LNS QUICK LOAD SERVO S3 Guide

MADE IN USA
Serial Nr:
LNS America, Inc.
USA
4621 East Tech Drive
Cincinnati, Ohio 45245
Phone# [phone]
http://www.LNSAmerica.com
Main fax# [phone]
Service fax# [phone]
SERVO S3SERVO S3
SERVO S3
QUICK LOAD
QUICK LOAD
QUICK LOAD
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL

E2
10.03.2006
Table of Contents
Chapter 1: .......................................................................................1-1
Alarms .........................................................................................................1-1
A002 – Emergency Stop Line Open.............................................................................................1-3
A003 – Lathe Emergency Stop Line Open..................................................................................1-4
A004 – Bar Feeder Emergency Stop ...........................................................................................1-5
A006 – Air Pressure Failure .........................................................................................................1-6
A007 – Main Access Cover Open ................................................................................................1-7
A009 – Bar Feeder Retracted or Not Locked In It’s Working Position......................................1-8
A011 – Magazine Protection Grid Open......................................................................................1-9
A023 – Servo Drive Alarm ..........................................................................................................1-10
A024 – Servo Motor Not Ready..................................................................................................1-11
A025 – Servo Motor Positioning Following Error.....................................................................1-12
A042 – Home Position Proximity Switch SQ5 Signal Missing ................................................1-12
A042 – Home Position Proximity Switch SQ5 Signal Missing ................................................1-13
A044 – Bar Loading Error...........................................................................................................1-14
A046 – Clamping Device Has Closed Prior to Feed Out Complete.........................................1-15
A047 – Signal A2 Interrupted During Loading Cycle...............................................................1-16
A048 – Safety Time for Part Feed Out Elapsed ........................................................................1-17
A049 – Measuring Cell SQ@ Is Activated Too Early................................................................1-18
A050 – Signal A2 Interrupted During Production Cycle and the Clamping ...........................1-19
A051 – Bar Stock Loading Error................................................................................................1-20
A052 – Safety Time for Top-Cut Positioning Elapsed..............................................................1-21
A053 – Lathe Did Not Resume Its Production Cycle................................................................1-22
A083 – Upper Position Fault ......................................................................................................1-23
A088 – Loading Channel Will Not Move to Lower Position.....................................................1-24
A091 – Measuring Cell SQ3 Signal Defective...........................................................................1-25
Lower Position Fault...................................................................................................................1-26
Loading Channel Upper Position Default .................................................................................1-27
Loading Channel Upper Motion Default....................................................................................1-28
Loading Channel Lower Motion Default....................................................................................1-29
Loading Channel Did Not Reach Its Lower Position................................................................1-30
Drive For Diameter Adjustment Error .......................................................................................1-31
Door Lathe Open.........................................................................................................................1-32
Servo Amplifier/PLC Communication Fault..............................................................................1-33
Diameter Change Control Device Is Out of Sync .....................................................................1-34
SPS No Response.......................................................................................................................1-35
Mitsubishi Servo Amplifier Alarm List......................................................................................1-36
Chapter 2: .......................................................................................2-1
Common Issues...........................................................................................2-1
Low Voltage / PLC Shutdown ......................................................................................................2-2
Vibration Issues............................................................................................................................2-3
Servo Motor Following Error During Sequence 12 ....................................................................2-4
Part Feed Out Accuracy ...............................................................................................................2-5
Chapter 3: .......................................................................................3-1
Procedures..................................................................................................3-1
End of Bar Adjustment.................................................................................................................3-2
Alignment Procedure....................................................................................................................3-3
Pusher Changeover......................................................................................................................3-7
Carriage Unit Belt Tension Adjustment ....................................................................................3-10
Servo Motor Belt Tension Adjustment......................................................................................3-12
Diameter Adjustment Motor Replacement................................................................................3-14
QUICK LOAD SERVO S3

