Index MBL22-8 Series User manual

OPERATING INSTRUCTIONS
Extension of the machine
Bar loading magazine
INDEX
MBL22‑8,
INDEX
MBL24‑6,
INDEX
MBL32‑6,
INDEX
MBL40‑6,
INDEX
MBL40‑8
Multi spindle turning machines
Control system C200‑sl
DIM063EN - 2021-09-27
1021 ec 20058068 Stangenlademagazin INDEXMBL

Note on applicability
Illustrations in this publication may deviate from the product supplied. Errors and omissions due to technical
progress expected.
A word on copyright
This document is protected by copyright and was originally compiled in German.
The duplication and distribution of this document or parts thereof is prohibited without prior consent of
the copyright owner, and any violators will be prosecuted. All rights, including the right to translate, are
reserved.
©Copyright by INDEX-Werke GmbH & Co. KG
Englisch

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CONTENTS
Bar loading magazine MBL22‑8, MBL24‑6, MBL32‑6, MBL40‑6, MBL40‑8
DIM063EN - 2021-09-27
INDEX Multi spindle turning machines Control system C200-sl
Contents
Safety information............................................................................................................................ 9
Preliminary observations ................................................................................................................................. 10
Definitions ......................................................................................................................................................... 11
Environmental conditions ................................................................................................................................... 11
Use according to the regulations and warning notices concerning possible maloperation ................................ 11
Description of the machine ............................................................................................................................ 11
Intended use................................................................................................................................................... 11
Limits of use................................................................................................................................................... 12
Spatial limits .............................................................................................................................................. 12
Time limits................................................................................................................................................. 12
Forseeable non-intended use:........................................................................................................................ 13
Field of use..................................................................................................................................................... 13
User group...................................................................................................................................................... 13
Operator obligations ........................................................................................................................................... 14
Personal safety equipment................................................................................................................................. 14
Personnel qualification ....................................................................................................................................... 14
General safety information .............................................................................................................................. 15
Machining of bar stock ....................................................................................................................................... 15
Chucking pressure and chucking power............................................................................................................. 15
Changing tools.................................................................................................................................................... 15
Safety functions and equipment......................................................................................................................... 16
Work area enclosure and work area door....................................................................................................... 16
Pressure tanks.................................................................................................................................................... 16
Electrical energy ................................................................................................................................................. 16
Operating fluids and additives ............................................................................................................................ 16
IT and data security ............................................................................................................................................ 16
Specific safety instructions.............................................................................................................................. 17
Engineered safety features .............................................................................................................................. 19
Light curtains...................................................................................................................................................... 20
Mobile separating safety installations ................................................................................................................ 20
Safety switches of the channel interlock............................................................................................................ 20
Safety switches for channel aperture monitoring .............................................................................................. 20
Drum stroke........................................................................................................................................................ 20
Emergency-OFF ................................................................................................................................................. 21
Plates.................................................................................................................................................................. 22
Noise emission .................................................................................................................................................. 23
Noise emissions of the bar loading magazine ................................................................................................ 23
Contents ............................................................................................................................................................. 3

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Bar loading magazine MBL22‑8, MBL24‑6, MBL32‑6, MBL40‑6, MBL40‑8
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INDEX Multi spindle turning machines Control system C200-sl
Situational safety information ......................................................................................................................... 24
Transport and packing ........................................................................................................................................ 24
Assembly and installation................................................................................................................................... 24
Commissioning (set-up mode) ........................................................................................................................... 24
Operation (production mode) ............................................................................................................................. 24
Maintenance and repair ...................................................................................................................................... 25
Storage and decommissioning ........................................................................................................................... 25
Disposal.............................................................................................................................................................. 25
Product monitoring ........................................................................................................................................... 25
Declarations of Conformity .............................................................................................................................. 25
Design and Functions ....................................................................................................................... 27
General description........................................................................................................................................... 28
Control of the machine ....................................................................................................................................... 28
Control system INDEX C200-sl...................................................................................................................... 28
Control system INDEX C200-4D.................................................................................................................... 28
Top view ............................................................................................................................................................. 30
Dimensions......................................................................................................................................................... 31
Work stations at the bar loading magazine......................................................................................................... 33
Schematic illustration of the loading magazine functions............................................................................ 34
Technical data.................................................................................................................................... 36
Operating ........................................................................................................................................... 37
Operating elements .......................................................................................................................................... 38
Operating panel at the rear side of the loading magazine .................................................................................. 38
Handheld Terminal Keba KeTop T20................................................................................................................ 39
Front view........................................................................................................................................................... 39
Rear view............................................................................................................................................................ 40
Cleaning the touch screen.................................................................................................................................. 41

