LNS QUICK SIX Programming manual

MADE IN USA
Serial Nr:
Phone# [phone]
http://www.LNSAmerica.com
Main fax# [phone]
Service fax# [phone]
LNS America, Inc.
USA
4621 East Tech Drive
Cincinnati, Ohio 45245
CNC
CNC
CNC
QUICK SIX
QUICK SIXQUICK SIX
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL

E1
11.10.2005
Table of Contents
Chapter 1: .......................................................................................1-1
Alarms .........................................................................................................1-1
ALARM HISTORY..........................................................................................................................1-4
A001 – Emergency Line Open......................................................................................................1-5
A003 – Lathe Emergency Stop Line Open..................................................................................1-6
A004 – Bar Feeder Emergency Stop ...........................................................................................1-7
A005 – Oil Pressure Failure..........................................................................................................1-8
A006 – Air Pressure Failure .........................................................................................................1-9
A007 – Main Access Cover Open ..............................................................................................1-10
A009 – Bar Feeder Retracted.....................................................................................................1-11
A012 – Bar Magazine Indexing Interrupted...............................................................................1-12
A023 – Servo Drive Alarm ..........................................................................................................1-13
A024 – Servo Motor Not Ready..................................................................................................1-14
A025 – Servo Motor Positioning Error ......................................................................................1-15
A042 – Home Position Proximity Switch SQ7 Missing............................................................1-16
A044 – Bar Loading Error...........................................................................................................1-17
Servo Amplifier/PLC Communication Fault..............................................................................1-18
A045 – Bar Magazine Indexing Motor Faulty............................................................................1-19
A046 – Chuck Closed Prior to Feed Out Complete..................................................................1-20
A048 – Safety Time for Part Feed Out.......................................................................................1-21
A049 – Measuring Cell SQ@ is Activated too Early.................................................................1-22
A050 – A2 Interrupted During Loading......................................................................................1-23
A053 – Lathe Did Not Resume Its Production Cycle................................................................1-24
Pusher Support Up Motion Not Completed..............................................................................1-25
Pusher Support Down Motion Not Completed.........................................................................1-26
Guiding Channel First Section Not Fully Open ........................................................................1-27
Guiding Channel First Section Not Fully Closed .....................................................................1-28
Guiding Channel Second Section Not Fully Open...................................................................1-29
Guiding Channel Second Section Not Fully Closed ................................................................1-30
A082 – Bar Dropping Fingers Malfunction................................................................................1-31
A116 – Bar Stock Loading Error................................................................................................1-32
A118 – Measuring Cell SQ1 Signal Defective...........................................................................1-33
Software Sequence.....................................................................................................................1-34
Mitsubishi Servo Amplifier Alarm List ......................................................................................1-36
Chapter 2: .......................................................................................2-1
Common Issues...........................................................................................2-1
Low Voltage / PLC Shutdown ......................................................................................................2-2
Cannot Change Application Setup Parameters..........................................................................2-3
Multiple Bars have been Loaded into the Channel ....................................................................2-3
Oil Is Leaking on the Floor / In the Machine...............................................................................2-4
Vibration Issues............................................................................................................................2-4
Chapter 3: .......................................................................................3-1
Procedures..................................................................................................3-1
Belt Tension Adjustment..............................................................................................................3-2
Pusher Changeover......................................................................................................................3-4
Cutting the Pusher........................................................................................................................3-6
Reference Procedure....................................................................................................................3-9
Replacing Guide Elements.........................................................................................................3-11
SQ1 Adjustment – Measuring Cell.............................................................................................3-13
SQ2 Adjustment – Bar Loading Detection Switch ...................................................................3-14
SQ7 Adjustment – Home Position Proximity Switch ...............................................................3-16
SQ12 Adjustment – Safety Reflector Switch ............................................................................3-17
SQ14 Adjustment – Dropping Finger Counting Proximity Switch..........................................3-19
QUICK SIX