Home Position Proximity Switch Adjustment – SQ5 ...............................................................3-18
Magazine and Loading Finger Adjustment...............................................................................3-20
Measuring Cell Adjustment – SQ3.............................................................................................3-21
Pusher Reversing Distance Adjustment...................................................................................3-24
Reference Procedure..................................................................................................................3-25
Reset Interface Parameters........................................................................................................3-27
Calibration of the Loading Table ...............................................................................................3-31
Chapter 4:.......................................................................................4-2
Software Update/Restore ...........................................................................4-2
Determining Display Firmware.....................................................................................................4-3
PLC Fault .......................................................................................................................................4-4
Restore PLC Program From Memory Card to PLC – v1.17a......................................................4-4
PLC Fault .......................................................................................................................................4-7
Restore Bar Feeder Parameters from MMI to PLC – v1.17a......................................................4-7
Software Update..........................................................................................................................4-10
Restore Bar Feeder Parameters From MMI to PLC – v1.17a...................................................4-10
Software Update..........................................................................................................................4-13
Restore Display Data from Memory Card to MMI – v1.17a......................................................4-13
Software Update..........................................................................................................................4-17
Restore PLC Program from Memory Card to PLC – v1.17a.....................................................4-17
PLC Fault – v2.08 ........................................................................................................................4-21
Software Update – v2.08.............................................................................................................4-24
Chapter 5:.......................................................................................5-1
Barfeed Applications ..................................................................................5-1
Application Setup..........................................................................................................................5-2
Chapter 6:.......................................................................................6-1
Preventative Maintenance..........................................................................6-1
Daily Maintenance.........................................................................................................................6-2
Weekly Maintenance.....................................................................................................................6-2
Monthly Maintenance....................................................................................................................6-2
Annual Maintenance .....................................................................................................................6-2
Chapter 7:.......................................................................................7-1
Spare Parts..................................................................................................7-1
Recommended Spare Parts List..................................................................................................7-2
Parts Order Form ..........................................................................................................................7-3
Electrical Box Components .........................................................................................................7-4
Loading Table sub-assembly (Left/Rear Load)Loading Table sub-assembly (Left/Rear Load)7-5
Loading Table sub-assembly (Left/Rear Load)...........................................................................7-6
Loading Table sub-assembly (Left/Rear Load)...........................................................................7-7
Pusher Locking sub-assembly (Left/Rear Load)........................................................................7-8
Pusher Locking sub-assembly (Left/Rear Load)........................................................................7-9
Loading Table sub-assembly (Left/Front Load) .........................................................................7-9
Loading Table sub-assembly (Left/Front Load) .......................................................................7-10
Loading Table sub-assembly (Left/Front Load) ......................................................................7-11
Loading Table sub-assembly (Left/Front Load) .......................................................................7-12
Pusher Locking sub-assembly (Left/Front Load).....................................................................7-12
Pusher Locking sub-assembly (Left/Front Load).....................................................................7-13
Pusher Locking sub-assembly (Left/Front Load).....................................................................7-14
Loading Table Microswitch sub-assembly ...............................................................................7-14
Loading Table Microswitch sub-assembly ...............................................................................7-15
Servo Motor sub-assembly ........................................................................................................7-16
Linear Rail Assembly..................................................................................................................7-17
QUICK LOAD SERVO S3

1-1Chapter 1: Alarms
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.
Chapter 1:
A
Figure 1-1 Remote control station
QUICK LOAD SERVO S3

1-2 Chapter 1: Alarms
Desi
g
nation Descri
p
tion
A Remote control station
B 24 pin connector with cover (depending on interface)
C Control cabinet
M1 Servo motor
M2 Motor for diameter adjustment
QS1 Main disconnect switch
SQ1 Loading channel upper position switch
SQ2 Loading channel lower position switch
SQ3 Measuring cell
SQ4 Proximity switch for diameter adjustment
SQ5 Home position proximity switch
SQ10 Main access cover safety switch
SQ11 Magazine grid cover safety switch
SQ12 Retraction system in position switch / key
QUICK LOAD SERVO S3

1-3Chapter 1: Alarms
A002 – Emergency Stop Line Open
QUICK LOAD SERVO S3
EMERGENCY STOP
LINE OPEN!
********************
POSSIBLE CAUSES:
BAR FEEDER OR LATHE
EMERGENCY STOP,
PUSH BUTTON PUSHED
IN, CONNECTION OR
WIRING PROBLEM IN
CIRCUITRY A002
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 page 4-16 in the Quick Load
Servo S3 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 diagram on page 4-16 in the Quick Load
Servo S3 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.

1-4 Chapter 1: Alarms
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 (I0.7). 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 7 = 1
MODULE 0
76543210
10000000
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
2 Bit 7 = 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.
QUICK LOAD SERVO S3

1-5Chapter 1: Alarms
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 (I0.6). 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 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.
2 Bit 6 = 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.
QUICK LOAD SERVO S3

1-6 Chapter 1: Alarms
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 (I0.1 – 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 1 = 1
MODULE 0
76543210
10
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.
QUICK LOAD SERVO S3
Flip the toggle switch on the PLC to the RUN position.
2 Bit 1 = 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.

1-7Chapter 1: Alarms
A007 – Main Access Cover Open
QUICK LOAD SERVO S3
A007
MAIN ACCESS COVER
OPEN!
CLOSE MAIN COVER TO
RESUME OPERATIONS
Description:
The Main Access Cover Open alarm occurs whenever the PLC detects input (I0.2 – SQ10). The problem is generated, as a safety
precaution, when the main access 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 2 = 1
MODULE 0
76543210
100
Close the main access cover.
2 Bit 2 = 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.