LNS GT 112-E Instruction Manual
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LNS GT 112-E Instruction Manual

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Instruction manual
ENG
LNS America
4621 East Tech Drive
v02.0 October 2017
Cincinnati, Ohio 45245

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Summary of Contents for LNS GT 112-E

  • Page 1 Instruction manual LNS America 4621 East Tech Drive v02.0 October 2017 Cincinnati, Ohio 45245...

  • Page 2: Table Of Contents

    4-10 PLC I/O 4-11 DIAGRAMS 4-12 INTERFACE 4-16 SAFETY SWITCHES 4-20 5 PNEUMATICS GENERAL DESCRIPTION F.R.L. AIR FILTERING UNIT SOLENOID VALVE MANIFOLD MAINTENANCE PNEUMATIC DIAGRAMS 6 HYDRAULICS GENERAL DESCRIPTION LAYOUT OF THE ELEMENTS DESCRIPTION of THE ELEMENTS MAINTENANCE GT 112-E...
  • Page 3 ERROR MESSAGE DESCRIPTION AND TROUBLE SHOOTING GUIDE SERVO AMPLIFIER ERROR MESSAGES 9-18 FACTORS AFFECTING PERFORMANCE 9-33 MAINTENANCE 9-35 10 APPENDICES APPENDIX A: PROGRAMMING EXAMPLE 10-1 APPENDIX B: ODERING FORM 10-2 APPENDIX C: ADDRESS LNS 10-3 APPENDIX D: PART PRINTS GT 112-E...

  • Page 4: Basic Notions

    This sign indicates that safety measures must be taken to avoid possible electrical shocks or mishaps. The notes stress interesting points or comments, and provide useful advice for optimal system operation. This sign serves to point out the portion mentioned on the description. GT 112-E...

  • Page 5: Rights

    (such as rotating speed and temperature). Therefore these consumables are excluded in the warranty. Design and specifications are subject to change without prior notice. GT 112-E...

  • Page 6: Safety Instructions

     For the use and maintenance of the bar feeder, use only parts provided by or  recommended by LNS. If it is necessary to move the bar feeder after it has been originally installed, do not reinstall  it before first contacting our representative.
  • Page 7 Chapter 1 BASIC NOTIONS 1 - 4 GT 112-E...

  • Page 8: Technical Data

    RPM capability of the system GT 112-E is available for loading bar stock diameter from (Ø0.8) Channel Ø1 ~...

  • Page 9: Bar Diameter Measurement

    = b ×1.154 a = b ×1.41 Pusher collet size = a Channel size Pusher collet size Inch/mm Conversion To convert to millimeters: multiply inches × 25.4 To convert to inches: multiply millimeters X 0.0394 GT 112-E...

  • Page 10: Floor Plan

    Chapter 2 TECHNICAL DATA 2 - 3 2.4 FLOOR PLAN GT 112-E...
  • Page 11 Chapter 2 TECHNICAL DATA 2 - 4 GT 112-E...

  • Page 12: Layout Of The Elements

    Description Pusher (not visible) AC Servo motor Vise( Material clamping device) Remnant detecting sensor Guiding channel Remnant box Remote control (HMI) Cover Top cut measurement device Front stand Rear stand Electrical cabinet Hydraulic pump Hydraulic tank Synchronization device GT 112-E...
  • Page 13 Chapter 2 TECHNICAL DATA 2 - 6 GT 112-E...

  • Page 14: Setting Into Operation

    A pusher and guiding channel set may be mounted in the bar feeder. Depending on the purchase order, other sets may be delivered in a separate box. The electrical interface diagram is placed inside the electrical cabinet. Documentation, tools, pusher collets, lathe connecting parts, front tube/telescopic tube, and other accessories are packed separately. GT 112-E...
  • Page 15 For installing the bar feeder, it’s advisable to contact us or one of our branches offices or one of your local LNS representatives. We cannot be held responsible for any malfunction or any damage to the bar feeder or the lathe due an incorrect installation in which we did not take part <...

  • Page 16: Positioning Of The Bar Feeder

    Chuck / collet Loading flag  Front tube length check The front tube (if provided) should be able to cover the space between the bar feeder and the spindle. This will prevent the bar to be exposed. Joint pipe Spindle GT 112-E...
  • Page 17 10mm LONGER than the telescopic tube minimum retracted length (collapsed). Note: Depending on the configuration of the machine, the telescopic tube stroke and other mechanical interface components may influence the final position of the bar feeder behind the lathe. GT 112-E...

  • Page 18: Mounting

    9. Anchor the bar feeder to the floor using anchoring bolts(G) and according to instructions in the manual (3.3.3.) 10. Prior to securing the bar feeder to the floor it is recommended to check again the bar feeder alignment. The bar feeder alignment is critical for good performance. GT 112-E...
  • Page 19 (Please refer to 3.3.2 for bar feeder leveling) Using an alignment tool (LNS or others) proceed to the alignment of the bar feeder so that the nylon string is perfectly centered at the back of the lathe spindle and the front of the bar feeder.

