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LNS QL Servo 80 S2 Service Manual Download Page 1

For CNC machine tool peripherals,

it’s 

LNS

, then all the rest

QUICK LOAD SERVO 80 S2 BARFEED

Service Manual

9.020.

02.EN

.US

Summary of Contents for QL Servo 80 S2

Page 1: ...For CNC machine tool peripherals it s LNS then all the rest QUICK LOAD SERVO 80 S2 BARFEED Service Manual 9 020 02 EN US ...

Page 2: ...GENERAL SERVICE MANUAL QL Servo 80 S2 ...

Page 3: ...RAL SERVICE MANUAL QL Servo 80 S2 IMPORTANT READ THIS MANUAL CAREFULLY BEFORE USING AND RETAIN FOR FUTURE REFERENCE Published 07 2020 LNS America 2020 9 020 02 EN V00 0 Service manual Printed in LNS America ...

Page 4: ...HER REVERSING DISTANCE 21 REFERENCE PROCEDURE 23 CALIBRATION OF THE LOADING TABLE 24 LOCKER ADJUSTMENT 25 FINDING SOFTWARE PLC VERSIONS 30 SOFTWARE UPDATE 30 PLC BATTERY REPLACEMENT 31 3 MECHANICAL EQUIPMENT 32 LOADING MAGAZINE 32 PUSHER CARRIER 35 LOADING PUSHER 36 FEEDING PUSHER 36 RETRACTION 38 SHAFT LOADING KIT OPTION 39 ADDITIONAL SHAFT LOADING PUSHER OPTION 40 FRONT PROTECTION COVER OPTION 4...

Page 5: ... 90 INSPECTIONS 90 UPDATING THE PROGRAM ON A PLC 91 CLEANING 98 7 TECHNICAL CHARACTERISTICS 98 8 DISPOSAL 100 MACHINE 100 9 TROUBLESHOOTING 102 ALARMS 102 SEQUENCE LISTING 108 MITSUBISHI ALARM LIST MRJ 4 110 MITSUBISHI WARNING LIST MRJ 4 114 PLC INPUTS OUTPUTS 115 PRODUCT MANUALS 116 AFTER SALES SERVICE 118 10 APPENDICES 120 GLOSSARY 120 WIRING DIAGRAM 020 40 620K CE MRJ 4 121 WIRING DIAGRAM 020 4...

Page 6: ...GENERAL SERVICE MANUAL QL Servo 80 S2 ...

Page 7: ...ted components from other manufacturers In the case of these components their respective manufacturers have carried out a risk assessment and have declared that their design is fully compliant with the European standards in force Information regarding the proper use of these integrated components is available in the component instructions and provided by the various manufacturers The feeder compli...

Page 8: ...not avoided may result in serious or fatal injury CAUTION Type and origin of danger Consequences of non compliance with the warning What to do to avoid danger Warnings of a potentially dangerous situation which if not avoided may cause minor injuries NOTICE Type and origin of danger Consequences of non compliance with the warning What to do to avoid danger Warnings of a potentially dangerous situa...

Page 9: ... left right front and rear refer to the direction of use of the machine COPYRIGHT Any reproduction recording or distribution of all or part of this manual in any form or by any means mechanical photographic audio or other is strictly prohibited without the express written permission of LNS LNS accepts no liability for any errors in this manual and any resulting complications The product names indi...

Page 10: ...he interface or inside the electrical cabinet while the bar feeder or the lathe is powered on It is strictly forbidden to bridge or remove circuit breakers and main switches especially safety switches To ensure the safety of components and personnel observe the points indicated for lifting and moving the bar feeder It is expressly forbidden to stay near the suspended load or in the operating area ...

Page 11: ...atory that the lateral level of the bar feed system is perfect just make sure that the latter is as straight as possible The longitudinal level of the bar feed system must be adjusted according to the level of the lathe even if the lathe lies only over three points and cannot be perfectly levelled Should the level of the bar feed system not correspond to that of the lathe the feeding pusher might ...

Page 12: ...ening bolts 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 4 Using the central jackscrew 2 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 2 ...

Page 13: ...t 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 Final check by raising the table an...

Page 14: ...s 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 at locations 3 but not at 4 8 After anchoring the unit recheck the level and the alignment of the unit 3 3 4 ...

Page 15: ...nto the loading table and verify that it can be loaded into the spindle of the lathe without hitting the sides of the spindle or spindle liner Note If the bar hits side to side the alignment will have to be adjusted PUSHER CHANGEOVER PROCEDURE INFORMATION The following conditions must be met to complete this procedure Bar feeder switch on Loading table in lower position Pusher at the mechanical ho...

Page 16: ...rds the bar feeder front but don t extract it completely out of the carrier 4 Pull the white bushing on the front guide bearing towards the rear of the bar feed to extract it Remove the pusher completely from bar feed 5 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 6 Assemble the pusher adapter on the new...

Page 17: ...r 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 The carrier must be flush on the right side of carrier bushing 1 8 Slide back the carrier to the home position Close the main access cover BELT TENSION ADJUSTMENT INFORMATION The following conditions must be met ...

