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Edge Technologies Rebel 102SE Manual

Bar feeder
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Table of Contents

Section
1.1
Contents of the Manual ------------------------------------------------------------------------------
1.2
Machine Data Plate -----------------------------------------------------------------------------------
1.2
Technical Support -------------------------------------------------------------------------------------
2.1
Description of the Machine -------------------------------------------------------------------------
2.2
Machine Footprint -------------------------------------------------------------------------------------
2.3
Specifications and Capacities ----------------------------------------------------------------------
2.4
Bar stock requirements ------------------------------------------------------------------------------
2.5
Safety ----------------------------------------------------------------------------------------------------
2.5.1 Covers ---------------------------------------------------------------------------------------------------
2.5.2 Axial Shifting Switch ----------------------------------------------------------------------------------
2.5.3 Lathe Door Safety -------------------------------------------------------------------------------------
2.5.4 Emergency Stop Buttons ----------------------------------------------------------------------------
3.1
Lifting and Moving by Forklift -----------------------------------------------------------------------
3.2
Lifting by Crane ----------------------------------------------------------------------------------------
4.1
Lathe Preparation -------------------------------------------------------------------------------------
4.2
Distance from the Lathe -----------------------------------------------------------------------------
4.3
Axial Shifting Device ----------------------------------------------------------------------------------
4.4
Magazine Attachment ---------------------------------------------------------------------------------
4.5
Alignment -------------------------------------------------------------------------------------------------
4.6
Anchoring the Bar Feeder ----------------------------------------------------------------------------
4. Installation of the Bar Feeder
I
Rebel 102SE
Page
1
2
2
3
3
4
4
5
5
5
6
6
7
8
9
9
10
12
14
15

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Summary of Contents for Edge Technologies Rebel 102SE

  • Page 1: Table Of Contents

    Table of Contents Rebel 102SE General Information Section Page Contents of the Manual ------------------------------------------------------------------------------ Machine Data Plate ----------------------------------------------------------------------------------- Technical Support ------------------------------------------------------------------------------------- 2. Technical Information Description of the Machine ------------------------------------------------------------------------- Machine Footprint ------------------------------------------------------------------------------------- Specifications and Capacities ---------------------------------------------------------------------- Bar stock requirements ------------------------------------------------------------------------------ Safety ---------------------------------------------------------------------------------------------------- 2.5.1 Covers ---------------------------------------------------------------------------------------------------...
  • Page 2 Table of Contents Rebel 102SE Electrical Connection ----------------------------------------------------------------------------------- 15 Initial Magazine Finger Adjustment ----------------------------------------------------------------- 15 Resetting the Home Position ------------------------------------------------------------------------- 18 5. Adjustments and Settings Adjustment of Magazine Angle ----------------------------------------------------------------------- 20 Changing Bar Pushers ---------------------------------------------------------------------------------- 21 Axial Shifting ---------------------------------------------------------------------------------------------- 22 6.
  • Page 3 Table of Contents Rebel 102SE 6.3.10 Automatic Screen Functions -------------------------------------------------------------------------- 29 7. Setup Wizard Setup Wizard Screens ---------------------------------------------------------------------------------- 30 8. Maintenance Periodic Maintenance ----------------------------------------------------------------------------------- 37 Drive Belt Tension Adjustment ----------------------------------------------------------------------- 38 Lubrication ----------------------------------------------------------------------------------------------- 39 Maintenance Screens ----------------------------------------------------------------------------------- 40 9. User Parameters User Parameters 1 through 8 10.
  • Page 4 Table of Contents Rebel 102SE Alarms 27 – 29 ----------------------------------------------------------------------------------------------------- 78 Alarms 30 – 32 ----------------------------------------------------------------------------------------------------- 79 Alarms 33 – 35 ----------------------------------------------------------------------------------------------------- 80 Alarms 36 – 38 ----------------------------------------------------------------------------------------------------- 81 Alarms 39 – 41 ----------------------------------------------------------------------------------------------------- 82 Alarms 42 – 44 ----------------------------------------------------------------------------------------------------- 83 Alarms 45 –...