Chapter 4:.......................................................................................4-1
Software Update/Restore ...........................................................................4-1
PLC Fault .......................................................................................................................................4-3
Restore PLC Program From Memory Card to PLC – v1.17a......................................................4-3
PLC Fault .......................................................................................................................................4-6
Restore Bar Feeder Parameters from MMI to PLC – v1.17a ......................................................4-6
Software Update............................................................................................................................4-9
Restore Bar Feeder Parameters From MMI to PLC – v1.17a .....................................................4-9
Software Update..........................................................................................................................4-12
Restore Display Data from Memory Card to MMI – v1.17a......................................................4-12
Software Update..........................................................................................................................4-16
Restore PLC Program from Memory Card to PLC – v1.17a.....................................................4-16
PLC Fault – v2.08 ........................................................................................................................4-20
Software Update – v2.08.............................................................................................................4-23
Chapter 5:.......................................................................................5-1
Preventative Maintenance..........................................................................5-1
Daily Maintenance.........................................................................................................................5-2
Weekly Maintenance.....................................................................................................................5-2
Monthly Maintenance....................................................................................................................5-2
Annual Maintenance.....................................................................................................................5-3
Chapter 6:.......................................................................................6-1
Spare Parts..................................................................................................6-1
Recommended Spare Parts List..................................................................................................6-2
Parts Order Form ..........................................................................................................................6-3
Electrical Box Components .........................................................................................................6-4
Stands............................................................................................................................................6-5
Carriage Assembly L/R.................................................................................................................6-6
Carriage Assembly L/F .................................................................................................................6-7
Guiding Channel Cylinder............................................................................................................6-8
Driveshaft L/F................................................................................................................................6-9
Encoder Sub-Assembly L/R.......................................................................................................6-10
Encoder Sub-Assembly L/F........................................................................................................6-11
Main Chassis and Cover L/R......................................................................................................6-12
Main Cover Switch Sub-Assembly L/R......................................................................................6-13
Bar Magazine Rack L/R...............................................................................................................6-14
Bar Magazine Rack L/F...............................................................................................................6-15
Retract Switch Assembly L/R.....................................................................................................6-16
Retract Switch Assembly L/F.....................................................................................................6-17
Flexible Track Assembly L/F......................................................................................................6-18
Belt Drive L/R...............................................................................................................................6-19
Belt Drive L/F...............................................................................................................................6-20
Front Pusher Support.................................................................................................................6-21
Chain Loader...............................................................................................................................6-22
Chain Loader L/F.........................................................................................................................6-23
QUICK SIX

Chapter 1: Alarms
QUICK SIX
1-1
Chapter 1:
Alarms
n 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
troubleshooting guide discusses every alarm that the bar feed may generate. In conjunction with each alarm will be a
brief description of what the alarm is and a few tips and procedures of how to correct the problem.
A
Figure 1-1 Remote control station

1-2 Chapter 1: Alarms
QUICK SIX
SQ12
SQ11
M5 SQ14
SQ12
SQ2

Chapter 1: Alarms
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1-3
Desi
g
nation Descri
p
tion
A Remote control station
B Control cabinet
C Optional interface cable outlet
M1 Hydraulic pump motor
M2 Servo motor
M3 Motor dropping fingers
M5 Motor bar loader
QS1 Main disconnect switch
SP1 Pneumatic pressure switch
SP2 Hydraulic pressure switch
SQ1 Positioning stopper proximity switch
SQ2 Bar stock presence proximity switch
SQ3 Opening guiding channel control switch
SQ4 Closing guiding channel control switch
SQ5 Bearing blocks 1 open
SQ6 Bearing blocks 2 closed
SQ7 Control switch: pusher in rear/park position
SQ8 Bearing blocks 2 open
SQ9 Bearing blocks 1 closed
SQ10 Retraction system in position switch (option)
SQ11 Main access cover safety switch
SQ12 Magazine safety switch – transmitter / deflector
SQ14 Dropping fingers up
SQ15 Proximity switch dropping fingers 0-point
SQ16 Signal A (Encoder)
SQ17 Control switch main cover closed
SQ18 Dropping fingers safety
STP Emergency stop