  • Page 20: Connection

    For the pneumatic connection, please see Chapter 5, Pneumatics.  For the hydraulic connection, please see Chapter 6, Hydraulics.  For the mechanical connection, please see Chapter 7, General description.  For the parameter setting, please see Chapter 8, Operation.  GT 112-E...
  • Page 21 Chapter 3 SETTING INTO OPERATION 3 - 8 GT 112-E...

  • Page 22: Electrics

    Loading motor B18120500 Bar measuring device B18120400 Home position Guiding channel opened C11111100 Guiding channel closed Vice system SQ10 4.484 Retraction safety (Option) SQ11 4.894 Main cover Safety SQ12 B18120500 Loading Sensor B18160110 Loading button B18160110 Unloading button GT 112-E...
  • Page 23 Chapter 4 ELECTRICS 4 - 2 4.2 ELECTRICAL CABINET 4.2.1 Electrical cabinet SERVO AMP Analog module PCB BOARD POWER SUPPLY RELAY TRANSFORMER KS, K8, K9, K10 GT 112-E...
  • Page 24 B24110200 CE Relay (DCS version) 4.932 Electromagnetic Multi voltage 4.932 Transformer B55000051 contactor transformer B11000027 Fuse Dual Channel B23160003 Safety(Option) B66000011 Fuse Holder B66000007 Relay R14,R15 RELAY B11000065 Relay Base (for 2 position retraction) B13204037 Cable GT 112-E...
  • Page 25 Control circuit terminal (L1, L2) Used to connect to 100-230 VAC power supply Main circuit terminal (R, S, T) Used to connect 200-230 VAC power supply Heatsink Used to secure servo drive and for heat dissipation Protective earth Display GT 112-E...
  • Page 26 4A, the breaker trips and lever B flips down. The power supply to the PLC and 24V DC power supply is immediately interrupted. After the problem is fixed, reset the breaker by flipping lever B up. Lever B GT 112-E...
  • Page 27 Output signals indication LED. Indicate the status of outputs Y0 to Y27. PLC status indication LED. Communication port. b) Analog module The analog signals serves to control the torque and speed of the servo motor. Designation Description Torque control output contacts Speed control output contacts Power indication LED GT 112-E...

  • Page 28: Electrical Components

    220V AC input terminals 24V DC output terminals 4.2.7 PCB (Printed Circuit Board) PCB is a board with circuit printed and electrical components welded on the surface. It offers sockets and terminals for electrical components like relays, cables and fuses. GT 112-E...
  • Page 29 Connect to PLC input contacts X20, X21 TB27 +24, +24, +24, M, S11, S12 Connect to K8 safety relay TB28 K1, K2, K3, K4, K5, EM1 Short circuit TB29 M, +24, 1 Connect to SP1 air pressure switch TB30 GT 112-E...
  • Page 30 The incoming power must be connected to the primary terminal block. Use the contacts corresponding to the supplied power (346V AC to 440V AC, see drawing below). The outgoing power is always connected to the 220V AC terminals of the secondary terminal Block. Secondary terminal block Primary terminal block Part number? GT 112-E...

  • Page 31: Symbols

    Electromagnetic switch KM1 / K1 Pressure switch SP1, SP2 SQ1, SQ2, SQ3 SQ4, Proximity switch Relay KS, K7, R1 ~ R5 Remote control buttons S1 ~ S7 Servo motor YV1, YV2A, YV2B, Solenoid valve YV7, YV3, YV8, YV9, YV11 GT 112-E...

  • Page 32: Plc I/O

    Chapter 4 ELECTRICS 4 - 11 4.4 PLC I/O Circuit diagram: XM1.25.A001G GT 112-E...

  • Page 33: Diagrams

    Chapter 4 ELECTRICS 4 - 12 4.5 DIAGRAMS 4.5.1 AC circuit Circuit diagram: XM1.25.A001G GT 112-E...
  • Page 34 Chapter 4 ELECTRICS 4 - 13 4.5.2 Emergency stop circuit Circuit diagram: XM1.25.A001G GT 112-E...
  • Page 35 Chapter 4 ELECTRICS 4 - 14 Circuit diagram: XM1.25.A001G GT 112-E...
  • Page 36 Chapter 4 ELECTRICS 4 - 15 Circuit diagram: XM1.25.A001G GT 112-E...

  • Page 37: Interface

    The universal interface consist most signals which might be transmitted between the lathe and bar feeder. The later the user can change the wiring according to the lathe requirement or contact us for technical advisement. GT 112-E...
  • Page 38 Chapter 4 ELECTRICS 4 - 17 Interface diagram: BXA00001 GT 112-E...
  • Page 39 The signal logic will be handled according to PI11 setup. g) Lathe door signal A7 (PLC input X37) Door closed signal is used to control the speed of bar feeder in manual mode when lathe door is closed/open. GT 112-E...
  • Page 40 Generally the spindle rotates at slow speed when the new bar stock is passing through. For lathes not able to rotate the spindle with the chuck open this signal can be used as an external command to turn the spindle. Refer to service parameter PI43 for more information. GT 112-E...

