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CHAPTER 4: ELECTRICS

4-17

ECOLOAD S2

8. SAFETY

SWITCHES

8.1. Main access cover safety sensor (SQ10)

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

8.2. Magazine cover safety sensor (SQ11)

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

8.3. Retraction system safety sensor (SQ12)

The sensor should be mounted on the bar feeder stand and the
latch should be mounted on the retraction system.
When the retraction system is locked with the switch key plugged,
wire 3 and wire 4 will be engaged, keeping emergency top circuit
closed.

Please follow the right picture for SQ12 wire connection in the
switch. Check circuit diagram for connecting to the PLC.

Swing arm

Switch key

Switch SQ10, SQ12

Switch SQ11

Wire 16

Wire +24

Wire 17

Wire 116

Wire 17

Wire +24

Wire 117

Wire 116

Wire 14

Wire 2

Wire 3

Wire 1

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Summary of Contents for Eco Load S2

Page 1: ...LNS SA 2534 Orvin Switzerland www LNS group com Instruction manual ENG 9 ECO 01 ...

Page 2: ......

Page 3: ...RETRACTION SYSTEM optional 3 4 4 POSITIONING 3 6 5 LEVELING 3 7 6 ALIGNMENT 3 10 7 MOUNTING OF THE MAGAZINE 3 12 8 ANCHORING 3 16 9 CONNECTION 3 17 CHAPTER 4 ELECTRICS 4 1 1 ELECTRICAL EQUIPMENT 4 2 2 ELECTRICAL CABINET 4 3 3 POWER SUPPLY 4 4 4 DIAGRAMS 4 6 5 PLC Programmable logic controller 4 8 6 PCB Printed Circuit Board 4 12 7 INTERFACE 4 13 8 SAFETY SWITCHES 4 17 CHAPTER 5 PNEUMATICS 5 1 1 PN...

Page 4: ...R 6 13 CHAPTER 7 OPERATION 7 1 1 REMOTE CONTROL 7 2 2 HMI Human Machine Interface 7 4 3 POWERING AND EMERGENCY STOP 7 6 4 AUTOMATIC MANUAL SEQUENCE 7 8 5 OPERATION PARAMETERS 7 11 6 SERVICE PARAMETERS 7 16 CHAPTER 8 TROUBLESHOOTING GUIDE 8 1 1 ALARMS 8 2 CHAPTER 9 APPENDICES 9 1 1 ORDERING FORM 9 2 2 PROGRAMMING EXAMPLE 9 3 3 LNS ADDRESSES CONTACTS 9 4 ...

Page 5: ...CHAPTER 1 BASIC NOTIONS 1 1 ECOLOAD S2 CHAPTER 1 BASIC NOTIONS ...

Page 6: ...o the chapter on the device to be set for example see chapter or see point 1 2 Captions Whenever possible the reference numbers contained in the instruction manual are shown with the LNS ordering number of the indicated element To make it easier to place an order of supplies a form has been included in the annex at the end of this manual 1 3 Symbols and terminology This sign recommends following t...

Page 7: ... its subsidiaries cannot be made responsible for the debts losses expenses or damage incurred or suffered by the buyer of this product or a third party following an accident incorrect use or misuse or stemming from modifications repairs or transformations not authorized by LNS SA LNS SA and its subsidiaries cannot be held responsible for damage and problems arising from the use of options and prod...

Page 8: ...ised standards have been used Concerning the Machinery Directive EN ISO 12100 2010 Safety of machinery Basic concepts principles EN ISO 14121 2 2013 Safety of machinery Risk assessment EN ISO 13857 2008 Safety of machinery Safety distances to prevent hazard zones being reached by upper and lower limbs ISO 14120 2002 Safety of machinery Conception of movable guards EN ISO 13850 2006 Safety of machi...

Page 9: ... or damage to components use only the indicated points for lifting and moving the bar feeder system No one should be near the hanging load or within the operating range of the overhead hoist crane forklift or any other means used for lifting and transportation Do not knock the bar feeder while moving it as this could damage it Do not move the bar feeder while it is electrically powered on Don t hi...

Page 10: ... if certain safety devices have not been included 6 SECURITY ANALYSIS FOR THE CORRECT INCORPORATION Before considering assembling the machine it is necessary to consider the following points Consider security strategies that reduce risks to an acceptable level Define the tasks required for applications to predict and assess the need of access and or for the approach Identify sources of risks inclu...

Page 11: ...gnation Description A Emergency stop button on remote control B Emergency stop button on electrical cabinet C Main access cover D Magazine cover SQ10 Safety switch of the main access cover SQ11 Safety switch of the magazine cover SQ12 Safety switch of the retraction system SQ10 SQ12 SQ12 A B C D ...

