Edge Rebel 80 General Information Manual Download Page 62

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10. Factory Parameters

Rebel

Pusher Feed Direction:

Allows direction of operation of the jog buttons on the HMI and

Remote Pendant to be reversed to accommodate different lathe configurations. Choices are

Left to Right and Right to Left.

Summary of Contents for Rebel 80

Page 1: ...and Capacities 4 2 4 Bar stock requirements 4 2 5 Safety 5 2 5 1 Covers 5 2 5 2 Axial Shifting Switch 5 2 5 3 Lathe Door Safety 6 2 5 4 Emergency Stop Buttons 6 3 Transportation and Handling 3 1 Lifting and Moving by Forklift 7 3 2 Lifting by Crane 8 4 Installation of the Bar Feeder 4 1 Lathe Preparation 9 4 2 Distance from the Lathe 9 4 3 Axial Shifting Device 10 4 4 Magazine Attachment 12 4 5 Al...

Page 2: ...3 6 1 1 Status LEDs 23 6 1 2 Pusher Jog Buttons 23 6 1 3 V Tray Up and Down Buttons 24 6 1 4 Pre Auto and Automatic Manual Buttons 24 6 2 Sequence for Manually Changing Bars 24 6 2 1 Unload Bar from Lathe 24 6 2 2 To Load a New Bar 25 6 3 HMI Control Panel 25 6 3 1 Starting the Bar Feeder 25 6 3 2 Setting the Measurement Standard to Inches or Millimeters 26 6 3 3 Manual Screen Functions 26 6 3 4 P...

Page 3: ...Drive Belt Tension Adjustment 38 8 3 Lubrication 39 8 4 Maintenance Screens 40 9 User Parameters 9 User Parameters 1 through 8 10 Factory Parameters 10 Factory Parameters 11 through 21 44 11 Service Technician Parameters 10 Service Technician Parameters 22 through 42 53 12 Alarms Alarms 1 4 73 Alarms 5 13 74 Alarms 14 19 75 Alarms 20 23 76 Alarms 24 26 77 ...

Page 4: ... 80 Alarms 36 38 81 Alarms 39 41 82 Alarms 42 44 83 Alarms 45 47 84 Alarms 48 51 85 Alarms 52 70 86 Alarms 93 96 87 13 Electrical System Electrical schematic table of contents 88 Schematic 89 14 Parts Parts ordering information 106 Electrical components 106 Exploded views 107 ...

Page 5: ... points of information are preceded by the following symbols and text Warning Indicates a potential danger to life or risk of personal injury Exercise extreme caution Caution Indicates a possible hazardous condition Take precautions according to the instructions following these warnings to help prevent injury to personnel or damage to the equipment Important Information precedes special or technic...

Page 6: ...ation Technical Support For technical support please contact the Edge Technologies Service Department by phone at 314 692 8388 or by email edgeservice edgetechnologies com Important information When calling for technical support please have the machine model type and serial number on hand Refer to the machine data plate for this information G I E C B A DRIVING VOLTAGE FEEDING VOLTAGE WEIGHT TYPE N...

Page 7: ...axial shifting device to allow the bar feeder to be moved away from the lathe spindle for maintenance or spindle liner changes with no loss of alignment Soft load bar presentation to reduce the jarring effect of heavy bars dropping into the channel Parameter driven fully automatic bar diameter adjustment and pusher thrust Fixed piece feeding sub spindle mode and push to a stop methods of bar feedi...

Page 8: ...indle while turning it may prevent loading if bar condition is such that the bar collides with the back of the lathe spindle or it binds while feeding into the spindle Bars of small diameter may not pick up properly from the magazine if they are not straight Excessive chips burrs or dirt may cause binding within the spindle The ends of the bar should be relatively straight to the diameter of the b...

Page 9: ...e devices must not be bypassed or tampered with 2 5 1 Covers The bar feeder is supplied with covers to prevent access to moving parts during operation The hood of the bar feeder is equipped with a safety switch S6 to place the machine in alarm if the hood is not closed The magazine cover prevents access to the material on the rack and the bar separators 2 5 2 Axial Shifting Switch The bar feeder i...

Page 10: ... the HMI control panel housing Button ES2 is the emergency stop button on the remote pendant control Pressing either emergency stop button disconnects the Emergency Stop Relay The emergency stop relay turns off relays MC1 and MC2 which disconnects power from the servo drive and the outputs from the bar feeder to the lathe Contacts from the emergency stop buttons are incorporated into the interface...

