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MADE IN USA
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10.03.2006

Table of Contents
Chapter 1: ....................................................................................... 1-1

Alarms .........................................................................................................1-1
A002 – Emergency Stop Line Open.............................................................................................1-3
A003 – Lathe Emergency Stop Line Open ..................................................................................1-4
A004 – Bar Feeder Emergency Stop ...........................................................................................1-5
A006 – Air Pressure Failure .........................................................................................................1-6
A007 – Main Access Cover Open ................................................................................................1-7
A009 – Bar Feeder Retracted or Not Locked In It’s Working Position......................................1-8
A011 – Magazine Protection Grid Open ......................................................................................1-9
A023 – Servo Drive Alarm ..........................................................................................................1-10
A024 – Servo Motor Not Ready..................................................................................................1-11
A025 – Servo Motor Positioning Following Error.....................................................................1-12
A042 – Home Position Proximity Switch SQ5 Signal Missing ................................................1-12
A042 – Home Position Proximity Switch SQ5 Signal Missing ................................................1-13
A044 – Bar Loading Error...........................................................................................................1-14
A046 – Clamping Device Has Closed Prior to Feed Out Complete.........................................1-15
A047 – Signal A2 Interrupted During Loading Cycle ...............................................................1-16
A048 – Safety Time for Part Feed Out Elapsed ........................................................................1-17
A049 – Measuring Cell SQ@ Is Activated Too Early ................................................................1-18
A050 – Signal A2 Interrupted During Production Cycle and the Clamping ...........................1-19
A051 – Bar Stock Loading Error ................................................................................................1-20
A052 – Safety Time for Top-Cut Positioning Elapsed..............................................................1-21
A053 – Lathe Did Not Resume Its Production Cycle................................................................1-22
A083 – Upper Position Fault ......................................................................................................1-23
A088 – Loading Channel Will Not Move to Lower Position .....................................................1-24
A091 – Measuring Cell SQ3 Signal Defective ...........................................................................1-25
Lower Position Fault...................................................................................................................1-26
Loading Channel Upper Position Default .................................................................................1-27
Loading Channel Upper Motion Default....................................................................................1-28
Loading Channel Lower Motion Default....................................................................................1-29
Loading Channel Did Not Reach Its Lower Position................................................................1-30
Drive For Diameter Adjustment Error .......................................................................................1-31
Door Lathe Open.........................................................................................................................1-32
Servo Amplifier/PLC Communication Fault..............................................................................1-33
Diameter Change Control Device Is Out of Sync .....................................................................1-34
SPS No Response.......................................................................................................................1-35
Mitsubishi Servo Amplifier Alarm List ......................................................................................1-36

Chapter 2: ....................................................................................... 2-1

Common Issues...........................................................................................2-1
Low Voltage / PLC Shutdown ......................................................................................................2-2
Vibration Issues ............................................................................................................................2-3
Servo Motor Following Error During Sequence 12 ....................................................................2-4
Part Feed Out Accuracy ...............................................................................................................2-5

Chapter 3: ....................................................................................... 3-1

Procedures ..................................................................................................3-1
End of Bar Adjustment .................................................................................................................3-2
Alignment Procedure....................................................................................................................3-3
Pusher Changeover ......................................................................................................................3-7
Carriage Unit Belt Tension Adjustment ....................................................................................3-10
Servo Motor Belt Tension Adjustment ......................................................................................3-12
Diameter Adjustment Motor Replacement................................................................................3-14

QUICK LOAD SERVO S3

 Home Position Proximity Switch Adjustment – SQ5 ...............................................................3-18
Magazine and Loading Finger Adjustment ...............................................................................3-20
Measuring Cell Adjustment – SQ3.............................................................................................3-21
Pusher Reversing Distance Adjustment ...................................................................................3-24
Reference Procedure ..................................................................................................................3-25
Reset Interface Parameters........................................................................................................3-27
Calibration of the Loading Table ...............................................................................................3-31

Chapter 4: ....................................................................................... 4-2

Software Update/Restore ...........................................................................4-2

Determining Display Firmware.....................................................................................................4-3
PLC Fault .......................................................................................................................................4-4
Restore PLC Program From Memory Card to PLC – v1.17a......................................................4-4
PLC Fault .......................................................................................................................................4-7
Restore Bar Feeder Parameters from MMI to PLC – v1.17a ......................................................4-7
Software Update..........................................................................................................................4-10
Restore Bar Feeder Parameters From MMI to PLC – v1.17a ...................................................4-10
Software Update..........................................................................................................................4-13
Restore Display Data from Memory Card to MMI – v1.17a ......................................................4-13
Software Update..........................................................................................................................4-17
Restore PLC Program from Memory Card to PLC – v1.17a.....................................................4-17
PLC Fault – v2.08 ........................................................................................................................4-21
Software Update – v2.08.............................................................................................................4-24

Chapter 5: ....................................................................................... 5-1

Barfeed Applications ..................................................................................5-1

Application Setup..........................................................................................................................5-2

Chapter 6: ....................................................................................... 6-1

Preventative Maintenance..........................................................................6-1
Daily Maintenance.........................................................................................................................6-2
Weekly Maintenance .....................................................................................................................6-2
Monthly Maintenance....................................................................................................................6-2
Annual Maintenance .....................................................................................................................6-2

Chapter 7: ....................................................................................... 7-1

Spare Parts..................................................................................................7-1
Recommended Spare Parts List ..................................................................................................7-2
Parts Order Form ..........................................................................................................................7-3
Electrical Box Components .........................................................................................................7-4
Loading Table sub-assembly (Left/Rear Load)Loading Table sub-assembly (Left/Rear Load)7-5
Loading Table sub-assembly (Left/Rear Load)...........................................................................7-6
Loading Table sub-assembly (Left/Rear Load)...........................................................................7-7
Pusher Locking sub-assembly (Left/Rear Load) ........................................................................7-8
Pusher Locking sub-assembly (Left/Rear Load) ........................................................................7-9
Loading Table sub-assembly (Left/Front Load) .........................................................................7-9
Loading Table sub-assembly (Left/Front Load) .......................................................................7-10
Loading Table sub-assembly (Left/Front Load) ......................................................................7-11
Loading Table sub-assembly (Left/Front Load) .......................................................................7-12
Pusher Locking sub-assembly (Left/Front Load).....................................................................7-12
Pusher Locking sub-assembly (Left/Front Load).....................................................................7-13
Pusher Locking sub-assembly (Left/Front Load).....................................................................7-14
Loading Table Microswitch sub-assembly ...............................................................................7-14
Loading Table Microswitch sub-assembly ...............................................................................7-15
Servo Motor sub-assembly ........................................................................................................7-16
Linear Rail Assembly..................................................................................................................7-17

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-1

Chapter 1:
Alarms
A
n error has occurred during setup or cycling of the bar feeder. When an error occurs, an alarm message is generated on
the remote control station. Also provided are some possible causes as to why the error has occurred. This
troubleshooting guide discusses every alarm that the bar feed may generate. In conjunction with each alarm will be a
brief description of what the alarm is and a few tips and procedures of how to correct the problem.

Figure 1-1 Remote control station

QUICK LOAD SERVO S3

1-2 Chapter 1: Alarms

Designation Description
A Remote control station
B 24 pin connector with cover (depending on interface)
C Control cabinet
M1 Servo motor
M2 Motor for diameter adjustment
QS1 Main disconnect switch
SQ1 Loading channel upper position switch
SQ2 Loading channel lower position switch
SQ3 Measuring cell
SQ4 Proximity switch for diameter adjustment
SQ5 Home position proximity switch
SQ10 Main access cover safety switch
SQ11 Magazine grid cover safety switch
SQ12 Retraction system in position switch / key

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-3

A002 – Emergency Stop Line Open

EMERGENCY STOP
LINE OPEN!
********************

POSSIBLE CAUSES:
BAR FEEDER OR LATHE
EMERGENCY STOP,
PUSH BUTTON PUSHED
IN, CONNECTION OR
WIRING PROBLEM IN
CIRCUITRY A002

Description:
The Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.0). The problem is generated anytime the
safety circuit contactor (K1) is not energized and all safety switches are in operating position. (Refer to page 4-16 in the Quick Load
Servo S3 Instruction Manual).

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

• Verify that the 1/0 connector is plugged into the PLC
MODULE 0 correctly.
1 Bit 0 = 0 76543210 • Verify that the circuitry is wired correctly to the
0 electrical diagram on page 4-16 in the Quick Load
Servo S3 Instruction Manual.
MODULE 0 Alarm needs to be cleared. Press the STOP key on
2 Bit 0 = 1 76543210 the remote control station to clear the message and
1 reset the alarm.

For case 1, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

QUICK LOAD SERVO S3

1-4 Chapter 1: Alarms

A003 – Lathe Emergency Stop Line Open

LATHE EMERGENCY
STOP LINE OPEN!

POSSIBLE CAUSES:
- EMERGENCY STOP
PUSHED IN
- WIRING PROBLEM

A003

Description:
The Lathe Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.7). The problem is generated when
the lathe E-stop push button is pressed in.

Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 0 Alarm needs to be cleared. Press the STOP key on the
1 Bit 7 = 1 76543210 remote control station to clear the message and reset
10000000 the alarm.

MODULE 0
2 Bit 7 = 0 76543210 Reset the E-stop push button on the lathe.
0

For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-5

A004 – Bar Feeder Emergency Stop

BAR FEEDER
EMERGENCY STOP!

POSSIBLE CAUSES:
- EMERGENCY STOP
BUTTON PUSHED IN
- WIRING PROBLEM

A004

Description:
The Bar Feeder Emergency Stop alarm occurs whenever the PLC does not detect input (I0.6). The problem is generated E-stop push
button on the remote control station is pressed in.

Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 0 Alarm needs to be cleared. Press the STOP key on the
1 Bit 6 = 1 76543210 remote control station to clear the message and reset
1000000 the alarm.

MODULE 0
Reset the E-stop push button on the remote control
2 Bit 6 = 0 76543210
station.
0

For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

QUICK LOAD SERVO S3

1-6 Chapter 1: Alarms

A006 – Air Pressure Failure

AIR PRESSURE
FAILURE!

POSSIBLE CAUSES:
- AIR PRESSURE
BELOW 3 BAR(45PSI)
-AIR PRESSURE SWITCH
SP1 MIS-ADJUSTED
-AIR PRESSURE SWITCH
DEFECTIVE A006

Description:
The Air Pressure Failure alarm occurs whenever the PLC does not detect input (I0.1 – SP1) after a period of 5 seconds. The problem
is generated anytime air pressure is not sufficient, below 45psi, to make the air pressure switch.

Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 0 Alarm needs to be cleared. Press the STOP key on the
1 Bit 1 = 1 76543210 remote control station to clear the message and reset
10 the alarm.

Raise the incoming air pressure on the air regulator to

MODULE 0 (recommended) 75 psi. and no higher than 90 psi.
2 Bit 1 = 0 76543210
Flip the toggle switch on the PLC to the RUN position.
0
Replace the air pressure switch.

For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-7

A007 – Main Access Cover Open

MAIN ACCESS COVER

OPEN!

CLOSE MAIN COVER TO

RESUME OPERATIONS

A007

Description:
The Main Access Cover Open alarm occurs whenever the PLC detects input (I0.2 – SQ10). The problem is generated, as a safety
precaution, when the main access cover is opened to prevent any movement in the bar feeder if the operator or service technician
needs to perform any work inside the unit.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 0
1 Bit 2 = 1 76543210 Close the main access cover.
100
MODULE 0 Alarm needs to be cleared. Press the STOP key on the
2 Bit 2 = 0 76543210 remote control station to clear the message and reset
0 the alarm.

For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.

QUICK LOAD SERVO S3

1-8 Chapter 1: Alarms

A009 – Bar Feeder Retracted or Not Locked In It’s Working Position

BAR FEEDER RETRACTED

OR NOT LOCKED IN ITS
WORKING POSITION!

SIGNAL SQ10 MISSING

SECURE BAR FEEDER

IN ITS WORKING
POSITION TO RESUME
OPERATIONS
A009

Description:
The Bar Feeder Retracted alarm occurs whenever the PLC detects input (I0.4 – SQ12). The problem is generated when the bar
feeder is retracted for spindle liner changeover.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 0
Put the bar feeder back in its working position and lock
1 Bit 4 = 1 76543210
the latches.
10000
MODULE 0 Alarm needs to be cleared. Press the STOP key on the
2 Bit 4 = 0 76543210 remote control station to clear the message and reset
0 the alarm.

For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-9

A011 – Magazine Protection Grid Open

MAGAZINE PROTECTION
GRID OPEN!

CLOSE GRID TO RESUME

OPERATIONS

A011

Description:
The Magazine Protection Grid Open alarm occurs whenever the PLC detects input (I0.3 – SQ11). The problem is generated, as a
safety precaution, if the magazine protection grid is raised.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 0
1 Bit 3 = 1 76543210 Close the magazine protection grid.
1000

MODULE 0 Alarm needs to be cleared. Press the STOP key on the

2 Bit 3 = 0 76543210 remote control station to clear the message and reset
0 the alarm.

For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset
the alarm.

QUICK LOAD SERVO S3

1-10 Chapter 1: Alarms

A023 – Servo Drive Alarm

SERVO DRIVE ALARM!

-TURN OFF MAIN POWER

-WAIT FOR 2 SECONDS
-RESTORE MAIN POWER

IF PROBLEM PERSISTS
REFER TO INSTRUCTION
MANUAL A023

Description:
The Servo Drive Alarm occurs if the Mitsubishi servo amplifier generates an alarm.

Solution:
Turn the main power off to the Quick Load Servo S3 for 2 seconds and turn the power back on.

Note: If the alarm keeps recurring, check the alarm code on the Mitsubishi servo
amplifier and refer to Mitsubishi Servo Amplifier Alarm List pg. 1-37.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-11

A024 – Servo Motor Not Ready

SERVO MOTOR
NOT READY!

-VERIFY CN1B
CONNECTOR
-CHECK PLC OUTPUT
Q 4.4 (MUST BE ON)

A024

Description:
The PLC outputs a signal (Q4.4) to servo amplifier, which engages the servo motor and puts the servo motor in a “servo lock”
condition. If the servo amplifier does not recognize the signal after 3 seconds, this alarm is generated.

