FMB Maschinenbaugesellschaft mbH & Co. KG
Paul-Hohe-Straße 1
97906 Faulbach
Telefon:
Fax:
+49 9392 801 0
+49 9392 801 20
Mail: [email protected]
Web: www.fmb-machinery.de
Original operating instructions
FMB turbo 2-20
series 1
from RM-Nr. 102068
OMRON
NOTICE!
The technical documentation of the FMB loading magazine comprises:
• FMB - operating instructions
• FMB - spare parts list
• FMB - electrical circuit diagram
turbo 2-20
series 1
Contents
0. Safety instructions for operating the loading magazine ............................................. 4
0.1 Explanation of symbols and signs .......................................................................... 4
0.1.1 Safety symbols at the loading magazine .................................................... 4
0.2 Operation ............................................................................................................... 5
0.3 Maintenance and repairs ....................................................................................... 7
0.4 Intended use .......................................................................................................... 7
0.5 Patent rights ............................................................................................................ 8
0.6 Safety Measures .................................................................................................... 8
0.7 Safety equipment ................................................................................................... 9
0.7.1 Covers ....................................................................................................... 9
0.7.2 Guide tube/Telescopic tube between loading magazine and lathe ........... 10
0.7.2.1 Lathe with movable spindle stock ................................................. 10
0.7.2.2 Lathe with fixed spindle stock ....................................................... 11
0.7.3 Emergency stop device ............................................................................ 11
0.7.4 Protection doors on the lathe ................................................................... 11
0.8 Safety instructions for working with the portable control panel ............................. 12
1. Technical data and operating material ....................................................................... 13
1.1 Technical data / Storage conditions ..................................................................... 13
1.2 Electrical connection between loading magazine and lathe ................................. 14
1.3 Oil filling ............................................................................................................... 14
1.4 Requirements for the material bars and their preparation .................................... 15
1.5 Speed limitations ................................................................................................. 17
2. Transport for installation and dismantling ................................................................. 18
2.1 Preparation of the loading magazine for transport ............................................... 18
2.1.1 Transport of the switch cabinet ................................................................ 19
2.2 Transport by crane............................................................................................... 20
2.3 Transport by forklift truck ..................................................................................... 21
2.4 Transport by other means .................................................................................... 22
3. Installation ............................................................................................................. 23
3.1 Installation chart................................................................................................... 23
3.2 Condition of the floor ............................................................................................ 25
3.3 Aligning the loading magazine ............................................................................. 25
3.4 Fixing to the floor ................................................................................................. 26
3.5 Compressed air supply ........................................................................................ 26
3.6 Electrical connections .......................................................................................... 27
3.7 Preventing hazardous confined spaces ............................................................... 27
3.8 Repairs to the lathe.............................................................................................. 27
3.9 Forward limit stop for the pusher ......................................................................... 28
3.10 Synchronizing device ......................................................................................... 30
4. Notes on the interface .................................................................................................. 32
4.1 Contacts from the lathe to the loading magazine ................................................. 32
4.2 Contacts from the loading magazine to the lathe ................................................. 33
4.3 Program suggestion for lathe ............................................................................... 34
5. Commissioning the FMB loading magazine ............................................................... 35
5.1 Conditions for commissioning .............................................................................. 35
5.1.1 Fixing the loading magazine - work based on installation chart ................ 35
5.1.2 Connection to the lathe ............................................................................ 35
5.1.3 Supply media ........................................................................................... 35
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 1
turbo 2-20
series 1
5.1.4 Oil filling ................................................................................................... 35
5.1.5 Spindle reduction ..................................................................................... 36
5.1.6 Mechanical adjustment ............................................................................ 36
5.1.7 Training of staff / Study of the operating instructions................................ 36
5.2 Switching on the unit for the first time .................................................................. 37
5.3 Switching the Unit ON and OFF........................................................................... 38
5.3.1 Switching the Unit ON .............................................................................. 38
5.3.2 Switching the Unit OFF ............................................................................ 38
5.3.3 Operation with Parts Counter ................................................................... 39
5.3.3 Operation with Parts Counter ................................................................... 39
5.3.4 Operation with Programmed OPERATION TIME ..................................... 39
5.4 Settings on the controller ..................................................................................... 40
5.4.1 Setting the cut-off position (end of first insert) .......................................... 40
5.4.2 Setting the interval feed when processing polygonal material .................. 41
5.4.3 Setting bar end values ............................................................................. 42
5.4.4 Setting the "POS.REVERSE ROTATION RETURN" value ...................... 42
5.4.5 Follow-up with sub-spindle (option) .......................................................... 43
5.4.6 Machining of 2 different part lengths (OPTION) ....................................... 44
5.5 Parameter list ...................................................................................................... 45
5.6 Overview of positions for setting parameters ....................................................... 46
6. Control panel ................................................................................................................ 46
6.1 Menu levels on the control panel ......................................................................... 48
6.1.1 Switching between operating levels ......................................................... 50
6.2 Operating menu: PART and SERVICE ................................................................... 51
6.2.1 Menu: PART ............................................................................................ 52
6.2.1.1 Menu: PART STANDARD SETTINGS ......................................... 52
6.2.1.2 Menu: PART SPECIAL SETTINGS .............................................. 53
6.2.1.3 Menu: PART SELECT .................................................................. 54
6.2.1.4 Menu: PART COUNTER / TIME ................................................... 54
6.2.2 Menü: SERVICE ...................................................................................... 55
6.2.2.1 Menü: SERVICE POSITIONEN.................................................... 55
6.2.2.2 Menu: SERVICE FEED FORCE................................................... 56
6.2.2.3 Menu: SERVICE SPEED ............................................................. 56
6.2.2.4 Menu: SERVICE CURRENT POSITIONS .................................... 57
6.2.2.5 PLC STATUS: INPUTS ................................................................ 57
6.2.2.6 PLC STATUS: OUTPUTS ............................................................ 57
6.2.3 Menu: FMB .............................................................................................. 58
6.2.4 Menu: SETUP .......................................................................................... 58
7. Assembly description .................................................................................................. 59
7.1 Support structure ................................................................................................. 59
7.2 Steady rest .......................................................................................................... 59
7.3 Gripper - Function and Mode of Operation .......................................................... 61
7.4 Lateral material Storage ...................................................................................... 62
7.4.1 Setting the material diameter ................................................................... 62
7.5 Drive .................................................................................................................... 63
7.5.1 Clutches ................................................................................................... 63
7.5.2 Motor ........................................................................................................ 63
7.5.2.1 Motor with worm gear ................................................................... 63
7.5.2.2 Speed regulating rheostat ............................................................ 63
7.5.4 Crank ....................................................................................................... 64
Page 2
Edition 04/12
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GB/O
Operating Instructions
turbo 2-20
series 1
7.6 Refitting the magazine ......................................................................................... 65
7.6.1 Pusher ..................................................................................................... 65
7.6.2 Clamping sleeves/clamping mandrels/centring sleeves - Function and
use ........................................................................................................... 65
7.6.2.1 Working with clamping sleeve ...................................................... 66
7.6.2.2 Working with clamping mandrel.................................................... 67
7.6.2.3 Working with centring sleeve ........................................................ 67
7.6.2.4 Collet of the lathe ......................................................................... 68
7.6.5 Removing and fitting of capacacity adjustment set................................... 71
7.6.5.1 Replacement of pusher ................................................................ 72
7.6.5.2 Replacement of short pusher ....................................................... 73
7.6.5.3 Replacement of insert at remnant flap .......................................... 73
7.6.5.4 Replacement of inserts ................................................................. 74
7.6.5.5 Replacement of guide tube .......................................................... 75
7.6.5.6 Replacing the reduction inserts in the telescopic tube .................. 75
7.6.5.7 Illustration: Refitting the magazine ............................................... 76
7.6.5.8 Installation Example: Capacity adjustment set D13/1405/22003200-3800-4200 .............................................................................. 77
7.7 Oil Supply ............................................................................................................ 78
8. Functional Description................................................................................................. 79
8.1 Mode of Operation ............................................................................................... 79
8.2 Automatic Workflow ............................................................................................. 80
9. Faults/Error messages ................................................................................................. 84
9.1 Faults display ....................................................................................................... 84
9.2 Error Messages ................................................................................................... 85
9.3 Display status of the CPU .................................................................................... 89
10. Removing a Material Bar from Guide Channel ......................................................... 90
11. Maintenance Works and Settings ............................................................................. 91
11.1 Maintenance to be carried out regularly ............................................................. 91
11.2 Maintenance unit ............................................................................................... 92
11.3 -Q1 Feed Clutch Maintenance ........................................................................... 93
11.4 Battery ............................................................................................................... 94
11.4.1 Replacing the battery ............................................................................. 95
11.5 Disassembling, respectively assembling the CPU or one of the I/O-modules .... 96
11.6 New program for PLC ........................................................................................ 97
12. Electric and Pneumatic Parts .................................................................................... 98
12.1 Arrangement of electrical and pneumatic equipment ......................................... 99
13. Parts list of pneumatic parts ..................................................................................... 99
13.1 Pneumatic diagram, Page 1..............................................................................101
13.2 Pneumatic diagram, Page 2..............................................................................101
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 3
turbo 2-20
series 1
0. Safety instructions for operating the loading magazine
0.1 Explanation of symbols and signs
You will find this symbol alongside all working safety
instructions in these operation instructions wherever there is
danger to life or the risk of personal injury.
Pay attention to these instructions and take great care in such
cases.
Attention!
This symbol can be found in these operation instructions
wherever special care is necessary to ensure that guidelines,
regulations, notes and the correct sequences of operation are
observed, and in order to prevent damage to and destruction of
the unit.
0.1.1 Safety symbols at the loading magazine
Warning of a hazard area
Warning of hazardous voltage
Warning of hand injury
Page 4
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
0.2 Operation
• Safety devices such as protection doors and covers must neither be dismantled nor
rendered inoperable. They must be closed before operating the loading magazine and
must not be opened during operation.
• Any changes to the loading magazine which have an adverse effect on safety must be
reported immediately to the parties responsible.
• Do not switch off the loading magazine at the main switch while a program is running.
This could result in damage.
• Only press the emergency stop key if there is a danger to persons or a risk of damage
to the unit (also before carrying out maintenance and repair work).
