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CHAPTER 8: MALFUNCTIONS/MAINTENANCE

103

QUICK LOAD SERVO S3T

CHAPTER 8:

MALFUNCTIONS/MAINTENANCE

Summary of Contents for SERVO S3 T

Page 1: ...For CNC machine tool peripherals it s LNS then all the rest QUICK LOAD SERVO S3 T BARFEED Instruction Manual 9 021 04 US...

Page 2: ......

Page 3: ...21 3 ELECTRICAL CONNECTIONS 32 4 PNEUMATIC CONNECTIONS 32 CHAPTER 4 ELECTRICS 33 1 ELECTRICAL EQUIPMENT 34 2 ELECTRICAL CABINET 36 3 ELECTRIC DIAGRAMS 43 4 INTERFACE 44 CHAPTER 5 PNEUMATICS 47 1 PNEUM...

Page 4: ...MATIC CYCLE 98 6 END OF BAR POSITION 99 7 TOP CUT POSITION 101 8 POWERING DOWN 102 CHAPTER 8 MALFUNCTIONS MAINTENANCE 103 1 ALARMS 104 2 MAINTENANCE 113 CHAPTER 9 APPENDICES 115 1 ORDERING FORM 116 2...

Page 5: ...CHAPTER 1 BASIC PRINCIPLES 3 QUICK LOAD SERVO S3T CHAPTER 1 BASIC PRINCIPLES...

Page 6: ...u are handling the system please refer to the chapter on the device to be set for example see chapter or see point 1 2 Captions Whenever possible the reference numbers contained in the instruction man...

Page 7: ...ble 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 t...

Page 8: ...ds have been used as a basis Concerning the Machinery directive EN ISO 12100 2010 Safety of machinery General principles for design EN ISO 14121 2 2013 Safety of machinery Risk assessment EN ISO 13857...

Page 9: ...d on It is strictly prohibited to jump wire or remove circuit breakers master switches and especially safety switches To avoid any harm to persons or damage to components use only the indicated points...

Page 10: ...ble By pressing the emergency stop button located on the remote control the functions of the bar feeder and the lathe are immediately stopped LNS or its local representative may not be held liable for...

Page 11: ...CHAPTER 2 TECHNICAL DATA 9 QUICK LOAD SERVO S3T CHAPTER 2 TECHNICAL DATA...

Page 12: ...ermitted bar weight 150 lb bar 67 kg bar Pneumatic pressure 90 psi 6 bar Maximum pneumatic consumption 1 6 gallons per loading cycle 6 liters per loading cycle Supply voltage Volts 220 480 V 50 Hz 60...

Page 13: ...CHAPTER 2 TECHNICAL DATA 11 QUICK LOAD SERVO S3T 2 1 Loading from the rear left transverse movement...

Page 14: ...12 CHAPTER 2 TECHNICAL DATA QUICK LOAD SERVO S3T 2 2 Loading from the rear left longitudinal movement...

Page 15: ...CHAPTER 2 TECHNICAL DATA 13 QUICK LOAD SERVO S3T 2 3 Loading from the front left transverse movement...

Page 16: ...14 CHAPTER 2 TECHNICAL DATA QUICK LOAD SERVO S3T 2 4 Loading from the front left longitudinal movement...

Page 17: ...ion grid for the bar magazine B Bar magazine C Loading table support D Retraction device E Electrical cabinet F Protection cover G Air handling H Interface plug depending on the interface not visible...

Page 18: ...16 CHAPTER 2 TECHNICAL DATA QUICK LOAD SERVO S3T...

Page 19: ...CHAPTER 3 SYSTEM START UP 17 QUICK LOAD SERVO S3T CHAPTER 3 SYSTEM START UP...

Page 20: ...ight 71 70 1 2 Unpacking For practical and safety reasons the bar feeder must be unpacked in a spacious well lit location Check to ensure that the lifting capacity of the hoisting crane or lift truck...

Page 21: ...ystem C is supplied partially assembled but is not fitted on the bar feeder A pusher is supplied installed on the bar feeder The additional pushers are affixed underneath the bar magazine D The techni...

Page 22: ...bar feeder may also be moved using a lift truck E In this case position the lift truck underneath the bar feeder frame Move the bar feeder taking care that it remains horizontal and that no one is nea...

Page 23: ...thout the protective panels Bring the loading table support close to the bar magazine Unlock and remove the pins located on the mounting forks Lift the bar magazine Insert the fork on the setting leve...

Page 24: ...be installed after the bar magazine has been moved 1 Lift the magazine A and measure the distance X where it should be positioned 2 If necessary remove the protective panels B and C Unscrew the screws...

