LNS GT 112-E User manual

Instruction manual ENG
LNS America
4621 East Tech Drive
Cincinnati, Ohio 45245 v02.0 October 2017

TABLE of CONTENTS
i
GT 112-E
TABLE OF CONTENTS
1 BASIC NOTIONS
1.1
STRUCTURES
1-1
1.2
RIGHTS
1-2
1.3
SAFETY INSTRUCTIONS
1-3
2 TECHNICAL DATA
2.1
CHARACTERISTICS
2-1
2.2
CAPACITY(DIAMETER)
2-1
2.3
BAR DIAMETER MEASUREMENT
2-2
2.4
FLOOR PLAN
2-3
2.5
LAYOUT OF THE ELEMENTS
2-5
3 SETTING INTO OPERATION
3.1
TRANSPORTATION
3-1
3.2
POSITIONING OF THE BAR FEEDER
3-3
3.3
MOUNTING
3-5
3.4
CONNECTION
3-7
4 ELECTRICS
4.1
LAYOUT OF THE ELEMENTS
4-1
4.2
ELECTRICAL COMPONENTS
4-2
4.3
SYMBOLS
4-10
4.4
PLC I/O
4-11
4.5
DIAGRAMS
4-12
4.6
INTERFACE
4-16
4.7
SAFETY SWITCHES
4-20
5 PNEUMATICS
5.1
GENERAL DESCRIPTION
5-1
5.2
F.R.L. AIR FILTERING UNIT
5-2
5.3
SOLENOID VALVE MANIFOLD
5-4
5.4
MAINTENANCE
5-6
5.5
PNEUMATIC DIAGRAMS
5-7
6 HYDRAULICS
6.1
GENERAL DESCRIPTION
6-1
6.2
LAYOUT OF THE ELEMENTS
6-1
6.3
DESCRIPTION of THE ELEMENTS
6-2
6.4
MAINTENANCE
6-4

ii
TABLE of CONTENTS
GT 112-E
7 GENERAL DESCRIPTION
7.1
SCREW TYPE LOADING SYSTEM
7-1
7.2
GUIDING SYSTEM
7-2
7.3
PUSHER ASSEMBLY
7-6
7.4
ROTATING SLEEVE
7-8
7.5
COLLET
7-9
7.6
DIAMETER CHANGEOVER
7-10
7.7
BELT
7-12
7.8
VISE (self-centering)
7-13
7.9
BAR MEASURING DEVICE
7-14
7.10
HEADSTOCK SYNCHRONIZATION DEVICE
7-15
7.11
LATHE CONNECTING PARTS
7-16
7.12
RETRACTION SYSTEM (OPTION)
7-17
7.13
BAR PREPARATION
7-18
7.14
SPINDLE REDUCTION TUBES
7-19
8 OPERATION
8.1
REMOTE CONTROL OPERATION
8-1
8.2
POWERING AND EMERGENCY STOP
8-5
8.3
AUTOMATIC/MANUAL SEQUENCE
8-7
8.4
OPERATION PARAMETERS
8-9
8.5
SERVICE PARAMETERS
8-20
9 TROUBLE SHOOTING GUIDE
9.1
WARNING MESSAGES
9-1
9.2
ERROR MESSAGE MAP
9-4
9.3
ERROR MESSAGE DESCRIPTION AND TROUBLE
SHOOTING GUIDE
9-5
9.4
SERVO AMPLIFIER ERROR MESSAGES
9-18
9.5
FACTORS AFFECTING PERFORMANCE
9-33
9.6
MAINTENANCE
9-35
10 APPENDICES
APPENDIX A: PROGRAMMING EXAMPLE
10-1
APPENDIX B: ODERING FORM
10-2
APPENDIX C: ADDRESS LNS
10-3
APPENDIX D: PART PRINTS
A-1

