SMW Spacer Barfeed 2003manual.pdf

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Installation

Operation

& Maintenance

for:

SPACE SAVER 2003

SPACE SAVER 2003 HD

SMW Part #

43100005





1

SMW SPACESAVER 2003

CNC Technology manufactures the SMW SPACESAVER, a company located in Czech

Republic. It is distributed in North America exclusively by SMW Systems.

9828 S. Arlee Ave.

SANTA FE SPRINGS

CALIFORNIA 90670

1-800-423-4651www.smwsystems.com

SMW SMW SYSTEMS INC. 562-949-7991



2



Safety recommendations

3

READ COMPLETE INSTRUCTIONS CAREFULLY

BEFORE OPERATING MAGAZINE BARFEED

Since we are continuously improving the design of our magazine barfeeds, it is possible that

the illustrations may vary from the equipment you received. Concerning the electrical and

pneumatic diagrams, always refer to this manual.

However, some previously accepted shop practices may not reflect current safety regulations

and procedures, and should be reviewed to ensure compliance with the current local safety and

health standards.

We recommend that all shop supervisors, maintenance personnel and machine tool operators

be advised of the importance of safe maintenance, setup and operation of this equipment. Our

recommendations are described below.

Read these safety recommendations before you start working with your

magazine barfeed:

· Read appropriate manual or instructions before attempting operation or maintenance of the

barfeed. Make sure you understand all instructions.

· Do not operate equipment unless proper maintenance has been regularly performed and

equipment is known to be good working order.

· Do not remove any warning or instruction tags from magazine barfeed.

· Do not loosen any screws secured by paint.

· Do not operate equipment if unusual or excessive heat, noise, smoke or vibration

occur. Report any excessive of unusual vibration, sounds, smoke or heat as well as any

damaged parts.

· Make sure equipment is properly grounded. Consult National Electric Code and alllocal codes.

· Disconnect main electrical power before attempting a repair or maintenance.

· Do not reach into any control or power case area unless electrical power is off.

· Do not touch electrical equipment when hands are wet or when standing on a wet

surface.

· Allow only authorized personnel to repair electrical equipment.

· Replace blown fuses with fuses of the same size and type as originally furnished.

· Keep the area around the machine well lit and dry.

· Have the correct type of fire extinguisher available when machining combustiblematerial and keep chips clear of the work area.

· Do not use a toxic or flammable substance as a solvent cleaner or coolant.

· Do not alter the machine to bypass any interlock, overload, disconnect or other safety

device.



Safety recommendations

4

· Remove any loose parts or tools left on the machine or in the work area before operating

machine. Always check machine and work area for loose tools and parts especially after

maintenance personnel have done work.

· Before pressing the cycle start push-button, make certain that proper functions are

programmed and that all controls are set in the desired modes.· Know where all stop push buttons are located in case of an emergency.

· Check the condition of the barfeed before operating (water trap is empty, the air

pressure and the status of the indicator lights are correct.)

· Make certain that all guards are in good condition and are functioning properly before the

cycle is started.

· Don t operate the loading mechanism if the gauge on the channel scale (fig. 4.3/3) is set

to a diameter larger than 80 mm. (102 mm on SS2003 HD)

· Check setup, tooling and security of workpiece if the machine has been off for any

length of time and its going to work without operator.

· Do not take off safety covers when machine is working.

· Do not remove or load workpieces while any part of the machine is in motion.

· Do not operate any machine wearing rings, watches, jewelry, loose clothing or neckties, or

long hair not contained by net or shop cap.

· Do not leave tools, workpieces or other loose items where they can come in contact with

a moving component of the machine.

· Do not attempt to brake or slow the machine with your hands.

· Any attachments, tools or machine modifications not obtained from our company, must

be reviewed by qualified safety engineer before installation.

· Use caution around exposed mechanism and tooling especially when setting up. Be carefulof sharp edges on tools.

· Use only a soft-faced hammer.

· Do not exceed the rated capacity of machine.

· Do not machine bar stock exceeding the length of a lathe spindle.

· Use spindle liners inside the spindle.

· If it is possible, program the magazine barfeed to retract the pusher fully out of the

spindle before the spindle starts to rotate. Pusher of diameter 6 mm is necessary to pull

all the way out of the spindle every time.

· Make certain that the magazine barfeed is properly aligned with the lathe and bolted to thefloor.

· If bar stock will not feed properly, carefully diagnose the problem to determine the best

corrective measure. (before continuing to operate the machine)

· Do not simply increase air pressure without determining the cause of the problem.

Excessive air pressure is extremely dangerous and must be avoided.

FOR YOUR PROTECTION - WORK SAFELY



Contents

5

CONTENTS

CONTENTS 5

1 DESCRIPTION 9

1.1 GENERAL 9

1.2 APPLICATIONS 9

1.3 CONCEPT 9

1.4 FLOOR PLAN 11

1.5 MAIN DIMENSIONS 12

1.6 TECHNICAL CHARACTERISTICS 13

1.7 OPERATION 15

1.8 SUPERVISION AND SECURITY 15

1.9 ELECTRIC SUPPLY 15

1.10 PNEUMATIC SUPPLY 15

1.11 INSTALLATION 161.12 IDENTIFICATION 16

2 TRANSPORTATION AND UNPACKING 17

3 INSTALLATION - SET UP 19

3.1 PREPARATION BEFORE MAGAZINE BARFEED INSTALLATION 19

3.2 ELECTRICAL AND PNEUMATIC CONNECTIONS 20

3.3 INSTALLATION - MAGAZINE BARFEED FLOOR MOUNTING 22

3.3.1 GENERAL 22

3.3.2 HEIGHT AND SIDE POSITION PRE-ADJUSTMENT 23

3.3.3 ALIGNMENT 24

3.3.4 TABLE INSTALATION 294 UTILIZATION 30

4.1 PRELIMINARY CONDITIONS 30

4.1.1 FOUNDATION, ALIGNMENT 30

4.1.2 SAFETY 30

4.1.3 OPERATOR 30

4.2 NORMAL (OR STANDARD) PRODUCTION PROCEDURES 30

4.3 GUIDING TECHNIQUE 31

4.4 BAR STOCK FEED 32

4.5 INSTALLATION OR EXCHANGE OF A SPINDLE LINER 32

4.6 ADJUSTING CHANNEL HEIGHT 33

4.7 ADJUSTING THE BAR TRAY 334.8 PNEUMATIC CIRCUIT 35

4.8.1 GENERAL 35

4.8.2 SETTINGS - MAINTENANCE 36

4.8.3 ADJUSTING MOVEMENT SPEED 36

4.9 PUSHER 37

4.9.1 INSTALLATION OF PUSHER 37

4.9.2 ASSEMBLY AND DISASSEMBLY OF PUSHER 37

4.9.3 ADJUSTMENT OF PUSHER LENGTH 37

4.10 ELECTRICAL PART 38

4.10.1 OPERATING PANEL 38

4.10.2 ERROR SIGNALS AND MEANING OF LAMPS H14 AND H15 40

4.10.3 EXPLANATION AND FUNCTION OF THE SWITCHES 424.10.4 SETTING THE PROXIMITY SWITCHES B24 AND B25 44

4.10.5 HOW TO PROGRAM THE LATHE 45

4.10.6 FLOW DIAGRAM OF THE MAGAZINE BARFEED PROGRAM 47



Contents

6

4.10.7 GETTING THE AUTO CYCLE STARTED AND STOPPED 49

4.10.8 INTERFACE 50

4.10.9 MODIFICATION OF THE PROGRAM CONTROL 53

4.11 LOADING MECHANISM REVERSE ROTATION 54

ADDENDUM 1 MAGAZINE BARFEED - LATHE COOPERATION DIAGRAM 56

ADDENDUM 2 ELECTRICAL DIAGRAMS 62

ADDENDUM 3 STANDARD INTERFACE DIAGRAMS 74

ADDENDUM 4 PNEUMATIC DIAGRAM 78

ADDENDUM 5 SPARE PARTS 82

ADDENDUM 6 METHODS HOW TO TROUBLESHOOT 86

6.1 METHODS HOW TO TROUBLESHOOT PLC 88

6.2 METHODS HOW TO TROUBLESHOOT PUSHER/CHANNEL 88

6.3 METHODS HOW TO TROUBLESHOOT WARNING SIGNALS 89

6.4 METHODS HOW TO TROUBLESHOOT VARIOUS PROBLEMS 90

ADDENDUM 7 INPUTS AND OUTPUTS 92

7.1 IDENTIFICATION OF ERRORS INPUTS 94

7.2 IDENTIFICATION OF DEFECTS OUTPUTS 96

7.3 TROUBLESHOOTING MATRIX ERROR 97

ADDENDUM 8 CONTROL SHEET FOR INSTALLATION 99



Contents

7

FIGURE LISTING

Fig. 1.1 - General arangement 10 Fig. 1.2 - Floor plan 11

Fig. 1.3 - Main dimensions 12

Fig. 1.4 - Data tag 16

Fig. 2.1 - Lifting and locating the magazine barfeed 17

Fig. 3.1 - Pneumatic and electrical connections 20

Fig. 3.2 - Look at the opened electrical box 21

Fig. 3.3 - Elements for height and side alignment and adjustment 22

Fig. 3.4 - Height and side pre-adjustment 23

Fig. 3.5 - Centering magnetic gauge - rear view of the spindle 24

Fig. 3.6 - Alignment kit 25

Fig. 3.7 - Alignment 27

Fig. 3.8 - Lagging magazine barfeed to the floor 28

Fig. 4.1 - Kinds of spindle liners 31

Fig. 4.2 - The barfeeding 32

Fig. 4.3 - Setup of the channel height 33

Fig. 4.4 - The tray (table) setting for correct bar separation 34

Fig. 4.5 - The pneumatic circuit 35

Fig. 4.6 - The water trap, regulator and solenoid valve 36

Fig. 4.7 - Pusher Assembly and disassembly 37

Fig. 4.8 - Operating panel 38

Fig. 4.9 - Location of the switches 42 Fig. 4.10 - Setting the proximity switches B24 and B25 44



Contents

8



Chapter 1. Description

9

1 DESCRIPTION

1.1 GENERAL

The magazine barfeed Spacesaver 2003 has been designed to fit all types of automatic lathes.The machine head stock length determines the bar length. This allows automatic bar loading

and bar feeding at a low cost to a CNC lathe user, creating a highly efficient and economic

manufacturing process.

