG 32 only. When the oil is less than 30%, follow the procedures below to refill it.

Disconnect the air inlet tube.

Remove the plug and fill the oil up to the position shown on the figure.

For the best performance, the oil should drop once every pusher complete forward/backward moving cycle. If the working environment is humid or lathe does not installed air filter system users can drop more. Adjust the amount according to actual production conditions.

Connect the air inlet tube and turn air source on.

Decreasing oil dribbling

Oil dribbling nozzle

Increasing oil dribbling

Oil refill plug

Oil level


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CHAPTER 6: GENERAL DESCRIPTION 6-1

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CHAPTER 6: GENERAL DESCRIPTION

6-2 CHAPTER 6: GENERAL DESCRIPTION

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1. LOADING SYSTEM Please read the safety precautions described at the beginning of this manual before handling the following devices.

The loading system consists of bar magazine, loading fingers, stopping fingers and the loading cylinders. This system serves to storage and load bar stocks into the guiding channel. In order to load the bar stocks smoothly during automatic mode, the elements must be properly adjusted according to the bar stock profile and dimension.

1.1. Description of the elements

Designation Description Function

A Magazine To storage the bar stocks.

B Magazine cover To prevent any object to access into bar feeder.

C Magazine safety switch To detect if the magazine cover is open.

D Magazine rear stopper To constrict the area for placing the bar stocks.

E Magazine stands To support the magazine.

F Loading fingers To load the bar stock into channel.

G Stopping fingers To position the bar stock at loading position.

A

C

G

B

D

E

F


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1.2. Adjustment of the loading system

1.2.1. Stopping fingers The stopping fingers should be adjusted according to bar diameter so that only one bar stock will be loaded per loading cycle.

1.2.2. Magazine height As a generally rule, the magazine could be adjusted as the angle shown. For profiled bar stocks (square, pentagonal, hexagonal...) or smaller diameter ones, the angle could be increased by adjusting nuts A and B for loading more smoothly.

1.2.3. Refill of stock When refilling bar stocks, the rear end of the bar stocks should always be aligned to the magazine rear stopper.

B

A

15°

Stopping finger


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2. FEEDING SYSTEM The feeding system consists of the pusher assembly, rodless transmission device and TOP CUT measuring device. With this system, the rodless cylinder drives the pusher forward and backward hence accomplish bar stock feeding.


A Rodless cylinder

B Pusher carrier

C Encoder

D Guiding rod

E TOP CUT measuring device

F Front damping adjustment valve

G Rear damping adjustment valve

H Channel

I Pushing force adjustment knob

J Channel height adjustment

K Channel height locking knobs

G B A H

K

J

I

D C K

F

E


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3. TRANSMISSION Please read the safety precautions described at the beginning of this manual before handling the following devices.

Transmission unit consists of rodless cylinder and encoder. The pusher carrier is driven by the pneumatic rodless cylinder. Without mechanical connection between the pusher and bar stock, it should keep some distance between pusher and rotating bar stock. Generally transmission pushes forward when lathe chuck is open; push backward when lathe chuck is close.

The encoder is connected with the pusher carrier by a belt. While pusher is moving, the position will be calculated by encoder. PLC reads the position of the pusher through pulse from encoder and sends out signal accordingly. If the pusher is not stopped at specific positions, alarms will arise. A stopper inside the lathe for positioning the bar stock is always needed when the lathe connected with bar feeder. When the pusher is stopped by lathe stopper and no longer moving during automatic or manual mode, PLC output contact Y05 arises and sending START signal to lathe for initiating the next lathe machining cycle.


A Rodless cylinder

B Belt

C Pusher carrier

D Encoder

A D B C


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4. PUSHER Please read the safety precautions described at the beginning of this manual before handling the following devices.

4.1. Description The pusher assembly is composed of short and long pusher.

Item Function Note

Short pusher First feed The movement inside bar feeder

Long pusher

TOP CUT

The movement outside bar feeder Feeding during production

Remnant ejection

There are 3 different diameters of pusher available for the bar feeder as shown below.

Pusher diameter Applicable bar stock diameter range (in mm)

Ø 6mm Ø 5 – 15

Ø 12mm Ø 15 – 25

Ø 20mm Ø 25 up

Ø 6 Ø 12Ø 20


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4.2. Pusher replacement

1. Move the channel to 15° position ( )

2. Move the pusher to middle of the channel ( )

3. Remove the lock nut and PE bushing set screw.

4. Be careful with the spring compressed behind the pusher rod. Hold the pusher rod tight before removing the set screw for fixing the pusher on the cylinder. When the set screw removed, gently release the pusher.

5. Carefully move the pusher rod forward. Move the pusher backward for completely removing it from the pusher assembly as well as the PE bushing.

4

5

3


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6. Mount the PE bushing. Insert the front end of pusher rod into the PE bushing. Ensure the spring is inside the adapter. Insert the rear end of the pusher rod into the adapter

7. Lock the set screw for fixing the pusher rod.

Ensure that the top surface of the set screw is lower than the adapter’s.

8. Lock the set screw for fixing the PE bushing and lock nut.

9. Move the pusher back to origin reference.

6

8

7

The top surface of the set screw is lower than the adapter surface.

Adapter surface


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4.3. Pushing force adjustment The pushing force could be changed by adjusting the air regulator according to the bar stock diameter. Since the pushing force is reduced by various bar stock boundary conditions includes material density, surface condition, rodless cylinder performance... and so forth, there is no firm recommended value for specific bar stock diameter. But the user could set as the reference table below then adjust according to real producing conditions.

Bar stock diameter (mm) Suggested regulator pressure (bar)

below 10 3

10 ~ 30 3 ~ 4

above 30 4 ~ 6

Turn the knob clockwise to increase the pushing pressure and turn it counter-clockwise to reduce it.

