LNS QUICK LOAD SERVO S3 Guide

MADE IN USA
Serial Nr:
LNS America, Inc.
USA
4621 East Tech Drive
Cincinnati, Ohio 45245
Phone# 513.528.5674
http://www.LNSAmerica.com
Main fax# 513.528.5733
Service fax# 513.528.8320
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.

1-8 Chapter 1: Alarms
A009 – Bar Feeder Retracted or Not Locked In It’s Working Position
QUICK LOAD SERVO S3
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 (I0.4 – SQ12). 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 4 = 1
MODULE 0
76543210
10000
Put the bar feeder back in its working position and lock
the latches.
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 solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

1-9Chapter 1: Alarms
A011 – Magazine Protection Grid Open
MAGAZINE PROTECTION
GRID OPEN!
CLOSE GRID TO RESUME
OPERATIONS
A011
Description:
The Magazine Protection Grid Open alarm occurs whenever the PLC detects input (I0.3 – SQ11). The problem is generated, as a
safety precaution, if the magazine protection grid is raised.
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 3 = 1
MODULE 0
76543210
1000
Close the magazine protection grid.
2 Bit 3 = 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 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

1-10 Chapter 1: Alarms
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 Load Servo S3 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 pg. 1-37.
QUICK LOAD SERVO S3

1-11Chapter 1: Alarms
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.
QUICK LOAD SERVO S3

1-12 Chapter 1: Alarms
A025 – Servo Motor Positioning Following Error
SERVO MOTOR
POSITIONING
FOLLOWING ERROR!
DURNG 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 LNS America, Inc. for further information.
QUICK LOAD SERVO S3

1-13Chapter 1: Alarms
A042 – Home Position Proximity Switch SQ5 Signal Missing
Description:
The Home Position Proximity Switch SQ5 Signal Missing alarm occurs if input (I1.4 – SQ5) is not detected before the v-channel
moves to the upper position and the encoder reads the home position (0.0mm). The problem is normally generated when the switch
is mis-adjusted.
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 4 = 1
MODULE 1
76543210
10000
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
2 Bit 4 = 0
MODULE 1
76543210
0
•Check the adjustment of the SQ5 switch.
•Check the tension of the drive belt. If it is not tight,
adjust. Refer to the Quick Load Servo S3 Instruction
Manual, pg. 6-14.
•Re-reference the bar feeder.
HOME POSITION
PROXIMITY SWITCH SQ5
SIGNAL MISSING!
POSSIBLE CAUSES:
-SQ5 SIGNAL SWITCH
DEFECTIVE OR MIS-
ADJUSTED
-BROKEN BELT
A042
QUICK LOAD SERVO S3

1-14 Chapter 1: Alarms
A044 – Bar Loading Error
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.
QUICK LOAD SERVO S3

1-15Chapter 1: Alarms
A046 – Clamping Device Has Closed Prior to Feed Out Complete
CLAMPING DEVICE HAS
CLOSED PRIOR TO
COMPLETING THE
FEED OUT
POSSIBLE CAUSES:
-LATHE PROGRAMMING
ERROR
-CLAMPING SIGNAL
FAULTY (PLC INPUT
A1) A046
Description:
The Clamping Device Has Closed Prior To Completing The Feed Out alarm occurs if the input for the clamping device closed is
detected before the value of the Input Part Length parameter is reached.
Solution:
Verify that the clamping device is closing properly and that the Clamping Signal Active interface parameter is set in conjunction with
how the interface signal is being sent.
QUICK LOAD SERVO S3

1-16 Chapter 1: Alarms
A047 – Signal A2 Interrupted During Loading Cycle
SIGNAL A2 (LATHE IN
AUTOMATIC MODE)
INTERRUPTED DURING
LOADING CYCLE!
RESUME AUTOMATIC
CYCLE OFTHE LATHE
AND THE BAR FEEDER
A047
Description:
The Signal A2 Interrupted During Loading Cycle alarm occurs whenever PLC input (I3.1) drops out during the loading cycle.
Solution:
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Remove the
bar stock from the loading channel and reset the bar feeder and the lathe in automatic cycle.
QUICK LOAD SERVO S3

1-17Chapter 1: Alarms
A048 – Safety Time for Part Feed Out Elapsed
SAFETY TIME
FOR PART FEED OUT
ELAPSED!
POSSIBLE CAUSES:
-PROGRAMMING ERROR
-MECH. INTERFERENCE
-INTERFACE PROBLEM
A048
Description:
The Safety Time For Part Feed Out Elapsed alarm occurs if the value set in OVERALL PART LENGTH is not reached within 1 minute
after the bar feed is commanded to feed out.
Solution:
Case Application Solution
1 Feed out with turret and
with m-code
•Check that the position of the turret is correct for
the length of the part feed.
•Check for mechanical obstacle preventing the bar
from completing the feed out.
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
2 Feed out with turret and
without m-code
•Check that the position of the turret is correct for
the length of the part feed.
•Check for mechanical obstacle preventing the bar
from completing the feed out.
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
3 Feed out without turret
and with m-code
•Check for mechanical obstacle preventing the bar
from completing the feed out.
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
4 Feed out without turret
and without m-code
•Check for mechanical obstacle preventing the bar
from completing the feed out.
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
Contact LNS America, Inc. for further information.
QUICK LOAD SERVO S3
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