The spindle liner centers the bar on lathe center and guides the bar into the spindle. The

spindle liner also prevents damage to the spindle if, during rotation, bar is released from

chucking device in lathe, or when the bar is bent. .

This magazine barfeed was designed for machining round bars, square, hexagonal or shaped

stock. Machining square, hexagonal or shaped bars requires a lathe spindle orientation device.

Machining square bars requires rotating the channels ! bar guiding block ! 180 degrees. When

machining bars of special shape it is necessary to install special shaped liner or guide. This

liner is not part of the basic equipment of magazine barfeed.

Its compact design reduces space required behind the lathe.

The bar diameter adjustment is simple and fast, and remnant ejection does not require a

special device.

1.2 APPLICATIONS

The magazine barfeed SS 2003 allows:

§ automatic low cost CNC lathe operation

§ utilization of limited floor space due to its small footprint and its lateral loading.

§ accurate job at high speed, not affected by the magazine barfeed.

§ continuous operation, avoiding changeovers in setup.§ solves problems due to bent bars or geometry faults.

§ the automatic change of bar stock, by a pre-programmed PLC.

1.3 CONCEPT

The concept and function is very simple, the magazine barfeed SS 2003 is very viable with a

long lasting life and requires minimum maintenance. Its operation is simple even for an in-

experienced operator.

The operation panel (1.1/1) displays all of the rotary switches, emergency stop and indicator

lights useful to the operator. Only the main switch (1.1/8) is located on the frame. The barstock to be machined is stored on an inclined tray (1.1/2) with a threaded rod height

adjustment.




10

(1.1/5) and introduced to the lathe spindle by rotating claws (1.1/12), fixed channel (1.1/10)

and pusher (1.1/11).

The rear side of the magazine barfeed includes air inlet (1.1/3). On the bottom are holes for

electrical connection (1.1/7). The operation height of frame (1.1/4) is adjustable with screws

(1.1/9) located in 2 adjustable legs (1.1/6).

11

6

9

4

3

2

7

8

5

10

12

1

Fig. 1.1 - General arangement




11

1.4 FLOOR PLAN

Fig. 1.2 - Floor plan




12

1.5 MAIN DIMENSIONS

Fig. 1.3 - Main dimensions




13

1.6 TECHNICAL CHARACTERISTICS

Barstock range SS 2003 SS 2003 HD

Round bar diameter 6 to 80 mm 6 to 102 mm

Hexagonal bar stock 8 to 68 mm 8 to 85 mmSquare bar stock 8 to 55 mm 8 to 70 mm

Length of bar stock

Length is limited to the total length of the spindle (including cylinder and chucking device)

and not to exceed the length of the magazine barfeed # 60 inches or 1524 mm.

Capacity of material rack

bar diameter - 102 mm (SS 2003 HD only) 3 bars (due to weight limit of 500 lbs)

bar diameter - 80 mm 6 bars (due to weight limit of 500 lbs)

bar diameter - 65 mm 13 bars (due to weight limit of 500 lbs)

bar diameter - 38 mm 22 bars bar diameter - 6 mm Over 100 bars

Guiding technology

Bar is guided (centered) in the spindle with a spindle liner and pushed by the pusher to a turret

stop (see chapter 1.7).

Speed rotation

According to the RPM rating of the lathe and quality of the spindle liner.

Material advancementBy pneumatic pusher, adjustable feeding speed up to 1170 inch/min or 30 m/min.

Straightness of bar stock

No specific recommendations for bar preparation. The bar must go easily into spindle liner

with clearence defined in chapt.4.3. Bar straightness recommended at 0.5 mm/meter or .006

per foot.

Time of automatic reload cycle

About 25 seconds from tray into spindle.

Set-up timeAbout 2 minutes to go from one diameter to another + a spindle liner change time

Application, Adaptation

On most CNC lathes equipped with a barfeed interface

Electrical equipment

PLC driven by 24VDC

Power supply 200-575VAC 50/60Hz max. 4Amp.

Electrical cabinet according to VDE standards.




14

Compressed air connections

Air pressure requirement - 58 psi to 14.5 psi (4 - 10 bar)

The magazine barfeed is equipped with a pressure regulator and water trap. A supply hose

with an inside diameter of at least 8-mm is required. The air consumption per full stroke is 1,2

l of compressed air, it means approximately 20 l/hour, if machining 5-6 bars is machined.

Equivalent noise level

Noise level, caused by magazine barfeed in its work area does not reach 70 dB due to bar

cushioning loading mechanism. Improper manual loading of bigger bars to the rack may

cause noise (when the bar hits the rack or when the bar is moving on the rack).

Weight

360 kg

Packing

Magazine barfeed is packed in water-resistant plastic cover and transported inside woodencrate.




15

1.7 OPERATION

The magazine barfeed SS2003 feeds barstock into the lathe according to the following

sequence:

a. The bar stock is loaded into to channel by the electrical loading mechanism. The channel

locates the bar on the spindle center.

b. The flag advances the bar stock into the spindle. Then the flag fully retracts.

c. Pusher is lowered onto the spindle axis.

d. The pusher advances the bar stock into the open collet (or chuck) against turret stop.

e. The collet (or chuck) is closed and the pusher retracts.

f. The lathe machines part.

g. The next bar is fed to the turret after spindle stops rotation and the chuck opens (or when

the lathe gives appropriate signal).

h. The signal !end of bar (EOB)! is given during the last feeding when bar stock length is

sufficient to machine still one part but no more. EOB starts the NC part program whichfinishes last part and gives signal to eject the remnant.

i. The pusher ejects the remnant.

j. When the remnant is ejected pusher retracts and a new bar is loaded

1.8 SUPERVISION AND SECURITY

The magazine barfeeder is equipped with a programmable logic controller (PLC) that controls

all functions and binary signals are processed.

1.9 ELECTRIC SUPPLY

The magazine barfeed is equipped with an input transformer, primary from 200 to 575 VAC,50/60 Hz (2. Fuses till 240 V 4A, for higher voltage 2A), and secondary 24 VDC after

rectifier for PLC input and output circuits and bar loading motor.

Its consumption is 0.25 kW. The connections between the lathe and the magazine barfeed are

illustrated in Addendum 3 Interface. (Modified diagrams exist for specific lathes)

1.10 PNEUMATIC SUPPLY

The pneumatic circuit of the magazine barfeed requires a supply of filtered (not oiled)

compressed air between 4 and 10 bars (60 - 120 psi). Inside diameter supply hose is 8 mm. Its

average consumption is 0.7 cubic feet per hour. (Supposing 5-6 bars is machined). A relief

valve avoids all excess pressure problems and assures total security.




16

1.11 INSTALLATION

The magazine barfeed installation is assured by the SMW service engineers or by agreed

agents. The presence of a lathe engineer during the installation is required.

1.12 IDENTIFICATION

The serial number for each magazine barfeed is shown on the data tag, which is located at the

rear side of the unit. Include this number in all correspondence regarding this magazine

barfeeder.

Fig. 1.4 - Data tag



Chapter 2. Transportation and unpacking

17

2 TRANSPORTATION AND UNPACKING

The magazine barfeed is packed in plastic cover and transported in wooden crate (see

dimensions in chapter 1 - technical specifications).

It is bolted to the bottom of the crate by screws.- the weight of a crate is 140 kg

WARNING

In order to prevent damage of the magazine barfeed during unpacking, the

following recommendations must be strictly observed. SMW cannot accept any

responsibility for unpacking and installation carried out by untrained personnel.

To unpack magazine barfeed:

§ Place the crate containing magazine barfeed in the area near lathe.§ Remove the top and sides of the crate.

§ Check if everything is in good condition and complete (according to packing list).

WARNING

The magazine barfeed must be lifted using only the bottom part of the frame.

Never use any other part of the magazine barfeed for lifting, otherwise this could

cause permanent damage to the unit. Use strong enough lifting straps. If there isnot enough space (under the frame) for the lifting straps, use the height adjustable

legs to lift the unit. You can also use forklift. Lifting forks must be placed only

under the frame.

- Place the magazine barfeed at the rear end of the machine, as shown in fig. 2.1, note the

distance !A! (50 mm max.) measured between the rear of the spindle and the cover of the

magazine barfeed. If this distance is bigger, it may cause problems with loading shorter bars

Fig. 2.1 - Lifting and locating the magazine barfeed



Chapter 2. Transportation and unpacking

18

Standard accessories supplied with the magazine barfeed

Accessories required for the alignment, operation and maintenance are supplied with each

magazine barfeed SS2003. During unpacking, check for the following:

Qty Designation

5 Floor lag bolts

5 Flat washers for lag bolts

1 Alignment kit

1 Operators manual

2 Touch-up paint

1 Hexagonal channel adjusting key

1 Handle for opening electrical box

Other non # standard accessories would be defined in the packing list.




19

3 INSTALLATION - SET UP

3.1 PREPARATION BEFORE MAGAZINE BARFEED

INSTALLATION (SUMMARY)

WARNING

In order to guarantee quick and trouble free installation, the assembly and

operation must be undertaken by SMW technicians or its agreed representatives.

It is in the customer!s interest that the maintenance supervisor and operator are

present during installation in order to receive proper training in the use of this

magazine barfeed.

Furthermore, it is recommended to respect the following points:

a) The lathe

§ It must be equipped with an automatic chucking device.

§ It must be ready for production via NC program and equipped with proper tools.

§ At installation day it must be available (no production or programming).

§ It must be prepared with proper electrical interface.

Note: It is strongly recommended to bolt the lathe to the floor in order to avoid lathe

movement.

b) Spindle liners for lathe spindle

It is customer ¢s responsibility to ensure that all necessary spindle liners for lathe spindle are

available for the type and size of bar stock that is going to be machined during the first month

of production. The explanations regarding spindle liners are given in chapter 4.3 figure 4.1.

c) Compressed air supply

An air supply hose must be available for the magazine barfeed installation (pressure 4 to 10

bars). Inside diameter of the hose should be 8 mm.

d) Bar stock

To perform tests during the installation, the customer will furnish prepared bar stock.

e) Foundation

The floor foundation for the magazine barfeed must be made of high quality concrete. The

legs of the magazine barfeed will be anchored to the concrete using the lag bolts provided.