4.4. Damping force adjustment With the increasing pushing force, the impact might be larger when pusher arrives at the front or rear limitation. To avoid this, the bar feeder allows the user to give damping effect on each end as shown below. Turn the valve clockwise to increase the damping distance or turn it counter-clockwise to decrease it.

Pressure gauge

Increase pressure

Decrease pressure

Lock/unlock

Increase damping distance

Rear end

Lock/unlock

Decrease damping distance

Front end


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5. CHANNEL SET

5.1. Description The channel set serves to support the bar stock during loading and FIRST FEED. The channel has 2 operating positions. Only specific operation could be operated at each position.

5.2. 15° position This position serves to push the bar stock forward outside the bar feeder (i.e. inside the lathe spindle) by moving long pusher forward.

By pressing button on the remote control when pusher is at home position, take actions below by sequence:

1. The channel drops down to lower position.

2. The channel swings to 15° position, engages the long pusher with rodless cylinder carrier and position the long pusher at bar feeder feeding center.

3. The loading fingers swing to lower position.

4. The long pusher is able to move accordingly either in manual or automatic mode.

4

2 1

3

Bar feeder feeding center


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5.3. 0° position This position serves to feed a new bar stock out of the bar feeder (i.e. feed it into the lathe spindle) by moving short pusher forward.

By pressing button on the remote control when pusher is at home position, actions below take place by sequence:

1 The loading fingers swing up and load a bar stock into the channel.

2 The channel swings to 0° position and disengages the long pusher from rodless cylinder carrier.

3 The channel lifts up to upper position and position the bar stock to bar feeder feeding center.

The channel upper position should be adjusted according to bar stock diameter.

4 The short pusher is able to move accordingly either in manual or automatic mode.

4

1

2

3

Bar feeder feeding center


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5.4. Height adjustment The channel upper position must be adjusted according to bar stock diameter therefore the bar stock is positioned at the bar feeder feeding center when the channel is at 0° position. Follow the procedures below to adjust the channel upper position:

1. Loose 2 locking handles as shown.

2. Adjust the knob according to bar stock diameter. The upper index indicates inch and the lower index indicates mm. Turn the knob clockwise to increase dimension and turn the knob counter clockwise to reduce it.

3. Lock locking handles after adjustment is finished.

Align this corner to the bar stock dimension.

Increase bar stock dimension.

Decrease bar stock dimension.

Lock

Unlock

Lock

Unlock

1 1

2


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6. SPINDLE LINER The spindle liner acts as an extension of guiding system. It fills the gap between the bar stock and spindle inner surface hence constrict the space of vibration. The spindle liner serves to support the pusher and bar stock inside the spindle when the spindle inner diameter is larger than pusher’s. The bar feed system is delivered without spindle liner. The spindle liner is not a must but strongly recommended to be prepared and installed by the customer.

6.1. Design The material could be either steel or plastic like teflon or PE. Both single tube and combination of multiple pieces of short tubes are available. The only target is to cover the whole spindle length as complete as possible. Below we suggest multiple spindle liner. Two kinds of spindle liner are needed:

6.2. Model A Type A is supposed to be repeatedly inserted into spindle which fits most of its overall length.

6.2.1. Dimension Overall length L :

Obtained by divided the spindle length by the quantity the user wants to make. Generally the length of each length could be 50 ~ 100mm.

OD1:

The outside diameter of the spindle liner. Generally 1mm smaller than the spindle inner diameter.

ID:

The inner diameter of the spindle liner. Generally 1mm larger than the bar stock outside diameter.

t:

For reference only. Generally the thickness should not be smaller than 5mm.

n X Model A

Model B


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6.3. Model B The one which seals the rear end of the spindle. There are 3 different designs available of the last piece. Select the mode which fit the lathe spindle or consult us for technical support.

Model B.1 Model B.2 Model B.3

6.3.1. Model B.1 All the dimensions are same as Model A except:

OD2: 1 or 2mm larger than the spindle inner diameter.

Entrance chamfer C : C = 0.5 X t

6.3.2. Model B.2 All the dimensions are same as Model A except:

OD2 : 1 or 2mm larger than the spindle inner dimension by entwining tape on the surface.


6.3.3. Model B.3 This type could be applied when there are screw holes on rear end of the spindle. The user can make a ring to stop the spindle. The inner diameter of this ring should be located between the outside and inner diameter of the spindle liner.

All the dimensions are same as Model A except :


CHAPTER 7: OPERATION 7-1

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CHAPTER 7: OPERATION

7-2 CHAPTER 7: OPERATION

ECOLOAD S2

1. REMOTE CONTROL Please read the safety instructions provided at the beginning of this manual before handling the following devices.

The remote control offers interface signal indicating LEDs and buttons for operating the bar feed system when it’s in MANUAL mode.

1.1. Signal display area M CODE Indicates the lathe chuck M code signal is ON/OFF when the signal is ON/OFF. CHUCK Indicates the lathe chuck is open/closed when the LED is ON/OFF. B.D.T Indicates the END OF BAR signal is ON/OFF when the LED is ON/OFF. START Indicates the START signal is ON/OFF when the LED is ON/OFF. ALARM Indicates the ALARM signal is ON/OFF when the LED is ON/OFF. * These signals will be effected by lathe actions, not by service parameter setup.

Emergency Stop Button

Signal Display Area

Function Keys


ECOLOAD S2

1.2. Functions keys

Emergency stop

When a dangerous situation arises, pressing the emergency stop button immediately interrupts the bar feeder. The bar feeder will send alarm signal to the lathe and interrupt the lathe if interface is wired accordingly. Error message e01 will be shown on the HMI display. To cancel the alarm, release the button by rotating it clockwise and pressing the MANUAL mode key.

Auto ready

To switch the bar feeder to AUTOMATIC ready mode. In AUTOMATIC ready mode, the key LED is ON. The bar feeder is available to be switched to AUTOMATIC mode. To switch to AUTOMATIC ready mode, following conditions must be fulfilled:

The V channel is at 15° position for long pusher feeding.