  • Page 41: Safety Switches

    Fig. B alarm message “AL03” is displayed reminding the operator to move back bar feeder in the working position before starting the lathe in production. Please refer to 4.4 and 4.5 for wire connection in the switch. SQ10 GT 112-E...

  • Page 42: Pneumatics

    TOP CUT measurement device cylinder C12115100 Sectional channel covers cylinder C12110200 Material clamping device cylinder C12115200 Channel opening/closing cylinder LtoRF: XM1.27.A301A Air control unit (Invisible) RtoLF: XM1.27.A302A C11121400 Air pressure switch (Invisible) RtoLF: XT032020210 Air filtering system LtoRF: XT032020220 GT 112-E...

  • Page 43: Air Filtering Unit

    Air pressure required: 75-90 PSI (5-6bar) of shop air, preferably clean and dry. 5.2.1 Layout of the elements Designation Part number Description C13120300 Air inlet Pressure regulator Pressure gauge Condensate collector C11120100 Lubricator Oil cup Oil refilling plug Regulated air outlet C13110500 8mm / G1/4 push-in fitting GT 112-E...
  • Page 44 Unlocking the adjusting knob by pulling it upward. To increase the pressure, turn the knob clockwise. To decrease the pressure, turn it counter clockwise. The operational pressure should be kept at 5 bar. When the setting is finished, lock the knob by pressing it downward. GT 112-E...

  • Page 45: Solenoid Valve Manifold

    Pressure switch (PE converter) Material clamping device (vice) TOP CUT measuring device channel cover channel cover C1110100 channel cover channel cover YV10 front rest (Option) YV11 channel cover YV12 Guiding channel opening YV2A C11110200 Guiding channel closing YV2B GT 112-E...
  • Page 46 2. Set the lower pressure limit with screw B. This setup will define when the pressure switch senses an abnormal pressure drop and generate a low pressure alarm. Factory setup is: 43 PSI (3 bar). GT 112-E...

  • Page 47: Maintenance

    In manual mode press on the remote control. Connect the air inlet hose and turn air source back on. Oil refill plug Oil dribbling nozzle Decrease Increase oil oil dripping dripping Keep the oil level around this position GT 112-E...

  • Page 48: Pneumatic Diagrams

    Chapter 5 PNEUMATICS 5 - 7 5.5 PNEUMATIC DIAGRAMS Pneumatic diagrams: XM1.27.P003A GT 112-E...
  • Page 49 Chapter 5 PNEUMATICS 5 - 8 Pneumatic diagrams: XM1.27.P003A GT 112-E...
  • Page 50 Chapter 5 PNEUMATICS 5 - 9 Pneumatic diagrams: XM1.27.P003A GT 112-E...
  • Page 51 Chapter 5 PNEUMATICS 5 - 10 GT 112-E...

  • Page 52: Hydraulics

    3. To absorb the vibration created during high rpm machining. 6.2 LAYOUT OF THE ELEMENTS Designation Part number Description X135010000xx Remnant tray Guiding channels Hydraulic tank C14110300 Drain plug (underneath the oil tank) C17120400 Oil level indicator XT135050000 Hydraulic pump motor GT 112-E...

  • Page 53: Description Of The Elements

    The remnants might be lying between the material clamping device space and interfere with the next bar stock insertion or loading. The tray may be too heavy to empty. Remnants accumulation should remain below the cutout in the remnant tray. The opening of remnant tray GT 112-E...
  • Page 54 Slowly pour the oil into the oil tank directly as shown. The oil level should be kept around H mark on the level indicator when the hydraulic pump is not running. Pour the oil here Oil level indicator Viscosity index (CST@ 40°C / 104°F) ISO VG 68 61.2 ~ 74.8 ISO VG 100 90.0 ~ 110 GT 112-E...

  • Page 55: Maintenance

    Clean the drain plug. Apply the seal on the plug and screw the drain plug back in. Refill the tank with new oil and according to chapter 6.3.4 until the level indicates oil level at H. Confirm there is no leaks from the drain plug. Install the remnant tray back. GT 112-E...

  • Page 56: General Description

    In response to operation required, it also offers a function to invert materials backward. These two buttons are only available in manual mode. Use the button to load or unload bar stocks. Unload Load GT 112-E...

