LNS QL Servo 80 S2 User manual

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QUICK LOAD SERVO 80 S2 BARFEED
Service Manual
9.020.02.EN.US

GENERAL
SERVICE MANUAL – QL Servo 80 S2

GENERAL
SERVICE MANUAL – QL Servo 80 S2
IMPORTANT
READ THIS MANUAL CAREFULLY BEFORE USING
AND RETAIN FOR FUTURE REFERENCE.
Published: 07/2020
© LNS America 2020 – 9.020.02.EN (V00.0) – Service manual – Printed in LNS America

GENERAL
SERVICE MANUAL – QL Servo 80 S2
TABLE OF CONTENTS
1. GENERAL .................................................................................................................................6
ABOUT THIS SERVICE MANUAL ............................................................................................6
WHO IS THIS MANUAL FOR?..................................................................................................6
OTHER APPLICABLE DOCUMENTS.......................................................................................6
IN THE CASE OF DAMAGE CAUSED DURING TRANSPORTATION....................................6
SYMBOLS AND WARNING LABELS........................................................................................7
CONVENTIONAL TERMS AND SYMBOLS..............................................................................8
COPYRIGHT..............................................................................................................................8
LIABILITY...................................................................................................................................8
SAFETY INSTRUCTIONS.........................................................................................................9
2. PROCEDURES........................................................................................................................10
SETUP, ALIGNMENT, AND ANCHOR PROCEDURE ...........................................................10
PUSHER CHANGEOVER PROCEDURE...............................................................................14
BELT TENSION ADJUSTMENT..............................................................................................16
HOME POSITION PROXIMITY SWITCH SQ5 ADJUSTMENT..............................................17
DIAMETER ADJUSTMENT MOTOR PROXIMITY SWITCH – SQ4.......................................18
MEASURING CELL ADJUSTMENT – SQ3 ............................................................................19
PUSHER REVERSING DISTANCE ........................................................................................21
REFERENCE PROCEDURE...................................................................................................23
CALIBRATION OF THE LOADING TABLE.............................................................................24
LOCKER ADJUSTMENT.........................................................................................................25
FINDING SOFTWARE/PLC VERSIONS.................................................................................30
SOFTWARE UPDATE.............................................................................................................30
PLC BATTERY REPLACEMENT ............................................................................................31
3. MECHANICAL EQUIPMENT ..................................................................................................32
LOADING MAGAZINE.............................................................................................................32
PUSHER CARRIER.................................................................................................................35
LOADING PUSHER.................................................................................................................36
FEEDING PUSHER.................................................................................................................36
RETRACTION..........................................................................................................................38
SHAFT LOADING KIT (OPTION)............................................................................................39
ADDITIONAL SHAFT LOADING PUSHER (OPTION)............................................................40
FRONT PROTECTION COVER (OPTION).............................................................................41
ORIENTATION KIT FOR SQUARE STOCKS (OPTION)........................................................42
4. ELECTRICAL EQUIPMENT....................................................................................................44
SAFETY COMPONENTS........................................................................................................44
ELECTRICAL CABINET..........................................................................................................45
REMOTE CONTROL...............................................................................................................48
SERVO AMPLIFIER ................................................................................................................51
PROGRAMMABLE LOGIC CONTROLLER............................................................................53
ACCESSORY COMPONENTS ...............................................................................................54
IDENTIFICATION MARKINGS – TYPE OF MATERIAL .........................................................55
CONNECTIONS ......................................................................................................................56
5. SETTINGS...............................................................................................................................60
DESCRIPTION ........................................................................................................................60
ACCESS TO FUNCTIONS......................................................................................................60
END OF BAR POSITION.........................................................................................................70
TOP-CUT POSITION...............................................................................................................72