Solution:
• Verify that the CN1B connector is seated properly in the allotted socket on the servo amplifier.
• Verify that the PLC output (Q4.4) is turning on when the manual or automatic cycle is started.
• Verify that the K1 contactor is activated; input (I0.0) should be on.
If the problem persists please contact LNS America, Inc. for further information.

QUICK LOAD SERVO S3

1-12 Chapter 1: Alarms

A025 – Servo Motor Positioning Following Error

SERVO MOTOR
POSITIONING
FOLLOWING ERROR!
DURNG SEQUENCE
NUMBER [@@]

POSSIBLE CAUSE:
MECHANICAL OBSTACLE
PREVENTS BAR STOCK
TO FEED OUT
A025

Description:
The Servo Motor Following Error alarm occurs due to a mechanical obstacle preventing the bar stock from feeding out. The torque on
the servo motor will build up when the obstacle prohibits the stock from moving, once the torque reaches a certain limit the PLC
instructs the servo amplifier to quit pushing and this alarm message appears on the remote control station.

Solution:

Seq. # Solution
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the
message and reset the alarm.
• Check for any mechanical obstacles that the bar stock may be hitting. Remove obstacle
if this is the case.
##
• Check the bar stock diameter. Make sure that the actual diameter is the same as the
value entered in for the corresponding parameter in the Part Setup menu.
• Check the alignment between the bar feeder and the lathe. The lathe or the bar feeder
may have shifted over a long period if either is not lagged to the floor securely.

If the problem persists please contact LNS America, Inc. for further information.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-13

A042 – Home Position Proximity Switch SQ5 Signal Missing

HOME POSITION
PROXIMITY SWITCH SQ5
SIGNAL MISSING!

POSSIBLE CAUSES:
-SQ5 SIGNAL SWITCH
DEFECTIVE OR MIS-
ADJUSTED
-BROKEN BELT

A042

Description:
The Home Position Proximity Switch SQ5 Signal Missing alarm occurs if input (I1.4 – SQ5) is not detected before the v-channel
moves to the upper position and the encoder reads the home position (0.0mm). The problem is normally generated when the switch
is mis-adjusted.

Solution:
Press the STOP key on the remote control station to clear the message and reset the alarm. Press the HELP key. Press F4 (Page
Down icon) twice.

Case Input Remote Pendant Solution

MODULE 1 Alarm needs to be cleared. Press the STOP key on the
1 Bit 4 = 1 76543210 remote control station to clear the message and reset
10000 the alarm.

• Check the adjustment of the SQ5 switch.

MODULE 1 • Check the tension of the drive belt. If it is not tight,
2 Bit 4 = 0 76543210 adjust. Refer to the Quick Load Servo S3 Instruction
0 Manual, pg. 6-14.
• Re-reference the bar feeder.

QUICK LOAD SERVO S3

1-14 Chapter 1: Alarms

A044 – Bar Loading Error

BAR LOADING ERROR!

HEX, SQUARE BARS

POSSIBLE CAUSES:
-LOADING SAFETY TIME
ELAPSED
-BAR STOCK NOT FED
THROUGH THE COLLET
OF THE LATHE

A044

Description:
The Bar Loading Error alarm occurs during the top-cut positioning sequence when loading profiled material. During the loading cycle,
for profiled material, the bar stock is brought to the back of the clamping device. When this position is reached, the spindle is jogged
at a very low rpm and the pusher begins a pecking motion until the profile of the material and the profile of the chuck jaws are aligned
and the bar is fed out to the top-cut position. If the top-cut position is not reached after 20 pecking cycles, this alarm is generated.

Solution:
Alarm needs to be cleared. Press the STOP button on the remote control station to clear and reset the alarm. Remove the bar from
the spindle and restart the top-cut positioning cycle.
If the problem persists please contact LNS America, Inc. for further information.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-15

A046 – Clamping Device Has Closed Prior to Feed Out Complete

CLAMPING DEVICE HAS

CLOSED PRIOR TO
COMPLETING THE
FEED OUT

POSSIBLE CAUSES:
-LATHE PROGRAMMING
ERROR
-CLAMPING SIGNAL
FAULTY (PLC INPUT
A1) A046

Description:
The Clamping Device Has Closed Prior To Completing The Feed Out alarm occurs if the input for the clamping device closed is
detected before the value of the Input Part Length parameter is reached.

Solution:
Verify that the clamping device is closing properly and that the Clamping Signal Active interface parameter is set in conjunction with
how the interface signal is being sent.

QUICK LOAD SERVO S3

1-16 Chapter 1: Alarms

A047 – Signal A2 Interrupted During Loading Cycle

SIGNAL A2 (LATHE IN
AUTOMATIC MODE)
INTERRUPTED DURING
LOADING CYCLE!

RESUME AUTOMATIC
CYCLE OFTHE LATHE
AND THE BAR FEEDER

A047

Description:
The Signal A2 Interrupted During Loading Cycle alarm occurs whenever PLC input (I3.1) drops out during the loading cycle.

Solution:
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Remove the
bar stock from the loading channel and reset the bar feeder and the lathe in automatic cycle.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-17

A048 – Safety Time for Part Feed Out Elapsed

SAFETY TIME
FOR PART FEED OUT
ELAPSED!

POSSIBLE CAUSES:
-PROGRAMMING ERROR
-MECH. INTERFERENCE
-INTERFACE PROBLEM

A048

Description:
The Safety Time For Part Feed Out Elapsed alarm occurs if the value set in OVERALL PART LENGTH is not reached within 1 minute
after the bar feed is commanded to feed out.

Solution:

Case Application Solution

• Check that the position of the turret is correct for
the length of the part feed.
• Check for mechanical obstacle preventing the bar
Feed out with turret and
1 from completing the feed out.
with m-code
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
• Check that the position of the turret is correct for
the length of the part feed.
• Check for mechanical obstacle preventing the bar
Feed out with turret and
2 from completing the feed out.
without m-code
Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
the alarm.
• Check for mechanical obstacle preventing the bar
from completing the feed out.
Feed out without turret
3 Alarm needs to be cleared. Press the STOP key on the
and with m-code
remote control station to clear the message and reset
the alarm.
• Check for mechanical obstacle preventing the bar
from completing the feed out.
Feed out without turret
4 Alarm needs to be cleared. Press the STOP key on the
and without m-code
remote control station to clear the message and reset
the alarm.

Contact LNS America, Inc. for further information.

QUICK LOAD SERVO S3

1-18 Chapter 1: Alarms

A049 – Measuring Cell SQ@ Is Activated Too Early

MEASURING CELL SQ@

IS ACTIVATED TOO
EARLY!

POSSIBLE CAUSES:
-BAR STOCK EXCEEDS
MAXIMUM SAFETY
LENGTH
-BAR STOCK LIMITERS
NOT IN CORRECT
LOCATION A049

Description:
The Measuring Cell SQ3 Activated Too Early alarm occurs if input (I1.2 – SQ3) is activated before maximum safety length has been
reached during bar measuring.

Solution:
Press the STOP key on the remote control station to clear the message and reset the alarm.
Press the MENU key.
Press the #5 (Service) key.
Enter the password (2534) to access the Service parameters.
Press the F3 (ENTER) key.
Press the F3 (ENTER) key again for Bar Feeder Setup Parameters.
Press the F4 (PAGE DOWN) key. Maximum Bar Stock Length
The value of this parameter should not exceed the length of the spindle in the lathe. If the value does exceed the length of
the spindle, enter the new value and readjust the mechanical limiter of the loading magazine to the correct distance.
Measure the length of the bar stock being run. The length should not exceed the value set in this parameter.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-19

A050 – Signal A2 Interrupted During Production Cycle and the Clamping

Device Opened
SIGNAL A2 (LATHE IN
AUTOMATIC MODE)
INTERRUPTED DURING
PRODUCTION CYCLE
AND THE CLAMPING
DEVICE OPENED!

RESTART AUTOMATIC
CYCLE OF THE
BAR FEEDER AND THE
LATHE A050

Description:
The Signal A2 Interrupted During Production alarm occurs if the signal for clamping device closed is detected while the bar feed is in
automatic production and input (I3.1 – A2) is not active.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 3 Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
1 Bit 1 = 1 76543210
the alarm. Restart the bar feeder and the lathe
10 automatic cycle.
MODULE 3 Alarm needs to be cleared. Press the STOP key on the
remote control station to clear the message and reset
2 Bit 1 = 0 76543210
the alarm. Restart the bar feeder and the lathe
0 automatic cycle.

QUICK LOAD SERVO S3

1-20 Chapter 1: Alarms

A051 – Bar Stock Loading Error

BAR STOCK LOADING

ERROR!

POSSIBLE CAUSES:
-MAGAZINE EMPTY
-BAR STOCK SELECTION
FINGERS MIS-ADJUSTED
-WRONG LOADING FLAG
INSTALLED
-INCORRECT BAR STOCK
LENGTH A051

Description:
The Bar Stock Loading Error alarm occurs if input (I1.2 – SQ3) is still active after the loading flag returns home after positioning the
new bar into the spindle for top-cut. This alarm is also generated during the loading cycle if input (I1.2 – SQ3) does not detect a new
bar and the v-channel drops to the lower position.

Solution:
Press the STOP key on the remote control station to clear the message and reset the alarm. Press the HELP key. Press F4 (Page
Down icon) twice.

Case Input Remote Pendant Solution

MODULE 1
76543210 • Check that the loading flag is pushing the new bar
1 Bit 2 = 1
past the measuring cell (SQ3).
100
MODULE 1 • Load bar stock onto the magazine rack.
2 Bit 2 = 0 76543210 • Check that the loading fingers are set to pick up a
0 single bar.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-21

A052 – Safety Time for Top-Cut Positioning Elapsed

SAFETY TIME FOR

TOP-CUT POSITIONING
ELAPSED!

POSITIONING POINT
OUT OF SAFETY
TOLERANCES

A052

Description:
The Safety Time For Top-Cut Positioning Elapsed alarm occurs when the bar is being commanded to top-cut position and the position
is not reached after 5 minutes.

Solution:
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Restart the
bar feed and lathe in automatic production.

QUICK LOAD SERVO S3

1-22 Chapter 1: Alarms

A053 – Lathe Did Not Resume Its Production Cycle

LATHE DID NOT

RESUME ITS
PRODUCTION CYCLE!

POSSIBLE CAUSES:
-LATHE CLAMPING
DEVICE NOT CLOSED
-CLAMPING
CONFIRMATION SIGNAL
MISSING (INTERFACE,
PLC INPUT A1) A053

Description:
The Lathe Did Not Resume Its Production Cycle alarm occurs if the bar feed does not recognize the chuck signal input (I3.0 – A1)
within 1 minute after reaching top-cut position.

Solution:
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Restart the
bar feeder and the lathe automatic cycle.

QUICK LOAD SERVO S3

Chapter 1: Alarms 1-23

A083 – Upper Position Fault

UPPER POSITION
FAULT!

POSSIBLE CAUSES:
UPPER POSITION
SWITCH SQ2 DEFECTIVE
OR MIS-ADJUSTED
(SIGANL ALWAYS ON)

A083

Description:
The Upper Position Fault alarm occurs if the v-channel moves to the lower position and input (I1.1 – SQ2) is still active when input
(I1.0 – SQ1) is turned on.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 1 • Check the adjustment of upper position switch
Bit 0 = 1 SQ2.
1 76543210
Bit 1 = 1 • Check the functionality of upper position switch
11 SQ2.
MODULE 1 Alarm needs to be cleared. Press the STOP key on the
Bit 0 = 1
2 76543210 remote control station to clear the message and reset
Bit 1 = 0
1 the alarm.

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1-24 Chapter 1: Alarms

A088 – Loading Channel Will Not Move to Lower Position

LOADING CHANNEL WILL

NOT MOVE TO ITS
LOWER POSITION!

POSSIBLE CAUSES:
LOWER POSITION
SWITCH SQ1
DEFECTIVE OR
MIS-ADJUSTED
(SIGNAL ALWAYS ON)
A088

Description:
The Loading Channel Will Not Move To Its Lower Position alarm occurs if input (I1.0 – SQ1) becomes active while in the upper
position, after the loading flag has positioned the new bar into the spindle for top-cut, the carrier flag has retracted to the home
position and the v-channel is ready to drop to the lower position.

Solution:

Case Input Remote Pendant Solution

MODULE 1 • Check the functionality of lower position switch
Bit 0 = 1
1 76543210 SQ1.
Bit 1 = 1
11 • Check the wiring of lower position switch SQ1.
MODULE 1 Alarm needs to be cleared. Press the STOP key on the
Bit 0 = 0
2 76543210 remote control station to clear the message and reset
Bit 1 = 1
10 the alarm.

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Chapter 1: Alarms 1-25

A091 – Measuring Cell SQ3 Signal Defective

MEASURING CELL SQ3

SIGNAL DEFECTIVE!

POSSIBLE CAUSES:
-CELL OBSTRUCTED
-CELL DEFECTIVE
-OBSTACLE DETECTED

A091

Description:
The Measuring Cell SQ3 Signal Defective alarm occurs if input (I1.2 – SQ3) is active for longer than 1 second before the v-channel
moves to the upper or lower position.

Solution:

Case Input Remote Pendant Solution

MODULE 1 • Remove any obstacle that measuring cell might be
picking up.
1 Bit 2 = 1 76543210
• Check the measuring cell adjustment (refer to
100 Measuring Cell Adjustment – SQ3, pg. 3-21)
MODULE 1 Alarm needs to be cleared. Press the STOP key on the
2 Bit 2 = 0 76543210 remote control station to clear the message and reset
0 the alarm.

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1-26 Chapter 1: Alarms

Lower Position Fault

LOWER POSITION
FAULT!

POSSIBLE CAUSES:
LOWER POSITION
SWITCH SQ1 DEFECTIVE
OR MIS-ADJUSTED
(SIGNAL ALWAYS ON)

Description:
The Lower Position Fault alarm occurs if the v-channel moves to the upper position and input (I1.0 – SQ1) is still active when input
(I1.1 – SQ2) is turned on.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 1 • Check the adjustment of lower position switch SQ1.
Bit 0 = 1
1 76543210 • Check the functionality of lower position switch
Bit 1 = 1
11 SQ1.