  • Page 57: Guiding System

    XM1.31.A402A.14 XM1.31.A401A.14 3.2M 12’ XM1.31.A501A.08 XM1.31.A501A.11 XM1.31.A502A.14 XM1.31.A501A.14 XM1.31.A601A.08 XM1.31.A601A.11 XM1.31.A602A.14 XM1.31.A601A.14 4.0M XM1.31.A203A.08 XM1.31.A203A.11 XM1.31.A203A.14 XM1.31.A203A.14 2.0M XM1.31.A303A.08 XM1.31.A303A.11 XM1.31.A303A.14 XM1.31.A303A.14 2.5M XM1.31.A403A.08 XM1.31.A403A.11 XM1.31.A403A.14 XM1.31.A403A.14 3.2M 12’ XM1.31.A503A.08 XM1.31.A503A.11 XM1.31.A503A.14 XM1.31.A503A.14 XM1.31.A603A.08 XM1.31.A603A.11 XM1.31.A603A.14 XM1.31.A603A.14 4.0M GT 112-E...
  • Page 58 Part no. Ø6 XM1.31.A003A.06 Ø8 XM1.31.A003A.08 7.2.1.3 Auxiliary thin bar loading plate This component is installed in home position. It is designed for vary small and thin material (about 1mm) to prevent it from getting stuck when loading. GT 112-E...
  • Page 59 This design is specific to thin materials for an optimally closed guiding. Channel open/close cylinder Take LtoR, 2.5M bar feeder with 3 sectional channel cover as an example: channel cover channel cover channel cover Slightly open in sectional GT 112-E...
  • Page 60 ID x OD x L (mm) 017.23.008/530 Ø6.4 x Ø8 L=530mm Ø6 Ø5 112.03.634B Ø7 x Ø12 L=1000mm Ø6 Ø5 112.03.644B Ø8 x Ø12 L=1000mm Ø8 Ø7 112.03.454 Ø11 x Ø18 L=1000mm Ø11 Ø10 112.03.464 Ø14 x Ø18 L=1000mm Ø14 Ø13 GT 112-E...

  • Page 61: Pusher Assembly

    (end of bar). Two pusher lengths are available: Specification Available length of pusher Short pusher 830mm Long pusher 1080mm (Standard for USA) Long pusher Pusher carrier Loading flag Flags GT 112-E...
  • Page 62 LtoRF Bar feeder RtoLF Bar feeder Ø (mm) Short pusher Long pusher (USA) Short pusher Long pusher (USA) XM1.15.A051B.05 XM1.15.A005B.05 XM1.15.A052B.05 XM1.15.A006A.05 XM1.15.A051B.07 XM1.15.A005B.07 XM1.15.A052B.07 XM1.15.A006A.07 XM1.15.A051B.10 XM1.15.A005B.10 XM1.15.A052B.10 XM1.15.A006A.10 XM1.15.A051A.13 XM1.15.A005B.13 XM1.15.A052A.12 XM1.15.A006A.13 RtoLF Bar Feeder LtoRF Bar Feeder GT 112-E...

  • Page 63: Rotating Sleeve

    The user is strongly recommended to inspect its status regularly in order to keep the bar feeder running at the best performance. The rotating sleeve is a wear item, and LNS recommends keeping a spare on hand. Part Number Size 1.440...

  • Page 64: Collet

    Barstock dimension Channel Rotating sleeve / Collet part number Minimum Maximum size, mm collet adapter diameter, mm diameter, mm 1.440 4.00 1.648/05-xx.xx 0.80 015.15.1064 5.55 15053/07-xx.xx 2.00 028.031.024 8.33 15053/10-xx.xx 3.00 028.031.044 11.11 15053/12-xx.xx 5.00 028.031.044 12.00 15053/13-xx.xx 11.00 GT 112-E...

  • Page 65: Diameter Changeover

    Emergency Stop button to disable all functions and movements of the bar feeder. Take out pusher, loading flag and remove pusher hooks. Release hooks Remove the guiding channels, store in a clean location and install newly selected channels. GT 112-E...
  • Page 66 Press to close the guiding channels and press to move pusher back to its home position. Adjust 2’nd front rest to the new bar diameter (If there is equipped with the option). Partial diameter changeover is complete. GT 112-E...

  • Page 67: Belt

    Check tension once every 6 months. 1. Slightly loosen the two screws “A”. (A half to one turn) 3. Secure by locking the two screws “A” (see step one) 2. Turn the screw “B” clockwise using wrench to retighten the belt. GT 112-E...

  • Page 68: Vise (Self-Centering)

    Wearing protective gloves is recommended. The clamping blades must be replaced when worn out. Proceed as follows: 1. Unscrew the two screws (D) and remove the blades (B). 2. Install the new blades and lock the screws. GT 112-E...

  • Page 69: Bar Measuring Device

    TOP CUT distance is not dictated by the bar stock length. Once the bar feeder position is fixed (via parameter), the TOP CUT position is only related to the distance from the bar feeder to the face of the lathe chuck. Bar measuring flag GT 112-E...

  • Page 70: Headstock Synchronization Device

    When the collet is open the synchronization system is disabled while the servo drive maintains a reduced torque to keep the bar in contact with the cut-off tool and preventing short parts. This mode applies to Swiss type lathes only. GT 112-E...

  • Page 71: Lathe Connecting Parts

    Please contact our office for further information. Example: The LNS joint pipe safety connection maintains a continuous connection between the GT 112-E and the machine sliding headstock. This feature allows the headstock to move forward to make parts without the danger of exposed bar stock. The inside diameters of these joint pipes match those of the bar feed’s guide channels.
  • Page 72 The safety switch SQ10 will engage (Refer to chapter 4.6) After completing the maintenance operations, bring the bar feeder back in the forward working position, secure with lock screw (B) and tighten the side screws (A) (max. 75 Nm). GT 112-E...