Page 25: ...of the spindle from the entry to in front of the collet Lift the protection grid Unscrew the retaining screws for the rear limiter Place the limiter at the distance measured in the spindle L max meas...

Page 26: ...transverse movement as required A Left rear loading longitudinal movement B Left rear loading transverse movement C Left front loading longitudinal movement D Left front loading transverse movement D...

Page 27: ...E 3 Push the rails C underneath the unit 4 Move the bearings apart and place them opposite the mounting holes 5 Insert the retaining screws F and screw them into the bearings D without tightening them...

Page 28: ...device O 15 Couple the safety switch SQ12 with the key Q which is located at the front of bar feeder rail then screw R the switch onto the retraction system If the mounting holes for the switch are n...

Page 29: ...E 3 Push the rails C underneath the unit 4 Move the bearings apart and place them opposite the mounting holes 5 Insert the retaining screws F and screw them into the bearings D without tightening the...

Page 30: ...device O 15 Couple the safety switch SQ12 with the key Q which is located at the front of bar feeder rail then screw R the switch onto the retraction system If the mounting holes for the switch are n...

Page 31: ...lade D Carefully unscrew the 16 screws C Adjust the height of the bar feeder by loosening or tightening the central screw B A hexagonal tube is supplied with the unit and can be used to access the set...

Page 32: ...he bar feeder and lathe do not match there is a risk the pusher will touch the inside of the spindle Place a spirit level on the loading table Use the screws A to set the correct level Manually lock t...

Page 33: ...fectly aligned it should be anchored to the ground to make it stable To accomplish this 4x 2 anchorage points A have been provided Eight anchoring bolts must be provided by the customer minimum M10 x...

Page 34: ...e modes associated with each task Risks can come from o the machine in which the QUICK LOAD SERVO III unit is integrated o its association with other equipment o People s interaction with the machine...

Page 35: ...CHAPTER 4 ELECTRICS 33 QUICK LOAD SERVO S3T CHAPTER 4 ELECTRICS...

Page 36: ...s because of risks of electrocution In case of possible electrical malfunctions it is advisable to contact LNS or their local representative 1 1 Description This chapter contains all of the elements r...

Page 37: ...6 servomotor M2 4 307 Motor for setting the diameter SQ1 4 484 Control switch table in lowered position SQ2 4 484 Control switch table in raised position SQ3 44 0072 Light sensor SQ4 4 391 Proximity s...

Page 38: ...mmable controller PCD3 PLC AJ1 44 0105 Servo amplifier 400W FU1 4 399 1A fuse motor M2 K3 4 507 Safety contactor KS 4 925 Start relay K8 K9 4 931 Safety control relay K10 4 932 Safety breaker option K...

Page 39: ...reaker QF1 protects the two phases which power the transformer Should the latter require excessive power 2 Amps the breaker activates and the lever B flips down The power supply to the transformer is...

Page 40: ...a turn to the 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...

Page 41: ...dvisable to keep spares on hand When a battery becomes low the amplifier signals this through a control light The battery is not rechargeable and must be replaced right away The replacement must be do...

Page 42: ...40 CHAPTER 4 ELECTRICS QUICK LOAD SERVO S3T Cover Locking clip Click in to close Open the battery compartment Remove the battery from its housing and replace Close the battery compartment...

Page 43: ...ery module M1 Slot for software updates M2 Slot for memory expansion in use as standard Battery module Batt The PLC does not need a backup battery on the information module Run The PLC is in RUN mode...

Page 44: ...ng position probe up O41 Not used I10 SQ3 Positioning stop probe O42 Not used I11 SQ4 Diameter setting motor M2 probe O43 Not used I12 SQ5 Original pos carrier servo O44 Not used I13 SQ30 Empty bar ma...

Page 45: ...CHAPTER 4 ELECTRICS 43 QUICK LOAD SERVO S3T 3 ELECTRIC DIAGRAMS...

Page 46: ...their own thermal protection systems breakers thermal relays fuses etc The power supply for the bar feeder should be connected to the output of a breaker mounted in the electrical control box of the l...

Page 47: ...he mode of the lathe collet As long as this signal is present the signal of the foot switch to open and close the lathe collet must be locked The lathe should not start up in automatic cycle until the...

Page 48: ...he options are available only to optimize production conditions a R5 auxiliary end of bar relay This signal may be used to reduce the length of the remnant in case the remnants exceed the maximum admi...

Page 49: ...CHAPTER 5 PNEUMATICS 47 QUICK LOAD SERVO S3T CHAPTER 5 PNEUMATICS...

