SMW SPACESAVER 2400T User manual

SMW SYSTEMS LLC 9828 S. Arlee Ave Santa Fe Springs, CA. 90670
Phone: [phone] Fax: [phone]
SPACESAVER 2400T
SPACESAVER 2400S
CNC LATHE BARFEEDER
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL

Safety Instructions
SS2400T/S 3
Before starting the work with the barfeeder pay attention to the following instructions:
With regard to continuous improving of barfeeders it is possible that the illustrations and
descriptions provided in this manual can differ in details from the delivered equipment. When
working with electric circuits follow the regularly updated diagrams in this manual. If you find
diagrams attached to this manual, please use them, because they contain changes which
have not yet been addressed in the printed copy of the manual sent to you.
The barfeeder enables the simplest and safest feeding of bars into the spindles of standard
CNC lathes.
Some common workshop practices do not meet the labour safety principles and should be
checked or revised according to the following recommendations. Any barfeeder operator
should observe the labour safety principles. Furthermore the operator should ensure that the
machine is installed by a specialist, and should carry out regular inspection of the barfeeder's
functions and condition.
Before starting the work with the barfeeder read carefully the following instructions:
•Before barfeeder operation or maintenance, read carefully both this Manual and the
attached supplementary information. Make sure that you have understood everything
well.
•Make sure that the barfeeder is properly set, aligned with the lathe and fastened to the
ground.
•Do not work with the equipment which has not been properly installed, checked and
prepared for operation and is not regularly maintained.
•Do not remove any safety plates and labels with signs or warnings, and follow the
instructions shown on them.
•Do not slacken screw joints which are secured by paint.
•Do not work with the equipment which produces excessive noise, heat or vibration. In
your own interest call immediately attention of the personnel responsible for the
barfeeder operation and maintenance to the problem.
•Make sure that the machine is properly grounded in accordance with valid standards.
•Disconnect the machine from electric power supply before any repair or maintenance.
•Do not touch electric control or power parts until they are disconnected from electric
power supply.
•Do not touch electric equipment by wet hands or while you are standing in a moist
environment.
•Electric equipment of the barfeeder can only be repaired by an authorized person.
•Replace the fuses only by the fuses of the same rating and type as those which have
been installed by the manufacturer.
•Keep the space around the machine dry, clean and properly lighted.
•Have suitable extinguishers ready at work with flammable substances.
•Remove turnings and all other waste, especially flammable one, from the barfeeder
regularly.
•Do use flammable or toxic substances instead of cleaning agents.
•Do not change the connection or function of safety switches, indicators and fuses, and do
not short-circuit or otherwise by-pass this equipment.
•Before the use the barfeeder remove all parts and tools from the barfeeder and its
vicinity, in particular from the vicinity of its moving parts.

Safety Instructions
4SS2400T/S
•If the machine has been out of service for a longer time, check the machining program,
part clamping and setting of the barfeeder parameters before fully automatic operation of
the lathe with the barfeeder.
•Do not remove or unlock safety guards during barfeeder operation.
•Do not remove or add bars while the barfeeder is running.
•Do not wear rings, bracelets, watches, too free clothing etc at work with the barfeeder.
Long hair should be protected by a suitable cap.
•Do try to stop or slow down the barfeeder by your own hands.
•Accessories, which were not delivered by the manufacturer within the basic shipment,
must be checked thoroughly by authorized personnel in installation.
•Be especially careful close to unprotected moving parts, in particular in their initial setting.
Beware of sharp edges of parts.
•Use only hammers with a soft head (if you must use the hammer).
•Observe operating limits of the equipment given in the specification.
•Use spindle insert to ensure correct position of the bar in the lather spindle.
•Do not process the bars exceeding the length of the lathe spindle/spindle insert.
•Make sure that the channel is empty before loading a bar from the table into the channel.
•Always set the parameter #101 with a sufficient margin to eliminate contact of the pusher
with the rotating spindle
•Set a minimum value of the parameter #300. Too high feeding force overloads both the
barfeeder and the lathe.
•Before start of the work make sure that all safety circuits are active.
•Check where all Stop and Total Stop pushbuttons are located.
•Prior to activation of the automatic cycle make sure that all required functions are
properly set and that all controls are set to correct position.
Observe labour safety principles!!!

