TABLE OF CONTENTS - LNS North America · 2019. 5. 18. · LNS SA and its subsidiaries cannot be...

QUICK LOAD SERVO S3 T

V4.00_2

TABLE OF CONTENTS

CHAPTER 1: BASIC NOTIONS.............................................................. 1-11. STRUCTURE......................................................................................................................... 1-22. RIGHTS ................................................................................................................................. 1-33. DECLARATION OF COMPLIANCE ..................................................................................... 1-44. SAFETY INSTRUCTIONS..................................................................................................... 1-55. SAFETY DEVICES................................................................................................................ 1-6

CHAPTER 2: TECHNICAL DATA........................................................... 2-11. CHARACTERISTICS............................................................................................................. 2-22. FLOOR PLANS ..................................................................................................................... 2-23. LAYOUT OF THE ELEMENTS ............................................................................................. 2-7

CHAPTER 3: SETTING INTO OPERATION ...........................................3-11. TRANSPORTATION ............................................................................................................. 3-22. MOUNTING ........................................................................................................................... 3-53. ELECTRICAL CONNECTIONS .......................................................................................... 3-164. PNEUMATICAL CONNECTIONS ....................................................................................... 3-16

CHAPTER 4: ELECTRICS......................................................................4-11. ELECTRICAL EQUIPMENT.................................................................................................. 4-22. ELECTRICAL CABINET ....................................................................................................... 4-43. ELECTRICAL DIAGRAMS ................................................................................................. 4-104. INTERFACE ........................................................................................................................ 4-20

CHAPTER 5: PNEUMATICS ..................................................................5-11. PNEUMATICAL EQUIPMENT .............................................................................................. 5-22. AIR FILTERING UNIT ........................................................................................................... 5-33. PNEUMATIC VALVE............................................................................................................. 5-44. PNEUMATIC DIAGRAMS..................................................................................................... 5-5

CHAPTER 6: GENERAL DESCRIPTION ............................................... 6-11. BAR MAGAZINE ................................................................................................................... 6-22. LOADING TABLE ................................................................................................................. 6-63. PUSHER CARRIER............................................................................................................... 6-84. LOADING PUSHER .............................................................................................................. 6-95. FEEDING PUSHER............................................................................................................. 6-106. BELT.................................................................................................................................... 6-147. RETRACTION ..................................................................................................................... 6-158. OPTIONS............................................................................................................................. 6-17

CHAPTER 7: OPERATION.....................................................................7-11. POWERING UP ..................................................................................................................... 7-22. REMOTE CONTROL............................................................................................................. 7-3


3. SET UP .................................................................................................................................. 7-74. SETTINGS ........................................................................................................................... 7-115. AUTOMATIC CYCLE .......................................................................................................... 7-326. END OF BAR POSITION..................................................................................................... 7-337. TOP-CUT POSITION ........................................................................................................... 7-358. POWERING DOWN............................................................................................................. 7-36

CHAPTER 8: MALFUNCTIONS / MAINTENANCE ................................ 8-11. ALARMS ................................................................................................................................ 8-22. MAINTENANCE................................................................................................................... 8-11

CHAPTER 9: APPENDICES................................................................... 9-11. ORDERING FORM ................................................................................................................ 9-22. PROGRAMMING EXAMPLE................................................................................................. 9-33. LNS ADDRESSES & CONTACTS ........................................................................................ 9-4

CHAPTER 1: BASIC NOTIONS 1-1


CHAPTER 1:BASIC NOTIONS

1-2 CHAPTER 1: BASIC NOTIONS


1. STRUCTUREThis manual consists of various chapters, each containing several points, paragraphs, etc. Lists may becontained in paragraphs.

The page number is indicated in the top outer corner of the page. The chapter number and title are indicated in the top inner corner of the page. The model of the bar feed system is indicated in the bottom right-hand corner of the page.

1.1. Cross-referencesEach chapter generally contains all of the information related to the description and settings of thedevices and elements represented therein.

Therefore, if a setting must be made while you are handling the system, please refer to the chapter on thedevice to be set, for example: (see chapter *) or (see point *).

1.2. CaptionsWhenever possible, the reference numbers contained in the instruction manual are shown with the LNSordering 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 thismanual.

1.3. Symbols and terminology

This sign recommends following the directions very closely avoiding causing anincident that could result in injury, damage to the equipment, or data loss.

This sign indicates that safety measures must be taken to avoid possible electricalshocks or mishaps.

The notes stress interesting points or comments, and provide useful advice foroptimal system operation.

This sign points out an advice about environmental protection.



2. RIGHTSAll rights reserved. Reproduction, recording or transmission of all, or any portion, of this manual, in anyform or through any means whatsoever, whether mechanical, photographic, sound or other, without theexpress written authorization of LNS SA, is prohibited. LNS SA disclaims all responsibility for errors whichmay be contained in this manual and the problems which may result therefore.

LNS SA and its subsidiaries cannot be made responsible for the debts, losses, expenses, or damageincurred, or suffered, by the buyer of this product, or a third party, following an accident, incorrect use, ormisuse, 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 ofoptions and products other than LNS products, or products approved by LNS SA.

The names of the products indicated in this manual are registered trademarks.

The instructions found in this manual are only for information ; they are subject to change without notice.



3. DECLARATION OF COMPLIANCESample representation; the original document is always shipped with the unit.

EC DECLARATION OF CONFORMITY

We declare that the following machinery complies with the next directives :- Machinery Directive: 98/37/EC- Low Voltage Directive: 2006/95/EC- EMC Directive: 2004/108/ECManufacturer : LNS SA

Route de FrinvillierCH- 2534 OrvinSuisse

Compiling relevant technical information : Plaseco Kurt De PauwChemin des Petits-Clos 12CH- 1744 ChénensSuisse

Description of the machine : Automatic barfeed systemType : QUICK LOAD SERVO S3 TSerial number : (see number on official document)

The following transposed harmonised standards have been used :

- Concerning the Machinery Directive : EN 14121 - 1 & 2 : Safety of machinery – Risk assessment, EN 12100 - 1 & 2 : Safety of machinery – Basic concepts & principles, EN 294 : Safety of machinery – Safety distances, EN 13850 : Safety of machinery – Emergency stop equipment, EN 953 : Safety of machinery – Conception of movable guards, EN 954-1 : Safety of machinery – Safety related parts of control systems, EN 1037 : Safety of machinery – Prevention of unexpected start-up, EN 1088 : Safety of machinery – Interlocking devices, EN 60204-1 : Safety of machinery – Electrical equipment of machines, CEI 60812 : Safety of machinery – FMECA Analysis,

- Concerning the Low Voltage Directive : IEC 60439-1/3 : Low-voltage switchgear and control gear assemblies

- Concerning the EMC Directive : EN 61000-6-4 : Generic emissions standard, Industrial environment EN 61000-6-2 : Generic immunity standard, Industrial environment

Place and date : Seal and signature :



4. SAFETY INSTRUCTIONSOnly people who know the product and are sufficiently qualified, may install, put the spindle inuse, maintain and, where necessary, repair. The customer must ensure that the provisionsregarding internal monitoring, the indication prescribed events, organization of work, stafftraining is available with instructions for assembly.

All persons who perform work on this machine, must have read and understood the noticeinstructions. LNS disclaim all responsibility for possible accidents or property damage causedwhen safety instructions are not followed :

Do not handle the equipment without havingknowledge of the safety instructions and theinstructions for use. Safety instructions forthe bar feed system, as well as the CNClathe, must be strictly observed.

Non-qualified personnel, children, andpersons under the influence of alcohol ormedication should not handle the equipment.

Loose garments, long hair and jewellery canbe dangerous.

Do not remove any covers while the barfeeder or the machine is under electricalpower.

Do not conduct any maintenance operationsduring the automatic cycle.

Do not grasp moving or rotating objects, ornearby elements.

If certain safety shields or safety covers areremoved to conduct maintenance, they mustbe reinstalled as soon as the maintenancework is completed.