Auto start

To switch the bar feeder to AUTOMATIC mode. In AUTOMATIC mode, the key LED is ON. The bar feeder is running the automatic sequence controlled by the lathe. To switch to AUTOMATIC mode, the following conditions must be fulfilled :

The V channel is at 15° position for long pusher feeding and bar feeder is in AUTOMATIC ready mode.

Manual

Switch the bar feeder to MANUAL mode. When the bar feeder is on MANUAL mode, the key LED is ON and the user could operate the bar by function keys.

Reset the bar feeder from an emergency stop.

Rightward

Move pusher rightward. Only available when the bar feeder is in MANUAL mode

Indicate the position of pusher. When the pusher passes FIRST FEED position set up on P08, the LED will be ON.

Leftward

Move pusher leftward (to home position). Only available when the bar feeder is in MANUAL mode.

When the pusher arrives at home position, the LED will be ON.

15° Position

Only available when bar feeder is in MANUAL mode and the pusher is at home position. Tilt V channel to 15° position for long pusher feeding. The channel and loading fingers will be let down. When the channel arrives at 15° position, the LED will be ON.

0° Position

Only available when bar feeder is in MANUAL mode and the pusher is at home position. Tilt V channel to 0° position for short pusher feeding. The channel and loading fingers will be lifted up. When the channel arrives at 0° position, the LED will be ON.


ECOLOAD S2

2. HMI (Human Machine Interface) The HMI allows the user to read messages and set parameters

2.1. Text display area The display provides parameters, status information and error messages:

After powering up, the screen shown left is displayed. Press key to switch to the parameter screen as shown on the right. In the parameter screen, 3 selections are available:

1. : To access the OPERATION PARAMETER screen.

2. : To access the SERVICE PARAMETER screen.

3. : To display the software version. Both HMI and PLC has their own software as shown. This information is sometimes necessary when you contact us for technical support.

2.2. Status indication area Alarm (red) This LED will be ON when

powering up the bar feeder. After initialization of the HMI the LED will turn OFF. there is a communication failure between the PLC and the HMI.

RS-232 (green) The RS-232 interface is not used and the LED remains OFF.

RS-485 (green) The RS-485 LED indicates communication activity between the PLC and HMI.

Text display area

Command Keys

Status indicating area

Current pusher position

Numerical Key Pad


ECOLOAD S2

2.3. Command keys

Increase / decrease the numerical value of a specific digit. Example :

If one digit is “4”, increase it to “5” by pressing or decrease it to “3” by

pressing .

Move the blinking cursor to the left / right. Example : If the cursor is current staying at ”4” of number “345”, move it to digit “3” by pressing

or move the cursor to “5” by pressing .

By pressing this key to exit from a parameter setup page without changing the setting.

Use this key to validate a new parameter setting.

2.4. Numerical key pads

Shown as , , , , and .

They serve to enter numbers or execute functions attributed to them.

1. When editing parameter values, the key pad can be used as alternative to the previously described Up/Down keys. Numbers are entered according to the following table:

Number 1 2 3 4 5 6 7 8 9

Key Combination

+

+

+

+

+

2. On some screens functions are assigned to the keys. The assigned function is indicated by an icon displayed above the corresponding key.

Example : On the screen shown, key can be used to return to the previous screen.


ECOLOAD S2

3. POWERING AND EMERGENCY STOP

3.1. Powering up The pusher carrier of bar feeder is equipped with an absolute encoder that continuously reads the position of the pusher. When the bar feeder is powered down or there is a power failure, this position is kept in the memory by the PLC. During powering off, the encoder does not work.

When powering up, the pusher position value saved is immediately taken into account, thus avoiding any input from the beginning. The PLC reads signals from sensors and gives the operator allowable operations only.

Make sure it is turned OFF before opening the electrical cabinet. Do not change the pusher position when bar feeder is powered OFF

because the position reading does not match the pusher’s actual position.

For example, when pusher is at home position but the current position is not 0, take either one approach below to reset the original position: 1. Move the pusher back to home position.

Power the bar feeder OFF and ON. 2. Move the pusher back to home position then keep pressing the button for 3 seconds.

Power ON Power OFF

Turn the button clockwise to power ON the bar feeder.


ECOLOAD S2

3.2. Emergency stop buttons When a dangerous situation arises, press one of the emergency stop buttons. Actions below will be initiated and interrupts the bar feeder and the lathe (if interface wired accordingly): 1. PLC output contact Y04 is ON.

2. Alarm e01 is shown on HMI.

3. PLC output contacts from Y13 to Y16 are OFF.

4. PLC output contact Y17 is ON.

When the emergency situation is fixed, release the emergency stop button and press the manual key on the remote control to restart the bar feeder.

3.2.1. Emergency stop button on the cabinet, STP1

3.2.2. Emergency stop button on the remote control, STP2

INTERRUPTIONRESET

INTERRUPTION RESET


ECOLOAD S2

4. AUTOMATIC / MANUAL SEQUENCE

4.1. Turn the frame to 15° in manual mode Conditions below must be fulfilled:

1. The lathe is not in AUTOMATIC mode. 2. The V Channel is at 0° position (SR1 ON). 3. No material inside lathe spindle. Steps to move the frame to 15°:

1. Press key to return short pusher to home position (SR3 ON).

2. Press key to proceed the followings Short pusher starts FIRST FEED to assure there is no material on V channel. Short pusher returns to home position (SR3 ON) automatically. Lower V channel and tilt to 15° position (SR2 ON).

4.2. Turn the frame to 0° in manual mode Conditions below must be fulfilled:

1. The lathe is not in AUTOMATIC mode. 2. The V channel is at 15° position (SR2 ON). Steps to move the frame to 0°:


2. Press key to raise V channel and tilt to 0° position (SR1 ON).

4.3. Continue an interrupted machining Conditions below must be fulfilled:

1. The lathe is not in AUTOMATIC mode. 2. The lathe chuck is open. 3. The lathe stopper is positioned at part length position. 4. Bar stock is still in the spindle. 5. The V channel is at 15° position (SR2 ON).