Table of Contents
SS2400T/S 5
TABLE OF CONTENTS
LIST OF FIGURES 9
IDENTIFICATION OF INSTRUCTIONS 10
1DESCRIPTION 1-1
1.1 GENERAL DESCRIPTION 1-1
1.2 APPLICATION 1-1
1.3 CONCEPT 1-2
1.4 TECHNICAL SPECIFICATION 1-2
1.5 PROCESS DESCRIPTION 1-6
1.6 INSTALLATION 1-6
1.7 IDENTIFICATION AND SERIAL NUMBER 1-6
2TRANSPORT AND UNPACKING 2-1
3INSTALLATION 3-1
3.1 PREPARATION 3-1
3.2 BARFEEDER ALIGNMENT 3-2
3.2.1 GENERAL 3-2
3.2.2 PRESETTING THE HEIGHT AND SIDE POSITION 3-2
3.2.3 GEOMETRIC ALIGNMENT WITH THE LATHE 3-3
3.3 ELECTRICAL CONNECTION 3-5
3.4 MAGAZINE INSTALLATION 3-6
4OPERATION 4-1
4.1 PRIMARY PREREQUISITES 4-1
4.1.1 PUTTING INTO OPERATION,ANCHORING,ALIGNMENT 4-1
4.1.2 SAFETY OF OPERATION 4-1
4.1.3 ATTENDANCE 4-1
4.2 WORKING PROCEDURES 4-1
4.2.1 FEEDING TO STOPPER 4-1
4.2.2 FEEDING TO POSITION (SS2400S) 4-2
4.3 BAR GUIDING 4-2
4.4 BAR FEEDING 4-3
4.4.1 FEEDING TO STOPPER 4-3
4.4.2 FEEDING TO POSITION (SS2400S) 4-3
4.5 INSTALLATION OR REPLACEMENT OF SPINDLE INSERT (AT CHANGE OF THE BAR
DIAMETER) 4-4
4.6 SETTING THE CHANNEL POSITION (AT CHANGE OF THE BAR DIAMETER) 4-4
4.7 SETTING THE MAGAZINE POSITION (AT CHANGE OF THE BAR DIAMETER) 4-4
4.8 PUSHER 4-5
4.9 BARFEEDER CONTROL 4-6
4.9.1 E-STOP PANEL 4-6
4.9.1.1 Power On button (S10) 4-6
4.9.1.2 Mode Switch (S3) 4-6
4.9.2 KEYS 4-7
4.9.2.1 Mode Keys Aut, Man, Dat 4-7
4.9.2.2 Start/Stop Key 4-7
4.9.2.3 Function Keys F1, F2, F3 and More Key 4-7
4.9.2.4 Info Key 4-8

Table of Contents
6SS2400T/S
4.9.2.5 Navigation Keys 4-8
4.9.2.6 Numeric Keys 4-8
4.9.2.7 Enter Key 4-8
4.9.2.8 Esc key 4-8
4.9.3 STATUS BAR 4-9
4.9.4 USER LEVELS AND THEIR MEANING 4-10
4.9.4.1 Changing User Level 4-10
4.9.5 MANUAL MODE 4-11
4.9.5.1 Move to a Reference 4-11
4.9.5.2 Standard Motions of the Barfeeder 4-11
4.9.5.3 Loader REVERSING 4-12
4.9.5.4 Material Switch Calibration (SS2400S) 4-12
4.9.6 AUTOMATIC MODE 4-13
4.9.6.1 Indicator of Bar Handling Method 4-13
4.9.6.2 Automatic Cycle Startup 4-13
4.9.6.3 Automatic Cycle Termination 4-13
4.9.6.4 Bar Counter 4-14
4.9.6.5 Quick Adjustment of the Feeding Force (#300) 4-14
4.9.6.6 Opened Cover of the Magazine 4-14
4.9.7 LATHE OPERATION WITHOUT THE BARFEEDER 4-15
4.10 BARFEEDER PARAMETERS 4-16
4.10.1 DATA MODE 4-16
4.10.1.1 Parameter Selection 4-16
4.10.1.2 Parameter Types 4-17
4.10.1.2.1 Parameters of List Type 4-17
4.10.1.2.2 Parameters of Position Type 4-17
4.10.1.2.3 Parameters of Other Type 4-17
4.10.1.2.4 Job Selection Function 4-17
4.10.2 OPERATOR PARAMETERS 4-18
4.10.2.1 #100 – End oF Bar 4-19
4.10.2.2 #101 – Pusher Retract Position 4-19
4.10.2.3 #300 – Feeding Force 4-20
4.10.2.4 #010 – Push Mode (SS2400S) 4-20
4.10.2.5 #105, #106 – Feeding Length (SS2400S) 4-20
4.10.2.6 #107 – New Bar Face Position (SS2400S) 4-21
4.10.2.7 #011 – Machine Work Mode (SS2400S) 4-21
4.10.2.8 #102 – Collet Face Position 4-22
4.10.2.9 #301 – Retract Delay 4-22
4.10.2.10 #003 – End of Bar M-Code (EOB M-Code) 4-23
4.10.2.10.1 Special EOB M-Code Case 4-23
4.10.2.10.2 EOB M-Code Use 4-23
4.10.2.11 #004 – Ejecting Control 4-24
4.10.2.12 #400 – Jobs Table 4-24
4.10.3 SERVICE PARAMETERS 4-26
4.10.3.1 #000 – Automat Mode 4-26
4.10.3.1.1 Normal Automatic Mode 4-26
4.10.3.1.2 Automatic Mode Simulation 4-27
4.10.3.1.3 Test Mode 4-28
4.10.3.2 #001 – Feeding on M-Code 4-29
4.10.3.3 #002 – End of Bar Timing 4-29
4.10.3.4 #005 – Clamping Device 4-30
4.10.3.5 #006 – Language 4-30
4.10.3.6 #007 – K4 Relay 4-30
4.10.3.7 #008 – M-Code Style 4-30

