LNS Quick Load Servo 65 Programming manual

Troubleshooting
manual
ENG
9.020.01.ANG

E1
12.11.2006
Table of Contents
Chapter 1:........................................................................................1-1
Alarms................................................................................................................................1-1
Switches and cells list..................................................................................................................1-2
A01 – Emergency stop line open ................................................................................................1-3
A02 – Main access cover open....................................................................................................1-4
A03 – Magazine protection grid open.........................................................................................1-5
A04 – Bar feeder retracted or not locked in its working position.............................................1-6
A11 – Measuring cell SQ3 signal defective ................................................................................1-7
A12 – Home position proximity switch SQ5 signal missing.....................................................1-8
A15 – Safety time for loading channel up and down motion elapsed......................................1-9
A16 – Safety time for diameter adjustment elapsed................................................................1-10
A21 – Measuring cell SQ3 activated too early..........................................................................1-11
A22 – Signal A2 "lathe in automatic mode" interrupted during loading cycle......................1-12
A23 – Safety time for loading profiled bar elapsed..................................................................1-13
A24 – Safety time for top-cut positioning elapsed ..................................................................1-14
A25 – Lathe did not resume its production cycle....................................................................1-15
A26 – Clamping device closed prior to completing the feed out............................................1-16
A27 – Clamping device opened during production cycle without lathe auto mode.............1-17
A28 – Parts counting parity error by M-code quantity and automatic part counting ...........1-18
A30 – Bar stock loading error....................................................................................................1-19
A41 – Servo amplifier / PLC communication fault...................................................................1-20
A42 – Servo drive alarm @@.....................................................................................................1-21
A43 – Amplifier battery low........................................................................................................1-22
A44 – Servo motor not ready.....................................................................................................1-23
A45 – Servo motor positioning error during sequence @@...................................................1-24
A50 – Servo amplifier firmware not compatible with PLC.......................................................1-25
Bar Feeder Software Sequence of Events................................................................................1-26
Mitsubishi Servo Amplifier Alarm List......................................................................................1-27
Chapter 2:........................................................................................2-1
Common Issues ................................................................................................................2-1
Vibrations......................................................................................................................................2-2
Servo Motor Following Error During Sequence 9......................................................................2-3
Part feed out accuracy.................................................................................................................2-4
Chapter 3:........................................................................................3-1
Procedures ........................................................................................................................3-1
Alignment Procedure ...................................................................................................................3-2
Pusher Changeover Procedure...................................................................................................3-6
Belt Tension Adjustment .............................................................................................................3-9
Home Position Proximity Switch SQ5 Adjustment.................................................................. 3-10
Diameter Adjustment Motor Proximity Switch – SQ4..............................................................3-11
Measuring Cell Adjustment – SQ3 ............................................................................................3-12
Pusher Reversing Distance.......................................................................................................3-14
Reference Procedure..................................................................................................................3-15
Calibration of the Loading Table...............................................................................................3-17
Chapter 4:........................................................................................4-1
Software.............................................................................................................................4-1
Software / PLC Versions..............................................................................................................4-2
Software Update ...........................................................................................................................4-3
Battery Replacement....................................................................................................................4-5
QUICK LOAD SERVO 65/80

Chapter 5: .......................................................................................5-1
Maintenance......................................................................................................................5-1
Monthly Maintenance ...................................................................................................................5-2
Annual Maintenance.....................................................................................................................5-2
Chapter 6: .......................................................................................6-1
Spare Parts........................................................................................................................6-1
Recommended Spare Parts List..................................................................................................6-2
Mechanical Assemblies................................................................................................................6-3
Base.............................................................................................................................................6-11
Crossing Slide.............................................................................................................................6-20
Loading Mechanism ...................................................................................................................6-23
Protections..................................................................................................................................6-33
Foot..............................................................................................................................................6-35
Loading Magazine.......................................................................................................................6-37
Retraction....................................................................................................................................6-42
Pusher..........................................................................................................................................6-45
Accessories & Options...............................................................................................................6-51
Floor Plans ..................................................................................................................................6-53
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-1
Chapter 1:
Alarms
An error has occurred during setup or cycling of the bar feeder. When an error occurs, an alarm message
is generated on the remote control station. Also provided are some possible causes as to why the error
has occurred.
This chapter:
•discusses every alarm that the bar feed may generate,
•explains the possible causes,
•suggests a few tips and procedures of how to correct the problem.