Page 11: ...avy and take proper precautions 3 1 Lifting and Moving by Forklift Lifting and moving the bar feeder by forklift is the preferred method of handling the machine The machine should be moved only by personnel qualified in the operation of forklifts The forks must extend past the machine cabinet see the drawings below Lift the machine from the side opposite the magazine maintaining sufficient clearan...

Page 12: ...ed lifting bars that extend at least 12 inches past the sides of the cabinet are required Ideally the lifting bars will have eyebolts attached The lifting bars are placed under the pan of the bar feeder next to the electrical cabinet see diagram The lifting straps or chains should be padded to prevent damage to the sheet metal covers The machine should be lifted slowly a short distance The balance...

Page 13: ...n Prior to beginning the bar feeder installation the lathe must be properly leveled It is strongly recommended that the lathe be anchored to the floor to prevent it from shifting 4 2 Distance From Lathe The bar feeder should be placed as closely as possible to the rear of the lathe while maintaining sufficient clearance to allow the bar feeder to be moved on the axial shifting device The area to b...

Page 14: ...ial track slide rails on the floor Locate and fasten the foot lock cross rail to end of the axial track rail sides that would be the open hood side of the bar feeder Locate and fasten the cross rail rod between the rear of axial track slide rails Be sure to loosen the 4 axial track jack screws so there is zero preload on the floor Loosen the socket head cap screws that fasten the mounting lock pla...

Page 15: ...oss rail It may be necessary to adjust lock stops on the foot lock cross rail so there is no movement of the bar feeder once locks are engaged Be sure it does not require excessive force to lock or unlock the bar feeder with the foot lock rail There should be just enough force to remove bar feeder movement when locked Attach the axial track switch to the left front under side of the bar feeder Adj...

Page 16: ...during shipment and must be installed on site Before lifting the magazine loosen screws 2 2 places and remove screws 1 3 places Attach the two braces with the bolts 5 Lift the magazine and slide it into the feeder so the center section is between the bar lifters 2 Thread the screws of the braces into the nuts on the underside of the magazine 4 Secure the magazine with the 3 screws 1 Adjust the mag...

Page 17: ...4 Installation Rebel 80 13 ...

Page 18: ...Technologies Parts department at 314 692 8388 or email edgeservice edgetechnologies com 4 5 1 Alternate method of alignment Elevation of the bar feeder is adjusted by the two jack screws located at the center of each stand Loosen the four bolts securing the leg to the stand 1 Turn the jack screw 2 to raise or lower the bar feeder center height The side to side alignment is set by sliding the bar f...

Page 19: ... not a problem as long as the bar moves freely Bar centered in spindle Resting on bottom of spindle 4 6 Anchoring the bar feeder When the alignment is correct the bar feeder must be anchored to the floor to prevent it from moving out of position The bar feeder is supplied with diameter anchor bolts to secure the axial track to the floor It is recommended to drill the holes for the anchor bolts thr...

Page 20: ...rface connection for the bar feeder a plug and cables will be supplied The lathe must support a magazine type bar feeder interface for the machines to be connected Caution Failure to follow the procedure in section 4 8 may result in damage to the magazine feed motor and linkage This procedure is for the initial setup only and should not be performed again unless instructed to do so by the Edge Tec...

Page 21: ... adjust the fingers so the vertical face of the V Tray tabs are just smaller than the bar diameter On larger bar you will not be able to get the bar in a under flush position due to capacity restraints As an option V Tray up and down buttons on the pendant may be sued to move fingers Once the proper position has been determined select the number pad and input the diameter of the bar and select ENT...

Page 22: ...aded jumps out of place or tries to load with the loading bar check bar stock diameter value in the part program is correct for the bar size in use If bar diameter is correct the restart finger set procedure 4 9 Resetting the bar pusher home procedure Any time pusher has been moved manually without power to the bar feeder it is possible to lose the home position Please follow the procedure below t...

Page 23: ...ry slow during the referencing If the pusher is further from home procedure will take longer Additionally the Set Jog Pusher screen allows for additional testing functions Pusher Advance Advances the pusher Pusher Retract Retracts the pusher Jog Speed Toggling through speeds 1 through 5 will increase and decrease the pusher retracting and pusher advancing functions Go To Home Position Pusher retra...

Page 24: ...0 degrees for round stock keeping in mind that the heavier materials require less incline For hex shaped material the incline should be set to around 20 degrees Never exceed 20 degrees or bar feeder damage will occur The magazine incline is adjusted by first loosening the screws 1 then turning the nuts 2 to reach the desired angle Tighten the screws 1 when finished Both of the braces should be set...