Steps to switch the bar feeder to auto mode:

1. Manually move the pusher forward until the bar stock pushes against the stopper by pressing

button. Then close the chuck and release key.

2. Press and by sequence to switch the bar feeder to AUTOMATIC mode. 3. Switch the lathe to auto mode.

Never switch the bar feeder into AUTOMATIC mode when the chuck is open!!! Never switch the lathe to AUTOMATIC mode before switching the bar feeder to AUTOMATIC mode.


ECOLOAD S2

4.4. Start a new machining Conditions must be fulfilled before proceeding automatic sequence:

1. The lathe is not in AUTOMATIC mode. 2. The lathe chuck is open. 3. The lathe stopper must be positioned at the TOP CUT position. 4. The lathe program is already set properly. 5. The bar feeder is installed and anchored.

The bar stocks are put on the magazine. 6. All parameters are set properly. 7. The bar feeder has been properly set according to pneumatics, electrics and mechanics according to

bar stock dimension and machining conditions. 8. V channel is at 15° position (SR2 ON). Steps to set automatic sequence: 1. Manually move the lathe stopper to TOP CUT position.

2. Press until the long pusher moves back to home position (SR3 ON).

Press to raise the V channel and tilt it to 0° position (SR1 ON) for loading a new bar. Position the short pusher at feeding position.

3. Press to move the short pusher forward for feeding the new bar out of bar feeder.


5. Press to lower the V channel and tilt it to 15° position (SR2 ON). Position the long pusher at feeding position.

6. Press until the long pusher pushes the bar stock against the stopper. Do not release till the chuck closes.

7. Close lathe chuck.

8. Switch the bar feeder into AUTOMATIC mode by pressing and in sequence. The related LED will ON.

9. The long pusher moves back to home position (SR3 ON). Manually do the bar preparation on the lathe.

10. Switch the lathe to auto mode. Never switch the bar feeder into AUTOMATIC mode the chuck is open!!! Never switch the lathe into AUTOMATIC mode before switching the bar feeder is in AUTOMATIC mode.


ECOLOAD S2

4.5. Bar feeder in automatic mode Steps continue 4.4:

4.5.1. Automatic cycle - Production 11. Check END OF BAR signal.

- If it’s activated, proceed step 20. - If it’s not activated, proceed the next step.

12. Position the stopper of the lathe at part length position. 13. Chuck open 14. Pusher feeds forward until the bar stock touches against the stopper.

After the start delay time set on P09, START signal will arise 15. The chuck closes according to the START signal. 16. Receive CHUCK CLOSE signal.

After the backward delay time set on P09, the long pusher will retract back according to P02 or P04 setup.

17. Machining the part. 18. Go back to step 11.

4.5.2. Automatic cycle - Bar change

19. Lathe stopper moves to spare for long pusher to push remnant out of lathe spindle completely.

20. Chuck open

21. Receive CHUCK OPEN signal.

Pusher ejects the remnant according to ejection position set on P07 and START signal arises.

22. Pusher retracts back to home position (SR3 ON).

Position the stopper at TOP CUT position according to START signal.

23. The V channel is raised and tilted to 0° position (SR1 ON) and a new bar is loaded.

The short pusher is at feeding position.

24. The short pusher feeds the bar stock out of the bar feeder according to P08 setup.

25. The short pusher returns back to home position (SR3 ON).

26. V channel is lowered and tilted to 15° position (SR2 ON).

The long pusher is at feeding position.

27. The pusher moves forward till the bar stock touches against the stopper and then START signal

arises.

28. Close the chuck according to START signal.

29. Receive CHUCK CLOSE signal.

After the backward delay time set on P09, the long pusher will retract back according to P02 or P04

setup.

30. Initiate TOP CUT.

31. Go back to step 11.

4.6. Switch the bar feeder into manual sequence The following conditions must be fulfilled before proceeding to the manual sequence.

1. Lathe finishes a machining cycle and currently interrupts. 2. Lathe chuck is closed Steps to switch the bar feeder into manual mode:

1. Switch the bar feeder into MANUAL mode by pressing button. 2. Switch the lathe to MANUAL mode

Never open the lathe chuck when the bar feeder is in AUTOMATIC mode. Switch the bar feeder into manual mode first then switch the lathe into manual mode.


ECOLOAD S2

5. OPERATION PARAMETERS The operation parameters are most frequently changed parameters for controlling the bar feeder when it’s in AUTOMATIC mode. All the operation parameters could be changed according to the machining requirement. To achieve the best performance, the operator is strongly recommended to read this chapter before proceeding any modification.

5.1. Accessing After selecting the operation parameters by pressing F0, the following screen will be displayed

Navigation : Page up / down to display parameter screens.

to

Edition : 1. Press F0 for the 1st parameter displayed. 2. Press F1 for the 2nd parameter displayed. 3. Press F2 for the 3rd parameter displayed.

Press F4 to return to the previous screen.

Validation of the changes : After editing the value, you must press this key to save the new setting.


ECOLOAD S2

5.2. Description Only parameters inside rectangular are adjustable. Unit for all the length / position related parameters is mm.

The bar stock positioning control logic The ECOLOAD S2 pusher was designed to be stopped with auxiliary of the stopper inside the lathe. Whenever the chuck is open and the lathe is in automatic mode, the pusher feeds forward all the time until it was stopped or arrives at end of its stroke. When the pusher is stopped by the stopper (via bar stock), the bar feeder sends START signal to the lathe via interface accordingly. The lathe should never proceed any further action – the next machining cycle or bar change, without this signal.

P01 Feeding distance check This parameter should be MODIFIED if if production part changed.