Page 50: ...lements namely Loading the bar onto the loading table Locking the pusher To guarantee optimal operation of the bar feeder a minimum pressure of 5 bar 75 PSI and a maximum pressure of 6 bar 90 PSI is m...

Page 51: ...se long enough to allow the complete travel 500 mm of the retraction system to be used When the pipe is connected it should not trail on the ground as it could be damaged 1 Place a clamp A around the...

Page 52: ...tenance When the key B is released the pneumatic cylinder returns to its rest position except for pneumatic cylinders activated by 2 solenoid valves Designation Description A Air outlet B Manual activ...

Page 53: ...S 51 QUICK LOAD SERVO S3T 4 PNEUMATIC DIAGRAM 4 1 Symbols Symbol Description Designation Pressure control unit SP1 Pneumatic cylinder 3 95020 A 30 3 406 Air handling 3 636 Solenoid valve YV1A YV1B 4 2...

Page 54: ...52 CHAPTER 5 PNEUMATICS QUICK LOAD SERVO S3T...

Page 55: ...CHAPTER 6 GENERAL DESCRIPTION 53 QUICK LOAD SERVO S3T CHAPTER 6 GENERAL DESCRIPTION...

Page 56: ...start to pile up the gradient can be decreased A protection grid prohibits access to the magazine during the automatic cycle In manual mode the grid which is fitted onto hinges can be retracted to en...

Page 57: ...IPTION 55 QUICK LOAD SERVO S3T 1 2 Layout of the elements Designation Description A Bar magazine B Protection grid C Rear limiter D Loading table support E Positioning stops F Support rod SQ11 Safety...

Page 58: ...ngth of the spindle from the entry to in front of the collet Lift the protection grid Unscrew the retaining screws for the rear limiter Place the limiter at the distance measured in the spindle L max...

Page 59: ...move the rear limiter to reduce the loading time Lift the protection grid Install a bar on the bar magazine pressing against the front limiter Move the rear limiter 1 millimeter behind the bar Check...

Page 60: ...ar feeder loading table performs two functions 1 Selection of the material When the table A is in the lowered position the pusher B is opposite the spindle C The pneumatic cylinders are active the tab...

Page 61: ...3 The bar is now opposite the lathe spindle 3 The remote control prompts the icons F4 FWD Press the F3 key approx 3 seconds until the loading table calibration icon F1 appears 4 The loading table cali...

Page 62: ...ading pusher is fitted When the bar is positioned in the spindle the carrier slides freely along the pusher which remains immobile When the carrier returns to the park position an actuator locks the p...

Page 63: ...020 A 30 Locking actuator M1 servomotor 4 LOADING FINGER Unlike the pusher the loading pusher must not be replaced when the bar diameter or profile changes It is possible to load bars of the same leng...

Page 64: ...use this number 2 supports with additional rollers designed to provide better support for small diameter bars are supplied with pushers with a diameter of 6 35 mm Their positions on the loading table...

Page 65: ...the pusher forward sliding it inside the guiding bushing E 4 When the rear of the pusher been freed enough for it to be removed pull the guiding bushing E backwards to remove it from its housing 5 The...

Page 66: ...stopped This setting must be performed on all the pushers when the bar feeder is installed and may only be altered under certain circumstances when the clamping unit is replaced collet chuck The end...

Page 67: ...ear of each tube They also protect the bar feeder from contamination from the lathe s cutting fluid 2 The second consists of replacing the pusher tip C with a special tip D with a diameter of 130 mm a...

Page 68: ...this case reload the motor s original reference points see chapter 7 The same procedure applies if the belt is replaced Procedure 1 Bar feeder in STOP position 2 Open the protection cover 3 Insert a...

Page 69: ...uipped with a bar feeder certain elements motors spindle reduction tubes etc become inaccessible and sometimes it is difficult or even impossible to proceed with their maintenance To facilitate these...

Page 70: ...ngs B the bar feeder slides along two cylindrical rails A which guarantee its alignment when it is in the working position In this position the bar feeder is secured by two robust hooks C A safety swi...

Page 71: ...angle converter D An additional limiter C Depending on the configuration various items are available Bar feeder version Item no Left rear 021 002 163 Left front 021 002 153 8 2 Kit for quick part loa...

Page 72: ...aded are tubes an adapter is needed in order to create a flat surface plate between the pusher and tube The adapter must be adapted to the outer diameter of the tube by turning the outside of the adap...