Chapter 1 BASIC NOTIONS
1 - 1
GT 112-E
1 Basic notions
1.1 STRUCTURE
This manual consists of various chapters, each containing several points, paragraphs, etc. Lists
may be contained in paragraphs.
The page number is indicated in the top right-hand corner of the page.
The model of the bar feeder is indicated in the bottom right-hand corner of the page.
Each chapter generally contains all information related to the description and settings of the
devices and elements represented.
Therefore, if a setting must be made while you are handling the system, please refer to the
chapter on the device to be set, for example “see chapter xxx”.
Whenever possible, the part numbers contained in the instruction manual are shown with the
indicated element. The customers can order parts with the number accordingly.
Signs below serve as a tool of reading this manual:
This sign recommends the directions very closely avoiding causing
an incident that could result in injury, damage to the equipment, or
data loss.
This sign indicates that safety measures must be taken to avoid
possible electrical shocks or mishaps.
The notes stress interesting points or comments, and provide useful
advice for optimal system operation.
This sign serves to point out the portion mentioned on the
description.

1 - 2
Chapter 1 BASIC NOTIONS
GT 112-E
1.2 RIGHT
All rights reserved. Reproduction, recording or transmission of all, or any portion, of this manual,
in any form or through any means whatsoever, whether mechanical, photographic, sound or
other multimedia, without the express written authorization of us is prohibited. We disclaim all
responsibility for errors which may be contained in this manual and the problems which may
result therefore.
We are not accountable to any improper operation and any damage, debts due to misuse out of
compass including unauthorized transportation, handling, installation, repair and design change
made by the buyer or a third party. The unit will accordingly not be covered under the warranty.
We cannot take responsibility for any design changes made by clients or a third party. Design
changes refer to the modification of equipment, added or deleted items on bar feeder function
change, quantity change of bar feeder components, material change, setting method change,
and any modification on software designed.
We cannot be held responsible for damage or defect arises from using unauthorized items or
products, clients or a third party to set up, add or modify unapproved component.
The names of the products indicated in this manual are registered trademarks.
The manual is conformed to the specification of unit. We keep development and innovation so
will make the manual update periodically. Design or specification change is subject to change
without prior notice.
The operating life of consumables such as guide channels, rotating sleeves, collets, pushers,
inserts and bushings of front rest, and other accessories depends on the working conditions
(such as rotating speed and temperature). Therefore these consumables are excluded in the
warranty.
Design and specifications are subject to change without prior notice.

Chapter 1 BASIC NOTIONS
1 - 3
GT 112-E
1.3 SAFETY INSTRUCTIONS
Do not handle the equipment without having knowledge of the safety instructions and the
instructions for use. Safety instructions for the bar feeder, as well as the CNC lathe, must
be strictly observed. We disclaim all responsibility for possible accidents or property
damage caused by not following our safety instructions.
Non-qualified personnel, children, and people under the influence of alcohol or medication
should not handle the equipment.
Loose garments, long hair and jewelry can be dangerous.
Do not remove any covers while the bar feeder or the machine is under electrical power.
Do not conduct any maintenance operations during the automatic cycle.
Do not grasp moving or rotating objects, or nearby elements.
If certain safety shields or safety covers are removed to conduct maintenance, they must
be reinstalled as soon as the maintenance work is completed.
No servicing should be carried out on the interface or inside the electrical cabinet while the
bar feeder or the lathe is under electrical power.
It is strictly prohibited to jump wire or remove circuit breakers, main switches, and
especially safety switches.
To avoid any harm to people, or damage to components, use only the indicated points for
lifting and moving the bar feeder system. No one should be near the handing load, or within
the operating range of the overhead hoist/crane, forklift, or any other means used for lifting
and transportation. Do not knock the bar feeder while moving it as this could damage it.
Do not move the bar feeder while it is electrically powered on.
Please use the bar feeder in a clean environment.
Please do not use the bar feeder with extreme heat or in a high humidity environment.
The working area surrounded the bar feeders should always be clear of objects and well lit.
The presence of oil on the ground could cause falls; it is important to maintain the floor
cleaning on a regular basis.
Do not place the machine in a damp area and make sure that water or oil does not come
into contact with the electrical equipment.
Do not open the clamping device (collet or chuck) of the lathe manually when the bar
feeder is in AUTOMATIC mode (interface).
Each time the diameter is changed, also adapt spindle reduction tube. The use of spindle
reduction tubes is highly recommended for machining bars with diameters smaller than the
maximum capacity of the spindle.
There is no battery inside the PLC. Do not attempt to recharge it.
For the use and maintenance of the bar feeder, use only parts provided by or
recommended by LNS.
If it is necessary to move the bar feeder after it has been originally installed, do not reinstall
it before first contacting our representative.
The rotating bar stock should never protrude the rear of the lathe spindle.
We disclaim all responsibility for possible accidents or property damage when safety device
is removed.