Table of Contents
SS2400T/S 7
4.10.3.8 #103 – Barfeeder Stroke 4-31
4.10.3.9 #108 – Material Switch Position (SS2400S) 4-31
4.10.3.10 #009 – Factory Reset 4-31
4.11 HOW TO PROGRAM A LATHE WITH THE BARFEEDER 4-33
4.11.1 FEEDING TO STOPPER 4-33
4.11.2 FEEDING TO POSITION (SS2400S) 4-34
4.11.3 PARAMETER SETTING EXAMPLE 4-35
5MAINTENANCE 5-1
5.1 ROUTINE MAINTENANCE 5-1
5.2 ERROR MESSAGES 5-2
5.3 ELECTRIC EQUIPMENT 5-6
5.3.1 ARRANGEMENT AND PURPOSE OF SWITCHES 5-6
5.3.2 ARRANGEMENT OF INSTRUMENTS IN THE SWITCHBOARD 5-7
5.3.3 CONTROL 5-7
5.3.3.1 PLC 5-7
5.3.3.1.1 Battery 5-8
5.3.3.2 I/O modulE X3 5-8
5.3.3.3 Drive SM1 5-9
5.3.3.3.1 Selected states of the drive 5-9
5.3.4 INTERFACE DESCRIPTION 5-10
5.3.5 DIAGNOSTICS 5-12
5.3.5.1 Diagnostic Data 5-12
5.3.5.2 Information Data (Software Options) 5-12
5.3.6 WIRING DIAGRAMS 5-13
5.4 SPARE PARTS 5-23
5.4.1 ELECTRIC SPARE PARTS 5-23

Table of Contents
8SS2400T/S

Table of Contents
SS2400T/S 9
LIST OF FIGURES
Fig.1.1 Main Dimensions of the Barfeeder 1-5
Fig.1.2 Nameplate 1-6
Fig.2.1 Barfeeder Lifting and Setting 2-1
Fig.3.1 Setting the Height and Side Position 3-2
Fig.3.2 Setting Kit 3-3
Fig.3.3 Barfeeder Anchoring 3-5
Fig.3.4 Electrical Connection 3-5
Fig.3.5 Magazine Installation 3-6
Fig.4.1 Bar Guiding in the Spindle Insert 4-2
Fig.4.2 Bar Feeding 4-3
Fig.4.3 Channel Position Setting 4-4
Fig.4.4 Magazine Position Setting 4-5
Fig.4.5 Pusher Dismantling and Mounting 4-5
Fig.4.6 Control Panel 4-6
Fig.4.7 Keys 4-7
Fig.4.8 Status Bar 4-9
Fig.4.9 Automatic Mode 4-13
Fig.4.10 Data Mode 4-16
Fig.4.11 Linear Operator Parameters 4-18
Fig.4.12 Setting the Parameter #100 – End of Bar 4-19
Fig.4.13 Jobs Table 4-25
Fig.5.1 Routine Maintenance 5-1
Fig.5.2 Electric Element Layout 5-6
Fig.5.3 Arrangement of Instruments in the Switchboard 5-7
Fig.5.4 Control 5-7
Fig.5.5 Drive SM1 5-9
Fig.5.5 Electric Spare Parts 5-23

Identification of Instructions
10 SS2400T/S
IDENTIFICATION OF INSTRUCTIONS
•Important instructions are emphasized in this manual as follows:
Failure to observe these instructions can result in
injury of the operator.
Failure to observe these instructions can result in
damage to the barfeeder or the lathe.
Other important instructions
•Parameter numbers are identified as #xxx in this manual, where xxx is the parameter
number.