Page 12: ...1 8 CHAPTER 1 BASIC NOTIONS ECOLOAD S2 ...

Page 13: ...CHAPTER 2 TECHNICAL DATA 2 1 ECOLOAD S2 CHAPTER 2 TECHNICAL DATA ...

Page 14: ...0 kg Compressed air supply 6 kg cm2 Air consumption 1 585 gal 6 liters per loading cycle Power supply 200 480V AC 0 4A 50 60 Hz Cycle time to change bars 10 seconds Magazine capacity 25 Max admissible weight on the magazine 705 lb 320 kg X axis retraction displacement 12 300mm Z axis retraction displacement 23 585mm 2 FLOOR PLANS The following floor space plans indicate the most frequently used di...

Page 15: ...CHAPTER 2 TECHNICAL DATA 2 3 ECOLOAD S2 2 1 Without retraction system ˈ ˈʳˀʳ ˁˈˠ ˈʳˀʳ ˁ ˠ ˉ ˊˊ ˆˉˌ ˉ ʳˀʳ ˁ ˠ ˌ ˋʳˀʳ ˁˈˠ ˉ ˋ ˋˈ ʳˀʳ ˈ ˆˋˈ ˉˉ ˋ ...

Page 16: ...2 4 CHAPTER 2 TECHNICAL DATA ECOLOAD S2 2 2 X axis retraction system ˆˉ ˇˊˋ ˇˊˉ ˈ ˉ ˇ ˈ ʳˀˆ ˌˁˈ ...

Page 17: ...CHAPTER 2 TECHNICAL DATA 2 5 ECOLOAD S2 2 3 Z axis retraction system ˋˆˊ ˊˋˊ ˌˊ ˉ ˁˈ ʳ ˆˇ ˈ ...

Page 18: ...nation Description A Main access cover B HMI C Remote control D Electrical cabinet E Pusher F Pusher carrier G Loading channel H Protection grate I Magazine J Magazine inclination adjustment K Retraction system optional L Front stand M Rear stand A B C D E F G H I J K M L ...

Page 19: ...CHAPTER 3 SETTING INTO OPERATION 3 1 ECOLOAD S2 CHAPTER 3 SETTING INTO OPERATION ...

Page 20: ...ft truck is adequate before proceeding with the handling of the merchandise No one should be near the hanging load or within the operating range of the overhead hoist crane forklift or any other means used for lifting and transportation 1 If the bar feed system is received in a crate start by unscrewing the top panel 2 Remove the front 3 Remove the side walls From this point on the bar feed system...

Page 21: ...capacity of both the hoist and straps must be larger than 1 ton 3 Raise the hoist to tighten the straps 4 Remove the screws for holding the bar feeder to the pallet during transportation 5 Lift the bar feeder and remove the pallet Ensure that the bar feeder is balanced 6 Move the bar feeder taking care that it remains horizontal and that no one is nearby or under the suspended load Do not knock th...

Page 22: ...nt gives more space on the longitudinal direction Please follow the steps below to install the retraction system Lift the bar feeder according to the corresponding procedure in this chapter Remove the safety sensor protector and sensor by sequence Screw the retraction system toward the bar feeder stand Notice the locking device must be placed toward the front of the bar feeder Move the bar feeder ...

Page 23: ...tion system toward the bar feeder stand Notice the locking device must be placed toward the front of the bar feeder Move the bar feeder backward and forward couple times and confirm the retraction system was mounted properly Mount the safety sensor and sensor protector by sequence Insert the cable into the electrical cabinet from the opening behind the bar feeder Make sure that the cable will not ...

Page 24: ...the lathe and bar feeder should not exceed 100mm In the other words the bar stock length should not exceed spindle length 4 1 Bar feeder without retraction system 4 2 Bar feeder with retraction system If the bar feeder is equipped with retraction system please position the bar feeder after the retraction is locked on the bar feeder 100 mm Max Side view 100 mm Max ...

Page 25: ...etraction system Put the level on position C and D of bar feeder stand by sequence as shown Loose 8 nuts A on the stand Level the bar feeder by adjusting 8 screws B Turn the bolt clockwise until it touch against the ground and to lift the bar feeder or turn it counter clockwise to drop the bar feeder Lock nuts A after the leveling is finished A B C D ...

Page 26: ...n C and D of bar feeder stand by sequence as shown Loose nuts A on the stand Level the bar feeder by adjusting screws B and E on each stand Turn B clockwise until it touch against the plate under the stands to lift the bar feeder or turn it counter clockwise to drop Lock all nuts A after the leveling is finished A B C D E ...

Page 27: ...feeder stand by sequence as shown Loose nuts A on the stand Level the bar feeder by adjusting screw B on each stand Turn itclockwise until it touch against the plate under the stands to lift the bar feeder or turn it counter clockwise to drop Do not adjust nuts and bolts remarked E Lock all nuts A after the leveling is finished B C D A E ...