The foundation should be of sufficient strength and size to support the magazine barfeed and

the lathe without vibration.

WARNING

A complete description of the pre-installation requirements is provided to the

customer at ordering time to guard against last minute installation problems.




20

3.2 ELECTRICAL AND PNEUMATIC CONNECTIONS

The magazine barfeed must be connected to the shops compressed air system.

§ Connect the magazine barfeed with compressed air. Adjust the pressure reducing valve of

horizontal cylinder (fig. 3.1/5) to pressure from 2 to 6 bars (pressure depends on size ofthe bars). Adjust relief valve (fig. 3.1/6) to a pressure approximately 0.5 bar higher.

§ Connect the power cable to the lathe by selecting the proper tap on the barfeeds

transformer (acceptable voltages are: 200, 240, 400, 440, 480, 575, AC single phase) and

interface cable to proper positions on terminal strip.

Note: Some types of lathes require two separated cables for the interface and power

connection, some use just one cable.

6

5

4

1

3

2

Fig. 3.1 - Pneumatic and electrical connections

1. Water trap on air inlet unit

2. Interface cable

3. Power cable

4. Compressed air supply hose

5. Air inlet unit with Water trap (filter/valve reducing pressure of horizontal

movement/pressure gauge)

6. Relief valve




21

To access electrical equipment after installation, open the door on the magazine barfeeder

frame and unscrew the top of electrical box.

WARNING:

Turn off main power BEFORE opening electrical box.

S12

Fig. 3.2 - Look at the opened electrical box



Chapter 3. Installation - set up

22

3.3 INSTALLATION - MAGAZINE BARFEED FLOOR

MOUNTING

3.3.1 GENERAL

The alignment of the magazine barfeed relative to the lathe is the most important operation of

the installation and must be carried out with extreme care. The time spent is insignificant

when compared to the possible damage to the lathe or magazine barfeed of misalignment

(axes of lathe and magazine barfeed are not in the correct position).

Accurate alignment of the barfeed is critical to correct operation.

Refer to the installation plans and follow the indicated distances as precisely as possible (see

chapter 2 fig. 2.1).

Locking nut on height

ad ustment screw

Height adjustment screw

Stud bolt for clamping of

leg and leg pad (2x)

Leg pad

Screws for height

adjustment (2x)

Screws for height position

fixing (4x)

Fig. 3.3 - Elements for height and side alignment and adjustment




23

3.3.2 HEIGHT AND SIDE POSITION PRE-ADJUSTMENT

For the height pre-adjustment to the magazine barfeed refer to the following procedure:

§Check with water level, that the barfeed magazine is correctly leveled (with no bodytorsion) if not, correct the position with screws for the height adjustment on the leg pads.

Both leg pads must firmly lay on the floor.

§ Install the pusher

§ Loosen 4 screws on both legs

§ To the holes for stud bolts (fig. 3.4/1), insert appropriate spacer tubes (between stud bolts

and holes), which secure clearance for light side alignment later.

§ Using the 4 screws for height adjustment, lift the magazine barfeed legs upon the leg pad

with clearance for light alignment (about 5 mm). Check horizontal position of the frame in

both directions. Tighten the stud bolts.

§ Using the height adjustment screw, adjust the magazine barfeed approximately to the

height position. Tapping the pad, adjust the magazine barfeed approximately to the correctside position.

§ The pusher should be on centerline with the spindle liner.

§ Continue with alignment according to chapter 3.3.3

Fig. 3.4 - Height and side pre-adjustment




24

3.3.3 ALIGNMENT

a) Preparation

To properly align the magazine barfeed to the lathe, an alignment kit including ring insertedinto lathe clamping device (3.6/1) and rear carrier of alignment cord (3.6/4) a centering gauge

(3.6/3) and an alignment cord (3.6/2), is supplied with each magazine barfeed.

To perform the alignment, proceed as follow:

§ Remove the pusher

§ Install the alignment kit supplied (fig. 3.6)

1. part 3.6/1 in the lathe¢s clamping device

2. part 3.6/3 in the pusher front carrier

3. part 3.6/4 in the pusher rear carrier

§ Fix flag at the rear (using the mechanical stopper)

§ Pass the alignment cord 3.6/2 through rings 3.6/1, 3.6/3 and 3.6/4.§ In the ring 3.6/4 secure the cord with a knot.

§ Tie the alignment cord between 40 to 60 kg and fasten it to the ring 3.6/1 on the front of

clamping device.

§ Place the centering magnetic gauge on the rear of the spindle with the point toward the

center of the spindle bore, where the alignment cord goes through 3.6/2. The centering

gauge must be made from a piece of flexible magnetic strip.

WARNING

When performing the alignment operations, make sure that the alignment cord

does not touch any metallic part at the front of the magazine barfeed or at the rearof the spindle.

Fig. 3.5 - Centering magnetic gauge - rear view of the spindle

1. Centering magnetic gauge

2. Alignment cord




25

Fig. 3.6 - Alignment kit




26

b) Rough alignment before lagging to floor

All vertical and horizontal adjustments necessary to align the magazine barfeed to the lathe

are made with the adjustable front and rear leg (fig. 3.3 and 3.4)

Adjusting the rear legs (furthest from the lathe) will affect the alignment string relative to the

gauge (3.5/1) on the back of the spindle.

Adjusting the front legs (nearest the lathe) will affect the centering ring (3.6/3) relative to the

alignment string.

Always adjust the rear legs, then the front legs, as the rear adjustment alters the front centering

ring by a large amount, while the front adjustment alters the rear only minimally.

To get the correct height, use again the height adjustment screws in the legs. Check the height

with the centering ring (3.6/3) and the magnetic centering gauge (3.5/1) on the back of the

spindle. The general tolerance of final position is +/- 0.2 mm. The alignment tolerance before

anchoring to the floor should be +/- 0.5 mm.

WARNING

If the final positioning tolerance of 0.2 mm is not respected, it risks damage to

the lathe or the magazine barfeed during the automatic functioning, pusher could

touch the spindle liners in the spindle. SMW declines all responsibilities in case of

damage to the machines (lathe or magazine barfeed) due to the misalignment.




27

1. Check for any interference between cord and any part of the lathe or magazine barfeed

2. Rough align the magazine barfeed.

3. Center cord on spindle back by adjusting rear legs of the magazine barfeed. Once again

check for any interference of the wire.

OK

4. Center cord on front pusher guide by adjusting the front legs of the magazine barfeed.

Once again check for any interference of the wire.

OK

5. Carefully block adjusting screws (se chapter 3.3.1 and 3.3.2). Recheck the cord for

alignment and start again point 3 to 5 if necessary (if you did not get necessary tolerance).

Fig. 3.7 - Alignment




28

c) Anchoring the magazine barfeed to the floor

When the alignment is correct, bolt the magazine barfeed to the floor with the expansion bolts

(2 per each leg and 1 for table support) supplied.

§ Drill one hole per leg, using a masonry drill bit, to a depth of at least 110-120 mm

(preferably all the way through the floor)

§ Insert an expansion bolt before drilling the second hole.

§ The expansion bolts should not touch the bottom of the drilled holes.

§ Make sure that all expansion bolts are in place and tightened use the supplied washers (the

washers used to bolt the magazine barfeed to the wooden crate).

Fig. 3.8 - Lagging magazine barfeed to the floor

d) Final alignment

Fine adjustment may be necessary to complete the magazine barfeed alignment. Take out the

spacers from the holes around the stud bolts connecting the leg with pad and repeat operations

described in point b) on previous page, but move the magazine barfeed only on the leg pad.

When the magazine barfeed is adjusted in the correct position tighten all locking nuts and

fixing screws, then re-check the magazine barfeed alignment. The final positioning tolerance

is ± 0.2 mm. When the magazine barfeed is perfectly aligned, remove the alignment kit and

store it for future use.




29

3.3.4 TABLE INSTALATION

To finish installation is necessary to install the table.

· Remove the table switch from transport position inside the low machine cover and let

it hang freely on the cable at the back of barfeed.· Remove the right screw for table installation at the end distant from the lathe.

· Disconnect table tray (4.4/3) from table frame (Loose 4 screws securing the top on the

frame at the bottom of the material tray and remove the top out by unscrewing the

central screw 4.4/1 for setting the position of the material tray.

· Install the table frame by inserting the frame on left screw, insert the second screw

(right) and check, that the frame is roughly in center. If not, remove some spacers

under table fixing screws and finally tighten these screws.

· Fix the table leg by expansion screw to the floor.

· Install table tray 4.4/3 on the frame and center it in such way, that the claws will be in

center of the slots in table tray.

· Check, if the table is parallel to the channel.

· Last two items can be reach by correct setting 4 screws under table tray. At the end fix

these screws to allow free movement of table tray on table frame activated by screw

4.4/1.

· Install the table cover using two screws on the side of it. Insert necessary number of

spacers to keep free movement up and down in grooves at basic barfeed body.

· Install the table switch. SS2003 has switch completed with lever, which must be turn

from the barfeed body. SS2003 HD has switch on special mounting assembly. In all

cases check correct function of the switch. Opening the table cover must disconnect

PLC input 24. (Check it in manual mode, pushing Start, when this Input is displayed

on Output 14). To see the function of this switch, you must have the channel in production position (not in the red field).



Chapter 4. Utilization

30

4 UTILIZATION

4.1 PRELIMINARY CONDITIONS

4.1.1 FOUNDATION, ALIGNMENT

The magazine barfeed must be carefully installed referring to the instructions in chapter 3.

4.1.2 SAFETY

The interface and the safety connections between the lathe and the magazine barfeed must be

correctly connected and systematically checked.

SMW declines all responsibilities if the interface wiring is not installed correctly (refer

to addendum 3)!

4.1.3 OPERATOR

A complete understanding of the lathe and magazine barfeed is essential for correct

functioning of the equipment and operator safety.