Page 18: ...ent 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 HOME POSITION PROXIMITY SWITCH SQ5 ADJUSTMENT INFORMATION The following conditions must be met to complete this procedure Bar feeder switch on Bar feed in STOP mode Pusher at the mechanical home position ...

Page 19: ... 5 mm an no more than 65 mm 1 Tighten down Any slight movement forward of the carrier should deactivate the proximity sensor 4 Close the main access cover Press the STOP key on the remote control to clear any alarm DIAMETER ADJUSTMENT MOTOR PROXIMITY SWITCH SQ4 INFORMATION The following conditions must be met to complete this procedure No bar stock in the magazine Loading table in lower position B...

Page 20: ...on the bar stock should touch the table stops and the selection fingers 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 MEASURING CELL ADJUSTMENT SQ3 INFORMATION The following conditions must be met to complete this procedure No bar stock in the magazine Loading table in lower position Ba...

Page 21: ...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 View from front of barfeed 3 Loosen screws and adjust the cell so that the red sensor 1 is reflecting off the center of the bar and tighten the cell down View from front of barfeed 4 Turn the gain adjustment counter clockwise to the minimum position A ...

Page 22: ...he 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 INFORMATION If the pusher does not touch the spindle before the End of Bar position is reached then the default value will remain as...

Page 23: ...until the tip of the pusher sags and is touching the spindle or spindle liner if one is installed 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 4 P...

Page 24: ... 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 3 Press on the key corresponding to MANUAL MODE 4 Press on the key corresponding to MANUAL MODE 5 Press on the key corresponding to REFERENCE MAIN MENU 1 1 PART SETUP 2 APPLICATION SETUP 3 POSITION TORQUE 4 MISC FUNCTIONS 5 SERVICE LOADING CHANNEL IN AN INTERMEDIATE...

Page 25: ...2 to move up the loading table in upper position The bar now faces the spindle of the lathe Press the STOP key 3 In the main menu select the menu SERVICE with the up down keys then press on the key corresponding to ENTER 4 In the service menu select the menu BAR FEED SETUP then press on the key corresponding to ENTER 5 Press on the key corresponding to PAGE DOWN until the text NUMBER OF PULSES FOR...

Page 26: ...nsert in the pusher locking ball assembly This can be corrected by first determining the direction of the adjustment needed and then making the simple adjustment DETERMINING INSERT ADJUSTMENT NEEDED 1 The locker assembly on the Quick Load 80 S2 may not unlock when the table is in the upper position due to improper adjustment of the Insert in the Pusher Locking Ball Assembly 2 Determine Insert adju...

Page 27: ... the pin can be manually moved in order to lower the table Insert Too Far In You can determine that the insert is screwed too far in to the locking ball by determining if the pin cannot be moved manually at all ADJUSTMENT FOR INSERT TOO FAR OUT 1 If the insert is out too far press FW on the remote and there will be a small gap between the pusher carrier and the pusher locking ball ...

Page 28: ... pusher carrier or by moving the pin using a screwdriver 3 Lower the Table and Adjust Once released take the remote and forward FW the pusher carrier to the end of the machine then RW to return it back This will produce a down arrow on the remote Press the down arrow to lower the table and press the stop button on the remote 4 Pull the pusher away from the locking ball ...

Page 29: ...clockwise in no more than turn increments Repeat the process to raise and lower the table to verify the adjustment was successful ADJUSTMENT FOR INSERT TOO FAR IN 1 If the locker assembly will not unlock because the insert is too far in lower the table by pressing on the KA2 button Note KA1 is to raise the table Hold until table is completely lowered ...

Page 30: ...to turn the insert counter clockwise to adjust It may be beneficial to over adjust the insert outward to avoid having to jump the electrical panel a second time Repeat the process to raise and lower the table to verify the adjustment was successful The pusher should successfully unlock without clicking sounds if correctly adjusted ...

Page 31: ...1 In the working menu press the key on the remote control Press the Page Down key to read more information SOFTWARE UPDATE INFORMATION The following conditions must be met to complete this procedure Bar feeder power on 1 In the electrical cabinet open the PLC cover 2 Insert the card containing the new software in the M1 labeled bay A chamfer avoids any bad insertion ...

Page 32: ...operational again Take out the card containing the software Close the PLC cover and the electrical cabinet PLC BATTERY REPLACEMENT INFORMATION The following conditions must be met to complete this procedure Bar feeder power on 1 In the electrical cabinet open the PLC cover 2 Take the battery support out of the bay labeled BATT 3 Replace the battery with an identical type Check that the battery is ...

Page 33: ... the other hand bars with small diameters overlap then the slope can or must be reduced A protection grid impedes access to the loading table during the automatic cycle In manual mode the grid mounted onto hinges can be lifted and thus allows the operator to conduct the necessary maintenance operations In no case should a rotating bar extend past the rear of the lathe spindle The lathe spindle giv...