CHAPTER 1: ALARMS1-2
Switches and cells list
S
Q
5
M1
S
Q
10
M3
S
Q
4
S
Q
1
A
S
Q
11
S
Q
12
S
Q
3
B
M2
Designation Part No. Description
A 4.869 Remote control station
B - Electrical cabinet (not shown here)
M 1 4.706 Servo motor
M 2 4.839 Loading table motor
M 3 4.838 Diameter selection fingers motor
QS 1 4.242 Main disconnect switch
SQ 1 4.391 Proximity switch, loading table in lower position
SQ 3 4.474 Positioning optical cell
SQ 4 4.391 Proximity switch, diameter selection fingers in origin position
SQ 5 4.391 Pusher in home position switch
SQ 10 4.763 Cover closed safety switch
SQ 11 4.763 Magazine cover closed safety switch
SQ 12 4.763 Retraction system safety switch
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-3
A01 – Emergency stop line open
EMERGENCY STOP
LINE OPEN!
POSSIBLE CAUSES:
-CONNECTION
-PROBLEM IN
CIRCUITRY A01
Description:
The « emergency stop line open » alarm occurs whenever the lathe or the bar feeder goes into an
emergency stop condition and does not receive signal (I16). The problem is generated anytime there is
an open in the safety circuit.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 K1 = 0
•Check the emergency buttons state on the bar feeder and the lathe.
•Check the PLC connection.
•Check the wiring according to the electrical diagram.
•Press the STOP button on the remote control to reset the alarm.
2 K1 = 1 Press the STOP button on the remote control to reset the alarm.

CHAPTER 1: ALARMS1-4
A02 – Main access cover open
MAIN ACCESS COVER
OPEN!
CLOSE MAIN COVER TO
RESUME OPERATIONS
A02
S
Q
10
Description:
The « main access cover open » occurs whenever the PLC does not detect input (I17 – SQ10). The
problem is generated when the main access cover on the bar feeder is open, exposing automated
mechanical parts.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 SQ10 = 0 •Close the cover.
•Check the SQ10 switch is adjusted correctly.
2 SQ10 = 1 Press the STOP button on the remote control to reset the alarm.
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-5
A03 – Magazine protection grid open
SQ11
MAGAZINE PROTECTION
GRID OPEN!
CLOSE GRID TO RESUME
OPERATIONS
A03
Description:
The « magazine protection grid open » occurs whenever the PLC does not detect input (I18 – SQ11). The
problem is generated when the protection grid on the bar feeder is open, or if the switch is defective.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 SQ11 = 0 •Close the protection grid.
•Check that the SQ11 switch is adjusted correctly.
2 SQ11 = 1 Press the STOP button on the remote control to reset the alarm.

CHAPTER 1: ALARMS1-6
A04 – Bar feeder retracted or not locked in its working position
BAR FEEDER
RETRACTED OR
NOT LOCKED IN ITS
WORKING POSITION!
A04
SQ12
Description:
The « bar feeder retracted or not locked in its working position » alarm occurs whenever the PLC does
not detect input (I19 – SQ12). The problem is generated when the bar feeder is retracted in reduction
tube change position or if the retraction system is not locked.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 SQ12 = 0 Set the bar feeder back in operating position and lock it.
2 SQ12 = 1 Press the STOP button on the remote control to reset the alarm.
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-7
A11 – Measuring cell SQ3 signal defective
MEASURING CELL SQ3
SIGNAL DEFECTIVE!
- CELL DEFECTIVE
- OBSTACLE DETECTED
- CELL OBSTRUCTED
A11
SQ3
Description:
The « measuring cell SQ3 signal defective » alarm occurs whenever the PLC detects input (I25 – SQ3)
during more than 1 second before the loading table goes up or down. The problem is generated when the
switch is obstructed, defective or if any obstacle is detected in the switch detecting range.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 SQ3 = 1 •Remove any obstacle in the detecting range of the switch.
•Check that the SQ3 switch adjustment.
2 SQ3 = 0 Press the STOP button on the remote control to reset the alarm.

CHAPTER 1: ALARMS1-8
A12 – Home position proximity switch SQ5 signal missing
HOME POSITION
PROXIMITY SWITCH SQ5
SIGNAL MISSING!
- DEFECTIVE
- MIS-ADJUSTED
A12
S
Q
5
Description:
The « home position proximity switch SQ5 signal missing » alarm occurs whenever the PLC does not
detect input (I27 – SQ5) when the encoder reads the home position (0.0 mm). The problem is generated
when the switch is defective or mis-adjusted.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 SQ5 = 1 Press the STOP button on the remote control to reset the alarm.
2 SQ5 = 0 •Check that the SQ5 switch is adjusted correctly.
•Check the belt tension.
•Reference back the origin points (home position).
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-9
A15 – Safety time for loading channel up and down motion elapsed
SAFETY TIME FOR
LOADING CHANNEL
UP AND DOWN MOTION
ELAPSED!
A15
Description:
The « safety time for loading channel up and down motion elapsed » alarm is generated:
when the loading table goes up and the PLC does not count the necessary quantity of pulses to reach the
requested position with in the delay of 8 seconds;
when the loading table goes down and the PLC does not detect the input (I24 – SQ1) with in the delay of
8 seconds.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 SQ1 = 1 Press the STOP button on the remote control to reset the alarm.
2 SQ1 = 0 •Check the SQ1 switch.
•Check that the table can move up and down without obstacle or resistance.