No servicing should be carried out on theinterface or inside the electrical cabinet whilethe bar feeder or the lathe is under electricalpower.

It is strictly prohibited to jump wire or removecircuit breakers, main switches, andespecially safety switches.

To avoid any harm to persons, or damage tocomponents, use only the indicated pointsfor lifting and moving the bar feeder system.No one should be near the hanging load, orwithin the operating range of the overheadhoist/crane, forklift, or any other means usedfor lifting and transportation. Do not knockthe bar feeder while moving it as this coulddamage it.

Do not move the bar feeder while it iselectrically powered on.

Don’t hit the barfeed when moving it, thiscould result in damages.

The work area surrounding the bar feedsystem should always be clear of objectsand well lit. The presence of oil on theground could cause falls; it is important tomaintain the floor clean on a regular basis.

Do not place the machine in a damp areaand make sure that water or oil does notcome into contact with the electricalequipment.

Do not open the clamping device (collet orchuck) of the lathe manually when the barfeeder is in automatic mode (Interface).

Each time the diameter is changed, alsoadapt spindle reduction tube. The use ofspindle reduction tubes is highlyrecommended for machining bars withdiameters smaller than the maximumcapacity of the spindle.

Do not attempt to recharge the batteries ofthe PLC.

For the use and maintenance of the barfeeder, use only parts provided by orrecommended by LNS.

If it is necessary to move the bar feeder onceit has been originally installed, do notreinstall it before first contacting LNS or itslocal representative.

The rotating bar should never protrude therear of the lathe spindle.

The maximum length (max. L) the bar feedersystem is allowed to load is given by thelength of the lathe spindle. The bar shouldnever extend more than 3 times its diameterbeyond the lathe clamping device withoutsupport.

LNS disclaim all responsibility for possibleaccidents or property damage caused whensafety instructions are not followed.



5. SAFETY DEVICESThe QUICK LOAD SERVO S3 T bar feed system has been designed with a focus on maximum safetyduring its handling and complies with all EC requirements.

Safety covers and devices make access to the moving parts of the bar feed system impossible. Safetyswitches keep the bar feed system from operating when these protections are open.

By pressing the emergency stop button located on the remote control, the functions of the bar feedsystem and the lathe are immediately stopped.

The LNS company, or its local representative, may not be held responsible for possibleaccidents or property damage, whether caused directly or not, by any means whatsoever,if certain safety devices have not been included.

5.1. Layout

Designation Description

A Main access cover

B Protection grid for magazine table

C Emergency Stop push button (not shown here)

SQ10 Safety switch for main access cover

SQ11 Safety switch for magazine protection grid

SQ12 Safety switch for retraction device (in position switch)

CHAPTER 2: TECHNICAL DATA 2-1


CHAPTER 2:TECHNICAL DATA

2-2 CHAPTER 2: TECHNICAL DATA


1. CHARACTERISTICS

Note : Depending on the country and the standards in effect, certain technical data, such as thepower supply, may vary. Please see the technical card delivered with the device.

Weight 570 Kg

Overall length 2048 mm

Overall width 1486 mm

Magazine depth 1000 mm

Height 1248 - 1748 mm

Centerline range 900 - 1149mm / 1150 - 1400 mm

X and Z axis retraction travel 600 mm

Minimum diameter (round) 6 mm

Maximum diameter (round) 120 mm

Minimum bar stock length 300 mm (*)

Maximum bar stock length 1600 mm (*)

Maximum bar stock weight 67 kg/barstock

Air pressure 5 bar

Maximum air consumption 6 litres (per loading cycle)

Main electrical power (volts) 220 - 480 volts / 50 Hz - 60 Hz

Maximum current rate (amps) 1 A

Pushing force/torque 167 Nm

Maximum feed rate > 100 m/min

Loading cycle for bar stock 8 - 12 secs.

Loading cycle for shaft loading (one shot) 4 - 7 secs.

(*) Depending on the barfeeder, these technical data may vary. Please refer to the Options for QUICKLOAD SERVO S3 T.

2. FLOOR PLANS

The following floor space plans indicate the mostfrequently used dimensions for placing the bar feedsystem. Details on the dimensions of other parts orelements of the bar feed system will be furnished uponrequest.

The plans 2.1. / 2.2. show the QUICK LOAD SERVO S3T bar feed system with left/rear loading (A).

The plans 2.3. / 2.4. show the QUICK LOAD SERVO S3T bar feed system with left/front loading (B).

All dimensions are in millimeters.



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3. LAYOUT OF THE ELEMENTS


A Protection gate

B Loading magazine

C Magazine slope adjustment

D Retraction system

E Electrical control

F Access door

G Air filtering unit

H Interface plug (acc. to OEM requirements) (not shown here)

I Remote control (not shwn here)

J Carrier

K Feeding pusher (not shown here)

L Loading table

M Loading fingers

A

B

D C E

F

G

I

J

M

L

CHAPTER 3: SETTING INTO OPERATION 3-1


CHAPTER 3:SETTING INTO OPERATION

3-2 CHAPTER 3: SETTING INTO OPERATION


1. TRANSPORTATION

Please read the safety precautions described at the beginning of this manual beforehandling the following devices.

1.1. DescriptionDepending on its destination, the QUICK LOAD SERVO S3 T bar feed system may be delivered either ona pallet, or packed in a wooden crate. When sea or air transports it, the second solution is recommended.

Crate PalletWeight 820 Kg 640 KgWidth 1150 mm 1150 mmLength 2750mm 2250 mmHeight 1800 mm According to the centerline height

1.2. UnpackingFor practical and safety reasons, the bar feed system must be unpacked in a spacious, well-lit location.

Check to see that the lifting capacity of the hoisting crane, or lift truck, is adequate beforeproceeding 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 usedfor lifting and transportation.

1) If the bar feed system is received in a crate, startby unscrewing the front panel.

2) Remove the top.

3) Remove the side-walls.

From this point on, the bar feed system is unpacked inthe same way as when delivered on a pallet.



The bar feed system is always delivered as follows :

Magazine (A) is assembled on the bar feed system, but the two support axles (B) are bolted onthe pallet. The outer side of the magazine rests on the pallet.

The retraction mechanism (C) is supplied partly assembled, but is not mounted onto the bar feedsystem.

A feeding pusher is supplied mounted on. The additional pushers, are affixed under the loadingtable (D).

The notice instruction and the accessories are delivered in a separate package (E).

The bar feed system is held on the pallet by bolts and nuts (F).

Take out the parts, and place them in an easily accessible area for mountingthe bar feed system.



1.3. Preparation for mountingFor mounting and installing the bar feed system, it is advisable to contact LNS or one of its agents. Thelatter cannot be held responsible for any malfunction resulting from an incorrect installation in which theydid not take part.

Note: If the eyed screws are not mounted, they should be among the parts in the separate package

Introduce two straps (A) into the lifting screws (B)and hook them to a pulley (C). Lift the pulley tostretch the straps

Remove the bolts (F) (see previous page), whichkeep the bar feed system in place on the pallet fortransportation.

Lift the bar feed system (1) and remove the crate.

Now the bar feed system can also be moved with alift truck (E). In this case, place the arms of the lifttruck underneath the body of the bar feed system.

Move the bar feed system, taking care that itremains horizontal, and that no one is nearby orunder the suspended load.

Do not knock the bar feed system as you move it;this may damage it.

Place the bar feed system behind the lathe, asclose as possible, and in an approximate alignmentwith the spindle. For the placement, the stationaryand mobile space requirements for the lathe andbar feed system should be taken into account.

The distance between the lathe and the bar feed system should not exceed 20 mm.Should an obstacle impose a greater distance, contact LNS or their local representative.

The area around the lathe and bar feed system must be cleared to allow for their maintenance andhandling. It should also remain clear after the installation is completed.



2. MOUNTING

2.1. Mounting loading magazine

If, during the installation, it seems that the table collides with the lathe, it is possible tomove it back. The loading table is mounted towards the front of the unit at the factory, and,except in special cases, it should not be moved.Protection plates must be installed to the front of the table. It is strictly prohibited tooperate the device without the metal protection plates.