Page 28: ...t B tightly contact to the plate C Open the electrical cabinet Loose nuts A on both sides total 6 nuts Adjust the bar feeder height by turning nuts B on each stand Note that nut D must be always locked and should not be adjusted After finishing all adjustments lock A and close both stand covers A B D C ...

Page 29: ...OLOAD S2 6 1 Center adjustment Continuously adjust nuts B until the pusher is at central of the spindle on both front and rear sides When the alignment is finished lock all the nuts A A B C D Spindle rear end Spindle front end Pusher Spindle ...

Page 30: ... it on the bar feeder before installation Please follow the procedures below to install the magazine according to your bar feeder type 7 1 Standard bar feeder without retraction system 1 Unlock the magazine brackets by loosing screws pointed Magazine kit for bar feeders without retraction system Magazine kit for bar feeders with retraction system ...

Page 31: ... magazine stands C as shown 4 Loose nut D Tilt the magazine by adjusting nut E Lock nut D after the adjustment is finished Please note there is no firm value of this angle It must be adjusted according to the bar stock diameter and surface condition 5 Lock the magazine brackets by tightening screws pointed A B C D E 15 Keep the stem straight ...

Page 32: ...r feeders with retraction system 1 Unlock the magazine brackets by loosing screws pointed 2 Mount the magazine body and middle rod B and lock them with the brackets 3 Mount the magazine basement C as shown 4 Connect magazine stand D and fix as shown A B C D ...

Page 33: ... basement wheels J are able to contact with the ground Then lock nuts H 7 Loose nut C Tilt the magazine by adjusting nut L Lock nut K after the adjustment is finished Please note there is no firm value of this angle It must be adjusted according to the bar stock diameter and surface condition 8 Lock the brackets which loosed on step 1 F F E E G G H H H H J J 15 K L ...

Page 34: ...r your bar feeder accordingly 8 1 Bar feeder without retraction system Anchor the bar feeder at location A of each stand and location B of the magazine stands total 6 anchor spots 8 2 Bar feeder with X axis retraction system Anchor the bar feeder at location A of the retraction system guiding rail total 4 anchor spots 8 3 Bar feeder with Z axis retraction system Anchor the bar feeder at location A...

Page 35: ... feeder has been aligned and anchored to the ground the bar feeder must be connected to the interface of the lathe and compressed air need to be connected For the electrical connection please see Chapter 4 Electrics For the pneumatic connection please see Chapter 5 Pneumatics ...

Page 36: ...3 18 CHAPTER 3 SETTING INTO OPERATION ECOLOAD S2 ...

Page 37: ...CHAPTER 4 ELECTRICS 4 1 ECOLOAD S2 CHAPTER 4 ELECTRICS ...

Page 38: ...it of the bar feed system The electrical parts and groups which may require a setting at some time or other are described herein in detail 1 2 Layout of the elements Designation Description A Electrical cabinet B Remote control C Encoder HMI Human Machine Interface QS1 Main power switch LS1 TOP CUT measuring sensor SR1 Guiding channel in 0 position sensor SR2 Guiding channel in 15 position sensor ...

Page 39: ...S 4 3 ECOLOAD S2 2 ELECTRICAL CABINET Designation Description A Transformer B Protective ground terminal PCB Printed Circuit Board PCB PLC Programmable Logic Controller PLC QF2 24V DC power supply breaker A QF2 PLC PCB B ...

Page 40: ...cting the interface cable to the lathe make sure the transformer wiring meet the power supply AC System DC System AC 110V PLC 24 M Lathe QS1 Transformer AC 20V Bridge Rectifier P 3 1 Main power switch QS1 Make sure it is turned OFF before opening the electrical cabinet Power ON Power OFF Direction of power supply ...

Page 41: ...orresponding to the supplied power 190V AC to 480V AC see drawing below There are 2 sets of independent power supply unit on the secondary terminal Unit A supplies 110V AC Unit B supplies couple alternatives output power but the wiring must ALWAYS connected to 0V 20V Never connect the unit B to 0V 24V 3 4 24V DC power supply The bridge rectifier converts the AC power from transformer and offer 24V...

Page 42: ...Designation 1 AS1 Pressure switch 2 C1 Capacity 3 CS1 Main disconnect switch 4 DE Bridge rectifier 5 F2 Fuse 6 LED0 LED13 Light emitting diode 7 QF2 Circuit breaker 8 R1 R5 Relay 9 S1 S7 Buttons 10 SR1 SR2 SR3 Proximity switch 11 STP1 STP2 Emergency stop button 12 AS1 Pressure switch ...