Page 73: ...CHAPTER 7 OPERATION 71 QUICK LOAD SERVO S3T CHAPTER 7 OPERATION...

Page 74: ...he value saved is immediately taken into account thus avoiding any referencing position The status parameters saved in the PLC prior to powering off are then checked by the PLC which analyses them The...

Page 75: ...reducing the access time to the necessary functions The screen continuously and clearly shows the status of the bar feeder and the production allowing the functions diagnostics and error signals to b...

Page 76: ...back to start Stop after machining one bar Back to previous page Switch to manual mode Go to next page Pusher forward picture may be reversed depending on the feed side Fit the loading table load a ba...

Page 77: ...tion Confirm Teach data Cancel Value modification by correction Confirm In settings mode to validate a new parameter or a new value press and hold until the icon disappears approximately 3 seconds Inc...

Page 78: ...the button anticlockwise 2 5 MODE buttons 2 5 1 MENU key The MENU key allows access to the main menu where the parameters concerning production the interface and the general settings can be reviewed a...

Page 79: ...tions are necessary to prepare the device to handle another range of diameters The set up must be modified when following parameters change 1 Bar stock diameter 2 Bar stock shape 3 Part length 3 1 Bar...

Page 80: ...ble is raised Profiled material 1 When the knurled screw B is turned the positioning stops E are angled Tighten until the lower nuts H press against the block G in position 2 2 Place two bars D on the...

Page 81: ...collet has the great advantage of holding the bar at two points separated by about 1 5 the diameter with clamping 2 times 350 degrees over about 0 5 times the diameter Efficiency excellent 3 jaws chu...

Page 82: ...ore and the rotating bar The greater the clearance the more frequent the vibrations Using reduction tubes helps to reduce this clearance Guiding is thus improved but in addition the insertion of the b...

Page 83: ...ters when feeding the material can be positioned in the lathe s clamping unit Then during the production cycle each time the clamping unit is opened the material is moved forward with precision Inform...

Page 84: ...and values of the part e g Bar shape round hex square other Bar diameter Feeding length Number of collet openings Application Used to quickly set the working mode by selecting the desired application...

Page 85: ...al loading length Lt included the work piece length Lp the thickness of the top cut tool C and the thickness of the facing tool not represented on this picture depends on the part program Number of op...

Page 86: ...etween 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 More information in section 7 of this chapter Auxili...

Page 87: ...device is closed the pusher retracts to ensure it is not in contact with the rotating bar The retraction value is factory set at 4 mm but can be altered as required Depending on the play between the p...

Page 88: ...to ensure that longer bars cannot be loaded When the first bar is loaded the bar feeder measures the length of the bar which explains why the loading pusher moves slowly From the second bar the loadin...

Page 89: ...to this point b The turret is moving to position The turret comes to the bar stock end the bar feed starts pushing against the turret Then the turret moves to the desired feeding length the bar feed s...

Page 90: ...ered position the manual functions are deactivated The end of bar position does not require any particular setting for this type of work Contact your LNS agent for more information on this application...

Page 91: ...of bar position is always the same In very special cases a different end of bar setting needs to be selected More information in section 6 of this chapter Top cut position may not be visible During f...

Page 92: ...he feeder suggests a suitable thrust torque The operator can modify this torque if required When the material to be loaded has a high specific weight the torque must also be high Conversely low specif...

Page 93: ...he unit has closed completely Mechanical opening time for the clamping system may not be visible For clamping with a chuck an opening time may have to be configured to prevent the lathe starting up be...

Page 94: ...the parameters for this ID with new ones Once confirmed the parameters of the old ID are permanently overwritten in the Parts Library and cannot be recovered Active part shows the part currently load...

Page 95: ...alues 80 400 rpm 2 Loading cycle speed min max factory values 100 3000 rpm 3 Speed without bar min max factory values 1000 4000 rpm 4 Bar feed rate min max factory values 100 3000 rpm 5 Speed at front...

Page 96: ...pindle fixed or mobile no yes 9 Parameter access End of bar yes no 10 Parameter access Top cut position no yes 11 Parameter access Lathe collet signal inversion no yes 12 Parameter access Loading push...

Page 97: ...on the screen displays the help screens to troubleshoot or gather information about the software and components 1 Software This screen displays the current software running the bar feeder and its ver...

Page 98: ...CHAPTER 7 OPERATION QUICK LOAD SERVO S3T 3 Inputs This screen shows the current input signals being used in the barfeed 4 Outputs This screen shows the current output signals being used in the barfee...

Page 99: ...97 QUICK LOAD SERVO S3T 5 Alarms list This screen shows the history of the last 10 alarms 6 Memory list This screen helps entering and monitoring specific bits status in green red and register values...