Bring the axle for setting the slope near the loading table. Unlock and remove the pins in the settingforks, and then:

Lift the loading table.

Insert the fork located next to the setting lever on one of the eyed support piece of the loading table(preferably centred on the loading table). Insert the pin and secure it with the latch.

Insert the fork located at the other end of the setting axle on the eyed support piece


A Magazine loading table

B Slope adjusting axle

C Adjusting handle

D Eyed support piece on loading table

E Eyed support piece



2.2. Position setup of the tableIf, during the installation, it appears that the magazine table collides with the lathe, or hinders themaintenance of the lathe, the table can be moved backwards.

A Service parameter, indicating the position of the loading table, must be changed. In thiscase, only a LNS or certified technician is allowed to move the magazine loading table.

Procedure:

The axle for setting the slope must be installed after the table has been moved.

1. Lift loading table (A) and measure the distance (X) at which it should be positioned.

2. If need be, remove the metal protection plates (B) and (C).Remove screws (D) of the hinge connecting the loading table to the bar feed system.

3. Move the table the (X) distance previously measured. Mount the hinge with screws (D).

Special protection plates (provided upon request) must be installed to the front of the tableas well as in replacement of protection plates (B) and (C). It is strictly prohibited to operatethe device without the metal protection plates.

Proceed with the installation of the axle for setting the slope, as explained in the previous section.



2.3. Mounting limitersThe magazine of the QUICK LOAD SERVO S3 T bar feed system can simultaneously accept bars ofvarious lengths, from 300 mm to 1600 mm.

The maximum length (max. L.) Thelength of the lathe spindledetermines the length of bar stockthat may be loaded. It is strictlyprohibited to run a bar that extendspast the rear of the lathe spindle.The bar may not extend more thanthree times its diameter beyond thefront of the lathe clamping devicewithout support.

The bars are kept in place by two limiters. The first onestationary (A), is located to the front, and is an integralpart of the loading table. The second one (B), movable,is located on the table and fastened with screws.

Measure the length of the spindle from the rear tothe front face of the clamping device.

Lift the protection grid. Undo the lock screwsholding the rear limiter in place.

Place the limiter at the measured distance(L.max.) by measuring from the front limiter.Tighten the lock screws.

Apply the self-adhesive marker on the loadingtable. This marker will serve, in the future, to setthe position of the limiter without having tomeasure the length of the spindle each time.

This allows the loading pusher to advance at greatspeed up to the rear limiter, and then to slow downto avoid a collision at the time it comes intocontact with the bar. Moreover, if the bar loaded istoo long, the bar feed system notices it when measuring it and stops the loading cycle.

Input the maximum length (L.max.) in the Service parameters. Only LNS or itsrepresentative is allowed to change this value in the parameter.



2.4. Mounting retraction device


Before handling the retraction mechanism, check to see that the interface cables betweenthe spindle and the bar feed system are long enough

The retraction mechanism may be assembled as necessary, to ensure longitudinal or lateral movement.

A Longitudinal retraction for Left/Rear Load

B Lateral retraction for Left/Rear Load

C Longitudinal retraction for Left/Front Load

D Lateral retraction for Left/Front Load


A Guiding rails

B Sliding bearings

C Latches

D Latch handle

E Bracket (for lateral or longitudinal retraction)

F Auto lock device (not shown here)

SQ12 Retraction system in position switch

On delivery, the elements of the retraction mechanism are not assembled on the bar feed system, as theycan be installed either laterally or in line with the lathe.



Installing the retraction mechanism laterally:

1. Bring the rails on their correct side.

2. Put the sliding bearings (D) in front of the opening (E).

3. Push the rails (C) under the unit.

4. Spread the sliding bearings to face the fixing holes.

5. Put the fixing screws (F) in the bearings (D) without tightening.

6. Install the cross girders (G) against the rails (C).

7. Loose the fixing screws (H) and (I) (16 in all) on each anchoring square.

8. Install the four levelling screws (J) to guarantee the parallel of the rails.



9. Tighten the screws (F) of the sliding bearings (D).

10. Slide the plates (K) under the rails, then screw the screws (L) until they rest on the plates.

11. Install the two loading table supports (M). Install the loading table.

12. With screws (J), lift the bar feed system (5 mm between base plate and floor) and level it.

13. Tighten the screws (H) and (I) and the locknuts (N)

14. Install the auto-lock device (O).

15. Introduce the key (Q) located at the front of the rail of the barfeeder in the safety switch, then fix thesafety switch on the retraction device with the screws (R). If the fixing holes of the switch are notperfectly lined up, loosen the screws of the key (S), fix the switch and then the key.

16. Proceed to the alignment as indicated on chapter 3/point 2.5.

When the barfeeder is fixed to the floor, check the alignment of the switch with the key by movingthe barfeeder backward and forward again to its working position.



Installing the retraction mechanism longitudinally:

1. Bring the rails on their correct side.

2. Put the sliding bearings (D) in front of the opening (E).

3. Push the rails (C) under the unit.

4. Spread the sliding bearings to face the fixing holes.

5. Put the fixing screws (F) in the bearings (D) without tightening.

6. Install the cross girders (G) against the rails (C).

7. Loose the fixing screws (H) and (I) (16 in all) on each anchoring square.

8. Install the four levelling screws (J) to guarantee the parallel of the rails.



9. Tighten the screws (F) of the sliding bearings (D).

10. Slide the plates (K) under the rails, then screw the screws (L) until they rest on the plates.

11. Install the two loading table supports (M). Install the loading table.

12. With screws (J), lift the bar feed system (5 mm between base plate and floor) and level it.

13. Tighten the screws (H) and (I) and the locknuts (N)

14. Install the auto-lock device (O).

15. Introduce the key (Q) located at the front of the rail of the barfeeder in the safety switch, then fix thesafety switch on the retraction device with the screws (R). If the fixing holes of the switch are notperfectly lined up, loosen the screws of the key (S), fix the switch and then the key.

16. Proceed to the alignment as indicated on chapter 3/point 2.5.

When the barfeeder is fixed to the floor, check the alignment of the switch with the key by movingthe barfeeder backward and forward again to its working position.



2.5. Adjusting the table height

Remove front cover (A).

Check that the central screw (B) rests on the plate (D).

Carefully loosen the 16 screws (C).

Adjust the height of the bar feed system by tightening or loosening the central screw (B).

A hexagonal tube, delivered with the system, allows access to the adjusting screw from the top,through the loading table.

When the correct height is reached, tighten the screws (C) and proceed with the alignment of thebar feed system.

Remount the plate (A).



2.6. Alignment

Before aligning the bar feed system, check to see that the lathe is stable and, if possible,levelled.

Reminders: The bar feed system should be placed as close as possible to the lathe spindle. To obtain a perfect alignment, it is advisable to install the largest feeding pusher. If a spindle liner is installed, make sure that its I.D. is larger than the O.D. of the feeding pusher. It is not mandatory 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 pushermight touch the inside of the spindle.

Place the level on the loading channel. Adjust the levelwith the screws (A).

Lock the feeding pusher manually, and move it behindthe lathe spindle.

If necessary, adjust the height, see preceding page, untilthe feeding pusher is in the centre of the spindle.

Simultaneously, proceed with the lateral alignment, bymoving the device (with a plastic hammer, for example).

Move feeding pusher forward, checking its entrance intothe spindle. If the feeding pusher deviates, check againwhether the bar feed system is level.

The feeding pusher must be centred at the point of entry(1), as well as behind the collet of the lathe (2), andshould never come into contact with the I.D. of thespindle.

When the alignment is considered satisfactory, lock allscrew nuts.

Remove the eyed screws and install the plastic caps on the main access cover (the plastic caps shouldbe among the parts in the separate package).



2.7. Anchoring to the groundOnce the bar feed system is in place, and perfectly aligned, it should be anchored to the ground to makeit stable. To accomplish this, 4 x 2 anchorage points (A) have been provided.

8 anchorage bolts (B) must be furnished by the client (Minimum M 10 x 100 mm) (Minimum 1/2" x 4").

