Table of Contents - LNS North America · 2019. 5. 18. · 1-2 CHAPTER 1: ALARMS Switches and cells list SQ5 M1 SQ10 M3 SQ4 SQ1 A SQ11 SQ12 SQ3 B M2 Designation Part No. Description

Troubleshooting manual ENG

9.020.01.ANG

Table of ContentsChapter 1:........................................................................

Alarms.......................................................................................................Switches and cells list...................................................................................A01 – Emergency stop line open .................................................................A02 – Main access cover open.....................................................................A03 – Magazine protection grid open ..........................................................A04 – Bar feeder retracted or not locked in its working position..............A11 – Measuring cell SQ3 signal defective .................................................A12 – Home position proximity switch SQ5 signal missing ......................A15 – Safety time for loading channel up and down motion elapsed.......A16 – Safety time for diameter adjustment elapsed...................................A21 – Measuring cell SQ3 activated too early.............................................A22 – Signal A2 "lathe in automatic mode" interrupted during loading cA23 – Safety time for loading profiled bar elapsed.....................................A24 – Safety time for top-cut positioning elapsed .....................................A25 – Lathe did not resume its production cycle .......................................A26 – Clamping device closed prior to completing the feed out...............A27 – Clamping device opened during production cycle without lathe auA28 – Parts counting parity error by M-code quantity and automatic parA30 – Bar stock loading error.......................................................................A41 – Servo amplifier / PLC communication fault ......................................A42 – Servo drive alarm @@........................................................................A43 – Amplifier battery low...........................................................................A44 – Servo motor not ready........................................................................A45 – Servo motor positioning error during sequence @@......................A50 – Servo amplifier firmware not compatible with PLC..........................Bar Feeder Software Sequence of Events...................................................Mitsubishi Servo Amplifier Alarm List .........................................................

Chapter 2:........................................................................

Common Issues .......................................................................................Vibrations .......................................................................................................Servo Motor Following Error During Sequence 9.......................................Part feed out accuracy ..................................................................................

Chapter 3:........................................................................

Procedures ...............................................................................................Alignment Procedure ....................................................................................Pusher Changeover Procedure ....................................................................Belt Tension Adjustment ..............................................................................Home Position Proximity Switch SQ5 Adjustment.....................................Diameter Adjustment Motor Proximity Switch – SQ4.................................Measuring Cell Adjustment – SQ3 ...............................................................Pusher Reversing Distance ..........................................................................Reference Procedure.....................................................................................Calibration of the Loading Table ..................................................................

Chapter 4:........................................................................

Software....................................................................................................Software / PLC Versions ...............................................................................Software Update ............................................................................................Battery Replacement .....................................................................................

QUICK LOAD

E112.11.2006

................1-1

.........................1-1 ............................... 1-2 ............................... 1-3 ............................... 1-4 ............................... 1-5 ............................... 1-6 ............................... 1-7 ............................... 1-8 ............................... 1-9 ............................. 1-10 ............................. 1-11 ycle...................... 1-12 ............................. 1-13 ............................. 1-14 ............................. 1-15 ............................. 1-16 to mode ............. 1-17

t counting ........... 1-18 ............................. 1-19 ............................. 1-20 ............................. 1-21 ............................. 1-22 ............................. 1-23 ............................. 1-24 ............................. 1-25 ............................. 1-26 ............................. 1-27

................2-1

.........................2-1 ............................... 2-2 ............................... 2-3 ............................... 2-4

................3-1

.........................3-1 ............................... 3-2 ............................... 3-6 ............................... 3-9 ............................. 3-10 ............................. 3-11 ............................. 3-12 ............................. 3-14 ............................. 3-15 ............................. 3-17

................4-1

.........................4-1 ............................... 4-2 ............................... 4-3 ............................... 4-5

SERVO 65/80

Chapter 5: .......................................................................................5-1

Maintenance ......................................................................................................................5-1 Monthly Maintenance ...................................................................................................................5-2 Annual Maintenance .....................................................................................................................5-2

Chapter 6: .......................................................................................6-1

Spare Parts ........................................................................................................................6-1 Recommended Spare Parts List ..................................................................................................6-2 Mechanical Assemblies................................................................................................................6-3 Base .............................................................................................................................................6-11 Crossing Slide.............................................................................................................................6-20 Loading Mechanism ...................................................................................................................6-23 Protections ..................................................................................................................................6-33 Foot ..............................................................................................................................................6-35 Loading Magazine.......................................................................................................................6-37 Retraction ....................................................................................................................................6-42 Pusher..........................................................................................................................................6-45 Accessories & Options...............................................................................................................6-51 Floor Plans ..................................................................................................................................6-53

QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS


1-1

Chapter 1: Alarms

An error has occurred during setup or cycling of the bar feeder. When an error occurs, an alarm message is generated on the remote control station. Also provided are some possible causes as to why the error has occurred.

This chapter:

• discusses every alarm that the bar feed may generate, • explains the possible causes, • suggests a few tips and procedures of how to correct the problem.

CHAPTER 1: ALARMS 1-2

Switches and cells list

1

0

M3

4

S

DesignaA

B

M 1

M 2

M 3

QS 1

SQ 1

SQ 3

SQ 4

SQ 5

SQ 10

SQ 11

SQ 12

QUICK LOA

SQ1

A

B

tion Part No. Description 4.869 Remote control station

- Electrical cabinet (not sh

4.706 Servo motor

4.839 Loading table motor

4.838 Diameter selection finge

4.242 Main disconnect switch

4.391 Proximity switch, loading

4.474 Positioning optical cell

4.391 Proximity switch, diame

4.391 Pusher in home position

4.763 Cover closed safety swi

4.763 Magazine cover closed

4.763 Retraction system safet

D SERVO 65/80

own here)

rs motor

table in lower pos

ter selection fingers

switch

tch

safety switch

y switch

Q11

SQ12

SQ3

M

SQ1

SQ

SQ5

M2

ition

in origin position

CHAPTER 1: ALARMS


1-3

A01 – Emergency stop line open

EMERGENCY STOP LINE OPEN! POSSIBLE CAUSES: -CONNECTION -PROBLEM IN CIRCUITRY A01

Description:

The « emergency stop line open » alarm occurs whenever the lathe or the bar feeder goes into an emergency stop condition and does not receive signal (I16). The problem is generated anytime there is an open in the safety circuit.

Solution:

In the working screen, press the key on the remote control. Press the key corresponding to Page Down until the INPUTS page is displayed:

Case Input Solution

1 K1 = 0

• Check the emergency buttons state on the bar feeder and the lathe. • Check the PLC connection. • Check the wiring according to the electrical diagram. • Press the STOP button on the remote control to reset the alarm.

2 K1 = 1 Press the STOP button on the remote control to reset the alarm.


A02 – Main access cover open

MAIN ACCESS COVER OPEN! CLOSE MAIN COVER TO RESUME OPERATIONS A02

SQ10

Description:

The « main access cover open » occurs whenever the PLC does not detect input (I17 – SQ10). The problem is generated when the main access cover on the bar feeder is open, exposing automated mechanical parts.

Solution:


Case Input Solution

1 SQ10 = 0 • Close the cover. • Check the SQ10 switch is adjusted correctly.

2 SQ10 = 1 Press the STOP button on the remote control to reset the alarm.


CHAPTER 1: ALARMS


1-5

A03 – Magazine protection grid open

SQ11

MAGAZINE PROTECTION GRID OPEN! CLOSE GRID TO RESUME OPERATIONS A03

Description:

The « magazine protection grid open » occurs whenever the PLC does not detect input (I18 – SQ11). The problem is generated when the protection grid on the bar feeder is open, or if the switch is defective.

Solution:


Case Input Solution

1 SQ11 = 0 • Close the protection grid. • Check that the SQ11 switch is adjusted correctly.



A04 – Bar feeder retracted or not locked in its working position

BAR FEEDER RETRACTED OR NOT LOCKED IN ITS WORKING POSITION! A04

SQ12

Description:

The « bar feeder retracted or not locked in its working position » alarm occurs whenever the PLC does not detect input (I19 – SQ12). The problem is generated when the bar feeder is retracted in reduction tube change position or if the retraction system is not locked.