• Ensure that the loading magazine is securely fixed and has adequate stability during
transport (see section 2).
• The loading magazine should be set up in such a way that the center line of the pusher
and the center line of the lathe spindle are aligned with each other (see section 3).
• Check the electrical interface and the operating voltage before starting up the loading
magazine (see section 4).
• Before starting up the loading magazine, fill up with 50 liters of one of the oil grades
recommended in section 1.3 of these instructions.
• Do not throw waste material into the oil.
• Speed limitations (vibrations, noise) resulting from workpiece dimensions and
out-of-true material bars should also be taken into consideration.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 5
turbo 2-20
series 1
ATTENTION!
When working on the open guide channel
and swung out pusher the safety bolts
always must be inserted!
Unscrew the 2 M10x60 safety bolt out of the side storage and
insert the long thread side into the Ø10 drilled hole.
Safety bolt front
(Cover of channel opened)
Safety bolt rear
(Pusher swung out)
Safety bolt
Insert safety bolt here!
Page 6
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
0.3 Maintenance and repairs
•
Servicing, maintenance and repairs may only be carried out by specially trained
personnel or suitably instructed persons.
•
During all work on the loading magazine, particularly when the covers are open, press
the emergency stop key and close the compressed air valve of the loading magazine.
For maintenance or repair work, the main switch of the lathe must be switched off.
The unit must be depressurized and disconnected from the electrical supply.
•
During repair work on electrical equipment, the relevant regulations must be observed.
(DIN EN 60204 (VDE 0113), DIN VDE 0100; DIN EN 50178 (VDE0160); accident
prevention regulations as issued by the Employer's Liability Insurance Associations.)
•
Special care must be taken if the unit has to be kept ready for operation during certain
types of repair work. Ensure that no persons are in the danger zone.
•
Any safety devices that have been removed for the purpose of maintenance and repair
work should be refitted immediately on completion of the work.
•
Use only clean oils as recommended in section 1.3 of these instructions.
0.4 Intended use
The FMB-loading magazine is determined for assembly with machine tools and exclusively
serves to supply lathes with round, square or hexagonal bar and tube shaped materials.
The commissioning is forbidden until it has been ascertained that the unit is in accordance
with the EC directives.
Material diameters should be in accordance with the "Technical Data" section.
Other profile materials should be used after loading magazine manufacturer consultation
only.
Intended use also results from the technical data, from the requirements of oil fillings,
material bars and speed limitations (see point 1, Technical Data, with sub-points).
When the requirements as specified by the manufacturer are met, the loading magazine
will work below the maximum permissible noise level.
The loading magazine shall only be used in dry rooms having a temperature between +15º
C and +40º C and a humidity of 30% to 75% (non-condensing). Altitude must not exceed
1000 meters above sea level.
Intended use also includes the observance of the operating, maintenance and overhaul
conditions as specified by manufacturer.
The loading magazine shall not be used by any other persons than those being acquainted
therewith and taught in its inherent dangers.
The relevant regulations for the prevention of accidents as well as all other commonly
recognized safety rules should be observed.
Any application going beyond should be deemed as not being in accordance with the
intended use. Manufacturer shall not be liable for any damages resulting therefrom; the
risk shall solely be borne by user.
Any unauthorized loading magazine modification shall exempt the manufacturer from any
and all liabilities for damages resulting therefrom.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 7
turbo 2-20
series 1
0.5 Patent rights
We reserve the right of ownership to these operating instructions and the attached
documents at all times.
These may not be copied, duplicated or passed on, or made available to third parties,
without our written permission.
0.6 Safety Measures
Read and carefully observe these Operating Instructions before
commissioning the loading magazine!
The loading magazine shall only be used, maintained and
repaired by persons being familiar with these Operating
Instructions and the applicable regulations on work safety and
accident prevention.
Ignoring such instructions and spec sheets may cause physical
injury and material damage.
The operator must be aware of the "Technical Instructions on
Hazardous Matters" and respective specification sheets of the
applied oil and to observe them.
The flawless and safe operation of the loading magazine presupposes proper transport,
professional installation and commissioning as well as careful operation and maintenance.
The loading magazine is constructed in compliance with the state of the art and safe for
operation. Danger, however, may emanate from the loading magazine, if it is improperly
used by untrained personnel or for unintended improper applications.
For loading magazine manufacture and documentation preparation, the following
regulations were taken into account:
EC-Council Directive on Machines (2006/42/EC)
DIN EN ISO 12100
DIN EN 60204
DIN EN 62079
In case of deliveries within the EU, the loading magazine is "CE" marked.
Besides, the "EC Conformity Declaration" is attached.
Attention: We would like to point out that the operator of the unit must guarantee the EC
conformity.
Page 8
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
0.7 Safety equipment
0.7.1 Covers
In accordance with current regulations, the loading magazine is guarded by covers to
prevent access to moving parts. The cover above the lateral material storage is guarded
by a safety switch.
The power supply to the solenoid valves is disconnected by safety switch –B74, –B75 and
the safety relay –K20.
Additionally, the opened position of the cover will be evaluated in the PLC.
The contactors –K21 and –K22, which cut-off both the driving motor and feed clutch
–Q1, are separated from the voltage supply, too.
In case of an opened cover, an error message will be shown on the control panel display:
FAULT:
COVER NOT CLOSED
-B74/B75/B76/K20
Automatic mode is switched off.
For conversion work the sequence of steps specified in the
Operating Instructions must be followed!
Before opening the covers press the emergency stop key and close
the compressed air shut-off valve on the loading magazine to
depressurize the unit.
Covers of any sort must not be removed or disabled during
operation of the loading magazine. This also applies to all parts of
the covers that are not electrically monitored or permanently bolted
in position.
During the loading magazine operation, it is not allowed to reach
through the loading aperture. Risk of personal injury!
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 9
turbo 2-20
series 1
0.7.2 Guide tube/Telescopic tube between loading magazine and lathe
0.7.2.1 Lathe with movable spindle stock
Before commissioning, the specified guide tube/telescopic tube
shall be mounted in between the lathe spindle and the loading
magazine. During loading magazine operation, the guide
tube/telescopic tube must be present.
Movable spindle stock lathes must not be operated without
telescopic tubes or fixed spindle-reducing elements projecting
from the loading magazine into the spindle of the lathe.
Attention!
Attention!
Assemble the telescopic tube as described in the drawing
enclosed. This drawing can be requested from FMB by stating the
respective order number.
see section 5.1.5 "Spindle reduction"
The guide tube/telescopic tube bridges the distance between the loading magazine’s front
end and the spindle end of the lathe. It serves as a protective cover and prevents rotating
parts from being ejected.
The inner diameter of the guide tube/telescopic tube depends on the pusher built-in.
Fixed Spindle Reducing Element:
Should assembly of a telescopic tube be impossible, the lathe can be operated with a fixed
spindle-reducing element. To this effect, the guide tube of the loading magazine as
contained in the capacity adjustment sets slid into the spindle. Thus, maximum possible
bar diameter is restricted.
The following should be noted:
• The guide tube’s outer diameter must be 1 to 2 mm smaller than the spindle’s inner
diameter.
• Guide tube length must be specified such that it bridges the gap between loading
magazine and spindle, whilst excluding any potential spindle destruction.
• The guide tube’s inner diameter must be 2 mm bigger than the diameter of the pusher
built-in.
• The smallest wallthickness of the guide tube should be 2 mm at least.
Page 10
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
0.7.2.2 Lathe with fixed spindle stock
Before commissioning, the specified guide tube shall be mounted in
between the lathe spindle and the loading magazine. During loading
magazine operation, the guide tube must be present.
The guide tube bridges the distance between the loading magazine’s front end and the
spindle end of the lathe. It serves as a protective cover and prevents rotating parts from
being ejected.
The guide tube’s inner diameter depends on the pusher built-in. When installing the
loading magazine, the guide tube’s length must be taken into account (see sect. 3).
It shall be specified such that there is a distance of 5 mm at max. between the end of the
lathe spindle and the front end of the guide tube or such that the tube projects into the
lathe spindle. This gap must not be within operator’s reach!
0.7.3 Emergency stop device
As required by DIN EN 60204 (VDE 0113), an emergency stop device is fitted to the bar
loading magazine. The 24 V DC power supply to all PLC outputs is disconnected by
pressing the emergency stop key -S69 on the control panel.
The following message appears on the control panel:
FAULT:
EMERGENCY STOP LOADING MAGAZINE -S69
The emergency stop message is also sent to the lathe and has to be properly processed
there.
If an emergency stop key is pressed on the lathe, the loading magazine controller must
also be switched off.
The following message appears on the control panel:
FAULT:
EMERGENCY STOP LATHE
0.7.4 Protection doors on the lathe
When breaking the contact "protection door closed", the contactors –K21 and
–K22 switch-off the voltage supply to the driving motor -M1 and feed coupling –Q1.
This means that movement of the pusher with the material bar is no longer possible.
The risk of personal injury from the material bar in the lathe workshop while the protection
door is not closed can safely be ruled out.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 11
turbo 2-20
series 1
0.8 Safety instructions for working with the portable control
panel
Attention !
At regular intervals (6 months) the emergency stop key must
be checked to ensure it is working properly. The loading
magazine must be switched off on actuation of the emergency
stop key.
• The housing of the control panel must not be opened (except loading a new operating
software).
• Do not place the control panel in direct sunlight or other heat sources.
• Do not place the control panel where there are mechanical vibrations, excessive dust,
moisture or strong magnetic fields.
• Do not clean the housing, control panel or operating elements with solvent, abrasives or
scouring pads. Only clean with a soft cloth, slightly moistened with water or a mild
cleaning agent.
• Take care to ensure that debris or liquids do not enter the inside of the unit.
The unit’s protective covers and cable feeds should be checked for damage at regular
intervals. The screw fixings of the housing must be checked for completeness.
• If the control panel is subjected to a sharp impact (e.g. if it is dropped), the emergency
stop key must be checked to ensure it is working.