Once the anchoring bolts are tightened, check the alignment again, and correct it if necessary.



2.8. Security analysis for the correct incorporationBefore 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, including failures and failure modes associated with each task. Risks

can come from:o machine in which the device QUICK LOAD SERVO S3 T is integrated;o its association with other equipment,o People’s interaction with the machine.

Evaluate and assess the risks associated by using the machine QUICK LOAD SERVO S3 T:o programming riskso operation riskso risks of useo maintenance risks

Choose methods of protection :o the use of protective deviceso the introduction of signalso compliance with safe work procedures

3. ELECTRICAL CONNECTIONSSee CHAPTER 4: ELECTRICS, section 4. INTERFACE.

4. PNEUMATICAL CONNECTIONSSee CHAPTER 5: PNEUMATICS, section 2. AIR FILTERING UNIT.

CHAPTER 4: ELECTRICS 4-1


CHAPTER 4:ELECTRICS

4-2 CHAPTER 4: ELECTRICS


1. ELECTRICAL EQUIPMENT

Please read the safety instructions provided at the beginning of this manual beforehandling the following devices.

Particular attention should be given to the handling of electrical elements because of risksof electrocution. In case of possible electrical malfunctions, it is advisable to contact LNSor their local representative.

1.1. DescriptionThis chapter contains all of the elements regarding the electrical circuit of the bar feed system. Theelectrical parts, and groups, which may require a setting, at some time or other, are described herein indetail.

Whenever possible, the article numbers of the elements are shown in tables below each drawing.



1.2. Layout of the electrical elements on the bar feed system

Designation Reference no. Description

A 4.972 Remote control (not shown here)

B - Interface connector depending on lathe (not shown here)

C - Control cabinet

QS1 4.242 Main disconnect switch

M1 4.706 Servo motor

M2 4.830 Motor for diameter adjustment

SQ1 4.484 Loading table in lower position

SQ2 4.484 Loading table in upper position

SQ3 4.473 Measuring cell

SQ4 4.391 Proximity switch for diameter adjustment

SQ5 4.391 Proximity switch for pusher in home position

SQ10 4.763 Main access cover safety switch

SQ11 4.277 Magazine grid cover safety switch

SQ12 4.291/4.292 Retraction system in position switch (incl. key)

C

QS1

SQ12

SQ11SQ10

M1

SQ5SQ3

SQ1 SQ4

SQ2 M2



2. ELECTRICAL CABINET

2.1. Layout of the elements in the electrical cabinet


- - Input – output terminal blocks X1 (YV1 – YV8)

- 6.182 Ethernet switch

- - Safety terminal blocks X3 (T1 – T6)

- 4.917 Programmable controller PCD3 (PLC)

AJ1 4.705 Servo amplifier 400W

FU1 6.107 Diameter adaption motor fuse 2A

K3 4.932 Safety contactor

KS 4.925 Start relay

K8-K9 4.931 Safety control module

K10 4.932 Safety contactor

KA1 4.925 Relay : Motor M2 “Up”

KA2 4.925 Relay : Motor M2 “Down”

QF1 4.815 Circuit breaker 4A

QS1 4.242 Main disconnect switch

R1-R5 4.925 Interface relay (not shown here)

T1 4.769 Transformer 1ph

T2 4.779 24 VDC Power supply 150W

T2

K10

AJ1

T1

QF1

KA1 KA2

K3K9K8QS1

D

FU1

KS

X1 X3



2.2. Description of the elements in the cabinet

2.2.1. Main disconnect switch QS1In accordance with the requirements of the international IEC standards, when the main disconnect switchis at 0off, it interrupts the input of the three phases in the control cabinet of the bar feed system.

2.2.2. Circuit breaker QF1 (4 Amps)Circuit breaker QF1 protects the two phases, which power thetransformer.Should the latter require excessive power (>4 Amps), the breakeractivates and lever (B) flips down.

The power supply to the transformer is immediately interrupted toavoid material damages.

After having located and repaired the problem causing thisinterruption, reset the lever (B) of the circuit breaker.


A Power in connecting terminal

B Lever on/off

C Power out connecting terminal

A

B

C

DD



2.2.3. Transformers 230 V (T1) and 24 VDC (T2)The transformers T1 and T2 power the entire low voltage network of the bar feed system, as well as aportion of the interface signals, (see section 3. INTERFACE in this chapter).

The transformer T1 has an output of 230 Volts which powers the amplifier of the SERVO motor

A fuse installed in a support protects the transformer T1 output.

To replace the fuse:

1. Unscrew the cap a quarter of 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 220 to 480 volts, 50 or 60 Hz. Measure thepower provided by the lathe, and, if necessary, adapt the cable on the power terminal block (A).


A Primary terminal block, 220V-480V / 50hz or 60 Hz ± 15%

B Secondary terminal block, 230 V

C Fuse (3.15 A)

The transformer T2 has an output of 24 VDC and powers the rest of the barfeed.

The transformer T2 output is protected by the fuse FU1 installed in a support in the electrical controlcabinet.

Although fuses seldom need replacing, is it advisable to keep some spare ones on hand.

A

B

C



2.2.4. Servo amplifierBy means of the SERVO amplifier, the programmable controller controls the movements of the motor.

The input values, as well as the position of the pusher carrier, are continuously registered. The values aresaved by means of a battery, and, therefore, the axles do not need to be placed at zero when the barfeed system after powered up.

Although the batteries last for a relatively long time (4-7 years), it is advisable to keep spare ones on hand.When a battery becomes low, the amplifier signals this through a control light. The battery is notrechargeable, and must be replaced right away. The replacement must be done while the bar feedsystem is still powered up.

Procedure :1. Raise cover (I), Pull out plug (D).2. Ease clip to the right and remove the battery. The wires on the extremities of the battery connecting

it to the switch are part of the battery.3. Install the new battery inside the support, connect the plug and close the cover.

Used batteries must be disposed off in an ecologically safe manner.


A 230 V + ground power supply

B Power output to SERVO motor

C Battery (ordering number 4.714)

D Battery plug

E Emergency stop contact

F Encoder connecting plug

G Programmable controller / SERVO amplifier connecting plug

H Alarm and codes display of amplifier

I Cover

D

H

CI

F

A

E

G A

B



2.2.5. Programmable controller (PLC)The programmable controller (PLC) continuously scrutinizes all data from the remote control, probes,switches, cells, interface, etc.

The program loaded into the PLC manages this information. The PLC then distributes the interfacesignals, controls the SERVO drives as well as the pneumatic valves, and displays the appropriatemessages on the remote control station.


A Information module

M1 Slot for software updates

M2 Slot for memory expansion (in use as standard)

Information module:Batt: The PLC does not need a backup battery on the information module.Run: The PLC is in RUN mode. This is the standard mode.Halt: The PLC is in HALT mode. Contact your LNS SA dealer.Error: The PLC is in a failure mode. Contact your LNS SA dealer.

M1 slot:Usually this slot is left unused, and is used for software updates through flash (red) cards. Do not insertany flash card unless instructed by LNS SA.

M2 slot:This slot is used by a flash (blue) card as memory expansion. Do not remove the flash card unlessinstructed by LNS SA.