  • Page 5: General Information

    1. General Information Rebel 102 SE General Information Please read and understand the Manual before operating the bar feeder Contents of this Manual The bar feeder manufacturer has provided this manual as an integral part of the machine. Adherence to the instructions of the manual will help prevent injury to the operator and damage to the machine as well as helping to realize the maximum potential of the bar feeder and machine tool.

  • Page 6: Machine Data Plate

    When inquiring about or ordering parts please have the machine model (type) and serial number on hand. Refer to the machine data plate for this information. Technical Support For technical support please contact the Edge Technologies Service Department by phone at 314-692-8388 or by email edgeservice@edgetechnologies.com Important information When calling for technical support please have the machine model (type) and serial number on hand.

  • Page 7: Technical Information

    2. Technical Information Rebel 102 SE Technical Information Description of the Machine The Rebel 102 SE is a PLC controlled, full servo automatic bar feeder designed to load and feed bar stock up to 4 inches in diameter. Features of the Rebel 102 SE include: ▪...

  • Page 8: Specifications And Capacities

    2. Technical Information Rebel 102 SE Specifications and Capacities Bar diameter capacity 8mm to 102mm (.315” to 4.00”) Maximum bar length 60” (NOT TO EXCEED SPINDLE LENGTH) Magazine rack capacity 30” (60 ½” bars, 30 1.0” bars, 15 2.0” bars) Bar weight 175 lbs.

  • Page 9: Safety

    2. Technical Information Rebel 102 SE Safety The bar feeder is designed to be safe and reliable to operate. However, the machine can be dangerous if used improperly by untrained personnel. Personnel should be familiar with the operating instructions of the equipment before using and must follow standard safety practices. The bar feeder is equipped with safety devices to prevent accidental damage to the machine and injury to the operator.

  • Page 10: Lathe Door Safety

    2. Technical Information Rebel 102 SE 2.5.3 Lathe Door Safety An input to the bar feeder for monitoring the lathe door is available. If used, this input will prevent movement of the bar pusher when the lathe door is open. 2.5.4 Emergency Stop Buttons There are two emergency stop buttons on the bar feeder.

  • Page 11: Transportation And Handling

    3. Transportation and Handling Rebel 102 SE Transportation and Handling Warning The weight of the bar feeder without packaging is approximately 1100 lbs. Verify the equipment to be used for moving the bar feeder is rated to safely lift the weight of the bar feeder plus the packaging material.

  • Page 12: Lifting By Crane

    3. Transportation and Handling Rebel 102 SE Lifting with a crane Lifting and moving the bar feeder with a crane is possible if a forklift is not available. The crane must be capable of lifting at least 1,100 lbs. The machine should only be moved by personnel qualified in the operation of the crane.

  • Page 13: Lathe Preparation

    4. Installation Rebel 102 SE Installation Caution The following instructions should be carried out only by skilled, trained personnel. Proper alignment and installation is crucial to achieve optimal performance of the bar feeder. Improper alignment can cause difficulty during loading, damage to the bar feeder and damage to the actuator and spindle bearings on the lathe.

  • Page 14: Axial Shifting Device

    4. Installation Rebel 102 SE Axial Shifting Device The axial shifting device can be configured to move the bar feeder away from the lathe either parallel or perpendicular to the spindle axis. No additional parts are required for changing direction of the axial shift. 4.3.1 Prepare the axial track slide ·...
  • Page 15 4. Installation Rebel 102 SE · Raise and support the bar feeder to install the axial track roller slides to the base of the bar feeder. · Once axial track roller slides are installed place bar feeder onto axial track slide rails. Be sure the roller bearings engage the slide track.