This setup allows the operator to assign the maximum and minimum feeding distance that the bar feeder should alert. When those values are exceeded, the bar feeder will arise alarm accordingly.

Too short dist

The minimum allowed feeding distance. The bar feeder arises an alarm if the feeding distance is smaller than this value when chuck/collet is open.

Too long dist

The maximum allowed feeding distance. The bar feeder arises an alarm if the feeding distance is larger than this value either the chuck/collet is open or close.

P02 Pusher retract position 2 of 2

The pusher retraction POSITION to avoid its tip contacting with rotating spindle. Refer to P04 for reference. Position

Current pusher position measured from home position SR3.

P-bar position

The POSITION where the pusher should be POSITIONED so that its tip does not droop and contact the rotating spindle.


ECOLOAD S2

P03 Feeding length This parameter should be MODIFIED if production part changed.

The distance of bar stock needed to be fed for making a part.

Position

Current pusher position (measured from home position).

Part Length

The needed feeding part length is :

< part length > + < cut off width >

P04 Pusher retract position 1 of 2

The pusher retracting DISTANCE to avoid its tip contacting The pusher retraction DISTANCE to avoid its tip contacting with rotating spindle.

Position


Return Stroke

The DISTANCE that the pusher should RETRACT so that it’s tip does not contact the rotating bar stock.

Due to there is no rotating adapter between the pusher and the bar stock, the pusher tip must not contact any rotating component or it will be damaged. Below is the summary for those cases and their solutions :

Direction Situation Solution Parameter

Axial The pusher touches the bar stock rear end.

Keep the pusher away from the rotating bar stock when feeding is accomplished.

P04

Lateral The pusher touches the rotating spindle because it’s own weight droop it’s tip.

Keep the pusher behind the position where its tip starts to droop to the rotating spindle.

P02

P05 Top cut distance

Position

The distance which the tip of a new bar travels after it touches the TOP CUT sensor. Top cut

The position where the tip of a new bar will be positioned in AUTO cycle.

Return Stroke

Top cut


ECOLOAD S2

TOP CUT TOP CUT is the process which cuts few millimeters off from a new bar stock tip for creating a precise positioning reference of the next feeding. It presents the distance where the end face of a bar stock needs to travel from the bar feeder for proceeding TOP CUT machining. This position is controlled by the lathe stopper as well.

TOP CUT position is measured from the TOP CUT sensor LS1. The PLC reads and starts to count the pusher’s moving distance right after the bar tip hit the sensor and activates START signal when the PLC detects the bar stock hits stopper behind TOP CUT position.

P06 Bar End position This parameter should be modified if production part changed.

Position


Bar end cycles

BAR END signal counter.

Bar end point

The position where the rest bar stock is inadequate to produce a complete part according to P03 setup.

Setup procedure

Get a remnant which is 20mm longer than the lathe chuck.

Align the remnant with chuck surface and clamp it. Move the pusher forward until the pusher tip touches against the rear end of the clamped remnant. Enter the value of Position into “Bar end point”.

The BAR END position could be adjusted if the remnant is too long. But the pusher should NEVER insert into the chuck when BAR END signal is arose.

BAR END position

The pusher position where the rest bar stock length is inadequate to produce a complete part according to P03 setup. When pusher passes this position during automatic mode, the bar feeder activates BAR END signal according.

P07 Ejection position

Position


Bar out point

The position where the pusher ejects the remnant in AUTO mode. The actual BAR OUT POINT is about P07+100 mm.

Ejection position Before proceeding the bar change process, the spindle must be emptied to leave space for new bar stock. The position where the pusher ejects the remnant is called ejection position.


ECOLOAD S2

P08 FIRST FEED

Position

Current short pusher position measured from home position SR3.

1’st feed limit

The distance where the short pusher needs to travel for moving the bar stock completely out of the channel.

This parameter must be set to 1594 and should never be changed.

FIRST FEED A bar stock’s first movement right after it’s loaded into a bar feeder. The purpose is to move the bar stock completely out of the bar feeder (i.e. insert into the spindle).

P09 SIGNAL TIMER

This setup allows the operator to postpone signal/action which taking place before/after chuck close. Time unit is 1 second.

Start delay

Timer for postponing sending START signal.

Backward delay

Timer for postponing pusher retraction action.

P10 Application setup

0：

Standard program. Bar change starts when receiving the BAR END signal.

1：

One shaft loading. This is a special bar change program. If P10 set 1, after chuck is closed, pusher returns to home position for bar change (without receiving BAR END signal)

P11 Dry run state

The lathe is unable to work without Automatic mode signal (R4) sent from the bar feeder. When the lathe is turning for measuring a sample, the bar feeder will send R4 signal to the lathe during dry run state. If the following conditions are fulfilled: Bar feeder is in manual mode V channel is at 0° position Pusher is at home position (SR3 ON) TOP CUT is activated Set P10 dry run ON, then bar feeder will switch to DRY RUN state and output R4 signal to the lathe without pressing any button on the remote control. If there is any error messages arise, it will deactivate DRY

RUN state and turn P11 setup OFF.


ECOLOAD S2

6. SERVICE PARAMETERS Service parameters must only be modified by technicians of or personnel authorized by LNS. Incorrect setup might cause unexpected malfunction or damage on either bar feeder or lathe. Accessing these parameters is password protected. Please contact LNS or its official agent in your country for getting technical support in case any modification is needed.

6.1. Accessing After selecting the service parameters, the following screen will be displayed:

Navigation : Page up / down to display parameter screens.

Edit the parameter value.

Return to previous page

Validation of the changes : After editing the value, you must press this key to save the new setting.