A



2.2.6. PLC inputs / outputs

Inputs Outputs

Input Des. Description Output Des. Description

I0 K8 Safety relay O32 YV1A Lower loading tableI1 SP1 Air pressure switch O33 YV1B Raise loading tableI2 SQ10 Main cover safety O34 KA1 Motor M2 upI3 SQ11 Loading magazine grid safety O35 KA2 Motor M2 downI4 SQ12 Retraction safety switch O36 SON Servo motor ONI5 - Not in use O37 - Not in useI6 - Not in use O38 YV3 Guiding profiled bar (option)I7 - Not in use O39 - Not in useI8 SQ1 Loading table in lower position O40 YV2 Telescopic pusher (option)I9 SQ2 Loading table in upper position O41 - Not in use

I10 SQ3 Measuring cell O42 - Not in useI11 SQ4 Diameter adjustment O43 - Not in useI12 SQ5 Pusher in home position O44 - Not in useI13 SQ30 Loading magazine empty (option) O45 - Not in useI14 SQ31 Telescopic pusher (option) O46 - Not in useI15 - Not in use O47 KS Start relayI16 - Not in use O48 - Not in useI17 - Not in use O49 - Not in useI18 - Not in use O50 - Not in useI19 - Not in use O51 - Not in useI20 - Not in use O52 - Not in useI21 - Not in use O53 - Not in useI22 - Not in use O54 - Not in useI23 - Not in use O55 - Not in use

Interface Interface

I24 A1 Clamping device signal - - Not in useI25 A2 Lathe in auto cycle - - Not in useI26 A3 Feed order - - Not in useI27 A4 Push order - - Not in useI28 A.. Programmable interface input - - Not in useI29 A.. Programmable interface input - - Not in useI30 A.. Programmable interface input - - Not in useI31 A.. Programmable interface input - - Not in use



3. ELECTRICAL DIAGRAMS



4. INTERFACE

Before connecting, check to make sure that the voltage of the bar feed systemcorresponds to the one provided by the lathe. The voltage of the bar feed system isindicated on the identification plate. Only LNS (or certified) technician is authorized tomodify the interface or parameter system.

4.1. DescriptionThe interface cable(s), between the bar feed system and the lathe is (are) provided by LNS.

Although an example of an interface diagram is provided, the diagram for the interface corresponding toyour device, essential when making the electrical connection, is located inside the electrical cabinet.

When making connections, ensure that the cables are long enough to allow the entire travel of theretraction system (600 mm).

Should the interface instructions not be observed during the setting into operation, thedamaged elements as well as the resulting damages are not covered by warranty.

4.2. Connections

4.2.1. Power supplyVoltage: 3 x 220-480 V, 50 / 60 Hz + Ground (± 10%)Maximum current: 1 A

In the case where the voltage supplied by the lathe does not match that provided for the barfeed, thetransformer T1 must be adapted.

The LNS bar feed systems are equipped with their own thermal protection systems (breakers, thermalrelays and fuses, etc.). The power supply for the bar feed system should be connected to the output of abreaker mounted in the electrical control box of the lathe (10 A max.).

For the wiring inside the lathe, the section of the cables should be at least 1.5 mm2 (AWG 16).

4.2.2. Signals from the lathe to the barfeed systemAlways refer to the electrical diagrams shipped with the bar feed system and placed in the electricalcabinet. Although an example of an interface diagram is provided, the diagram for the interfacecorresponding to your device, essential when making the electrical connection, is located inside theelectrical cabinet.

a) 24 V dc power supplyCorresponds to the +24 V of the bar feed system. This power shall be used to connect the signals fromthe lathe to the PLC.

All signals from the lathe to the PLC shall be powered by the +24 V dc of the bar feed system. All signals from the bar feed system to the lathe shall be powered by the +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-XT9This signal is part of a safety link (Emergency Stop circuit) of the bar feed system. XT8-XT9 correspondsto the Emergency Stop signal of the lathe. If the circuit is open, the bar feed system will go into anEmergency Stop mode.

When the lathe is in an Emergency Stop mode, or if the safety line of the bar feed system is interrupted,an alarm will go off and the R1 relay of the bar feed system will be triggered (see description of the R1relay, below).



c) Lathe clamp signal (PLC input A1)This signal is for checking the mode of the lathe clamping device (open), and is mainly used for thefeeding of a part, which takes place each time the clamp opens.

For safety reasons, wire a normally open contact, coming from the signal of the latheclamp. A clamp open signal must be selected.

d) Lathe in automatic cycle (PLC input A2)This signal indicates that the lathe is in automatic cycle.

e) Load command (PLC input A3)Should the lathe be equipped with a sub-spindle or the lathe is of twin spindle type, should the partrequire multiple feeds, this signal will be used as a load command from the lathe.

For safety reasons, and to prevent collisions between the part being transferred to the second spindleand the newly loaded bar stock when there is a simultaneous loading, the lathe must control the loadingof a new bar.

f) Feeding pusher control (PLC input A4)This signal orders the forward movement of the feeding pusher and the bar, independently of the mode ofthe lathe clamp.

As long as this signal is present, the signal of the foot switch to open and close theclamping device of the lathe must be locked. The lathe should not start up in automaticcycle as long as the clamping device does not grip the bar.

4.2.3. Signals from the bar feeder to the lathe

a) R1 alarm relayWhen the bar feed system is in normal operation, the R1 relay signal is energized. In the event of analarm or break in the emergency stop circuit, this relay is de-energized.

For safety reasons, this signal should bring to a stop all of the axis movements of the lathe as well as therotation of the spindle.

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 latheEither: - Confirmation of the feeding pusher forward commandAnd/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 theloading cycle or the part feed out.

The operational cycle of relay R2 (pulsed, latched, etc.) is controlled by Services parameters.



c) R3 end of bar signal relayWhen the feeding pusher reaches the End of Bar position, relay R3 energizes. This signal is used toindicate to the lathe that there is not enough material left to make another part. The CNC must jump into asub-program to allow the remnant to be dejected.

The operational cycle of relay R3 (pulsed, latched, etc.) is controlled by Services parameters.

d) R4 automatic mode relayThis signal is present as soon as the bar feed system is in automatic cycle (Aut + Start).

e) Emergency stop button of the bar feed system (EM1-EM2)When the Emergency Stop button is pressed, the contact opens. The lathe must be in Emergency Stopmode, and the feeding pusher signal from the lathe must turn off. Two normally closed contacts of theEmergency Stop button are available for connection in the Emergency Stop circuit of the lathe.

4.2.4. OptionsThe options described below are an integral part of the standard equipment of the LNS bar feed systems.

These signals, however, are not required for the proper operation of the devices, or the safety locking forprotecting persons and materials. The options are available only to optimize production conditions.

a) R5 auxiliary end of bar relayThis signal may be used to reduce the length of the remnant in case the remnants exceed the maximumadmissible length for the parts catcher of the lathe or its chip conveyor. Relay R5 energizes as soon asthe feeding pusher reaches the programmed position

b) R6 bar stock magazine empty relayContact of relay R6 (optional). Relay R6 engages after verification of the presence of a bar during theloading cycle of a new bar.

4.2.5. Recapitulation of safety instructions related to the interface

The lathe foot switch for opening the lathe clamping device should not be operational during theautomatic cycle of the lathe.

The lathe pedal should not be operational as long as the feeding pusher feed command signal ispresent.

Whenever possible, it is advisable to interlock lock the manual command for opening the latheclamping device while the feeding pusher command signal is on.

If the lathe is in the Emergency Stop mode, the bar feed system must also be under theEmergency Stop mode, and vice-versa.

If the bar feed system generates an alarm, the lathe must go into alarm mode. The feedingpusher feed command signal must go off, the spindle axis and rotation must stop.

CHAPTER 5: PNEUMATICS 5-1


CHAPTER 5:PNEUMATICS

5-2 CHAPTER 5: PNEUMATICS


1. PNEUMATICAL EQUIPMENT


1.1. DescriptionThe following automatic movements of the bar feed system are done via pneumatic elements, namely: Bar stock loading into the loading table Pusher locking system Loading table moving / down

To guarantee an optimal operation of the bar feed system, a minimum pressure of 5 bars (75 PSI), and amaximum pressure of 6 bars (90 PSI) is mandatory.

1.2. Layout of the pneumatic elements


A 3.636/3.638 Air filtering unit

B 3.407 Cylinder for feeding pusher locking mechanism

C 3.95020.A.30 Cylinder for loading channel up/down motion

D 3.656 Pneumatic valve battery

A

C

B

CD



2. AIR FILTERING UNIT

2.1. DescriptionThe air filtering device serves to filter air and to set its pressure before it is distributed into the pneumaticcircuit of the bar feed system.

The air must be furnished at a maximum pressure of 6 bar, and whenever possible, clean and dry.