1-4 Chapter 1: Alarms
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ALARM HISTORY
MOST RECENT
ALARMS
Description:
The Most Recent Alarms feature allows the user to view the 20 most recent alarms that have occurred on the bar feed. This is helpful
when determining what to look at as far as troubleshooting problems that have recently taken place, especially when the
troubleshooting involves contacting LNS America, Inc. for assistance and the message has already been cleared.
On certain lathes, once the bar feed sends an alarm to the machine, the machine will in return send an emergency stop alarm to the
bar feed which overrides any bar feed alarms. Once the bar feed alarm is overridden the only way to pinpoint the original bar feed
alarm is to enter into the alarm history.
This menu is located HELP menu, to locate the alarm history follow the steps below:
Step 1: Press the HELP key on the remote control station at any time.
Step 2: Press the PAGE DOWN key 6 times.
Use the PAGE UP and PAGE DOWN keys to scroll through alarms. The alarms are are listed with the most recent alarm being the
first to appear to the 20th most recent alarm being listed last.

Chapter 1: Alarms
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1-5
A001 – Emergency Line Open
EMERGENCY
LINE OPEN
POSSIBLE CAUSES:
-CONNECTION
-PROBLEM IN
CIRCUITRY
A001
Description:
The Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.0). The problem is generated anytime the
safety circuit contactor (K1) is not energized and all safety switches are in operating position. (Refer to the Quick Six Instruction
Manual).
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 0 = 0
MODULE 0
76543210
0
•Verify that the 1/0 connector is plugged into the PLC correctly.
•Verify that the circuitry is wired correctly to the electrical diagrams
in the Quick Six Instruction Manual.
2 Bit 0 = 1
MODULE 0
76543210
1
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
For case 1, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

1-6 Chapter 1: Alarms
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A003 – Lathe Emergency Stop Line Open
LATHE EMERGENCY
STOP LINE OPEN!
POSSIBLE CAUSES:
- EMERGENCY STOP
PUSHED IN
-WIRING PROBLEM
A003
Description:
The Lathe Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.3). The problem is generated when
the lathe E-stop push button is pressed in.
Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 3 = 1
MODULE 0
76543210
1000
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
2 Bit 3 = 0
MODULE 0
76543210
0
Reset the E-stop push button on the lathe.
For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

Chapter 1: Alarms
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1-7
A004 – Bar Feeder Emergency Stop
BAR FEEDER
EMERGENCY STOP!
POSSIBLE CAUSES:
- EMERGENCY STOP
BUTTON PUSHED IN
-WIRING PROBLEM
A004
Description:
The Bar Feeder Emergency Stop alarm occurs whenever the PLC does not detect input (I0.2). The problem is generated E-stop push
button on the remote control station is pressed in.
Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 2 = 1
MODULE 0
76543210
100
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
2 Bit 2 = 0
MODULE 0
76543210
0
Reset the E-stop push button on the remote control station.
For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

1-8 Chapter 1: Alarms
QUICK SIX
A005 – Oil Pressure Failure
OIL PRESSURE
FAILURE!
POSSIBLE CAUSES:
-PRESSURE SWITCH SP2
DEFECTIVE OR
MIS-ADJUSTED
-PUMP FAILURE
-TANK EMPTY
A005
Description:
The Oil Pressure Failure alarm occurs whenever the PLC does not detect input (I0.6 – SP2) while the hydraulic pump is running. The
problem is generated after 30 seconds when oil pressure is not sufficient, below the factory setting of point of release of 0.5 bars, to
activate the oil pressure switch. The bar feed does not alarm out until the chuck is open.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 6 = 1
MODULE 0
76543210
1000000
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
Check the oil level indicator on the side of the hydraulic tank and
make sure there is sufficient oil. Recommended 10 gallons of ISO
100 type oil.
2 Bit 6 = 0
MODULE 0
76543210
0 Replace the oil pressure switch.
For case 2, after the solutions have been completed, Press the STOP key on the remote control station to clear the message and
reset the alarm.