GENERAL
SERVICE MANUAL – QL Servo 80 S2
REQUEST FOR REFERENCE POINT................................................................................... 74
APPLICATION SETUP ...........................................................................................................75
SETTINGS RELATED TO MACHINED PARTS .....................................................................76
EXAMPLE 1: ROUND BARS..................................................................................................76
EXAMPLE 2: HEXAGONAL BARS......................................................................................... 79
EXAMPLE 3: SQUARE BARS................................................................................................82
PARTS LIBRARY.................................................................................................................... 84
6. MAINTENANCE...................................................................................................................... 90
INSPECTIONS........................................................................................................................ 90
UPDATING THE PROGRAM ON A PLC................................................................................ 91
CLEANING.............................................................................................................................. 98
7. TECHNICAL CHARACTERISTICS........................................................................................ 98
8. DISPOSAL............................................................................................................................ 100
MACHINE..............................................................................................................................100
9. TROUBLESHOOTING.......................................................................................................... 102
ALARMS................................................................................................................................ 102
SEQUENCE LISTING........................................................................................................... 108
MITSUBISHI ALARM LIST MRJ-4........................................................................................110
MITSUBISHI WARNING LIST MRJ-4................................................................................... 114
PLC INPUTS/OUTPUTS.......................................................................................................115
PRODUCT MANUALS.......................................................................................................... 116
AFTER-SALES SERVICE.....................................................................................................118
10. APPENDICES....................................................................................................................... 120
GLOSSARY........................................................................................................................... 120
WIRING DIAGRAM 020-40-620K CE MRJ-4 ......................................................................121
WIRING DIAGRAM 020-40-650B CE DCS MRJ4............................................................... 131
ORDER FORM......................................................................................................................142

GENERAL
SERVICE MANUAL – QL Servo 80 S2

GENERAL
SERVICE MANUAL – QL Servo 80 S2
1. GENERAL
ABOUT THIS SERVICE MANUAL
This service manual describes the maintenance and setting procedures for the bar feeder.
For more information on best practices for installation and use, refer to the instruction manual.
WHO IS THIS MANUAL FOR?
Service technicians:
•Qualified technicians who are authorized to:
- assemble and install the machine
- perform repair and maintenance work
- operate on electrical equipment
- modify certain components of the machine
Manufacturer:
•Qualified technicians who are authorized to:
- assemble and install the machine
- perform repair and maintenance work
- operate on electrical equipment
•Engineers/experts who are authorized to:
- modify the machine software
- modify certain components of the machine
OTHER APPLICABLE DOCUMENTS
The machine contains integrated components from other manufacturers.
In the case of these components, their respective manufacturers have carried out a risk assessment, and have declared that
their design is fully compliant with the European standards in force.
Information regarding the proper use of these integrated components is available in the component instructions and provided
by the various manufacturers.
The feeder complies with the European standards that are specified in the declaration of conformity and integration.
IN THE CASE OF DAMAGE CAUSED DURING TRANSPORTATION
LNS accepts no responsibility in case of deterioration or degradation of the products during their transportation.
LNS will assert a claim for loss or damage to those carriers that have been arranged by LNS. If LNS does not make the
freight arrangements, we are not responsible for the freight issues once the article has been loaded on the truck from our
dock.
If you notice that the product is damaged at the time of delivery. Please take pictures, and contact LNS.

GENERAL
SERVICE MANUAL – QL Servo 80 S2
SYMBOLS AND WARNING LABELS
Warning labels and consequences in case of non-compliance with the safety instructions
DANGER
Type and origin of danger!
Consequences of non-compliance with the warning.
What to do to avoid danger.
Warnings of imminent danger, which, if not avoided, may result in:
serious or fatal injury
WARNING
Type and origin of danger!
Consequences of non-compliance with the warning.
What to do to avoid danger.
Warnings of potential danger, which, if not avoided, may result in:
serious or fatal injury
CAUTION
Type and origin of danger!
Consequences of non-compliance with the warning.
What to do to avoid danger.
Warnings of a potentially dangerous situation, which, if not avoided, may cause:
minor injuries.
NOTICE
Type and origin of danger!
Consequences of non-compliance with the warning.
What to do to avoid danger.
Warnings of a potentially dangerous situation, which, if not avoided, may cause:
Material damage.
INFORMATION
Type and origin of danger!
Consequences of non-compliance with the warning.
What to do to avoid danger.
Information and notes
CAUTION
Type and origin of danger!
Consequences of non-compliance with the warning.
What to do to avoid danger.

GENERAL
SERVICE MANUAL – QL Servo 80 S2
Warnings of a danger, which, if not avoided, may lead to:
damage to the environment
CONVENTIONAL TERMS AND SYMBOLS
The instructions for use of the following conventional terms and symbols:
General risks
Risks of electrocution
Crushing hazard
Harmful to the environment
Material damage
Information, notes
→
Return
1), 2)
Instructions for individual actions consisting of several steps
The diagrams of the plates illustrated in this manual make no distinction between the different models.
Therefore, they apply to all models covered by this service manual.
The service manual uses the following designations to define the position of an element in space (positioning).
The terms "left", "right", "front" and "rear" refer to the direction of use of the machine.
COPYRIGHT
Any reproduction, recording or distribution of all or part of this manual, in any form or by any means, mechanical, photographic,
audio, or other, is strictly prohibited without the express written permission of LNS.
LNS accepts no liability for any errors in this manual and any resulting complications.
The product names indicated in this manual are registered trademarks.
LIABILITY
LNS and its subsidiaries accept no liability for any debts, losses, expenses or damages incurred or suffered by the purchaser
of this product or a third party as a result of an accident, misuse or improper use, or effects arising from unauthorized
modification, repair or alteration by LNS.
LNS and its subsidiaries will not be liable for damages and problems arising from the use of options and products other than
those provided or approved by LNS.