ECOLOAD S2

6.2. Description

MODE 1 Simulation

When this MODE is ON, the bar feeder runs feeding and bar change cycles automatically and not controlled by either interface signals or manual operation. This MODE is for factory test or exhibition purpose only. When it’s connected with the lathe, it must always be turned OFF. 0 - Turn SIMULATION OFF 1 - Turn SIMULATION ON

MODE 2 Chuck signal (A1) logic setup

0 - CHUCK signal is ON when chuck is open 1 - CHUCK signal is OFF when chuck is open.

MODE 3 CNC alarm signal (A2) logic setup

0 – Lathe alarm signal is ON when there is an alarm. 1 – Lathe alarm signal is OFF when there is an alarm.

MODE 4 M-function (A3) logic setup 1 of 2

“M-function” represents a signal in addition to chuck signal for confirming lathe chuck status. (also refer to MODE 7 for further information) 0 – M-function signal is ON when the lathe activates M-function. 1 – M-function signal is OFF when the lathe activates M-function.

MODE 5

This parameter intentionally left blank.


ECOLOAD S2

MODE 6


MODE 7 M-function (A3) logic setup 2 of 2

Define if the bar feeder needs M-function or not.

0 – Bar feeder feeds the bar stock according to chuck signal only.

1 – Bar feeder feeds the bar stock according to both chuck signal and M-function signal.

MODE 8


MODE 9 Bar feeder status check

Define if the bar feeder check itself is in AUTOMATIC mode when the chuck signal is turned ON/OFF for 3 cycles. If this check is activated and the result is negative, the bar feeder activates alarm e11.

0 – Deactivate this check.

1 – Activate this check.

MODE 10 PLC output contact Y05 setup

Define how PLC output contact Y05 act during production. (refer to figure below)

0 – the signal is referred as CYCLE START signal

1 – this signal is referred as WORKING signal.


ECOLOAD S2

Chuck signal

Mode 10 = 0

Mode 10 =1

Bar end

MODE 11 / 12 / 13 /22 BAR END signal setup

Refer to the figure below.

Chuck signal

MODE

11 12 13 22

0 0 0 0

1 0 0 0

0 1 0 0

0 0 1 0

0 0 0 1

Last feeding Bar change Machining Bar change Stopper

Y05

Top cut

Eject remnant

Eject remnant

Top cut

Last part feeding Bar change

BAR END signal

Chuck close

Chuck open


ECOLOAD S2

MODE 14 START signal setup

Define when START signal is sent during remnant ejection.

0 – Start signal is sent after pusher is pushed to P07 position.

1 – Start signal is sent if pusher touches any obstacle during remnant ejection.

MODE 15 HMI Language setup

0 – Optional language.

1 – English

MODE 16 INCHING setup

This parameter defines if the pusher movement activated. The INCHING signal is not affected.

0 – Activate pusher movement.

1 – Deactivate pusher movement.

INCHING

When the bar feeder system is loading profiled bar stocks (hex, square...) or round ones without proper preparation, it’s quite easily to struggle to push them through the lathe chuck. To solve this problem, the bar feeder offers a function called “INCHING”.

The function INCHING consists of 2 actions :

1) Move the pusher back and forth repeatedly.

2) Send continuous signal to the lathe as an external command to rotate the spindle. This signal is specially created for the lathes whose spindle is not allowed to rotate while chuck is open. This signal is also called INCHING signal.

MODE 17 BAR END signal setup

Define when the BAR END signal becomes OFF.

0 – When the V channel goes down with SR2 ON and the pusher starts feeding, BAR END signal is removed.

1 – After remnant is ejected and the pusher returns to home position (SR3 ON), BAR END signal is removed.


ECOLOAD S2

MODE 18 Length check skip

Define the number of feeding length check skipped after a new bar stock was loaded at TOP CUT position. This number is available from 1 to 5.

MODE 19 Length unit setup

Define the unit used of those parameters related to length on HMI. 0 – mm

1 – inch

MODE 20 Interface test state

Define if the actions below will be taking place.

Please note that this function is designed only for testing bar feeder connected to lathe. Please turn off this function during general application.

The LED of AUTO START button will be blinking. The texts displayed on the HMI will be blinking. The functions below will be deactivated :

1) Too long / too short 2) Magazine empty 3) TOP CUT position

When the bar feeder is proceeding bar feeding in auto mode, the pusher stops automatically when part length has been arrived.

The bar feeder stops proceeding FIRST FEED positioning until the user press [AUTO START] button.

0 Disable this function 1 Enable this function

MODE 21 No upper limit

Define if the limitation of P01 “Too long dist” is deactivated.

0 – activate the limitation of P01 “Too long dist”.

1 – deactivate the limitation of P01 “Too long dist”.


ECOLOAD S2

CHAPTER 8: TROUBLESHOOTING GUIDE 8-1

ECOLOAD S2

CHAPTER 8: TROUBLESHOOTING GUIDE

8-2 CHAPTER 8: TROUBLESHOOTING GUIDE

ECOLOAD S2

1. ALARMS Please read the safety instructions provided at the beginning of this manual before handling the following devices. Particular attention should be given to the handling of electrical elements because of risks of electrocution. In case of possible electrical malfunctions, it is advisable to contact LNS or their local representative.

This chapter lists all the error messages description and brief troubleshooting. The error messages aim to remind the operator that an abnormal situation probably exists. Whenever an error message activated, please follow the description and troubleshooting guide to check the problem. If necessary, contact us for technical support.

1.1. WARNING MESSAGES Warning messages are designed to remind users the bar feeder status. Those messages are used to remind operator the bar feeder working status. Under the following conditions, there will be a warning message shown but Y04-alarm is not switched on.

Warning messages

Description

When the sensor SR1(0 ˚ position) and sensor SR2(15 ˚position) are ON or OFF at the same time, alarm e16 will arise. Press the STOP button on the remote control box and the warning message will arise.

Trouble shooting

1. Check SR1 and SR2 to see if the switches are broken. 2. Check if PLC input contact X03 and X04 or the connecting

line are broken.