4.2 NORMAL (or STANDARD) PRODUCTION PROCEDURES

When changing bar stock (type, material, shape, size) a few adjustments of the magazine

barfeed and the lathe is required:

When changing the diameter of the bar stock:

1. Change spindle liners

2. Adjust correct height of channel (channel loader height)

3. Adjust loading bar tray position to separate 1 bar only4. Change pusher

For large size bar stock:

1. Change pusher size

2. Adjust loading table angle

3. Adjust air pressure on the magazine barfeed

4. Adjust pusher speed

When you change the length of the part:

1. Adjust !End of Bar ! switch B24, always place the front part of the bar in a position so that

the bar will actuate the switch B27 (material available)

When changing the clamping device type

1. Set the switch B25 (remnant ejection), with the end of the pusher 3-5 mm in front of the

chucking device.

2. Set the mechanical stop of the pusher so that the pusher doesnt go behind this point and

the switch B25 is activated.

3. Set switch B24. The position of B24 depends on position of B25 and length of the

machined part.

When changing diameter

1. If possible retract the pusher all the way from the lathe spindle.

2. If the pusher comes in contact with the spindle during machining set the PLC to retract the

pusher all the way.




31

4.3 GUIDING TECHNIQUE

The bar stock is guided into the lathe by a spindle liner. The inside diameter of the spindle

liner should be about 0.75 mm (0.030!) larger than the diameter of the bar. This allows very

accurate guiding of the bar stock in the spindle, providing optimal speed and performance.

Spindle liner - made of a steel tube

Diameter - spindle liner inside diameter = bar diameter + (min. 0.5 - max. 2.5)

mm

Concentricity - spindle liner with spindle = 0.1 mm maximum (.004 inch)

Cone - spindle liner max. 3 x 30°

Straightness - of pushed bar max. 0.5 mm/meter

Maximum clearance from the end of spindle liner to the back of the clamping device - 30 mm

(1.18 inch)

The bar diameter is much smaller than spindle inside diameter

The bar diameter is a little smaller than spindle inside diameter

Fig. 4.1 - Kinds of spindle liners




32

4.4 BAR STOCK FEED

The pusher assembly feeds bar stock to the previously adjusted turret stop. The spindle must

not be rotating as the stock is being loaded.

Fig. 4.2 - The barfeeding

4.5 INSTALLATION OR EXCHANGE OF A SPINDLE LINER

(WHEN CHANGING DIAMETER OF THE BAR STOCK)It is the customer ¢s responsibility to ensure that spindle liners are available for the required

type and size of bar stock. The clearance between bar stock and spindle liner must be about

0.75 mm (0.030!) (refer to chapter 4.3).

To install a spindle liner proceed as follows:

§ Raise the pusher to the top position (using the button on operator ¢s console in MANUAL

mode)

§ After opening of top cover loosen 2 locking screws 4.3/1 and lower the channel to the

lowest position by rotating handle 4.3/2 (off the scale 4.3/3 into the red field)

§ Remove the spindle liner from the lathe spindle§ Install the $new spindle liner into the spindle

§ Adjust channel height to suit the new bar stock diameter and tighten the locking screws

4.3/1.

WARNING

If the channel is out of permitted range of diameter (max.Æ

80 mm), and the red

field on the scale 4.3/3 is displayed, operating the loading mechanism may cause

damage to the loading mechanism or other parts.




33

4.6 ADJUSTING CHANNEL HEIGHT - When changing bar stock

diameter

§ Raise the pusher to the top position (using the button on the operator ¢s console in

MANUAL mode)§ After lifting the top cover loosen three fixing screws of the channel loader 4.3/1

§ Using the setting nut 4.3/2 set the channel loader to the position according to the bar stock

diameter, using the scale 4.3/3.

§ Put a new bar into the channel and manually move the bar into the spindle, check

alignment of the bar and of the spindle liner. If necessary, lightly re-adjust the channel

height.

§ Tighten the locking screws of the channel 4.3/1.

11 2 13

Fig. 4.3 - Setup of the channel height

4.7 ADJUSTING THE BAR TRAY - When changing bar stock

diameter

To ensure proper selection of one bar at a time, the table must be correctly positioned for the

bar stock.

§ Using the button S7 on the operator ¢s console in MANUAL mode move the loading

mechanism up into a position so that the claws are just bellow the bar stock tray.

§ Put bars (minimum 2) on the tray

§ Loosen nut 4.4/1 of setting screw 4.4/2 and use this screw to set the tray 4.4/3 to a position

so that the claws separate first bar and do not push second bar away. Try bar loading

sequence in MANUAL mode.

§Check if the side distance screws under the table are tightened. If necessary use thesescrews to set the table to right position according to the claws. For round bars, 3 to 10

degrees tray angle is advised according to the bar stock diameter.

For hexagonal and square bars over 20 degrees angle is advised.

WARNING

When the bar is loading, the channel must be empty. No other bar or tool is

allowed to be in channel at the time of loading a new bar. This is to prevent

damage or personal injury that may result.




34

3

1

2

4

Fig. 4.4 - The tray (table) setting for correct bar separation

Note: Bar stock must be cut to a proper length so that the bar is still supported by the

channel when being loaded into the spindle. The minimal length of the bar is determined by

the distance between the end of the channel and the end of the spindle. The bar s center of gravity must be still in the channel, and the front of the bar already in the spindle liner to

prevent bar falling to floor or becoming lodged between spindle liner and channel during

reloading process.

Note: The lathe must be equipped with a spindle orientation to load hexagonal or square

bar stock. When machining square bar stock a 90° adapter must be placed on front of the

channel loader.




35

4.8 PNEUMATIC CIRCUIT

4.8.1 GENERAL

The Pneumatic circuit controls the movement of the pusher with solenoid valves (see pneumatic diagram in addendum 4)

The air supply unit (fig. 4.5/3) located on the rear side of the magazine barfeed secures

cleaning and drying of air and pressure adjustment.

12534

Fig. 4.5 - The pneumatic circuit

1. Horizontal pneumatic rod-less cylinder for flag and pusher motions

2. Solenoid valve (see - fig. 4.6)

3. The water trap and regulator unit (see - fig. 4.6)

4. Pressure switch

5. Relief valve




36

4.8.2 SETTINGS - MAINTENANCE

A

B

C

Y23

Y22

E

D

Fig. 4.6 - The water trap, regulator and solenoid valve

Settings

§ With relief valve (A) set pressure indicated on pressure gauge (B) to range from 1 bar for

light bars to max. 6 bar for heavy bars. This setting determines per application bar pushing

force. Too much pressure may cause damage to pusher mechanism or bar stock.

§ Set relief valve (C) pressure to 0.5 bar higher than the pressure setting on gauge (B).

Note: To guarantee correct function of the pneumatic components (especially speed of

movement) it is necessary to have an air flow rate of at least 17 to 20 liter/minute at the inletto the barfeed.

Maintenance

The air supply unit is equipped with a water trap (D), so check at least once a week or when

changing air pressure (changing size of bar stock.) Also check the tightness of the pneumatic

circuit and if the water trap bowl is empty.

4.8.3 ADJUSTING MOVEMENT SPEED

Setting is performed on the screws 4.6/E located on the solenoid valves in the magazine

barfeed.Speed decreases when you turn the setscrews clockwise (use 4-mm hex key.)

Y22 Solenoid valve moves pusher forward.

Y23 Solenoid valve retracts pusher.

Speed should be set to the point, when the time of movement is:

a) movement of pusher forward 4.5 sec

b) movement of pusher retraction 3.5 sec




37

4.9 PUSHER

4.9.1 INSTALLATION OF PUSHER

One pusher (Æ10 mm) is delivered with the magazine barfeed Spacesaver 2003.§ 1 pusher of diameter 10 mm for bar stock of diameter 15 - 80 mm - with solid tip

§ 1 pusher of diameter 18 mm for bar stock of diameter 40mm and higher # with solid tip

(SS2003 HD only)

4.9.2 ASSEMBLY AND DISASSEMBLY OF PUSHER

§ Loosen 2 hexagonal screws 4.7/2 on the lock of rear pusher holder and pusher 4.7/1 with

rear holder pull out from front bushing 4.7/3.

§ Change bushing in front holder for bushing adequate to size of the new pusher.

§ Insert pusher into the front bushing, rear holder put to the lock of pusher and tighten using

the 2 hexagonal screws.

§ Check and adjust position of pusher mechanical stop.

4.9.3 ADJUSTMENT OF PUSHER LENGTH

§ Loosen the pusher mechanical stop.

§ Move the pusher forward by hand until it passes through the collet by 0.25 in.

§ Move the mechanical stop of the pusher forward until it touches the front support.

§ Tighten the mechanical stop.

§ Check if the switch B25 gives signals in this position. Adjust the switch, if necessary.

34

12

Fig. 4.7 - Pusher Assembly and disassembly

1. pusher 2. hexagonal screw on the pusher lock

3. front bushing 4. mechanical stop guide bar




38

4.10 ELECTRICAL PART

4.10.1 OPERATING PANEL

Q1 Main switch (located on left side of the frame)0 = OFF, 1 = ON

S3S9 S5 H14 H15 S1S7

Fig. 4.8 - Operating panel

S1 Emergency (total) stop Immediately switches off the magazine barfeed and sends

error signal to the lathe, which should also stop.

S3 Operation mode selector switch

CHUCKING this allows the lathe to operate without magazine barfeed.

These conditions on the unit are necessary:

1. Main switch on the magazine barfeed is !ON! 2. Pusher is fully retracted (out of the spindle)

MANUAL This allows to operate the unit manually. When the pusher is in the

highest or the lowest position the flag (pusher) can be operated forward or backward.

When the flag is fully back, the loading mechanism can move (the loading claws can

rotate) and at the same time the pusher raise or lower.

AUTO This allows fully automatic barfeeding/machining cycle.

COUNT This has the same function as!AUTO

! but it stops the unit, when theselected number of bars has been completed. To select the number of bars to be

machined, push the switch S9 forward (each push for one bar). If you select just

function COUNT the unit will stop when machining bar is completed. The count setting

is not dependent on the condition of lathe. When re-selecting AUTO mode, the counter

will be reset (the number on the bar counter will be reset).