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INDEX Multi spindle turning machines Control system C200-sl
Meaning and functions of the softkeys at the manual control unit .................................................................... 42
Basic keys - available in every screen............................................................................................................. 42
Override keys ................................................................................................................................................. 42
Operating sequences - Operation .................................................................................................................. 43
Bundle loader unit .......................................................................................................................................... 44
Rack loader unit.............................................................................................................................................. 45
Spot-drilling unit ............................................................................................................................................. 46
Z axis of the spot-drilling unit ......................................................................................................................... 47
Spot-drilling unit drill ....................................................................................................................................... 47
Bar lift - Bar insertion unit............................................................................................................................... 48
Channel on the left/right, channel lubrication................................................................................................. 49
Slider .............................................................................................................................................................. 50
Gripper unit..................................................................................................................................................... 51
Paging - alarm list/alarm protocol ................................................................................................................... 52
Service functions............................................................................................................................................ 52
Operating philosophy ....................................................................................................................................... 53
From the basic screen to the navigation screen................................................................................................. 53
From the Navigation screens to the Operation screens..................................................................................... 54
Navigation „Basic screen / Information“ ........................................................................................................ 54
Navigation „Part processes“.......................................................................................................................... 55
Navigation „Individual functions“................................................................................................................... 56
Operation mode types and function types..................................................................................................... 57
Operation modes................................................................................................................................................ 57
Automatic mode............................................................................................................................................. 57
Set-up mode................................................................................................................................................... 57
Function types.................................................................................................................................................... 58
Manual............................................................................................................................................................ 58
Cycle............................................................................................................................................................... 58
RESET key at the machine control panel............................................................................................................ 59
Start pre-conditions.......................................................................................................................................... 60
Loading of bars.................................................................................................................................................. 61
Loading the magazine by means of the rack loader unit .................................................................................... 61
Loading bars in case of a magazine with rack loader unit .................................................................................. 64
Loading by means of the bundle loader unit ...................................................................................................... 65
Loading bars in case of a magazine with bundle loading unit ............................................................................ 68
Hoisting belt settings ..................................................................................................................................... 69

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Bar loading magazine MBL22‑8, MBL24‑6, MBL32‑6, MBL40‑6, MBL40‑8
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INDEX Multi spindle turning machines Control system C200-sl
Carrying out operating functions via the control system of the machine................................................... 71
User settings ...................................................................................................................................................... 71
Operate units...................................................................................................................................................... 71
Start bar loading cycle .................................................................................................................................... 72
Clamp / unclamp material............................................................................................................................... 72
Push material bars forward / backward .......................................................................................................... 72
Measure material bar...................................................................................................................................... 72
Manual spot-drilling of bars ............................................................................................................................ 73
Manual bar loading ......................................................................................................................................... 74
By means of this function, ............................................................................................................................ 74
Set‑up ................................................................................................................................................. 75
Spot-drilling unit................................................................................................................................................ 76
Adjustment of the lifting stroke height ............................................................................................................... 76
Drill: cutting data ................................................................................................................................................ 79
Drilling process ................................................................................................................................................... 80
User settings for spot-drilling ............................................................................................................................. 81
Pre-selection counter for spot-drilling................................................................................................................. 82
Drilling tools........................................................................................................................................................ 83
Change drill......................................................................................................................................................... 83
Change of the collet at the gripper unit of the spot-drilling unit ......................................................................... 85
Clamping pressure of the chucking cylinder....................................................................................................... 85
Discharging of the chip container ....................................................................................................................... 86
Spot-drill monitoring ........................................................................................................................................ 87
Mode of operation.............................................................................................................................................. 87
Reactions in case of limit value excess .............................................................................................................. 88
Set-up screen ..................................................................................................................................................... 88
Display elements of the set-up screen............................................................................................................... 89
Additional information......................................................................................................................................... 92
Important notes.................................................................................................................................................. 93
Bar lift ................................................................................................................................................................. 94
Re-adjustment of the holding-down devices at the bar lift ................................................................................ 94
Adjustment of the stoppers to the bar diameter ................................................................................................ 95
Checking the lifting of the bar ........................................................................................................................ 96
Adjust angle of the bar insertion guiding devices............................................................................................... 97
Channels............................................................................................................................................................. 98
Opening the channels......................................................................................................................................... 98
Closing the channels .......................................................................................................................................... 100
Refitting the material diameter........................................................................................................................... 101
Slider................................................................................................................................................................... 103
User settings for the slider ................................................................................................................................. 104