1 - 4
Chapter 1 BASIC NOTIONS
GT 112-E

Chapter 2 TECHNICAL DATA
2 - 1
GT 112-E
2 TECHNICAL DATA
2.1 CHARACTERISTICS
Model
2.0M
2.5M
3.2M
12’
4.0M
Channel cover
2 Sections
3 Sections
4 Sections
5 Sections
5 Sections
Bar diameter range
(Ø0.8) Ø1 ~ Ø12.7mm
(Ø0.8mm, the specification may vary depending on application.)
Max. bar length
2060mm
2560mm
3260mm
3736mm
4056mm
Magazine capacity
30pcs / 15pcs
Overall length
2825mm
3380mm
4080mm
4550mm
4870mm
Overall width
432mm
Machine weight
333kg
375kg
414kg
433kg
455kg
Hydraulic oil volume
ISO 100 7.4 gallons (28 liters)
Air pressure
5~7 kgf/cm²
Power supply
208-230V 3p (400-480V power supply is available depending on
application)
2.2 CAPACITY (DIAMETER)
Channel size
Pusher size
Recommended bar range
6
5
(0.8)1 ~ 4
8
7
2~7 [without prep up to 5.5]
11
10
4~10 [without prep up to 8]
14
13
4 ~ 12.7 [without prep up to 11]
Unit: mm
2.2.1 Barstock Straightness Specifications and Performance
For optimum rotational performance speeds, bar stock straightness needs to be .5 mm (.020”)
per meter (3.25’) per side, non-accumulative. Bar stock out of this tolerance will not run at
optimum RPM. Other factors such as material type (brass, copper, bronze and other malleable
materials), clamping efficiency of the machine workholding, and alignment of the bar feed, oil
type, bar preparation and spindle liners will affect optimum RPM capability of the system
GT 112-E is available for loading bar stock diameter from (Ø0.8)
Ø1 ~ Ø12.7mm.
However, for optimum machining performance, the gap between bar
Stock and the guiding channel should be kept below 4mm. The bigger
the gap the more chances of vibrations especially with bent bar stock.
Each guiding channel has a range of 10mm above the bar diameter.
Channel
size

2 - 2
Chapter 2 TECHNICAL DATA
GT 112-E
2.3 BAR DIAMETER MEASUREMENT
a= bar diameter
b≠bar diameter
1
2
3
Pusher collet size = a
Inch/mm Conversion
To convert to millimeters: multiply inches × 25.4
To convert to inches: multiply millimeters X 0.0394
a
b
a = b ×1.41
a
b
a = b ×1.154
a
Channel
size
Pusher collet
size

Chapter 2 TECHNICAL DATA
2 - 3
GT 112-E
2.4 FLOOR PLAN
<LtoRF Bar Feeder>

2 - 4
Chapter 2 TECHNICAL DATA
GT 112-E
<RtoLF Bar Feeder>

Chapter 2 TECHNICAL DATA
2 - 5
GT 112-E
2.5 LAYOUT OF THE ELEMENTS
Designation
Description
A
Pusher (not visible)
B
AC Servo motor
C
Vise( Material clamping device)
D
Remnant detecting sensor
E
Guiding channel
F
Remnant box
G
Remote control (HMI)
H
Cover
I
Top cut measurement device
J
Front stand
K
Rear stand
L
Electrical cabinet
M
Hydraulic pump
N
Hydraulic tank
O
Synchronization device
E
A
H
K
L
N
M
F
O
B
I
J
C, D
G