39

S5 Start switch

To activate AUTO mode push START button. The unit is now ready for automatic

cycle.

S7 Pusher up and down

Permits pusher up or down travel. You can select this operation, only when the

magazine barfeed is set in the manual mode and the flag is fully retracted.

S9 Pusher forward and backward

This allows the movement of the pusher or flag backward and forward depending on if

the pusher is in up or down position. This movement is operational only when the

magazine barfeed is set in the manual mode and the pusher is in limit up/down position.

S11 Pusher fully retracted

When the switch is in one of positions (I0,21 is active) the pusher will move fully back

(out of spindle), after it has pushed material and the material has been clamped. Whenthe switch is in the other position (I0,21 is not active), the pusher will move back about

50 mm from end of material after the material has been clamped.

Note 1: There are two reasons to use the full retraction of the pusher:

1. When there is vibration problem (magazine barfeed or pusher).

2. When there is danger of contact of the pusher with the spindle liner (when

using pusher and its outside diameter is close to inside diameter of the

spindle liner).

Note 2: It is recommended, to fully retract pusher out of the spindle.

S12 Reversing of the loading motor directionReversing of the motor is possible only in the manual mode and it is used if collision or

binding of loading device occurs. The switch is located on side of the electric box. If the

reversion is activated in auto mode an error is signaled. . This reverse movement can be

also used for changing spindle liners or testing channel position setup for huge bars. In

all this cases the table must be free.




40

4.10.2 ERROR SIGNALS AND MEANING OF LAMPS H14 AND H15

Lamps H14 (green) and H15 (red) are basic indicators of the magazine barfeed condition. If

the magazine barfeed is OK the green lamp is on. When an error occurs, the red lamp is on.

Basic rules:

§ If the red lamps is flashing fast (period 0.1 s) without stopping or with 1-sec intervals, the

magazine barfeed is in some error situation, refer to !error signals! on the next page. You

can stop this situation when you switch to manual mode.

§ If the red lamp is flashing slowly (period 1 s) the magazine barfeed is doing the start

sequence, or its signaling that the lathe is not ready for the automatic operation (signal

!lathe in AUTO! is missing), refer to !Basic meaning of the lamps! on the next page.

§ If the red lamp is ON all the time, the magazine barfeed correctly finished operation

because the set number of bars was machined or there is no material, refer to ! basic

meaning of the lamps! on the next page. If the green lamp is flashing (period 1 s) and the

red lamp is not ON, the pusher is pushing forward (to working area of the lathe) or itsloading a bar, refer to !Basic meaning of the lamps! on the next page.

Motor reversal: If the motor reversal (S12) is selected, the red and green lamps are

flashing alternately (period 1 s) in all modes.

Emergency stop: If any of the emergency stop buttons is pressed, or the top cover of the

magazine barfeed is open an error is caused !Emergency stop!. But this also causes

disconnection of power supply to the part of PLC output. PLC so both the lamps are OFF.

After the top cover is closed, power is supplied again to the PLC outputs, and both lamps

being on indicate the error.

All errors of magazine barfeed are indicated by PLC output LED!s, when MD LED is

ON (O0.8, O0.9, O0.14 and O0.15; see next page).

Interruption of power supply: This interruption in automatic mode will cause canceling

of the auto mode, when the supply returns, it will signal fault !emergency stop!. Any fault

condition (caused before power supply interruption) is preferred to !emergency stop! signal

caused by power supply interruption. So just turning the barfeed ON/OFF wont remove any

AUTO mode fault. You need to reset the barfeed, using the S3 mode selector switch by

switching it to MANUAL mode, to remove any fault.

Note: In MANUAL mode when the start button is pressed, adequate outputs O0.14 and

O0.15 to inputs I0.24 (input from tray hood switch) and I0.25 (input from K1R relay -

indication of loading mechanism rotation direction).




41

A l a r m 1 (

O 0 . 8

)

A l a r m 2 (

O 0 . 9

)

A l a r m 3 (

O 0 . 1

4 )

A l a r m 4 (

O 0 . 1

5 )

H 1 4 g r

e e n

( O 0 . 6

)

H 1 5 r e

d

( O 0 . 5

)

B i t n u m b e r

Value from SS2003_2E, SS2003_3E (HD) version

Explanatory note:OFF.............Switch offON; l .......... Is ON permanentlyOFF/0.1....... Switch off/ flashing in interval 0.1 sec0.1 ............... Flashing in interval 0.1 sec1; ¥............. Flashing in interval 1 secMBF............. Magazine barfeed

Basic meaning of lamps H14 and H15 in automatic mode of MBF

1 1 MBF is starting

OFF 1 MBF is in starting position and lathe is not in AUTO mode

ON 1 B47 Channel is in the low limit position loading impossible

ON OFF MBF in AUTO or COUNT mode all is OK

1 OFF MBF is loading or pushing bar

ON ON Number of bars are finished COUNT mode

OFF ON Bar is not available

Error signals of MBF in automatic mode (MD mode activated MD LED is ON)

l 1 0.1 B42 M-function during controlled ejection of bar remnant

l OFF 0.1 B41 Slow controlled ejection of bar remnant (max. 8 sec)

l l OFF 0.1 B36 Slow movement (- 4 s, ¯ 1.5 s, ¬® 8 s; HD:- 7 s, ¯ 2.5 s)

l OFF OFF/0.1 B37 The error of vertical movement switch

l l OFF OFF/0.1 B38 The error of horizontal movement switch

l l OFF 0.1 B39 The error of material available switch B27.

l l l OFF 0.1 B40 The chuck closed during bar loading

l 0.1 0.1 B45 The !Lathe AUTO mode" signal is lost during loading

l l 1 0.1 B46 M-function is not finished

l l OFF/0.1 0.1 B34 Open chuck/collet during starting

l l l 0.1/OFF OFF/0.1 B57 Motor reversall l OFF 0.1 B48 Undefined starting position of pusher

l l l OFF 0.1 B49 Low input air pressure

l l l OFF/0.1 OFF/0.1 B50 Emergency stop (I0.0=OFF)

l l l l 0.1 0.1 B60 Loading impossible B28 is not active

¥ 0.1 0.1 B59 NK1, B20 or B21 signals lost

User error identification

When AUTO or COUNT mode of BF is active:

§ When is not any fatal error of BF, all output LEDs mean the states of the PLC outputs.

§ When is any fatal error of BF present, the PLC is changing regularly the meaning of the

output LEDs:MD LED is ON Þ Output LEDs are showing any fatal error (see the error

matrix on this page).

MD LED is OFF Þ Output LEDs are showing the states of the PLC outputs.

Note: MD LED (MD mode) is permanently SET after the PUSHER UP button pressing.

MD mode is permanently RESET after the PUSHER DOWN button pressing.

MD mode is regularly changing after the PUSHER BACK button pressing.

Note: MD LED is next to output LED s of PLC.




42

4.10.3 EXPLANATION AND FUNCTION OF THE SWITCHES

B21

B20

B27

B24

B25

B28

ENCODER (NK1, NK2, B26)

S20

SQ23

Fig. 4.9 - Location of the switches

B20 Pusher up

Input 12 on the PLC is activated if the pusher is its highest position

B21 Pusher down

Input 13 on the PLC is activated if the pusher is in its lowest position

Note: The end switches B20 and B21 can activate only when the claws are rotating in

normal direction. If the claws rotate against this direction, lever end switches B20 and B21

are not activated refer to chapter 4.11.

NK1 Pusher/flag backward

Input 14 on the PLC is activated if the pusher or flag is fully backward.

NK2 Flag forward

Signal from the magnetic lever end switch located in measuring strip. Input 15 on the

PLC is activated if the flag is fully forward. The front of the flag is in the same

position as the front of the channel, so the bar left the channel.




43

B24 End of bar

Input 16 on the PLC is activated if the pusher is in position when there is not enough

material to machine another part. (flag passed proximity switch B 24).

B25 Remnant ejected

Input 17 on the PLC is activated if the pusher is stopped by the mechanical stop. The

proximity switch confirms that the remnant has been successfully ejected. In this

position the front end of the pusher little bit further than the front end of the chucking

device (3-5 mm).

B26 Pusher/flag in motion

Signal from the movement detector in measuring strip. As the flag is moving the input

18 on the PLC alternately activates and de-activates. This is used to find out if the flag

is moving.

S20 Pressure switchThe input 19 on the PLC is activated, if the air pressure is OK. If the air pressure

coming in the unit is lower than 2,5 bars and the magazine barfeed is pushing material

using the flag/pusher, an error of the magazine barfeed is signaled.

B27 Material available

Input 20 on the PLC is activated as the loading mechanism is loading the bar into the

channel. If there is no bar on the claw, when loading, input 20 is not activated and an

error of the magazine barfeed is signaled.

B28 Loading possibleInput 24 on the PLC is activated as the material channel is in loading position. Input 24

is not activated as the material channel is in down position for spindle liner change

(the loading is impossible).




44

4.10.4 SETTING THE PROXIMITY SWITCHES B24 AND B25

H ..... Length of machined partI....... Thickness of the cutting toolJ ...... Machining safety zone

K ..... Length of chuck jaws

B24

B25

Fig. 4.10 - Setting the proximity switches B24 and B25

B24 End of bar

This switch is set in a distance !A! behind the switch B 25. This distance is sum of

distance of part (H), thickness of the cutting tool (I) and clamping length of jaws of theclamping device (K). This setting will ensure that there is always enough material to

clamp the bar, while the last part is being machined (see fig. 4.10). Although safety

zone (J) influences length of the remnant, it has no influence on distance !A! between

proximity switches B 24 and B 25.

B25 Remnant ejected

When the pusher is on mechanical stop (D) the proximity switch must be set above the

metal strip of the flag. Mechanical stop of the pusher is activated if the front end of the

pusher exceeds (0.25-in.) the front of the jaws (see fig. 4.10).

Note: The proximity switches should be set so there is 1 mm between the switch and the

surface that activates it.