Page 43: ...CHAPTER 4 ELECTRICS 4 7 ECOLOAD S2 4 2 Circuit diagram ...

Page 44: ...ddition the PLC powers HMI with 24V DC Designation Description A Input contacts All connected wires are labeled B Input contacts notation C Input signals indication LED Indicate the status of inputs X0 to X43 D PLC status indication LED E Output signals indication LED Indicate the status of outputs Y0 to Y27 F Communication port G Output contacts notation H Output contacts All connected wires are ...

Page 45: ...CHAPTER 4 ELECTRICS 4 9 ECOLOAD S2 5 2 PLC I O DIAGRAMS ...

Page 46: ... 15 position SR2 Sensor X05 5 TOP CUT measuring sensor LS1 Sensor X07 7 empty X10 10 Emergency stop circuit Emergency stop circuit X11 11 Chuck signal A1 Interface signals X12 12 Lathe alarm A2 X13 13 M function A3 X14 14 empty A4 X15 15 empty X16 16 Bar feeder in manual mode S1 Remote control buttons X17 17 Bar feeder is ready for automatic mode S2 X20 20 Bar feeder in automatic mode S3 X21 21 Ma...

Page 47: ...V DC input for terminals Y04 Y05 Y06 Y07 Y04 4 Bar feeder alarm Relay R1 Interface signal Y05 5 START signal Relay R2 Interface signal Y06 6 BAR END signal Relay R3 Interface signal Y07 7 Bar feeder is in automatic mode Relay R4 Interface signal Void contact COM4 24V DC input for terminals Y10 Y11 Y12 Y13 Y10 10 Inching signal Relay R5 Interface signal Y11 11 empty Y12 12 empty Y13 13 Pusher backw...

Page 48: ...inal of the bridge rectifier TB9 18 XT9 AS1 1 Terminal for connecting AS1 switch TB10 100 101 103 102 104 M Terminal for connecting encoder and switch SR1 SR3 TB11 M 24 100 101 Power supply terminal of encoder TB12 120 117 122 124 123 121 116 Terminal for connecting remote control buttons S1 S7 TB13 EM2 EM2 EM1 K 5 24 Terminal for connecting the STP1 emergency stop button TB14 105 24 M Power suppl...

Page 49: ... can be found in the electrical cabinet Before connecting the bar feeder make sure the installed interface is suitable for your lathe Contact us for any related questions A correct connection between lathe and bar feeder is critical for safe and reliable operation It is recommended to request a trained technician to install the bar feeder Should the interface instructions not be observed during th...

Page 50: ...able Interface signals from the lathe to the bar feeder Interface signals from the bar feeder to the lathe Bar feeder interface cable wire number Interface cable connector model Terminal number Interface signals designation Connector pin number ...

Page 51: ...y R2 Generally this signal is for confirming the bar stock hit the stopper during feeding so that the lathe chuck should be closed according d R3 BAR END end of bar relay When the pusher reaches BAR END position during feeding relay R3 energizes This signal is used to indicate that the rest bar stock length is not long enough to machine a complete part according to part length Refer to operation p...

Page 52: ...MODE 2 setup d Lathe alarm PLC input X12 terminal A2 This signal indicates that a lathe alarm is arising The signal logic could be inverted by MODE 3 setup e M function PLC input X13 terminal A3 This signal serves as an auxiliary signal for confirming chuck status To activate this function please refer to MODE 7 for further information The signal logic could be inverted by MODE 4 setup f Spare sig...

Page 53: ...e cover is closed with the switch key plugged wire 117 and 17 will be engaged but wire 116 and 24 will be disengaged so will not send signal to PLC input contact X16 The bar feeder hence is able to be switched to AUTOMATIC mode When the cover is open wire 117 and 17 will be disengaged but wire 116 and 24 will engaged sending signal to PLC input contact X16 The bar feeder will be switched to manual...

Page 54: ...4 18 CHAPTER 4 ELECTRICS ECOLOAD S2 ...

Page 55: ...CHAPTER 5 PNEUMATICS 5 1 ECOLOAD S2 CHAPTER 5 PNEUMATICS ...

Page 56: ...mum pressure of 5 bars 75 psi and a maximum pressure of 6 bars 90 psi is mandatory 1 2 Layout of the pneumatic elements Designation Description A Channel swinging bar stock loading cylinder B Channel lifting cylinder not visible C Pusher driving cylinder D Solenoid valves generally covered and not visible E F R L combination unit F Pusher backward damping adjustment G Pusher forward damping adjust...

Page 57: ...CHAPTER 5 PNEUMATICS 5 3 ECOLOAD S2 2 PNEUMATIC CIRCUIT DIAGRAM ...