Solution:


Case Input Solution 1 SQ12 = 0 Set the bar feeder back in operating position and lock it.



CHAPTER 1: ALARMS


1-7

A11 – Measuring cell SQ3 signal defective

MEASURING CELL SQ3 SIGNAL DEFECTIVE! - CELL DEFECTIVE - OBSTACLE DETECTED - CELL OBSTRUCTED A11

SQ3

Description:

The « measuring cell SQ3 signal defective » alarm occurs whenever the PLC detects input (I25 – SQ3) during more than 1 second before the loading table goes up or down. The problem is generated when the switch is obstructed, defective or if any obstacle is detected in the switch detecting range.

Solution:


Case Input Solution

1 SQ3 = 1 • Remove any obstacle in the detecting range of the switch. • Check that the SQ3 switch adjustment.



A12 – Home position proximity switch SQ5 signal missing

HOME POSITION PROXIMITY SWITCH SQ5 SIGNAL MISSING! - DEFECTIVE - MIS-ADJUSTED A12

5

Description:

The « home position proximity switch SQ5 signal missing » alarm detect input (I27 – SQ5) when the encoder reads the home position when the switch is defective or mis-adjusted.

Solution:

In the working screen, press the key on the remote control. PrDown until the INPUTS page is displayed:

Case Input Solution 1 SQ5 = 1 Press the STOP button on the remote control

2 SQ5 = 0 • Check that the SQ5 switch is adjusted cor• Check the belt tension. • Reference back the origin points (home po


SQ

occurs whenever the PLC does not (0.0 mm). The problem is generated

ess the key corresponding to Page

to reset the alarm.

rectly.

sition).

CHAPTER 1: ALARMS


1-9

A15 – Safety time for loading channel up and down motion elapsed

SAFETY TIME FOR LOADING CHANNEL UP AND DOWN MOTION ELAPSED! A15

Description:

The « safety time for loading channel up and down motion elapsed » alarm is generated:

when the loading table goes up and the PLC does not count the necessary quantity of pulses to reach the requested position with in the delay of 8 seconds;

when the loading table goes down and the PLC does not detect the input (I24 – SQ1) with in the delay of 8 seconds.

Solution:


Case Input Solution 1 SQ1 = 1 Press the STOP button on the remote control to reset the alarm.

2 SQ1 = 0 • Check the SQ1 switch. • Check that the table can move up and down without obstacle or resistance.


A16 – Safety time for diameter adjustment elapsed

SAFETY TIME FOR DIAMETER ADJUSTMENT ELAPSED! A16

Description:

The « safety time for diameter adjustment elapsed » alarm is generated :

during the loading when the PLC not count the necessary quantity of pulses from the diameter adjustment motor to reach the requested position within 6 seconds;

when the diameter adjustment fingers return towards the origin when the PLC does not detect the input (I27 – SQ4) within 6 seconds.

Solution:


Case Input Solution 1 SQ4 = 1 Press the STOP button on the remote control to reset the alarm.

2 SQ4 = 0 • Check the SQ4 switch. • Check that the diameter adjustment fingers can move without any obstacle or

resistance.


CHAPTER 1: ALARMS


1-11

A21 – Measuring cell SQ3 activated too early

MEASURING CELL SQ3 ACTIVATED TOO EARLY! - BAR STOCK EXCEEDS PERMITTED MAX.LENGTH - WRONG SET UP - CELL DEFECTIVE A21

SQ3

Description:

The « Measuring cell SQ3 activated too early » alarm occurs when the PLC detects input (I25 – SQ3) before the safety maximum length has been reached during the bar stock length measuring.

Solution:

Press the STOP key on the remote control to clear the message and reset the alarm.

Press the key corresponding to the MENU.

Choose the SERVICE item. Press the key corresponding to ENTER to confirm.

From the service menu, choose the BAR FEEDER SETUP item. Press the key corresponding to ENTER to confirm.

Press the key corresponding to PAGE DOWN as many times as necessary to display the text "MAXIMUM BAR STOCK LENGTH".

Note: This value cannot exceed the spindle length. If necessary, correct this value.

Measure the bar stock. This bar length cannot exceed the value entered in the remote control.


A22 – Signal A2 "lathe in automatic mode" interrupted during loading cycle

SIGNAL A2 (LATHE IN AUTOMATIC MODE) INTERRUPTED DURING LOADING CYCLE! A22

Description:

The « Signal A2 "lathe in automatic mode" interrupted during loading cycle » alarm is generated if the signal (I41 – A2) is interrupted in the loading cycle.

Solution:

Verify the lathe/bar feeder connection.

Verify the wiring of the signal A2.

Check the lathe programming.


CHAPTER 1: ALARMS


1-13

A23 – Safety time for loading profiled bar elapsed

SAFETY TIME FOR LOADING PROFILED BAR ELAPSED! A23

Description:

The «Safety time for loading profiled bar elapsed » alarm is generated when profiled bar stocks are pushed to top-cut position. In this case, the material is pushed near the back of the clamping device. Then, the spindle rotates very slowly while the bar feeder pushes the bar stock against the clamping device, until the bar shape corresponds with the clamping device's shape, goes through and reaches the top-cut position.

After 20 attempts, this alarm is generated.

Solution:

Press the STOP key on the remote control to clear the message and reset the alarm.

Remove the bar out of the spindle.

Start the top-cut cycle again.

If the problem persists, please contact LNS AMERICA, INC..


A24 – Safety time for top-cut positioning elapsed

SAFETY TIME FOR TOP-CUT POSITIONING ELAPSED! A24

Description:

The « safety time for top-cut positioning elapsed » alarm when the bar stock is in loading cycle for top cut, if the top cut position is not reached within 5 minutes.

Solution:

Press the STOP button on the remote control to reset the alarm. Restart the automatic cycle on bar feeder and lathe.


CHAPTER 1: ALARMS


1-15

A25 – Lathe did not resume its production cycle

LATHE DID NOT RESUME ITS PRODUCTION CYCLE! A25

Description:

The « Lathe did not resume its production cycle » alarm occurs when the bar feeder does not detect the clamping device signal (I40 – A1) within the minute following the reach of the top cut positioning.

Solution:



A26 – Clamping device closed prior to completing the feed out

CLAMPING DEVICE CLOSED PRIOR TO COMPLETING THE FEED OUT! A26

Description:

The « Clamping device closed prior to completing the feed out » alarm occurs whenever the clamping device closing signal is detected before the value entered in parameter "overall part length feed out" has been reached.

Solution:

Check that the clamping device is closing correctly.

Check that the signal "Clamping device closing" is correctly interfaced and programmed.


CHAPTER 1: ALARMS


1-17

A27 – Clamping device opened during production cycle without lathe auto mode

CLAMPING DEVICE OPENED DURING PRODUCTION CYCLE WITHOUT LATHE IN AUTO MODE A27

Description:

The « Clamping device opened during production cycle without lathe auto mode » alarm occurs when the PLC detects the clamping device opening signal (I40 – A1) while the bar feeder in auto cycle and lathe not in auto mode – input (I41 – A2).

Solution:



A28 – Parts counting parity error by M-code quantity and automatic part counting

PARTS COUNTING PARITY ERROR BY M-CODE QUANTITY AND AUTOMATIC PART COUNTING A28

Description:

The « Parts counting parity error by M-code quantity and automatic part counting » alarm occurs whenever clamping device openings quantity does not match the value « number of clamping device openings » while the input (I43 – A4) is activated.

Solution:

Press the STOP button on the remote control to reset the alarm. Restart the automatic cycle of the bar feeder and the lathe.


CHAPTER 1: ALARMS


1-19

A30 – Bar stock loading error

BAR STOCK LOADING ERROR! -MAGAZINE RACK EMPTY -WRONG SET UP A30

Description:

The « Bar stock loading error » alarm is generated when no material is detected in the guidance zone and the PLC detects the input (I25 – SQ3) when the loading finger is at the most advanced position. That means that there is no material on the loading table.

Solution:

Load new material on the magazine.