2.2. Layout of the elements

2.3. ConnectionThe pneumatic connection (C) is located behind the control cabinet.

For the pneumatic connections of the bar feed system, the customer must provide a hose (B) with aninside diameter of 1/2" (12.7 mm). For USA, 3/8" (9.5mm).

Provide an air hose long enough to allow the complete travel (600 mm) of the retraction system.

When the hose is connected, it should not lie on theground because it could become damaged.

1. Place clamp (A) around hose (B).

2. Insert fitting (C) into hose.

3. Tighten the flange (A) to make it airtight.

2.4. Settings1. Unlock the adjusting knob by pulling it upward.

To increase the pressure, turn it clockwise. To decrease it, turnit in the opposite direction. The operational pressure should beset at 5 bar.

2. When the settings are done, lock the adjuster by pushing itdownward.


A Pressure regulatorB Pressure gauge with pressure switchC InletD Regulated pressure outletE DecanterF Automatic purging

CAB

A

C B

E

D

F



3. PNEUMATIC VALVE

3.1. DescriptionThe pneumatic battery includes the control and monitoring elements of the barfeed system pneumaticcircuit.



A Inlets

B Outlets

C Silencer

3.3. Manual operationDirectly controlled by the PLC, the electro-valves activate the pneumatic cylinders.

By pressing a key (B), the pneumatic cylinders can be activated manually. This manoeuvre may prove tobe useful during tests or maintenance.

When the (B) key is released, the pneumatic cylinder returns to its resting position (except for pneumaticcylinders activated by 2 electro-valves).


A Air outlet

B Manual activation key

3.4. Air pressure switchTo guarantee an optimal work of the bar feed system, the servicepressure must be at least 5 bars (75 Psi). The pressure switch serves toconfirm that this pressure is present and adequate.

The air pressure switch is directly integrated into the pressure gauge.

Set up procedure for the pressure switch: Remove the glass of the pressure gauge With a screwdriver, turn the setting screw Place back the glass

AB

CB A



4. PNEUMATIC DIAGRAMS

4.1. Symbols

Symbol Description Designation

Pressure switch SP1

Pneumatic cylinder 3.301

Air filtering unit 3.305

Electro-valve YV1A / YV1B

4.2. Pneumatic diagram

CHAPTER 6: GENERAL DESCRIPTION 6-1


CHAPTER 6:GENERAL DESCRIPTION

6-2 CHAPTER 6: GENERAL DESCRIPTION


1. BAR MAGAZINE


1.1. DescriptionPlaced to the side of the QUICK LOAD SERVO S3 T bar feed system, the loading magazine, 1,000 mmdeep, can receive bars of various lengths, between 300 mm and 1600 mm.

To facilitate the moving of the bars on the magazine table, the latter is equipped with a grate on which thebars are placed. If, however, certain bars (i.e. profiled bars) cannot slide, the slope can be increased viaan axle located under the table. If, on the other hand, bars with small diameters overlap, then the slopecan or must be reduced.

A protection grid impedes access to the loading table during the automatic cycle. In manual mode, thegrid, mounted onto hinges, can be lifted, and thus allows the operator to conduct the necessarymaintenance operations.

In no case should a rotating bar extend pastthe rear of the lathe spindle. The lathe spindlegives the maximum length the bar feedsystem can load. The bar may not extendmore than three times its diameter beyondthe front of the lathe clamping device withoutsupport. A limiter makes it possible to set themaximum bar length on the table.

When they are on the loading table, stopping fingers laid out on an axle holds the bars. The position ofthe fingers is set automatically when the loading diameter is entered into thebar feed system parameters.





A Magazine table

B Protection grid

C Rear limiter

D Slope inclination adjusting axle

E Fingers for bar selection

F Holding rod

SQ11 Grid closed safety switch



1.3. Limiters

1.3.1. Rear Limiter

The magazine of the QUICK LOAD SERVO S3 T bar feed system can simultaneously accept bars ofvarious lengths, from 300 mm to 1600 mm.

The maximum length (max. L.) of the lathespindle determines the length of bar stockthat may be loaded. It is strictly prohibited torun a bar that extends past the rear of thelathe spindle. The bar may not extend morethan three times its diameter beyond thefront of the lathe clamping device withoutsupport.

The bars are kept in place by two limiters. The first one stationary (A), is located to the front, and is anintegral part of the loading table. The second one (B), movable, is located on the table and fastened withscrews.

1. Measure the length of the spindlefrom the rear to the front face of theclamping device.

2. Lift the protection grid. Undo the lockscrews holding the rear limiter inplace.

3. Place the limiter at the measureddistance (L.max.) by measuring fromthe front limiter. Tighten the lockscrews.

4. Apply the self-adhesive marker onthe loading table. This marker willserve, in the future, to set theposition of the limiter without havingto measure the length of the spindleeach time.

5. This allows the loading pusher toadvance at great speed up to therear limiter, and then to slow down toavoid a collision at the time it comesinto contact with the bar. Moreover, ifthe bar loaded is too long, the barfeed system notices it whenmeasuring it and stops the loadingcycle.

Input the maximum length (L.max.) in the Service parameters. Only LNS or itsrepresentative is allowed to change this value in the parameter.



1.3.2. Loading variable barsAlthough the QUICK LOAD SERVO S3 T bar feed system can load bars of various lengths it is advisableto place them on the loading table in order of decreasing length, and to center them (A) between thelimiters so that they do not go side-ways (B).

1.3.3. Loading constant barsQUICK LOAD SERVO S3 T may also be used as a loading magazine for piston rods, axles, or forgedparts.

A corresponding interface, however, is required if one wishes to attain minimum loadingtimes. These possibilities should be studied beforehand and discussed with themanufacturer of the lathe or the Distribution Company.

When the parts are of the same length, it is possible to move the rear limiter to decrease the loading time.

1. Lift the protection grid.

2. Place a bar on the loading table, leaning against the front limiter.

3. Move the rear limiter to 1 mm behind the bar. Check that the limiter is parallel by rolling the baron the table.

4. Tighten the lock screws.

5. Close the protection grid.

6. A parameter must be changed, see chapter 7 / point 4.2.1

To facilitate the moving of the bars on the magazine table, the latter is equipped with a grate on which thebars are placed. If, however, certain bars (i.e. profiled bars) cannot slide, the slope can be increased viaan axle located under the table. If, on the other hand, bars with small diameters overlap, then the slopecan or must be reduced.

1.3.4. Loading of profiled barsAccording to the profile of the bars to be loaded, some settings and some optional accessories arenecessary. Please contact your LNS agent.



2. LOADING TABLE


2.1. DescriptionWhen positioned on the magazine, the bars rest against the loading fingers (B). The fingers are locatedon an axle (C) connected to the loading table (D). The setting of the fingers is done automatically by theM2 electrical motor at the same time as the setting of the loading table (centerline height).

The loading table of the QUICK LOAD SERVO S3 T bar feed system has two functions:

1. Selection of material:When slide (A) is in a low position, feeding pusher (B) faces spindle (C). The pneumaticcylinders are activated, the channel rises and selects a bar (D) leaning against the stops (E) ofthe loading table.

2. Guiding the material:When in a high position, the loading channel faces the spindle. The bar can then be introducedinto the spindle.

In order for the bar always to be perfectly aligned with the center of the spindle, regardless of its diameter,the height of the loading table is automatically set by a motor (M2) when the diameter of the bar isentered into the parameters (See Chapter 7 / point 4.2.1).



2.2. Loading table calibrationIn order to ensure optimal loading, it is essential that the bar be perfectly aligned with the spindle,regardless of its diameter. Whenever the diameter or the profile is changed, the position of the table isautomatically adjusted according to the diameter and the profile entered in the QUICK LOAD SERVO S3T by the operator.

If, for any reason whatsoever, the position of the table should be incorrect (either too high or too low), itcan be corrected.

The pneumatic cylinders, controlling the vertical movement of the table, release thepressure to allow motor M2 to proceed with the setting. After the setting is complete, theyare reactivated.