Page 25: ...the notch to release the bar pusher from the carriage Slide the bar pusher forward far enough to be able to raise the rear of the pusher clear of the carriage Pull the pusher backward to clear the front plate and lift and the bushing out of the machine Installation of the bar pusher is the process in reverse Slide the front of the pusher into to hole for the bushing slide the pusher hub into place...

Page 26: ...etracted to the home position Release the foot lock cross rail holding the bar feeder in place on the axial track Push the bar feeder away from the lathe Stops on the axial track will prevent the bar feeder from traveling beyond a safe distance Once the axial track safety switch is disengaged the bar feeder will disable automatic mode functions To move the bar feeder back into position simply push...

Page 27: ...e bar feeder is currently at the end of its feeding cycle and will need to perform a bar change Feed M code The bar feeder is currently feeding with an M Code signal 6 1 2 Pusher Jog Buttons These buttons allow the operator to jog the bar pusher and pre feed pusher in forward and reverse Auto Pre Auto Jog Forward Jog Reverse Manual Emergency Stop LED Status Indicators V Tray up Jog Reverse Jog For...

Page 28: ...he operator must first press the Pre Auto button then the Automatic button Manual mode is selected by pressing the Manual button alone 6 2 Sequence for Manually Changing Bars 6 2 1 Unload bar from lathe Remove the bar stock from the lathe spindle by following these steps Retract the bar pusher to the home position using the reverse jog button Raise the channel by pressing and holding the Channel U...

Page 29: ...s on this feature 6 3 HMI Control Panel The HMI is a microprocessor based touch screen unit that receives the user input commands directly through the touch screen There are many obvious defined buttons or keys when pressed an action of some type appears on screen There are undefined buttons or keys when a value or description is pressed an action of some type appears on screen Understanding this ...

Page 30: ... feeder the location of the bar pusher from the home position the position of the V channel the status of the lathe collet and the current or last completed operation of the control Buttons on the panel include the setup button for selecting an existing program to load or edit or for creating a new program The bottom section of the screen has forward and reverse jog arrows bar on and bar off funct...

Page 31: ...ams To select an existing program press the Program button Enter the required password when prompted The display will show the program menu screen with the first 8 program file locations Select the part program number required If the program number you are trying to recall is not displayed select Load and Save Parts Pressing the up down or groups of 10 and 100 keys will scroll through the file loc...

Page 32: ...up a bar from the magazine and carrying it up to the loading position 6 3 8 Bar On Button Note Lathe collet or chuck must be open for bar on Pressing the Bar On button will mimic the operations of loading a new bar in the Automatic mode The steps performed are The bar pusher retracts to the home position The V Tray will raise picking up a bar from the magazine and carrying it up to the loading pos...

Page 33: ...utomatic Screen Functions The Automatic screen allows the operator to monitor the location of the bar pusher and the remaining number of parts that can be made from the material in the lathe spindle by selecting the selecting dual active switch Whichever parameter is active touching the key will change to the next parameter As on the Manual screen the status of the lathe collet channel position an...

Page 34: ... is usually set to the value of the overall part length the width of the cut off tool any facing stock The value is used to determine if enough material is left on the bar stock to make another part If the material is advanced using a sub spindle the value would be set to equal the total length of the sub spindle movement when the lathe collet is open Bar Diameter The parameter is used to set the ...

Page 35: ... diameter setting to set the height of the V tray to match the centerline of the lathe spindle Facing Length The parameter allows the user to set the distance the new bar will stick out of the chuck or collet at the end of the bar load sequence Open Collet Speed Sets the forward speed of the bar pusher in the automatic cycle ...

Page 36: ...automatic cycle Jaw Collet Length The jaw or collet length is used in the calculation of the facing position The measurement for a jaw chuck the distance from the end of the jaws to the face of the chuck plate The measurement for a collet chuck is the length of the ID of the collet that holds the material ...

Page 37: ...orward travel distance of the bar pusher CAUTION SETTING THIS PARAMETER AT A VALUE THAT IS TOO SMALL MAY CAUSE THE MATERIAL TO BE THROWN FROM THE LATHE CHUCK Feed Outs Per Part Enter the number of times the material is advanced during the machining of one part This parameter allows the end of bar signal to be sent only before the first feed out when more than one feed out is called for This preven...

Page 38: ...he back end of the bar stock to measure the length of the material and then return to the home position It will then monitor the open collet signal and deduct the feed length from the length of the bar stock as measured during the touch off When the remaining length of material is less than the part length setting the end of bar signal is sent to the lathe Chucker Mode This setting allows the lath...

Page 39: ...s reached Remnant Type Selects between modes of remnant disposal Choices are Extraction Ejection and Return Wait Extraction At the last available part from a bar the bar pusher remains at the pullback distance until the bar change is commanded by the lathe The pusher then retracts to the home position in preparation for a new bar to be loaded The remnant is pushed out of the chuck with the new bar...