Page 12
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
1. Technical data and operating material
1.1 Technical data / Storage conditions
Material aperture in guide channel: 20 mm
(max. pusher diameter 23 mm)
Power consumption:
1,5 kW
Feed force:
max. 300 N (infinitely variable)
Insertion speed:
0 to 300 mm/s (adjustable)
Return speed:
max. 600 mm/s
Load capacity max.:
200 mm
(Holding down device 150 mm)
Extended storage 380 mm
(Holding down device 240 mm)
2200
3200
3800
4200
60 kg
90 kg
110 kg
120 kg
--
140 kg
160 kg
180 kg
Remnant length:
max. 420 mm
Dimensions:
see installation chart sect. 3.
Weight:
2,2 m – 450 kg
3,2 m – 550 kg
3,8 m – 600 kg
4,2 m – 650 kg
without oil filling, packaging and material
Loading time:
approx. 26 s (for 3200 mm bars)
Oil filling:
50 l oil,(viscosity: 100 cSt at +40 ºC)
not included in scope of delivery
Operating conditions:
• Ambient temperature range from +15 ºC to +40 ºC (dictated by the viscosity of the oil).
• Relative humidity 30 % to 75 % (non-condensing).
• The elevation must not exceed 1000 m above M.S.L.
Storage conditions:
The loading magazine must only be stored in a dry area with an ambient temperature of
-20 ºC to +65 ºC.
Operating voltage:
3 x 400 V/50 Hz standard version (200 V on request).
According to DIN EN 60204 (VDE 0113), the continuous operating voltage must be 100 %
± 10 % of the mains voltage. The frequency must be between 0.99 and 1.01 of the rated
frequency.
Control voltage:
24 V DC
Compressed air supply:
min. 0.6 MPa (6 bar) max. 1.0 MPa (10 bar)
Compressed air consumption:
approx. 4 litres per loading action and
approx. 0.3 litres per double stroke of steady rest
Noise level:
max. 48 ± 5 db(A) (during bar change)
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 13
turbo 2-20
series 1
1.2 Electrical connection between loading magazine and lathe
You can find details of the electrical connections and voltage supply of the loading
magazine in the documentation. Electrical connections must be carried out by an
authorised electrician; the VDE (German) and local regulations must be strictly observed,
particularly with regard to safety measures.
1.3 Oil filling
The operator must be aware of the "Technical Instructions on
Hazardous Matters" and respective specification sheets of the
applied oil and to observe them.
Oils conforming to the specifications of
DIN 51 517-2 CL 100
DIN 51 524-1 HL 100
DIN ISO 3448 ISO VG 100 are prescribed.
We recommend the following oil grades:
Öl/Oil/Huile
Hersteller
Producer
Fabricant
Type
100 cSt DIN (51 562-1)
bei +40 °C mm2/s
ARAL
MOTANOL HE100
SHELL
MORLINA 100
MOBIL / ESSO
DTE 27
Note:
Oil change intervals depend on the degree of contamination.
The statutory requirements for disposing of waste oil must be complied with.
Page 14
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
1.4 Requirements for the material bars and their preparation
The straightness of the bars influences the achievable speeds to
a very great extent. With profile materials, speed limitations must
be expected.
The speed of rotation that can be achieved with the material bars depends on their
material accuracy.
The negative influence of untrueness increases as the diameter increases. Apart from
straightness, ovality and imbalance also affect the achievable speed. Deviation from
straightness should not exceed a tolerance of 0.5 mm per metre. The unit of measure
"mm per metre" refers to an even curvature over the stated measured length of 1 metre,
and on no account to a short kink within a length of one metre.
Measuring points
rotated by 90°
Gauge
• The start of the bar must be burr-free for automatic insertion of the material bar into the
lathe spindle and collet. This is necessary as the collets only open a few millimetres.
• The end of the bar must not be bent or distorted by the cutting process.
• Bars must not be contaminated by swarf, sand etc.
• Square or hexagonal material bar, on the other hand, does not require an all-round
chamfer for automatic insertion into the collet, but must have a flat end surface which is
sawn, turned or cleanly sheared off.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 15
turbo 2-20
series 1
Pointing or chamfering of bar ends with circular cross sections is generally not necessary,
since the bar is lifted to the centre of the pusher by the gripper and securely pressed into
the clamping sleeve through the insertion taper.
Chamfering or pointing of the bar end is, however, advisable for bar diameters
approximating to the diameter of the pusher, where the thin-walled clamping sleeve no
longer has an insertion taper.
Bar diameter considerably
smaller than pusher diameter
Bar diameter approximately
pusher diameter
If the guide channel is to be used to its full capacity, the ends of the material bars must be
turned to allow them to be held by the clamping sleeve. It must be noted here that the
pusher can never be larger than the maximum bar diameter to be machined by the lathe.
(see pt. 7.6.2.1)
Bar diameter
= max. nominal passage
Clamping sleeve
Turning off
Standard guide channels
Bar
capacity D
Round ∅
23
20 (23)
20
18 (20)
18
16 (18)
16
14 (16)
15
13 (15)
13
11 (13)
10
8 (10)
7
5 (7)
() Size in brackets for turning the bar end.
Page 16
permitted bar dimensions
Hexagonal AF
17,5
15,5
14
12
11
9,5
6,5
4
Edition 04/12
RM-Nr. 102068
GB/O
Square AF
14
12,5
11
10
9
7
5
3,5
Operating Instructions
turbo 2-20
series 1
1.5 Speed limitations
The maintenance work stated in section 11.1 is to be done regularly.
The possible speed must be set in such a way that damage to
engineering and persons is ruled out.
In cases of danger, the system must be switched off. It may only be
put back into operation after a complete remedy of the cause.
If the possibilities on site are not sufficient, consult an expert (FMB
service engineer).
The loading magazine cannot be run at the full speed of the lathe in all situations.
Speed limitations can become necessary for the following reasons:
•
•
•
•
•
•
•
•
•
•
•
Bent bars
Incorrect choice of guide channel
Incorrect choice of guide jaws
Use of coolant lubricants with a viscosity <100 cSt in the loading magazine
Use of centring sleeves
Material to be processed (e.g. copper, aluminium)
Pipes with uneven wall thickness
Pipes without stoppers (imbalance due to coolant lubricants and chips in the pipe)
Profile material
Exceeding the max. admissible sound level of 80 db(A)
Danger for persons and engineering
Please remember that negative factors add up.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 17
turbo 2-20
series 1
2. Transport for installation and dismantling
Attention!
The lifting and transport equipment used must comply with
current regulations. No persons are allowed within their swivel
and operating range. The operators of the lifting and rigging
equipment must have the necessary qualifications.
The loading magazine is fixed to a pallet for transportation in the original delivery from
FMB. Each support of the loading magazine is attached to the pallet by 2 hexagonal head
wood screws 8x80 DIN 571 and 2 washers A 8 DIN 9021.The pallet may not be removed
until the loading magazine has been placed behind the lathe.
Remove the hexagonal head wood screws to lift the loading magazine off the pallet!
The condition of transport equipment and routes must be such that damage to property or
injury to persons cannot occur. These must be checked before transport, if necessary.
2.1 Preparation of the loading magazine for transport
The following work must be carried out:
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Remove any material bar from the unit (support and channel must be empty).
Move pusher backwards as far as it will go.
Loosen the synchronizing bar from the spindle head (only on long lathe).
Leave the loading magazine standing for at least 8 hours to allow the oil to drain
completely into the oil reservoir.
Drain oil reservoir and dispose of the oil in accordance with statutory regulations.
Separate oil hose connections must be protected against loss of remnant oil.
Switch off the master switch of lathe.
Disconnect the electrical connection to the lathe and all electrical connections
between loading magazine and switch cabinet (remove the connectors).
Depressurize compressed air supply to the loading magazine (branch valve, main
valve etc.)
Vent the loading magazine by closing the shut-off valve on the maintenance unit and
loosen the hose connection.
Suspend the switch cabinet on the beam and fit it on the gibs provided with 4 cheese
head screws, M 8x20 DIN 912, and 4 Nord Lock washers (see point 2.1.1).
Loosen floor attachments (remove the hexagonal nuts of the UPAT plugs).
Attach the parts for crane transport supplied by FMB (see sect. 2.2) and remove all
connections between the loading magazine and fixed parts.
Lift the loading magazine with the help of a crane (s.sect. 2.2) or forklift truck
(s.sect.2.3).
If the loading magazine is to be transported by means other than a crane, it must be
placed on a pallet supplied by FMB and firmly attached to the pallet by at least
4 hexagonal wood screws 8x80 DIN 571 and 4 DIN 9021 washers A 8 through the
existing anchor holes in the support baseplates.
Immediately after the loading magazine has been lifted, the plugs protruding from the
floor must be cut off at floor level by suitable means, or removed from the floor (trip
hazard).
Page 18
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
2.1.1 Transport of the switch cabinet
Attention!
If the switch cabinet remains on the beam during the operation of
the loading magazine, FMB assumes no liability for damage
occurring to the control unit.
The switch cabinet weighs 100 kg. Suitable lifting equipment is to
be used to lower it.
The switch cabinet is only fitted to the beam of the loading magazine for transport.
Before start of operation, it must be placed on the floor in order to avoid damage to the
electronic parts of the controls by vibrations.
The following steps are necessary:
1. Support the switch cabinet with suitable lifting equipment (e.g. elevating truck, fork-lift
truck)
2. Loosen 4 cheese head screws, M 8x20 DIN 912
3. Move the switch cabinet to the side and dismount it
4. Carefully lower the switch cabinet and place it on the floor.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 19
turbo 2-20
series 1
2.2 Transport by crane
The fixing bolts are not designed as load-carrying bolts. The
transport beam must be fitted to the carrier in accordance with the
transport drawing.
Before the magazine is lifted, it must be ensured that the loading
magazine has been prepared in accordance with section 2.1 and
that there are no persons in the hazard zone.
The parts supplied are designed only for the specified load cases.
The oil reservoir must be empty.
Only rigging material suitable for the specified loads and conforming to the regulations
may be used. It must be attached as shown on the transport drawing. (the weight of the
pallet is approx. 200 kg)
The increased weight must be taken into consideration when transporting the loading
magazine by crane with the FMB pallet attached to the magazine. The FMB pallet must be
attached in accordance with sect. 2.1. The attachment points for the slings are shown on
the transport drawing. The transport beams 23-2130-0056-S (2060-779) supplied by FMB
must be fitted in accordance with the drawing.