A41 – Servo amplifier / PLC communication fault

SERVO AMPLIFIER/PLC COMMUNICATION FAULT! -TURN OFF MAIN POWER -WAIT FOR 2 SECONDS -RESTORE MAIN POWER A41

Description:

The «Servo amplifier / PLC communication fault » alarm occurs whenever the PLC sends a message to the servo amplifier, and the amplifier does not confirm it sending back a checksum. The problem occurs if:

sent data do not correspond to received data

the servo amplifier does not answer within 10 seconds.

during starting the bar feeder, PLC and servo amplifier parameters do not correspond.

Solution:

Verify the PLC/servo amplifier connection (F110).

Verify the PLC power supply (24V DC). Power variations may influence the PLC efficiency.



CHAPTER 1: ALARMS


1-21

A42 – Servo drive alarm @@

SERVO DRIVE ALARM! [@@] -TURN OFF MAIN POWER -WAIT FOR 2 SECONDS -RESTORE MAIN POWER A42

Description:

The « Servo drive alarm @@ » alarm occurs whenever the servo amplifier generates an alarm.

Solution:

Turn off main power, wait 2 seconds, and restore main power.

If the problem persists, find the displayed alarm number on the servo amplifier and refer to the Mitsubishi® servo amplifier alarm list in the manual


A43 – Amplifier battery low

AMPLIFIER BATTERY LOW! REPLACE BATTERY IMMEDIATELY A43

Description:

The « Amplifier battery low » alarm occurs whenever the voltage of the integrated amplifier battery is too low.

Solution:

Replace the battery as soon as possible (refer to the instruction manual).


CHAPTER 1: ALARMS


1-23

A44 – Servo motor not ready

SERVO MOTOR NOT READY! - VERIFY CN1B CONNECTOR -CHECK PLC OUTPUT 52 A44

Description:

The PLC sends a signal (O52) to the servo motor to set it in « servo lock » position. If the servo amplifier does not recognize the signal within 3 seconds, this alarm is generated.

Solution:

Verify the CN1B cable connection to the amplifier.

Verify that the output (O52) is activated when the automatic or manual cycle is started.

Verify that the K1 relay is active; the input (I16) must be active.

If the problem persists, please contact LNS America, Inc.


A45 – Servo motor positioning error during sequence @@

SERVO MOTOR POSITIONING ERROR! DURING SEQUENCE:[@@] -MECHANICAL OBSTACLE PREVENTS BAR STOCK TO FEED OUT A45

Description:

The «Servo motor positioning error during sequence @@ » alarm occurs whenever the motor encounters some unexpected resistance. In this case, the motor raises the pushing torque to a defined limit. Over this point, the PLC stops the pushing and activates this alarm.

Solution:

Press the STOP button on the remote control to reset the alarm.

Verify any mechanical obstacle preventing the bar stock to feed out.

Verify the bar stock diameter. It must correspond to the entered value in the remote control, display "applications".

Verify the alignment between the lathe and the bar feeder. This may slightly vary if one or both machines have not been anchored to the ground.



CHAPTER 1: ALARMS


1-25

A50 – Servo amplifier firmware not compatible with PLC

SERVO AMPLIFIER FIRMWARE NOT COMPATIBLE WITH PLC! -REPLACE SERVO AMPLIFIER A50

Description:

Only an adapted firmware to our servo motor will work. Otherwise, the « Servo amplifier firmware not compatible with PLC » alarm is generated.

Solution:

Please contact LNS AMERICA, INC. to update your firmware.


Bar Feeder Software Sequence of Events

Sequence no. Movement 0 Stop mode and manual functions

1 Production cycle.

2 Loading start. The pusher returns back to home position.

3 Diameter selection start.

4 The loading table starts moving up

5 The loading flag moves to the bar stock rear.

6 The loading flag pushes the bar stock under the measuring cell SQ3

7 Calculation

8 The loading flag pushes the bar stock behind the clamping device.

9 The loading flag pushes the bar stock to the EOB or to the top cut position.

10 Production cycle with loading table in upper position.

11 The loading flag moves back to home position.

12 The loading table starts moving down.

13 The pusher moves to the bar stock rear.

14 The pusher moves the bar stock behind the clamping device.

15 The pusher positions the bar stock in top cut position

16 In top cut position.


CHAPTER 1: ALARMS


1-27

Mitsubishi Servo Amplifier Alarm List

CAUTION • Excessive adjustment or change of parameter setting must not be made as it will make operation instable.

POINT Using the optional servo configuration software, you can refer to unrotated servo motor reasons, etc.

The following faults may occur at start-up. If any of such faults occurs, take the corresponding action.

Position control mode

(1) Troubleshooting No . Start-up sequence Fault Investigation Possible cause Reference

Not improved if connectors CN1A, CN1B, CN and CN3 2are disconnected.

1. Power supply voltage fault 2. Servo amplifier is faulty.

Improved when connectors CN1A and CN1B are disconnected.

Power supply of CNP1 cabling is shorted.

Improved when connector CN2 is disconnected.

1. Power supply of encoder cabling is shorted. 2. Encoder is faulty.

• LED is not lit. • LED flickers.

Improved when connector CN3 is disconnected.

Power supply of CN3 cabling is shorted.

1 Power on

Alarm occurs. Refer to Section Alarm and warning list and remove cause. Section 11.2 Alarm occurs. Refer to Section Alarm and warning list and remove cause. Section 11.2 2 Switch on servo-

on signal. Servo motor shaft is not servo-locked (is free).

1. Check the display to see if the servo amplifier is ready to operate. 2. Check the external I/O signal indication to see if the servo-on (SON) signal is ON.

1. Servo-on signal is not input. (Wiring mistake) 2. 24VDC power is not supplied to COM.

Section 6.6 of the Mitsubishi Servo Amplifier manual

Rotation ripples (speed fluctuations) are large at low speed.

Make gain adjustment in the following procedure: 1. Increase the auto tuning response level. 2. Repeat acceleration and deceleration several times to complete auto tuning.

Gain adjustment fault Chapter 7 of the Mitsubishi Servo Amplifier manual

3 Gain adjustment

Large load inertia moment causes the servo motor shaft to oscillate side to side.

If the servo motor may be run with safety, repeat acceleration and deceleration several times to complete auto tuning.

Gain adjustment fault Chapter 7 of the Mitsubishi Servo Amplifier manual

4 Cyclic operation Position shift occurs Confirm the cumulative command pulses, cumulative feedback pulses and actual servo motor position.

Pulse counting error, etc. due to noise.

When alarm or warning has occurred

POINT • Configure up a circuit that will detect the trouble (ALM) signal and turn off the

servo-on (SON) signal at occurrence of an alarm.


Alarms and warning list

When a fault occurs during operation, the corresponding alarm or warning is displayed. If any alarm or warning has occurred, refer to Section Alarm definitions and causes and take the appropriate action. Set "1 " in parameter No. 59 to output the alarm code in ON/OFF status across the corresponding pin and SG. Warnings (AL.90 to AL.E9) have no alarm codes. Any alarm code is output at occurrence of the corresponding alarm. In the normal status, the signals available before alarm code setting (CN1B-19, CN1A-18, and CN1A-19) are output.

The alarms marked in the alarm deactivation column can be deactivated by the corresponding operations.

(Note 2) Alarm code Alarm deactivation

Display CN1B-19 pin

CN1A-18 pin

CN1A-19 pin

Name Power OFF→ ON

Press "SET" on current alarm

screen.

Alarm reset (RES) signal

AL.10 0 1 0 Undervoltage AL.12 0 0 0 Memory error 1 AL.13 0 0 0 Clock error AL.15 0 0 0 Memory error 2 AL.16 1 1 0 Encoder error 1 AL.17 0 0 0 Board error AL.19 0 0 0 Memory error 3 AL.1A 1 1 0 Motor combination error AL.20 1 1 0 Encoder error 2 AL.24 1 0 0 Main circuit error AL.25 1 1 0 Absolute position erase AL.30 0 0 1 Regenerative error AL.31 1 0 1 Overspeed AL.32 1 0 0 Overcurrent AL.33 0 0 1 Overvoltage AL.35 1 0 1 Command pulse frequency error AL.37 0 0 0 Parameter error AL.45 0 1 1 Main circuit device overheat AL.46 0 1 1 Servo motor overheat AL.50 0 1 1 Overload 1 (Note 1) (Note 1) (Note 1) AL.51 0 1 1 Overload 2 (Note 1) (Note 1) (Note 1) AL.52 1 0 1 Error excessive AL.8A 0 0 0 Serial communication time-out

error

AL.8E 0 0 0 Serial communication error

Ala

rms

88888 0 0 0 Watchdog AL.90 Home position return incomplete AL.92 Open battery cable warning AL.96 Home position setting warning AL.98 Software limit warning AL.9F Battery warning AL.E0 Excessive regenerative warning AL.E1 Overload warning AL.E3 Absolute position counter warning AL.E6 Servo emergency stop warning

War

ning

s

AL.E9

Main circuit off warning

Removing the cause of occurrence deactivates the alarm automatically.