MODULE 1 Alarm needs to be cleared. Press the STOP key on the

Bit 0 = 0
2 76543210 remote control station to clear the message and reset
Bit 1 = 1
10 the alarm.

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Chapter 1: Alarms 1-27

Loading Channel Upper Position Default

LOADING CHANNEL
UPPER POSITION
DEFAULT!

POSSIBLE CAUSES:
-LOWER POSITION
SWITCH SQ1 SIGNAL
REMAINS ON
-DEFECTIVE SWITCH
-ELECTRICAL OR
MECHANICAL PROBLEM

Description:
The Loading Channel Upper Position Default alarm occurs if the loading channel moves to the upper position and input (I1.1 – SQ2)
does not turn on within 10 seconds and input (I1.0 – SQ1) and output (Q4.1 – YV1B) are still active.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 1 • Check the functionality of the lifting cylinders.
Bit 0 = 1
76543210 • Check the functionality of lower position switch
1
Bit 1 = 0 SQ1.
1 • Check the wiring of lower position switch SQ1.
MODULE 1 Alarm needs to be cleared. Press the STOP key on the
Bit 0 = 0
2 76543210 remote control station to clear the message and reset
Bit 1 = 1
10 the alarm.

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1-28 Chapter 1: Alarms

Loading Channel Upper Motion Default

LOADING CHANNEL
UPPER MOTION
DEFAULT!

POSSIBLE CAUSES:
-UPPER POSITION
SWITCH SQ2 DEFECTIVE
OR MIS-ADJUSTED
-MECHANICAL OBSTACLE
-PNEUMATIC PROBLEM
-MOTION INTERRUPT

Description:
The Loading Channel Upper Motion Default alarm occurs if the loading channel moves to the upper position and input (I1.1 – SQ2)
does not turn on within 10 seconds, output (Q4.1 – YV1B) is still active and input (I1.0 – SQ1) is inactive.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

• Check the functionality of the lifting cylinders.
MODULE 1 • Check for air leaks on the air valve assembly.
76543210 • Check the adjustment of upper position switch
1 Bit 1 = 0
SQ2.
10 • Check the functionality of upper position switch
SQ2.
MODULE 1 Alarm needs to be cleared. Press the STOP key on the
2 Bit 1 = 1 76543210 remote control station to clear the message and reset
10 the alarm.

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Chapter 1: Alarms 1-29

Loading Channel Lower Motion Default

LOADING CHANNEL
LOWER MOTION
DEFAULT!

POSSIBLE CAUSES:
-LOWER POSITION
SWITCH SQ1 DEFECTIVE
OR MIS-ADJUSTED
-MECHANICAL OBSTACLE
-PNEUMATIC PROBLEM
-MOTION INTERRUPT

Description:
The Loading Channel Lower Motion Default alarm occurs if the loading channel moves to the lower position and input (I1.0 – SQ1)
does not turn on within 10 seconds, output (Q4.0 – YV1A) is still active and input (I1.1 – SQ2) is inactive.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

• Check the functionality of the lifting cylinders.
MODULE 1 • Check for air leaks on the air valve assembly.
1 Bit 0 = 0 76543210 • Check the adjustment of lower position switch SQ1.
0 • Check the functionality of lower position switch
SQ1.
MODULE 1 Alarm needs to be cleared. Press the STOP key on the
2 Bit 0 = 1 76543210 remote control station to clear the message and reset
1 the alarm.

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1-30 Chapter 1: Alarms

Loading Channel Did Not Reach Its Lower Position

LOADING CHANNEL DID

NOT REACH ITS LOWER
POSITION!

POSSIBLE CAUSES:
-UPPER POSITION
SWITCH SQ2 SIGNAL
REMAINS ON
-DEFECTIVE SWITCH
-PNEUMATIC PROBLEM
-ELECTRICAL PROBLEM

Description:
The Loading Channel Did Not Reach Lower Position alarm occurs if the v-channel is moving to the lower position and input (I1.0 –
SQ1) is not detected after 10 seconds and input (I1.1 – SQ2) is still active.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

MODULE 1 Alarm needs to be cleared. Press the STOP key on the
Bit 0 = 1
1 76543210 remote control station to clear the message and reset
Bit 1 = 0
1 the alarm.
• Check the functionality of the lifting cylinders.
MODULE 1 • Check for air leaks on the air valve assembly.
Bit 0 = 0
2 76543210 • Check the functionality of upper position switch
Bit 1 = 1
10 SQ2.
• Check the wiring of upper position switch SQ2.

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Chapter 1: Alarms 1-31

Drive For Diameter Adjustment Error

DRIVE FOR DIAMETER

ADJUSTMENT ERROR!

POSSIBLE CAUSES:
-MOTION DETECTION
SWTICH SQ4 DEFECTIVE
OR MIS-ADJUSTED
-DEFECTIVE MOTOR M2
-OUT OF SYNC
-MECHANICAL PROBLEM

Description:
The Drive For Diameter Adjustment Error alarm occurs when the diameter adjustment motor is activated and one of the following
conditions occurs:
1. Input (I1.3 – SQ4) is on for longer than 1 second.
2. Input (I1.3 – SQ4) is off for longer than 1 second.
3. Relays KA1 or KA2 are on for longer than 1 minute.

Solution:

Condition Solution

• Check the adjustment of the proximity switch

1
• Recalibrate the loading table (refer to Calibration of the Loading Table, pg. 3-31)

• Check the adjustment of the proximity switch

2
• Recalibrate the loading table (refer to Calibration of the Loading Table, pg. 3-31)

• Replace the diameter adjustment motor - M2 (refer to Diameter Adjustment Motor

3 Replacement, pg. 3-14)
• Recalibrate the loading table (refer to Calibration of the Loading Table, pg. 3-31)

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1-32 Chapter 1: Alarms

Door Lathe Open

DOOR LATHE OPEN!

CLOSE DOOR LATHE

TO RESUME OPERATIONS

Description:
The Door Lathe Open message occurs only on Guildemeister machines when the door of the lathe is opened. A separate input signal
(I0.5) is added as a safety precaution for the operator. When the lathe door is open the bar feed generates this message preventing
the bar feeder from pushing.

Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution

• Close the lathe door.
MODULE 0 • If the door was opened during a part feed out, the
76543210 alarm needs to be cleared. Press the STOP key on
1 Bit 5 = 1
the remote control station to clear the message and
100000 reset the alarm. Restart the bar feed and lathe in
automatic production.
MODULE 0 Alarm needs to be cleared. Press the STOP key on the
2 Bit 5 = 0 76543210 remote control station to clear the message and reset
0 the alarm.

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Chapter 1: Alarms 1-33

Servo Amplifier/PLC Communication Fault

SERVO AMPLIFIER/PLC
COMMUNICATION FAULT

-TURN OFF MAIN POWER

-WAIT FOR 2 SECONDS
-RESTORE MAIN POWER

IF PROBLEM PERSISTS
VERIFY CONNECTIONS
PLC TO AMPLIFIER

Description:
The Servo Amplifier/PLC Communication Fault alarm occurs when the PLC sends a message to the servo amplifier and the message
is not confirmed by the servo amplifier via a checksum or vice versa. This is generated if one of three conditions is not met:
1. The data sent did not match the data received.
2. After 10 seconds, no response from the Servo Amplifier.
3. On power up, the amplifier and PLC parameters do not match.

Solution:
• Verify that the CN3 connector is connected properly on the servo amplifier as well as on the PLC.
• Verify the 24VDC supply for the PLC. Any voltage fluctuation can result in poor performance of the PLC.
If the problem persists please contact LNS America, Inc. for further information.

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1-34 Chapter 1: Alarms

Diameter Change Control Device Is Out of Sync

ATTENTION!
THE DIAMETER CHANGE
CONTROL DEVICE IS
OUT OF SYNC!

MOVE LOADING CHANNEL

TO ITS UPPER
POSITION AND PROCEED
TO ITS RECALIBRATION

**REFER TO MANUAL**

Description:
The Diameter Change Control Device Is Out Of Sync alarm occurs if there is a mechanical problem after entering a new diameter in
the Part Setup menu.

Solution:
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Press the
function key on the remote control station corresponding to the Manual Mode icon. Press the function key on the remote control
station corresponding to the V-channel Upper Position icon. Follow the Calibration of the Loading Table pg. 3-31 procedure in
Chapter 2: Common Issues.

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Chapter 1: Alarms 1-35

SPS No Response

S P S

N O

R e s p o n s e

X A t t a c h e d

Description:
The SPS No Response alarm occurs when there is a communication problem between the remote control station and the LNS PLC.

Solution:

Cause Solution
• Check the connectors between the PLC and the remote control station,
located inside the cross piece to make sure they are attached correctly.
Bad connection
• Check for continuity between the PLC and the remote control station and
also at the connectors.
• If the battery voltage in the PLC is low the Battery LED (red) will illuminate.
If the bar feed is powered off during this time the PLC will lose its memory.
PLC program loss
Replace the PLC battery (3VDC Lithium/CD2032). Download the PLC
program from the Smart Media Card; refer to PLC fault.

• Check the incoming voltage to the PLC. Fluctuation in the DC voltage can
Low voltage
cause the PLC as well as the remote control station to function improperly.

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1-36 Chapter 1: Alarms

Mitsubishi Servo Amplifier Alarm List

CAUTION • Excessive adjustment or change of parameter setting must not be made as it will make operation
instable.

POINT
Using the optional servo configuration software, you can refer to unrotated servo motor reasons, etc.

The following faults may occur at start-up. If any of such faults occurs, take the corresponding action.

Position control mode

(1) Troubleshooting
No. Start-up sequence Fault Investigation Possible cause Reference
1 Power on • LED is not lit. Not improved if connectors 1. Power supply voltage fault
• LED flickers. CN1A, CN1B, CN2 and CN3 2. Servo amplifier is faulty.
are disconnected.
Improved when connectors Power supply of CNP1
CN1A and CN1B are cabling is shorted.
disconnected.

Improved when connector 1. Power supply of encoder

CN2 is disconnected. cabling is shorted.
2. Encoder is faulty.

Improved when connector Power supply of CN3 cabling

CN3 is disconnected. is shorted.

Alarm occurs. Refer to Section Alarm and warning list and remove cause. Section 11.2
2 Switch on servo- Alarm occurs. Refer to Section Alarm and warning list and remove cause. Section 11.2
on signal. Servo motor shaft is 1. Check the display to see if 1. Servo-on signal is not Section 6.6
not servo-locked the servo amplifier is ready input. of the
(is free). to operate. (Wiring mistake) Mitsubishi
2. Check the external I/O 2. 24VDC power is not Servo
signal indication to see if the supplied to COM. Amplifier
servo-on (SON) signal is manual
ON.

3 Gain adjustment Rotation ripples Make gain adjustment in the Gain adjustment fault Chapter 7 of
(speed fluctuations) following procedure: the
are large at low 1. Increase the auto tuning Mitsubishi
speed. response level. Servo
2. Repeat acceleration and Amplifier
deceleration several times to manual
complete auto tuning.
Large load inertia If the servo motor may be Gain adjustment fault Chapter 7 of
moment causes the run with safety, repeat the
servo motor shaft to acceleration and Mitsubishi
oscillate side to side. deceleration several times to Servo
complete auto tuning. Amplifier
manual
4 Cyclic operation Position shift occurs Confirm the cumulative Pulse counting error, etc.
command pulses, due to noise.
cumulative
feedback pulses and actual
servo motor position.

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Chapter 1: Alarms 1-37
When alarm or warning has occurred

POINT
• Configure up a circuit that will detect the trouble (ALM) signal and turn off the servo-on (SON)
signal at occurrence of an alarm.

Alarms and warning list

When a fault occurs during operation, the corresponding alarm or warning is displayed. If any alarm or warning has occurred, refer to
Section Alarm definitions and causes and take the appropriate action. Set "1 " in parameter No. 59 to output the alarm code in
ON/OFF status across the corresponding pin and SG. Warnings (AL.90 to AL.E9) have no alarm codes. Any alarm code is output at
occurrence of the corresponding alarm. In the normal status, the signals available before alarm code setting (CN1B-19, CN1A-18, and
CN1A-19) are output.
The alarms marked  in the alarm deactivation column can be deactivated by the corresponding operations.
(Note 2) Alarm code Alarm deactivation
Press
Alarm
"SET" on
Display CN1B- CN1A-18 CN1A-19 Name Power reset
current
19 pin pin pin OFF→ ON (RES)
alarm
signal
screen.
AL.10 0 1 0 Undervoltage   
AL.12 0 0 0 Memory error 1 
AL.13 0 0 0 Clock error 
AL.15 0 0 0 Memory error 2 
AL.16 1 1 0 Encoder error 1 
AL.17 0 0 0 Board error 
AL.19 0 0 0 Memory error 3 
AL.1A 1 1 0 Motor combination error 
AL.20 1 1 0 Encoder error 2 
AL.24 1 0 0 Main circuit error 
AL.25 1 1 0 Absolute position erase 
AL.30 0 0 1 Regenerative error   
Alarms

AL.31 1 0 1 Overspeed   
AL.32 1 0 0 Overcurrent   
AL.33 0 0 1 Overvoltage 
AL.35 1 0 1 Command pulse frequency error   
AL.37 0 0 0 Parameter error 
AL.45 0 1 1 Main circuit device overheat   
AL.46 0 1 1 Servo motor overheat   
AL.50 0 1 1 Overload 1 (Note 1) (Note 1) (Note 1)
AL.51 0 1 1 Overload 2 (Note 1) (Note 1) (Note 1)
AL.52 1 0 1 Error excessive   
AL.8A 0 0 0 Serial communication time-out   
error
AL.8E 0 0 0 Serial communication error   
88888 0 0 0 Watchdog 
AL.90 Home position return incomplete
AL.92 Open battery cable warning
AL.96 Home position setting warning
AL.98 Software limit warning
Warnings

AL.9F Battery warning Removing the cause of occurrence

AL.E0 Excessive regenerative warning deactivates the alarm automatically.
AL.E1 Overload warning
AL.E3 Absolute position counter warning
AL.E6 Servo emergency stop warning
AL.E9 Main circuit off warning

Note: 1. Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence.
2. 0: Pin-SG off (open)
1: Pin-SG on (short)

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1-38 Chapter 1: Alarms

• When any alarm has occurred, eliminate its cause, ensure safety, then reset the alarm, and
restart operation. Otherwise, injury may occur.