3. Press the button or on the remote control box to reset the status of channel.


ECOLOAD S2

1.2. Error message map The table offers the sequence while both bar feeder and lathe are running under AUTOMATIC mode and the timing of related alarms are activated. Please note the table simplified AUTOMATIC sequence and only presented general selected necessary steps. The table is just a reference which may not fit users’ production situations. The real machining procedure should depend on the program users installed.

Auto

Chuck close_A1

Bar end

Pusher retract (P04,P02)

Send R3 to CNC

No

Yes

Machining

Chuck open A1 (Mode 7 for M code_A3)(e12,e17,e18,e20,e22)

Bar end

Eject Remnant to the lathe P07(e23)

No

Yes

Pusher returns to home position(e,10,e18)

Load a new bar(e15)

First feed(e2,e7,e9,e10,e17,e25)

Send R5 to CNC (optional)

Short pusher returns to home position(e14,e18)

Long pusher feeds to lathe(e6,e10,e19)

Send R5 to CNC (optional)

TOP CUT position P05

Send start signal R2 to CNC(e20,e26)

Send Start signal R2 to CNC

Push to stopper AS2_X06

: Barfeeder action

: Lathe action

Auto: Continue an interruptedmachining in Auto mode


ECOLOAD S2

1.3. Error message description and troubleshooting guide An error code means signals combination from sensors which match error code definition in the PLC program. Follow the troubleshooting procedures below to solve the problems and reset the bar feeder from the error by pressing the MANUAL mode key.

e01 Emergency stop circuit is open

Description

Emergency stop circuit which goes through contacts below is open :

emergency stop button on HMI. emergency stop button on remote control. emergency stop contacts on the lathe air pressure switch retraction system safety sensor

Troubleshooting

1. Check if emergency stop button on HMI is pressed. If so, please reset it.

2. Check if emergency stop button on remote control is pressed. If so, please reset it.

3. Check if emergency stop contacts on the lathe were wired to bar feeder emergency stop loop and is open. If so, please reset it.

4. Check if the air pressure is not enough. The air pressure switch will trip if the air pressure is lower than 4 kg/cm2.

5. Check if the retraction system safety sensor is connected and open.

e02 FIRST FEED setup is too big

Description

The short pusher exceeds the position of <P08+20mm>.

Troubleshooting Check if 1st feed limit (P08) setup is too small.

e03 BAR END setup is too small

Description

When bar feeder is switched into automatic mode, the pusher’s current position is larger than the BAR END position

Troubleshooting Check if Bar End setup is too small.


ECOLOAD S2

e04


e05


e06 Top cut setup is too long

Description

Positions BAR END, EJECTION and FIRST FEED have been passing through but TOP CUT position is not arrived.

Troubleshooting

1. Check if TOP CUT setup is too long. 2. Check if BAR END, EJECTION and FIRST FEED setup

are too small.

e07 No material on the magazine

Description

FIRST FEED position has been exceeded but the TOP CUT sensor was not activated.

Troubleshooting

1. Check if bar stock on the magazine is exhausted, if so, please re-load bar stocks.

2. Check if Top cut sensor is broken.

e08 Lathe alarm

Description

An alarm has arisen on the lathe.

Troubleshooting

Reset the lathe alarm according to the lathe’s troubleshooting guide


ECOLOAD S2

e09 FIRST FEED process could not be initiated 1 of 2

Description

For bar feeders that MODE 7 = 1. When the bar feeder is ready for proceeding FIRST FEED, M-code is not activated within 15 seconds.

Troubleshooting

1. Check if M-code signal is wired in the interface cable. If not, wire it and test the signal again.

2. Check if M-code on the lathe is activated. If not, activate it.

e10 FIRST FEED process could not be initiated 2 of 2

Description

For bar feeders that MODE 7 = 0. When the bar feeder is ready for proceeding FIRST FEED, chuck signal is not activated within 15 seconds.

Troubleshooting

1. Check if lathe chuck is open. 2. Check if the chuck signal was sent from the lathe. 3. Check if the bar feeder receives the chuck signal.

e11 Bar feeder is not in automatic mode

Description

The bar feeder is still in manual mode when the lathe chuck has been turned ON/OFF 3 cycles.

Troubleshooting

Switch the bar feeder into automatic mode if it is supposed to be.

e12 Feeding length is too long

Description

When lathe chuck is open, the pusher feeding length is larger than “P01: Too long” setup.

Troubleshooting

1. Check if the lathe stopper is correctly positioned. 2. Check if parameter “P01: Too long” set correctly. 3. Check if the pusher overlaps the bar stock.


ECOLOAD S2

e13 Feeding length is too short

Description

When lathe chuck is open, the pusher feeding length is smaller than parameter P01 <Too short dist> setup.

Troubleshooting

1. Check if the lathe stopper is correctly positioned. 2. Check if parameter P01<Too short dist> correctly set up. 3. Check if the lathe chuck is too tight. 4. Check if the spindle is blocked.

e14 15° positioning is failed

Description

The bar feeder fails to position the channel set at 15° position.

Troubleshooting

1. If positioning is accomplished, check if sensor SR2 is broken.

2. If the positioning is not completed, check if anything blocks the channel set.

3. Check if the air pressure is too low to operate the cylinders.

4. Check if the air tubes, valves or cylinders are leaking.

e15 0° positioning is failed

Description

The bar feeder fails to position the channel set at 0° position.

Troubleshooting

1. If positioning is accomplished, check if sensor SR1 is broken.

2. If the positioning is not completed, check if anything blocks the channel set.

3. Check if the air pressure is too low to operate the cylinders.

4. Check if the air tubes, valves or cylinders are leaking.

e16 Check SR1, SR2

Description

Sensor SR1 (0˚ position) and sensor SR2 (15˚ position) are ON or OFF at the same time, this alarm will arise.

Troubleshooting

1. Check SR1 and SR2 to see if they are broken. 2. Check if PLC input contact X03 and X04 or the connecting

line are broken.