45

4.10.5 HOW TO PROGRAM THE LATHE

FEEDING PROGRAM - the lathe must analyze signal end of bar, which is input of PLC and

it may be checked by parameter PLC, M-code or by mode !/!.

EOB controlled with a "/" command (EOB = end of bar)

§ Spindle stop

§ !/! command no EOB: go to the next line

with EOB: call the loading program or sub-program

§ Move the turret stop to the front end of the bar (2 mm distance between bar and stopper).

§ Open the collet/chuck jaws. (Possible M-code as another order for the magazine barfeed to

push bar).

§ Time to push the bar out

(Max 4 seconds for pusher fully out, Max 1 seconds when pusher is left in the spindle)

§ The pusher will push the bar to the turret stop.

§ Move the stop in position to machine a new part (max. speed 5m/min).§ Close the collet/chuck jaws.

§ Time for pusher to leave the part (about 0.5 seconds - pusher stays in the spindle)

(Max 4 seconds for the pusher fully out, Max 1 s when pusher is left in the spindle)

§ Machine the part.

EOB controlled with a M function

§ Spindle stop

§ M code no EOB: go to the next line

with EOB: call the loading program or sub-program

§Move the turret stop to the front end of the bar (2 mm distance between front of theclamping device and stopper).

§ Open the collet/chuck jaws. (Possible M-code as another order for the magazine barfeed to

push bar).

§ Time to push the bar out

(Max 4 seconds for the pusher fully out, Max 1 second when pusher is left in the spindle)

§ Magazine barfeed push the bar to the turret stop.

§ Move the stop in position to machine a new part (max. speed 5m/min).

§ Close the collet/chuck jaws.

§ Time for pusher to leave the part.


§ Machine the part.




46

RE-LOAD CYCLE PROGRAM

§ Spindle stop

§ Move the turret head stopper to the front end of the bar (2 mm distance between bar and

stopper).

§ Open the collet/chuck jaws.

§ M-code (to eject the remnant - start loading cycle)

§ Dwell 2 seconds (if does not need to be programmed, if the magazine barfeed cancels the

static M - code)

§ Move the turret stop in Z+ so that you get distance between collet/chuck jaws and the stop.

This distance must be big enough to eject the remnant. Max speed 5m/min.

§ Dwell 8 sec. This dwell will ensure that the magazine barfeed can send out an alarm

before the lathe moves in Z- if the remnant has not been ejected.

§ Move the turret stop to the front of collet/chuck (2 mm between front of the clamping

device and the stopper)

§ M-code (to push a new bar to the lathe turret stop)

§ Move the stop in position to machine a new part (max. speed 5m/min).§ Close the collet/chuck jaws.

§ Time for pusher to leave the part.


§ Go back to the main program

WARNING

It is unconditionally necessary to enter 8-second dwell after the remnant ejection!

If this dwell is shorter, a collision of turret head and remnant can occur, if the

remnant has not been ejected because it is blocked. This dwell does not influence

the time to load a new bar, because the magazine barfeed during this dwell isloading a new bar. It is possible to shorter other time dwells after testing. Test only

the last bar (pusher all the way out).




47

4.10.6 FLOW DIAGRAM OF THE MAGAZINE BARFEED PROGRAM

program of version SS2003_xx

mode without M-function

Waiting

inputs and

outputs

Pusher forward

End of bar

?

Pusher retract Pusher retract

Waiting

Push remnant to

turret stop(optional)

Ejecting of

remnant by

pusher and M-

function finish

Pusher

backward

Chuck open

Chuck closedChuck closed

25 mm retraction or fullretraction

depends on S11 switch

Chuck open & M-function

Remnant on stop (B26)

Remnant ejected (B25)

I 0.03

O0.02

I 0.16

I 0.03

O0.03

I 0.03

I 0.09

O0.02

I 0.18

O0.02

O0.12

I 0.17

O0.03

Continue from end of next

page

no yes




48

inputs and

outputs

Loadnew bar

Material

available

(B27)

Pusher

down

Push new bar by

flag

Flag backward

Pusher down

Waiting

Shift of new bar to

stop of tool head

by pusher

Pusher up (SQ20)

Flag back (NK1)

Pusher down (SQ21)

M-function

O0.00

I 0.20

I 0.12

O0.02

O0.1

I 0.13

O0.02

Pusher back

no yes

Pusher down (SQ21)

Flag in front (NK2)

Bar on stop (B26)

M-function finish

pusher is still

pushing

Chuck closed

Continue on midle of

previous page

I 0.14

I 0.15

O0.03

I 0.14

I 0.09

I 0.18

O0.12

O0.02

I 0.03

End




49

4.10.7 GETTING THE AUTO CYCLE STARTED AND STOPPED

a. Before starting work and turning the lathe ON check:

1. That pusher is fully back and down (out of spindle).

2. That magazine barfeed is connected with the air supply and its main switch isturned ON.

3. That mode selector switch on magazine barfeed is in mode Chucking, which

allows independent work of the lathe.

b. Start the lathe and prepare the magazine barfeed for auto cycle.

1. After turning the lathe on, reach references and do all steps to start auto cycle. The

magazine barfeed when in !Chucking! mode wont influence your work. Clamp a

bar in the clamping device by hand, after you have done all preparation steps. Set

the requirement to pull the pusher out of the spindle using the switch S11.

2. Put the magazine barfeed into Auto mode and press Start button.

Operations:

a. Choose Auto mode using the switch S3.

Activate Start using button S5.

Spacesaver will now check position of material using the pusher. Green (H14) and red

(H15) lamp is flashing in 1-s intervals. If this process is successfully finished, some of

these conditions will stabilize.

1. Green lamp (H14) is ON.

Lathe and magazine barfeed are ready to machine.

2. Red lamp (H15) is flashing in 1-s intervals.

Lathe is not set in auto mode (input I0.11 is not activated)

Conditions necessary for lathe to start automatic operation of lathe and magazine

barfeed:1. Collet/Chuck jaws are closed (input 10.3 is not activated)

2. Lathe in auto mode and magazine barfeed operation allowed.

3. Magazine barfeed is ON.

Conditions necessary for magazine barfeed to start automatic operation of lathe and

magazine barfeed:

1. Pusher is fully down and back (inputs I0.13 and I0.14 activated)

c. To start Automatic operation of lathe with magazine barfeed, start lathe Automatic

cycle.

d. Finish the combined operation of lathe and magazine barfeed as follows:

Choose the Count mode on magazine barfeed (with number of bars to be finished, ifnecessary). After the set number of bars is finished, no more bars are loaded and

automatic operation of lathe will be stopped by alarm - both lamps (green and red) are

ON (not flashing). Then switch the magazine barfeed into Chucking mode and do all

finishing steps of the lathe alone. Do not turn the magazine barfeed off using the

main switch (this switch is just for service purposes).




50

4.10.8 INTERFACE

FROM THE LATHE TO THE MAGAZINE BARFEED

These signals on the lathe side are carried out by relay contacts or by switches. Signals aresupplied 24 VDC from the magazine barfeed.

Emergency (Total) stop on the lathe

pin 4 and 5 on X1 - input I0.00 on PLC indicates status.

Immediately stops magazine barfeed and lathe.

Lathe in AUTO mode

pin 11 on X1 - input I0.11 on PLC signals status.

Allows magazine barfeed to run in automatic mode. After the magazine barfeed is started, the

green lamp is ON (continuous). If signal from the lathe is not active, the green lamp is OFF

and the red lamp is flashing in 1-second intervals.Signal activated - lathe auto cycle

Signal not activated - lathe manual cycle only

Note: This is a safety signal from the lathe, proper operation requires this signal at I0,11

prior to the receipt of I0,03 or the barfeed will fault. This signal can be accomplished though

either an ! AUTO! output from the lathe, or (preferably) a ! Lathe door closed ! signal. This

input is allowed to drop out (opening lathe door) under the condition that the pusher is not

requested to perform forward motion, otherwise a fault will occur.

Clamping device open (collet)

Pin 12 on X1 - Input I0.03 on PLC signalizes status.The signal to the magazine barfeed to feed bars.

Signal activated - collet open

Signal not activated - collet closed (the logic of this signal can be also reversed,

see input I0.22)

Note: When the collet is closed, the pusher stays 0.5 or 3 seconds under pressure.(See

4.10.9.)

Note: By choosing mode of the magazine barfeed, it is possible to complete the condition to

push with M-code (for signal collet open).




51

M-code

Pin 9 on X1 - Input I0.09 on PLC signals status.

It can be pulsing (after certain amount of time the signal vanishes without magazine barfeed

initiative) or latching which requires a finish signal provided by the barfeed to confirm end of

M-function. The latching signal is preferred. The lathe is programmed according to type of

M-code. In loading cycle the first M-code is used as a signal to eject remnant and load a new

bar into the spindle. A second occurrence of the same M-code is the order to push the new bar

to the lathe stop.

FROM MAGAZINE BARFEED TO THE LATHE

These signals are carried out by relay contacts on magazine barfeed side.

Signals are supplied 24 VDC from the lathe.

Emergency stop on the lathe

pin 21 and 22 on X1 - Immediately stops magazine barfeed and lathe.

Magazine barfeed OK

pin 14 on X1 - Output O0.07 on PLC

Safety signal from magazine barfeed informs lathe that magazine barfeed is OK and it is ready

for function.

Signal activated - no errors on magazine barfeed

Signal not activated - magazine barfeed signals error

Note: This signal is also activated when the main switch on magazine barfeed is ON,magazine barfeed is in CHUCKING mode and pusher is fully back (I0.14 is activated). This

allows lathe function without using the magazine barfeed.

Note: This signal always reports an error when in MANUAL mode.




52

End of bar - EOB

Pin 16 on X1 - PLC output O0.10 signals status.

Signal activated - end of bar reached

Signal not activated - end of bar not reached (enough material to clamp)

This signal will be sent to the lathe during feeding cycle, when pusher passes proximity switchB24 (end of bar) and is canceled on beginning of loading cycle. Position of proximity switch

B24 is set per application.