  • Page 73: Bar Preparation

    For safety and performance reasons the bar end must be chamfered at a 60 degree angle. Please contact our office for further details. GT 112-E...

  • Page 74: Spindle Reduction Tubes

    (diameter of the bar + 1 mm), but should always be larger than that of the diameter of the feeding pusher. For inserting and removing the spindle reductions, move the bar feed system using the retraction device (Chapter 7/ Point 8) or slide the spindle liner through the bar feeder if design permits. GT 112-E...
  • Page 75 Chapter 7 GENERAL DESCRIPTION 7 - 20 GT 112-E...

  • Page 76: Operation

    Error message e01 will be shown on the HMI display. To cancel the alarm, release the button by rotating it clockwise Pressing the Manual key will then reset the Emergency stop alarm condition. GT 112-E...
  • Page 77 Move the pusher leftward. Only available when bar feeder is in MANUAL mode. Slow Leftward Press then press Move the pusher leftward with 2% of the general speed. Only available when the bar feeder is in MANUAL mode. GT 112-E...
  • Page 78 1. If the channel is opened by pressing when the long pusher is at a position exceeding “1 FEED LOADING FLAG POSITION+ 150mm” and the chuck of the lathe open the guiding channel will close when pressing GT 112-E...
  • Page 79 8 - 4 8.1.2 Text display area Working stage Operating mode Unit Current position Parameters Barfeed setting status R- The rest length of bar P- Available machining pieces S- Speed (RPM) T- Torque (%) 1234- Bar end times (cycle) GT 112-E...

  • Page 80: Powering And Emergency Stop

    Do not move or change the pusher position by hand when bar feeder is powered OFF. In case the pusher was accidently moved before powering down move the pusher back to its home position. Turn the bar feeder OFF and power back GT 112-E...
  • Page 81 An alarm AL01 is arising at HMI. When the emergency is removed, release the emergency stop button and press the manual key on remote control to restart the bar feeder. Emergency stop button on the remote control RESET EMERGENCY STOP GT 112-E...

  • Page 82: Automatic/Manual Sequence

    Manually advance the bar until it touches the bar stopper in the lathe. Then close the chuck of the lathe and retract the bar stopper. Press to switch bar feeder GT 112-E...
  • Page 83 Switch the bar feeder to manual mode first. Switch the lathe to manual mode and open the chuck of lathe last. Never open the chuck of the lathe when the lathe is in manual mode and the bar feeder is in AUTOMATIC mode. GT 112-E...

  • Page 84: Operation Parameters

    AUTOMATIC mode. To obtain optimum performance, the operator is strongly recommended to read this chapter before making any changes to the parameters. 8.4.1 Accessing After selecting the operation parameters by pressing F0, the following screen will be displayed GT 112-E...
  • Page 85 To compensate the Pusher torque rate pusher friction (For Depend on “PART SETUP” sliding headstock machine) Against the cut-off tool (For sliding headstock machine) LANGUAGE Language Subject to actual use Unit of measure Subject to actual use Functions Dry run GT 112-E...
  • Page 86 The diameter of the guiding elements is always proposed for change after the pusher changeover cycle. NUMBER OF CLAMPING DEVICE OPENINGS Number of lathe clamping openings during the machining of one part. Used to prevent undesired part feed out during clamping opening. GT 112-E...
  • Page 87 1 bar by 2 turns. 3. When this setting value is equal to zero, the screw will only load 1 bar by 1 turn. (By default for USA, this value should always be set to 7.0) GT 112-E...
  • Page 88 It defines the position of first feeder when a new bar is loaded. This setup can shorten the time of FIRST FEED. Move first feeder forward to loading flag position manually then insert the value according to the current pusher position. GT 112-E...
  • Page 89 Depending on the lathe and its options, the auxiliary end of bar may be used in several ways, for example for the opening of an external rest. The procedure is the same as this for the end of bar setting. GT 112-E...
  • Page 90 INSERTION TRAVEL DISTANCE Specifies the stroke of the pusher for the insertion of the bar into the pusher collet. EXTRACTION TRAVEL DISTANCE Specifies the stroke of the pusher for the extraction of the bar from the pusher collet. GT 112-E...
  • Page 91 The torque applied during machining operations. AGAINST THE CUT-OFF TOOL (For sliding headstock machine) This setup defines the torque applied when the bar stock pushes against the tool. Language LANGUAGE Allows the user to choose the barfeed HMI language. GT 112-E...
  • Page 92 (SQ1 ON)”, Press “DRY RUN”, the bar feeder will switch to DRY RUN mode. Interface output signal (R4) will automatically turn on and interface signals from the lathe will be ignored. Press “STOP” to exit. GT 112-E...