Hook the slings in the eyebolts (4 eyebolts).
Page 20
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
2.3 Transport by forklift truck
For transport with a forklift truck, the loading magazine must be prepared in accordance
with section 2.1.
An FMB pallet attached to the loading magazine in accordance with section 2.1 must be
used for transport with the forklift truck. A pallet can be ordered from FMB.
The forks should be positioned under the load’s center. If necessary, the center should be
determined anew in order to prevent the load from slipping away. During transport, no
personnel shall stay within the dangerous area.
Mind the weights to be lifted (see section 1.1).
For transport, ascertain centre of
gravity, add weight to front part if
necessary.
Secure magazine to pallet with
4 wood crews 8x80 DIN 571 and
4 washers A8 DIN 9021.
Pallet
Fork spacing at maximum
Pallet
Pay attention to centre
of gravity!
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 21
turbo 2-20
series 1
2.4 Transport by other means
tension belt
Except during transport by crane, the loading magazine must be placed on an FMB pallet
and properly secured (section 2.1).
The loading magazine must be prepared in accordance with section 2.1 before each
transport. A pallet can be ordered from FMB.
For transport by mobile means of transport, (e.g. lorry, container, ship) the pallet with the
loading magazine must also be secured against forces of inertia.
There must not be any persons in the hazard zone during transport..
Page 22
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
RM-Nr. 102068
GB/O
265
246
90
Position Synchronized bar
M 1:10
compressed air
supply 6 bar
292
418
574
85
UPAT-UKA3 M16 anchor bolt (4 per magazine) not included in scope of delivery
1405(2200) 2405(3200) 3005(3800) 3405(4200)
942
Ø20
M16
200
160
670
First insert
1405 – appr. 1165
1655 – appr. 1415
center of channel
center
height
850 - 1120
1121 - 1250
support
2005-306
2031-002
163
Dimensions subject to alteration!
2205(2200) 3205(3200) 3805(3800) 4205(4200)
ATTENTION ! Switch cabinet must be placed on the floor before starting up the loading magazine
950
490
460
Edition 04/12
73
251 202
154.5
137.5
230
108
350
with extended
pusher
235
Operating Instructions
19.5
center height
(see table)
155
Vst 1405: 3215(2200) 4215(3200) 4815(3800) 5215(4200)
Vst 1655: 3465(2200) 4465(3200) 5065(3800) 5465(4200)
turbo 2-20
series 1
3. Installation
3.1 Installation chart
Variants A, D
Page 23
545
156
RM-Nr. 102068
GB/O
155
574
85
154.5
1405(2200) 2405 (3200) 3005 (3800) 3405 (4200)
942
Vst 1405: 3215(2200) 4215(3200) 4815(3800) 5215(4200)
Vst 1655: 3465(2200) 4465(3200) 5065(3800) 5465(4200)
108
235
163
137.5
73
90
Position Synchronized bar
M 1:10
950
Ø20
M16
200
160
2205(2200) 3205(3200) 3805(3800) 4205(4200)
center of channel
545
350
265
418
292
202 251
230
1121 - 1250
850 - 1120
center
height
compressed air
supply 6 bar
246
Dimensions subject to alteration!
2031-002
2005-306
support
ATTENTION ! Switch cabinet must be placed on the floor before starting up the loading magazine
UPAT-UKA3 M16 anchor bolt (4 per magazine) not included in scope of delivery
670
First insert
156
Edition 04/12
490
460
center height
(see table)
19.5
Page 24
1405 – appr. 1165
1655 – appr. 1415
with extended pusher
turbo 2-20
series 1
Variants B, C
Operating Instructions
turbo 2-20
series 1
3.2 Condition of the floor
For data of the lathe, please refer to the documentation. The building intended for the
installation of the loading magazine must be designed to take the loads that occur. The
possible dead loads and operating loads from the loading magazine in conjunction with the
lathe must be taken into account.
Ready for operation, the loading magazine weighs:
● turbo 2-20
loaded with ∅20 / 2200 long
weight approx. 600 kg
● turbo 2-20
loaded with ∅20 / 3200 long
weight approx. 750 kg
● turbo 2-20
● turbo 2-20
loaded with ∅20 / 3800 long
weight approx. 850 kg
weight approx. 900 kg
loaded with ∅20 / 4200 long
The building must be suitable for installing the unit. An expert must be consulted in case of
doubt. Lines of any kind (power, water and other lines) must not be installed underneath
the loading magazine.
3.3 Aligning the loading magazine
Attention!
As alignment of the loading magazine is crucial for correct
functioning, it is recommended that this work should be carried
out by experienced FMB service technicians. Commissioning of
the loading magazine must be carried out in accordance with
section 5.
The loading magazine must be set up in such a way that the centre line of the lathe
spindle is exactly in line with the centre line of the pusher. If these are not in line, the
operation of the loading magazine will present problems (seizure of the pusher with the
spindle; severe vibration; damage to the lathe spindle).
The following work must be carried out:
1. Preassembly of the supports and of the remnant bin with oil pump with the magazine
body (reverse order section 2.1).
2. Rough lateral alignment of the centre of the loading magazine
3. Rough levelling with the help of the M 20 threaded spindle on the supports (use the
soleplates supplied).
4. Mount the capacity adjustment set provided for the loading magazine.
5. The magazine should be set up longitudinally as close as possible to the lathe.
6. Fine adjustment of the magazine, preferably by using optical equipment from Messrs.
Breithaupt in Kassel. To do this, the pusher must be accurately aligned in its forward
and rear positions.
7. Assembly of the guide tube/telescopic tube as enclosed in the loading magazine
manufacturer’s delivery between the magazine and the lathe in accordance with sect.
7.6.5.5 or sect. 7.6.5.6.
8. Mount the limit stop for the pusher (see section 3.9).
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 25
turbo 2-20
series 1
3.4 Fixing to the floor
Attention!
The fastening elements are not included in the scope of delivery.
Load-bearing parts of building structures and other equipment
must not be damaged by the anchors.
Before starting to drill the holes for the anchors, check the floor
for utility lines (electric cables, water, gas lines etc.).These must
not be affected by the drilling. Consult an expert if necessary.
After alignment of the loading magazine with the lathe spindle (section 3.3) it must be
attached to the floor at the relevant places with 4 heavy-duty M 12 anchor bolts (see
installation chart)
The plugs must be inserted in the floor and the loading magazine secured to the floor
using the anchor bolts.
Unevenness in the floor can be compensated using M 16x60 setscrews (4x/support).
If other fixing methods are to be used, they must have the same effect as described
above.
3.5 Compressed air supply
The connecting line must be installed so as to avoid any risk of
injury to persons or damage to property.
The compressed air is connected to a 1/4" hose nozzle on the maintenance unit of the
loading magazine. A shut-off valve must be installed upstream of the loading magazine.
The compressed air connection must satisfy the following parameters:
Pressure:
0.6 MPa – 1.0 MPa
Compressed air consumption:
approx.
4 litres per loading action
approx. 0.3 litres per double stroke of steady rest
The air must be dry and filtered.
Page 26
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
3.6 Electrical connections
Attention!
Check the interface in accordance with the FMB-electrical
documentation and the explanations under section 4 of these
instructions.
Attention!
The correct functioning of the emergency stop device and
electrically monitored covers must be checked before initial
commissioning. (see section 0.7.1 and 0.7.3)
The oil pump must rotate in the direction of the arrow on the
ventilator cover. If the oil pump rotates in the wrong direction, no
oil is pumped into the channel. The direction of rotation can be
changed by reversing to wires in the power supply cable. To
reverse the wires, switch off the master switch on the lathe.
The electrical connection between the magazine and the lathe is given in the enclosed
documentation on page 3 (interface). The plug contact assignment and the operating
voltage are determined by the lathe and are already factory-set.
According to DIN EN 60204 (VDE 0113), the continuous operating voltage must be 100 %
± 10 % of the rated voltage. The frequency must be between 0.99 and 1.01 of the rated
frequency.
When the lathe has been prepared for installation of the loading magazine, the direction of
rotation of the oil pump should be checked after the electrical connection has been
established.
3.7 Preventing hazardous confined spaces
The loading magazine must be installed in such a way that it is always accessible from all
sides for maintenance, repair and other work. All control elements must be accessible and
allow easy operation.
It must be possible to open the switch cabinet at all times. Machines or aggregates
installed in the immediate vicinity must be taken into account. Risk of personal injury or
damage to property must be ruled out during all work on the loading magazine.
3.8 Repairs to the lathe
Adequate space must be available if more extensive repairs of the necessary quality have
to be carried out on the lathe without endangering persons or property. This means that
the loading magazine may have to be removed from its location. In this context, the
transport and installation instructions (sections 2 and 3) must always be observed.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 27
turbo 2-20
series 1
3.9 Forward limit stop for the pusher
Before starting up the loading magazine the forward stroke of the pusher must be limited in
order to prevent it from protruding into the workspace of the lathe. It could otherwise be
seized and set in circular motion, or collide with tools or moving parts, resulting in damage
to the loading magazine and the lathe.
In order to limit the stroke of the pusher, a stop must be fitted in the carriage guide of the
loading magazine.
The following work must be carried out:
(See also the illustration on the next page)
1. Switch the loading magazine to manual mode.
2. Open guide channel.
3. Press the emergency stop key and close the compressed air shut-off valve on the
magazine to depressurize the unit.
4. Open the cover.
5. Remove any material bar from the channel. Empty side storage.
6. Close cover, release emergency stop key, open compressed air shut-off valve and
reset fault.
7. Move the pusher into the collet of the lathe, as shown in the illustration on the next
page.
8. Press the emergency stop key and close the compressed air shut-off valve.
9. Open the cover.
10. Secure the channel using safety bolts (see illustr. section 0.2)
11. Loosen the premounted limit stop at the front using an offset screwdriver (shaft length
12 mm) and push it as far as the carriage. Secure the limit stop again when it has been
positioned (see drawing on next page)
12. Remove safety bolts for channel opener.
13. Close cover, release emergency stop key, open compressed air shut-off valve and
reset fault.