Page 40: ...Ejection mode except that when the lathe collet closes after feeding the last part from the bar stock the pusher retracts to home position The V channel lifts and takes a new bar from the magazine The bar feeder waits for the part to be finished and a signal to begin the bar change to be sent from the lathe The remnant is ejected through the lathe collet by the new bar as is feeds to the facing po...

Page 41: ...e performed regularly The area around the bar feeder should be kept clean to avoid safety issues 8 1 Periodic Maintenance The items on the chart below should be performed at the intervals as listed Component Action Frequency Hours Regular Period 200 1250 2500 Fasteners Check tightness Yearly V Channel Check wear and clean Friction points Lubrication Drive belt Tension Bar feed interior Clean chips...

Page 42: ...side of the pulley shaft Turn the tightening screws clockwise to draw the pulley shaft forward and tighten the belt Jog the pusher forward and backward several times and observe the tracking of the belt on the front and rear pulleys If the belt pulls to one side loosen the opposite side tensioning screw When the belt is tracking properly retighten the two bolts on the pulley shaft alternating betw...

Page 43: ...to be lubricated are the linear way of the bar pusher carriage grease fitting pivot points of the magazine the cam and follower bearing of the V channel lifting assembly located inside the electrical cabinet and the bar pusher selector cams A light film of oil should be maintained on the bar pusher to lubricate the bar pusher support bushing ...

Page 44: ... that only one bar is picked up at a time for loading The fingers automatically adjust to the correct position when the bar diameter and material profile are set in the part program Jog Set Fingers Pressing this button calls up the screen to allow adjustment and manual jogging of the fingers If the fingers do not correctly separate the bars on the magazine the adjustment can be changed from this s...

Page 45: ...Down These buttons allow the user to manually raise and lower the V Tray to any position within the limits of the travel as defined by the bar diameter on parameter page 3 Move VTray Up Move VTray Down Buttons cause the V Tray to move to the upper and lower limits of travel as defined by the bar diameter entered on parameter page 3 V Tray Counter Shows the number of pulses from the S03 switch for ...

Page 46: ...able Servo or Servo Disabled When the message is Disable Servo pressing the button will turn off the servo drive and allow the bar pusher to be moved by hand Pressing the button when it says Servo Disabled will re engage the servo drive Jog Speed Pressing this button will cycle through the 5 choices for the jogging speed of the bar pusher Settings range from 1 extremely slow to 5 rapid Pusher Retr...

Page 47: ... are momentary on buttons that allow the V Tray to be raised or lowered within the safety limits of the bar feeder Jog To Bigger Smaller Diameter The buttons allow the bar separator fingers to be manually adjusted This is helpful in the event of over travelling the screw for the fingers Pusher Advance Retract Allows the short pusher or the bar pusher to be moved forward or backward Modify V Tray H...

Page 48: ...e options are values these will toggle through the choices each time the screen is pressed Parameter Page 1 FEED LENGTH 1 Total length of part being machined Calculate the proper setting by adding the Length of part Width of cut off tool facing stock Feed out 1 1 The distance the material will feed out during first feed of a part on fixed headstock lathe Distance headstock will pull material durin...

Page 49: ...ed out 1 3 Used when making multiple feed outs per part Feed out 1 3 is the third of 3 possible feed outs per part Parameter is disabled if set to zero Press the Feed out 1 3 dimension button to access page 1 3 and additional options ...

Page 50: ... for the centerline of the different material shapes in the channel Facing Length Distance past face of collet or check material will be loaded to during facing bar change or bar on sequence Collet Chuck There are three options for the facing length setting Pressing the Collet Chuck button toggles between the three options This feature allows for three different facing positions for different chuc...

Page 51: ...rom bar Min Chucking length for chuck The actual chuck length Required to determine the amount of material needed for gripping to determine number of parts remaining from bar Torque override Sets the clutch force for the bar pusher when in automatic with the lathe collet open The setting is expressed as a percentage of the default setting chosen according to the bar diameter parameter Adjustable r...

Page 52: ...ted Close Collet Timeout Time between when lathe collet closes and then opens when bar feed is in auto if time is reached then alarm is generated Open Collet Push Delay After lathe collet open signal is received pusher will delay pusher movement for set time Close Collet Push Delay After lathe collet close signal is received pusher will continue pusher movement for set time then stop ...