Chapter 1: Alarms
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1-9
A006 – Air Pressure Failure
AIR PRESSURE
FAILURE!
POSSIBLE CAUSES:
-AIR PRESSURE BELOW
3 BAR(45PSI)
-AIR PRESSURE SWITCH
SP1 MIS-ADJUSTED
-AIR PRESSURE SWITCH
DEFECTIVE
A006
Description:
The Air Pressure Failure alarm occurs whenever the PLC does not detect input (I0.5 – SP1) after a period of 5 seconds. The problem
is generated anytime air pressure is not sufficient, below 45psi, to make the air pressure switch.
Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 5 = 1
MODULE 0
76543210
100000
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
Raise the incoming air pressure on the air regulator to
(recommended) 75 psi. and no higher than 90 psi.
2 Bit 5 = 0
MODULE 0
76543210
0 Replace the air pressure switch.
For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

1-10 Chapter 1: Alarms
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A007 – Main Access Cover Open
MAIN ACCESS COVER
OPEN!
CLOSE MAIN COVER TO
RESUME OPERATIONS
A007
Description:
The Main Access Cover Open alarm occurs whenever the PLC detects input (I0.4 – SQ11 / SQ17). The problem is generated, as a
safety precaution, when the main access cover or grid protection cover is opened to prevent any movement in the bar feeder if the
operator or service technician needs to perform any work inside the unit.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 4 = 1
MODULE 0
76543210
10000
Close the main access cover / grid protection cover.
2 Bit 4 = 0
MODULE 0
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

Chapter 1: Alarms
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1-11
A009 – Bar Feeder Retracted
BAR FEEDER RETRACTED
OR NOT LOCKED IN ITS
WORKING POSITION!
SIGNAL SQ10 MISSING
SECURE BAR FEEDER
IN ITS WORKING
POSITION TO RESUME
OPERATIONS
A009
Description:
The Bar Feeder Retracted alarm occurs whenever the PLC detects input (I0.1 – SQ10). The problem is generated when the bar
feeder is retracted for spindle liner changeover.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 1 = 1
MODULE 0
76543210
10
Put the bar feeder back in its working position and lock in place.
2 Bit 1 = 0
MODULE 0
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

1-12 Chapter 1: Alarms
QUICK SIX
A012 – Bar Magazine Indexing Interrupted
BAR MAGAZINE
INDEZING
INTERRUPTED!
POSSIBLE CAUSES:
-REFLECTIVE SENSOR
OBSTRUCTED
-REFLECTIVE SENSOR
MISALIGNED
-REFLECTIVE SENSOR
DEFECTIVE A012
Description:
The Bar Magazine Indexing Interrupted alarm occurs when the loader rack is indexing and the input signal (I2.0 – SQ12) turns off.
Solution:
Case Input Remote Pendant Solution
1 Bit 2 = 1
MODULE 2
76543210
1
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
Check to see if there is any obstruction interfering with the reflector.
Make sure that the SQ12 switch is adjusted and aligned correctly.
2 Bit 2 = 0
MODULE 2
76543210
0 If the input still does not turn on, the problem can be isolated to a
defective switch or defective cable. Replace the cable and switch.
For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

Chapter 1: Alarms
QUICK SIX
1-13
A023 – Servo Drive Alarm
SERVO DRIVE ALARM!
-TURN OFF MAIN POWER
-WAIT FOR 2 SECONDS
-RESTORE MAIN POWER
IF PROBLEM PERSISTS
REFER TO INSTRUCTION
MANUAL
A023
Description:
The Servo Drive Alarm occurs if the Mitsubishi servo amplifier generates an alarm.
Solution:
Turn the main power off to the Quick Six for 2 seconds and turn the power back on.
Note: If the alarm keeps recurring, check the alarm code on the Mitsubishi servo
amplifier and refer to Mitsubishi Servo Amplifier Alarm List.

1-14 Chapter 1: Alarms
QUICK SIX
A024 – Servo Motor Not Ready
SERVO MOTOR
NOT READY!
-VERIFY CN1B
CONNECTOR
-CHECK PLC OUTPUT
Q 4.4 (MUST BE ON)
A024
Description:
The PLC outputs a signal (Q4.4) to servo amplifier, which engages the servo motor and puts the servo motor in a “servo lock”
condition. If the servo amplifier does not recognize the signal after 3 seconds, this alarm is generated.
Solution:
•Verify that the CN1B connector is seated properly in the allotted socket on the servo amplifier.
•Verify that the PLC output (Q4.4) is turning on when the manual or automatic cycle is started.
•Verify that the K1 contactor is activated; input (I0.0) should be on.
If the problem persists please contact LNS America, Inc. for further information.