Page 28
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
Lathe collet
Note longitudinal stroke
pusher clamping sleeve
max. extended pusher
Limit stop secured during
installation of magazine
according to max. extended
pusher
Front edge of carriage with
max. extended pusher
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 29
turbo 2-20
series 1
3.10 Synchronizing device
Attention!
The synchronizing device must be set in such a way that the
synchronizing bar is aligned with the direction of movement of
the lathe carriage (spindle head).
With long turning lathes (moving spindle head) the synchronizing bar must be fixed to the
spindle head
turbo 2-20
Synchronized bar
Long turning lathe
Page 30
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Feed toothed belt
Guide bush
Collet
Moving spindle head
Do not touch the moving synchronizing bar! Risk of squashing!
Fixture for attaching the
synchronising bar to the spindle head
-Q6 (synchronising clutch)
Synchronising toothed belt
Synchronising bar
Material bar
If the collet is open, –Q1 is actuated at low pressure in order to hold the material
bar in position when the spindle head is moved.
When the collet is closed, –Q1 is disconnected and –Q6 is actuated.
-Q6 is is linked to the spindle head via the synchronising toothed belt and bar. It is
synchronized with the feed toothed belt and the attached pusher, without applying
any pressure on the material bar.
-Q1 (feed clutch)
Pusher
turbo 2-20
series 1
Diagram of the synchronizing device
Page 31
turbo 2-20
series 1
4. Notes on the interface
Attention!
The standard circuit is adapted to the lathe.
For relay and contact designations as well as plug pin
assignment see electrical circuit diagram.
4.1 Contacts from the lathe to the loading magazine
•
Collet open:
The feed mechanism of the loading magazine is switched on with this contact.
•
End of program cycle, start bar change:
For lathes with program jump, the contact should be ready in the bar starting program
before "Collet open".
•
Lathe ready for operation, release for automatic mode:
Only if this contact is available can the loading magazine be switched to automatic
mode.
•
Loading magazine on (option):
The lathe uses this contact (pulse) to start the automatic mode of the loading
magazine.
•
Protection door closed:
Only if this contact is available can a feed movement be effected by the magazine.
•
Follow-up with SUB-spindle (option):
M command from lathe. If this signal is issued before the collet opens (pushing
command), the next follow up of thrust power/velocity "FOLLOW UP PART" will be
changed over to thrust power/velocity "FOLLOW UP PART WITH SUB-SPINDLE".
•
EMERGENCY STOP lathe:
Potential-free contact from lathe. This contact is integrated into the
Emergency stop circuit of the magazine.
,
Page 32
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
4.2 Contacts from the loading magazine to the lathe
•
No fault bar loading magazine (-K30):
No fault if contact is closed. If there is a fault, contact is opened. If a fault is signalled,
the spindle of the lathe must not be able to move.
•
End of bar change, program start (-K1):
Contact can be transmitted from the magazine as an impulse or as a permanent
contact, depending on the lathe control system. This is a signal to the lathe that the bar
has been inserted into the lathe, or read-in enable, program start.
•
Bar end or program stop (-K9):
Contact can be transmitted from the magazine as a make or break contact, depending
on the lathe.
This contact is made during processing of the last workpiece or after completion of
processing of the last workpiece. This is a signal to the lathe that the material bar has
been finished.
•
Bar end long part (-K91) (option):
When working with two different part lengths, this signal is given at the end of the long
part (enter long part under part length 1). If the signal "BAR END" (–K9) is not given
yet, only short parts will be produced (enter short part under part length 2).
•
Automatic mode on (-K90) (option):
Contact is closed if the magazine is in automatic mode.
•
EMERGENCY STOP loading magazine:
Potential-free contact from magazine. This contact must also be integrated into the
EMERGENCY STOP circuit of the lathe.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 33
turbo 2-20
series 1
4.3 Program suggestion for lathe
Parts program
•
•
•
•
Move turret into position
Collet open (signal to the loading magazine)
Dwell time (pushers follows-up)
Close collet
Processing
Enquiry bar end
Yes / No
(-K9)
Jump - bar starting program
Start of set parts program
Bar starting program
•
•
•
•
•
•
•
•
Move turret into position
Spindle speed (approx. 50 rpm required for profile material)
Collet open
Signal start bar change (end of program cycle)
The automatic lathe must wait until the new material bar has been fed into it and the
signal "K1" is available.
Close collet
Cut off bar´s front
Return to the parts program
Attention!
Page 34
Example is only intended for information purposes!
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
5. Commissioning the FMB loading magazine
5.1 Conditions for commissioning
Attention!
It is advisable to have commissioning carried out by the FMB
Service department.
The loading magazine must be in the original condition as delivered by FMB. All parts
required for operation must be correctly fitted.
5.1.1 Fixing the loading magazine - work based on installation chart
Before commissioning, the loading magazine must be set up and secured in accordance
with section 3.
5.1.2 Connection to the lathe
The alignment and the distance between the loading magazine and the lathe (see section
3) must be checked. The electrical power supply cable must connected in accordance with
the regulations (see section 3.6).
5.1.3 Supply media
The compressed air supply must be guaranteed (see section 1).
The compressed air system of the loading magazine must be checked for leaks before
commissioning. (Soap suds are suitable for this purpose)
There must be no pressure losses.
A pressure of 0.6 MPa must be set at the maintenance unit (see section 11.2).
The pressure switch -B11 triggers a fault message if the pressure falls to less than 0.4
MPa.
5.1.4 Oil filling
Before initial commissioning the oil reservoir must be filled with 50 l of one of the oil types
specified in section 1.3.
Before starting filling, the oil reservoir must be checked for leaks.
The oil hoses and pipes fitted must not be kinked or blocked. The oil flow must not be
obstructed. The return lines must be installed with a steep gradient.
Before commissioning the oil pump must carry out a trial run (30 min.) during which the
following items must be checked:
• Direction of rotation of the oil pump (reverse electrical connections in accordance with
section 3.6 if required)
• Check the oil flow through the guide channel (must be completely flooded after a short time)
• Check the loading magazine for leaks, particularly during extension and retraction of the
pusher, when the guide channel is full of oil.
• Check oil return to the oil reservoir.
When machining tube material cooling water must not get into the oil system of the loading
magazine. Danger that the oil tank will be overflowing!
Secure the tube end against the outflow of cooling water.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 35
turbo 2-20
series 1
5.1.5 Spindle reduction
Attention!
If the diameter difference between the pusher and the interior
diameter of the spindle (tension, pressure tube) or spindle
reduction is smaller than 2 mm, you must expect the pusher to
jam in the spindle.
In order to avoid damage to the lathe and the loading magazine, the interior diameter of
the spindle or spindle reduction must be at least 2 mm larger than the diameter of the
pusher installed in the magazine. Special solutions for smaller diameter differences can be
inquired from FMB.
If smaller capacity adjustment set are used, the spindle must be reduced as a matter of
principle. Spindle reductions can be purchased from the manufacturer of the lathe and
must have a removable fitting flange. Attention is to be paid to the fact that the spindle
reduction can be changed with the loading magazine fitted.
5.1.6 Mechanical adjustment
Before commissioning, the following assemblies must be correctly set for the material to
be processed.
• Guide channel (see section 7.6.4)
• Steady rest (see section 7.2)
• Lateral material storage (see section 7.4)
5.1.7 Training of staff / Study of the operating instructions
Attention!
It is advisable to have the staff instructed and trained by the
FMB service department.
The staff responsible for operation must be trained before commissioning.
The operating instructions form the basis for this.
They must be studied carefully by every user.
Page 36
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
5.2 Switching on the unit for the first time
Mounting of the loading magazine must be complete and all electrical and pneumatic
connections must be properly in place.
The mechanical adjustment work listed in sections 5.1.1 to 5.1.5 must be completed.
The guide tube/telescobic tube (sect. 7.6.5.5 or sect. 7.6.5.6) must be installed.
1. Switch on the master switch at the lathe.
2. Loading magazine ready (Reference starting point for the first part, see lathe operating
manual).
3. Prepare loading magazine. Since the position of the pusher may have shifted during
transport, the PLC travel counter must be set to "0". To do this, press the key ....
(BACKWARD) in manual mode until the pusher is in the rear limit position.
4. Under "POSITIONS" in the "SERVICE" menu the following settings must be made:
"FIRST INSERT TRAVEL", "POSITION FRONT LIMIT", "TRAVEL INTERVAL ON" and
"POSITION REVERSE ROTATION RETURN". To do this, the pusher and clamping
sleeve are moved to the appropriate position using
"FORWARD" or
"BACKWARD" in MANUEL MENU. The display indicates the actual position. This
value has to be entered into the menu section "POSITIONS".
5. The steady and the synchronized clutch function can then be selected in the "PART"
menu under "SELECT".
6. At "PART LENGTH" under "STANDARD" in the "PART" menu, the length of the part
produced on the lathe must be entered in mm. This value is used by the PLC to
calculate the bar end (see section 5.4.3).
7. After switching to the Automatic menu, the steady rest, the brake, the interval in-feed
or the function without gripper can be selected.
8. Using "S.1" or "S.17" the step where automatic mode is to be started is now selected.
The selected step appears in the display.
Start at step 1 if there is a remnant or no material at all in the clamping sleeve.
Start at step 17 if the material bar is in the lathe spindle and is still to be finished.
9. With key
starts up automatic mode.
10. If the bar change has been started without a remnant, the program continues without a
fault message if the key
is pressed in steps 1 to 4.
11. When the unit is switched on at beginning of work, the processing can be continue in
the step in which the unit has been switched off.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 37
turbo 2-20
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5.3 Switching the Unit ON and OFF
5.3.1 Switching the Unit ON
The main switch at the lathe must be in position ON. When the automatic lathe is ready for
operation, automatic operation of loading magazine can be started with the
key in the
AUTO-MENU. The loading magazine then continues its operation at the stepping point
where it was switched off. If, in switched-off condition, any change has been made, switchon should be done in the sequence as described in sect. 5.2.
5.3.2 Switching the Unit OFF
Attention!
Automatic operation should be shut down with the
key,
preferably after the material bar has been changed and after
several workpieces have been produced with closed clamping
devise.
The unit is to be switched off at the lathe.
Self-acting automatic operation switch-off after consumption of the material bar stock or
response of safety devices at the lathe or within the loading magazine.