Page 58: ...h pre mounted quick acting coupler and probe Before connection confirm the factory air pressure is not higher then 8 bar 14 psi Connect this tube on both F R L unit and factory compressed air source 3 4 Settings 1 Unlock the adjusting knob by pulling it upward 2 To increase the pressure turn it clockwise To decrease the pressure turn it counter clockwise The operational pressure should be set betw...

Page 59: ... position by pressing it down and turning 90 clockwise To release the locking position turn the knob 90 counter clockwise This manoeuvre may prove to be useful during tests or maintenance When the button is released the pneumatic cylinder returns to its resting position except for pneumatic cylinders activated by double effect solenoid valve 4 4 Air pressure switch To guarantee an optimal work of ...

Page 60: ...ack of lubricant on account of times and again operation Resistance will increase for cylinder to push the pusher if there is not enough lubricant or foreign matters like iron chippings adhering to it As times of operation passing through it will be unable to move on account of magnetism losing According to the location where the bar feeder is placed it is required to add solid grease from oil fil...

Page 61: ...ining is needed Whenever the condensate is found inside the collector drain the condensate by pushing the plug upward and check the humidity control system 6 2 Check lubricator The oil consumption varies with the bar feeder applications The oil height should not exceed half of the oil cup height It is recommended to use oil ISO VG 32 only When the oil is less than 30 follow the procedures below to...

Page 62: ...5 8 CHAPTER 5 PNEUMATICS ECOLOAD S2 ...

Page 63: ...CHAPTER 6 GENERAL DESCRIPTION 6 1 ECOLOAD S2 CHAPTER 6 GENERAL DESCRIPTION ...

Page 64: ...thly during automatic mode the elements must be properly adjusted according to the bar stock profile and dimension 1 1 Description of the elements Designation Description Function A Magazine To storage the bar stocks B Magazine cover To prevent any object to access into bar feeder C Magazine safety switch To detect if the magazine cover is open D Magazine rear stopper To constrict the area for pla...

Page 65: ...loading cycle 1 2 2 Magazine height As a generally rule the magazine could be adjusted as the angle shown For profiled bar stocks square pentagonal hexagonal or smaller diameter ones the angle could be increased by adjusting nuts A and B for loading more smoothly 1 2 3 Refill of stock When refilling bar stocks the rear end of the bar stocks should always be aligned to the magazine rear stopper B A...

Page 66: ... rodless cylinder drives the pusher forward and backward hence accomplish bar stock feeding Designation Description A Rodless cylinder B Pusher carrier C Encoder D Guiding rod E TOP CUT measuring device F Front damping adjustment valve G Rear damping adjustment valve H Channel I Pushing force adjustment knob J Channel height adjustment K Channel height locking knobs G B A H K J I D C K F E ...

Page 67: ...e chuck is close The encoder is connected with the pusher carrier by a belt While pusher is moving the position will be calculated by encoder PLC reads the position of the pusher through pulse from encoder and sends out signal accordingly If the pusher is not stopped at specific positions alarms will arise A stopper inside the lathe for positioning the bar stock is always needed when the lathe con...

Page 68: ...is composed of short and long pusher Item Function Note Short pusher First feed The movement inside bar feeder Long pusher TOP CUT The movement outside bar feeder Feeding during production Remnant ejection There are 3 different diameters of pusher available for the bar feeder as shown below Pusher diameter Applicable bar stock diameter range in mm Ø 6mm Ø 5 15 Ø 12mm Ø 15 25 Ø 20mm Ø 25 up Ø 6 Ø 1...

Page 69: ...bushing set screw 4 Be careful with the spring compressed behind the pusher rod Hold the pusher rod tight before removing the set screw for fixing the pusher on the cylinder When the set screw removed gently release the pusher 5 Carefully move the pusher rod forward Move the pusher backward for completely removing it from the pusher assembly as well as the PE bushing 4 5 3 ...

Page 70: ...nsert the rear end of the pusher rod into the adapter 7 Lock the set screw for fixing the pusher rod Ensure that the top surface of the set screw is lower than the adapter s 8 Lock the set screw for fixing the PE bushing and lock nut 9 Move the pusher back to origin reference 6 8 7 The top surface of the set screw is lower than the adapter surface Adapter surface ...

Page 71: ...ducing conditions Bar stock diameter mm Suggested regulator pressure bar below 10 3 10 30 3 4 above 30 4 6 Turn the knob clockwise to increase the pushing pressure and turn it counter clockwise to reduce it 4 4 Damping force adjustment With the increasing pushing force the impact might be larger when pusher arrives at the front or rear limitation To avoid this the bar feeder allows the user to giv...

Page 72: ...he bar feeder i e inside the lathe spindle by moving long pusher forward By pressing button on the remote control when pusher is at home position take actions below by sequence 1 The channel drops down to lower position 2 The channel swings to 15 position engages the long pusher with rodless cylinder carrier and position the long pusher at bar feeder feeding center 3 The loading fingers swing to l...