  • Page 16: Magazine Attachment

    4. Installation Rebel 102 SE The axial track in position switch (LS03) is on the inside of one axial track. The two latches are mounted to the outside of the tracks. The tracks should be leveled in both the X and Z axis. Keep the rails as close as possible to the floor.
  • Page 17 4. Installation Rebel 102 SE...

  • Page 18: Alignment

    Damage to the bar pusher or lathe spindle may occur. Alignment The preferred and most precise method of bar feeder alignment is with the Edge Technologies Laser Alignment kit, part number EZ90001 by contacting Edge Technologies Parts department at (314) 692-8388 or email edgeservice@edgetechnologies.com...

  • Page 19: Anchoring The Bar Feeder

    4. Installation Rebel 102 SE · Place the bar on the V-tray and raise the V-tray to position using the tray up button. · Slide the stock toward the spindle. · Look into the spindle from the chuck end and observe the ring of light around the bar stock.

  • Page 20: Electrical Connection

    This procedure is for the initial setup only and should not be performed again unless instructed to do so by the Edge Technologies service department. Initial magazine finger adjustment · Remove any stock from the magazine.
  • Page 21 4. Installation Rebel 102 SE · Select Jog/Set Fingers. · Select a bar diameter between 8mm-40mm measure and record as this number will be input to. Place the bar on the magazine against the fingers. · Using adjust the fingers so the vertical face of the V- Tray tabs are just smaller than the bar diameter.
  • Page 22 4. Installation Rebel 102 SE · To store the value select · The current diameter will update to the diameter of the bar. · Select “Go to Maint Screen” to exit The ideal position of the fingers is to have a just under flush position adjustment and to only pick up one bar upon V-Tray loading.
  • Page 23 4. Installation Rebel 102 SE · Position pusher approximately 1 inch from the home position with pendant. Select “Reference Lost”. If reference is not lost this will read “Reference OK”. The movement of the pusher back to home position is very slow during the referencing. If the pusher is further from home procedure will take longer.

  • Page 24: Adjustments And Settings

    5. Adjustments and Settings Rebel 102 SE Adjustment and Settings Adjustment of Magazine Angle The magazine angle should be set according to the shape and weight of the material used. Generally the magazine incline should be set in the range of 5 to 10 degrees for round stock, keeping in mind that the heavier materials require less incline.

  • Page 25: Changing Bar Pushers

    5. Adjustments and Settings Rebel 102 SE Changing bar pushers To change the bar pusher, start with the V-channel in the down position. Remove the 3 screws that hold the front bushing in place and slide the bushing onto the bar pusher. At the rear hub of the pusher, flip the selector cam out of the notch to release the bar pusher from the carriage.

  • Page 26: Axial Shifting

    5. Adjustments and Settings Rebel 102 SE Axial Shifting The axial shifting device allows the bar feeder to be moved away from the lathe in either the X axis (shown) or the Z axis depending on the customer’s preference at time of set-up. The bar feeder can then be returned to its original position without loss of alignment.

  • Page 27: Control Operation And Description

    6. Control Operation and Description Rebel 102 SE Rebel 102 SE Remote Pendant Emergency Stop LED Status Indicators Auto Pre-Auto V-Tray up Manual Jog Reverse Jog Forward V-Tray Down Control Pendant Functions 6.1.1 Status LEDs · Feeder Alarm-- Bar feeder is currently in error ·...

  • Page 28: V-Tray Up And Down Buttons

    6. Control Operation and Description Rebel 102 SE 6.1.3 V-Tray Up and Down Buttons V-Tray Up V-Tray Down These buttons allow the operator to jog the V-Tray up and down. When jogging up the limit of rise is controlled by the stock diameter listed in the parameters in the current bar feeder program.

  • Page 29: To Load A New Bar

    6. Control Operation and Description Rebel 102 SE 6.2.2 To load a new bar · Load a bar onto the magazine. · Raise the channel with the Channel Up button. The bar will fall onto the channel as it rises. ·...