Page 34: ...tch SLOPE OF THE MAGAZINE TABLE When profiled bar stock is loaded and the bars do not slide easily the slope of the table may be increased A reference mark 1 indicates two positions one position for round bars and another of greater slope for profiled bars Lifting the loading magazine and moving the locking leg 2 on the notches of the loading magazine will vary the slope ...

Page 35: ...e front face of the clamping device 2 Lift the protection grid Undo the lock screws holding the rear limiter in place 3 Place the limiter at the measured distance L max by measuring from the front limiter Tighten the lock screws 4 Apply the self adhesive marker on the loading table This marker will serve in the future to set the position of the limiter without having to measure the length of the s...

Page 36: ...ording to the profile of the bars to be loaded some settings and some optional accessories are necessary Please contact your LNS agent PUSHER CARRIER Description An AC Mitsubishi motor drives the carrier for the feeding pusher and the loading pusher with a built in absolute encoder By means of a timing belt the SERVO motor starts drives the carrier While the loading pusher is advancing towards the...

Page 37: ...eding pusher To do this a special extended loading pusher available as an option is required Selected parameters must then be chosen FEEDING PUSHER DESCRIPTION Three feeding pushers are necessary to cover the entire range of the QUICK LOAD SERVO 80 S2 barfeed system Each pusher has a defined range of operation Pusher diameter Diameter Range 6 mm 1 4 6 mm 15 mm 1 4 1 2 12 mm 1 2 16 mm 27 mm 2 3 1 2...

Page 38: ... regard to loading the tubing standard feeding pushers may be used as long as the inside diameter of the tubes is smaller than the outside diameter of the pushers If this is not the case caps A to be installed into the tubes B must be manufactured For the caps to stay in place while the bar is rotating they should be fitted with an O Ring ...

Page 39: ... when it is in operational position In this position the bar feed system is fastened by two solid hooks 3 A safety switch SQ12 impedes any handling as long as the bar feed system is not in operational position Designation Description 1 Guiding rails 2 Sliding wheels 3 Latch handle 4 Bracket for lateral or longitudinal retraction SQ12 Retraction system in position switch ...

Page 40: ... loading pusher replacing the loading pusher A limiter on the bar magazine protects from loading shafts of wrong length avoiding a crash in the bar feed and into the lathe s spindle The diameter selection fingers might be replaced also by the adjustable ones and their position must be adapted to the loaded shaft length LAYOUT OF THE ELEMENTS Designation Description 1 Limiter 2 Shaft loading pusher...

Page 41: ... loading table is in low position the manual functions are disabled For this type of work the End of bar position does not require a particular setting Lmin 100mm INFORMATION The extended loading pusher is delivered as an option The assembly and setting directions are enclosed with the product V EXTENSION KIT 120 OPTION DESCRIPTION This option extends the guiding length of 150 up to 300 mm by moun...

Page 42: ... Front protection cover FRONT PROTECTION COVER OPTION DESCRIPTION In the case the bar feed cannot be mounted very close to the lathe an adjustable 150 to 300 mm front protection cover protects the working gap between the lathe and the bar feed LAYOUT OF THE ELEMENTS Designation Description 1 Front protection cover ...

Page 43: ...r stocks to 90 making the positioning of the bar stock easier into the clamping device of the lathe The limiter prevents the bars from falling directly onto the orientation kit and allows the bars to rotate and be correctly oriented when pushed forward LAYOUT OF THE ELEMENTS Designation Description 1 Orientation part 2 Limiter INFORMATION This option limits the maximum bar stock length to 1555 mm ...

Page 44: ...MECHANICAL EQUIPMENT SERVICE MANUAL QL Servo 80 S2 ...

Page 45: ...NTS These components are installed to ensure safe use of the bar feeder SWITCHES Designation Description A Remote control station B Control cabinet M1 Servo motor M2 Loading table motor not visible M3 Diameter adjustment motor QS1 Main power switch not visible SQ1 Loading table lower position switch SQ3 Measuring cell SQ4 Diameter adjustment motor origin M3 switch SQ5 Servo motor origin switch SQ1...

Page 46: ...ELECTRICAL EQUIPMENT SERVICE MANUAL QL Servo 80 S2 ELECTRICAL CABINET LAYOUT OF THE ELEMENTS IN THE ELECTRICAL CABINET ...

Page 47: ...1 Circuit breaker 4A QS1 Main disconnect switch R1 R5 Interface relay T1 Transformer 1ph T2 Transformer 24 VDC Power supply 150W MAIN POWER SWITCH QS1 When the main disconnect switch is at O off it interrupts the three phase input in the bar feeder control cabinet CIRCUIT BREAKER QF1 4 AMPS Circuit breaker QF1 protects the two phases which power the transformer Designation Description 1 Input term...

Page 48: ... left 2 Remove and replace the fuse with an identical one and put the cap back On the primary side the transformer accepts a voltage of 200 V 480 V 50 Hz 60 Hz Measure the power provided by the lathe If necessary adapt the terminal block wiring Designation Description 1 Primary terminal block 200 V 480 V 50 Hz 60 Hz 15 2 Secondary terminal block 230 V 3 Fuse 3 15 A The transformer T2 has an output...