Page 73: ...w take place by sequence 1 The loading fingers swing up and load a bar stock into the channel 2 The channel swings to 0 position and disengages the long pusher from rodless cylinder carrier 3 The channel lifts up to upper position and position the bar stock to bar feeder feeding center The channel upper position should be adjusted according to bar stock diameter 4 The short pusher is able to move ...

Page 74: ... below to adjust the channel upper position 1 Loose 2 locking handles as shown 2 Adjust the knob according to bar stock diameter The upper index indicates inch and the lower index indicates mm Turn the knob clockwise to increase dimension and turn the knob counter clockwise to reduce it 3 Lock locking handles after adjustment is finished Align this corner to the bar stock dimension Increase bar st...

Page 75: ...ingle tube and combination of multiple pieces of short tubes are available The only target is to cover the whole spindle length as complete as possible Below we suggest multiple spindle liner Two kinds of spindle liner are needed 6 2 Model A Type A is supposed to be repeatedly inserted into spindle which fits most of its overall length 6 2 1 Dimension Overall length L Obtained by divided the spind...

Page 76: ...n the spindle inner diameter Entrance chamfer C C 0 5 X t 6 3 2 Model B 2 All the dimensions are same as Model A except OD2 1 or 2mm larger than the spindle inner dimension by entwining tape on the surface Entrance chamfer C C 0 5 X t 6 3 3 Model B 3 This type could be applied when there are screw holes on rear end of the spindle The user can make a ring to stop the spindle The inner diameter of t...

Page 77: ...CHAPTER 7 OPERATION 7 1 ECOLOAD S2 CHAPTER 7 OPERATION ...

Page 78: ...al display area M CODE Indicates the lathe chuck M code signal is ON OFF when the signal is ON OFF CHUCK Indicates the lathe chuck is open closed when the LED is ON OFF B D T Indicates the END OF BAR signal is ON OFF when the LED is ON OFF START Indicates the START signal is ON OFF when the LED is ON OFF ALARM Indicates the ALARM signal is ON OFF when the LED is ON OFF These signals will be effect...

Page 79: ...The V channel is at 15 position for long pusher feeding and bar feeder is in AUTOMATIC ready mode Manual Switch the bar feeder to MANUAL mode When the bar feeder is on MANUAL mode the key LED is ON and the user could operate the bar by function keys Reset the bar feeder from an emergency stop Rightward Move pusher rightward Only available when the bar feeder is in MANUAL mode Indicate the position...

Page 80: ...e SERVICE PARAMETER screen 3 To display the software version Both HMI and PLC has their own software as shown This information is sometimes necessary when you contact us for technical support 2 2 Status indication area Alarm red This LED will be ON when powering up the bar feeder After initialization of the HMI the LED will turn OFF there is a communication failure between the PLC and the HMI RS 2...

Page 81: ... setup page without changing the setting Use this key to validate a new parameter setting 2 4 Numerical key pads Shown as and They serve to enter numbers or execute functions attributed to them 1 When editing parameter values the key pad can be used as alternative to the previously described Up Down keys Numbers are entered according to the following table Number 1 2 3 4 5 6 7 8 9 Key Combination ...

Page 82: ...m the beginning The PLC reads signals from sensors and gives the operator allowable operations only Make sure it is turned OFF before opening the electrical cabinet Do not change the pusher position when bar feeder is powered OFF because the position reading does not match the pusher s actual position For example when pusher is at home position but the current position is not 0 take either one app...

Page 83: ...accordingly 1 PLC output contact Y04 is ON 2 Alarm e01 is shown on HMI 3 PLC output contacts from Y13 to Y16 are OFF 4 PLC output contact Y17 is ON When the emergency situation is fixed release the emergency stop button and press the manual key on the remote control to restart the bar feeder 3 2 1 Emergency stop button on the cabinet STP1 3 2 2 Emergency stop button on the remote control STP2 INTE...

Page 84: ...is at 15 position SR2 ON Steps to move the frame to 0 1 Press key to return short pusher to home position SR3 ON 2 Press key to raise V channel and tilt to 0 position SR1 ON 4 3 Continue an interrupted machining Conditions below must be fulfilled 1 The lathe is not in AUTOMATIC mode 2 The lathe chuck is open 3 The lathe stopper is positioned at part length position 4 Bar stock is still in the spin...

Page 85: ... to home position SR3 ON Press to raise the V channel and tilt it to 0 position SR1 ON for loading a new bar Position the short pusher at feeding position 3 Press to move the short pusher forward for feeding the new bar out of bar feeder 4 Press key to return short pusher to home position SR3 ON 5 Press to lower the V channel and tilt it to 15 position SR2 ON Position the long pusher at feeding po...