  • Page 30: Setting The Measurement Standard To Inches Or Millimeters

    6. Control Operation and Description Rebel 102 SE 6.3.2 Setting the Measurement standard inches or millimeters. The bar feeder can measure distance in inches and millimeters. The easiest way to change the measurement standard is from the manual or automatic screens. Selecting the distance readout on the screen the standard will change, following image.
  • Page 31 Passwords can be set up to 9 digits in length. Passwords are typically assigned and given to an upper level manager, shop foreman or whom the customer assigns. If the passwords are somehow lost please call EDGE Technologies Service Department.

  • Page 32: Forward And Reverse Jog Buttons

    6. Control Operation and Description Rebel 102 SE Select “yes” when prompted to load part. Manual screen will then appear. Note: It is important to understand the difference between a part program number and a file location number. A Part program number is assigned during initial part parameter setting. File location is the saved location number of a part program.

  • Page 33: Automatic Screen Functions

    6. Control Operation and Description Rebel 102 SE recalculate the remaining number of pieces left on the bar. The measurement is also needed for the bar feeder to determine the end of the rapid travel forward when the signal is activated. The lathe collet must be closed before the measuring process can begin.

  • Page 34: Setup Wizard

    7. Setup Wizard Rebel 102 SE Setup Wizard Screens The Setup Wizard Screens provide a simplified method of creating a bar loader program by entering values in the following screens. A complete list of the operating parameters can be found in section 8. To start the Setup Wizard select the Wizard button. Follow the screens to create a new part program.

  • Page 35: Setup Wizard Screens

    7. Setup Wizard Rebel 102 SE Material Shape: Select the shape of the material to be run. The selection is used along with the bar diameter setting to set the height of the V-tray to match the centerline of the lathe spindle. Facing Length: The parameter allows the user to set the distance the new bar will stick out of the chuck or collet at the end of the bar load sequence.
  • Page 36 7. Setup Wizard Rebel 102 SE Torque Override: Sets the amount of force applied to the bar stock during the automatic cycle. Jaw / Collet Length: The jaw or collet length is used in the calculation of the facing position. The measurement for a jaw chuck the distance from the end of the jaws to the face of the chuck plate.
  • Page 37 7. Setup Wizard Rebel 102 SE Minimum Chucking Length: This parameter is used to set the minimum portion of the gripping surface used of the chuck jaw or collet pads. It is usually set to the full length of the gripping surface.
  • Page 38 7. Setup Wizard Rebel 102 SE Feeding Type: Selects between modes of feeding material in automatic. Turret Stop: The bar feeder begins to push when the lathe collet opens and stops pushing after it presses against the stop. The bar feeder will use feed-out lengths 1 through 3 if set. Position: The bar feeder pushes the length set in the parameter Part Length 1.
  • Page 39 7. Setup Wizard Rebel 102 SE Facing Type: Selects between modes of bringing a new bar to facing position and restarting the lathe at the end of a bar change. Choices are Position and Turret Stop. Position: - the bar feeder advances the bar to the position set by parameter Facing Length and stops.
  • Page 40 7. Setup Wizard Rebel 102 SE Eject with pusher: After feeding the last available part length into the lathe the pusher retracts to the home position when the collet closes. When the lathe sends the bar change command the bar pusher moves forward to eject the remnant from the lathe collet, then returns to the home position to continue the bar change cycle.

  • Page 41: Maintenance

    8. Maintenance Rebel 102 SE Maintenance Hazard Warning Before doing bar feeder maintenance turn off the main power switch on the cabinet door. For consistent operation of the bar feeder maintenance checks should be performed regularly. The area around the bar feeder should be kept clean to avoid safety issues. Periodic Maintenance The items on the chart below should be performed at the intervals as listed.