Page 53: ...f the back end of the bar stock to measure the length of the material and then return to the home position It will then monitor the open collet signal and deduct the feed length from the length of the bar stock as measured during touch off When the length of material is less than the part length setting the end of bar signal is sent to the lathe Chucker Mode Places the bar feeder into a suspend mo...

Page 54: ... remnant disposal Choices are Extraction Ejection and Return Wait Extraction Pull back remnant Ejection After feeding the last available part length into the lathe the pusher retracts to the home position when the collet closes When the lathe sends the bar change command the bar pusher moves forward to eject the remnant from the lathe collet then returns to the home position to continue the bar ch...

Page 55: ...feeder zero point As the bar advances the material into the lathe the bar pusher moves back the distance in the pusher back off parameter until the point of pull back equals the pusher pull back closed collet parameter setting Then when the lathe collet closes the bar pusher moves back to the pull back position each time the collet closes Pusher Back off Pull back Speed Sets the backward speed of ...

Page 56: ...9 User Parameters Rebel 80 52 Parameter Page 8 Change Program Number Allows change of the present part program number Will not allow duplicating an existing program number ...

Page 57: ...ance minus the chucking length the part parameters If maximum end of bar is reached first then it is used instead Max End of Bar Collet Sets the forward limit of the bar pusher stroke when using a collet chuck The position is typically set with the tip of the bar pusher even with the rear of the gripping surface of the collet pads The control calculates the end of bar signal position by subtractin...

Page 58: ...bel 80 54 Max End of Bar Chuck This parameter is the same as the Max End of Bar Collet parameter except that the dimension is measured with the tip of the bar pusher even with the back of the gripping portion of the chuck jaws ...

Page 59: ...on must allow the pre feed pusher to place the rear of the bar stock ahead of the bar pusher and not after the grippers Flag open closed distance This parameter is to calibrate the amount of movement that is needed before it recognizes that the flag has been triggered Headstock Type Set this parameter for the type of lathe The choices are Fixed Sliding and Sliding Bushing ...

Page 60: ... when the Remnant Handling parameter on parameter page 5 is set to Ejection Max Bar Length Sets the maximum allowable length of bar stock to be loaded into the lathe The length must be set so that no material extends past the back of the actuator on the lathe when a new bar is loaded The parameter is usually set to the measurement of the back of the spindle or actuator to the facing position ...

Page 61: ...ed Double Pulse Signal pulses when the end of bar position is reached and again when the facing position is reached Signal pulses for the duration set in parameter End Of Bar Pulse on page 16 Feed Confirmation Signal Type Selects between different modes of generating a signal for confirmation of bar feeding Choices are Not Used No signal is output Finished Feeding Signal is sent when the pusher fi...

Page 62: ...rs Rebel 80 58 Pusher Feed Direction Allows direction of operation of the jog buttons on the HMI and Remote Pendant to be reversed to accommodate different lathe configurations Choices are Left to Right and Right to Left ...

Page 63: ...onfirming that the bar change is complete Impulse on Time Sets a length of time for the bar feeder to send a signal to the lathe to rotate the spindle during bar change This parameter works with Impulse Off Time Impulse off Time Sets a length of time for the bar feeder to turn off the Impulse On Timer during the bar change The combination of these two parameters causes the lathe spindle rotation t...

Page 64: ...he end of bar signal is set to pulse Feed Confirm Pulse Sets the length of time in seconds for the signal to remain on when the feed confirmation signal is set to pulse Cycle Start Pulse Sets the length of time in seconds for the cycle start signal to remain on Demo Mode Activates or deactivates the demonstration program of the bar feeder ...

Page 65: ... Open signal from the lathe as either a normally open or normally closed signal Lathe Alarm Allows the bar feeder to accept the Lathe Alarm signal from the lathe as either a normally open or normally closed signal Feed M Code Allows the bar feeder to accept the Feed Stop signal from the lathe as either a normally open or normally closed signal Lathe Specific Special setting for specific lathes tha...

Page 66: ...ly closed Axial track Changes the axial track safety alarm to either trigger when the axial track switch is Normally Open or normally closed Auto start mode This setting allows the bar feeder to automatically switch into automatic mode when the lathe goes into automatic mode this will only work if the lathe is able to send an automatic mode signal to the bar feeder ...

Page 67: ...r change Bar measuring speed Speed at which the pre feed pusher moves at until the bar hits the measuring flag during pre feed Pre feed speed Speed at which the pre feed pusher moves at after the bar hits the measuring flag during pre feed 1st feed return speed Speed of the pre feed pusher as it retracts to the home position after completing the 1st feed cycle ...