Page 49: ... of the bar feeder and its production It also allows the functions diagnostics and error signals to be checked or analyzed at any time Designation Description 1 Emergency stop button 2 Display 3 Multi function keys 4 Direction keys Numeric key pad 5 Stop Key INFORMATION Some software settings are protected by a password Password protected settings are used for basic machine configuration and shoul...

Page 50: ...ble are the following Icon Signification Icon Signification Referencing position ENTER Confirm Switch to automatic mode START Start sequence Stop after machining one bar stock SET Set up Switch to manual mode ESC Escape FWD Pusher forward picture may be reversed PAGE UP Return to previous menu REW Pusher reverse picture may be reversed PAGE DOWN Jump to next menu TOP CUT Automatic Top Cut position...

Page 51: ... a dangerous situation arises pressing the emergency stop switch interrupts immediately all bar feed system and lathe functions if interface is wired accordingly To cancel the alarm release the switch by rotating its red knob counter clockwise then press STOP STOP KEY The STOP key allows interrupting the sequence under way Important the automatic cycle of the lathe must first be interrupted By pre...

Page 52: ... at zero for the powering on of the bar feeder INFO The life of a battery can be 2 3 years When the battery 3 is depleted the amplifier 1 displays the alarm 9F 1 The battery is not rechargeable and must be replaced right away To ensure no data is lost the replacement must take place when the bar feeder is powered down To access the battery compartment 1 Disconnect the connector 2 2 Unlock the batt...

Page 53: ...ecycled by an authorized local service To replace the battery 1 Gently press the locking clip 2 2 Open the battery compartment by removing the cover 1 3 Remove the battery 3 from its housing and replace it 1 Refit the cover 1 2 Press firmly on the cover 1 until a click of the locking clip is heard 3 Refit the battery compartment in its original position 4 Reconnect the connector 3 to the amplifier...

Page 54: ...ontrols the motors and displays the appropriate messages on the remote control Designation Description 1 Battery 2 Cover 3 Battery module 4 M2 Slot for software update card Do not remove the flash card unless instructed by LNS 5 M1 Slot for memory expansion Used to store parts library files To replace the battery 1 Lift the cover 2 by tilting it backward 2 Remove the info module 3 3 Remove the bat...

Page 55: ...ol components motors hydraulic pump etc TABLE LIFTING MOTOR The table lifting motor raises and lowers the table in order to pick bars and load SERVO MOTOR The Servo motor controls the drive of the notched belt FINGER ADJUSTMENT MOTOR The finger adjustment motor positions the fingers to the correct position to hold back the bars in the magazine ...

Page 56: ...tors Contactor KM M Motors M Q Mechanical connection devices for power circuits Circuit breaker QF Motor protection switch QM Sectioning device QS S Connection devices for line circuits drive control signaling circuits etc Selector or switch SA Pressure sensor SP Position sensor including proximity sensor SQ Rotation sensor SR T Transformers Current transformers TA X Terminals Y Mechanical devices...

Page 57: ... 24 V dc of the lathe For the other types of connections please contact LNS S A or their local representative b EMERGENCY STOP signal of lathe XT8 XT9 This signal is part of a safety link Emergency Stop circuit of the bar feed system XT8 XT9 corresponds to the Emergency Stop signal of the lathe If the circuit is open the bar feed system will go into an Emergency Stop mode When the lathe is in an E...

Page 58: ...MATION When the bar feed system is in alarm mode the feeding pusher control signal should also de energize b R2 start and stop of the lathe Either Confirmation of the feeding pusher forward command And or Confirmation of the loading of a new bar After the loading and positioning of the new bar on the lathe spindle relay R2 confirms the end of the loading cycle or the part feed out INFORMATION The ...

Page 59: ...sible length for the parts catcher of the lathe or its chip conveyor Relay R5 energizes as soon as the feeding pusher reaches the programmed position b R6 bar stock magazine empty relay Contact of relay R6 optional Relay R6 engages after verification of the presence of a bar during the loading cycle of a new bar RECAPITULATION OF SAFETY INSTRUCTIONS RELATED TO THE INTERFACE The lathe foot switch f...

Page 60: ...ELECTRICAL EQUIPMENT SERVICE MANUAL QL Servo 80 S2 ...

Page 61: ...otor intelligently manages the loading into the lathe This section indicates the activating and setting procedures for these functions A few simple operations are necessary to prepare the device to handle another range of diameters The set up must be modified when following parameters change Bar stock diameter Bar stock shape Part length The procedures to be followed are explained in this chapter ...

Page 62: ...tures and on the lathe following modes may be available 4 Sub spindle 5 Shaft loading 6 etc Position torque Quick access to the following position and torque values End of bar Top cut Auxiliary end of bar Torque for the bar stock loading Torque for the part feeding Misc functions Allows the access to specific settings like Language Measure unit Reference Service Reserved for maintenance to LNS tec...