Page 100: ...RWARD COMMAND FROM LATHE END OF BAR NO YES NO YES LOADING TABLE MOVES UP NO LOADING TABLE MOVES DOWN PUSHER MOVES BAR TO TOP CUT POSITION COLLET CLOSES SUB PROGRAM COMPLETE RETURN TO MAIN PART PROGRAM...

Page 101: ...length Min is obtained when the feeding pusher is just behind the clamping device while the last part is being machined The maximum Max remnant length is obtained when there is not enough material for...

Page 102: ...esponding to the icon The display shows the current end of bar position Select the field named Enter the new value enter the correction to be considered and confirm with ok Press the icon to add the v...

Page 103: ...alidate a new parameter or a new value keep ENTER pressed until the icon disappears 1 STOP Press the key STOP 2 MENU Press the key MENU 3 POSITIONS Press the key POSITIONS on the screen 4 PAGE DOWN Pr...

Page 104: ...RT The loading table is raised and loads a bar The feeding pusher inserts the bar into the lathe spindle The loading pusher retracts and the loading table is lowered The feeding pusher is now facing t...

Page 105: ...CHAPTER 8 MALFUNCTIONS MAINTENANCE 103 QUICK LOAD SERVO S3T CHAPTER 8 MALFUNCTIONS MAINTENANCE...

Page 106: ...to the electrical drawings Check the PLC connection AL02 MAIN ACCESS COVER OPEN Description The PLC does not detect the input I2 SQ10 for the safety sensor on the protection cover The problem is gene...

Page 107: ...bar Adjust pressure switch SP1 Replace pressure switch SP1 AL07 Not used AL08 Not used AL09 Not used AL10 SWITCH SQ1 FAULT Description The PLC does not detect input I8 SQ1 Solutions Check probe SQ1 A...

Page 108: ...LE Description A mechanical blockage prevents the table being lowered Solutions Check that no mechanical obstruction is preventing the table being lowered AL16 PROBE SQ3 FAULT Description The PLC does...

Page 109: ...e bar feeder Solutions Check presence of bars on the ramp Load bar stock to continue the production AL22 LOADING CYCLE INTERRUPTED Description Signal A2 automatic cycle has been lost Solutions Check t...

Page 110: ...e wiring AL27 THE PART FEED OUT TIME HAS ELAPSED Description The time allotted to reach the position has elapsed Solutions Signal A1 missing Check the presence of the signal when the collet is closed...

Page 111: ...and pin reduction AL38 CC LINK COMMUNICATION FAULT Description There is a communication issue between the lathe and the bar feeder Solutions Contact your LNS agent AL39 CUT OFF FEED FAULT Description...

Page 112: ...ar diameter and the bar shape AL44 PART LOADING FAULT Description M Code request parameter deactivated Solutions Check that the M Code request is active AL45 POSITION NOT REACHED Description An obstac...

Page 113: ...eck the connection between the PLC and amplifier Check the 24V power supply is not fluctuating AL49 AMPLIFIER BATTERY LOW Description The voltage level of the battery located on the motor power driver...

Page 114: ...1 0 0 Main circuit error AL 25 1 1 0 Complete position clearance AL 30 0 0 1 Regeneration error AL 31 1 0 1 Overspeed AL 32 1 0 0 Electrical current too high AL 33 0 0 1 Electrical voltage too high A...

Page 115: ...tch off the power until the battery has been replaced 2 3 Belt It is possible that after a certain amount of use the bar feeder belt will require tensioning Refer to chapter 6 GENERAL DESCRIPTION sect...

Page 116: ...114 CHAPTER 8 MALFUNCTIONS MAINTENANCE QUICK LOAD SERVO S3T...

Page 117: ...CHAPTER 9 APPENDICES 115 QUICK LOAD SERVO S3T CHAPTER 9 APPENDICES...

Page 118: ...uld be photocopied duly filled out and returned to your retailer or nearest LNS agent Company name Person in charge Address ZIP City Country Phone Fax Type of device Serial number Qty Order no Descrip...

Page 119: ...AM JUMPS SUB PROGRAM N CLOSE CLAMPING UNIT N TURRET HOME N TURRET HOME M CODE FEED OK N N CLOSE CLAMPING UNIT N START SPINDLE PART PROGRAM N COOLANT ON N X Z G F T S M N TOP CUT N MACHINE PART N N PAR...

Page 120: ...118 CHAPTER 9 APPENDICES QUICK LOAD SERVO S3T 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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