Page 68: ...d Speed at which the pre feed pusher moves at until the bar hits the measurement flag during pre feed Also known as1st Feed Speed 1 Pre Feed speed Speed at which the pre feed pusher moves at until the bar hits the measurement flag during pre feed Also known as1st Feed Speed 2 1st Feed Return Speed Speed of the pre feed pusher as it retracts to the home position after completing the 1st feed cycle ...

Page 69: ...stance Facing Speed 2 Forward speed of the bar pusher during the distance specified in the Facing Speed Slowdown Distance Parameter during facing Speed pusher moves at during pecking cycle Facing Speed Slowdown Distance Distance before pusher reaches facing position when pusher slows down to facing speed 2 This distance is measured from the facing position back toward the bar feeder ...

Page 70: ...force developed by the clutch when moving the bar pusher forward in manual mode via the jog buttons or through the input for Manual Forward in the bar feeder to lathe interface if used Range of setting is 50 Manual Reverse Speed Speed of the pusher and pre feed pusher in reverse when commanded to move via the jog buttons or through the input for Manual Reverse in the bar feeder to lathe interface ...

Page 71: ...arameters Rebel 80 67 Parameter Page 26 Touch off pusher Speed Speed pusher moves during the measurement of the bar in the spindle Max Machine Length Maximum pusher stroke of bar feed Distance from pusher home to facing flag ...

Page 72: ...meter is Bar loader Shaft load for specific applications Beta testing purpose Beta single step Testing purpose Make Part the default Part This option allows you to set a part program to the default program and you can call it by pressing get default in the program menu Factory Data Reset This option resets the factory settings to how they were just after installation Servo Data reset This option r...

Page 73: ...cess very little of the factory settings and all of the part parameters Delete part Full access to part menus cannot access factory settings New Program Can create edit and load part programs but cannot delete them or access factory settings Edit Program Can edit and load part programs but cannot create or delete them or access factory settings Load program Can load part programs but cannot create...

Page 74: ...to select the I O version that is to be used for the bar feeder Normal operation is Rebel 102 wiring Version 2 Finger Scaling This parameter adjusts the amount of movement per count the fingers will move This is in millimeters V Tray start count offset This adjust the V Tray offset in millimeters V Tray scaling This adjusts the amount of movement per count the V Tray moves in millimeters ...

Page 75: ...Technician Parameters Rebel 80 71 Parameter Page 41 Copy Factory to default Change factory defaults to current settings Reset factory data Initializing factory settings to Edge Installer Parameters Complete reset ...

Page 76: ...eed Speed pusher returns at during bar change Slow jog speed Speed pusher returns at during bar change Medium fog speed Speed pusher returns at during bar change Fast jog speed Speed pusher returns at during bar change Rapid jog speed Speed pusher returns at during bar change ...

Page 77: ...port Release E Stop on Lathe Make sure lathe is not in an alarm other than a bar feeder alarm Release E Stop on Bar Feeder Pendant Release E Stop on Bar Feeder Control Panel Check relay K41 K41 not energized Torque setting exceeded Reduce the Open Collet Torque on User Parameter page 3 Max torque on time exceeded Reduce the length of time the lathe collet is open when the bar feeder is in automati...

Page 78: ...heck to see if the V channel beam is level check for obstructions to the V channel Pusher flag not lined up with opening Not applicable on the Rebel 102SE Pusher not at home position Re zero the bar pusher Flag stuck in down position Manually operate the measuring flag Check for debris impeding the operation of the flag Check the flag for damage Material impeding flag movement Remove the material ...

Page 79: ...turn on and off Adjust max feed parameter position Verify the position Check parameter collet or chuck mode Check the setting of this parameter verify it is set correctly as the two parameters can have different max feed positions Rezero barfeed Start with the guide channel closed and the pusher forward about 12 inches Press and hold the forward and reverse buttons on the pendant After 8 seconds t...

Page 80: ... closed longer than set time allowed in collet close timeout parameter Pusher could not return home within the time allotted An internal timer for pusher return has been exceeded Check for pusher impedance in channel Check for blockage of the bar pusher a bent bar pusher check front pusher bushing Not used on the Rebel 80 ...

Page 81: ...he lathe collet and compare to the bar feeder screen to see if they match Check interface See interface drawing specific to the lathe check connections for the collet open signal Check input on PLC X27 Input 27 should toggle on and off with the opening and closing of the lathe collet Check signal for collet close Verify that the lathe collet is not closed Check Y33 cycle start signal Output Y27 an...

Page 82: ...Flashing or burrs on bar The front of the bar must be at least burr free and should have a small chamfer Steps in spindle A spindle liner may be required to provide a clear path for the material A larger chamfer on the front end of the bar may help the material past the steps Collet too small for material Not applicable on the Rebel 80 Material too large for lathe collet Verify the collet diameter...