CAUTION • If an absolute position erase alarm (AL.25) occurred, always make home position setting again.
Otherwise, misoperation may occur.

POINT
• When any of the following alarms has occurred, always remove its cause and allow about 30
minutes for cooling before resuming operation. If operation is resumed by switching control circuit
power off, then on to reset the alarm, the servo amplifier and servo motor may become faulty.
• Regenerative error (AL.30)
• Overload 1 (AL.50)
• Overload 2 (AL.51)
• The alarm can be deactivated by switching power off, then on press the "SET" button on the
current alarm screen or by turning on the reset (RES).
For details, refer to Alarms and warning list.

Alarm definitions and causes

When an alarm occurs, the trouble (ALM) switches off and the dynamic brake is operated to stop the servo motor. At this time, the
display indicates the alarm No.
The servo motor comes to a stop. Remove the cause of the alarm in accordance with this section. The optional servo configuration
software may be used to refer to the cause.
Display Name Definition Cause Action
AL.10 Undervoltage Power supply voltage 1. Power supply voltage is low. Review the power supply.
dropped. 2. There was an instantaneous
MR-J2S- CP: control power failure of 60ms or
160V or less longer.
MR-J2S- CP1: 3. Shortage of power supply
83V or less capacity caused the power supply
voltage to drop at start, etc.
4. Power was restored after the bus
voltage had dropped to 200VDC.
(Main circuit power switched on
within 5s after it had switched off.)
5. Faulty parts in the servo amplifier Change the servo amplifier.

Checking method
Alarm (AL.10) occurs if power is
switched on after disconnection of
all cables but the control circuit
power supply cables.

AL.12 Memory error 1 RAM, memory fault Faulty parts in the servo amplifier Change the servo amplifier.
AL.13 Clock error Printed board fault
AL.15 Memory error 2 EEP-ROM fault Checking method
Alarm (any of AL.11 to 13 and 15)
occurs if power is switched on after
disconnection of all cables but the
control circuit power supply cables.

AL.16 Encoder error 1 Communication error 1. Encode connector (CN2) Connect correctly.
occurred between disconnected.
encoder and servo 2. Encoder fault Change the servo motor.
amplifier. 3. Encoder cable faulty Repair or change the cable.
(wire breakage or short)
4. Wrong combination of servo Use correct combination.
amplifier and servo motor

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Chapter 1: Alarms 1-39
Display Name Definition Cause Action
AL.17 Board error CPU/parts fault Faulty parts in the servo amplifier Change the servo amplifier.
AL.19 Memory error 3 ROM memory fault
Checking method
Alarm (A.17 or A.18) occurs if
power is switched on after
disconnection of all cables but the
control circuit power supply
cables.
AL.1A Motor Wrong combination Wrong combination of servo Use correct combination.
combination of servo amplifier amplifier and servo motor
error and servo motor. connected.
AL.20 Encoder error 2 Communication 1. Encoder connector (CN2) Connect correctly.
error occurred disconnected.
between encoder 2. Encoder fault Change the servo motor.
and servo amplifier. 3. Encoder cable faulty(wire Repair or change the cable.
breakage or shorted)
AL.24 Main circuit Ground fault 1. Power input wires and servo Connect correctly.
error occurred at the motor output wires are in contact
servomotor outputs at main circuit terminal block
(U, V and W (TE1).
phases) of the 2. Sheathes of servo motor power Change the cable.
servo amplifier. cables deteriorated, resulting in
ground fault.
3. Main circuit of servo amplifier Change the servo amplifier.
failed.

Checking method
AL.24 occurs if the servo is
switched on after disconnecting
the U, V, and W power cables
from the servo amplifier.
AL.25 Absolute Absolute position 1. Reduced voltage of super After leaving the alarm occurring for a
position erase data in error capacitor in encoder few minutes, switch power off, then on
again. Always make home position
setting again.
2. Battery voltage low Change battery.
3. Battery cable or battery is Always make home position setting
faulty. again.
Power was 4. Super capacitor of the absolute After leaving the alarm occurring for a
switched on for the position encoder is not charged few minutes, switch power off, then on
first time in the again. Always make home position
absolute position setting again.
detection system.
AL.30 Regenerative Permissible 1. Wrong setting of parameter No. Set correctly.
alarm regenerative power 0
of the built-in 2. Built-in regenerative brake Connect correctly
regenerative brake resistor or regenerative brake
resistor or option is not connected.
regenerative brake 3. High-duty operation or 1. Reduce the frequency of positioning.
option is exceeded. continuous regenerative operation 2. Use the regenerative brake option of
caused the permissible larger capacity.
regenerative power of the 3. Reduce the load.
regenerative brake option to be
exceeded.

Checking method
Call the status display and check
the regenerative load ratio.
4. Power supply voltage is Review power supply
abnormal. MR-J2S- CP:260V or
more Change servo amplifier or regenerative
MR-J2S- CP1:135V or more brake option.
5. Built-in regenerative brake Change the servo amplifier.
resistor or regenerative brake
option faulty.
Regenerative 6. Regenerative transistor faulty.
transistor fault
Checking method
1) The regenerative brake option
has overheated abnormally.
2) The alarm occurs even after
removal of the built-in
regenerative brake resistor or
regenerative brake option.

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1-40 Chapter 1: Alarms
AL.31 Overspeed Speed has 1. Input command pulse Set command pulses correctly.
exceeded the frequency exceeded the
instantaneous permissible instantaneous speed
permissible speed. frequency.
2. Small acceleration/deceleration Increase acceleration/deceleration time
time constant caused overshoot to constant.
be large.
3. Servo system is instable to 1. Re-set servo gain to proper value.
cause overshoot. 2. If servo gain cannot be set to proper
value:
1) Reduce load inertia moment ratio; or
2) Reexamine
acceleration/deceleration time
constant.
4. Electronic gear ratio is large Set correctly.
(parameters No. 4, 5)
5. Encoder faulty. Change the servo motor.
AL.32 Overcurrent Current that flew is 1. Short occurred in servo Correct the wiring.
higher than the amplifier output phases U, V and
permissible current W.
of the servo 2. Transistor (IPM) of the servo Change the servo amplifier.
amplifier. amplifier faulty.

Checking method
Alarm (AL.32) occurs if power is
switched on after U, V and W are
disconnected.
3. Ground fault occurred in servo Correct the wiring.
amplifier output phases U, V and
W.
4. External noise caused the Take noise suppression measures.
overcurrent detection circuit to
misoperate.
AL.33 Overvoltage Converter bus 1. Lead of built-in regenerative 1. Change lead.
voltage exceeded brake resistor or regenerative 2. Connect correctly.
400V. brake option is open or
disconnected.
2. Regenerative transistor faulty. Change servo amplifier
3. Wire breakage of built-in 1. For wire breakage of built-in
regenerative brake resistor or regenerative brake resistor, change
regenerative brake option servo amplifier.
2. For wire breakage of regenerative
brake option, change regenerative
brake option.
4. Capacity of built-in regenerative Add regenerative brake option or
brake resistor or regenerative increase capacity.
brake option is insufficient.
5. Power supply voltage high. Review the power supply.
AL.35 Command pulse Input pulse 1. Pulse frequency of the manual Change the pulse frequency to a
frequency error frequency of the pulse generator is too high. proper value.
command pulse is 2. Noise entered the pulses of the Take action against noise.
too high. manual pulse generator.
3. Manual pulse generator failure Change the manual pulse generator.
AL.37 Parameter error Parameter setting 1. Servo amplifier fault caused the Change the servo amplifier.
is wrong. parameter setting to be rewritten.
2. Regenerative brake option not Set parameter No.0 correctly.
used with servo amplifier was
selected in parameter No.0.

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Chapter 1: Alarms 1-41

Display Name Definition Cause Action

AL.45 Main circuit Main circuit device 1. Servo amplifier faulty. Change the servo amplifier.
device overheat overheat 2. The power supply was turned The drive method is reviewed.
on and off continuously by
overloaded status.
3. Air cooling fan of servo 1. Exchange the cooling fan or the
amplifier stops. servo amplifier.
2. Reduce ambient temperature.
AL.46 Servo motor Servo motor 1. Ambient temperature of servo Review environment so that ambient
overheat temperature rise motor is over 40°C. temperature is 0 to 40°C.
actuated the 2. Servo motor is overloaded. 1. Reduce load.
thermal protector. 2. Review operation pattern.
3. Use servo motor that provides larger
output.
3. Thermal protector in encoder is Change servo motor.
faulty.
AL.50 Overload 1 Load exceeded 1. Servo amplifier is used in 1. Reduce load.
overload protection excess of its continuous output 2. Review operation pattern.
characteristic of current. 3. Use servo motor that provides larger
servo amplifier. output.
2. Servo system is instable and 1. Repeat acceleration/ deceleration to
Load ratio 300%: hunting. execute auto tuning.
2.5s or more 2. Change auto tuning response
Load ratio 200%: setting.
100s or more 3. Set auto tuning to OFF and make
gain adjustment manually.
3. Machine struck something. 1. Review operation pattern.
2. Install limit switches.
4. Wrong connection of servo Connect correctly.
motor. Servo amplifier's output
terminals U, V, W do not match
servo motor's input terminals U, V,
W.
5. Encoder faulty. Change the servo motor.

Checking method
When the servo motor shaft is
rotated with the servo off, the
cumulative feedback pulses do
not vary in proportion to the rotary
angle of the shaft but the
indication skips or returns
midway.
AL.51 Overload 2 Machine collision or 1. Machine struck something. 1. Review operation pattern.
the like caused 2. Install limit switches.
max. output current 2. Wrong connection of servo Connect correctly.
to flow successively motor. Servo amplifier's output
for several terminals U, V, W do not match
seconds. servo motor's input terminals U, V,
W.
Servo motor 3. Servo system is instable and 1. Repeat acceleration/deceleration to
locked: 1s or more hunting. execute auto tuning.
2. Change auto tuning response
setting.
3. Set auto tuning to OFF and make
gain adjustment manually.
4. Encoder faulty. Change the servo motor.

Checking method
When the servo motor shaft is
rotated with the servo off, the
cumulative feedback pulses do
not vary in proportion to the rotary
angle of the shaft but the
indication skips or returns
midway.

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1-42 Chapter 1: Alarms

Display Name Definition Cause Action

AL.52 Error excessive The droop pulse 1. Acceleration/deceleration time Increase the acceleration/deceleration
value of the constant is too small. time constant.
deviation counter 2. Internal torque limit 1 Increase the torque limit value.
exceeded the (parameter No.28) is too small.
encoder resolution 3. Motor cannot be started due to 1. Review the power supply capacity.
#10 [pulse]. torque shortage caused by power 2. Use servo motor that provides larger
supply voltage drop. output.
4. Position control gain 1 Increase set value and adjust to ensure
(parameter No.7) value is small. proper operation.
5. Servo motor shaft was rotated 1. When torque is limited, increase the
by external force. limit value.
2. Reduce load.
3. Use servo motor that provides larger
output.
6. Machine struck something. 1. Review operation pattern.
2. Install limit switches.
7. Encoder faulty Change the servo motor.
8. Wrong connection of servo Connect correctly.
motor. Servo amplifier's output
terminals U, V, W do not match
servo motor's input terminals U, V,
W.
AL.8A Serial RS-232C or RS- 1. Communication cable Repair or change communication cable
communication 422 communication breakage.
time-out error stopped for longer 2. Communication cycle longer Set correct value in parameter.
than the time set in than parameter No. 23 setting.
parameter No.23. 3. Wrong protocol. Correct protocol.
AL.8E Serial Serial 1. Communication cable fault Repair or change the cable.
communication communication (Open cable or short circuit)
error error occurred 2. Communication device (e.g. Change the communication device
between servo personal computer) faulty (e.g. personal computer).
amplifier and
communication
device (e.g.
personal
computer).
88888 Watchdog CPU, parts faulty Fault of parts in servo amplifier Change servo amplifier.

Checking method
Alarm (88888) occurs if power is
switched on after disconnection of
all cables but the control circuit
power supply cables.

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Chapter 1: Alarms 1-43

Remedies for warnings

If AL.E6 occurs, the servo off status is established. If any other warning occurs, operation can be continued but an alarm may take
place or proper operation may not be performed. Use the optional servo configuration software to refer to the cause of warning.
Display Name Definition Cause Action
AL.90 Home position In incremental system: 1. Positioning operation was performed 1. Perform home position
return 1. Positioning operation without home position return. return.
incomplete was performed without 2. Home position return speed could 2. Review home position
home position return. not be decreased to creep speed. return speed/creep
2. Home position return 3. Limit switch was actuated during speed/moving distance after
ended abnormally. home position return starting at other proximity dog.
than position beyond dog.
In absolute position 1. Positioning operation was performed 1. Perform home position
detection system: without home position setting. setting.
1. Positioning operation 2. Home position setting speed could 2. Review home position
was performed without not be decreased to creep speed. setting speed/creep
home position setting. 3. Limit switch was actuated during speed/moving distance after
2. Home position setting home position setting starting at other proximity dog.
ended abnormally. than position beyond dog.
AL.92 Open battery Absolute position 1. Battery cable is open. Repair cable or changed.
cable warning detection system battery 2. Battery voltage dropped to 2.8V or Change battery.
voltage is low. less.
AL.96 Home position Home position setting 1. Droop pulses remaining are greater Remove the cause of droop
setting warning could not be made. than the in-position range setting. pulse occurrence
2. Command pulse entered after Do not enter command
clearing of droop pulses. pulse after clearing of droop
pulses.
3. Creep speed high. Reduce creep speed.
AL.98 Software limit Software limit set in 1. Software limit was set within actual Set parameter No. 48 to 51
warning parameter is reached. operation range. correctly.
2. Point table of position data in excess Set point table correctly.
of software limit was executed.
3. Software limit was reached during Perform operation within
JOG operation or manual pulse software limit range.
generator operation.
AL.9F Battery warning Voltage of battery for Battery voltage fell to 3.2V or less. Change the battery.
absolute position
detection system
reduced.
AL.E0 Excessive There is a possibility Regenerative power increased to 85% 1. Reduce frequency of
regenerative that regenerative power or more of permissible regenerative positioning.
warning may exceed permissible power of built-in regenerative brake 2. Change regenerative
regenerative power of resistor or regenerative brake option. brake option for the one with
built-in regenerative larger capacity.
brake resistor or Checking method 3. Reduce load.
regenerative brake Call the status display and check
option. regenerative load ratio.
AL.E1 Overload There is a possibility Load increased to 85% or more of Refer to AL.50, AL.51.
warning that overload alarm 1 or overload alarm 1 or 2 occurrence level.
2 may occur.
Cause, checking method
Refer to AL.50, 51.
AL.E3 Absolute Absolute position 1. Noise entered the encoder. Take noise suppression
position counter encoder pulses faulty. measures.
warning 2. Encoder faulty. Change servo motor.
AL.E6 Servo EMG-SG is open. External emergency stop was made Ensure safety and
emergency stop valid. (EMG-SG opened.) deactivate emergency stop.
warning
AL.E9 Main circuit off Servo was switched on Switch on main circuit
warning with main circuit power power.
off.