GENERAL
SERVICE MANUAL – QL Servo 80 S2
SAFETY INSTRUCTIONS
NOTICE
The manufacturer accepts no responsibility for damage resulting from non-
compliance with the documentation.
•LNS accepts no responsibility for accidents or material damage resulting from failure to observe the safety instructions.
•Never handle the equipment without taking into account the safety instructions and instructions for use. Safety
instructions for the bar feeder, as well as the CNC lathe, must be strictly observed.
•The equipment must not be used or handled by unskilled personnel, children, or persons under the influence of alcohol
or medication.
•It is recommended not to wear jewelry and loose clothing, and to tie long hair.
•Always uncouple the bar feeder from the machine before removing the covers.
•It is strictly forbidden to remove safety equipment. If necessary, to ensure the smooth running of an adjustment or
maintenance procedure, it must be reinstalled immediately afterwards.
•Never walk on the belt.
•Never put your hands into the moving bar feeder.
•No servicing should be carried out on the interface or inside the electrical cabinet while the bar feeder or the lathe is
powered on.
•It is strictly forbidden to bridge or remove circuit breakers and main switches, especially safety switches.
•To ensure the safety of components and personnel, observe the points indicated for lifting and moving the bar feeder. It
is expressly forbidden to stay near the suspended load or in the operating area of the crane, the forklift truck or any other
lifting and transport equipment.
•Be careful not to hit the bar feeder when it is moving, as this may damage it.
•Never move the bar feeder while it is powered on.
•Always switch off the bar feeder prior to service, maintenance, or repair.
•The work area around the bar feeder must be well lit and clear. It is important to clean the floor on a regular basis, as the
presence of oil can result in falls.
•Do not place the machine in a damp area, and make sure that the water or oil never comes into contact with the
electrical equipment.
•Never try to recharge the batteries of the PLC.
•Always use the parts supplied or recommended by LNS for use/intervention on the bar feeder for maintenance purposes.
•If it is necessary to move the bar feeder after commissioning, always contact LNS or a local representative before
restarting the system.

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
2. PROCEDURES
SETUP, ALIGNMENT, AND ANCHOR PROCEDURE
INFORMATION
The following conditions must be met to complete this procedure:
•Bar feeder power off
•No pneumatic pressure
•Before proceeding with the alignment of the bar feed system, ensure
that the lathe is stable and levelled.
•If obstacles prevent the bar feed from being positioned within 200 mm
of the back of the spindle an extension will be required.
Reminders:
•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 pusher might touch the inside
of the spindle.
1
Position the bar feed as close as possible to the rear of the lathe. The distance between the front
of the bar feed and the back of the spindle should be as small as possible.
Level the bar feed in the x and y axis using a torpedo level. The level can be placed on the linear
belt rail to verify the y-axis and on the retract rails to verify the x-axis. Use the leveling screws (1)
on the retract to adjust unit to level.
1
1

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
2
Check to be sure that center jacking screw is flush with
the base prior to loosening bolts.
3
Carefully loosen the 12 screws located in the slots on
the base of the unit (6 each side). This will allow the unit
to be adjusted up and down.
4
Using the central jackscrew (2), adjust the unit so that the pusher is centered up and down at the
back of the spindle. Make sure that the unit raises or lowers uniformly.
2

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
5
Once the pusher is centered up and down, tighten the 12 screws to secure unit and recheck the
level of the unit.
6
Align the unit side to side by centering the pusher in the
back of the spindle and then extending the
pusher to the back of the collet and centering it
there.
Adjust the rear of the bar feed when centering to the
rear of the spindle and the front of the bar feed
when centering to the rear of the collet.
Once the pusher is centered at the back of the collet
recheck the alignment at the back of the
spindle by pulling the pusher back. Continue
until the pusher is centered at the rear of the
spindle and at the rear of the collet.
Final check by raising the table, and manually push a bar into the spindle. Be sure that the
bar does not bind/scrape in the front or the back of the spindle.