Page 83: ...ut longer that setting in parameter Tighten the pusher drive chain Verify the pusher collet is fully seated on the material Set long feed value longer than feedout for part The value should be set at least 1mm longer than the part feedout Material feedout shorter than setting in parameter Check open collet torque setting Check lathe collet spindle for debris Check for impedance to the bar pusher S...

Page 84: ...setting in parameter Check open collet torque setting Check lathe collet spindle for debris Check for impedance to the bar pusher Set short feed value shorter than feedout needed for part The value should be set at least 1mm shorter than the part feedout Material feedout longer that setting in parameter Tighten the pusher drive chain Verify the pusher collet is fully seated on the material Set lon...

Page 85: ...ut longer that setting in parameter Tighten the pusher drive chain Verify the pusher collet is fully seated on the material Set long feed value longer than feedout for part The value should be set at least 1mm longer than the part feedout Material feedout shorter than setting in parameter Check open collet torque setting Check lathe collet spindle for debris Check for impedance to the bar pusher S...

Page 86: ...setting in parameter Check open collet torque setting Check lathe collet spindle for debris Check for impedance to the bar pusher Set short feed value shorter than feedout needed for part The value should be set at least 1mm shorter than the part feedout Material feedout longer that setting in parameter Tighten the pusher drive chain Verify the pusher collet is fully seated on the material Set lon...

Page 87: ...od sends a signal to the PLC input X5 Check the switch to make sure it is connected Check input on PLC X5 Observe input X5 while opening and closing the hood The input should change state with the motion of the hood Check speed of prefeed return The speed may be too slow to accomplish the return within the allotted time Check zero sensor Verify operation of the sensor by observing the LED on switc...

Page 88: ...23 The input should turn on and off with the door opening and closing Load bar into barfeed Place material on the bar feeder magazine before the bar change begins Check operation and adjustment of the bar separators If the separators are not properly adjusted the bar stock may not fall into the channel Check the measuring switch The switch is on the measuring gate assembly Verify operation of the ...

Page 89: ...e ejection distance in parameter screen 13 Load bar shorter than spindle Bar length exceeds parameter value use shorter bar Alter maximum bar length in parameter page 13 but DO NOT allow the end of the bar to extend past the end of the spindle actuator as injury or death and machine damage may occur Check S1 switch is on Verify that the LED of the S01 switch is on when the pusher reaches the home ...

Page 90: ...r debris Check position of lathe stock stop Make sure the turret stop of the lathe is not preventing the bar pusher from reaching a programmed position Increase Torque Value Increase the torque over ride value on parameter page 3 Check for damaged channel sections Damaged channel may cause the pusher to stall Check for damaged pusher flags A damaged pusher flag may stall the bar pusher Replace PLC...

Page 91: ...er from the V channel motor to the finger motor when engaged Check proximity switch and input on the PLC The counter for the finger motor activates prox switch S02 The input on the PLC from the switch is X0 V tray position lost Follow the directions on the screen to reset the counter that tracks the position of the V channel V tray Overtravel The V tray has traveled in excess of it s limits in the...

Page 92: ... Panel Layout Rungs 21 30 Remote Pendant Layout Rungs 31 40 Main PC Board Rungs 41 50 Main Circuit 1 Rungs 51 60 Main Circuit 2 Rungs 61 70 PLC Input 1 Rungs 71 80 PLC Input 2 Rungs 81 90 PLC Input 3 Rungs 91 100 PLC Output 1 Rungs 101 110 PLC Output 2 Rungs 111 120 PLC Output 3 Rungs 121 130 Inverter Circuit Rungs 131 140 Pendant LED Circuit Rungs 141 150 Interface Input Signals Rungs 151 160 Int...

Page 93: ...E 11 12 13 14 15 16 17 18 19 20 A B C D E F G A B C D E F G 11 12 13 14 15 16 17 18 19 20 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 102 SE Electrical Panel Layout T998EL00201 01 29 09 D Feltz EDGE Technologies ...

Page 94: ...DATE 21 22 23 24 25 26 27 28 29 30 A B C D E F G A B C D E F G 21 22 23 24 25 26 27 28 29 30 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 Remote Pendant Layout T998EL00501 01 29 09 D Feltz EDGE Technologies ...

Page 95: ...ION DATE 31 32 33 34 35 36 37 38 39 40 A B C D E F G A B C D E F G 31 32 33 34 35 36 37 38 39 40 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 Main PC Board T998EL00601 01 29 09 D Feltz EDGE Technologies ...