Chapter 1 – Description
SS2400T/S 1-1
1 DESCRIPTION
1.1 GENERAL DESCRIPTION
The barfeeder SS2400T/S has been designed for work with any type of CNC lathe equipped
with an interface for the barfeeder with a magazine. The length of the bars is limited by the
length of the lathe spindle (with a clamping cylinder and clamping device). As the barfeeder
does not touch any rotating part of the lathe or rotating bar, it is possible to utilize full range
of operating speed of the lathe. Barfeeder design enables automatic loading and feeding of
bars into the lathe with minimum built-up area required. Barfeeder setting up and
programming is easy and fast.
Bars must be guided by the spindle insert in the lathe. The rest of the bar, from which it is not
possible to make a part, is forced by the barfeeder into the lathe workspace, with no
additional equipment needed.
The barfeeder is designed for work with bars of any cross sections. For feeding of non-
circular cross section bars the lathe must be equipped with a spindle orientation. At work with
bars of common cross sections a section insert must be installed in the loading channel of
the barfeeder, the insert is not a part of the standard equipment of the barfeeder.
1.2 APPLICATION
Barfeeders of SS2400 series are manufactured in the following modifications:
Barfeeder Feeding mode Other important functions
SS2400T Stopper ---
SS2400S Stopper or Position Functions for double-spindle lathe operation,
which uses the second spindle for feeding.
Barfeeders of SS2400 series provide:
Function T S
Cheap and effective automation of operation of any CNC lathe 99
Workspace saving thanks to side storage and loading of bars 99
Automatic loading of a new bar after processing of the previous bar 99
Precise work at high speed of the lathe spindle unaffected by the barfeeder 99
Processing of bars of imperfect shape or dimensions 99
Bar feed against the lathe stopper 99
Bar feed to a programmed position (without stopper) 89
For double-spindle lathes, feeding through the second spindle without time
delays necessary for the barfeeder operation
89

Chapter 1 – Description
1-2 SS2400T/S
1.3 CONCEPT
The barfeeder SS2400T/S is a powerful machine with a long service life and minimal
maintenance required. Its operation and functions are simple which facilitates the work even
to less skilled workers.
The barfeeder is controlled by means of the control panel in the right part of the machine,
where there is also the Q1 switch. There is an E-Stop pushbutton for emergency stop on the
control panel.
Bars are loaded in the magazine. Loading of bars into the lathe is ensured by a crank loading
mechanism with a flag and pusher.
On the rear side of the frame there are connectors X1, X2 for barfeeder interconnection with
the lathe.
1.4 TECHNICAL SPECIFICATION
Scope of application Bar dimension
Round cross section of bars 6 to 105 mm
(.250”-4.000”)
Hexagonal cross section of bars 8 to 90 mm
(.315”-3.500”)
Square cross section of bars 8 to 74 mm
(.315”-2.75”)
Pusher stroke
Design stroke 1539 mm
(60.59”)
Working stroke 1535 mm
(60.43”)
Maximum distance of the clamping device face from the pusher point
in back position
1530 mm
Bar length
Maximum length of bar handled by the barfeeder 1500 mm
(59.00”)
Actual max. len
g
th of the bar is limited b
y
the len
g
th of the
spindle (with clamping cylinder and clamping device).
Magazine capacity depending on the bar diameter
3 bars ∅105 mm
(4.00”)
Number limited by the table capacity ∅6 mm
(.250”)
Total weight of all bars on the table must not exceed
250 k
g
. (550 lbs.)

Chapter 1 – Description
SS2400T/S 1-3
Technology of bar handling
The bar is cantered in the lathe spindle by spindle inserts, and shifted by the pusher to a
stopper in the tool head.
Spindle speed
Depending on lathe design and quality of spindle insert.