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Chapter 2: Common Issues 2-1

Chapter 2:
Common Issues
T
he Quick Load Servo S3 is designed to be a user-friendly, simple, and reliable bar feeder, covering a range of diameters
¼” to 4 ¾”. Although easy to use, including extremely quick changeovers and the capability for unmanned operation this
unit is not flawless. A list of common issues that have been documented by service technicians and problems relayed back
from customers has been compiled in this manual. This chapter discusses the most common problems that have been
observed. Along with each problem, a brief description is given as well as quick reference charts of symptoms/solutions,
sequences, and procedures for adjustments, changeovers and alignment.

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2-2 Chapter 2: Common Issues

Low Voltage / PLC Shutdown

Description:
The Quick Load Servo S3 uses a LNS PCD2 controller (PLC) to send/receive inputs/outputs. The PLC is powered by a +24VDC input
supplied by a transformer. The input supply voltage must be regulated to ensure proper functioning. The remote control station,
which is used to send/receive data back and forth with the PLC, is powered by the +24VDC on the PLC.

Through the remote control station, the user can command the bar feeder to perform different functions by sending data to the PLC.
The PLC will then transfer data back to the remote control station to either inform the user the status of what the bar feeder is doing or
is waiting for the user to command the next task.

The following chart discusses possible problems, which may be occurring between the PLC and the remote control station:

Problem Possible Cause/s Solution/s

• The PLC toggle switch is not • Flip the toggle switch on the
in the RUN position PLC to the RUN position
• A sudden drop in the supply • Check the supply voltage on
voltage has caused a the PLC, can be low due to a
communication problem low incoming 3 phase
between the PLC and the voltage from the lathe
SPS No response remote control station • Check the battery voltage, if
• The battery was either it is low it will need to be
removed or battery voltage replaced with a 3VDC
was low while the bar feed Lithium/CD2032 battery and
was powered down which the program will need to be
caused the PLC to lose its restored (refer to)
program
• The PLC toggle switch is not • Flip the toggle switch on the
in the RUN position PLC to the RUN position
No operator action possible on • Low supply voltage on the • Check the supply voltage on
the remote control station PLC the PLC, can be low due to a
low incoming 3 phase
voltage from the lathe

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Chapter 2: Common Issues 2-3

Vibration Issues
The term “vibration” is being used regarding the Quick Load Servo S3, to indicate that the RPM performance of the lathe is physically
deteriorated, to the point of creating an unbalanced rotational oscillation of the bar stock, within the confines of the spindle of the lathe
that is detrimental to the machining process.
Various items can cause or enhance a lathe spindle vibration issue, requiring the reduction of the spindle rpm to bring the anomaly
back to a normal controlled rotation. These items can be related to the material, the lathe, or the bar feed.

Material
The material must be reasonably straight. LNS has a specification of 0.5mm / meter (non-accumulative). Remember when running a
spindle liner for a Quick Load, the ID of the liner may be only 0.040” over the stock size (which is 0.5m per side). This means you may
not only have a vibration issue, but the material may also be caught in a bind as it is loaded through the liner, if it doesn’t meet our
straightness specification.
If the material has been saw cut, the sharp edges and burrs must be removed
If the material is a hot roll type it may not meet our specifications.
If the material has been “cropped” to length the last 6”-12” of the end of the bar may be unusable due to being bent severely in the
process.

Note: Also, there is a possibility to have a severe angle on the end of the bar,
which has been cropped. This can lead to mis-positioning during part feed out,
depending on the surface area that the Quick Load’s pusher is pushing against, as
the bar has rotated in it’s orientation inside the spindle.

Lathe
The lathe should be level and on a solid foundation. LNS recommend that the lathe be bolted to the floor.
The headstock / actuator assembly should have minimal run out. *
Proper chucking device should be selected to match the machining application. *
The chucking device should have proper clamping pressure. *
The surface of the jaws or pads must make proper contact with the material. *
*Please reference OEM specifications.

Bar feed
The bar feed should be within proper alignment to the spindle of the lathe.
Since the pusher of the Quick Load is a fixed component and does not rotate, it cannot come in contact with the ID of the spindle or
with the rear of the bar stock unless the spindle is stopped.
Remember the pusher must also back off of the bar stock after the lathe’s collet closes prior to the spindle rotating (refer to Pusher
Reversing Distance, pg. 3-24).

Spindle Liner
Ensure that the properly sized spindle liner has been installed (0.040” ideal gap).
Ensure the liner is straight (check total run out), and has all o-rings intact.

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2-4 Chapter 2: Common Issues

Servo Motor Following Error During Sequence 12

SERVO MOTOR
POSITIONING
FOLLOWING ERROR!
DURNG SEQUENCE
NUMBER [12]

POSSIBLE CAUSE:
MECHANICAL OBSTACLE
PREVENTS BAR STOCK
TO FEED OUT

Description:
The Servo Motor Following Error! During Sequence Number [12] alarm occurs after the new bar has been measured and is being
advanced to top-cut position. The torque on the servo motor will build up when an obstacle prohibits the stock from moving, once the
torque reaches a certain limit the PLC instructs the servo amplifier to quit pushing and this alarm message appears on the remote
control station.

Solution:

Cause Solution
• Check that the correct bar stock diameter is entered for the parameter.
• Check that the correct spindle reduction tube is installed.
Hitting back of spindle • Verify the alignment of the bar feeder. If the alignment is off; realign and
then recalibrate the loading table, refer to Alignment Procedure pg. 3-3 and
Calibration of the Loading Table pg. 3-31.

Hitting back of
• Verify the correct collet/chuck is installed for the material being run.
clamping system

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Chapter 2: Common Issues 2-5

Part Feed Out Accuracy

Description:
The accuracy of the part positioning can be affected by many factors. Choosing the correct bar feed application and setting
the barfeed parameters correctly are crucial to ensuring the proper accuracy.

Part Setup Parameter:

1. Input overall part length (Located in: 1. Part setup menu)
The parameter determines how far the push rod will advance the barstock during a part feed out. This value should include
the finished part length, cut-off and facing. Otherwise, how much material must be fed out to make a complete part.

Application Selection: (Located in: 2. Application Setup)

1. Feed without help of the turret

This application requires that the lathe be equipped with a pull-to-close type clamping system. If a push-to-close type
clamping system is used then the “Feed with help of the turret” application must be selected. It is recommended by LNS that
when feeding without the help of the turret that a dead-length, parallel gripping type clamping device be used. This type of
clamping system will prevent the barstock from moving forward when the clamping device is closed, thus losing the
positioning accuracy.
2. Feed with help of the turret
This application can be selected when either a pull-to close or push-to-close type clamping system is installed but must
always be selected when a push-to-close type clamping system is installed. This is due to the barstock moving forward as
the draw tube pushes forward to close the clamping device.

For more information on setting up different applications see Chapter 5 - Bar feed Applications.

Parameters related to clamping device: (located in: 4. Miscellaneous Functions menu)

1. Time for clamping device to close (Parameter 74)
Once the clamping device close signal is output from the lathe the barfeed will wait for the time entered in this parameter to
expire then the push rod will reverse off the back of the part.
If this time is set to low then the push rod may reverse before the clamping device is physically closed. When this occurs
with a pull-to-close clamping system then the push rod will not be in place to support the barstock as the clamping device
closes. The push rod can overcome the weight of the barstock moving in the draw tube but can not overcome the force of
the clamping device this is why a dead-length, parallel gripping type clamping device is recommended.
Setting this time to high will not effect the part positioning. However, if this time is set to high the push rod may not reverse
off the barstock before the spindle begins to rotate. This can create excessive noise and possibly damage the push rod.
2. Time for clamping device to open (Parameter 75)
Once the clamping device open signal is output from the lathe the barfeed will wait for the time entered in this parameter to
expire then the push rod will advance the part the distance programmed.
If this time is set to low then the push rod may hit the back of the clamping device before it is physically open. This can
cause a variation of unexpected results.

For further information on part feed out accuracy with special applications (i.e. Shaft Loading) please contact your local LNS
representative.

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2-6 Chapter 2: Common Issues

Solution:

Cause Solution

• Verify that the top-cut position is programmed correctly

1st Part feed out after
• If performing a cut-off or facing operation on the barstock during top-cut,
top-cut positioning too
verify that the end of the barstock is in the same location as if a part was
short/long
cut-off after the cut-off or facing operation is complete.

• Verify that the correct value is entered into the “Input overall part length”
parameter
• If using a pull-to close type clamping system ensure that the time entered
into the “Time for clamping device to close” parameter is correct.
Part feed out to short • Make sure that the clamping device is not forcing the barstock back when
closing
• Verify that the lathe program is correct
• Verify that the barstock is concentric and clean of debris

• Verify that the correct value is entered into the “Input overall part length”
parameter
• If using a push-to-close type clamping system ensure the turret is being
Part feeds out too long
used to locate the part and that the turret is in the correct location
• Verify that the barstock is concentric and clean of debris

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Chapter 3: Procedures 3-1

Chapter 3:
Procedures
T
he following chapter includes simple step-by-step procedures for mechanical adjustments, replacing damaged or faulty
components and to resolve other issues related to the bar feeder. Along with some of these procedures are video clips
which show the actual procedure being performed in case the written procedure is too difficult to follow. The video clips
can be viewed on a PC with a compatible video card from the CD-ROM version of this manual.

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3-2 Chapter 3: Procedures

End of Bar Adjustment

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ Air pressure set at 5 bar (75psi.).
ƒ No bar stock in spindle.
ƒ V-channel in the lower position.
ƒ Bar feed in STOP mode.

Step 1: Press the MENU key on the remote control station.

Step 2: Press the #3 (Position/Torque) key on the remote control station.
Step 3: Press the F3 (SET) key on the remote control station.
Step 4: Press the F2 (TEACH IN) key on the remote control station.
Step 5: Press and hold the F-key corresponding to the pusher forward icon, until the pusher is ¼” behind the clamping system.
Step 6: Press and hold the F3 (ENTER) key on the remote control station. The End Of Bar is now set.
Step 7: Press the F2 (ESC) key on the remote control station.

Procedure complete.

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Chapter 3: Procedures 3-3

Alignment Procedure
This procedure is used to align the barfeed.

Procedure:

Conditions:
ƒ Bar feed power off.
ƒ No air pressure.

Step 1: Position the bar feed as close as possible to the rear of the lathe. The distance between the front of the bar feed and the
back of the spindle should be as small as possible. Note: If obstacles prevent the bar feed from being positioned within 8
inches of the back of the spindle an extension will be required.

Step 2: Level the bar feed in the x and y axis using a torpedo level. The level can be placed on the linear belt rail to verify the y-axis
and on the retract rails to verify the x-axis. Use the leveling screws on the retract to adjust unit to level.

Leveling screws

Leveling screws

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3-4 Chapter 3: Procedures

Step 3: Carefully loosen the 16 screws located in the slots on the base of the unit. This will allow the unit to be adjusted up and
down.

Step 4: Using the central jackscrew and the hexagonal tube supplied with the bar feed; adjust the unit so that the pusher is centered
up and down at the back of the spindle. Make sure that the unit raises or lowers uniformly.

Central jackscrew

Hexagonal tube

Pusher should be centered

vertically with the spindle.

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Chapter 3: Procedures 3-5
Step 5: Once the pusher is centered up and down, tighten the 16 screws to secure unit and recheck the level of the unit.

Step 6: Align the unit side to side by centering the pusher in the back of the spindle and then extending the pusher to the back of
the collet and centering it there. Adjust the rear of the bar feed when centering to the rear of the spindle and the front of the
bar feed when centering to the rear of the collet. Once the pusher is centered at the back of the collet recheck the
alignment at the back of the spindle by pulling the pusher back. Continue until the pusher is centered at the rear of the
spindle and the rear of the collet.

Pusher should be aligned

horizontal to the spindle and
the back of the collet

Step 7: Once the bar feed has been aligned, anchor it using the ½ inch anchor bolts supplied with the unit.

Anchor here

Anchor here

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3-6 Chapter 3: Procedures
Step 8: After anchoring the unit, recheck the level and the alignment of the unit.

Step 9: After the alignment has been rechecked, power and air will need to be hooked up to the bar feeder.

Step 10: Once the power and air have been hooked up, the bar feed must be calibrated. Refer to Calibration of the Loading Table,
pg. 3-31. After calibrating the bar feed, return to this procedure and move on to Step 11 for the final alignment.

Step 11: For final alignment, load a bar into the v-channel and verify that it can be loaded into the spindle of the lathe without hitting
the sides of the spindle or spindle liner. If the bar hits side to side the alignment will have to be adjusted.