Chapter 1: Alarms
QUICK SIX
1-15
A025 – Servo Motor Positioning Error
FRONT TOPMEASURING S
SIGNAL SQ1 MISSING!
POSSIBLE CAUSES:
-FRONT STOPPER DID
NOT MOVE UP
-SIGNAL SWITCH SQ1
DEFECTIVE OR
MIS-ADJUSTED
SERVO MOTOR
POSITIONING
FOLLOWING ERROR!
DURING SEQUENCE
NUMBER [@@]
POSSIBLE CAUSE:
MECHANICAL OBSTACLE
PREVENTS BAR STOCK
TO FEED OUT
A025
Description:
The Servo Motor Following Error alarm occurs due to a mechanical obstacle preventing the bar stock from feeding out. The torque on
the servo motor will build up when the obstacle prohibits the stock from moving, once the torque reaches a certain limit the PLC
instructs the servo amplifier to quit pushing and this alarm message appears on the remote control station.
Solution:
Seq. # Solution
##
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the
alarm.
•Check for any mechanical obstacles that the bar stock may be hitting. Remove obstacle if this is the case.
•Check the bar stock diameter. Make sure that the actual diameter is the same as the value entered in for the
corresponding parameter in the Part Setup menu.
•Check the alignment between the bar feeder and the lathe. The lathe or the bar feeder may have shifted over
a long period if either is not lagged to the floor securely.
If the problem persists please contact an LNS agency for further information.

1-16 Chapter 1: Alarms
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A042 – Home Position Proximity Switch SQ7 Missing
HOME POSITION
PROXIMITY SWITCH SQ7
SIGNAL MISSING!
POSSIBLE CAUSES:
-SQ7 SIGNAL SWITCH
DEFECTIVE OR MIS-
ADJUSTED
-CHAIN BROKEN
A042
Description:
The Home Position Proximity Switch SQ7 Signal Missing alarm occurs if input (I1.5 – SQ7) is not detected by the PLC either during
the re- referencing.
Solution:
Press the STOP key on the remote control station to clear the message and reset the alarm. Press the HELP key. Press F4 (Page
Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 5 = 1
MODULE 1
76543210
100000
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
Check to see if there is a mechanical obstruction preventing the
carrier flag from reaching the home position.
Make sure that the SQ7 switch is adjusted to within a sensing
distance of 0.5mm-1mm from the measuring stop.
2 Bit 5 = 0
MODULE 1
76543210
0 If the input still does not turn on, the problem can be isolated to a
defective switch or defective cable. Replace the cable and switch.
For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

Chapter 1: Alarms
QUICK SIX
1-17
A044 – Bar Loading Error
VISE COUPLING DEVICE
MALFUNCTION!
POSSIBLE CAUSES:
-COUPLING DEVICE
DEFECTIVE
-SQ6 SIGNAL SWITCH
DEFECTIVE OR
MIS-ADJSUTED
-MECHANICAL FAILURE
BAR LOADING ERROR!
HEX, SQUARE BARS
POSSIBLE CAUSES:
-LOADING SAFETY TIME
ELAPSED
-BAR STOCK NOT FED
THROUGH THE COLLET
OF THE LATHE
A044
Description:
The Bar Loading Error alarm occurs during the top-cut positioning sequence when loading profiled material. During the loading cycle,
for profiled material, the bar stock is brought to the back of the clamping device. When this position is reached, the spindle is jogged
at a very low rpm and the pusher begins a pecking motion until the profile of the material and the profile of the chuck jaws are aligned
and the bar is fed out to the top-cut position. If the top-cut position is not reached after 20 pecking cycles, this alarm is generated.
Solution:
Alarm needs to be cleared. Press the STOP button on the remote control station to clear and reset the alarm. Remove the bar from
the spindle and restart the top-cut positioning cycle.
If the problem persists please contact LNS America, Inc. for further information.