Page 86: ...ccording to START signal 23 The V channel is raised and tilted to 0 position SR1 ON and a new bar is loaded The short pusher is at feeding position 24 The short pusher feeds the bar stock out of the bar feeder according to P08 setup 25 The short pusher returns back to home position SR3 ON 26 V channel is lowered and tilted to 15 position SR2 ON The long pusher is at feeding position 27 The pusher ...

Page 87: ...trongly recommended to read this chapter before proceeding any modification 5 1 Accessing After selecting the operation parameters by pressing F0 the following screen will be displayed Navigation Page up down to display parameter screens to Edition 1 Press F0 for the 1st parameter displayed 2 Press F1 for the 2nd parameter displayed 3 Press F2 for the 3rd parameter displayed Press F4 to return to ...

Page 88: ... parameter should be MODIFIED if if production part changed This setup allows the operator to assign the maximum and minimum feeding distance that the bar feeder should alert When those values are exceeded the bar feeder will arise alarm accordingly Too short dist The minimum allowed feeding distance The bar feeder arises an alarm if the feeding distance is smaller than this value when chuck colle...

Page 89: ... s tip does not contact the rotating bar stock Due to there is no rotating adapter between the pusher and the bar stock the pusher tip must not contact any rotating component or it will be damaged Below is the summary for those cases and their solutions Direction Situation Solution Parameter Axial The pusher touches the bar stock rear end Keep the pusher away from the rotating bar stock when feedi...

Page 90: ... a complete part according to P03 setup Setup procedure Get a remnant which is 20mm longer than the lathe chuck Align the remnant with chuck surface and clamp it Move the pusher forward until the pusher tip touches against the rear end of the clamped remnant Enter the value of Position into Bar end point The BAR END position could be adjusted if the remnant is too long But the pusher should NEVER ...

Page 91: ...poning pusher retraction action P10 Application setup 0 Standard program Bar change starts when receiving the BAR END signal 1 One shaft loading This is a special bar change program If P10 set 1 after chuck is closed pusher returns to home position for bar change without receiving BAR END signal P11 Dry run state The lathe is unable to work without Automatic mode signal R4 sent from the bar feeder...

Page 92: ...hese parameters is password protected Please contact LNS or its official agent in your country for getting technical support in case any modification is needed 6 1 Accessing After selecting the service parameters the following screen will be displayed Navigation Page up down to display parameter screens Edit the parameter value Return to previous page Validation of the changes After editing the va...

Page 93: ...uck signal A1 logic setup 0 CHUCK signal is ON when chuck is open 1 CHUCK signal is OFF when chuck is open MODE 3 CNC alarm signal A2 logic setup 0 Lathe alarm signal is ON when there is an alarm 1 Lathe alarm signal is OFF when there is an alarm MODE 4 M function A3 logic setup 1 of 2 M function represents a signal in addition to chuck signal for confirming lathe chuck status also refer to MODE 7...

Page 94: ...E 8 This parameter intentionally left blank MODE 9 Bar feeder status check Define if the bar feeder check itself is in AUTOMATIC mode when the chuck signal is turned ON OFF for 3 cycles If this check is activated and the result is negative the bar feeder activates alarm e11 0 Deactivate this check 1 Activate this check MODE 10 PLC output contact Y05 setup Define how PLC output contact Y05 act duri...

Page 95: ...13 22 BAR END signal setup Refer to the figure below Chuck signal MODE 11 12 13 22 0 0 0 0 1 0 0 0 0 1 0 0 0 0 1 0 0 0 0 1 Last feeding Bar change Machining Bar change Stopper Y05 Top cut Eject remnant Eject remnant Top cut Last part feeding Bar change BAR END signal Chuck close Chuck open ...

Page 96: ...r round ones without proper preparation it s quite easily to struggle to push them through the lathe chuck To solve this problem the bar feeder offers a function called INCHING The function INCHING consists of 2 actions 1 Move the pusher back and forth repeatedly 2 Send continuous signal to the lathe as an external command to rotate the spindle This signal is specially created for the lathes whose...

Page 97: ...urn off this function during general application The LED of AUTO START button will be blinking The texts displayed on the HMI will be blinking The functions below will be deactivated 1 Too long too short 2 Magazine empty 3 TOP CUT position When the bar feeder is proceeding bar feeding in auto mode the pusher stops automatically when part length has been arrived The bar feeder stops proceeding FIRS...

Page 98: ...7 22 CHAPTER 7 OPERATION ECOLOAD S2 ...

Page 99: ...CHAPTER 8 TROUBLESHOOTING GUIDE 8 1 ECOLOAD S2 CHAPTER 8 TROUBLESHOOTING GUIDE ...