2 - 6
Chapter 2 TECHNICAL DATA
GT 112-E

Chapter 3 SETTING INTO OPERATION
3 - 1
GT 112-E
3 SETTING INTO OPERATION
3.1 TRANSPORTATION
The bar feeder may be delivered either on a pallet or packed in a wooden crate according to the
customer requirement. The uncrating and lifting instructions recommended below in order to
prevent any injuries to persons and damaged to objects.
3.1.1 Unpacking (wooden crate)
For practical and safety reasons, the bar feeder must be unpacked in a spacious, well-lit location.
1. If the bar feeder is received in a crate, start by unscrewing the top panel.
2. Remove the front.
3. Remove the side-walls.
A pusher and guiding channel set may be mounted in the bar feeder. Depending on the purchase
order, other sets may be delivered in a separate box. The electrical interface diagram is placed
inside the electrical cabinet. Documentation, tools, pusher collets, lathe connecting parts, front
tube/telescopic tube, and other accessories are packed separately.
1
2
3

3 - 2
Chapter 3 SETTING INTO OPERATION
GT 112-E
3.1.2 Preparing and Hoisting
For installing the bar feeder, it’s advisable to contact us or one of our branches offices or one of
your local LNS representatives. We cannot be held responsible for any malfunction or any
damage to the bar feeder or the lathe due an incorrect installation in which we did not take part
in.
< Procedures of preparation >
1.Insert two 25 mm dia. X 1 meter long bars into the holes of the stands, place the hoist vertically
above the bar feeder.
2.Place the straps over the ends of the bars, and then attach them to the hoist. The loading
capacity of both the hoist and straps must be larger than 1 ton (metric).
3.Raise the hoist to tighten the straps.
4.Remove the screws for holding the bar feeder to the pallet for transportation.
5.Carefully lift the bar feeder and remove the pallet. Ensure that the bar feeder remains
balanced.
6.Move the bar feeder towards its final destination behind the lathe making sure that it remains
horizontal, in balance and that no one is nearby or under the suspended load. Do not knock
the bar feeder against hard objects as you move it as it may damage it.
7.Place the bar feeder behind the lathe, as close as possible and in approximate alignment with
the lathe spindle centerline. For the appropriate placement space requirements for the lathe
and the bar feeder should be taken into account.
8.Installation of the stand leveling plates:
(1) Install leveling screws with bolts in the base plate of the front and rear stands
(2) Place the leveling plates (A) under the based plates of the stands so that the leveling
screws are in contact with the leveling plates. Preferably have the leveling plates square
with the edge of the base plates.
(3) Adjust the leveling screws (C) so that the base plates of the stands are at about 30 mm
from ground level trying to maintain and even pressure on each leveling screws.
(4) Do not tighten the lock nuts (B) until final alignment of the bar feeder.
(5) Refer to the next section for proceeding with installation.
A
B
C

Chapter 3 SETTING INTO OPERATION
3 - 3
GT 112-E
3.2 POSITIONING OF THE BAR FEEDER
3.2.1 Bar stock length check
3.2.1.1 Bar feeder installed behind a Fixed Headstock lathe:
Once the bar feeder is roughly positioned behind the lathe measure the distance (L1) from
behind the bar feeder vise jaws to the face of the chuck of the lathe. L1 should not be less that
the maximum bar length the bar feeder is capable of loading (refer to Technical Data). Move the
bar feeder accordingly until this criteria is met.
Front tube length check
The front tube (if provided) should be able to cover the space between the bar feeder and the
spindle. This will prevent the bar to be exposed.
.
Loading flag
Material clamping device
Chuck / collet
L1
Spindle
Joint pipe

3 - 4
Chapter 3 SETTING INTO OPERATION
GT 112-E
3.2.1.2 Bar feeder installed behind a Sliding Headstock (Swiss type) lathe:
Once the bar feeder is roughly positioned behind the lathe measure the distance (L1) from
behind the bar feeder vise jaws and 10 mm behind the guide bushing of the lathe. L1 should not
be less that the maximum bar length the bar feeder is capable of loading (refer to Technical Data).
Move the bar feeder accordingly until this criteria is met.
Note: Please refer to further instructions related to the Telescopic Tube and safety joint pipe
Telescopic Tube length check
Note: Depending on the configuration of the machine, the telescopic tube stroke and other
mechanical interface components may influence the final position of the bar feeder behind the
lathe.
Loading flag
Material clamping device
10mm
Collet
Guide bushing
L1
Max. bar length
L2
L3
Headstock in fully forward position L2
should be no less than 10mm SHORTER
than the telescopic tube maximum extended
length.
Headstock at maximum reverse position L3
should be no less than 10mm LONGER than
the telescopic tube minimum retracted length
(collapsed).
Max. +Z
Max. -Z