Note: 1. Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence.

2. 0: Pin-SG off (open)

1: Pin-SG on (short)


CHAPTER 1: ALARMS


1-29

CAUTION

• When any alarm has occurred, eliminate its cause, ensure safety, then reset the alarm, and restart operation. Otherwise, injury may occur.

• If an absolute position erase alarm (AL.25) occurred, always make home position setting again. Otherwise, misoperation may occur.

POINT • When any of the following alarms has occurred, always remove its cause

and allow about 30 minutes for cooling before resuming operation. If operation is resumed by switching control circuit power off, then on to reset the alarm, the servo amplifier and servo motor may become faulty. • Regenerative error (AL.30) • Overload 1 (AL.50) • Overload 2 (AL.51)

• The alarm can be deactivated by switching power off, then on press the "SET" button on the current alarm screen or by turning on the reset (RES).

For details, refer to Alarms and warning list.

Alarm definitions and causes When an alarm occurs, the trouble (ALM) switches off and the dynamic brake is operated to stop the servo motor. At this time, the display indicates the alarm No.

The servo motor comes to a stop. Remove the cause of the alarm in accordance with this section. The optional servo configuration software may be used to refer to the cause. Display Name Definition Cause Action

1. Power supply voltage is low. 2. There was an instantaneous control power failure of 60ms or longer. 3. Shortage of power supply capacity caused the power supply voltage to drop at start, etc. 4. Power was restored after the bus voltage had dropped to 200VDC. (Main circuit power switched on within 5s after it had switched off.)

Review the power supply. AL.10 Undervoltage Power supply voltage dropped. MR-J2S- CP: 160V or less MR-J2S- CP1: 83V or less

5. Faulty parts in the servo amplifier

Checking method Alarm (AL.10) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.

Change the servo amplifier.

AL.12 Memory error 1 RAM, memory fault AL.13 Clock error Printed board fault AL.15 Memory error 2 EEP-ROM fault

Faulty parts in the servo amplifier

Checking method Alarm (any of AL.11 to 13 and 15) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.


1. Encode connector (CN2) disconnected.

Connect correctly.

2. Encoder fault Change the servo motor. 3. Encoder cable faulty (wire breakage or short)

Repair or change the cable.

AL.16 Encoder error 1 Communication error occurred between encoder and servo amplifier.

4. Wrong combination of servo amplifier and servo motor

Use correct combination.


Display Name Definition Cause Action AL.17 Board error CPU/parts fault AL.19 Memory error 3 ROM memory fault

Faulty parts in the servo amplifier

Checking method Alarm (A.17 or A.18) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.


AL.1A Motor combination error

Wrong combination of servo amplifier and servo motor.

Wrong combination of servo amplifier and servo motor connected.

Use correct combination.

1. Encoder connector (CN2) disconnected.

Connect correctly.

2. Encoder fault Change the servo motor.

AL.20 Encoder error 2 Communication error occurred between encoder and servo amplifier. 3. Encoder cable faulty(wire

breakage or shorted) Repair or change the cable.

1. Power input wires and servo motor output wires are in contact at main circuit terminal block (TE1).

Connect correctly.

2. Sheathes of servo motor power cables deteriorated, resulting in ground fault.

Change the cable.

AL.24 Main circuit error

Ground fault occurred at the servomotor outputs (U, V and W phases) of the servo amplifier.

3. Main circuit of servo amplifier failed.

Checking method AL.24 occurs if the servo is switched on after disconnecting the U, V, and W power cables from the servo amplifier.


1. Reduced voltage of super capacitor in encoder

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

2. Battery voltage low

Absolute position data in error

3. Battery cable or battery is faulty.

Change battery. Always make home position setting again.

AL.25 Absolute position erase

Power was switched on for the first time in the absolute position detection system.

4. Super capacitor of the absolute position encoder is not charged

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

1. Wrong setting of parameter No. 0

Set correctly.

2. Built-in regenerative brake resistor or regenerative brake option is not connected.

Connect correctly

3. High-duty operation or continuous regenerative operation caused the permissible regenerative power of the regenerative brake option to be exceeded.

Checking method Call the status display and check the regenerative load ratio.

1. Reduce the frequency of positioning. 2. Use the regenerative brake option of larger capacity. 3. Reduce the load.

Review power supply 4. Power supply voltage is abnormal. MR-J2S- CP:260V or more MR-J2S- CP1:135V or more

Change servo amplifier or regenerative brake option.

Permissible regenerative power of the built-in regenerative brake resistor or regenerative brake option is exceeded.

5. Built-in regenerative brake resistor or regenerative brake option faulty.

AL.30 Regenerative alarm

Regenerative transistor fault

6. Regenerative transistor faulty.

Checking method 1) The regenerative brake option has overheated abnormally. 2) The alarm occurs even after removal of the built-in regenerative brake resistor or regenerative brake option.



CHAPTER 1: ALARMS


1-31

Display Name Definition Cause Action

1. Input command pulse frequency exceeded the permissible instantaneous speed frequency.

Set command pulses correctly.

2. Small acceleration/deceleration time constant caused overshoot to be large.

Increase acceleration/deceleration time constant.

3. Servo system is instable to cause overshoot.

1. Re-set servo gain to proper value. 2. If servo gain cannot be set to proper value: 1) Reduce load inertia moment ratio; or 2) Reexamine acceleration/deceleration time constant.

4. Electronic gear ratio is large (parameters No. 4, 5)

Set correctly.

AL.31 Overspeed Speed has exceeded the instantaneous permissible speed.

5. Encoder faulty. Change the servo motor. 1. Short occurred in servo amplifier output phases U, V and W.

Correct the wiring.

2. Transistor (IPM) of the servo amplifier faulty.

Checking method Alarm (AL.32) occurs if power is switched on after U, V and W are disconnected.


3. Ground fault occurred in servo amplifier output phases U, V and W.

Correct the wiring.

AL.32 Overcurrent Current that flew is higher than the permissible current of the servo amplifier.

4. External noise caused the overcurrent detection circuit to misoperate.

Take noise suppression measures.

1. Lead of built-in regenerative brake resistor or regenerative brake option is open or disconnected.

1. Change lead. 2. Connect correctly.

2. Regenerative transistor faulty. Change servo amplifier 3. Wire breakage of built-in regenerative brake resistor or regenerative brake option

1. For wire breakage of built-in regenerative brake resistor, change servo amplifier. 2. For wire breakage of regenerative brake option, change regenerative brake option.

4. Capacity of built-in regenerative brake resistor or regenerative brake option is insufficient.

Add regenerative brake option or increase capacity.

AL.33 Overvoltage Converter bus voltage exceeded 400V.

5. Power supply voltage high. Review the power supply. 1. Pulse frequency of the manual pulse generator is too high.

Change the pulse frequency to a proper value.

2. Noise entered the pulses of the manual pulse generator.

Take action against noise.

AL.35 Command pulse frequency error

Input pulse frequency of the command pulse is too high.

3. Manual pulse generator failure Change the manual pulse generator. 1. Servo amplifier fault caused the parameter setting to be rewritten.

Change the servo amplifier. AL.37 Parameter error Parameter setting is wrong.

2. Regenerative brake option not used with servo amplifier was selected in parameter No.0.

Set parameter No.0 correctly.


Display Name Definition Cause Action 1. Servo amplifier faulty. Change the servo amplifier. 2. The power supply was turned on and off continuously by overloaded status.