Page 100: ...scription and troubleshooting guide to check the problem If necessary contact us for technical support 1 1 WARNING MESSAGES Warning messages are designed to remind users the bar feeder status Those messages are used to remind operator the bar feeder working status Under the following conditions there will be a warning message shown but Y04 alarm is not switched on Warning messages Description When...

Page 101: ... on the program users installed Auto Chuck close_A1 Bar end Pusher retract P04 P02 Send R3 to CNC No Yes Machining Chuck open A1 Mode 7 for M code_A3 e12 e17 e18 e20 e22 Bar end Eject Remnant to the lathe P07 e23 No Yes Pusher returns to home position e 10 e18 Load a new bar e15 First feed e2 e7 e9 e10 e17 e25 Send R5 to CNC optional Short pusher returns to home position e14 e18 Long pusher feeds ...

Page 102: ... Check if emergency stop button on HMI is pressed If so please reset it 2 Check if emergency stop button on remote control is pressed If so please reset it 3 Check if emergency stop contacts on the lathe were wired to bar feeder emergency stop loop and is open If so please reset it 4 Check if the air pressure is not enough The air pressure switch will trip if the air pressure is lower than 4 kg cm...

Page 103: ...Check if TOP CUT setup is too long 2 Check if BAR END EJECTION and FIRST FEED setup are too small e07 No material on the magazine Description FIRST FEED position has been exceeded but the TOP CUT sensor was not activated Troubleshooting 1 Check if bar stock on the magazine is exhausted if so please re load bar stocks 2 Check if Top cut sensor is broken e08 Lathe alarm Description An alarm has aris...

Page 104: ... for proceeding FIRST FEED chuck signal is not activated within 15 seconds Troubleshooting 1 Check if lathe chuck is open 2 Check if the chuck signal was sent from the lathe 3 Check if the bar feeder receives the chuck signal e11 Bar feeder is not in automatic mode Description The bar feeder is still in manual mode when the lathe chuck has been turned ON OFF 3 cycles Troubleshooting Switch the bar...

Page 105: ...d check if anything blocks the channel set 3 Check if the air pressure is too low to operate the cylinders 4 Check if the air tubes valves or cylinders are leaking e15 0 positioning is failed Description The bar feeder fails to position the channel set at 0 position Troubleshooting 1 If positioning is accomplished check if sensor SR1 is broken 2 If the positioning is not completed check if anythin...

Page 106: ...trol and see if the cylinder is broken 3 Check if the pusher has returned to home position but sensor SR3 did not detect it 4 Check if VAL 1 is broken Refer to chapter 4 for further information e19 TOP CUT positioning is failed Description The bar feeder fails to position a new bar stock at TOP CUT position within 120 seconds Troubleshooting 1 Check if the bar stock is blocked inside the lathe spi...

Page 107: ...tup is too big and adjust it 2 Check if ejection position is too small and adjust it e23 Remnant ejection is failed Description The pusher fails to exceed remnant ejection position within 10 seconds after chuck open Troubleshooting 1 Check if the remnant blocked inside the spindle 2 Check if ejection position setup is too large e24 This message intentionally left blank e25 TOP CUT setup is smaller...

Page 108: ...lanation e27 signal is showed up in 1 second after P11 is set ON but conditions manual pusher in home position SR3 current position is smaller than 5mm TOP CUT is activated are not satisfied Troubleshooting Check and make sure each condition is fulfilled e28 Bar feeder in dry run Description Buttons on Remote control are pressed Explanation When dry run function is activated buttons on Remote cont...

Page 109: ...CHAPTER 9 APPENDICES 9 1 ECOLOAD S2 CHAPTER 9 APPENDICES ...

Page 110: ... photocopied duly filled out and returned to your retailer or nearest LNS agent Company name Person in charge Address ZIP City Country Phone Fax Type of device Serial number Qty Ordering no Description Expected delivery Location and date Signature and stamp of the company ...

Page 111: ...OSE COLLET N TURRET HOME N CLEAR TURRET M CODE DWELL LOAD N N CLOSE COLLET N START SPINDLE PART PROGRAM N COLLANT ON N X Z G F T S M N TOP CUT MATERIAL N MACHINE PART N N PARTS CATCHER IN IF AVAILABLE N N CUT OFF N END OF SUB PROGRAM N PARTS CATCHER OFF IF AVAILABLE RETURN TO MAIN PROGRAM N N N X Z G F T S M N N END OF PROGRAM LOOP Important The above is an example only Programming may change acco...

Page 112: ...9 4 CHAPTER 9 APPENDICES ECOLOAD S2 3 LNS ADDRESSES CONTACTS LNS Europe www lns europe com LNS America www lns america com LNS Asia www lns asia com ...

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