If the unit is switched off while the motor is still turning, the PLC distance counter must be
set to "0" after the unit is switched on (see sect. 5.2).
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Operating Instructions
turbo 2-20
series 1
5.3.3 Operation with Parts Counter
5.3.3 Operation with Parts Counter
In the MANUAL MENU, select the menu "PART" with the key "PART" and go to the menu
"PART COUNTER/TIME". Touch the numerical display of the desired value and enter the
desired value through the keyboard. Confirm that input with "ENT" and the window gets
closed, then. Leave the menu. Start "Automatic mode". When the desired value has been
reached, the counter cuts-off the automatic mode and the following error message
appears.
FAULT:
PART COUNTER DESIRED-VALUE REACHED
For resetting the actual value in the menu "PART COUNTER/TIME", actuate the key
"CLEAR". As for resetting the desired value, enter either "0" or a new desired value
(0=counter OFF).
As for data input, see also paragraph.
5.3.4 Operation with Programmed OPERATION TIME
In the MANUAL MENU, select the menu "PART" with the key "PART" and go to the menu
"PART COUNTER/TIME". Enter the desired value "Hours" or "Minutes" as described
under "Operation with parts counter" and leave the menu.
After reaching the desired value, the operating time switches off the automatic mode and
the following error message appears:
FAULT:
OPERATION TIME DESIRED-VALUE REACHED
For resetting the actual value in the menu "PART COUNTER/TIME", actuate the key
"CLEAR". As for resetting the desired value, enter either "0" with hours and minutes or the
new desired value (hours and minutes 0=operating time OFF).
As for data input, see also section 6.2.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 39
turbo 2-20
series 1
5.4 Settings on the controller
5.4.1 Setting the cut-off position (end of first insert)
1. From MANUAL-MENU switch to the "SERVICE" menu using key "SERV".
2. In menu item "POSITIONS" enter dimension E in mm for the "FIRST INSERT TRAVEL".
Dimension E is the distance from the switching flap of the starting switch -B7 to the cutoff position.
3. Then inspect the cut-off position in automatic mode.
4. If the position is not correct, enter the corrected value.
5. How to enter values at the control panel is described under sect. 6.
Collet of the lathe
Cut-off tool
-B7
Cut-off length
Long turning lathe
Cut-off length
X = Travel of spindle head/workpiece length
Page 40
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Operating Instructions
turbo 2-20
series 1
5.4.2 Setting the interval feed when processing polygonal material
To improve the feed of polygonal material into the lathe collet, the first forward feed stroke
of the material bar can be controlled in intervals.
Here, the drive unit is switched in return an run forward intermittently.
The interval feed function is switched on with key "INTV" in AUTO-MENU. The travel of the
intermittent forward feed stroke is entered in the submenu "POSITIONS" of the
"SERVICE" menu under "TRAVEL INTERVAL ON".
The start of the intermittent forward feed stroke is computed by the PLC by subtracting the
entered value from the cut-off position. Under "SPECIAL" in the "PART" menu, the run
forward time "CYCLE TIME INTERVAL ON" and the return time "CYCLE TIME INTERVAL
OFF" of the forward feed stroke can be entered. The time value is entered in tenths of a
second.
Collet of the lathe
Start interval feed
Cut-off tool
-B7
Cut-off length
E = First insert travel
I = Interval feed (Travel Interval ON)
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 41
turbo 2-20
series 1
5.4.3 Setting bar end values
Attention!
Before the bar end is set, the PLC travel counter must be set to 0.
(see section 5.2)
Move the pusher with clamping sleeve forwards into the lathe collet.
Enter the actual position minus 3 mm in the menu "SERVICE POSITIONS" with
"POSITION FRONT LIMIT". Then enter the length of the part to be produced in "PART
LENGTH" under menu item "PART STANDARD" menu. The PLC subtracts this length
from the front limit position to work out the bar end value.
If the bar end value is reached or exceeded in automatic mode while parts are being fed,
the stepping chain switches to step 18. The bar end signal is transmitted to the lathe by
the -K9 relay.
"POSITION FRONT LIMIT" does not need to be changed. The "PART LENGTH" value
must always be adapted to the dimensions of the current part.
5.4.4 Setting the "POS.REVERSE ROTATION RETURN" value
During a bar change the pusher moves the remnant at low speed. The motor switches to a
higher speed when the value set for "POS.REVERSE ROTATION RETURN" is reached.
The position at which the remnant left the lathe spindle must be determined. After this
value has been determined, it is entered in "POS.REVERSE ROTATION RETURN" under
"SERVICE POSITIONS" menu.
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Operating Instructions
turbo 2-20
series 1
5.4.5 Follow-up with sub-spindle (option)
Axial feeding in the loading magazine is switched over by means of an M function from the
lathe. The input values "FEED FORCE FOR PART FOLLOW-UP" and
"SPEED FOR PART FOLLOW-UP" are switched over to
"FEED FORCE FOR PART FOLLOW-UP SUB-SPINDLE" and
"SPEED FOR PART FOLLOW-UP SUB-SPINDLE".
The values are entered in the "MENU: PART STANDARD":
FEED FORCE F.PART FOL-UP SUB-SPINDLE:
30%
SPEED FOR PART FOL-UP SUB-SPINDLE:
200 mm/s
M-order contact must be applying prior to the "Collet open" signal.
Workflow:
• Open main spindle collet.
• Release pushing signal "Collet open".
• The loading magazine, pushes the material bar forward in the lathe’s working space in
compliance with the inputs made at the control panel.
• Close main spindle collet.
• The "Collet open" pushing signal will be switched off.
• The lathe machines the part length pushed forward.
•
•
•
•
•
•
•
The sub-spindle moves over the part.
Close sub-spindle collet.
Switch on "Follow-up with sub-spindle" M-function.
Open main spindle collet.
Release "Collet open" pushing signal.
The motor pushes the material bar using the values input for feed force and speed,
using the sub-spindle. The sub-spindle moves back to the beginning of the bar.
As the sub-spindle has finished movement, the "Collet open" pushing signal will be
switched off.
Operating Instructions
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Page 43
turbo 2-20
series 1
5.4.6 Machining of 2 different part lengths (OPTION)
When this option is selected the setting of two different part lengths at the control panel is
possible.
PART LENGTH1:
200 mm
PART LENGTH2:
50 mm
Part length 1 (long part) with possibility of entering
Part length 2 (short part) with possibility of entering
Two BAR END – contacts are reported to the lathe.
Bar end of long part –K91
Bar end of short part –K9
Working process:
If during the follow-up of the part length the BAR END of the "PART LENGTH1" (long part)
is recognized, this is reported to the lathe by relay –K91. The lathe must still process this
part (long part). During the follow-up afterwards the loading magazine pushes the "PART
LENGTH2" (short part) forwards. The lathe must carry out the part program for the short
parts. If now during the follow-up the BAR END of the "PART LENGTH2" (short part) is
recognized, this is reported to the lathe by relay –K9. The lathe machines the last part and
gives the signal "END OF PROGRAM CYCLE, START BAR CHANGE".
If during the follow-up of the part length the BAR END of the "PART LENGTH1" and the
"PART LENGTH2" is recognized simultaneously, the bar change is started after the last
long part is machined.
When working with only one part length, this is entered at "PART LENGTH1" and "0" at
"PART LENGTH2".
Page 44
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GB/O
Operating Instructions
Operating Instructions
GB/O
11
4
9
6
10
POSITION OPEN STEADY
*TRAVEL INTERVAL ON
*POSITION REVERSE
ROTATION
LIMIT POSITION SHORT
PUSHER FRONT
7
8
Machine
length
POSITION MATERIAL
DRAW OFF
*POSITION FRONT LIMIT
*FIRST INSERT TRAVEL
series 1
turbo 2-20
Parameterlist
Edition 04/12
RM-Nr. 102068
1508
1800
200
1350
50
2500
750
standard
values
actual
values
2200
1508
2800
200
2350
50
3500
750
standard
values
actual
values
3200
1508
3400
200
2950
50
4100
750
standard
values
actual
values
3800
1508
3800
200
3350
50
4500
750
actual
values
4200
standard
values
Pusher length 1405
turbo 2-20
series 1
5.5 Parameter list
This list gives the standard parameters.
After installing the loading magazine as described in sections 5.4, determine the values
marked *, and enter them in the control panel and in the following list.
How to enter values at the control panel is described under section 6.
Page 45
turbo 2-20
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TRAVEL INTERVAL ON
FIRST INSERT TRAVEL
5.6 Overview of positions for setting parameters
POSITION FRONT LIMIT
POSITION REVERSE ROTATION RETURN
PUSHER LENGTH
Move to position with front edge of
clamping sleeve
POSITION OPEN STEADY
POS. REVERSE ROTATION
LOW
(fixed value Pos. 11 + 450 mm)
Gripper blades
POSITION MATERIAL DRAW-OFF
Position carriage
on
limit stop
LIMIT POS. SHORT PUSHER
FRONT
POS. MATERIAL IS PRESSED UPON
(fixed value 22 mm)
POSITION REAR LIMIT
(Schalter –B1)
Limit stop
Page 46
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Operating Instructions
turbo 2-20
series 1
6. Control panel
1.1
1
4
3
4
2
With the function key (1) the switching status „ON“ is indicated by the black highlighted
function (1.1). As for the function keys (2) in the touchscreen the switching status is
displayed by a black highlighted background.
The signal stati (3) of the release, protective door and collet are for information purpose
only.
The menu keys (4) in the touchscreen enable paging.
Attention !
Operating Instructions
Depending on the countries the measure can be selected either
in "mm" or "INCH".
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6.1 Menu levels on the control panel
MANUAL-MENU
Draw remnant off and eject
Draw remnant off and eject it. Insert a new bar in the channel and draw it up.
Option:
When selecting "SELECT BRON MODE: WITHOUT FIRST INSERT" in the menu
"PART SELECT" the function BRON is switched off after pressing the new bar in.
When selecting "SELECT BRON MODE: WITH FIRST INSERT" the new bar is pushed
to the cut-off position in the lathe after pressing in. Thereafter the function BRON is
switched off. Now the automatic mode can be selected and the loading magazine can
be started in step 15. The "End of bar change, program start" signal (-K1) is given.