Bar stock should centered

inside the spindle or spindle
liner.

Procedure complete.

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Chapter 3: Procedures 3-7

Pusher Changeover

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ V-channel in the lower position.
ƒ Pusher at the mechanical home position against the reference plate.
ƒ Bar feed in STOP mode.

Step 1: Open the main access cover.

Step 2: Measure the distance of the End-of-Bar bushing.

Step 3: Pull the carrier away from the home position.

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3-8 Chapter 3: Procedures
Step 4: Loosen up the setscrews to release the pusher.

Step 5: Pull out the guide bushing from the front ring.

Step 6: Remove the pusher from the bar feed.

Step 7: Put the new pusher in the bar feed.
Step 8: Push the guide bushing in the front ring.

Step 9: Place the rear end of the pusher in the carrier and tighten the setscrews.

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Chapter 3: Procedures 3-9
Step 10: Close the main access cover.

Procedure complete.

The following is a video clip of the Pusher Changeover procedure. Must have the electronic file to play. This movie may take several
seconds to begin.

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3-10 Chapter 3: Procedures

Carriage Unit Belt Tension Adjustment

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ Bar feed in STOP mode.

Step 1: Open the main access cover.

Step 2: Pull the carriage unit forward towards the middle of the linear rail.

Step 3: On each end of the carriage unit are black plastic end caps. In the center of the end cap on either side, right above the belt
is an opening with a 3mm allen head tensioning screw inside. Turn the screw CW to add tension to the belt and CCW to
release tension.

3mm allen head screw

inside. Also, one on
other side (not shown).

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Chapter 3: Procedures 3-11

Step 4: Close the main access cover.

Procedure complete.

The following is a video clip of the Carriage Unit Belt Tension Adjustment procedure. Must have the electronic file to play. This movie
may take several seconds to begin.

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3-12 Chapter 3: Procedures

Servo Motor Belt Tension Adjustment

Procedure:

Conditions:
ƒ Bar feed power off.
ƒ Bar feed in STOP mode.

Step 1: Open the main access cover.

Step 2: Loosen the four nuts on the motor mount plate.

Step 3: Using a lever (ex. screwdriver), raise the motor to create tension on the belt.

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Chapter 3: Procedures 3-13
Step 4: Holding the belt taut, tighten the four nuts on the motor mount plate.

Step 5: Remove the lever and close the main access cover.

Procedure complete.

The following is a video clip of the Servo Motor Belt Tension Adjustment procedure. Must have the electronic file to play. This movie
may take several seconds to begin.

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3-14 Chapter 3: Procedures

Diameter Adjustment Motor Replacement

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ Bar feed in STOP mode.

Step 1: Remove the front panel on the sub-base.

Front panel

Step 2: Remove the two rear panels on the sub-base.

Step 3: Remove the four screws holding on the chain guard cover plate.

View from front panel View from rear panel

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Chapter 3: Procedures 3-15
Step 4: Remove the two screws holding on the adjustment motor.

View from front panel

Step 5: Disconnect the SQ4 cable from the mounted proximity switch.

Mounted prox. switch

SQ4 cable

Step 6: Disconnect the M2 cable from the XP1 connector and remove the bad motor.

Cable M2 XP1 connector

Bad motor

Step 7: Insert the new motor and connect the M2 cable to the XP1 connector.

Cable M2 XP1 connector

New motor

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3-16 Chapter 3: Procedures
Step 8: Connect the SQ4 cable to the new mounted proximity switch and reconnect the chain.

Step 9: While pulling the motor toward the front of the bar feed to keep the chain taut, tighten the two screws for the motor
assembly.

View from front panel

Step 10: Reassemble the chain guard.

View from front panel View from rear panel

Step 11: Reassemble the front panel.

Front panel

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Chapter 3: Procedures 3-17
Step 12: Reassemble the two back panels.

Procedure complete.

The following is a video clip of the Diameter Adjustment Motor Replacement procedure. Must have the electronic file to play. This
movie may take several seconds to begin.

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3-18 Chapter 3: Procedures

Home Position Proximity Switch Adjustment – SQ5

Conditions:
ƒ Bar feed power on.
ƒ Pusher at the mechanical home position against the reference plate (Servo amplifier should read “0.0”
ƒ Bar feed in STOP mode.

Tools:
• Home Position Bracket

Procedure:

Step 13: Re-reference the bar feed. (Refer to the Reference Procedure, pg. 3-25).
Step 14: Open the main access cover.

Step 15: Using the servo drive belt, move the carrier away from the home position until the proximity switch is turned off. Slowly
rotate the drive belt until the switch just turns back on. At this point, the servo amplifier should read between 0.4 – 0.7.
Adjust the slotted home position bracket until 0.4 – 0.7 value is achieved.

Servo drive belt

Slotted home
position bracket
Step 16: Close the main access cover.

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Chapter 3: Procedures 3-19

Step 17: Press the STOP key on the remote control station to clear and reset the alarm.

Procedure complete.

The following is a video clip of the Home Position Proximity Switch Adjustment procedure. Must have the electronic file to play. This
movie may take several seconds to begin.

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3-20 Chapter 3: Procedures

Magazine and Loading Finger Adjustment

The slope of the magazine rack needs to be adjusted when the shape of the material being loaded changes from round to profiled or
vise versa.
When loading round stock, if the slope of the magazine is too much it is possible for the material to stack up and cause double loading
if the weight of the material is great enough (especially when loading smaller diameter stock). Therefore, the slope must be reduced.
When loading profiled (ex. square/hex) stock, if the slope of the magazine is not great enough it can prohibit the ability of the material
to slide down the rack. Therefore, the slope must be increased.

Procedure: Round Profiled

Conditions:
ƒ No stock on the magazine.
ƒ Bare feed in STOP mode.

Step 1: Rotate the loader rack adjustment axle CCW to increase the slope of the magazine until the indicator on the side of the
magazine references the profiled material. Note: if there is not enough adjustment on the threaded rod, remove the pin and
lift the magazine up to the next hole and reinsert the pin. Caution when removing the pin, the magazine rack will drop if not
supported properly.

Procedure complete.

The following is a video clip of the Magazine and Loading Finger Adjustment from Round to Profiled procedure. Must have the
electronic file to play. Movie may take several seconds to begin.

Procedure: Profiled Round

Conditions:
ƒ No stock on the magazine.
ƒ Bare feed in STOP mode.

Step 1: Rotate the loader rack adjustment axle CW to decrease the slope of the magazine until the indicator on the side of the
magazine references the round material. Note: if there is not enough adjustment on the threaded rod, remove the pin and
drop the magazine down to the next hole and reinsert the pin. Caution when removing the pin, the magazine rack will drop if
not supported properly.

Procedure complete.

The following is a video clip of the Magazine and Loading Finger Adjustment from Profiled to Round procedure. Must have the
electronic file to play. Movie may take several seconds to begin.

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Chapter 3: Procedures 3-21

Measuring Cell Adjustment – SQ3

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ V-channel in the upper position.
ƒ Bar feed in STOP mode.

Step 1: Retract the bar feed for access to the front of the unit.
Step 2: Open the main access cover.

Step 3: Place a piece of 6mm (or smallest diameter stock available) into the v-channel and set parameter NEW BAR STOCK
DIAMETER for the corresponding diameter. (Note: the stock must be straight to obtain the ideal adjustment).

View from the front of the bar feed.

6mm bar stock

Step 4: Push the stock up so that it is sticking out the front of the bar feeder.
Step 5: Turn the gain adjustment on the measuring cell to the max position.

Gain adjustment

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3-22 Chapter 3: Procedures
Step 6: Loosen screws and adjust the cell so that the “red” sensor is reflecting off the center of the bar and tighten the cell down.

Front of bar feed

Step 7: Turn the gain adjustment CCW to the minimum position.

Turn gain adjustment

off.

Step 8: From the minimum position slowly turn the gain adjustment CW until the sensor detects the bar. Once the sensor detects
the bar continue to turn the gain CW another ½ turn.

Turn gain adjustment

up until sensor is lit.

Step 9: Remove the material from the v-channel and close the main access cover.

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Chapter 3: Procedures 3-23

Step 10: Press the STOP key on the remote control station to clear the Main Access Cover Open alarm.

Procedure complete.

The following is a video clip of the Measuring Cell Adjustment procedure. Must have the electronic file to play. This movie may take
several seconds to begin.

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3-24 Chapter 3: Procedures

Pusher Reversing Distance Adjustment

The pusher reverses a specified distance, after the chuck closes, so that it is not making contact with the rotating bar or the spindle.
Generally, the smaller the diameter of the pusher the greater the reversing distance. This is due to deflection (or sagging) of the
pusher, which is caused when the pusher is far up in the spindle of the lathe and can no longer support its own weight so the tip of the
pusher begins to sag.

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ V-channel in the lower position.
ƒ No bar stock in the spindle.
ƒ End of Bar Position is set.

Step 1: Press the icon for manual mode.

Run the pusher forward until the tip of the pusher sags and is touching the spindle (or spindle liner if one is installed). (Note:
if the pusher does not touch the spindle before the End of Bar position is reached, then the default value will remain as the
value for the Pusher Reversing Distance parameter. If this is the case, then return the pusher to the home position and this
procedure is complete, otherwise go to Step 3.)
Step 2: Reverse the pusher just slightly until there is ¼” clearance between the pusher and the bottom of the spindle.
Step 3: Record the value of the pusher position on the remote control station.
Take this value and subtract if from the value of the End of Bar position. Take this new value and enter it as the value for
the Pusher Reversing Distance parameter.

Procedure complete.

QUICK LOAD SERVO S3

Chapter 3: Procedures 3-25

Reference Procedure

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ Air pressure set at 5 bar (75psi).
ƒ Loading channel in the lower position.

Step 1: At the HOME PAGE, press the MENU key on the remote control station.

LOADING CHANNEL IN
ITS LOWER POSITION

PRESS F1 TO SELECT
AUTOMATIC MODE
OR
PRESS F2 TO SELECT
MANUAL MODE

Step 2: At the MAIN MENU, press the #4 key on the remote control station.

MAIN MENU

1. PART SETUP
2. APPLICATION SETUP

3. POSITION/TORQUE
4. MISCELLANEOUS
FUNCTIONS
5. SERVICE

Step 3: Press the F4 (PAGE DOWN) key on the remote control station until the “Request for Reference Point Settings” option
appears.
Step 4: Press and hold the F3 (ENTER) key until the screen returns to the Home Page.

REQUEST FOR
REFERENCE POINT
SETTINGS

PRESS F3 (ENTER) TO
CONFIRM AND FOLLOW
INSTRUCTIONS

Step 5: Press the F1 key on the remote control station for Manual Mode.

LOADING CHANNEL IN
AN INTERMEDIATE
POSITION

PRESS F1 TO SELECT
MANUAL MODE

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3-26 Chapter 3: Procedures
Step 6: Press the F1 key on the remote control station to begin the self-referencing sequence.

POSITIONING ERROR!

ENCODER LOST ITS

REFERENCE POSITION

RESET REFERENCE
POINT (ZERO POINT)

REFER TO INSTRUCTION
MANUAL

Sequence:
- The carriage unit retracts toward the home position, simultaneously, the PLC waits to detect the proximity switch-SQ5 (input
I1.4) and the servo amplifier looks for the torque to build up after hitting the mechanical stop.

REFERENCE POINT
POSITIONING
IN PROGRESS...

- Once the home position is set, the HOME PAGE will reappear on the remote control station.

LOADING CHANNEL IN
ITS LOWER POSITION

PRESS F1 TO SELECT
AUTOMATIC MODE
OR
PRESS F2 TO SELECT
MANUAL MODE

Procedure complete.

The following is a video clip of the Reference Procedure. Must have the electronic file to play this movie.

QUICK LOAD SERVO S3

Chapter 3: Procedures 3-27

Reset Interface Parameters

Procedure:

Conditions:
ƒ Bar feed power on.
ƒ Bar feed in STOP mode.
ƒ PLC in RUN mode.

Step 1: Press the MENU button on the remote control station.

Step 2: Press the #2 button on the remote control station.

Step 3: Press the F4 button on the remote control station.

QUICK LOAD SERVO S3

3-28 Chapter 3: Procedures
Step 4: Press the #8 button on the remote control station.

Step 5: Press the F3 button on the remote control station.

Step 6: Press the #2 button on the remote control station.

Step 7: Press the #5 button on the remote control station.

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Chapter 3: Procedures 3-29
Step 8: Press the #0 button on the remote control station.

Step 9: Press the #3 button on the remote control station.

Step 10: Press the F3 button on the remote control station.

Step 11: Press the #1 button on the remote control station.

QUICK LOAD SERVO S3

3-30 Chapter 3: Procedures
Step 12: Press the F3 button on the remote control station.

Step 13: Press the F1 button on the remote control station.

Step 14: Press the F1 button on the remote control station.

Procedure complete.

QUICK LOAD SERVO S3

Chapter 3: Procedures 3-31

Calibration of the Loading Table

To obtain optimal loading, the bar must be perfectly centered on the spindle, regardless of its diameter or profile. Whenever the
diameter or the profile is changed, the position of the loading table is automatically adjusted according to the parameters entered by
the operator. If, for any reason whatsoever, the position of the loading table would be incorrect (either too low or too high), it can be
corrected.
PART SETUP menu. The command asks the operator to confirm the
setting of the diameter. Using the keypad, enter the diameter of the bar
Procedure: used to center the table. Press the [F3] ENTER key twice to validate. (Also
refer to Alignment Procedure, pg. 3-3)

Conditions:
ƒ Bars are on the magazine.
ƒ The loading table is in the low position.
LOADING CHANNEL IN
ƒ Must be in Normal Operation. ITS LOWER POSITION

PRESS F1 TO SELECT
AUTOMATIC MODE
Step 1: Select manual mode by pressing the [F2] OR
PRESS F2 TO SELECT
key. MANUAL MODE

Bring the loading table in upper position [F2].