Conditions: Bars are on the magazine The loading table is in lower position

1 Select manual mode by pressing the [F2] key.

2 Bring the loading table in upper position [F3].

The bar now faces the spindle of the lathe.

3 The remote command offers icon [F4] + [FWD]. Toobtain the icon [F1] “Adjust the height of the loadingtable”, press and hold the [F3] key until the othericons disappear (3 seconds).

4 The icon [F1] “Adjust the height of the loading table”shows up.

Press the [F1] key.

5 Three icons are displayed :[F1] Lower the table[F2] ESC (exit)

[F4] Raise the table

Each time the [F1] or [F4] key is pressed, the verticalposition of the table is modified by 0.25 mm. Forsubstantial adjustments, keep pressing the key tokeep the table moving in a continuous motion.

6 When the desired position is reached, press the [F3]ENTER key to validate the choice and recalibrate thedevice at this new position.

7 Since the calibration must be changed, the command automatically accesses "Part setup -Material shape, diameter”.

The command asks the operator to confirm the setting of the diameter. Using the keypad, enter thediameter of the bar used to center the table. Press the [F3] ENTER to validate.



2.3. Positioning the roller supportsQUICK LOAD SERVO S3 T is delivered initiallywith 6 roller supports, laid-out to cover the entirelength of the bar magazine.

When limiter (B) is positioned during theinstallation (See point 1.4.1 / Lmax.), move thesupports (A) installed behind the limiter and installthem in the front, to assure better support of thebar.

3. PUSHER CARRIER


3.1. DescriptionBy means of a timing belt, the SERVO motor starts drives the carrier. While the loading pusher isadvancing towards the spindle, the feeding pusher remains stationary. When the carrier returns to itshome position, the feeding pusher is locked, which, at that point, is attached to the carrier.

The locking/unlocking mechanism of the feeding pusher is pneumatically connected to the valves of theloading channel :

1. Loading channel in loading position (upper position)The loading pusher faces the spindle, the feeding pusher is not locked.

2. Loading channel in working position (lower position)The feeding pusher faces the spindle, the feeding pusher is locked onto the carrier.

The length of the feeding pushers is unvarying and does not depend on the length of the spindle. Forsafety reasons, the feeding pushers are equipped with a mechanical stop.

To load tubes, profiled bars or short bars, optional accessories may be installed. Please contact yourlocal LNS representative.





A Carrier

B Loading pusher

C Feeding pusher

D Mechanical stop

E Linear rail

F Notched belt

G Linear unit belt

3.95020.A.30 Locking cylinder

M1 Servo motor

4. LOADING PUSHERContrary to the feeding pusher, the loading pusher (A) does not need to be replaced when the bardiameter changes.

Same-length bars may be loaded directly with a loading pusher without using the feeding pusher. To dothis, a special extended loading pusher, available as an option, is required. Selected parameters mustthen be chosen; see Chapter 7 / point 4.2.7.

3.95020.A.30



5. FEEDING PUSHER

5.1. DescriptionThree feeding pushers are necessary to cover the entire range of the QUICK LOAD SERVO S3 T barfeedsystem. Each pusher has a defined range of operation :

Pusher diameter Ordering Nr Diameter Range

**6,35 mm (1/4") *021.011.022 / 6 6 mm - 15 mm (1/4" - 1/2")

12 mm (1/2") *021.011.062 16 mm - 32 mm (>2/3" - 1 1/4")

25 mm (1") *021.011.022 / 25 33 mm - 120 mm (>1 1/4" - 4,7")

* This ordering number corresponds to the complete pusher, with all of the elements indicated below.When a feeding pusher is ordered for the first time, use this number.

** 2 extra roller supports, intended to bolster the support of bars of small diameter, are furnished withthe 6.35 mm diameter pushers. Their placement on the loading table will be determined by the length ofthe bars to be loaded.


Des.6,35 (1/4") 12 25

Desc.Ordering Nr Ordering Nr Ordering Nr

A -* -* - Pusher rod

B -* -* 914.06.06 Set screw

C -* -* 011.07.444 Head

D 011.07.234 011.007.184 011.07.014 Mechanical stop

E 021.05.244 021.05.164 011.007.194 Guide bushing

A+B+C **021.011.074 **021.011.294 **021.011.304 Pusher Assembly

* On 6.35 mm and 12 mm pushers, parts (A), (B), and (C) are welded.

** This number is used when the bar feed system is already fitted out with elements (D) and (E).



5.3. Pusher Replacement

1. Bring the loading channel into working modeposition (down position), then place the bar feedsystem into the STOP mode (remote station).

2. Loosen the fastening screws (A) sufficiently tofree the groove (C) that holds the pusher (B) inthe connecting piece (D).

3. Slide the pusher forward by making into theguide bushing (E).

4. When the rear of the pusher is sufficientlyloosened to be able to remove it, pull the guidebushing (E) toward the back to dislodge it.

5. The pusher is now free and can be removed.

6. Place the new pusher into the opening, andinsert the guide bushing.

7. Introduce the rear of the pusher into theconnection piece and push to a stop.

8. Tighten the fastening screws so that they lodgeinto the groove of the pusher.

9. Check to see that the mechanical stop sleeve isproperly positioned (see next section)



5.4. Mechanical stopThe feeding pusher of the QUICK LOAD SERVO S3 T bar feed system has a set length, which wasdetermined so that it can function with all types of lathes.

To make sure that they never collide with the clamping device (end of bar improperly adjusted, or inmanual mode, for example), the feeding pusher of the QUICK LOAD SERVO S3 T comes with amechanical safety stop.

When the mechanical stop (stop sleeve) comes into contact with the guide bushing, the feeding pusher isimmediately stopped.

This setting must be done on all feeding pushers when the bar feed system is beinginstalled, and should be modified ( not necessarily) only when the clamping device isreplaced (collet or chuck). In this case, the end of the bar position should also beadjusted.

Procedure:

1. Bring the loading channel into work position (downposition.

2. Open the main access cover.

3. Undo the set screws (A) of the stop sleeve.

4. Close the main access cover.

5. Move the feeding pusher forward to the end of thebar position (see Chapter 7, Handling).


7. Slide the mechanical stop against the guidebushing (B), and then move it back 2 mm (.08").

8. Tighten the set screws. Close the main access cover.



5.5. TubingWith regard to loading the tubing, standard feeding pushers may be used as long as the inside diameterof the tubes is smaller than the outside diameter of the pushers.

If this is not the case, there are two ways to proceed :

1. Making caps (A) and installing thembehind the tubes (B).

For the caps to stay in place while the baris rotating, they should be fitted with anO-Ring. This also prevents contaminatingthe barfeed with the cutting oil from thelathe.

2. Replacing the head of the pusher (C) witha special nose (D), 130 mm in diameter(available for pusher Ø 25 mm only).

Pos. Ordering No. Description

D 021.11.104.130 130mm disk

To feed properly inside the spindle (F),the outside diameter of the disk (D)should be turned to a diameter 4 mm(.015") smaller than that the insidediameter of the spindle (F) or of thespindle liner. The head must be adjustedbefore it is mounted onto the pusher.

Procedure:

1. Switch the bar feed system in STOPmode (remote station).

2. Undo the set screw (E) holding the head(C) onto the pusher.

3. Remove standard head.

4. Install special disk (D), by pushing it to astop in the pusher.

5. Secure disk with the set screw.



6. BELTAfter it has been in use for some time, the bar feed system may indicate, by means of a message on thedisplay, that the tension of the belt (A) should be adjusted.

Should the tension be adjusted, make sure that while adjusting the belt remains undertension in order not to lose the reference point. Should the reference point be lost, enterthe new reference point (Chapter 7 / point 5.2). Same procedure when the belt needsreplacement.

Procedure :

1. Switch the bar feed system to STOP mode (remote station).


3. Use a lever (C) in the opening between the pulleys to take the weight of the motor.

4. Holding the weight of the motor, loosen the fixing screws (B).

5. With the lever (C) push the motor up to tighten the dented belt (A).

6. Holding the belt taut, tighten the fixing screws (B).

7. Remove the lever and close the main access cover.



7. RETRACTION


Before handling the retraction mechanism, check to see that the interface cables betweenthe spindle and the bar feed system are long enough

7.1. DescriptionWhen a lathe is equipped with a bar feed system, 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 tasks, the QUICK LOAD SERVO S3 T is equipped with a retraction system, whichallows the operator to move the bar feeder.