Page 63: ...gs of the bar magazine loading fingers These two settings are driven by the remote control The PLC can therefore take this into account and adapt the torque of the pushers A greater precision in positioning can thus be guaranteed Moreover small diameter bars will not bend under the pressure of the pusher Round outer diameter Hexagonal square diameter across flats Overall part length In some cases ...

Page 64: ...nce after feeding In production cycle each time the clamping device of the lathe closes the feeding pusher moves backwards so as not to come into contact with the rotating bar The value of the reverse distance is set at 4 mm at the factory 1 Default value 4 mm 2 Outside of the spindle 3 Enter the desired value Optional auxiliary end of bar option When machining remnants A that are rather long a se...

Page 65: ... second machining NUMBER OF CLAMPING DEVICE OPENINGS FOR OVERALL PART LENGTH ESC ENTER PUSHER REVERSING DISTANCE 1 DEFAULT VALUE 2 OUTSIDE SPINDLE 3 OTHER VALUE ESC ENTER OPTIONNAL AUXILIARY END OF BAR 1 RELAY R5 2 RELAY R6 ESC ENTER PART FEED OUT LENGTH AFTER AUX EOB MM ESC ENTER NUMBER OF CLAMPING DEVICE OPENINGS FOR OVERALL PART LENGTH AFTER AUX END OF BAR ESC ENTER TOP CUT POSITION MM ESC ENTE...

Page 66: ...s the first bar length The second bar stock is no longer measured the loading flag moves forward at high rate to the rear of the bar stock reducing the bar stock loading Loading with fixed spindle liner installed option When a fixed spindle liner is installed in the spindle a new bar stock can be loaded during the machining of the current bar stock The bar feeder positions the bar stock in the spi...

Page 67: ...der ex hand loading pieces etc Shaft loading option In this work mode the feeding pusher is not used An extended loading pusher controls the loading When the loading table is in low position the manual functions are disabled For this type of work the End of bar position does not require a particular setting Pusher is used as mechanical stop in the spindle of the lathe option When pieces are loaded...

Page 68: ... actuator This positioning corresponds to a value Z programmed by the operator which is equal to the distance between the measuring cell and the position of the material in the lathe clamping device With this system the setting is the same for any bar length Auxiliary end of bar position option Depending on the lathe and its interface the auxiliary end of bar may be used in several ways for exampl...

Page 69: ...d from a collet to a chuck with jaws the clamping signal may need to be reversed Note that some lathes automatically reverse the signal Time for clamping device to close This is the time it takes for the clamping device to be physically closed The majority of CNC lathes are equipped with confirmation switches to provide this signal The time is set at a default value of zero seconds Time for clampi...

Page 70: ...ons by use of the barfeed 1 Signal inversion of the clamping device 2 length of the introducer depending on the turn functions and features unlocked on the barfeed following applications are available 1 Working with sub spindle 2 Fast loading of blanks 3 etc Special functions Access to various functions Working mode exhibition simulation etc Workshop configuration Parameter masking Allows to hide ...

Page 71: ...f the bars or parts the end of bar position is always the same In very special cases a different end of bar setting needs to be selected The length of the remnant may vary The minimum remnant length Min is obtained when the feeding pusher is just behind the clamping device while the last part is being machined The maximum remnant length Max is obtained when there is not enough material for machini...

Page 72: ...etting by teach in jump to point 6 5 By offset correction Press the key corresponding to the icon The current end of bar position Z is displayed Enter with the direction keys the correction to insert and press the icon to add the value or the icon to subtract it The new value is stored To exit the end of bar set mode press the key attributed to the icon ESC Jump to point 7 6 TEACH IN FWD ENTER TEA...

Page 73: ...e lathe chuck or actuator This positioning corresponds to a value Z programmed by the operator which is equal to the distance between the measuring cell and the position of the material in the lathe clamping device With this system the setting is the same for any bar length SETTING INFORMATION Before handling the bar feeder stop the lathe at the end of part cycle 1 STOP Press the key STOP 2 Enter ...

Page 74: ...splayed Enter with the direction keys the correction to insert and press the icon to add the value or the icon to subtract it The new value is stored To exit the top cut position set mode press the key attributed to the icon ESC Jump to point 8 7 TEACH IN START FWD ENTER TEACH IN By teaching Press the key attributed to the icon TEACH IN Press the key attributed to the icon START The loading channe...

Page 75: ...ows for locating the points of origin of the bar feed system positioning INFORMATION Before handling the bar feeder stop the lathe at the end of part cycle 1 STOP Press the key STOP 2 Enter the main menu 3 ENTER Enter the menu Misc applications 4 PG DOWN Go to the screen Request for reference point 5 BAS Press the ARROW DOWN for the selected mode ...

Page 76: ...ous functions Dry Run etc Additionally depending on the lathe and the unlocked functions following working modes may be available 4 Work with sub spindle 5 One shot shaft loading INFORMATION Following examples describe how to set a simple application Depending on the unlocked options several additional parameters may be added to end the setup Working example with feeding with turret moving to posi...