The drive method is reviewed. AL.45 Main circuit

device overheat Main circuit device overheat

3. Air cooling fan of servo amplifier stops.

1. Exchange the cooling fan or the servo amplifier. 2. Reduce ambient temperature.

1. Ambient temperature of servo motor is over 40°C.

Review environment so that ambient temperature is 0 to 40°C.

2. Servo motor is overloaded. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.

AL.46 Servo motor overheat

Servo motor temperature rise actuated the thermal protector.

3. Thermal protector in encoder is faulty.

Change servo motor.

1. Servo amplifier is used in excess of its continuous output current.

1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.

2. Servo system is instable and hunting.

1. Repeat acceleration/ deceleration to execute auto tuning. 2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain adjustment manually.

3. Machine struck something. 1. Review operation pattern. 2. Install limit switches.

4. Wrong connection of servo motor. Servo amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.

Connect correctly.

AL.50 Overload 1 Load exceeded overload protection characteristic of servo amplifier. Load ratio 300%: 2.5s or more Load ratio 200%: 100s or more

5. Encoder faulty.

Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway.

Change the servo motor.



Connect correctly.

3. Servo system is instable and hunting.

1. Repeat acceleration/deceleration to execute auto tuning. 2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain adjustment manually.

AL.51 Overload 2 Machine collision or the like caused max. output current to flow successively for several seconds. Servo motor locked: 1s or more

4. Encoder faulty.

Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway.

Change the servo motor.


CHAPTER 1: ALARMS


1-33

Display Name Definition Cause Action 1. Acceleration/deceleration time constant is too small.

Increase the acceleration/deceleration time constant.

2. Internal torque limit 1 (parameter No.28) is too small.

Increase the torque limit value.

3. Motor cannot be started due to torque shortage caused by power supply voltage drop.

1. Review the power supply capacity. 2. Use servo motor that provides larger output.

4. Position control gain 1 (parameter No.7) value is small.

Increase set value and adjust to ensure proper operation.

5. Servo motor shaft was rotated by external force.

1. When torque is limited, increase the limit value. 2. Reduce load. 3. Use servo motor that provides larger output.


7. Encoder faulty Change the servo motor.

AL.52 Error excessive The droop pulse value of the deviation counter exceeded the encoder resolution

10 [pulse].


Connect correctly.

1. Communication cable breakage.

Repair or change communication cable

2. Communication cycle longer than parameter No. 23 setting.

Set correct value in parameter.

AL.8A Serial communication time-out error

RS-232C or RS-422 communication stopped for longer than the time set in parameter No.23. 3. Wrong protocol. Correct protocol.

1. Communication cable fault (Open cable or short circuit)

Repair or change the cable. AL.8E Serial communication error

Serial communication error occurred between servo amplifier and communication device (e.g. personal computer).

2. Communication device (e.g. personal computer) faulty

Change the communication device (e.g. personal computer).

88888 Watchdog CPU, parts faulty Fault of parts in servo amplifier Checking method Alarm (88888) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.

Change servo amplifier.


Remedies for warnings

If AL.E6 occurs, the servo off status is established. If any other warning occurs, operation can be continued but an alarm may take place or proper operation may not be performed. Use the optional servo configuration software to refer to the cause of warning. Display Name Definition Cause Action

In incremental system: 1. Positioning operation was performed without home position return. 2. Home position return ended abnormally.

1. Positioning operation was performed without home position return. 2. Home position return speed could not be decreased to creep speed. 3. Limit switch was actuated during home position return starting at other than position beyond dog.

1. Perform home position return. 2. Review home position return speed/creep speed/moving distance after proximity dog.

AL.90 Home position return incomplete

In absolute position detection system: 1. Positioning operation was performed without home position setting. 2. Home position setting ended abnormally.

1. Positioning operation was performed without home position setting. 2. Home position setting speed could not be decreased to creep speed. 3. Limit switch was actuated during home position setting starting at other than position beyond dog.

1. Perform home position setting. 2. Review home position setting speed/creep speed/moving distance after proximity dog.

1. Battery cable is open. Repair cable or changed. AL.92 Open battery cable warning

Absolute position detection system battery voltage is low.

2. Battery voltage dropped to 2.8V or less.

Change battery.

1. Droop pulses remaining are greater than the in-position range setting.

Remove the cause of droop pulse occurrence

2. Command pulse entered after clearing of droop pulses.

Do not enter command pulse after clearing of droop pulses.

AL.96 Home position setting warning

Home position setting could not be made.

3. Creep speed high. Reduce creep speed. 1. Software limit was set within actual operation range.

Set parameter No. 48 to 51 correctly.

2. Point table of position data in excess of software limit was executed.

Set point table correctly.

AL.98 Software limit warning

Software limit set in parameter is reached.

3. Software limit was reached during JOG operation or manual pulse generator operation.

Perform operation within software limit range.

AL.9F Battery warning Voltage of battery for absolute position detection system reduced.

Battery voltage fell to 3.2V or less. Change the battery.

AL.E0 Excessive regenerative warning

There is a possibility that regenerative power may exceed permissible regenerative power of built-in regenerative brake resistor or regenerative brake option.

Regenerative power increased to 85% or more of permissible regenerative power of built-in regenerative brake resistor or regenerative brake option. Checking method Call the status display and check regenerative load ratio.

1. Reduce frequency of positioning. 2. Change regenerative brake option for the one with larger capacity. 3. Reduce load.

AL.E1 Overload warning

There is a possibility that overload alarm 1 or 2 may occur.

Load increased to 85% or more of overload alarm 1 or 2 occurrence level. Cause, checking method Refer to AL.50, 51.

Refer to AL.50, AL.51.

1. Noise entered the encoder. Take noise suppression measures.

AL.E3 Absolute position counter warning

Absolute position encoder pulses faulty.

2. Encoder faulty. Change servo motor. AL.E6 Servo

emergency stop warning

EMG-SG is open. External emergency stop was made valid. (EMG-SG opened.)

Ensure safety and deactivate emergency stop.

AL.E9 Main circuit off warning

Servo was switched on with main circuit power off.

Switch on main circuit power.


CHAPTER 2: COMMON ISSUES


2-1

Chapter 2: Common Issues

he Quick Load Servo 65 / 80 is designed to be a user-friendly, simple, and reliable bar feeder, covering a range of diameters 6 to 65 / 80, depending on the machine purchased. Although easy to use, including extremely quick changeovers and the capability for unmanned operation this unit is not flawless. A list of common issues that have been documented by service technicians and problems relayed back from customers has been compiled in this manual. This

chapter discusses the most common problems that have been observed. Along with each problem, a brief description is given as well as quick reference charts of symptoms/solutions, sequences, and procedures for adjustments, changeovers and alignment.

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2- CHAPTER 2: COMMON ISSUES 2-2

Vibrations Description: The term “vibration” is being used regarding the Quick Load Servo 65 / 80, to indicate that the RPM performance of the lathe is physically deteriorated, to the point of creating an unbalanced rotational oscillation of the bar stock, within the confines of the spindle of the lathe that is detrimental to the machining process.

Various items can cause or enhance a lathe spindle vibration issue, requiring the reduction of the spindle rpm to bring the anomaly back to a normal controlled rotation. These items can be related to the material, the lathe, or the bar feed.

Note: The bar feed must be installed according to LNS specifications.

Possible Causes Solutions

• Lathe leveling • The lathe should be level and on a solid foundation. LNS recommend that the lathe be bolted to the floor.

• Bad alignment between the lathe and the bar feeder;

• Check the alignment between the lathe and the bar feeder;

• Check that the pusher does not touch anything while the spindle is turning;

• Wrong choice of the reduction tube diameter;

• Ensure that the properly sized spindle liner has been installed (1mm ideal gap);

• Check the bar stock straightness (may be caught in a bind into the spindle liner);

• Ensure the liner is straight (check total run out), and has all o-rings intact;

• Bar stock material: Aluminum: should not generate any vibrations Steel: should not generate any vibrations Inox steel: can generate some vibrations Brass, copper and other soft materials: can generate some vibrations without affecting the machined part.

• Test with standard steel or aluminum bar stock.

• Material profile • Round bars should rotate without noise Profiled bars should generate acceptable noise/vibration.

• Bar straightness A straightness of 0.5 mm for 1000 mm is admissible.