  • Page 93: Service Parameters

    8.5 SERVICE PARAMETERS Service parameters must only be modified by trained technicians or personnel authorized by LNS representative. Incorrect setup might cause safety hazards and/or unexpected malfunction or damage on either bar feeder or lathe. Accessing these parameters is password protected.
  • Page 94 Manual reverse 400RPM With clamping closed (fixed 45RPM headstock) Torque rate Torque setting- Asia/ Western Subject to actual use OPTIONS Headstock synchronization No/ Yes Subject to actual use device Keep closed/ External stabilizer operation Keep closed With chuck open/close GT 112-E...
  • Page 95 5mm. PUSHER TYPE Allow to choose pusher with collet or pusher with cone. LOADING CYCLE ENABLE WHILE CLAMPING DEVICE Defines at End of Bar the loading cycle will initiate when receiving the chuck signal open or close. GT 112-E...
  • Page 96 This parameter checks if the bar feeder is already in AUTOMATIC mode when the chuck signal is turned ON/OFF for 3 cycles without receiving the Auto signal from the lathe. POSITION POSITION Defines the retraction distance of the pusher for spindle inching during loading of profiled bars. GT 112-E...
  • Page 97 FEED RATE/ TORQUE TORQUE RATE Sets the torque of servo motor to define the pushing force for bar insertion and extraction. DURING INSERTION The default value of torque: 250% DURING EXTRACTION The default value of torque: 250% GT 112-E...
  • Page 98 Defines if using the headstock synchronization device. EXTERNAL STABILIZER OPERATION Defines the action of optional external stabilizer before the pusher reaches the position set on second anti-vibration. Keep closed Follow the chuck moving open and close BOOSTER TYPE GT 112-E...
  • Page 99 1 When the lathe chuck is closed, no manual motion of the pusher is allowed. 2 When the lathe chuck is closed, manual motion of the pusher is allowed. GT 112-E...
  • Page 100 Bar change cycle initiates when receiving A3 signal after the End of Bar signal arises. Bar change cycle initiates at any time when A3 signal is received. ＊Refer to the timing chart <1> on 8.6.2.1 06- Loading cycle enable GT 112-E...
  • Page 101 When the lathe is switched to automatic mode, AUTO signal A2 turns ON. This parameter defines the type of A2 signal. A2 signal is a latched signal. A2 signal is a pulsed signal. 11- PUSH signal (A4) setup GT 112-E...
  • Page 102 Top Cut position and turns OFF when bar feeder starts a new loading cycle. This output indicates the bar feeder is in working mode. ＊Refer to the timing chart <3> on 8.6.2.1 14 R2 during End of Bar (Refer to INTERFACE13, 15, 16 for related setup) GT 112-E...
  • Page 103 R3 signal turns ON when the pusher reaches the End of Bar position and remains ON. It turns OFF according to INTERFACE18, 19, 20 or 33 setup. 2 R3 signal turns ON only while the pusher is in the End Of Bar position. GT 112-E...
  • Page 104 R3 signal turns OFF when the new bar reaches Top Cut position ＊Refer to the timing chart <4> on 8.6.2.1 20 R3 pulses for 2 sec. at End of Bar (Refer to INTERFACE17, 18, 19, 31, 32, 33 for related setup) GT 112-E...
  • Page 105 Safety setup. The chuck of the lathe must be closed before switching to automatic mode. The chuck condition of the lathe does not matter to switch the bar feeder to automatic mode. 24 Automatic signal connected to (A2) (Refer to INTERFACE09 for related setup) GT 112-E...
  • Page 106 Defines when the End of Bar signal R3 turns ON. R3 signal turns ON when the pusher reaches the End of Bar position during chuck opened. R3 signal turns ON when the last part is machined with chuck closed after the End of Bar. GT 112-E...
  • Page 107 2. R2 signal is pulsed for 1 second to confirm M-code for headstock synchronization enabled. 43 R5 is Defines function of R5 signal Used for Auxiliary End of Bar signal. Used for spindle Inching signal Used for Magazine Empty 44 Lathe door signal logic setup GT 112-E...
  • Page 108 A4 Push signal lit, the lathe commands pushing. A4 Push signal lit, the lathe commands not pushing. 47 Alarm signal (R1) logic setup Defines the situation when R1 is ON 1. No alarm 2. Alarm 49 A2 Signal definition GT 112-E...
  • Page 109 TEST INTERFACE MODE This mode is selected for test purpose only. It allows testing the interface signals (Input/Outputs) of the PLC. RUN OFF LNS factory test only. It’s only used for special test. 8.5.2.1 Timing chart reference GT 112-E...
  • Page 110 Chapter 8 OPERATION 8 - 35 <1> Start loading signal A3 <2> Push signal A4 GT 112-E...
  • Page 111 Chapter 8 OPERATION 8 - 36 GT 112-E...
  • Page 112 Chapter 8 OPERATION 8 - 37 <3> Start signal R2 INTERFACE13 INTERFACE14 INTERFACE15 INTERFACE16 GT 112-E...
  • Page 113 Chapter 8 OPERATION 8 - 38 <4> End of Bar signal R3 INTERFACE17 INTERFACE18 INTERFACE19 INTERFACE20 INTERFACE31 INTERFACE32 INTERFACE33 GT 112-E...
  • Page 114 Chapter 8 OPERATION 8 - 39 GT 112-E...