  • Page 42: Drive Belt Tension Adjustment

    Drive belt tension adjustment The drive belt adjustment on the Rebel 102SE is made by moving the front drive belt pulley by means of adjusting screws at the front of the bar feeder. Loosen the two bolts, one on each side of the pulley shaft.

  • Page 43: Lubrication

    8. Maintenance Rebel 102 SE Lubrication Friction points on the bar feeder should be lubricated monthly with a general purpose grease. Points to be lubricated are the linear way of the bar pusher carriage (grease fitting), pivot points of the magazine, the cam and follower bearing of the V-channel lifting assembly (located inside the electrical cabinet) and the bar pusher selector cams.

  • Page 44: Maintenance Screens

    8. Maintenance Rebel 102 SE Maintenance Screens To access the maintenance screens press the “Maint Screen” button from the start page. This will bring up the maintenance menu screen. From the Maintenance Menu screen the loading fingers, V-tray and bar pusher functions can be set.
  • Page 45 8. Maintenance Rebel 102 SE Touch the box under “To Set The Fingers To This Diameter” button. Input the bar diameter desired. Press the “Press This” button to store the actual position of the fingers to match the bar diameter in the part program. Press the “Go to Maint Screen”...
  • Page 46 8. Maintenance Rebel 102 SE Pusher position from zero: This box on the screen has two possible messages. It can display the bar feeder pusher position from the zero point and it can display the number of parts remaining on the bar to be run. Pushing the upper left button will toggle between the two screens.
  • Page 47 8. Maintenance Rebel 102 SE Jogging Press the Jogging button to display the screen below. The screen gives manual control to the main movement groups. Safeties Disabled: CAUTION! Activating the Safeties Disabled button on this page defeats the travel limits and required conditions normally in place to protect the machine. The possibility exists of binding up the V-tray motor at the bottom of the travel or overrunning the lifting cams at the top of the travel.

  • Page 48: User Parameters

    9. User Parameters Rebel 102 SE User Parameter menu screens used below are from the Setup Menu screens which are a condensed version of the Setup Wizard menu screens. The information is the same for the two screen layouts. It is important to understand basic screen functions and features. When selecting this will take you to the manual page.

  • Page 49: User Parameters 1 Through

    9. User Parameters Rebel 102 SE Feed-out 1-3: Used when making multiple feed-outs per part. Feed-out 1-3 is the third of 3 possible feed-outs per part. Parameter is disabled if set to zero. Press the Feed-out 1-3 dimension button to access page 1.3 and additional options.
  • Page 50 9. User Parameters Rebel 102 SE Parameter Page 3 Bar Diameter: Diameter of the material to be used. The control uses this information to set default values for the program. · Round- Measure outside diameter · Hex- Measure across flats ·...
  • Page 51 9. User Parameters Rebel 102 SE Parameter Page 4 Jaw/Collet length: The actual length of the collet or jaw depth. Required to determine the amount of material needed for gripping to determine number of parts remaining from bar. Min Chucking length for chuck: The actual chuck length. Required to determine the amount of material needed for gripping to determine number of parts remaining from bar.
  • Page 52 9. User Parameters Rebel 102 SE Parameter Page 5 Open Collet Timeout: Time between when lathe collet opens and then closes when bar feed is in auto if time is reached then alarm is generated. Close Collet Timeout: Time between when lathe collet closes and then opens when bar feed is in auto if time is reached then alarm is generated.
  • Page 53 9. User Parameters Rebel 102 SE Parameter Page 6 Feeding Type: Selects between modes of feeding material in automatic. Choices are · Position-- In Position mode the bar feeder pushes the length set in the parameter Part Length 1. In both modes the bar feeder will use the feed-out lengths 1 through 3 if they are set.
  • Page 54 9. User Parameters Rebel 102 SE Facing Type: Selects between modes of bringing a new bar to facing position and restarting the lathe at the end of a bar change. Choices are Position and Turret Stop. · In Position mode the bar feeder advances the bar to the position set by parameter Facing Length and stops.
  • Page 55 9. User Parameters Rebel 102 SE Parameter Page 7 Pusher Back Off Closed Collet: Sets the distance the bar pusher moves away from the bar stock toward the bar feeder’s home position when the lathe collet open signal turns off and the time setting in the closed collet delay parameter (if other than zero) elapses.
  • Page 56 9. User Parameters Rebel 102 SE Parameter Page 8 Change Program Number: Allows change of the present part program number. Will not allow duplicating an existing program number.