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INDEX Multi spindle turning machines Control system C200-sl
Dismantling of the slider..................................................................................................................................... 105
Mounting of the slider ........................................................................................................................................ 106
Exchange of slider-slaving bush ......................................................................................................................... 107
Refitting the slider .............................................................................................................................................. 108
Gripper unit......................................................................................................................................................... 109
Arresting the slider ............................................................................................................................................. 110
Slipping the bar over the slider ........................................................................................................................... 111
Pulling-off the remnant....................................................................................................................................... 112
Programming..................................................................................................................................... 113
Programming..................................................................................................................................................... 114
Assignments and machine data ......................................................................................................................... 114
M-commands - principle of the cycle................................................................................................................. 114
Programming example: for "Push material bar forward"..................................................................................... 114
Programming example for Push material bar forward until the bar strikes against the stop .............................. 115
Sub-programme MA12.MPF – without stop check........................................................................................ 116
Sub-programme MA12.MPF – with stop check ............................................................................................. 117
Transport, Installation, Commissioning......................................................................................... 119
Safety Instructions ............................................................................................................................................ 120
Instructions for shipment, installation, commissioning ...................................................................................... 120
General sources of danger during in-house transportation ............................................................................ 120
Dimensions and masses ................................................................................................................................ 120
Shipping- and lifting equipment...................................................................................................................... 120
Preparations....................................................................................................................................................... 121
Suitable transport- and lifting equipment ........................................................................................................... 121
Space requirements ........................................................................................................................................... 122
Foundations........................................................................................................................................................ 122
Environmental Conditions................................................................................................................................... 122
Power supply...................................................................................................................................................... 123
Compressed Air Supply...................................................................................................................................... 123
Pressure accumulator ......................................................................................................................................... 123
Media to be provided.......................................................................................................................................... 123
Pumps and Tanks ............................................................................................................................................... 124
Chip disposal / remnant disposal ........................................................................................................................ 124
Disposal of used media ...................................................................................................................................... 124
Compliance with water balance regulations....................................................................................................... 124
Delivery ............................................................................................................................................................. 125
Magazine ........................................................................................................................................................ 125
Other separate units....................................................................................................................................... 125
Transportation equipment .............................................................................................................................. 126

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Bar loading magazine MBL22‑8, MBL24‑6, MBL32‑6, MBL40‑6, MBL40‑8
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INDEX Multi spindle turning machines Control system C200-sl
Transport by crane ............................................................................................................................................ 127
Unloading the Magazine by means of a Crane or a Mobile Crane...................................................................... 129
Lowering the Magazine in the Place of Installation ............................................................................................ 130
Transport by means of Castor Trolleys ............................................................................................................... 131
Unloading and Transport of Separate Units........................................................................................................ 132
Unpacking the Accessories and checking them for Completeness ................................................................... 132
Installation of the magazine ............................................................................................................................. 133
Alignment of the bar loading magazine.......................................................................................................... 134
Entry of correction value between machine and loading magazine ................................................................... 134
Securing means for the transport ................................................................................................................... 135
Commissioning.................................................................................................................................................. 136
Cleaning the Magazine ....................................................................................................................................... 136
Checking supplies and restocking ...................................................................................................................... 136
Pressure accumulator ........................................................................................................................................ 136
Water cooling system......................................................................................................................................... 137
Functioning..................................................................................................................................................... 137
Electrical connection ......................................................................................................................................... 138
Switching-ON the Magazine .............................................................................................................................. 138
Preparation for repeated transport ................................................................................................................. 139
Lashing the magazine on the truck..................................................................................................................... 139
Annex ................................................................................................................................................. 141
Interchange parts .............................................................................................................................................. 142
Interchange parts for magazines MBL40-6 / MBL40-8 ..................................................................................... 142
Interchange parts for magazines MBL32-6 with spot-drilling unit ..................................................................... 143
Interchange parts for magazine MBL32-6 without spot-drilling unit .................................................................. 144
Interchange parts for magazine MBL24-6 / MBL22-8 with spot-drilling unit..................................................... 145
Interchange parts for magazine MBL22-8 without spot-drilling unit .................................................................. 146
Interchange parts for magazine MS24-6 without spot-drilling unit .................................................................... 147
Index ................................................................................................................................................... 149