Setting proximity switch B24 during testing EOB before machining:

Set the pusher tip 3 - 5 mm in front of the lathe-chucking device and mark position of

flag activating the proximity switch. If the EOB is checked in NC program before

feeding, move the EOB proximity switch to distance that equals to length of the part

plus length of clamping device jaws in direction from the lathe. If normal NC program

is running (see chapter 4.10.5) and signal EOB is not sent, the bar is normally moved to

distance that equals to length of the part. If this movement activates the proximity

switch program for machining last piece is called. The lathe should check for !END OF

BAR ! at the beginning of the program before it signals the barfeed to push out another part.

Checking EOB signal - EOB after loading cycle for part production:

Move the EOB proximity switch to the marked position that is shorter of clamping

distance. If you pass this position while pushing bar, it will signal that there is not

enough material for next clamping. So the EOB test is made after machining.

Spindle inhibit

Pin 17 on X1 - Output O0.11 on PLC signals status.

Signal tells to lathe that it can start spindle rotation.

Signal is activated - authorizes spindle rotationSignal is not activated - forbids spindle rotation

Note: In CHUCKING mode, the signal is active if the flag is in rear position.

M-code finish

Pin 18 on X1 - Output O0.12 on PLC signals status.

M-code finished.

Signal is activated - M-code canceled (finished)

Signal is not activated - M-code not canceled (finished)

Signals to the lathe that the M-code command has been satisfied...




53

4.10.9 MODIFICATION OF THE PROGRAM CONTROL

Function of the SS2003 can be modified using inputs I0.10, I0.22 and I0.23.

I0.10 Bar pushing after CHUCKING device opens.This PLC input defines if the bar should be pushed when the clamping device opens, or if

special order (M - code) to load bar is necessary.

I0.10 not active push when clamping device opens and M-code is present

I0.10 active push when clamping device opens

I0.22 Change of logic of signal "Clamping device opens" (I0.03)

This PLC input defines polarity of the signal !Chucking device open!.

I0.22 not active clamped when I0.03 in not active

I0.22 active clamped when I0.03 is active

I0.23 Time switch - chuck delayThis PLC input defines the pushing time backward after collet closing

I0.23 not active pushing time is 0,5 sec.

I0.23 active pushing time is 3 sec.




54

4.11 LOADING MECHANISM REVERSE ROTATION

You can use this mode only on a barfeed equipped with the option of choosing the direction of

loader rotation.You will use this mode just for special situation.. For example when adjusting the machine

and you may need to unload the bar from the channel back on the tray.

Steps

1. Remove bar from the tray or secure them so the claws do not push them back during the

reverse rotation.

2. Using the mode switch S3 choose Manual mode.

3. Switch the rotation direction switch S12 on the electric box of the magazine barfeed (see

fig. 3.2).

The magazine barfeed signals the reverse movement of the loading mechanism with

the red and green lamps. The lamps will alternate, one on while the other lamp is off.(see chapter 4.10.2)

4. With any button S7 for vertical movement of the pusher unload the bar from the channel

on the tray.

If one button S7 does not work, the other one S7 will work.

5. Now the claws are close to their down lower limit position. With maximum caution

continue moving the claws in the reversed direction until there are close to their upper

limit position. Here stop before the claws hit the bar we just unloaded.

6. Using the switch S12 choose normal direction of rotation of loading mechanism.

The magazine barfeed signals normal movement of the loading mechanism using the

lamps. The flashing of the lamps stops (see point 3).7. If everything is all right press the button S7 for pusher movement down (not up) and

hold it until the claws stop in position under the tray.

The loading claws will move in normal direction under the tray and pusher will be in

its lower limit position. In this position the loading mechanism stops to react on

signals from button S7.

Note: Lever switches B20 and B21 are activated only when the loading mechanism rotates

in normal direction. When the loading mechanism rotates in reversed direction, these two

lever switches are not active.

WARNING

If free movement of the claws through the tray is not addressed (see point 1), you

risk damage to the loading mechanism. Damage caused by not following the steps

on this page (chapter 4.11) is not covered under warranty.




55



Addendum 1

56

ADDENDUM 1

MAGAZINE BARFEED - LATHE

COOPERATION DIAGRAM

(Mode without M-function)



Addendum 1

57



Addendum 1

58

Addendum 1 # Magazine barfeed # lathe sequence diagram


Proximity switches

End of bar (EOB) B24 B25 Remnant ejected

ß ß

Step Barfeed Lathe

1a Waiting. Brings turret head

stopper to the

clamping device.

Check EOB.

If no EOB continue.

2a Opens the collet.Pusher forward. Ü

3a Pusher forward. Sets the stopper to

the length of the part

4a Closes the collet.Pusher Ü

backward.

5a Waiting. Machining the part.

6a Waiting. Cuts off the part.



Addendum 1

59

EOB B24



Proximity switchesEnd of bar (EOB) B24 B25 Remnant ejected

ß ß

Step Barfeed Lathe

1b Waiting. Brings turret head

stopper to the

clamping device.

Check EOB.

If no EOB continue.

2b Opens the collet.

Pusher forward. Ü

3b Pusher forward. Sets the stopper to

the length of the

part.

4b Closes the collet.

Pusher Ü

backward.

5b Waiting. Machining the part.

6b Waiting. Cuts off the part.



Addendum 1

60

Remnant ejected B25



Proximity switches

End of bar (EOB) B24 B25 Remnant ejected

ß ß

Step Barfeed Lathe

7 Waiting. Brings turret head

stopper to the

clamping device.

Check EOB.

CALL subprogram.

8

Opens the collet.Send M-code.

Pusher forward. Ü

9

Pushing out

the remnant.

End of M-function. Þ Turret moves away

to eject the remnant.

10 At B25 pusher moved Turret moves away

away. to eject the remnant.

11 Loading a new bar Dwell 8 s.

into the channel.

12 Flag forward to Turret moves into

introduce a new bar the position to receive

Into the spindle. new bar to departure

position (in front of

clamping device).



Addendum 1

61



Proximity switchesEnd of bar (EOB) B24 B25 Remnant ejected

ß ß

Step Barfeed Lathe

13 Sends M-code.

Pusher forward Ü

(loading the new bar).

14 As the new bar isagainst the turret -

end of M-code.

Þ Closes the collet.

15 Pusher backward.

16 Waiting. Machinig new barface.

Go back to the 1a step.



Addendum 2

62

ADDENDUM 2

ELECTRICAL DIAGRAMS



Addendum 2

63



Addendum 2

64



Addendum 2

65



Addendum 2

66



Addendum 2

67



Addendum 2

68



Addendum 2

69



Addendum 2

70



Addendum 2

71



Addendum 2

72



Addendum 2

73



Addendum 3

74

ADDENDUM 3

STANDARD INTERFACE DIAGRAMS



Addendum 3

75



Addendum 3

76



Addendum 3

77



Addendum 4

78

ADDENDUM 4

PNEUMATIC DIAGRAM



Addendum 4

79



Addendum 4

80



Addendum 4

81



Addendum 5

82

ADDENDUM 5

SPARE PARTS



Addendum 5

83



Addendum 5

84

Basic spare parts for SS2003:

a) Mechanical parts

Group/part No. Drawing No. Name, description

1-01 Alignment kit

09 38 002 Centering ring D 20/19

09 38 008 Cord holder

09 38 004 Bushing with screw M4

Alignment cord D 1,5

1-02 08 38 100 Adjusting key

1-03 Expansion screw

1-04 Complete pusher D 6

09 24 000 Pusher D 6

09 24 003 Bushing D 6

09 24 005 Holder D 61-05 Complete pusher D 10

09 27 000 Pusher D 10

09 27 003 Bushing D 10

09 27 005 Holder D 10

1-06 09 16 100 Proximity switch holder

1-07 09 38 005 Side alignment accessory kit

1-08 08 38 004 Spacer tubes

1-09 Complete pusher D 18

09 23 000 Pusher D 18

09 23 004 Bushing D 18

09 27 005 Holder D 10

1-10 Single-row ball bearing 6004 2ZR

1-11 Roller chain 081-1

1-12 Chain coupler 081

b) Pneumatic parts


2-01 Rod-less cylinder D 32 L 1660

type M/46132/1660

2-02 Air water trap & regulator

2-03 Solenoid valve unit2-04 Relief valve

2-05 Pressure switch

2-06 Hose D 8



Addendum 5

85

c) Electrical parts


3-04 Start button (T10 ACE)

3-05 Proximity switch (XS1N12PA340D)3-06 Proximity switch cable with connector

(XZCP1241 L5)

3-10 Relay 24VDC (RP700PC-P)

3-11 Relay ZT 4P 5A 24VDC (ZT570024)

3-12 PLC (TSX-1724012E)

3-13 EEPROM (TSX MC70E38)

3-17 Power module 24VDC

3-18 Main switch (S25JU1102A6)

3-19 Measuring strip ESSA (LRC 1660B)

3-20 Limit switch for loading - kit

3-21 Switch S11

3-22 Switch up/down, FWD/BWD

3-23 Mode overswitch

3-25 Cover switch XCK-T511

3-26 Power supply - rectifying board TRU-SU 06

3-27 Power supply - transformer TRONIC 000 4354

3-28 Motor 122194

3-31 Fuse T 8A

3-32 Fuse AL 15A

3-33 LED signal lamp red (XB5 AVB 3)

3-34 LED signal lamp green (XB5 AVB 4)3-35 Fuse GT 4A (200-240 V)

3-36 Fuse GT 2A (400-575 V)



Addendum 6

86

ADDENDUM 6

METHODS HOW TO TROUBLESHOOT



Addendum 6

87



Addendum 6

88

6.1 METHODS HOW TO TROUBLESHOOT PLC

All lamps are off, PLC does not responding

Check the fuses F1, F2, F3. Location of fuses shown in Addendum 2 on page 63.

Check also fuse connections.

Green lamp on PLC RUN/STOP is on but PLC is not responding

Check Input 0 on the PLC unit. If the LED is off, the Emergency-stop circuit of the lathe or

magazine barfeed is open. Check the wiring on pins 4 and 5 of X1 connector.

Also check the connections and relay for Emergency-stop on the lathe and the magazine

barfeed.