Page 77: ...ions must exist prior to applying this procedure The loading table is in low position 2 bars of the new diameter are on the loading table Bar feeder in STOP mode For other profiles than round hex or square please contact your local LNS representative EXAMPLE 1 ROUND BARS Bar profile round Bar diameter 20 0 mm Length of pieces to be machined 55 0 mm Thickness of the cut off tool 2 0 mm a Parameters...

Page 78: ...ding to the icon ENTER Note the procedure can be interrupted at any time by pressing the key corresponding to the icon ESC 5 left right up down ENTER ENTER Part setup Overall part length To change the value press any direction key A cursor is displayed under the first digit to modify the cursor position to modify the digit selection To store the value press the key corresponding to the icon ENTER ...

Page 79: ...e a clamping device opening To store the value press the key corresponding to the icon ENTER Note the procedure can be interrupted at any time by pressing the key corresponding to the icon ESC 7 ESC or STOP To exit the setup mode press the key ESC or STOP b Mechanical settings Install the 12 mm diameter pusher If the stock is tubing install the special adapter Check that the table and the loading ...

Page 80: ...mm INFORMATION The following conditions must exist prior to applying this procedure The loading table is in low position 2 bars of the new diameter are on the loading table Bar feeder in STOP mode a Parameters 1 Enter the main menu 2 ENTER Main menu Enter the menu part setup default see value between 3 ENTER Part setup menu profile Select the parameter hexagonal see value between ...

Page 81: ...ding to the icon ENTER Note the procedure can be interrupted at any time by pressing the key corresponding to the icon ESC 5 left right up down ENTER ENTER Part setup Overall part length To change the value press any direction key A cursor is displayed under the first digit to modify the cursor position to modify the digit selection To store the value press the key corresponding to the icon ENTER ...

Page 82: ... opening To store the value press the key corresponding to the icon ENTER Note the procedure can be interrupted at any time by pressing the key corresponding to the icon ESC 7 ESC or STOP To exit the setup mode press the key ESC or STOP b Mechanical settings Install the 20 mm diameter pusher If the stock is tubing install the special adapter Check that the table and the loading fingers are in the ...

Page 83: ...Enter the main menu 2 ENTER Main menu Enter the menu part setup default 3 ENTER Part setup menu profile Select the parameter square 4 left right up down ENTER ENTER Part setup menu Bar stock diameter To change the value press any direction key A cursor is displayed under the first digit to modify the cursor position to modify the digit selection To store the value press the key corresponding to th...

Page 84: ...icon ESC 6 up down ENTER Part setup menu Number of clamping device openings To change the value press on the up or down direction key see the value displayed between to add a clamping device opening to remove a clamping device opening To store the value press the key corresponding to the icon ENTER Note the procedure can be interrupted at any time by pressing the key corresponding to the icon ESC ...

Page 85: ...ystem SFS Maximum Number of Parts 500 Naming Convention Numeric 1 99999999 Note For the FTP connection a minimum Cat5e crossover cable is required FUNCTIONS Description The following items represent the applicable functions of the LNS Parts Library ADD PART F3 ADD If part exists there will be a prompt to overwrite DELETE PART F4 DEL Part must exist and not be the active part LOAD PART F1 LOAD Load...

Page 86: ... the bar feed is in stop mode and the loading table is in its lower position 2 Navigate to the last page of the Part Setup menu 3 Press the up arrow key to enter the Parts Library 4 Press the F3 key ADD Use the up down left right arrow keys to enter a Part Number Once the part number has been established press the F3 ENTER to save the file The Total Parts value will increase by one when the PLC ha...

Page 87: ...e F3 ENTER Note When attempting to load a part a prompt will be displayed to confirm that the intent is to load the part 4 A prompted will now appear asking for the confirmation that the correct changeover components have been installed This includes but not limited to Bar feed pusher All special bar feed application adaptations Machine tool spindle liner Machine tool clamping configuration Etc Pr...

Page 88: ...ar feed is powered on with the M1 memory card installed and properly configured the following screen will appear before the bar feed is functional Initializing the Parts Library is a memory re allocation process of the M1 memory card When a program is deleted from the Parts Library the memory allocated to that program is not released and is still considered used The re allocation process restores ...

Page 89: ...e PLC in order to access the files located on the memory card in slot M1 of the PLC Example 192 168 10 197 default Use the following information to setup FileZilla Host IP Address Example 192 168 10 197 Username part Password library Port N A BACKUP There are two files which must remain on the card in order for the Parts Library to function 1 PART00000000 DAT contains the active and total part cou...

Page 90: ... the following location on the M1 memory card M1_FLASH PART CLOSING THE FTP SESSION When closing the FTP session it is important to use the disconnect function of the FTP Client This closes the session on the PLC If the disconnect function is not used the FTP session on the PLC is not closed and remains open This can create problems if try to reconnect without power cycling the PLC ...

Page 91: ...hing and cutting hazards Always unplug the power plug and shut off the air supply before removing the cover Never operate the machine without having reinstalled the safety guards in terms of the maintenance work INSPECTIONS Component Maintenance operation Every day Every week Every month Every three months Every year Bar feeder Clean the sensors X Bar Feeder Clean the bar feeder X Air filtering un...