  • Page 57: Factory Parameters

    10. Factory Parameters Rebel 102 SE Parameter Page 11 Face of Collet: This parameter controls the stopping position of the front of the new material being loaded into the lathe during a bar change. The distance is usually the measurement from the facing flag to the face of the collet chuck.

  • Page 58: Factory Parameters 11 Through

    10. Factory Parameters Rebel 102 SE Max. End of Bar Chuck: This parameter is the same as the Max End of Bar Collet parameter except that the dimension is measured with the tip of the bar pusher even with the back of the gripping portion of the chuck jaws.
  • Page 59 10. Factory Parameters Rebel 102 SE Parameter Page 12 First Feeding Distance: This parameter controls the forward stopping point of the pre-feed pusher from the home. The position must allow the pre-feed pusher to place the rear of the bar stock ahead of the bar pusher and not after the grippers.
  • Page 60 10. Factory Parameters Rebel 102 SE Parameter Page 13 Ejection Distance: Sets a distance for the bar pusher to move forward past the Maximum End of Bar setting to eject the remnant into the lathe when the Remnant Handling parameter on parameter page 5 is set to Ejection.
  • Page 61 10. Factory Parameters Rebel 102 SE Parameter Page 14 End of Bar Type: Selects between different modes of generating the end of bar signal. Choices are: · Off at Bar Change--Signal resets when the command “Bar Change” is received from the lathe.
  • Page 62 10. Factory Parameters Rebel 102 SE Pusher Feed Direction: Allows direction of operation of the jog buttons on the HMI and Remote Pendant to be reversed to accommodate different lathe configurations. Choices are Left to Right and Right to Left.
  • Page 63 10. Factory Parameters Rebel 102 SE Parameter Page 15 Bar Change Return Delay: Sets a delay in seconds for the pusher to begin the return to home position after the bar change command is received. Cycle Start Delay: Sets a delay in sending the signal to the lathe confirming that the bar change is complete.
  • Page 64 10. Factory Parameters Rebel 102 SE Parameter Page 16 End Of Bar Pulse: Sets the length of time in seconds for the signal to remain on when the end of bar signal is set to pulse. Feed Confirm Pulse: Sets the length of time in seconds for the signal to remain on when the feed confirmation signal is set to pulse.
  • Page 65 10. Factory Parameters Rebel 102 SE Parameter Page 17 Manual / Auto: Allows the bar feeder to accept the Manual / Automatic signal from the lathe as either a normally open or normally closed signal. Lathe Door Safety: Allows the bar feeder to accept the Lathe Door Open signal from the lathe as either a normally open or normally closed signal.
  • Page 66 10. Factory Parameters Rebel 102 SE Parameter Page 20 Hood Switch: Changes the hood switch safety alarm to either trigger when the hood switch is normally open or normally closed. Axial track: Changes the axial track safety alarm to either trigger when the axial track switch is Normally Open or normally closed.
  • Page 67 10. Factory Parameters Rebel 102 SE Parameter Page 22 Bar change return speed: Speed for the bar pusher as it retracts to the home position at the beginning of a bar change. Bar measuring speed: Speed at which the pre-feed pusher moves at until the bar hits the measuring flag during pre-feed.