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
7
Once the bar feed has been aligned anchor it using the 4 anchor bolts supplied with the unit.
Don't anchor it at retract rail centers; just let the screws touch the ground. Anchor at
locations (3), but not at (4)
8
After anchoring the unit, recheck the level and the alignment of the unit.
3
3
4

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
9
After the alignment has been rechecked, power will
need to be hooked up to the bar feeder.
Once the power has been hooked up, the bar feed
must be calibrated. Refer to "Calibration of the
Loading Table" procedure.
For final alignment, load a bar into the loading table
and verify that it can be loaded into the spindle
of the lathe without hitting the sides of the
spindle or spindle liner.
Note: If the bar hits side to side the alignment will have to be adjusted.
PUSHER CHANGEOVER PROCEDURE
INFORMATION
The following conditions must be met to complete this procedure:
•Bar feeder switch on
•Loading table in lower position
•Pusher at the mechanical home position
•Bar feed in STOP mode
1
Move table forward
2
Open the main access cover.

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
3
Press the pusher adapter locking/unlocking finger toward the front of the bar feeder, then turn the
finger a ¼ of a turn clockwise. The finger must stay locked in forward position. Pull the
pusher towards the bar feeder front but don't extract it completely out of the carrier.
4
Pull the white bushing on the front guide bearing towards the
rear of the bar feed to extract it.
Remove the pusher completely from bar feed.
5
Disassemble the pusher adapter from the pusher body by pushing out the crossing shaft. Reset
the shaft in the pusher body to avoid losing it.
6
Assemble the pusher adapter on the new pusher body
with the corresponding shaft.

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
7
Put the corresponding white bushing on the pusher. Insert the front end of the pusher through the
front of the bar feed first, then slide the pusher adapter through the carrier so that it is
flush on the right hand side of the carrier.
When the pusher adapter is in place in the carrier, turn the finger ¼ of a turn back (counter-
clockwise). The finger must stay locked in rear position and the pusher must be totally
locked into the carrier. Slide the white bushing into the front guide bearing.
The carrier must be flush on the right side of carrier bushing (1)
8
Slide back the carrier to the home position. Close the
main access cover.
BELT TENSION ADJUSTMENT
INFORMATION
The following conditions must be met to complete this procedure:
•Bar feeder switch on
•Loading table in lower position.
•Pusher at the mechanical home position.
•Bar feed in [STOP]mode.
1

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
1
Open the main access cover.
2
Make sure the carrier is in home position.
3
In the middle of the linear rail, measure the belt vertical displacement from the belt to the rail.
Don't force it ! This displacement must be approx. 20 mm. If necessary, modify the belt
tension with the belt tensioner located at the front of the bar feed.
HOME POSITION PROXIMITY SWITCH SQ5 ADJUSTMENT
INFORMATION
The following conditions must be met to complete this procedure:
•Bar feeder switch on
•Bar feed in [STOP] mode.
•Pusher at the mechanical home position.

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
1
Open the main access cover.
2
Make sure the carrier is in home position.
3
Adjust the SQ5 proximity switch position just far enough to get a strong signal from the switch
(approx. 0,5 mm an no more than .65 mm) (1). Tighten down. Any slight movement
forward of the carrier should deactivate the proximity sensor.
4
Close the main access cover.
Press the [STOP] key on the remote control to clear any alarm.
DIAMETER ADJUSTMENT MOTOR PROXIMITY SWITCH – SQ4
INFORMATION
The following conditions must be met to complete this procedure:
•No bar stock in the magazine
•Loading table in lower position.
•Bar feed in [STOP] mode.
1

PROCEDURES
SERVICE MANUAL – QL Servo 80 S2
1
In the “Part Setup”, enter a bar stock diameter of 6 mm.
Place 2 pieces of 6mm bar stock on the magazine rack.
2
In manual mode, move up the loading table (if the adjustment fingers don't move, run the carrier
flag forward to the end and then back to the home position, drop the table down and then repeat
this step).
3
If the bar is not picked up by the table, the switch is set too high. Set it a little lower and repeat
points 2. In upper position, the bar stock should touch the table stops and the selection fingers.
4
Once the bar stock loads correctly, check that the bar feed does not load 2 bar stocks at once.
Note: the stock must be straight to obtain the ideal adjustment.
MEASURING CELL ADJUSTMENT – SQ3
INFORMATION
The following conditions must be met to complete this procedure:
•No bar stock in the magazine
•Loading table in lower position.
•Bar feed in [STOP] mode.
•Value entered in the "Part Setup", parameter "Bar stock diameter" must
be 6 mm (0.236”)
1
In manual mode, move the table to the upper position
Press the [STOP] key on the remote control.
Retract the far feed for access to the front of the unit.
Open the main access cover.