The bar now faces the spindle of the lathe.
The remote command offers icon [F4]
Forward. To obtain the icon [F3] Adjust the
LOADING CHANNEL IN
height of the loading table, press the [1] key. ITS LOWER POSITION

Step 2: Press the [F3] key. PUSHER POSITION

@@@@.@ MM

Step 3: Four icons are displayed: USEFUL MATERIAL

LENGTH UNTIL
END OF BAR
[F1] raise the table ####.# MM

[F2] ESC (exit without saving)

[F3] ENTER (save)
[F4] lower the table.
LOADING CHANNEL IN
THE UPPER POSITION
Note: BAR STOCK IS PRESENT
IN THE CHANNEL
The pneumatic cylinders, controlling the vertical LOADING FLAG
movement of the table, release the pressure to allow POSITION
@@@@.@ MM
motor M2 to proceed with the setting. After the setting
is complete, they are reactivated.
Each time the [F1] or [F4] key is pressed, the vertical
position of the table is modified by 0.25 mm. For
substantial adjustments, keep pressing the key to keep
the table moving in a continuous motion.
When the desired position is reached, press the [F3]
11
ENTER key to validate the choice and recalibrate the
device at this new position. Since the calibration must
be changed, the command automatically accesses the
LOADING CHANNEL IN
THE UPPER POSITION
BAR STOCK IS PRESENT
IN THE CHANNEL

LOADING FLAG
POSITION
@@@@.@ MM

LOADING CHANNEL IN
THE UPPER POSITION
BAR STOCK IS PRESENT
IN THE CHANNEL

LOADING FLAG
POSITION
@@@@.@ MM

QUICK LOAD SERVO S3

4-2 Error! Reference source not found. Error! Reference source not found.

Chapter 4:
Software
Update/Restore
W
ith the help of the latest technological innovations, it is possible to update new software and restore lost data through
the use of Smart Media. Smart Media, which is mainly used in photography, has been integrated for use with the
user-friendly remote control station. The Smart Media Card holds a backup program for the Quick Load Servo S3 if
at anytime there has been a power failure or any error has occurred in the user program. In addition, it automatically
backs up any application/interface parameters that have been set for the most recent application being run.
Following a few systematic procedures is all it takes to be up and running with the most up to date software or restoring lost PLC
programs and/or parameters.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-3

Determining Display Firmware

To ensure that the right procedure is used to perform a Software Update or to restore software, check the
display on the bar feed to determine its firmware version: 1.17a or 2.08.

In order to check the version of the firmware, turn the main bar feed power off and then back on again.
During the power up, the first screen will show the firmware version of the display.

Firmware v 1.17a Firmware v 2.08 Firmware v 2.08

(No card is present or the card is blank)

If the display has firmware version 1.17a, proceed to page 4-3. If the display has firmware version 2.08,
proceed to page 4-20.

QUICK LOAD SERVO S3

4-4 Error! Reference source not found. Error! Reference source not found.

PLC Fault
Restore PLC Program From Memory Card to PLC – v1.17a
This procedure is used due to a defective battery or a new PLC was installed.

Procedure
Step 1: Turn off the power to the bar feed.

Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position.

Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you)
into the slot.

Black side Chamfered edge

facing up away from you

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-5

Step 5: Press and hold the menu button while turning on the bar feed.
You may release the menu button when the following screen appears.

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F3 key for PLC Fault.

QUICK LOAD SERVO S3

4-6 Error! Reference source not found. Error! Reference source not found.

Step 10: When the PLC fault screen appears (seen below) press the F3 key (ENTER).

Step 11: Press F3 (ENTER) on the first screen that displays to Restore PLC Program from Memory Card to PLC.

Step 12: The PLC program will now be saved from the memory card to the PLC. This may take several minutes.

Step 13: Press F4 (OK).

Step 14: Turn off power to bar feeder.

Step 15: Move the RUN/STOP switch to RUN position.

Step 16: Restore power to the bar feeder.

Procedure complete.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-7

PLC Fault
Restore Bar Feeder Parameters from MMI to PLC – v1.17a
Procedure
Step 1: Turn off the power to the bar feed.

Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position.

Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from
you) into the slot.

Black side Chamfered edge

facing up away from you

QUICK LOAD SERVO S3

4-8 Error! Reference source not found. Error! Reference source not found.

Step 5: Press and hold the menu button while turning on the bar feed.
You may release the menu button when the following screen appears.

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F3 key for PLC Fault.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-9

Step 10: Press F4 (PAGE DOWN) until Restore Bar Feeder Parameters from MMI to PLC screen is displayed. Press F3 (ENTER).

Step 11: The parameters will then be restored from the MMI to the PLC.

Step 12: Press F4 (OK).

Step 13: Turn off power to bar feeder.

Step 14: Move the RUN/STOP switch to RUN position.

Step 15: Restore power to the bar feeder.

Procedure complete.

QUICK LOAD SERVO S3

4-10 Error! Reference source not found. Error! Reference source not found.

Software Update
Restore Bar Feeder Parameters From MMI to PLC – v1.17a
Procedure

Step 1: Turn off the power to the bar feed.

Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position.

Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you)
into the slot.

Black side Chamfered edge

facing up away from you

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-11

Step 5: Press and hold the menu button while turning on the bar feed.
You may release the menu button when the following screen appears.

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update.

QUICK LOAD SERVO S3

4-12 Error! Reference source not found. Error! Reference source not found.

Step 10: When you reach the Update PLC screen, press F3 (ENTER).

Step 11: Press F4 (PAGE DOWN) until you reach the screen to Restore Bar Feeder Parameters From MMI to PLC, and press F3
(ENTER).

Step 12: The bar feeder parameters will now be saved from the display to the PLC.

Step 13: Press F4 (OK).

Step 14: Turn off power to bar feeder.

Step 15: Move the RUN/STOP switch to RUN position.

Step 16: Restore power to the bar feeder.

Procedure complete.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-13

Software Update
Restore Display Data from Memory Card to MMI – v1.17a
This procedure is used to update the PLC software.

Procedure
Step 1: Turn off the power to the bar feed.

Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position.

Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you)
into the slot.

Black side Chamfered edge

facing up away from you

QUICK LOAD SERVO S3

4-14 Error! Reference source not found. Error! Reference source not found.

Step 5: Press and hold the menu button while turning on the bar feed.
You may release the menu button when the following screen appears.

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-15

Step 10: When you reach the Update PLC screen, press F3 (ENTER).

Step 11: Press F3 to restore data from memory card to the display (text and icons).

Step 12: The registers will then be restored from the memory card to the display.

Step 13: Press F4 (OK).

Step 14: Turn off power to bar feeder.

QUICK LOAD SERVO S3

4-16 Error! Reference source not found. Error! Reference source not found.

Step 15: Move the RUN/STOP switch to RUN position.

Step 16: Restore power to the bar feeder.

Procedure complete.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-17

Software Update
Restore PLC Program from Memory Card to PLC – v1.17a
*YOU WILL NEED TO RECORD YOUR PARAMETERS BEFORE PERFORMING THIS PROCEDURE.
The current parameter settings will not be saved. The parameters will need to be reprogrammed after the PLC program has been
restored.

Procedure

Step 1: Turn off the power to the bar feed.

Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position.

Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you)
into the slot.

Black side Chamfered edge

facing up away from you

QUICK LOAD SERVO S3

4-18 Error! Reference source not found. Error! Reference source not found.

Step 5: Press and hold the menu button while turning on the bar feed.
You may release the menu button when the following screen appears.

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-19

Step 10: When you reach the Update PLC screen, press F3 (ENTER).

Step 11: Press F4 (PAGE DOWN) until you reach the screen to Restore PLC Program from Memory Card to PLC, press F3 (ENTER).

Step 12: The PLC program will now be saved from the memory card to the PLC. This may take several minutes.

QUICK LOAD SERVO S3

4-20 Error! Reference source not found. Error! Reference source not found.

Step 13: Press F4 (OK).

Step 14: Turn off power to bar feeder.

Step 15: Move the RUN/STOP switch to RUN position.

Step 16: Restore power to the bar feeder.

Procedure complete.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-21

PLC Fault – v2.08

This procedure is used due to a defective battery or a new PLC was installed.

Procedure
Step 1: Turn off the power to the bar feed.

Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position.

Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you)
into the slot.
Black side Chamfered edge
facing up away from you

QUICK LOAD SERVO S3

4-22 Error! Reference source not found. Error! Reference source not found.

Step 5: Press and hold the menu button while turning on the bar feed.
You may release the menu button when the following screen appears.

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F3 key for PLC Fault.

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-23

Step 10: When the PLC fault screen appears (seen below) press the F3 key (ENTER).

Step 11: The current parameter settings will be saved. The display will then restore the PLC program to the PLC and the parameters
will then be restored to their previous settings.

Step 12: Press F4 (OK).

Step 13: Turn off power to bar feeder

Step 14: Move the RUN/STOP switch to RUN position.

Step 15: Restore power to the bar feeder.

Procedure complete.

QUICK LOAD SERVO S3

4-24 Error! Reference source not found. Error! Reference source not found.

Software Update – v2.08

This procedure is used to update the PLC software.

Procedure
Step 1: Turn off the power to the bar feed.

Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position.

Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you)
into the slot.

Black side Chamfered edge

facing up away from you

QUICK LOAD SERVO S3

Error! Reference source not found. Error! Reference source not found. 4-25

Step 5: Press and hold the menu button while turning on the bar feed.
You may release the menu button when the following screen appears.

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update.

QUICK LOAD SERVO S3

4-26 Error! Reference source not found. Error! Reference source not found.

Step 10: When you have reached the Update PLC screen press the F3 key (ENTER).

Step 11: The current parameter settings will be saved. The PLC program will then be updated and the parameters will then be
restored to their previous settings.

Step 12: Press F4 (OK).

Step 13: Turn off power to bar feeder

Step 14: Move the RUN/STOP switch to RUN position.

Step 15: Restore power to the bar feeder.

Procedure complete.
QUICK LOAD SERVO S3
Chapter 5: Barfeed Applications 5-1

Chapter 5:
Barfeed Applications
S
electing the correct application is a critical step in setting up the bar feed. This chapter defines the individual applications
choices found in the Application Setup. The differences between each of the applications determine how the feed out
process of the bar feeder will occur. Reference this section of the manual when changing applications on the lathe to
achieve ideal operating conditions and also to attain maximum efficiency of the Quick Load Servo S3 automated bar
feeding unit.

QUICK LOAD SERVO S3

 5-2 Chapter 5: Barfeed Applications

Application Setup
The Quick Load Servo S3 is equipped with 7 pre-defined applications and 1 custom application defined in any configuration by the
user.
An “application” is defined as a specific function of the barfeed in automatic operation coinciding with the material processing of the
lathe.
The pre-defined applications when selected will automatically enable the required “Application” parameters on the barfeed to allow the
base application to function without having to select each one individually.
There are three types of parameters “Application”, “Variable” and “Interface”.

Parameter types defined

A. Application Parameter
Parameter that alters the automatic operation of the bar feed. (Set by selecting application)

B. Variable Parameter
Parameter containing a value used in a calculation. (Must change when Dia., Part length or
Application changes)

C. Interface Parameter
Parameter related to the electrical interface between the barfeed and lathe. (Not affected by
changing applications)

Applications defined
1. FEED W/TURRET AND WITH M-CODE
- The turret of the lathe will control the positioning of the material as it is advanced by the barfeed.
- To advance the material the clamping device of the lathe must be open and an M-Code output from
the lathe sent to the barfeed to enable the feeding sequence.
- This application assumes that pre-loading of the material in the barfeed is required.

Parameters enabled: 6=2, 8A=3, 9=2, 16=2, 19=2, and 83=1 (all other “Application” type
parameters set to =1)

2. FEED W/TURRET AND WITHOUT M-CODE

- The turret of the lathe will control the positioning of the material as it is advanced by the barfeed.
- To advance the material an M-Code output from the lathe is not required. The barfeed will advance
the material when the clamping device opens and all other required conditions are satisfied.
- This application assumes that pre-loading of the material in the barfeed is required.

Parameters enabled: 6=2, 8A=3, 9=2, 19=2, and 83=1 (all other “Application” type parameters
set to =1)

3. FEED W/O TURRET AND WITH M-CODE

- The turret of the lathe is NOT required to control the positioning of the material as it is advanced by
the barfeed. The servo positioning capabilities of the barfeed will control the distance the material is
advanced based upon the value entered into the “Input overall part length” parameter located in “1.
Part Setup”.
- A pull-to-close type clamping system is required by this application for positioning accuracy. If a
push-to-close type system is used the turret must be used for positioning.
- To advance the material the clamping device of the lathe must be open and an M-Code output from
the lathe sent to the barfeed to enable the feeding sequence.
- This application assumes that pre-loading of the material in the barfeed is required.

QUICK LOAD SERVO S3

Chapter 5: Barfeed Applications 5-3
Parameters enabled: 6=2, 8A=1, 9=2, 16=2, 19=2, and 83=1 (all other “Application” type
parameters set to =1)

4. FEED W/O TURRET AND W/O M-CODE

- The turret of the lathe is NOT required to control the positioning of the material as it is advanced by
the barfeed. The servo positioning capabilities of the barfeed will control the distance the material is
advanced based upon the value entered into the “Input overall part length” parameter located in “1.
Part Setup”.
- A pull-to-close type clamping system is required by this application for positioning accuracy. If a
push-to-close type system is used the turret must be used for positioning.
- To advance the material an M-Code output from the lathe is not required. The barfeed will advance
the material when the clamping device opens and all other required conditions are satisfied.
- This application assumes that pre-loading of the material in the barfeed is required.