  • Page 68: Service Technician Parameters

    11. Service Technician Parameters Rebel 102 SE Parameter Page 22 Bar Change Return Speed: Speed of the bar pusher as it retracts to the home position at the beginning of a bar change. Bar measuring speed: Speed at which the pre-feed pusher moves at until the bar hits the measurement flag during pre-feed.

  • Page 69: Service Technician Parameters 22 Through

    11. Service Technician Parameters Rebel 102 SE Parameter Page 23 Facing Speed 1: Forward speed of the bar pusher during the facing operation until it reaches the Facing Speed Slowdown Distance. Facing Speed 2: Forward speed of the bar pusher during the distance specified in the Facing Speed Slowdown Distance Parameter during facing.
  • Page 70 11. Service Technician Parameters Rebel 102 SE Parameter Screen 24 Manual Forward Speed: Forward speed of the pusher and pre-feed pusher when commanded to move via the jog buttons or through the input for Manual Forward. Manual Forward Torque Override %: Sets the amount of force developed by the clutch when moving the bar pusher forward in manual mode via the jog buttons or through the input for ±...
  • Page 71 11. Service Technician Parameters Rebel 102 SE Parameter Page 26 Touch off pusher Speed: Speed pusher moves during the measurement of the bar in the spindle Max. Machine Length: Maximum pusher stroke of bar feed. Distance from pusher home to facing flag.
  • Page 72 11. Service Technician Parameters Rebel 102 SE Parameter Page 30 Auto Mode Script Selection: This option allows you to select the method that the bar feeder runs. It changes how the internal code is executed. Available script selections, · The default parameter is Bar loader. ·...
  • Page 73 11. Service Technician Parameters Rebel 102 SE Parameter Page 31 & 32 need image The password screens allow you to edit the passwords needed to access different settings. Only passwords that are equal to or below the level that you signed in with may be changed. Supervisor: Can access all the above listed screens.
  • Page 74 Rebel 102 SE Parameter Page 40 Note: From page 40 and on are reserved for Edge Technologies Service Technician and are not accessible normally. The top key is to select the I/O version that is to be used for the bar feeder. Normal operation is “Rebel 102 wiring Version 2.
  • Page 75 11. Service Technician Parameters Rebel 102 SE Parameter Page 41 Copy Factory to default: Change factory defaults to current settings. Reset factory data: Initializing factory settings to Edge Installer Parameters (Complete reset)
  • Page 76 11. Service Technician Parameters Rebel 102 SE Parameter Page 42 Creep jog speed: Speed pusher returns at during bar change. Slow jog speed: Speed pusher returns at during bar change. Medium fog speed: Speed pusher returns at during bar change. Fast jog speed: Speed pusher returns at during bar change.

  • Page 77: Alarms

    12. Alarms Rebel 102 SE -HMI Cable not attached to PLC - Check the cable from the PLC in the electrical cabinet (round black cable located on the front of the PLC next to the Run/Stop switch) to the back of the control panel (rectangular 9-pin plug connected to the COM 2 port).

  • Page 78: Alarms 14

    (if used, check the interface drawing specific to the lathe). -Parameter refers to the V-channel not lifting -Not enough air pressure to lift channel – Not applicable on the Rebel 102SE -Bind in channel opening mechanism – Check to see if the V-channel beam is level, check for obstructions to the V-channel.

  • Page 79: Alarms 20

    12. Alarms Rebel 102 SE -Rezero barfeed – Start with the guide channel closed and the pusher forward about 6 inches. Press and hold the forward and reverse buttons on the pendant. After 8 seconds the pusher will begin to move backward. Release the buttons. The pusher will move back to the proximity switch for zero and then stop.

  • Page 80: Alarms 24

    -Pusher could not return home within the time allotted – An internal timer for pusher return has been exceeded. -Check for pusher impedance in channel – Check for blockage of the bar pusher, a bent bar pusher, check front pusher bushing. Not used on the Rebel 102SE...