• Cut a bar stock in 2 and test; if the results are much better, this is an evidence about the bad bar straightness.

• Bar stock finish

• If the material has been saw cut, the sharp edges and burrs must be removed

• If the material is a hot roll type it may not meet our specifications.

• If the material has been “cropped” to length the last 6”-12” of the end of the bar may be unusable due to being bent severely in the process.

Note: Also, there is a possibility to have a severe angle on the end of the bar, which has been cropped. This can lead to mis-positioning during part feed out, depending on the surface area that the Quick Load’s pusher is pushing against, as the bar has rotated in it’s orientation inside the spindle.

The headstock / actuator assembly should have minimal run out. *

Proper chucking device should be selected to match the machining application. *

The chucking device should have proper clamping pressure. *

The surface of the jaws or pads must make proper contact with the material. *

*Please reference OEM specifications.




2-3

Servo Motor Following Error During Sequence 9

Description: The Servo Motor Following Error! During Sequence Number [9] alarm occurs after the new bar has been measured and is being advanced to top-cut position. The torque on the servo motor will build up when an obstacle prohibits the stock from moving, once the torque reaches a certain limit the PLC instructs the servo amplifier to quit pushing and this alarm message appears on the remote control station.

Solution: Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm.

Check that nothing can prevent the bar stock from moving forward.

Check that the correct bar stock diameter is entered for the parameter.

Cause Solution Hitting back of spindle Check that the correct bar stock diameter is entered for the

parameter.

Check that the correct spindle reduction tube is installed.

Verify the alignment of the bar feeder. If the alignment is off; realign and then recalibrate the loading table, refer to "Alignment Procedure" and "Calibration of the Loading Table"

Hitting back of clamping system Verify the correct collet/chuck is installed for the material being run.

If the problem persists, please contact LNS America, Inc.

2- CHAPTER 2: COMMON ISSUES 2-4

Part feed out accuracy

Description: The accuracy of the part positioning can be affected by many factors. Choosing the correct bar feed application and setting the barfeed parameters correctly are crucial to ensuring the proper accuracy.

Part Setup Parameter: 1. Input overall part length (Located in: 1. Part setup menu)

The parameter determines how far the push rod will advance the bar stock during a part feed out. This value should include the finished part length, cut-off and facing. In other words, the amount of material needed to make a complete part.

Application Selection: (Located in: 2. Application Setup) 1. Feed without help of the turret

This application requires that the lathe be equipped with a pull-to-close type clamping system. If a push-to-close type clamping system is used then the “Feed with help of the turret” application must be selected. It is recommended by LNS that when feeding without the help of the turret that a dead-length, parallel gripping type clamping device be used. This type of clamping system will prevent the bar stock from moving forward when the clamping device is closed, thus losing the positioning accuracy.

2. Feed with help of the turret

This application can be selected when either a pull-to close or push-to-close type clamping system is installed but must always be selected when a push-to-close type clamping system is installed. This is due to the bar stock moving forward as the draw tube pushes forward to close the clamping device.

Parameters related to clamping device: (located in: 4. Miscellaneous Functions menu) 1. Time for clamping device to close

Once the clamping device close signal is output from the lathe the barfeed will wait for the time entered in this parameter to expire then the push rod will reverse off the back of the part.

If this time is set to low then the push rod may reverse before the clamping device is physically closed. When this occurs with a pull-to-close clamping system then the push rod will not be in place to support the bar stock as the clamping device closes. The push rod can overcome the weight of the barstock moving in the draw tube but can not overcome the force of the clamping device this is why a dead-length, parallel gripping type clamping device is recommended.

Setting this time to high will not effect the part positioning. However, if this time is set to high the push rod may not reverse off the bar stock before the spindle begins to rotate. This can create excessive noise and possibly damage the push rod.




2-5

2. Time for clamping device to open

Once the clamping device open signal is output from the lathe the barfeed will wait for the time entered in this parameter to expire then the push rod will advance the part the distance programmed.

If this time is set to low then the push rod may hit the back of the clamping device before it is physically open. This can cause a variation of unexpected results.

For further information on part feed out accuracy with special applications, please contact your local LNS representative.

Cause Solution 1st Part feed out after top-cut positioning too short/long

• Verify that the top-cut position is programmed correctly

• If performing a cut-off or facing operation on the bar stock during top-cut, verify that the end of the bar stock is in the same location as if a part was cut-off after the cut-off or facing operation is complete.

Part feed out too short • Verify that the correct value is entered into the “Input overall part length” parameter

• If using a pull-to close type clamping system ensure that the time entered into the “Time for clamping device to close” parameter is correct.

• Make sure that the clamping device is not forcing the bar stock back when closing

• Verify that the lathe program is correct

• Verify that the bar stock is concentric and clean of debris

Part feed out too long • Verify that the correct value is entered into the “Input overall part length” parameter

• If using a push-to-close type clamping system ensure the turret is being used to locate the part and that the turret is in the correct location

• Verify that the bar stock is concentric and clean of debris

CHAPTER 3: PROCEDURES


3-1

Chapter 3: Procedures

he following chapter includes simple step-by-step procedures for mechanical adjustments, replacing damaged or faulty components and to resolve other issues related to the bar feeder.

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3- CHAPTER 3: PROCEDURES 3-2

Alignment Procedure Conditions:

- Bar feed power on.

Procedure:

Step 1: Position the bar feed as close as possible to the rear of the lathe. The distance between the front of the bar feed and the back of the spindle should be as small as possible. Note: If obstacles prevent the bar feed from being positioned within 200 mm of the back of the spindle an extension will be required.

Step 2: Level the bar feed in the x and y axis using a torpedo level. The level can be placed on the linear belt rail to verify the y-axis and on the retract rails to verify the x-axis. Use the leveling screws on the retract to adjust unit to level.

Leveling screws

Leveling screws




3-3

Step 3: Carefully loosen the 12 screws located in the slots on the base of the unit (6 each side). This will allow the unit to be adjusted up and down.

Step 4: Using the central jackscrew, adjust the unit so that the pusher is centered up and down at the back of the

spindle. Make sure that the unit raises or lowers uniformly.

Central jackscrew


Step 5: Once the pusher is centered up and down, tighten the 12 screws to secure unit and recheck the level of the unit.

Step 6: Align the unit side to side by centering the pusher in the back of the spindle and then extending the pusher to the back of the collet and centering it there.

Adjust the rear of the bar feed when centering to the rear of the spindle and the front of the bar feed when centering to the rear of the collet.

Once the pusher is centered at the back of the collet recheck the alignment at the back of the spindle by pulling the pusher back. Continue until the pusher is centered at the rear of the spindle and at the rear of the collet.

Step 7: Once the bar feed has been aligned anchor it using the 4 anchor bolts supplied with the unit. Don't anchor

it at retract rail centers; just let the screws touch the ground.

Anchor here

Don’t anchor here!!!

Anchor here




3-5

Step 8: After anchoring the unit, recheck the level and the alignment of the unit.

Step 9: fter the alignment has been rechecked, power will need to be hooked up to the bar feeder.

ading

Step 11: nt, load a bar into the loading table and verify that it can be loaded into the spindle of the

Note: If the bar hits side to side the alignment will have to be adjusted.

Procedure complete.

A

Step 10: Once the power has been hooked up, the bar feed must be calibrated. Refer to "Calibration of the LoTable" procedure. After calibrating the bar feed, return to this procedure and move on to Step 11 for the final alignment. For final alignmelathe without hitting the sides of the spindle or spindle liner.


Pusher Changeover Procedure

Conditions: - Bar feed power on. - Loading table in lower position. - Pusher at the mechanical home position. - Bar feed in STOP mode.

Procedure:

Step 1: Open the main access cover.

Step 2: Pull the carrier away from the home position.

Step 3: Press the pusher adapter locking/unlocking finger toward the front of the bar feeder, then turn the finger a

¼ of a turn clockwise. The finger must stay locked in forward position. Pull the pusher towards the bar feeder front but don't extract it completely out of the carrier.




3-7

Step 4: Pull the white bushing on the front guide bearing towards the rear of the bar feed to extract it.

Step 5: Remove the pusher completely from the bar feed.