Page 92: ...UPDATING THE PROGRAM ON A PLC 1 Release the bar feeder Turn the switch 1 in a counterclockwise direction to O off position 2 Remove the memory module from the slot for software update card 2 3 Remove the micro SD card 4 from the memory module 3 ...

Page 93: ...MAINTENANCE SERVICE MANUAL QL Servo 80 S2 4 Insert the micro SD card 2 into the adapter 1 5 Insert the adapter into the PC 6 Open the SBC SD FLASH EXPLORER software 7 Select File Open ...

Page 94: ...NANCE SERVICE MANUAL QL Servo 80 S2 8 The following screen is displayed Select the file SAIANTFS FFS on the card 9 The following screen is displayed 10 Select File Restore 11 Select the file XXXXXXXXS BACKUP ...

Page 95: ...E SERVICE MANUAL QL Servo 80 S2 12 Wait for the restoration of the files to be complete 13 Select File Save 14 Close the SBC SD FLASH EXPLORER software 15 Eject the PC adapter using the Windows Explorer function ...

Page 96: ...MAINTENANCE SERVICE MANUAL QL Servo 80 S2 ...

Page 97: ...ANCE SERVICE MANUAL QL Servo 80 S2 16 Remove the micro SD card 2 from the adapter 1 17 Insert the micro SD card 4 into the memory module 3 18 Insert the memory module 3 into the slot for software update card 5 ...

Page 98: ...Servo 80 S2 19 Engage the bar feeder Turn the switch 1 in a clockwise direction to I on position 20 Wait until the PLC is in RUN mode 21 Press the RUN HALT button approx 3 seconds until the LED RUN HALT 2 of the battery module flash ...

Page 99: ...itive areas and thus compromise the proper functioning of the bar feeder NOTICE Solvent based cleaning products damage the finishing paint Never clean the bar feeder with solvents such as acetone or thinners 7 TECHNICAL CHARACTERISTICS Weight 820 lbs 370 kg Retraction travel X and Z axis 23 6 in 600 mm Minimum diameter round 0 236 in 6 mm Maximum diameter round 3 15 in 80 mm Minimum bar stock leng...

Page 100: ...TECHNICAL CHARACTERISTICS SERVICE MANUAL QL Servo 80 S2 ...

Page 101: ...oper disposal of the machine can cause serious harm to the environment Deposit the machine at a recycling collection point Also inquire about local departments in charge of recycling Procedure 1 Clean the machine 2 Allow the machine to air dry 3 Lightly lubricate the moving parts 4 Turn the machine on 5 Purge all the lubricant from the system 6 Return components to the recycling point sorted accor...

Page 102: ...DISPOSAL SERVICE MANUAL QL Servo 80 S2 ...

Page 103: ...r open 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 SQ10 0 Close the cover Check the SQ10 switch SQ10 1 Press the STOP button on the remote control to reset the alarm 03 Magazine protection grid open The PLC does not detect input I18 SQ11 The problem is generated when the protection grid on ...

Page 104: ... origin points home position SQ5 1 Press the STOP button on the remote control to reset the alarm 15 Safety time for loading channel up and down motion elapsed when the loading table goes up and the PLC does not count the necessary quantity of pulses to reach the requested position in the delay of 8 seconds when the loading table goes down and the PLC does not detect the input I24 SQ1 in the delay...

Page 105: ...rm 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 try outs this alarm is gener...

Page 106: ...1 0 Press the STOP button on the remote control to reset the alarm Restart the automatic cycle on bar feeder and lathe I40 1 I41 1 Press the STOP button on the remote control to reset the alarm Restart the automatic cycle on bar feeder and lathe 28 Parts counting parity error by M CODE quantity and automatic part counting This alarm occurs whenever clamping device openings quantity does not match ...

Page 107: ...please contact LNS 42 Servo drive alarm This alarm occurs whenever the servo amplifier generates an alarm If the problem persists find the displayed alarm number on the servo amplifier and refer to the Mitsubishi servo amplifier alarm list 43 Amplifier battery low This alarm occurs whenever the voltage of the integrated amplifier battery is too low Replace the battery as soon as possible 44 Servo ...

Page 108: ...rify 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 If the problem persists please contact LNS 46 PLC battery low This alarm occurs whenever the voltage of the integrated amplifier battery is too low Replace the battery as soon as possible 48 Loading or unloading cycle interrupted This alarm is activated if the...

Page 109: ...TROUBLESHOOTING SERVICE MANUAL QL Servo 80 S2 SEQUENCE LISTING ...

Page 110: ...TROUBLESHOOTING SERVICE MANUAL QL Servo 80 S2 ...

Page 111: ...ion Process error 2 DB 16 C Encoder initial communication Process error 3 DB 16 D Encoder initial communication Process error 4 DB 16 E Encoder initial communication Process error 5 DB 16 F Encoder initial communication Process error 6 DB 17 0 0 0 Board error 17 1 Board error 1 DB 17 3 Board error 2 DB 17 4 Board error 3 DB 19 0 0 0 Memory error 3 FLASH ROM 19 1 FLASH ROM error 1 DB 19 2 FLASH ROM...