Remove long bar
Guide channel open / close
Pusher swing in / out
Select AUTO-MENU
Steady on / off
Gripper blades close / open
Select menu "PART"
Select menu "SERVICE"
Remnant flap open / close
Oil pump on / off in manual operation
Run forward with low speed;
Run backward with low speed;
and
with high speed.
and
with high speed.
Select menu "FMB"
Select menu "SETUP"
Select menu "FAULTS"
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Operating Instructions
turbo 2-20
series 1
AUTO-MENU
Standard:
AUTO-MENU
9999.99
CURRENT POS.:
± 9999.99
BAR LENGTH:
AUTOMATIC STOPPED
mm
FF: 99 %
STOP LATHE / START BAR CHANGE
STEP:
FAULT
99
CLEARANCE:
OFF
PROTEC.DOOR:
OPEN
COLLET:
CLOSE
MANUAL-
MENU
S.1
S.ST
S.17
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
TEST RUN!
STDY
INHE
ST-L
OILB
INTV
BRAK
W-OG
Interval insert on / off (for polygonal material)
Steady as aid to insertion on / off
Without gripper, disposal of remnant by lathe
(For release of the editing function ( ), press the key. After
3 seconds of waiting time have elapsed, press the key (
) another time.
The input time amounts to appr. 8 seconds ( ). Then the function key gets
automatically disabled ( ).
Select manual menu
Steady on / off
Oil blow-off device on / off (Option)
Brake on / off, (release and editing as with the function W-OG)
Lathe steady on / off
Select step 1 (return)
Select step 17 (parts production)
Switch step-by-step
Run forward with low speed;
and
Run backward with low speed;
with high speed.
and
with high speed.
Test of the magazine is running. Display only!
Select menu "FAULTS"
Operating Instructions
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Page 49
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6.1.1 Switching between operating levels
a) Switch from MANUAL-MENU to AUTO-MENU by pressing key AUTO-MENÜ.
b) Switch from AUTO-MENU to MANUAL-MENU by pressing key MANUAL-MENÜ.
Pressing the
page.
key in MANUAL-MENU and AUTO-MENU, calls up the appropriate Help
MANUAL-MENU:
AUTO-MENU:
Page 50
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Operating Instructions
turbo 2-20
series 1
6.2 Operating menu: PART and SERVICE
Attention !
The parameters in the menu SERVICE should only be changed
by qualified maintenance personnel or a FMB service
technician.
Call up the menu with the appropriate key.
Start editing of the parameters in the menus "PART" and "SERVICE" by touching the
respective numerical display or text to be selected.
Enter numerical parameters through the numerical board.
To select text parameters touch the text box.
As for the function keys in the menus "FMB" and "SETUP", the switching status "ON",
respectively the selection are alternatingly indicated in black highlighted manner.
Leave the Menus "PART", "SERVICE", "FMB" and "SETUP" with the key "MANUAL
MENU".
Operating Instructions
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Page 51
turbo 2-20
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6.2.1 Menu: PART
6.2.1.1 Menu: PART STANDARD SETTINGS
Function of the touchkeys:
Switching to MENU: PART STANDARD
Switching to MENU: PART SPECIAL
Switching to MENU: PART SELECT
Switching to MENU: PART COUNTER
Leave menu: PART, back to MANUAL-MENU
Page 52
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Operating Instructions
turbo 2-20
series 1
6.2.1.2 Menu: PART SPECIAL SETTINGS
MENU: PART SPECIAL
page 2
POSITION OPEN LATHE STEADY:
9999.99 mm
SWITCHING POSITION LATHE:
9999.99 mm
POSITION OIL PUMP ON:
9999.99 mm
POSITION OIL PUMP OFF:
9999.99 mm
MAX. BAR RETURN:
9999.99 mm
999.9
TIME OIL BLOW-OFF DEVICE ON / OFF:
PAGE 1
MANUAL-
MENU
Operating Instructions
PAGE 3
STANDARD
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s
SPECIAL
SELECT
COUNTER
TIME
Page 53
turbo 2-20
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6.2.1.3 Menu: PART SELECT
Selection options:
SELECT FIRST INSERT:
STANDARD
TO STOP
SELECT BRON MODE:
SELECT W-OG:
SELECT STEADY:
WITHOUT FIRST INSERT
WITH FIRST INSERT
WITHOUT PRESS UPON
WITH PRESS UPON
WITH PRESS UPON + BAR CHANGE
GUIDE STEADY
STEADY CLOSE TILL -B7
STEADY CLOSED WHEN PUSHING
SELECT LATHE STEADY:
ROLLER STEADY
JAW STEADY
JAW STEADY CLOSED WHEN PUSHING
SELECT SYNCHRO CLUTCH:
SELECT SPECIAL INSERT:
WITHOUT SYNCHRO
WITH SYNCHRO
WITH SYNCHRO +S.19
ON / OFF
6.2.1.4 Menu: PART COUNTER / TIME
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Operating Instructions
turbo 2-20
series 1
6.2.2 Menü: SERVICE
6.2.2.1 Menü: SERVICE POSITIONEN
Function of the touchkeys:
Switching to MENU: SERVICE POSITIONS
Switching to MENU: SERVICE FEED FORCE
Switching to MENU: SERVICE CURRENT POSITIONS
Switching to MENU: SERVICE SPEED
Leave MENU: SERVICE, back to MANUAL-MENU
Operating Instructions
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Page 55
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6.2.2.2 Menu: SERVICE FEED FORCE
6.2.2.3 Menu: SERVICE SPEED
Page 1
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Operating Instructions
turbo 2-20
series 1
6.2.2.4 Menu: SERVICE CURRENT POSITIONS
6.2.2.5 PLC STATUS: INPUTS
Switched-on inputs are highlighted with a black
circle ( ).
6.2.2.6 PLC STATUS: OUTPUTS
Switched-on outputs are highlighted with a
black circle ( ).
Operating Instructions
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turbo 2-20
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6.2.3 Menu: FMB
This menu is accessible for the FMB-service only.
6.2.4 Menu: SETUP
Enter activation code "222" in the input field.
Display: Control panel, program name and creation date
Display: PLC, program name and creation date
Screen brightness
Dimension unit selection, mm or inch
Operator language selection
Acoustic signal on / off
Page 58
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Operating Instructions
turbo 2-20
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7. Assembly description
7.1 Support structure
The assemblies carrier, supports and remnant oil reservoir form the support structure.
All parts of the loading magazine are mounted on the beam. This in turn is bolted to the
height-adjustable supports.
Each support is height-adjustable using an M 20 threaded spindle for each support.
Unevenness in the floor can be compensated by 4 M 16x60 setscrews, which must be
located in the soleplates supplied.
After adjustment the supports are fixed to the floor using M12 anchor bolts (see section 3).
The oil reservoir has a capacity of 50 l of oil (see sect.1 and 5) and is installed on the
beam of the loading magazine. It accommodates the oil pump and the shut-off valve for
the oil system.
The switch cabinet is positioned separately under the loading magazine. The PLC is
installed there.
7.2 Steady rest
Before opening the cover, press the EMERGENCY STOP key and
close the compressed air shut-off valve in order to ventilate the unit.
The steady rest guides the material bar between the guide channel and the guide tube. It
opens to admit the pusher, which usually has a larger diameter than the material bar itself.
The position for opening is entered in the MANUAL-MENU "SERVICE" under
"POSITIONS" "POSITION OPEN STEADY".
In closed position, the guide jaws are pressed together.
The open position of the steady rest is to be set so that the pusher can pass through but is
still guided somewhat by the guide jaws. For this purposes the adjusting screw is fitted
(see illustration).
Fixing screw
DIN 912
Adjusting screw
Guide jaws
Cover
Operating Instructions
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turbo 2-20
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Changing the guide jaws
The guide jaws of the steady rest must be matched to the diameter of the material.
Selection must be made in such a way that the diameter of the jaws is not greater than the
lathe spindle diameter, but 1 mm to 2 mm greater than the material to be machined.
To replace the cylinder bolts they must first be loosened.
Guide jaws are available in the following sizes:
Page 60
Guide Jaws
Ident no.
Material Ø to be machined
D24
2060-096
21 - 23 mm
D22
2060-095
20 - 21 mm
D20
2060-094
18 - 19 mm
D19
2060-093
16 - 18 mm
D17
2060-092
13 - 16 mm
D15
2060-091
13 - 14 mm
D14
2060-090
12 - 13 mm
D13
2060-089
11 - 12 mm
D12
2060-088
9 - 11 mm
D10
2060-087
7 - 9 mm
D8
2060-086
6 - 7 mm
D7
2060-085
5 - 6 mm
D6
2060-084
3 - 5 mm
D4
2060-083
2 - 3 mm
D2,5
2060-082
1,5 - 2 mm
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Operating Instructions
turbo 2-20
series 1
7.3 Gripper - Function and Mode of Operation
By means of the gripper it is possible to push the swung-in material bar, before machining,
into the clamping sleeve of the pusher and to remove the remnant therefrom.
The gripper is actuated via a pneumatic cylinder.
The closing motion is made through a guide plate and the bars are raised to the center of
the spindle automatically.
For draw-up, the material bar, or, in case of draw-off, the remnant is transported into the
gripping position between the gripper blades. Then the gripper is closed and the pusher’s
clamping sleeve is slid, by means of the main drive, on to the material bar for draw-up and,
for draw-off, pulled from the remnant.
To prevent shearing off when processing small diameters, the gripper force can be
regulated by means of an exhaust air restrictor at the valve block.
By adjustment of the gripper blades at the top, the centre of the spindle can be readjusted.
Adjustment via long hole
Operating Instructions
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Page 61
turbo 2-20
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7.4 Lateral material Storage
In the lateral material storage, the material bars are stocked up and separated for bar
change.
The separating device consists of the holding-down device and the spring-loaded pressure
plate, which are mounted over the length of the bar.
Holding-down device
Lever
Pressure plate
Cover for channel
7.4.1 Setting the material diameter
To set the required material diameter, 6 - 10 bars of the material to be processed must be
mounted.
The holding-down device must be set in such a way that the first bar falls in when the
channel is opened and the stored bars are securely held by the clamp.
The stored material bars must be able to follow on reliably when the channel is closed.