Parameters enabled: 6=2, 8A=1, 19=2, and 83=1 (all other “Application” type parameters set to
=1)

5. SUB-SPINDLE STANDARD
- This parameter is not visible by default, a password is required to unlock. Contact LNS America,
Inc. for more information.
- The sub-spindle is required to pull the material to the desired position. The turret is NOT used to
position the material.
- NO M-Code is used to advance the material.
- The headstock of the lathe must be none sliding type (NO Z-axis movement).
- “Variable” Parameter No. 83 “Number of clamping device openings for the overall part length” must
correspond to the number of times the clamping device opens on the lathe to make one complete
part.
- If more than one clamping device opening is required, “Variable” parameter “Input overall part
length” must equal the total distance of the number of sub-spindle pulls.
- The pusher will remain in its home position except for the loading of the new material into the
spindle.
- When the number of clamping device openings of the lathe equal Parameter No. 83 in continuous
cycle, the length of one part which is entered into Parameter “Input overall part length” is deducted
from the overall material length as was determined when the material was initially loaded or
calculated after a restart. This process continues until the barfeed has determined that not enough
material remains to make another part. At this point the End of Bar signal is output to the lathe.
- If the lathe is removed from automatic cycle and the clamping device opened the barfeed will drop
out of automatic cycle. When the barfeed is restarted in automatic cycle the pusher will advance to
locate the back end of the material. Once the material is located the remaining length of the bar
stock is recalculated.
- The material is loaded to its pre-load position and will remain there until: clamping device is open
and a M-Code output from lathe to barfeed confirming its is safe to load the new material into the
spindle.

Parameters enabled: 3=2, 6=2, 8A=3, 19=2, 25=2, 28=2, and 83=1 (all other “Application” type
parameters set to =1)

6. SUB-SPINDLE SLIDING HEADSTOCK

- This parameter is not visible by default, a password is required to unlock. Contact LNS America,
Inc. for more information.
- The sub-spindle is required to pull the material to the desired position. The turret is NOT used to
position the material.
- NO M-Code is used to advance the material.
- The headstock of the lathe is sliding type (move in a Z-axis movement).
- “Variable” Parameter No. 83 “Number of clamping device openings for the overall part length” must
correspond to the number of times the clamping device opens on the lathe to make one complete
part.
- If more than one clamping device opening is required, “Variable” parameter “Input overall part
length” must equal the total distance of the number of sub-spindle pulls.

QUICK LOAD SERVO S3

5-4 Chapter 5: Barfeed Applications
- The pusher will remain in its home position except for the loading of the new material into the
spindle.
- When the number of clamping device openings of the lathe equal Parameter No. 83 in continuous
cycle, the length of one part which is entered into Parameter “Input overall part length” is deducted
from the overall material length as was determined when the material was initially loaded or
calculated after a restart. This process continues until the barfeed has determined that not enough
material remains to make another part. At this point the End of Bar signal is output to the lathe
- If the lathe is removed from automatic cycle and the clamping device opened the barfeed will drop
out of automatic cycle. When the barfeed is restarted in automatic cycle the pusher will advance to
locate the back end of the material. Once the material is located the remaining length of the bar
stock is recalculated.
- The material is loaded to its pre-load position and will remain there until: clamping device is open,
output from lathe to barfeed confirming the headstock is in its home position and a M-Code output
from lathe to barfeed confirming its is safe to load the new material into the spindle.

Parameters enabled: 3=2, 6=2, 8A=3, 19=2, 25=2, 26=2, 28=2, and 83=1 (all other
“Application” type parameters set to =1)

7. ONE-SHOT SHAFT LOADING (High Speed Loading)

- This parameter is not visible by default, a password is required to unlock. Contact LNS America,
Inc. for more information.
- A pull-to-close type clamping system is required by this application for positioning accuracy. If a
push-to-close type system is used the turret must be used for positioning.
- Each piece of material is equal to one complete part
- NO pusher is to be installed on the barfeed.
- The headstock of the lathe can be either none sliding or sliding type (see point below for sliding
type).
- The loading flag must be configured to a specific length as to position the material to its desired
position inside the clamping device of the lathe (“Top-Cut Position”).
- Parameter No. 69 “Loading flag position” must equal the physical length of the modified loading
flag.
- The material is loaded to its pre-load position and will remain there until: clamping device is open
and a M-Code output from lathe to barfeed confirming its is safe to load the new material into the
spindle.
- If using a sliding type headstock lathe parameter 26 “Headstock home confirmation signal
connected to PLC input A7” must be set to 2. For more information on how to do this please
contact LNS America, Inc.

8. CUSTOM
- Password required
- Allows the user to select any combination of parameters to accommodate special applications.
- For information on how to use this function please contact LNS America, Inc.

QUICK LOAD SERVO S3

Chapter 6: Preventative Maintenance 6-1

Chapter 6:
Preventative
Maintenance
P
eriodic maintenance of the Quick Load Servo S3 bar feeding system can only serve to improve the operation and prolong
its useful life. Following a few simple steps can be extremely helpful and takes relatively no time at all. The list of
maintenance procedures has been broken down into four groups determined by the frequency with which each procedure
should be followed, however, some items should be checked more often depending on the operating environment that the
equipment is exposed.

QUICK LOAD SERVO S3

6-2 Chapter 6: Preventative Maintenance

Daily Maintenance

Verify the Air Pressure

The recommended setting for operation with optimum performance should be at a minimum pressure of 5 bar (75 psi.) and a
maximum pressure of 6 bar (90 psi.).

Weekly Maintenance

Verify that the Air Decanter is Empty

The air-filtering device is equipped with and automatic drainage valve, but depending on how much water is in the pneumatic circuit of
the building, the water that is recuperated can build up faster than it can be drained. Excess water in the air lines can cause
pneumatic cylinders to become defective. The water causes the o-rings inside the cylinder to swell up and no longer function
correctly.

Monthly Maintenance

Cleaning of the bar feeder

Wipe down the outside of the bar feeder with a cloth and any regular detergent. For cleaning the inside of the bar feed use a cloth or
brush, however, do not use these on any of the rollers or any other parts made of synthetic materials. The use of compressed air for
cleaning is not advisable, because chips and other particles can become lodged in sensitive areas and can impede the proper
operation of the bar feeder.

Annual Maintenance

Check the PLC battery

The PLC backup battery saves the PLC program in case of any power failure. The battery used in the LNS PCD2 is a non-
rechargeable 3VDC Lithium/ CD2032 battery. Over time, the battery will slowly discharge. The following chart shows the average life
expectancy of the battery:

Avg. Life Avg. Life

Use of Automation Expectancy: Expectancy:
25°C 55°C
100% off 0% on 3 years 6 months
0% off 100% on 5 years 4 years
30% off 70% on 4 years 1 year

Verify the alignment of the bar feeder

Check alignment of bar feeder to lathe spindle to make sure neither have shifted. In case the bar feeder or lathe has shifted, refer to
the Alignment Procedure pg. 3-3.

Belt Tension
After certain periods of time the linear rail belt may need to be tightened, refer to Belt Tension Adjustments pg. 3-10 & 3-12.

QUICK LOAD SERVO S3

7- 1 C HAP TER 7: Spare Parts

Chapter 7:
Spare Parts

Note: When ordering parts the following information will be needed to ensure
better customer support:

• Bar feeder type

• Bar feeder Serial Number (found on the sub-base)
• Bar stock diameter
• Lathe type (make and model)

QUICK LOAD SERVO S3

7-2 Chapter 7: Spare Parts
Recommended Spare Parts List
As an extended courtesy, a list of recommended spare parts has been compiled for the end user. The list consists of mechanical and
electrical parts that over time may become faulty due to everyday wear on the item. For machines that are running production during
multiple shifts or even 24/7, keeping an inventory of these spare parts can vastly minimize downtime. Keeping an inventory can also
be very cost effective since shipping costs can escalate immensely, especially in cases where rush delivery is necessary.

Qty Configuration Order # Drawing Description

. #
MECHANICAL
1 021.02.233-A 021.02.233-A Roller support
2 021.02.374-A 021.02.374-A Rollers for V-channel
1 6S80-007.C 1.830 Linear Rail Belt
2 6S80-007.D LNS.0825 Roller with eccentric bolt
2 6S80-007.E LNS.0824 Roller with stationary bolt
1 1.791 1.791 Servo motor drive belt
1 6S80-001.B 3.407-A Locking cylinder
1 6S80-001.A 3.330-A Air valve assembly
1 6S80-001.C PS923P Decanter
1 6S80-003.B 3.347-A Air regulator unit
6 MM set-up*
1 021-011-074 021-011-074 6mm Pusher
1 6S30-006.GBUSH 021.05.244-A 6mm Guide bushing
6Q30-
1 011.07.234-A 6mm End of bar bushing
006.EOBUSH
12 MM set-up*
1 021-011-294 021-011-294 12mm Pusher
1 6S30-012.GBUSH 021.05.164-A 12mm Guide bushing
6Q30-
1 011.07.034-A 12mm End of bar bushing
012.EOBUSH
25 MM set-up*
1 021-011-094 021-011-094 25mm Pusher
1 6S30-025.GBUSH 021.05.154-A 25mm Guide bushing
6Q30-
1 011.07.014-A 25mm End of bar bushing
025.EOBUSH
ELECTRICAL
1 4.484-A 4.484-A SQ1 & SQ2 switch
1 4.474-A 4.474-A SQ3 optical measuring cell
1 4.391-A 4.391-A SQ4 & SQ5 Proximity switch
1 4.284-A 4.284-A SQ10 main cover switch
1 4.277-A 4.277-A SQ11 grid safety switch
1 4.291-A 4.291-A SQ12 In position switch
1 4.292-A 4.292-A Key for in position switch (SQ12)
1 6S05-024 4.507-A K1 Main contactor
1 6.101 6.101-A Auxiliary contactor for K1
1 4.606 4.606-A KA1 & KA2 Relays
1 4.242 4.242-A QS1 Main disconnect switch
1 4.138 4.138-A QF1 Circuit breaker 2A
1 6S05-000.B 4.432 Emergency stop button
* Three feeding pusher are necessary to cover the entire range of the Quick Load Servo S3 bar feed
system. Each pusher has a defined range of operation (refer to the Instruction Manual pg. 6-13).
When ordering parts, to ensure better customer support, please specify the following information;
Type of bar feeder, bar feeder serial number, bar stock diameter, and lathe type (refer to Parts Order
Form pg. 7-3)

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-3
Parts Order Form

LNS America, Inc.

Date:

P.O. #
Phone #:

Bill to: Ship to:

Contact: Attn:

Ship via:

Model of Bar feeder: Serial # of Bar feeder:

Model of Lathe: Bar stock diameter:

Qty. Part # Description

Note: To place an order, this form should be photocopied, completed and faxed to (513) 528-8320
Please call (513) 528-5674
for price and availability of parts.

QUICK LOAD SERVO S3

7-4 Chapter 7: Spare Parts
Electrical Box Components

1 L1 3 L2 5 L3 13NO A1+
SIEMENS SIEMENS

S I I

SIEMENS SIEMENS
3TX71 3TX71

O O
V
DE
6000 V
DE
6000
3 3

2 T1 4 T2 6 T3 14NO A2-

SIEMENS
3TX71
SIEMENS
3TX71

C C
N N
1 1
A B
SIEMENS
3TX71

C
N
C
2
N
E
3
SIEMENS

N
3TX71

C
SIEMENS
3TX71

LNS SA LNS USA

Designation Part # Part # Description
A - N/A Interface terminal blocks (X2)
B 4.705 N/A Mitsubishi servo amplifier
C - N/A Emergency Stop circuit (X3)
D * N/A LNS PCD2 (PLC)
E - N/A 24VDC terminal blocks (X1)
F - N/A Inputs / Outputs (X1)
FU 1 - N/A Fused terminal / 1Amp for M2 motor protection
K1 4.507 6.100-A Main contactor
KA1 4.606 6.102-A Relay: Motor M2 “up”
KA2 4.606 6.102-A Relay: Motor M2 “down”
QF1-QF2 4.138 6.113-A Main circuit breaker
QS1 4.242 4.242 Main disconnect switch
R1-R5 4.606 6.102-A Interface relays
T1 4.192 4.688 Transformer
T2 - 6.115-A 24 Vdc power supply
* Not shown in this picture. The LNS PCD2 is located on the electrical panel door.

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-5
Loading Table sub-assembly (Left/Rear Load)

QUICK LOAD SERVO S3

7-6 Chapter 7: Spare Parts
Loading Table sub-assembly (Left/Rear Load)

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-7

Loading Table sub-assembly (Left/Rear Load)

QUICK LOAD SERVO S3

7-8 Chapter 7: Spare Parts
Pusher Locking sub-assembly (Left/Rear Load)

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-9

Pusher Locking sub-assembly (Left/Rear Load)

QUICK LOAD SERVO S3

7-10 Chapter 7: Spare Parts
Loading Table sub-assembly (Left/Front Load)

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-11

Loading Table sub-assembly (Left/Front Load)

QUICK LOAD SERVO S3

7-12 Chapter 7: Spare Parts

Loading Table sub-assembly (Left/Front Load)

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-13
Pusher Locking sub-assembly (Left/Front Load)

QUICK LOAD SERVO S3

7-14 Chapter 7: Spare Parts

Pusher Locking sub-assembly (Left/Front Load)

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-15
Loading Table Microswitch sub-assembly

QUICK LOAD SERVO S3

7-16 Chapter 7: Spare Parts
Servo Motor sub-assembly

QUICK LOAD SERVO S3

Chapter 7: Spare Parts 7-17
Linear Rail Assembly

Item # Item Description Qty

1 Belt guide table 1
2 8 x 24 mm bolt, washer 2
3 8 x 25 mm eccentric bolt, nut, washer 2
4 Belt guide bearings, grooved OD 4
5 End caps black plastic 2
4 x 12 mm screws, DIN 7971 16
Felt wiper 4
Spring 4
Plastic cover 4
6 Belt, 3868 mm 1
7 Belt clamp assembly 2
Top 2
Bottom, profile 2
3 x 5 mm belt clamp screws 8
8 Belt tensioner 1
9 4 x 10 mm screws & washers 4
10 4 x 35 mm adjustment screws 2
11 Drive box 2
12 Bearing housing 2
13 4 x 12 mm screws, DIN 7984 6
14 4 mm serrated Belleville washer 6
15 Adapter plates 2
16 5 x 14 mm adapter plate screws, DIN 7984 4
17 5 x 16 mm adapter plate screws, DIN 912 2
18 5 x 25 mm adapter plate screws, DIN 7984 8
19 5 mm serrated Belleville washers 14
20 Gear shafts 2
21 Drive box bearings 4
22 20 x 3 mm key 2
23 Extrusion, 1830mm 1
24 Rod, 1828 mm 2
25 T-slot 2

QUICK LOAD SERVO S3