Page 112: ...vercurrent detected at hardware detection circuit during operation DB 32 2 Overcurrent detected at software detection function during operation DB 32 3 Overcurrent detected at hardware detection circuit during a stop DB 32 4 Overcurrent detected at software detection function during a stop DB 33 0 0 1 Overvoltage 33 1 Main circuit voltage error EDB 35 1 0 1 Command frequency error 35 1 Command fre...

Page 113: ...TO2 off DB 70 1 1 0 Load side encoder initial communication error 1 70 1 Load side encoder initial communication Receive data error 1 DB 70 2 Load side encoder initial communication Receive data error 2 DB 70 3 Load side encoder initial communication Receive data error 3 DB 70 5 Load side encoder initial communication Transmission data error 1 DB 70 6 Load side encoder initial communication Transm...

Page 114: ... serial communication receive error SD 8E 2 USB communication checksum error serial communication checksum error SD 8E 3 USB communication character error serial communication character error SD 8E 4 USB communication command error serial communication command error SD 8E 5 USB communication data number error serial communication data number error SD 88888 Watchdog 8888 Watchdog Note 1 Leave for a...

Page 115: ...E2 Servo motor overheat warning E2 1 Servo motor temperature warning E3 Absolute position counter warning E3 1 Multi revolution counter travel distance excess warning E3 2 Absolute position counter warning E3 5 Encoder absolute positioning counter warning E5 ABS time out warning E5 1 Time out during ABS data transfer E5 2 ABSM off during ABS data transfer E5 3 SON off during ABS data transfer E6 S...

Page 116: ...N Motor Servo ON K3 I25 SQ3 Measuring cell O55 KS Start Relay I26 SQ4 Diameter change motor reference I27 SQ5 Pusher carrier home position switch I31 M3 Diameter change motor Interface Interface I40 A1 Clamping signal from the lathe O56 R1 Relay bar feed alarm I41 A2 Lathe in AUTO Cycle O57 R2 Relay loading cycle finish I42 A3 Start loading signal O58 R3 Relay end of bar I43 A4 Part feed out signa...

Page 117: ...ended you have DropBox downloaded to your smartphone If you do not have the DropBox app it s a free app and can be downloaded on your Smartphone quickly Below are steps to retrieve information from the QR code through DropBox HOW TO ACCESS PRODUCT INFORMATION THROUGH DROPBOX STEP 1 Upon downloading a Scanner App open the app When the message Launch website appears select Go Point your smartphone a...

Page 118: ...s select Go Point your smartphone at the QR code to be recognized STEP 2 STEP 3 When you hit Go you will see this screen Tap on the file name in the box STEP 4 Select the arrow in the top right hand corner of your screen STEP 5 Select Direct Download STEP 6 Upon selecting Direct Download steps 3 5 will need to be completed again for the file to be accessed STEP 7 Select Open in Adobe Acrobat ...

Page 119: ...OUBLESHOOTING SERVICE MANUAL QL Servo 80 S2 AFTER SALES SERVICE Customer Service Service BFsupport LNS northamerica com Customer Service Parts BFparts LNS northamerica com Phone 513 528 5674 Fax 513 528 5733 ...

Page 120: ...TROUBLESHOOTING 119 SERVICE MANUAL QL Servo 80 S2 ...

Page 121: ...e PLC controls the machine s operation Shaft Steel bar for supporting rotating elements or to transfer power SD card Removable memory card Secure Digital Informed persons Persons sufficiently informed or supervised by qualified personnel to enable them to avoid the dangers posed by electricity maintenance or operating staff Qualified personnel Persons with technical knowledge or experience suffici...

Page 122: ...APPENDICES 121 SERVICE MANUAL QL Servo 80 S2 WIRING DIAGRAM 020 40 620K CE MRJ 4 ...

Page 123: ...122 APPENDICES SERVICE MANUAL QL Servo 80 S2 ...

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Page 125: ...124 APPENDICES SERVICE MANUAL QL Servo 80 S2 ...

Page 126: ...APPENDICES 125 SERVICE MANUAL QL Servo 80 S2 ...

Page 127: ...126 APPENDICES SERVICE MANUAL QL Servo 80 S2 ...

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Page 129: ...128 APPENDICES SERVICE MANUAL QL Servo 80 S2 ...

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Page 131: ...130 APPENDICES SERVICE MANUAL QL Servo 80 S2 ...

Page 132: ...APPENDICES 131 SERVICE MANUAL QL Servo 80 S2 WIRING DIAGRAM 020 40 650B CE DCS MRJ4 ...

Page 133: ...132 APPENDICES SERVICE MANUAL QL Servo 80 S2 ...

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Page 141: ...140 APPENDICES SERVICE MANUAL QL Servo 80 S2 ...

Page 142: ...APPENDICES 141 SERVICE MANUAL QL Servo 80 S2 ...

Page 143: ...orm fill it out in its entirety and send it back to your nearest LNS reseller or retailer 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 ...

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