ECOLOAD S2

e17 FIRST FEED positioning is failed

Description

The bar feeder fails to position the bar stock at FIRST FEED position according to P08 setting within 10 seconds.

Troubleshooting

1. Check if the channel or lathe spindle is blocked. 2. Check if the pushing force is too small to push the bar

stock. Refer to chapter 6 to adjust it.

e18 Pusher failed to return to home position

Description

The bar feeder fails to retract the pusher back to home position within 15 seconds after EJECTION or FIRST FEED was accomplished.

Troubleshooting

1. Check if the lathe spindle blocked. 2. Switch the bar feeder into manual mode. Move the

pusher by remote control and see if the cylinder is broken.

3. Check if the pusher has returned to home position but sensor SR3 did not detect it.

4. Check if VAL 1 is broken. Refer to chapter 4 for further information.

e19 TOP CUT positioning is failed

Description

The bar feeder fails to position a new bar stock at TOP CUT position within 120 seconds.

Troubleshooting

1. Check if the bar stock is blocked inside the lathe spindle or chuck.

2. Check if the pushing force is too small to push the bar stock. Refer to chapter 6 to adjust it.

3. Check if the TOP CUT setup is correct.

e20 Failed to start the lathe

Description

The lathe chuck is not close in 10 seconds after START signal was sent.

Troubleshooting

1. Check if lathe receives START signal from bar feeder. 2. Check if the lathe closes the chuck according to the

START signal. 3. Check if the chuck signal was successfully transmitted via

the interface cable.


ECOLOAD S2

e21 Pusher moving distance is too long when chuck is closed

Description

The pusher moving distance is larger than <Too long dist> setup in P01 when the lathe chuck is closed.

Troubleshooting

1. Check if the chuck signal received but the lathe chuck is still closed.

e22 Check bar ejection setup

Description

Ejection position was exceeded prior to BAR END position.

Troubleshooting

1. Check if BAR END setup is too big and adjust it. 2. Check if ejection position is too small and adjust it.

e23 Remnant ejection is failed

Description

The pusher fails to exceed remnant ejection position within 10 seconds after chuck open.

Troubleshooting

1. Check if the remnant blocked inside the spindle. 2. Check if ejection position setup is too large.

e24

This message intentionally left blank.

e25 TOP CUT setup is smaller than bar stock length

Description

TOP CUT setup was detected to be smaller than the measured bar stock length during FIRST FEED.

Troubleshooting

1. Check if the TOP CUT setup value is too small. 2. Check if the TOP CUT device was activated earlier.


ECOLOAD S2

e26 Check TOP CUT setup

Description

New bar pushed to the lathe, if the pushing forward distance is greater than “Top-cut + part length + 50mm”, it will show this alarm.

Troubleshooting

1. Check if the TOP CUT setup is too small. 2. Check if the lathe stopper position is incorrect. 3. Check if the TOP CUT sensor was activated earlier.

e27 Dry run error

Description

The setting is not fulfilled with dry run mode.

Explanation

e27 signal is showed up in 1 second after P11 is set ON but conditions ” manual, pusher in home position(SR3), current position is smaller than 5mm, TOP CUT is activated ” are not satisfied.

Troubleshooting

Check and make sure each condition is fulfilled.

e28 Bar feeder in dry run

Description

Buttons on Remote control are pressed.

Explanation

When dry run function is activated, buttons on Remote control should not be pressed but it happened. Therefore P11 becomes OFF.

Troubleshooting

1. For keeping dry run function:

(1)Press button on remote control interface. (2)Reset P11 in ON

2. For not keeping dry run function:

Press button on remote control interface.

CHAPTER 9: APPENDICES 9-1

ECOLOAD S2

CHAPTER 9: APPENDICES

9-2 CHAPTER 9: APPENDICES

ECOLOAD S2

1. ORDERING FORM

This form should be photocopied, duly filled out, and returned to your retailer or nearest LNS agent Company name: Person in charge: Address: ZIP: City: Country: Phone: Fax: Type of device: Serial number:

Qty. Ordering no. Description

Expected delivery: Location and date: Signature and stamp of the company:

CHAPTER 9: APPENDICES 9-3

ECOLOAD S2

2. PROGRAMMING EXAMPLE MAIN PROGRAM

N... ”M” CODE “LATHE IN AUTOMATIC CYCLE”

N... SPINDLE STOP

N... COOLANT OFF

N... TURRET TO FEED IN POSITION

N... COLLET OPEN

N... TURRET TO FEED OUT POSITION

N... END OF BAR CHECK (PROGRAM JUMP) >

> SUB-PROGRAM

N... CLOSE COLLET

N... TURRET HOME

N... CLEAR TURRET

... “M”CODE (DWELL/LOAD)

N...

N... CLOSE COLLET

N... START SPINDLE

PART PROGRAM N... COLLANT ON

N... X, Z, G, F, T, S, M, ...

N... TOP CUT MATERIAL

N... MACHINE PART

N...

N... PARTS CATCHER IN (IF AVAILABLE)

N...

N... CUT OFF

N... END OF SUB-PROGRAM

N... PARTS CATCHER OFF (IF AVAILABLE)

< (RETURN TO MAIN PROGRAM)

N...

N...

N... X, Z, G, F, T, S, M, ...

N...

N... END OF PROGRAM (LOOP)

Important: The above is an example only. Programming may change according to the interface between the lathe and the bar feed.

9-4 CHAPTER 9: APPENDICES

ECOLOAD S2

3. LNS ADDRESSES & CONTACTS LNS Europe : www.lns-europe.com LNS America : www.lns-america.com LNS Asia : www.lns-asia.com

Documents

Instruction manual ENG - LNS North America · 2019-05-18 · the bar feed system, as well as the CNC lathe, must be strictly observed. Non-qualified personnel, children, and persons