Safety information

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INDEX Multi spindle turning machines Control system C200-sl
SAFETY INFORMATION
Preliminary observations
Preliminary observations
• In section "Safety instructions", we have described the information which is
required for safe operation of the INDEX MBL bar loading magazine.
• In addition, you must carefully read the document "Safety instructions for CNC
turning machines" which is pertaining to the turning machine and observe
all the instructions given there. In said document you will find further safety
instructions which are also valid for the INDEX MBL bar loading magazine
although they are not mentioned in the present document.
• In case you are not in possession of the document "Safety instructions for CNC
turning machines", you may order same from INDEX.

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Bar loading magazine MBL22‑8, MBL24‑6, MBL32‑6, MBL40‑6, MBL40‑8
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INDEX Multi spindle turning machines Control system C200-sl
SAFETY INFORMATION
Definitions
Definitions
Environmental conditions
Refer to document "Safety instructions for CNC turning machines", please.
Use according to the regulations and warning notices
concerning possible maloperation
Description of the machine
Machine: Bar loading magazine for multi-spindle turning machine
Machine type series: INDEX MBL22-8, MBL32-6, MBL40-6, MBL 40-8
Intended use
• Stockpiling and supply of bar material
• Loading of a multi-spindle turning machine
• Guidance of bar material
• Feed of bar material
• Disposal of remnants
• Spot-drilling of bar material
Use only after attachment and alignment at an INDEX MS22-8, MS32-6, MS40,
MS40-8 multi-spindle turning machine
Related documentation
• Operating instructions / Alignment instructions / Instructions for transportation

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SAFETY INFORMATION
Definitions
Limits of use
MBL22‑8 MBL24‑6 MBL32‑6 MBL40‑6
MBL40‑8
Minimum bar diameter D7 D7 D7 D13
Maximum bar diameter D22 / D24 D24 D32 D40
Bar length in case of
type 3300 (mm)
1500...3300 1500...3300 1500...3300 1500...3300
Bar length in case of
type 4300 (mm)
2000...4300 2000...4300 2000...4300 2000...4300
Maximum speed (1/min) 10 000 10 000 8 000 7000
depending on the nature of the bar material
Non-combustible metal bars
The bars must exhibit balanced mass.
Related documentation
• Document "Demands on material bars"
• Technical data
Spatial limits
Overall dimension of the loading magazine after assembly + 800 mm in all direc-
tions.
Related documentation
• Machine assembly plan
Time limits
Useful life: 10 years in three shift operation
Those parts subject to high stress exhibit a useful life of 20.000 hours.
Parts subject to wear and tear must be exchanged according to the maintenance
plan.
Related documentation:
• Maintenance plan INDEX MBL

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INDEX Multi spindle turning machines Control system C200-sl
SAFETY INFORMATION
Definitions
Forseeable non‑intended use:
• use at other than the indicated machines
• use of too small or too large bar diameters
• use of too short or too long bars
• use of other than the indicated materials
• excessive loading
• use of wrong accessory parts
• use / operation / maintenance by more than one person (exception: loading of
the rack loader unit)
• use without attachment respectively alignment at the multi-spindle turning
machine MS40
• use without lubrication of the guidance channels
• use without carrying through the necessary adjustment work (refitting)
• use of inappropriate bar material (with respect to straightness, eccentricity)
Related documentation:
• Operating instructions
Field of use
Only intended for Industrial use. The indicated technical data and limits must be
observed.
Like in case of the multi-spindle machine, basically, only one person may work at
the bar loading magazine. In an exceptional case, the operator must designate a
responsible.
User group
Expert staff: Transport, assembly, initial operation, loading, operation, set-up,
maintenance, dismantling
Qualification: Expert staff (e.g. master craftsman, set-up man, industrial me-
chanic): instruction / training required.
Semi‑skilled staff: operation, loading
Qualification: auxiliary force with operator training