Chapter 3 SETTING INTO OPERATION
3 - 5
GT 112-E
3.3 MOUNTING
3.3.1 Leveling
Attention: Prior to leveling and anchoring the bar feeder the lathe must be
leveled
1. Place the leveling pads (A) under each stands.
2. On each leg, loosen the lock nuts (B) of the leveling screws (C). Then, make sure that the
weight of the bar feed system is evenly distributed over the 12 support points.
3. Turn the screws (C) until they evenly touch the pads with an equal pressure on each pad.
4. Using a bubble level indicator level the bar feeder using the adjusting the leveling screws (C).
5. Loosen the lock nuts (D) and make sure that the central screws (E) of the front and rear feet
are supported. Loosen all locking screws (F).
6. Adjusting the central screws (E), set the height of the bar feed system. Normally, when the
reference point is known, this adjustment is approximately set at the factory.
7. Together with the vertical alignment, proceed with the lateral alignment, by shifting the
apparatus. Always maintain even pressure from the leveling screws to each leveling pad.
8. When the alignment is satisfactory, tighten all locking screws (F) and nuts (D). Check the
alignment and, if necessary, make the fine adjustment with the screws (C).
9. Anchor the bar feeder to the floor using anchoring bolts(G) and according to instructions in
the manual (3.3.3.)
10.Prior to securing the bar feeder to the floor it is recommended to check again the bar feeder
alignment. The bar feeder alignment is critical for good performance.
A
D
B
C
E
F
G

3 - 6
Chapter 3 SETTING INTO OPERATION
GT 112-E
3.3.2 Alignment
Important: Before proceeding with the alignment of the bar feed system, ensure that the
lathe is stable and preferably leveled.
The alignment may be carried out using a nylon string, an optical tool or other means. If you do
not have any alignment tools, contact LNS or their local representative. They may have
alignment tools available or recommend a tool or offer the installation by trained personnel.
For precise alignment, use a 1 or 2 mm diameter nylon string which passes through the back of
bar feeder to the lathe chuck. The string must be slightly under tension for precise alignment.
The purpose of this operation is to perfectly align the center of the bar feeder with the centerline
of the lathe spindle.
1. Clamp an alignment bushing into the chuck of the lathe.
2. Install a bushing at the rear of the bar feeder
3. Pull the string from the rear bushing in the bar feeder through the bushing clamped in the
chuck of the lathe.
(Please refer to 3.3.2 for bar feeder leveling)
4. Using an alignment tool (LNS or others) proceed to the alignment of the bar feeder so that
the nylon string is perfectly centered at the back of the lathe spindle and the front of the bar
feeder. Height adjustment are made using the lead screw in each stand,
5. Secure all screws, nuts and other components related to aligning the bar feeder
6. Remove bushings and nylon string

Chapter 3 SETTING INTO OPERATION
3 - 7
GT 112-E
3.3.3 Anchoring to the ground
Once the bar feed system is in place, and perfectly aligned, it should be anchored to the ground
to make it stable and secure. To accomplish this, 8 anchorage points are located in the base of
the front and rear legs. 8 anchoring 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
• Tighten the nuts of the leveling screws.
3.4 CONNECTION
Once the bar feeder has been aligned and anchored to the ground, the bar feeder must be
connected to the interface of the lathe and compressed air need to be connected.
For the electrical connection, please see Chapter 4, Electrics.
For the pneumatic connection, please see Chapter 5, Pneumatics.
For the hydraulic connection, please see Chapter 6, Hydraulics.
For the mechanical connection, please see Chapter 7, General description.
For the parameter setting, please see Chapter 8, Operation.
B