  • Page 81: Alarms 27

    S4 proximity switch. -Load bars on magazine -Check gripper sensor and adjust – Not applicable on the Rebel 102SE -Check input on PLC (X4) – Input 4 is turned on and off by the S04 switch on the measuring gate.

  • Page 82: Alarms 30

    -Collet too small for material –Not applicable on the Rebel 102SE. -Material too large for lathe collet – Verify the collet diameter versus the OD of the bar stock -Check signal from lathe –...

  • Page 83: Alarms 33

    12. Alarms Rebel 102 SE -Material feedout shorter than setting in parameter – Check open collet torque setting. Check lathe collet/spindle for debris. Check for impedance to the bar pusher. -Set short feed value shorter than feedout needed for part – The value should be set at least 1mm shorter than the part feedout.

  • Page 84: Alarms 36

    12. Alarms Rebel 102 SE -Material feedout longer that setting in parameter – Tighten the pusher drive chain. Verify the pusher collet is fully seated on the material. -Set long feed value longer than feedout for part – The value should be set at least 1mm longer than the part feedout.

  • Page 85: Alarms 39

    12. Alarms Rebel 102 SE -Material feedout shorter than setting in parameter – Check open collet torque setting. Check lathe collet/spindle for debris. Check for impedance to the bar pusher. -Set short feed value shorter than feedout needed for part – The value should be set at least 1mm shorter than the part feedout.

  • Page 86: Alarms 42

    12. Alarms Rebel 102 SE -Material feedout longer that setting in parameter – Tighten the pusher drive chain. Verify the pusher collet is fully seated on the material. -Set long feed value longer than feedout for part – The value should be set at least 1mm longer than the part feedout.

  • Page 87: Alarms 45

    12. Alarms Rebel 102 SE -When the bar feeder is in Auto and the lathe collet open, reverse movement in excess of 4mm was detected. -Check lathe is not pushing or pulling material back into barfeed – Check the bar feeder synchronization device.

  • Page 88: Alarms 48

    12. Alarms Rebel 102 SE -Open lathe collet – Verify that the lathe collet is open. -Check input X27 – The input should turn on and off with the collet opening and closing. -Close the lathe door – Verify that the lathe door is closed and the safety switches are enabled.

  • Page 89: Alarms 52

    12. Alarms Rebel 102 SE -Adjust facing position – Alarm occurs when facing mode is set to Turret Stop and the bar travels 5 – 25mm short of the turret stop or in excess of 250mm past the facing length. -Pusher could not reach ejection distance –...

  • Page 90: Alarms 93

    Release the buttons. The pusher will move back to the proximity switch for zero and then stop. -Introduction could not start – Not applicable on the Rebel 102SE -Check for obstruction in spindle – Check the lathe spindle for debris.
  • Page 91 12. Alarms Rebel 102 SE -Remove material from magazine – If material is on the magazine during the finger adjustment the motor may stall out. -Check for obstructions – Check the area around the lifting fingers on the magazine for foreign objects or debris that may block the movement of the fingers.

  • Page 92: Electrical System

    13. Electrical System Rebel 102 SE Electrical System Warning Danger of electrical shock. Only experienced personnel should open the electrical cabinet. Turn off the main switch on the electrical cabinet door before working on this unit. 12.1 Electrical schematic table of contents: Rungs 11 –...

  • Page 110: Electrical Components

    Rebel 102 SE Replacement Parts Replacement parts for your Rebel 102SE are available from our St. Louis facility. Please have your serial number available when calling. Our phone number is (314) 692-8388, please follow the prompts to reach the parts department.
  • Page 111 13. Replacement Parts Rebel 102 SE Power Supply J230100 Electrical Cabinet Components (continued) Inverter J220700 J631202 Programmable Logic Control J210700 Motion Module J220202 20SSC-H Relay & Pedestal J310203 + J310211 Emergency Stop Relay J310704 E-Stop Circuit Protection J310505 Circuit Protection J310505 No Fuse Breaker J310504...

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