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SAFETY INFORMATION
Definitions
Operator obligations
Refer to document "Safety instructions for CNC turning machines", please.
Personal safety equipment
Refer to document "Safety instructions for CNC turning machines", please.
Personnel qualification
Refer to document "Safety instructions for CNC turning machines", please.

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Bar loading magazine MBL22‑8, MBL24‑6, MBL32‑6, MBL40‑6, MBL40‑8
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INDEX Multi spindle turning machines Control system C200-sl
SAFETY INFORMATION
General safety information
General safety information
Machining of bar stock
Since the INDEX MBL bar loading magazine uses material bars, the following is
valid as a matter of principle:
• The spindle guidance channel must be adapted at the diameter and profile of
the bar stock (by means of half bearings, reducing tubes).
• The "Demands on material bars" apply (Document LY1002.10211).
Chucking pressure and chucking power
Refer to document "Safety instructions for CNC turning machines", please.
Changing tools
When tools are changed, there is a risk of injury from protruding and sharp-edged
tools.
In general:
• Tool holders must be moved to an ergonomically convenient position.
• Suitable protective measures must be taken (e.g., cloth or protective sleeves)
for protruding tools (e.g., boring bars).
• Suitable tools must be used.
• The required torque must be observed. The respective specifications can be
found in the tool holder catalogue.
Spot-drilling unit

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SAFETY INFORMATION
General safety information
Safety functions and equipment
Refer to document "Safety instructions for CNC turning machines", please.
Work area enclosure and work area door
Refer to document "Safety instructions for CNC turning machines", please.
Pressure tanks
Refer to document "Safety instructions for CNC turning machines", please.
Electrical energy
Refer to document "Safety instructions for CNC turning machines", please.
Operating fluids and additives
Refer to document "Safety instructions for CNC turning machines", please.
Inadmissible emissions (of gases, powders, oil mists) may happen at the spot-drill-
ing unit. For this reason, the spot-drilling unit must be connected to the exhaust
equipment of the machine.
In so doing, you must use the connecting element for the defined interface of the
exhaust equipment.
IT and data security
Refer to document "Safety instructions for CNC turning machines", please.
Spot-drilling unit

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Bar loading magazine MBL22‑8, MBL24‑6, MBL32‑6, MBL40‑6, MBL40‑8
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INDEX Multi spindle turning machines Control system C200-sl
SAFETY INFORMATION
Specific safety instructions
Specific safety instructions
As a matter of principle, you must wear and use your personal safety equip‑
ment.
The following specific dangers may occur at the spot-drilling unit:
• In case you use the confirmation key: Motions of the spot-drilling unit respec-
tively of the lifting unit. In such case you are in danger of being crushed. The
danger zones within the area of the Z axis traverse path as well as the area
between cylinder and stopper of the lifting unit must be vacant.
• Only qualified staff and especially trained personnel may make use of the con-
firmation key.
• Before light curtain reset at the bundle respectively rack loader unit, you must
check, whether the danger zone is vacant.
• Bundle loader unit: Caution when handling the bar bundle. Especially when you
undo the cording, some of the bars may suddenly get out of place.
• In case of the rack loader respectively bundle loader unit, there is the danger
of bars falling down. Before lowering the hoisting slings at the bundle loader
unit, you may, if necessary, at first have to pull bars present at the stopper of
the separating device back into the slings. Only thereafter, you may lower the
slings.
• Before loading bars into the supply area, the hoisting sling must be lowered
completely.
• In case of the rack loader unit, you must heed that the stoppers at the conveyor
chains must be adjusted to the respective bar diameter.
• Danger may also be caused by remnants falling down into the remnant container.
The danger zone is covered by the container. However, as soon as you remove
the container, one can access the danger zone. Therefore, remnant container
discharge must not happen simultaneously with bar change.
• On the loading side there is the danger of being crushed between the bars.
• In case of the rack loader unit, the bar ought to be deposited on the supply
area. Thereafter, from there, the bar rolls over the incline into the direction of
the conveyor chains.
Don't get your fingers in between the bars.
• In case of the bundle loader unit, the bars of the bundle may get out of place.
Therefore, special caution is advised, especially when cutting open the cording
or when removing the hoisting equipment.
• At the spot-drilling unit, there is the danger of being cut by chips or by sharp
tool edges.
• The weight of the chip respectively remnant container may exceed the lim-
its stipulated in the regulations concerning lifting and load. You must set the
respective counter in the control unit in such a way that the weight does not
exceed the admissible limits. After reaching the pre-set number of bore holes
respectively bar changes, an order "Discharge container" will appear.
• In case of the rack loader unit, you may have to call in a second person for the
lifting of the bars.