  • Page 115: Trouble Shooting Guide

    The remnant is too long or barstock is between the lathe and the bar feeder. Troubleshooting Manually remove the remnant. Description Lathe chuck is closed, press is invalid. Troubleshooting 1. Open lathe chuck. 2. Check INTERFACE00 setup related to lathe chuck signal. GT 112-E...
  • Page 116 START button when the short pusher is not yet at “BAR LOADING REAR LIMITER POSITION”. This message will then arise. Trouble shooting Press “Load / Unload” button to clear this message. Description This message will arise when manually press loading button. GT 112-E...
  • Page 117 <Note> Only applied when “INTERFACE24: Automatic signal connected to (A2)” is set 1. Troubleshooting 1. Switch lathe to AUTO mode. 2. If A2 signal is not used, please change the INTERFACE24 setup. Check if the “INTERFACE45: AUTO signal” setup is correct. GT 112-E...

  • Page 118: Error Message Map

    Chapter 9 TROUBLE SHOOTING GUIDE 9 - 4 9.2 ERROR MESSAGE MAP The following flow chart shows a basic sequence of event that includes the alarms that can occur during production operation (bar feeder + lathe). GT 112-E...

  • Page 119: Error Message Description And Trouble Shooting Guide

    Follow the troubleshooting instructions below to solve the problems and clear the alarms. To clear the alarm after troubleshooting presses STOP. If the alarm message remains active please contact LNS or one of its representatives for further technical assistance. AL01 Emergency Stop Line is open!
  • Page 120 60 seconds (SP2 OFF). This alarm only shown after the lathe finishes machining a workpiece and chuck is open. This switch is optional so this error message is only available when bar feeder installed this switch. GT 112-E...
  • Page 121 2. Check if switch SQ3 if defective or misadjusted. 3. Check if the air pressure is too low or if the guiding channel opening cylinder is too slow. 4. Press “STOP” button on HMI to clear the alarm. GT 112-E...
  • Page 122 1. Verify if the pusher is physically at home position and then check if the switch SQ2 is operational. 2. If the pusher is not physically at home position the servo motor encoder may be defective. 3. Press “STOP” button on HMI to clear the alarm. GT 112-E...
  • Page 123 6. Check if “TOP CUT POSITION” setup is incorrect. 7. Check if the bar measuring device of the bar feeder is malfunctioning. 8. Press “STOP” button on HMI to clear the alarm. GT 112-E...
  • Page 124 “part length” this alarm will turn on. Only valid with fixed headstock lathe. Trouble shooting 1. Check if the alignment of the bar feeder is correct. 2. Check if the channel and front tube sizes are correct and if obstructed. GT 112-E...
  • Page 125 The bar feeder monitors the pusher moving distance from the time the chuck closes to the time the chuck opens. If the distance is shorter than the “Too short” setup, this alarm will be generated. Only valid with Swiss type lathe. GT 112-E...
  • Page 126 2. If “BAR INSERT CHECK”=NO and insertion procedure is completed the pusher will move back and forth and the clamping vise will detect the bar stock. If no bar is detected the alarm will be generated. GT 112-E...
  • Page 127 Description When switching the bar feeder in simulation mode no material should be present. Troubleshooting 1. Check if the switch SQ6 on the clamping vise is defective of misadjusted. 2. Remove material is present in the bar feeder GT 112-E...
  • Page 128 AUTOMATIC mode but the bar feeder is still in MANUAL mode. The bar feeder is in MANUAL mode when the lathe chuck is opened and closed 3 times without starting the bar feeder in Automatic mode. Troubleshooting Switch the bar feeder to AUTOMATIC mode. GT 112-E...
  • Page 129 3. Check if the feeding mechanism is malfunction or if the chain is broken. 4. Check if the lathe chuck is malfunctioning or the clamping force setup is incorrect. 5. Press “STOP” button on HMI to clear the alarm. GT 112-E...
  • Page 130 1. Check if the servo motor is defective. 2. Check if switch SQ2 is defective of misadjusted. 3. Press “STOP” button on HMI to clear the alarm and press backward to bring the pusher to its home position. GT 112-E...
  • Page 131 Check if the servo amplifier and motor are malfunctioning. Check if the encoder of servo motor is functional. Check if the LED of encoder input on PLC is flickering. Press “STOP” button on HMI to clear the alarm. GT 112-E...