Green lamp RUN/STOP is flashing

The PLC is stopped (program is not running). To repair Re-Initialize PLC

Green (RUN/STOP) and red (I/O) lamps are flashing alternatelyThere is no program in PLC memory. To repair Re-Initialize PLC

Red I/O lamp is on

I/O Fault - Possible short-circuit on input or output side.

Red I/O lamp is flashing

RAM memory fault. To repair Re-Initialize PLC

Note: The BATT (battery) lamp is normally on.

6.2 METHODS HOW TO TROUBLESHOOT PUSHER/CHANNEL

Pusher drifting backward or forward/ Flag is not stopping immediately after forward-

backward button is released.

The solenoid valve does not work correctly.

Check guiding of flag carrier on horizontal pneumatic cylinder.

When checking solenoid valve first check if its electrical control works (lights PLC output

and valve solenoid is operated). If you identify the fault to be in the electrical part of the valve,

it is necessary to change this valve. If the electrical part is OK, check the mechanical part.

First remove electrical connector and try to control the valve by hand (manual over-ride

yellow control button). If the valve does not move, remove the inlet hose and spray lubricant

into the valve (for example WD. 40). If the function does not get any better its necessary to

change the valve.



Addendum 6

89

The pusher is moving slowly

First check the air pressure which must be set according to the size of the bar (2 # 5 bars). You

should also check the airflow that is adjustable by screw on the outlet of the solenoid valves.

Cause of the problem can be also partially blocked silencer (exhaust muffler) of the solenoid

valve. You can remove the valve and clean in degreasing agent. If you have very dirty air you

can see plenty of sediment in the supply hoses. The sediment may not cause immediate

problem, but it can later cause blockages throughout the system.

Pusher moves in the opposite direction when collet opens or closes

It is necessary to change logic of input I0.03, see chapter 4.10.9.

Pusher vibration

Magazine barfeed may not be aligned with the lathe spindle center (see Installation). Remove

the vibration by retracting pusher fully out of the spindle before machining part. To retract the

pusher out of the spindle put the switch S11 (located under operator s panel) in position when

input 21 on PLC is active. The cause of the vibration can also be worn-out bearings of the pusher, the front carrier or bent bar of the pusher. Æ6 mm pusher is necessary to pull fully out

of the spindle after any pushing of bar. Use the largest diameter pusher when possible and

optimal working pressure.

6.3 METHODS HOW TO TROUBLESHOOT WARNING

SIGNALS

Error signal of the lathe when magazine barfeed is not being used

Main switch of the magazine barfeed is not on, the mode selector switch of the magazine

barfeed is not in CHUCKING mode or pusher is not fully back.

You can clearly identify the error of the magazine barfeed in AUTO mode using the out puts

O0.08, O0.09, O0.14 and O0.15 on PLC of the magazine barfeed (see chapter 4.10.2).



Addendum 6

90

6.4 METHODS HOW TO TROUBLESHOOT VARIOUS

PROBLEMS

The magazine barfeed signals no material although the bar was loaded

Loaded bar must activate signal of proximity switch B27. Bars must be placed on the tray sothey will activate the proximity switch on the claw. The metal strip that activates the

proximity switch, must freely movable and it must activate the switch. If the switch does not

activate, check if the sensing distance between the switch and the metal strip is 1 mm, if

neccessary, replace the proximity switch.



Addendum 6

91



Addendum 7

92

ADDENDUM 7

INPUTS AND OUTPUTS



Addendum 7

93



Addendum 7

94

7.1 IDENTIFICATION OF ERRORS INPUTS

With S3 mode switch in CHUCKING position check function of all proximity switches. Input

I0.00 must be activated.

I0.00 Emergency stop - Must be active to turn on barfeed. If not check pins 4 and 5 of the

X1 connector.

I0.01 Input from mode switch S3 from MANUAL-AUTO-COUNT

I0.02 Input from mode switch S3 from MANUAL-AUTO-COUNT

I0.03 Input from lathe indicated collet status

signal not active - collet closed, signal active - collet opened

(if input I0.22 is not active)

I0.04 Input from S5 switch Start

I0.05 Input from S7 button pusher up

I0.06 Input from S7 button pusher down

I0.07 Input from S9 button pusher forward

I0.08 Input from S9 button pusher backward

I0.09 Input (order) from lathe for feeding bar stock (M-function)

I0.10 Input from mode switch

signal not active - mode with M-function, signal active - mode without M-function

I0.11 Input AUTO from the lathe

signal active - lathe in AUTO

I0.12 Input from B20 end switch

signal active - pusher up

I0.13 Input from B21 end switch

signal active - pusher down

I0.14 Input from NK 1 magnetic switch in measuring strip

signal active - pusher back

I0.15 Input from NK 2 magnetic switch in measuring strip

signal active - pusher forward

I0.16 Input from B24 proximity switch signal active - end of bar



Addendum 7

95

I0.17 Input from B25 proximity switch

signal active - remnant ejection confirmed

I0.18 Input from movement encoder

If the pusher moves, this input should be flashing.

I0.19 Input from S20 pressure switch

signal active - air supply is OK

I0.20 Input from B27 proximity switch for material available

signal active - bar is being loaded into the channel

I0.21 Input from S11 lever toggle switch

signal active - pusher fully out of the spindle after each feeding

I0.22 Input chuck reversal modereversal of logic of input I0.03 (see chapter 4.10.9)

I0.23 Input for 3 sec chuck delay

Increase the pusher dwell to 3 seconds to allow the chuck to close

I0.24 Input from the loading possible switch B28

signal is not active - channel in down position (loading impossible)

I0.25 Input from S12 direction of movement of the loading claws toggle switch

signal active - normal direction of claws movement



Addendum 7

96

7.2 IDENTIFICATION OF DEFECTS OUTPUTS

O0.00 Output for K1 relay - pusher up

O0.01 Output for K1 relay - pusher down

O0.02 Output for Y22 valve - pusher forward

O0.03 Output for Y23 valve - pusher backward

O0.04 Output for K4 relay - Top Cut Interlock

O0.05 Output for H15 - red lamp on panel ON

O0.06 Output for H14 - green lamp on panel ON

O0.07 Output for K2 relay - barfeed OK

O0.08 Output for K5 relay - Long EOB

Diagnostic when MD LED is ON - ALARM 1 (see chapter 4.10.2)

O0.09 Output for K5 relay - Mazak EOB

Diagnostic when MD LED is ON - ALARM 2 (see chapter 4.10.2)

O0.10 Output for K5 relay - Short EOB

O0.11 Output for K6 relay - spindle rotations authorized

O0.12 Output for K7 relay - M-function finished

O0.13 Output for K5 relay - Standard EOB

O0.14 Diagnostic when MD LED is ON - ALARM 3 (see chapter 4.10.2)

O0.15 Diagnostic when MD LED is ON - ALARM 4 (see chapter 4.10.2)

Note: In MANUAL mode when START button is pressed inputs I0.24 and I0.25 are

displayed at outputs O0.14 and O0.15



Addendum 7

97

7.3 TROUBLESHOOTING MATRIX ERROR

A l a r m 1

( O 0 . 8

)

A l a r m 2

( O 0 . 9

)

A l a r m 3

( O 0 . 1

4 )

A l a r m 4

( O 0 . 1

5 )

H 1 4 g

r e e n

( O 0 . 6

)

H 1 5 r e

d

( O 0 . 5

)

B i t n u m b e r

Value from SS2003_2E, SS2003_3E (HD) version

Explanatory note:OFF.............Switch off

ON; l .......... Is ON permanentlyOFF/0.1....... Switch off/ flashing in interval 0.1 sec0.1 ............... Flashing in interval 0.1 sec1; ¥............. Flashing in interval 1 secMBF............. Magazine barfeed

Basic meaning of lamps H14 and H15 in automatic mode of MBF

1 1 MBF is starting

OFF 1 MBF is in starting position and lathe is not in AUTO mode

ON 1 B47 Channel is in the low limit position loading impossible

ON OFF MBF in AUTO or COUNT mode all is OK

1 OFF MBF is loading or pushing bar

ON ON Number of bars are finished COUNT mode

OFF ON Bar is not available

Error signals of MBF in automatic mode (MD mode activated MD LED is ON)

l 1 0.1 B42 M-function during controlled ejection of bar remnant

l OFF 0.1 B41 Slow controlled ejection of bar remnant (max. 8 sec)

l l OFF 0.1 B36 Slow movement (- 4 s, ¯ 1.5 s, ¬® 8 s; HD:- 7 s, ¯ 2.5 s)

l OFF OFF/0.1 B37 The error of vertical movement switch

l l OFF OFF/0.1 B38 The error of horizontal movement switch

l l OFF 0.1 B39 The error of material available switch B27.

l l l OFF 0.1 B40 The chuck closed during bar loading

l 0.1 0.1 B45 The !Lathe AUTO mode" signal is lost during loading

l l 1 0.1 B46 M-function is not finished

l l OFF/0.1 0.1 B34 Open chuck/collet during starting

l l l 0.1/OFF OFF/0.1 B57 Motor reversal

l l OFF 0.1 B48 Undefined starting position of pusher

l l l OFF 0.1 B49 Low input air pressure

l l l OFF/0.1 OFF/0.1 B50 Emergency stop (I0.0=OFF)

l l l l 0.1 0.1 B60 Loading impossible B28 is not active

¥ 0.1 0.1 B59 NK1, B20 or B21 signals lost

User error identification

When AUTO or COUNT mode of BF is active:

§ When is not any fatal error of BF, all output LEDs mean the states of the PLC outputs.

§ When is any fatal error of BF present, the PLC is regularly changing the meaning of theoutput LEDs:

MD LED is ON Þ Output LEDs are showing any fatal error (see the error

matrix on this page).

MD LED is OFF Þ Output LEDs are showing the states of the PLC outputs.

Note: MD LED (MD mode) is permanently SET after the PUSHER UP button pressing.

MD mode is permanently RESET after the PUSHER DOWN button pressing.

MD mode is regularly changing after the PUSHER BACK button pressing.

Note: MD LED is next to output LED s of PLC.





Addendum 8

99

ADDENDUM 8

CONTROL SHEET FOR INSTALLATION

If the installation is being done by , they will proceed as follows:



Addendum 8

Documents

SMW Spacer Barfeed 2003manual.pdf