A Z-axis (longitudinal) retraction for Left/Rear Load

B X-axis (lateral) retraction for Left/Rear Load

C Z-axis (longitudinal) retraction for Left/Front Load

D X-axis (lateral) retraction for Left/Front Load





A Guiding rails

B Sliding bearings

C Latches

D Latch handle

E Bracket (for lateral or longitudinal retraction)

F Auto lock device (not shown here)

SQ12 Retraction system in position switch

7.3. Use of the retractionMounted onto four extremely rigid bearings (B), the bar feed system slides on two cylindrical rails (A) thatkeep it aligned when it is in operational position. In this position, the bar feed system is fastened by twosolid hooks (C).

A safety switch (SQ12) impedes any handling as long as the bar feed system is not in operationalposition.

To move the bar feed system, unlock the hooks by lifting the latching handles (D). An autolockdevice (F) will prevent the bar feed system to move back.

To bring the bar feed in operational position, lift the auto lock device.



8. OPTIONS


8.1. Kit for square stockThe use of an adaptor for square stocks is required in orderto orientate the square stock from the 120° V-channel intothe spindle centre.

This kit includes:- Steel angle support 120° to 90°- additional limiter

Depending on the unit configuration, different references areavailable :

Unit version Reference no.

Left / Rear loading rack 021.002.163

Left / Front loading rack 021.002.153

8.2. Kit for One Shot Shaft loadingParts of the same length can be loaded with a specially designed pusher (A).

The loading procedure is simplified, and the loading cycletime can be reduced with specific interface and adaptations.

This kit includes a loading pusher ø12 mm for shaft loading,adjustable to the part length.

Description Reference no.

One shot shaft loading 021.018.012



8.3. Loading of tubes

When bar stocks to be loaded are tubes, anadapter is necessary to create a flat contactsurface between the tube and the pusher.

The adapter must be adapted to the outsidediameter of the tube (by turning the outsidediameter of the adapter), and then be mounted onthe tip of the 25 mm pusher.

Pos. Ordering No. Description

D 021.11.104.130 130mm disk

CHAPTER 7: OPERATION 7-1


CHAPTER 7:OPERATION

7-2 CHAPTER 7: OPERATION


1. POWERING UP


The motor of the QUICK LOAD SERVO S3 T bar feed system is equipped with a built-in absoluteencoder that continuously controls the position of the pusher.

When the bar feed system is powered down or there is a power failure, this position is kept in the memoryby the PLC.

When powering up, the value saved is immediately taken into account, thus avoiding any input from thebeginning. The status parameters saved in the PLC prior to powering down are then checked by the PLCwhich analyses them. The latter then gives the operator access only to those handling operations, whichshould be undertaken.

To power up the bar feed system, turn (1) the switch handle tothe right, to the Ion position.

To power down, turn the switch to the left, to the 0off position.

The main switch can be locked with a padlock. This way, it isimpossible to turn the bar feed system on.

Push (2) the locking mechanism and insert (3) the padlock intothe opening. Lock the padlock.



2. REMOTE CONTROLThe ergonomic and user-friendly remote control with a clear built-in display facilitates the handling of thebar feed system. Depending on the sequence under way, the bar feed system gives access only to thosefunctions which are available, thus avoiding any incorrect handling, and reducing the access time to thenecessary functions.

The display reads, continuously and clearly, the status of the bar feed system and the production,allowing one to verify at all times the functions, diagnostics, error signals, or their analysis. The mostrecent error signals are saved in a register and can be recalled to establish the diagnostics.

The remote control has five distinct segments, namely: display (A), function keys (B), directional keys andnumeric pad (C), modes buttons with STOP, MENU and HELP buttons (D), and the emergency button (E).

A

B

C

E

D



2.1. DisplayThe liquid crystal display with touchscreen function provides the operator with all the necessary data, bothfor handling the bar feed system and for maintenance.

The icons available are the following:

Icon Signification Icon Signification

Referencing position Set a new value

Switch to automatic mode Escape

Stop after machining one bar stock Return to previous menu

Switch to manual mode Jump to next menu

Pusher forward (picture may bereversed)

Move the loading table up + load a new barinto the loading table

Pusher reverse (picture may bereversed)

Move the loading table down

Currentbarfeed

sequence

Current statusor workingmode

Unit system(mm or inch)

Clampingdevice status

Bar diameterand feedoutlength

Information lineon currentaction

Informationscreen on

currentaction or

mode

Currenttorque

applied

Currentfeeding axis

position

Available functions, depending onthe current situation



Switch between normal feed rate andslow feed rate (only in manual mode) foradded positioning accuracy

Automatic Top-Cut positioning in manualmode (picture may be reversed)

Validate Teach data

Cancel Offset correction

Confirm. In setup mode, the buttonmust be hold for 3 seconds tovalidate the change.

Increment data in offset correction mode

Start sequence Decrement data in offset correction mode

Enter the loading table calibration mode Lower the loading table (in calibration mode)

Rise the loading table (in calibrationmode)



2.2. Function keys F1 - F4These keys are located right below the display. The functions attributed to them are indicated on thedisplay by icons.

As the operator advances in the handling, the functions of the keys are automatically reattributed tocorrespond to the circumstance and availability of the bar feed system.

2.3. Left / right / up / down keysThese keys allow entering values (bar stock diameter, part length, etc.) or parameters.

2.4. Emergency stop buttonWhen a dangerous situation arises, pressing the emergency stop switch interrupts immediately all barfeed 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].

2.5. MODE buttons

2.5.1. MENU keyThe MENU key allows access to the main menu, where the parameters concerning the production, theinterface and the general settings of the barfeed can be reviewed and changed.

2.5.2. STOP keyThe STOP key allows interrupting the sequence under way.

Important: the automatic cycle of the lathe must first be interrupted.

By pressing the STOP key, allows to exit the setting mode, regardless of the level reached, and to returnto the work screen.

The STOP key is not an emergency button, and cannot be interpreted as such. Foremergency cases, always use the emergency button located on the top of theremote control.

2.5.3. HELP keyThe HELP key displays useful information about the software version, the firmware of the criticalcomponents, the current status of the inputs and outputs of the system.



3. SET UP


All handling, optional accessories and settings required by the bar feed system to carry out a specific jobare part of the set-up.

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

3.1. Barfeed mechanical setup

3.1.1. Pusher adaptation


Depending on the bar stocks to feed, a changeover of the pusher may be necessary. In this case, pleaserefer to CHAPTER 6, section 5.2. Pusher replacement of this user manual.



3.1.2. Fingers setup

If the slope of the table must be adjusted between the two indicated positions, adjust theslope to accommodate this setting. The main point is that only one bar should be loadedwhen the loading table rises.

Profiled bars1. While screwing the knurled knob (B), the loading fingers (E) tilt. Continue turning until the lower

nuts (H) rest against the block (G), in position 2.

2. Place two bars (D) on the table, against the loading fingers (E).

3. Load manually to check the adjustment.

Round bars1. Adjust the slope of the table to the round bar loading position.

2. Adjust the stops by unscrewing the knurled handle (B) until the top nuts (F) rest against the block(G), in position 1.



3.2. Lathe mechanical setup

3.2.1. Clamping method

Collets

There are different kinds of collets that are more or less effective:

a) Simple cone colletThe bar is held over about 350 degrees, over alength from 0.5 to 7 times the diameter.

Efficiency : good to very good

b) Bi-conical colletClamping over 1 or 2 x 350 degrees, over anapproximate length of 1.2 times the diameter.

Efficiency : very good to excellent

c) Double cone colletThe dou

TABLE OF CONTENTS - LNS North America · 2019. 5. 18. · LNS SA and its subsidiaries cannot be...

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