  • Page 132: Servo Amplifier Error Messages

    EE-PROM write-in and read-out is in error. AL018 Encoder output error The encoder output exceeds the rated output frequency AL019 Serial communication RS232/485 communication is in error. error AL020 Serial communication RS232/485 communication time out. time out AL021 Reserve Reserve GT 112-E...
  • Page 133 AL099 DSP firmware EE-PROM is not reset after the firmware version is upgrade upgraded. This fault can be cleared after setting P2-08 to 30 first, and then setting P2-08 to 28 next and restarting the servo drive. GT 112-E...
  • Page 134 Use voltmeter to check whether the Use correct power supply or Input power error input voltage is within the specified limit. stabilizing power. (Incorrect power input) GT 112-E...
  • Page 135 Check if regenerative switch transistor Please contact your distributor for switch transistor is short-circuited. assistance or contact with Delta. fault Parameter setting Confirm the parameter setting and Correctly reset parameter is in error specifications of regenerative again. resistor. GT 112-E...
  • Page 136 Turn OFF the power supply and restart the servo drive. Potential Cause Checking Method Corrective Actions Use pulse frequency detector to Correctly set the input pulse Pulse command measure input frequency. frequency. frequency is higher than rated input frequency. GT 112-E...
  • Page 137 Execute the drift adjustment executing the drift adjustment exceeded its again. (Set P2-08 to 20 first, and again, please contact your maximum allowable then set P4-10 to 5.) distributor for assistance or value. contact with Delta. GT 112-E...
  • Page 138 Check if there is overload or the Increase motor capacity or The drive has motor current is too high. reduce load. exceeded its rated load during continuous operation. Check the drive input wiring. Ensure all wiring is correct. Short-circuit at drive output. GT 112-E...
  • Page 139 E0001 is applied to the drive, it indicates displayed on LED display. that the data in EE- RPM is damaged or there is no data in EE-PROM. Please contact your distributor for assistance or contact with Delta. GT 112-E...
  • Page 140 Not receiving Check whether communication cable Tighten the communication cable, communication is loose or broken. make sure the communication command for a long cable is not damaged and ensure time. all wiring is correct. GT 112-E...
  • Page 141 Delta. are placed in separate conduits from the cables connected to R, S, T and U, V, W terminals to prevent the interference. 3. Check if the shielded cables are used when performing encoder wiring. GT 112-E...
  • Page 142 3. Check if the shielded cables are 3. Please use shielded cables used when performing encoder for Encoder wiring. wiring. 4. If the error does not clear after all the above actions are done, please contact your distributor for assistance or contact with Delta. GT 112-E...
  • Page 143 3. Please use shielded cables are used when performing for Encoder wiring. encoder wiring. 4. If the error does not clear after all the above actions are done, please contact your distributor for assistance or contact with Delta. GT 112-E...
  • Page 144 P1-57 and P1-58 are both too 58. Please note that the period of time set by small. over-low setting may results in parameter P1-58. malfunction, but over- high setting may let the motor protection function not operate. GT 112-E...
  • Page 145 05) to check if encoder errors encoder output. take corrective actions. occurred. (AL011, AL024, AL025, AL026) Output pulses Correctly set P1-76 and Check if conditions below occur, exceed hardware P1-46: P1-76 < Motor rotation speed, or tolerance. P1-76 > Motor rotation speed, and, GT 112-E...
  • Page 146 Checking Method Corrective Actions Check if EE-PROM is reset after EE-PROM is not Set P2-08 to 30 first, and then the firmware version is upgraded. reset after the 28 next, and restart the servo firmware version is drive. upgraded. GT 112-E...

  • Page 147: Factors Affecting Performance

    It is, therefore, highly recommended to install reduction liner inside the spindle as indicated in the start-up manual. GT 112-E...
  • Page 148 In general, the difficulty increases with the specific weight of the bar. Steel bars are relatively easy to guide. Because of their great flexibility and specific weight, brass bars are relatively difficult to guide at high speeds. Aluminum bars of aluminum are very easy to guide. GT 112-E...

  • Page 149: Maintenance

    At no time should solvents, such as acetone, or diluents be used for cleaning the bar feed system. At no time should cleaning products come into contact with electrical components. GT 112-E...
  • Page 150 Chapter 9 TROUBLE SHOOTING GUIDE 9 - 36 GT 112-E...

  • Page 151: Appendices

    N… PARTS CATCHER OFF (IF AVAILABLE) N… N… N… X, Z, G, F, T, S, M, ... N… N… N... END OF PROGRAM (LOOP) Important: The above is an example only. Programming may change according to the application. GT 112-E...

  • Page 152: Appendix B: Odering Form

    Chapter 10 APPENDICES 10 - 2 APPENDIX B: ORDERING FORM This form should be photocopied, duly filled out, and sent to LNS or to your nearest LNS Representative/Agent Company name: Person in charge: Address: ZIP: City: Country: Phone: Fax: Type of device: Serial number: Qty.

  • Page 153: Appendix C: Address Lns

    Chapter 10 APPENDICES 10 - 3 APPENDIX C: ADDRESS LNS LNS Japan : www.lns-japan.com GT 112-E...
  • Page 154 Chapter 10 APPENDICES 10 - 4 GT 112-E...
  • Page 155 GT 112-E XM1.00.A501B...
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  • Page 170 LtoRF Qty. Type Part No. Model 2.0M 2.5M Ø7 3.0M XM1.14.P046A.07 12’ 4.0M RtoLF Qty. Type Part No. Model 2.0M 2.5M Ø7 XM1.14.P047A.07 3.0M 12’ 4.0M GT 112-E XM1.14.A003B A-24...
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