Step 6: Disassemble the pusher adapter from the pusher body by pushing out the crossing shaft. Reset the shaft in the pusher body to avoid losing it.

Step 7: Assemble the pusher adapter on the new pusher body with the corresponding shaft.

Step 8: Put the corresponding white bushing on the pusher. Insert the front end of the pusher through the front of the bar feed first, then slide the pusher adapter through the carrier so that it is flush on the right hand side of the carrier.

Step 9: When the pusher adapter is in place in the carrier, turn the finger ¼ of a turn back (counter-clockwise). The finger must stay locked in rear position and the pusher must be totally locked into the carrier. Slide the white bushing into the front guide bearing.

Must be flush on the right side of the carrier bushing.


Step 10: Slide back the carrier to the home position. Close the main access cover.

Procedure complete.




3-9

Belt Tension Adjustment

Conditions: - Bar feed on. - Loading table in lower position. - Pusher at the mechanical home position. - Bar feed in STOP mode.

Procedure:


Step 2: Make sure the carrier is in home position.

Step 3: In the middle of the linear rail, measure the belt vertical displacement from the belt to the rail. Don't force it ! This displacement must be approx. 20 mm. If necessary, modify the belt tension with the belt tensioner located at the front of the bar feed.

Step 4: Once the tension is set, close the main access cover.

Procedure complete.


Home Position Proximity Switch SQ5 Adjustment

Conditions: - Bar feed power on. - Bar feed in STOP mode. - Pusher at the mechanical home position.

Procedure:


Step 2: Make sure the carrier is in home position.

Nylon bushing is the mechanical home position.

Step 3: Adjust the SQ5 proximity switch position just far enough to get a strong signal from the switch (approx. 0,5 mm) and tighten down. Any slight movement forward of the carrier should deactivate the proximity sensor.

~0,5 mm

Step 4: Close the main access cover.

Step 5: Press the [STOP] key on the remote control to clear any alarm. Reference the bar feed (see "Reference procedure").

Procedure complete.




3-11

Diameter Adjustment Motor Proximity Switch – SQ4

Conditions: - No bar stock in the magazine. - Loading table in lower position. - Bar feed in STOP mode.

Procedure: Note: The bar feed must be calibrated for a diameter of 6 mm.

Step 1: In the "Part Setup", enter a bar stock diameter of 6 mm. Step 2: Place 2 pieces of 6mm bar stock on the magazine rack.

Step 3: In manual mode, move up the loading table (if the adjustment fingers don't move, run the carrier flag

forward to the end and then back to the home position, drop the table down and then repeat this step).

Note: If the bar is not picked up by the table, the switch is set too high. Set it a little lower and repeat points 2 and 3. In upper position, the bar stock should touch the table stops and the selection fingers.

Step 4: Once the bar stock loads correctly, check that the bar feed does not load 2 bar stocks at once.

Note: the stock must be straight to obtain the ideal adjustment.

Procedure complete.


Measuring Cell Adjustment – SQ3

Conditions: - No bar stock in the magazine. - Loading table in lower position. - Bar feed in STOP mode. - Value entered in the "Part Setup", parameter "Bar stock diameter" must be 6 mm (0.236”).

Procedure:

Step 1: In manual mode, move up the loading table. Press the [STOP] key on the remote control.

Step 2: Retract the bar feed for access to the front of the unit.


Step 4: Place a piece or bar stock of 6 mm (or smallest diameter stock available) into the channel. (Note: the stock must be straight to obtain the ideal adjustment).

Step 5: Push the stock up so that it is sticking out the front of the bar feeder. Turn the gain adjustment clockwise

on the measuring cell to the max position. A ticking noise marks the end of the adjusting range.

Step 6: Loosen screws and adjust the cell so that the “red” sensor is reflecting off the center of the bar and tighten

the cell down.

View from the bar feed front

Red sensor

View from the bar feed front




3-13

TStep 7: urn the gain adjustment counter clockwise to the minimum position. A ticking noise marks the end of the

Step 8: rom the minimum position slowly turn the gain adjustment clockwise until the sensor detects the bar (a

Step 9: emove the material from the channel and close the main access cover.

ess Cover Open" alarm.

Procedure

adjusting range.

Fyellow LED will illuminate once the bar is detected). Once the sensor detects the bar continue to turn the gain clockwise another ½ turn.

R

Step 10: Press the [STOP] key on the remote control station to clear the "Main Acc

complete.


Pusher Reversing Distance

The pusher reverses a specified distance, after the chuck closes, so that it is not making contact with the rotating bar or the spindle. Generally, the smaller the diameter of the pusher the greater the reversing distance. This is due to deflection (or sagging) of the pusher, which is caused when the pusher is far up in the spindle of the lathe and can no longer support its own weight so the tip of the pusher begins to sag. Default value is 4 mm. Note: if the pusher does not touch the spindle before the End of Bar position is reached, then the default value will remain as

the value for the Pusher Reversing Distance parameter. If this is the case, then return the pusher to the home position and this procedure is complete.

Conditions: - Bar feed power on. - Loading table in lower position. - No bar stock loaded in the spindle. - End of bar already set.

Procedure: Default value In automatic mode, after clamping device closing, the pusher moves back by the default value, i.e. 4 mm.

Out of the spindle In automatic mode, after the clamping device closing, the pusher moves back to the home position. To apply this mode:

Step 1: Press the [STOP] key.

Step 2: Choose "PART SETUP" and press on the key corresponding to [ENTER].

Step 3: Press on the key corresponding to [ENTER] as many times as necessary to display the text "PUSHER REVERSE DISTANCE".

Step 4: With the up/down keys, select [2]. Press on the key corresponding to [ENTER].

Step 5: Exit the menu by pressing on the key corresponding to [ESC].

Enter value In automatic mode, after clamping device closing, the pusher moves back by the entered value.

Step 1: Press on the key corresponding to "MANUAL MODE".

Step 2: In manual mode, raise the loading table (if a bar is loaded remove the bar). Run the pusher forward until

the tip of the pusher sags and is touching the spindle (or spindle liner if one is installed).

Step 3: Record the value of the pusher position on the remote control station. Reverse the pusher just slightly until there is 5 mm clearance between the pusher and the bottom of the spindle. Record the value of the pusher position on the remote control station. Calculate the difference between both values.

Step 4: Press on the [STOP] key on the remote control.

Step 5: Select "PART SETUP" and press on the key corresponding to [ENTER].

Step 6: Press on the key corresponding to [ENTER] as many times as necessary to display the text "PUSHER REVERSE DISTANCE".

Step 7: With the up/down keys, select [3]. Press on the key corresponding to [ENTER].

Step 8: The text "PUSHER REVERSING DISTANCE AFTER CLAMPING DEVICE CLOSES" appears. Press on any arrow key.

Step 9: With the up/down and left/right keys, enter the calculated value. Press on the key corresponding to [ENTER].

Step 10: Exit the menu by pressing twice the key corresponding to [ESC].

Procedure complete.




3-15

Reference Procedure

Conditions: - Bar feed on. - Bar feed in STOP mode.

Procedure:

Step 1: Press on the key corresponding to [ ] on the remote control. Select menu [4] using the up/down arrow keys. Press on the key corresponding to [ENTER].

MAIN MENU [1] 1:PART SETUP 2:APPLICATION SETUP 3:POSITION/TORQUE 4:MISC. FUNCTIONS 5:SERVICE

Step 2: Press on the key corresponding to [PAGE DOWN] as many times as necessary until this text appears. Select option [2] using the up arrow key. Once [2] is selected, press and hold [ENTER] for 2-3 seconds. The screen will then return to the home page.

REQUEST FOR REFERENCE POINT [@] 1:NO 2:YES ESC ENTER

Step 3: Press on the key corresponding to [MANUAL MODE].

LOADING CHANNEL IN AN INTERMEDIATE POSITION - F1 MANUAL MODE

Step 4: Press on the key corresponding to [REFERENCE].

POSITIONING ERROR! ENCODER LOST ITS REFERENCE POINT... RESET REFERENCE POINT (ZERO POINT) -F1 START


Sequence: The carriage unit retracts toward the home position, simultaneously, the PLC waits to detect the proximity switch SQ5 and the servo amplifier looks for the torque to build up after hitting the mechanical stop.