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SAFETY INFORMATION
Specific safety instructions
• Part of the pneumatic or hydraulic circuit may still be under pressure after
switching the bar loading magazine OFF. This applies especially for connections
between non-return valves and actors.
Before de-airing, the respective unit must be moved into a safe home position
or must be secured against unintended movements.
This applies especially for the cylinders of the lift and for the swivelling move-
ments of the gripper unit.
• The electric motors may be getting very hot during operation. Therefore, there
is danger of being burnt at the crank casing.
• At the channel interlock, levers have been preloaded by means of torsion
springs. Such levers may only be moved via the respective movement com-
mand from the control unit. With manual unlocking, there is the danger that the
levers abruptly swivel back into their "locked" position.
• The top parts of the guidance channels may be tilted up. Such tilting-up must
always happen via the respective movement command from the control unit.
Thereby, the channel is being opened respectively closed by means of a lever
and retained in its position.
When opening the channel in another way than the above mentioned, there
is the danger of getting crushed between the fix and the movable part of the
guidance channel.
• The shifting of the drum may only be carried out by qualified INDEX staff!
Before shifting, the drum must be secured against torsions. Special caution is
advised when shifting the drum. There is the danger of being crushed between
drum and base frame.
• The connection point between the bar loading magazine and turning machine
must be secured by an appropriate hood system. The correct installation of said
hood system must be guaranteed.
Without such hoods, there is the danger of being drawn-in and cut by rotating
machine parts.
Please also observe the general and situational safety instructions as well
as the intended use of the bar loading magazine.
The necessary set‑up work is described in chapter "Set‑up". No other set‑
ups or modifications than those mentioned in the "Set‑up" chapter must be
carried out at the bar loading magazine.
Specifications concerning media supply have been set out in "Technical
Data" and must imperatively be observed.
In spite of all safety precautions, there still is a remaining risk e.g. due to
pressures existing in the pneumatic respectively hydraulic circuit or due to
bars or remnants falling down.
Therefore, special caution is advised, especially when carrying out mainte‑
nance or repair work.

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SAFETY INFORMATION
Engineered safety features
Engineered safety features
The bar loading magazine is safeguarded by means of different safety compo-
nents.
②②②②
③
③
④
①
②
①
①②
④

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SAFETY INFORMATION
Specific safety instructions
Light curtains
The light curtain at the bundle respectively rack loader unit impedes move-
ments within the reach of the lifting and the spot-drilling unit subsequent to
interruption of the light curtain. The collet chuck of the spot-drilling unit can
carry out a rapid retracting motion. The motions for bar guidance and bar feed
can continue so that continued production is guaranteed.
Mobile separating safety installations
These installations impede the access of the operator during ongoing mo-
tions. The mobile separating safety installations are equipped with a bolt
keeper for the safeguarding of running-out movements.
Safety switches of the channel interlock
These safety switches serve the enquiry of the channel interlock. Before
drum indexing or spindle rotation release, the channels must be locked.
Safety switches for channel aperture monitoring
These safety switches serve the monitoring of the channel aperture. Before
drum indexing or spindle rotation release, the channels must be locked.
Drum stroke
For service purposes, the drum may be pushed backward. The linked position
of the spindle is being enquired. If said position was not reached, any move-
ments at the bar loading magazine will be impeded.
①
②
③
④