Chapter 1 – Description
1-4 SS2400T/S
B: 150 mm
A: 150 mm
Bar preparation
No specific requirements for bar preparation.
Bar straightness
Bar must freely go into the user selected spindle insert.
Bar loading cycle
approx. 30 s
Setting time at change of bar diameter
Max. 2 minutes at change to other diameter + time of lathe spindle insert replacement
Use
With all CNC lathes equipped with an interface for the barfeeder with the magazine
Electric equipment
Power supply 200/230/400 VAC, 50/60 Hz, 320 VA
Power circuits 200 VAC, 24 VDC
Logic circuits 24 VDC
Colour design
Light grey
Weight
Unit Net 360 kgs. (794lbs.)
Packaging
Transport dimensions 2160x780x1230 mm (85”x30”x49”)
Barfeeders are sealed in plastic sheet and transported on non-returnable pallets or in
boxes. Pallet weight is approx.35 kg(77lbs.), the weight of the whole box approx. 140
kg.(309 lbs.)
Noise emission
The values have been stated in accordance
with ČSN EN ISO 4871 and basic standard
ČSN EN ISO 11201.
A B
w/o bars with bars w/o bars with
bars
Measured emission level of sound
pressure A, PpAd at the operator workplace
(dB)
67 69 68 71
Uncertainty, KpA (dB) 4 4 4 4

Chapter 1 – Description
SS2400T/S 1-5
Main dimensions
A
standard 825-1175 opce 990-1340
Fig.1.1 Main Dimensions of the Barfeeder
option

Chapter 1 – Description
1-6 SS2400T/S
1.5 PROCESS DESCRIPTION
SS2400T/S barfeeder feeds bars into the lathe as follows:
•The loading mechanism takes a bar from the magazine and puts it into a fixed loading
channel.
•The flag shifts the bar into the spindle and after it returns to back limit position.
•The pusher is tilted into the spindle axis.
•The pusher pushes the bar through the open clamping device against the stopper in the
tool head (SS2400T/S) or to a required position in front of the clamping device
(SS2400S).
•The clamping device closes, and the pusher returns.
•The lathe machines the part.
•Next bar feed is executed, when the spindle stops and clamping device opens.
•If the bar length is insufficient to make another part, the barfeeder sends the End of Bar
signal. The signal is tested by the lathe program which issues a command to eject the
rest of the bar and load a new bar.
•Following the End of Bar signal the clamping device opens to enable ejection of the rest
of the bar by the pusher.
•After ejection of the rest of the bar into the lathe workspace, the pusher tilts to upper
position, the loading mechanism takes a bar from the magazine, and the whole cycle is
repeated.
1.6 INSTALLATION
It is recommended that installation should be carried out by the manufacturer's staff or by
persons authorized by the manufacturer. Prior to installation, check the items specified in the
installation form, and verify whether suitable interface is installed on the lathe for the
barfeeder with the magazine.
1.7 IDENTIFICATION AND SERIAL NUMBER
Serial number of the barfeeder is shown on the nameplate fastened on the rear side of the
barfeeder under the magazine.
Fig.1.2 Nameplate

Chapter 1 – Description
SS2400T/S 1-7

Chapter 2 – Transport and Unpacking
SS2400T/S 2-1
2 TRANSPORT AND UNPACKING
Barfeeders are sealed in plastic sheet and transported on pallets or, exceptionally, in wooden
boxes (see Chapter 1.4 for dimensions). They are fastened by screws to the box
bottom/pallet.
To eliminate any damage, the following procedure must be observed
during unpackaging, otherwise the manufacture will bear no liability for
any damage in unpackaging not carried out according to this procedure.
Unpacking
•Put the box/pallet behind the lathe to the place where the barfeeder is to be installed.
•If the barfeeder is in the box, remove the cover and sides of the box.
•Remove the plastic sheet.
•Check whether the shipment is in order and complete (according to the packing list
attached to the Manual).
•Remove the barfeeder and its cover from the pallet.
•Lift the barfeeder by high-lift truck with forks under the lower part of the casing. If it is
difficult to slide the forks under the barfeeder, increase the height of the barfeeder pusher
axis, see Chapter 3.2.2.
Lift the Barfeeder only under the lower part of the casing. Never lift it
otherwise, or you could cause a damage.
•Put the barfeeder on the rear side of the lathe as shown in Fig.2.1. The distance between
the rear side (rear end) of the lathe spindle and front cover of the barfeeder should be as
small as possible. The gap between the barfeeder cover and lathe cover must not exceed
20 mm or it is necessary to disable insertion of the hand palm between the barfeeder and
the lathe.
Fig.2.1 Barfeeder Lifting and Setting

Chapter 2 – Transport and Unpacking
2-2 SS2400T/S
In unpacking check the completeness of standard accessories. .
Standard accessories of the barfeeder SS2400T/S
Type Quantity
anchor bolts 5
washers under anchor bolts 5
setting kit 1
setting wrench (speeder) 1
cellulose thinner reducible repair paint 1
User Manual 1
pusher with fixed stopper ∅10 mm 1
pusher with fixed stopper ∅18 mm 1
See the packing list for complete list of the delivered accessories.