Once the home position is set, the HOME PAGE will reappear on the remote control station.

REFERENCE POINT POSITIONING IN PROGRESS...

Procedure complete.




3-17

Calibration of the Loading Table

Whenever the diameter or the profile is changed, the centerline of the loading table is automatically adjusted according to the parameters entered by the operator.

If, for any reason whatsoever, the centerline of the loading table would be incorrect (either too low or too high), it can be corrected.

Conditions: - Bars on the magazine. - Loading table in lower position. - Bar feed in STOP mode.

Procedure: Step 1: Press on the key corresponding to [MANUAL MODE].

Step 2: Press on [F2] to move up the loading table in upper position. The bar now faces the spindle of the lathe.

Press the [STOP] key.

Step 3: In the main menu, select the menu [SERVICE] with the up/down keys, then press on the key corresponding to [ENTER].

Step 4: In the service menu, select the menu [BAR FEED SETUP], then press on the key corresponding to [ENTER].

Step 5: Press on the key corresponding to [PAGE DOWN] until the text "NUMBER OF PULSES FOR TABLE CENTERING CALIBRATION". Press on any arrow key.

Step 6: Enter with the up/down and left/right keys the password [2534], then press on the key corresponding to [ENTER].

Step 7: Enter with the up/down keys to modify the centerline of the loading table. One pulse is approx. 0,4 mm of vertical displacement. Examples:

Step 8: [10] = vertical displacement of approx. 4 mm upwards. [ -5] = vertical displacement of approx. 2 mm downwards. Once the right value has been entered, press on the key corresponding to [ENTER] to confirm.

Step 9: Press on the key corresponding to [ESC] to exit the menu.

Step 10: Press on the [F3] key to move down the loading table.

Step 11: Press on the [F2] key to move up the loading table. The correction of the loading table has been taken into account.

Procedure complete.

CHAPTER 4: SOFTWARE


4-1

Chapter 4: Software

ith the help of the latest technological innovations, it is possible to update new software and restore lost data.

The been a power failureany application/inter

PLC holds a backup program for the Quick Load Servo 65 / 80 if at anytime there has or any error has occurred in the user program. In addition, it automatically backs up face parameters that have been set for the most recent application being run.

Following a few systematic procedures is all it takes to be up and running with the most up to date software or restoring lost PLC programs and/or parameters.

W

CHAPTER 4: SOFTWARE 4-2

Software / PLC Versions To find the LNS software version: In the working menu, press the key on the remote control. Press the Page Down key to read more information.


CHAPTER 4: SOFTWARE


4-3

Software Update Conditions:


Procedure:

Step 1: In the electrical cabinet, open the PLC cover.

Step 2: Insert the card containing the new software in the "M1" labeled bay. A chamfer avoids any bad insertion.

Step 3: With a sharp object, press on the little button labeled Run/Halt for approx. 3 seconds, until the LED located at its left blinks.

CHAPTER 4: SOFTWARE 4-4

Step 4: The PLC is rebooted and the new software is loaded. This operation takes max. 10 seconds. When the

barfeed has saved all the parameters, it is operational again.

Step 5: Take out the card containing the software. Close the PLC cover and the electrical cabinet.

Procedure Complete.


CHAPTER 4: SOFTWARE


4-5

Battery Replacement Conditions:


Procedure:

Step 1: In the electrical cabinet, open the PLC cover.

Step 2: Take the battery support out of the bay labeled "BATT".

Step 3: Replace the battery with an identical type. Check that the battery is in the right direction. Step 4: Insert back the battery support in its bay. Close the PLC cover and the electrical cabinet.

Procedure Complete.

CHAPTER 5: MAINTENANCE


5-1

Chapter 5: Maintenance

eriodic maintenance of the Quick Load Servo 65 / 80 bar feeding system can only serve to improve the operation and prolong its useful life. Following a few simple steps can be extremely helpful and takes relatively no time at all. The list of maintenance procedures has been broken down into two groups determined by the frequency with which each procedure should be followed; however, some items should be checked more often depending on the

operating environment that the equipment is exposed. P

CHAPTER 5: MAINTENANCE


5-2

Monthly Maintenance

Verify the belt status Check carefully the wear of the belt. It should have no notches, no failing teeth, no gap.

In case of gap, adjust the tensioning (refer to the procedure "Belt tensioning adjustment").

In case of strong wear, replace the belt (refer to "Spare parts, Belt drive").

Cleaning of the bar feeder Wipe down the outside of the bar feeder with a cloth and any regular detergent. For cleaning the inside of the bar feed, use a cloth or brush, however, do not use these on any of the rollers or any other parts made of synthetic materials. The use of compressed air for cleaning is not advisable, because chips and other particles can become lodged in sensitive areas and can impede the proper operation of the bar feeder.

Annual Maintenance Check the PLC battery The PLC backup battery saves the PLC program in case of any power failure. The battery used in the controller is a non-rechargeable 3VDC Lithium/ CD2032 battery. Over time, the battery will slowly discharge and an alarm message will appear on the remote control station (Low PLC Battery).

The following chart shows the average life expectancy of the battery:

Use of automation Avg life expectancy:

25°C

Avg life expectancy:

55°C 100% off 0% on 3 years 6 months

0% off 100% on 5 years 4 years 30% off 70% on 4 years 1 year

Verify the alignment of the bar feeder Check alignment of bar feeder to lathe spindle to make sure neither have shifted. In case the bar feeder or lathe has shifted, align the bar feeder again.

CHAPTER 6: SPARE PARTS


6-1

Chapter 6:

Spare Parts

hen ordering parts the following information will be needed to ensure better customer support:

• Bar feeder type • Bar feeder serial number (located on the sub-base)

W • Bar stock diameter • Lathe type (brand & model)

CHAPTER 6: SPARE PARTS 6-2

Recommended Spare Parts List

As an extended courtesy, a list of recommended spare parts has been compiled for the end user. The list consists of mechanical and electrical parts that over time may become faulty due to everyday wear on the item. For machines that are running production during multiple shifts or even 24/7, keeping an inventory of these spare parts can vastly minimize downtime. Keeping an inventory can also be very cost effective since shipping costs can escalate immensely, especially in cases where rush delivery is necessary.

Designation Article No Description QS 1 4.242 Main disconnect switch

SQ 1 4.391 Proximity switch, loading table in lower position

SQ 3 4.474 Positioning optical cell

SQ 4 4.391 Proximity switch, diameter selection fingers in origin position

SQ 5 4.391 Pusher in home position switch

SQ 10 4.763 Cover closed safety switch

SQ 11 4.763 Magazine cover closed safety switch

SQ 12 4.763 Retraction system safety switch




6-3

Mechanical Assemblies 020.000.011 QLS 65 - Machine assembly – left/rear – longitudinal retraction


020.000.021 QLS 65 – Machine assembly – left/rear – transversal retraction




6-5

020.000.031 QLS 65 - Machine assembly – left/front – longitudinal retraction


020.000.041 QLS 65 - Machine assembly – left/front – transversal retraction




6-7

020.000.111 QLS 80 - Machine assembly – left/rear – longitudinal retraction


020.000.121 QLS 80 - Machine assembly – left/rear – transversal retraction




6-9

020.000.131 QLS 80 - Machine assembly – left/front – longitudinal retraction


020.000.141 QLS 80 - Machine assembly – left/front – transversal retraction




6-11

Base 020.001.213 QLS 65 - Base left/rear – Table base – fingers assembled


020.001.243 QLS 65 - Base left/front – Table base – fingers assembled




6-13

020.001.313 QLS 80 - Base left/rear – Table base – fingers assembled


020.001.343 QLS 80 - Base left/front – Table base – fingers assembled




6-15

020.001.603 QLS 65/80 - Sub-assembly electrical cabinet door


LOADING TABLE 020.002.103 QLS 65 - Sub-assembly table 1300 left/rear




6-17

020.002.123 QLS 80 - Sub-assembly t

Documents

Table of Contents - LNS North America · 2019. 5. 18. · 1-2 CHAPTER 1: ALARMS Switches and cells list SQ5 M1 SQ10 M3 SQ4 SQ1 A SQ11 SQ12 SQ3 B M2 Designation Part No. Description