Page 96: ...ON DATE 41 42 43 44 45 46 47 48 49 50 A B C D E F G A B C D E F G 41 42 43 44 45 46 47 48 49 50 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 Main Circuit 1 T998EL00701 01 29 09 D Feltz EDGE Technologies ...

Page 97: ...ON DATE 51 52 53 54 55 56 57 58 59 60 A B C D E F G A B C D E F G 51 52 53 54 55 56 57 58 59 60 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 Main Circuit 2 T998EL00702 01 29 09 D Feltz EDGE Technologies ...

Page 98: ...TION DATE 61 62 63 64 65 66 67 68 69 70 A B C D E F G A B C D E F G 61 62 63 64 65 66 67 68 69 70 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 PLC Input 1 T998EL00801 01 29 09 D Feltz EDGE Technologies ...

Page 99: ...TION DATE 71 72 73 74 75 76 77 78 79 80 A B C D E F G A B C D E F G 71 72 73 74 75 76 77 78 79 80 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL00802 01 29 09 D Feltz EDGE Technologies PLC Input 2 ...

Page 100: ...TION DATE 81 82 83 84 85 86 87 88 89 90 A B C D E F G A B C D E F G 81 82 83 84 85 86 87 88 89 90 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL00803 01 29 09 D Feltz EDGE Technologies PLC Input 3 ...

Page 101: ...ON DATE 91 92 93 94 95 96 97 98 99 100 A B C D E F G A B C D E F G 91 92 93 94 95 96 97 98 99 100 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL00901 01 29 09 D Feltz EDGE Technologies PLC Output 1 ...

Page 102: ...01 102 103 104 105 106 107 108 109 110 A B C D E F G A B C D E F G 101 102 103 104 105 106 107 108 109 110 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL00902 01 29 09 D Feltz EDGE Technologies PLC Output 2 ...

Page 103: ...11 112 113 114 115 116 117 118 119 120 A B C D E F G A B C D E F G 111 112 113 114 115 116 117 118 119 120 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL00903 01 29 09 D Feltz EDGE Technologies PLC Output 3 ...

Page 104: ... 122 123 124 125 126 127 128 129 130 A B C D E F G A B C D E F G 121 122 123 124 125 126 127 128 129 130 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL01701 01 29 09 D Feltz EDGE Technologies Inverter Circuit ...

Page 105: ...132 133 134 135 136 137 138 139 140 A B C D E F G A B C D E F G 131 132 133 134 135 136 137 138 139 140 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL00100 01 29 09 D Feltz EDGE Technologies Pendant LED Circuit ...

Page 106: ...2 143 144 145 146 147 148 149 150 A B C D E F G A B C D E F G 141 142 143 144 145 146 147 148 149 150 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL01401 01 29 09 D Feltz EDGE Technologies Interface Input Signals ...

Page 107: ...2 153 154 155 156 157 158 159 160 A B C D E F G A B C D E F G 151 152 153 154 155 156 157 158 159 160 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL01402 01 29 09 D Feltz EDGE Technologies Interface Ouput Signals ...

Page 108: ...3 164 165 166 167 168 169 170 A B C D E F G A B C D E F G 161 162 163 164 165 166 167 168 169 170 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL01201 01 29 09 D Feltz EDGE Technologies PC Board Circuit of Pendant LED ...

Page 109: ...2 173 174 175 176 177 178 179 180 A B C D E F G A B C D E F G 171 172 173 174 175 176 177 178 179 180 INITIALS CHK D BY DRAWN BY DRAWING NO SCALE DATE REV 1 1 REBEL 80 T998EL01301 01 29 09 D Feltz EDGE Technologies Main PC Board Circuit 1 ...

Page 110: ...Lamp J630101 HL1 Zero Home Sensor J310302 S01 Servo Motor J220802 M1 Power On Switch J310795 SS2 Human Machine Interface J210504 HMI Emergency Stop J310704 ES1 V Channel Down Limit Switch J310406 J631600 LS01 Electrical Door Switch J310406 J631600 LS02 Axial Track Switch J311802 LS03 Finger Adjust Motor T16380600 T16380700 M3 Finger Adjust Counter Switch J310302 S02 Main Switch J310502 SS1 V Chann...

Page 111: ...00 INV FG J631202 FG Programmable Logic Control J210700 PLC Motion Module J220202 20SSC H Relay Pedestal J310203 J310211 R15 Emergency Stop Relay J310704 E Stop Circuit Protection J310505 CP1 Circuit Protection J310505 CP2 No Fuse Breaker J310504 NFB1 Magnetic Contactor J312704 MC1 Magnetic Contactor J312704 MC2 ...

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