CHAPTER 1: ALARMS1-10
A16 – Safety time for diameter adjustment elapsed
SAFETY TIME
FOR DIAMETER
ADJUSTMENT ELAPSED!
A16
Description:
The « safety time for diameter adjustment elapsed » alarm is generated :
during the loading when the PLC not count the necessary quantity of pulses from the diameter adjustment
motor to reach the requested position within 6 seconds;
when the diameter adjustment fingers return towards the origin when the PLC does not detect the input
(I27 – SQ4) within 6 seconds.
Solution:
In the working screen, press the
key on the remote control. Press the key corresponding to Page
Down until the INPUTS page is displayed:
Case Input Solution
1 SQ4 = 1 Press the STOP button on the remote control to reset the alarm.
2 SQ4 = 0 •Check the SQ4 switch.
•Check that the diameter adjustment fingers can move without any obstacle or
resistance.
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-11
A21 – Measuring cell SQ3 activated too early
MEASURING CELL SQ3
ACTIVATED TOO EARLY!
- BAR STOCK EXCEEDS
PERMITTED MAX.LENGTH
- WRONG SET UP
- CELL DEFECTIVE A21
SQ3
Description:
The « Measuring cell SQ3 activated too early » alarm occurs when the PLC detects input (I25 – SQ3)
before the safety maximum length has been reached during the bar stock length measuring.
Solution:
Press the STOP key on the remote control to clear the message and reset the alarm.
Press the key corresponding to the MENU.
Choose the SERVICE item. Press the key corresponding to ENTER to confirm.
From the service menu, choose the BAR FEEDER SETUP item. Press the key corresponding to ENTER
to confirm.
Press the key corresponding to PAGE DOWN as many times as necessary to display the text
"MAXIMUM BAR STOCK LENGTH".
Note: This value cannot exceed the spindle length. If necessary, correct this value.
Measure the bar stock. This bar length cannot exceed the value entered in the remote control.

CHAPTER 1: ALARMS1-12
A22 – Signal A2 "lathe in automatic mode" interrupted during loading
cycle
SIGNAL A2 (LATHE
IN AUTOMATIC MODE)
INTERRUPTED DURING
LOADING CYCLE!
A22
Description:
The « Signal A2 "lathe in automatic mode" interrupted during loading cycle » alarm is generated if the
signal (I41 – A2) is interrupted in the loading cycle.
Solution:
Verify the lathe/bar feeder connection.
Verify the wiring of the signal A2.
Check the lathe programming.
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-13
A23 – Safety time for loading profiled bar elapsed
SAFETY TIME
FOR LOADING
PROFILED BAR
ELAPSED!
A23
Description:
The «Safety time for loading profiled bar elapsed » alarm is generated when profiled bar stocks are
pushed to top-cut position. In this case, the material is pushed near the back of the clamping device.
Then, the spindle rotates very slowly while the bar feeder pushes the bar stock against the clamping
device, until the bar shape corresponds with the clamping device's shape, goes through and reaches the
top-cut position.
After 20 attempts, this alarm is generated.
Solution:
Press the STOP key on the remote control to clear the message and reset the alarm.
Remove the bar out of the spindle.
Start the top-cut cycle again.
If the problem persists, please contact LNS AMERICA, INC..

CHAPTER 1: ALARMS1-14
A24 – Safety time for top-cut positioning elapsed
SAFETY TIME FOR
TOP-CUT POSITIONING
ELAPSED!
A24
Description:
The « safety time for top-cut positioning elapsed » alarm when the bar stock is in loading cycle for top cut,
if the top cut position is not reached within 5 minutes.
Solution:
Press the STOP button on the remote control to reset the alarm.
Restart the automatic cycle on bar feeder and lathe.
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-15
A25 – Lathe did not resume its production cycle
LATHE DID NOT
RESUME ITS
PRODUCTION CYCLE!
A25
Description:
The « Lathe did not resume its production cycle » alarm occurs when the bar feeder does not detect the
clamping device signal (I40 – A1) within the minute following the reach of the top cut positioning.
Solution:
Press the STOP button on the remote control to reset the alarm.
Restart the automatic cycle on bar feeder and lathe.

CHAPTER 1: ALARMS1-16
A26 – Clamping device closed prior to completing the feed out
CLAMPING DEVICE
CLOSED PRIOR
TO COMPLETING
THE FEED OUT!
A26
Description:
The « Clamping device closed prior to completing the feed out » alarm occurs whenever the clamping
device closing signal is detected before the value entered in parameter "overall part length feed out" has
been reached.
Solution:
Check that the clamping device is closing correctly.
Check that the signal "Clamping device closing" is correctly interfaced and programmed.
QUICK LOAD SERVO 65/80

CHAPTER 1: ALARMS
QUICK LOAD SERVO 65/80
1-17
A27 – Clamping device opened during production cycle without lathe
auto mode
CLAMPING DEVICE
OPENED DURING
PRODUCTION CYCLE
WITHOUT LATHE IN
AUTO MODE
A27
Description:
The « Clamping device opened during production cycle without lathe auto mode » alarm occurs when the
PLC detects the clamping device opening signal (I40 – A1) while the bar feeder in auto cycle and lathe
not in auto mode – input (I41 – A2).
Solution:
Press the STOP button on the remote control to reset the alarm.
Restart the automatic cycle on bar feeder and lathe.