The clamp is released by turning the clamping lever, and the holding-down device can be
set according to the material diameter to be processed.
Page 62
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Operating Instructions
turbo 2-20
series 1
7.5 Drive
The pusher and thus the material bar are pulled by a toothed belt. A drive motor with a
clutch and brake is mounted at the tail end, and the head end has an incremental shaft
encoder which informs the PLC of the position of the pusher.
7.5.1 Clutches
The feed clutch -Q1
The feed clutch -Q1 (electromagnetic clutch) transmits the movement from the feed motor
-M1 to the toothed belt where the pusher is mounted. It limits the torque to be transmitted.
The clutch is actuated by the PLC via an amplifier module (-TF1).
The feed force of the clutch is dependent on the direct voltage applied and can be set on
the control panel in the "MANU-MENU: PART STANDARD SETTINGS" and in the
MANUAL-MENU "SERVICE" under "FEED FORCE".
For the exact setting options refer to section 6.1.3.
Synchronizing clutch -Q6
(Connection to lathe with movable spindle stock)
The synchronizing clutch -Q6 is an electromagnetic single-disk clutch.
With closed collet, it transmits the movement of the spindle head to the toothed belt of the
loading magazine via a rigid mechanical connection. Thus, pusher movement is
synchronized to the material bar without exerting any pressure on the material bar.
In "SERVICE" menu under "POSITIONS" are the function "WITHOUT SYNCHRO", "WITH
SYNCHRO" and "WITH SYNCHRO+S.19" that can be selected. In step 19 when the collet
is open, the material bar can be slid again with the synchronization.
When selected "WITH SYNCHRO" the synchronization clutch will be switched on in step
16-19 in alternation with the feed clutch.
7.5.2 Motor
7.5.2.1 Motor with worm gear
The motor has a deep-drawn sheet steel case and shell-type magnets. The seal between
the motor and the gear cases guarantees a watertight connection. The rotor shaft has a
plain bearing on the motor side and a ball bearing on the gear side. A separate
compartment in the gear case holds the interference filter. Two flat plugs of different sizes
ensure protection against polarity reversal.
7.5.2.2 Speed regulating rheostat
This speed regulating rheostat was specially developed for low-voltage electric motors. On
account of the pulse width control, which works with an adjustable frequency between
600 Hz and approx. 2 kHz, the power loss remains low even at low speeds. Through the
use of a new type of MOSFET transistor with integrated current sensor, the output current
can be continuously adjusted from 0 to 10 A (without external current sensor resistor)
using a trimming potentiometer, thus protecting the electronics if the motor should
suddenly block. The adjustment range of the motor ranges from a complete standstill to
maximum speed.
Operating Instructions
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turbo 2-20
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Trimming potentiometer
Attention!
The trimming potentiometers are factory-set by FMB for
commissioning and should not be readjusted on site!
There are 2 trimming potentiometers on the board.
P1 for frequency adjustment and P3 for current limiting.
When a consumer is connected, potentiometer P3 is set in such a way that at the
maximum current of 6 A, for which this circuit is designed, current limiting begins to take
effect (the motor then does not pull through fully). Set potentiometer P1 in such a way that
a connected motor shows the smoothest running.
The speed setting is made by the PLC via an analogue voltage input. The speed can be
entered at the control panel. See section 6.1.3 for settings.
7.5.3 Synchronous belt drive
The pusher is moved with the help of the toothed belt drive unit.
The motor with clutch is mounted at the tail end, and the hand crank and shaft encoder are
fitted at the head end.
The toothed belt is thermally stable from -30 to +80 ºC, and resistant to petrol and oil. The
efficiency rating can be up to 98%.
Even in continuous duty there is no stretching of the tensile insert.
The material polyurethane is hydrolysis-resistant, non-ageing and stable to ozone and
sunlight.
7.5.4 Crank
Before the hand crank is fitted, the emergency stop key must be
pressed and the compressed air valve at the loading magazine
must be closed to depressurize the unit.
While the hand crank is fit, neither unlock the emergency stop
nor open the compressed air shut-off valve. In addition, firmly
plug the hole in the cover, when the hand crank is not used
(plug: FMB-Ident.-Nr. 2044-508).
Attention!
For a correct working of the PLC-travel-counter the hand crank
is only used with the actuated control system.
Preferably, electrical manual feed should be used. The hand
crank may only be used in exceptional cases.
In case that the pusher was moved by the hand crank while the
control system was switched off, the PLC-travel-counter must
be reset to "0" (see section 5.2)
For maintenance and adjustment work, a hand crank can be fitted to the clutch mounted at
the head end of the toothed belt drive unit. The hand crank is included in the delivery as
loose part and has to be removed after use.
Page 64
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GB/O
Operating Instructions
turbo 2-20
series 1
7.6 Refitting the magazine
7.6.1 Pusher
The pusher allows the bar end to be moved to behind the collet of the lathe. The tip is
fitted with a bearing insert on which the clamping sleeve is mounted with a locking bolt.
This collet must be changed depending on the material. Its tail end is connected to the
carriage of the belt drive unit by means of a lug.
Pusher
Mounting of the pusher for D ≥ 10 mm
Guide gib
Tallow drop screw with
Retaining ring (3 x)
Insert bottom
Tallow drop screw with
Retaining ring (2 x 3 St)
screwed from below
Carriage
Flag
Illustr.: Pusher with flag, tappet and carriage (FMB turbo 2-20 variants AD)
7.6.2 Clamping sleeves/clamping mandrels/centring sleeves - Function and use
For bar end guidance, clamping sleeves, clamping mandrels or centring sleeves are
required at the pusher.
The clamping sleeves, clamping mandrels and centring sleeves are attached to the
rotatable bearing insert of the feed bar by means of a locking bolt. (With the feed bar D7
the clamping sleeve is screwed in using a thread.)
In the event of frequent spindle head movements by the lathe, the material bar may pull
itself out of the clamping sleeve. We recommend the use of turned bolts for the bearing
inserts.
Clamping sleeve
Bearing insert
Bolt for bearing insert
When ordering these bolts for bearing inserts please quote the feed bar diameter and the
clamping sleeve designation SHK as well.
Bolt for bearing insert
ID No.
Drawing no.
D 10
2016-531
23-2118-3841-E
D 12
2016-532
23-2118-3842-E
D 15/18
2016-533
23-2118-3843-E
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 65
turbo 2-20
series 1
7.6.2.1 Working with clamping sleeve
Spindle passage
For hexagonal as well as square materials and, in particular, brass as well as light metal
profiles machining, clamping sleeves with punched in octagons or bihexagons should be
used.
It is possible to use clamping sleeves with external diameters smaller than the nominal
capacity. For the difference between the spindle passage Ds and the clamping sleeve
outer diameter D, the following applies:
"X" must be smaller than the material diameter
If the feed bar loses the material bar being worked on, the material can slip between
spindle and feed bar "X" and damage the spindle.
The use of a spindle reducer is recommended. (see Point 5.1.5)
When the feed channel is to be used up to full passage, the ends of the material bars
should be turned off for clamping sleeve reception. The diameter (H11) of the turn can be
based on an existing clamping sleeve. The turn is to be at least 55 mm in length and have
a truth of running of <0.1 mm.
bar diameter
= max. nominal passage
clamping sleeve
Example of order:
Turning off
Clamping sleeve SHK D 10 / 7.0
clamping diameter
given in 1/10 mm (here: 7.0 mm)
clamping sleeve outer diameter
(here: 10 mm)
= capacity adjustment setnominal diameter
Example of order:
Pusher diameter (mm)
bars up to ∅ (mm)
7
10
5,0
8,0
13
15
16
18
11,0 13,0 14,0 16,0
20
23
18
20
We exclusively recommend FMB clamping sleeves.
The necessary truth of running of the clamping sleeves, measured by the material bar
clamped, must be at least 0.1 mm. Possible speeds are decisively dependent on this.
Page 66
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RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
7.6.2.2 Working with clamping mandrel
Achtung !
Imbalance is to be taken into account when selecting the speed.
Clamping mandrels enable tube materials to be guided at their inner diameters.
The clamping mandrel used must have a truth of running of at least 0.1 mm. The pipe
end is to be closed with a stopper so that the lubricant of the lathe and the oil in the
loading magazine do not mix.
To avoid an imbalance due to coolant lubricants and chips, the use of a stopper on the
pipe end in the lathe is also recommended. It is pushed into the tube in processing by the
part length in question with a suitable tool of the lathe. Imbalance due to uneven walls are
to be taken into account when selecting the speed.
tube
7.6.2.3 Working with centring sleeve
Attention!
Centring sleeves cannot be used on movable spindle stock
lathes.
Attention!
As the material bar is not guided sufficiently when a centring
sleeve is used, a reduction in speed must be expected.
Attention!
When working with the centring sleeve, the remnant must be
removed forwards (by the lathe)!
If there is a significant difference between the material diameter
and the channel diameter used, a reduction of the maximum
possible speed must be expected.
Centring sleeves are used when material bars with approximately the guide channel
diameter are processed and no high demands are made of the necessary speed. The
difference in diameters may not exceed 1 mm. The bar end on the loading magazine side
must have a central chamfer which fits into the centring sleeve. The chamfer is to be at
least 10 mm x 45° and have a truth of running of <0.1. The remaining piece can be
pulled out to the back.
It is pushed into the lathe in a change of bars.
This function can not be used with long turning lathes !
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 67
turbo 2-20
series 1
Settings at the control panel
Function "W-OG" (without gripper, front removal of remnant) in the automatic menu.
(see sect. 6.1.7)
7.6.2.4 Collet of the lathe
When the material is being fed in, it is possible that the bar could become tilted at the
insertion taper of the collet. If this type of tilting occurs at the collet, the insertion taper of
the collet is too large and should be reworked (see drawing).
After processing
the collet
Before processing
the collet
Page 68
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
7.6.3 Guide tube/Telescopic tube between loading magazine and lathe
7.6.3.1 Lathe with movable spindle stock
Before commissioning, the specified guide tube/telescopic tube
shall be mounted between lathe spindle and loading magazine.
During loading magazine operation, the guide tube/telescopic tube
must be present.
Lathes with movable spindle stocks must not be operated without
telescopic tubes or fixed spindle reductions projecting from the
loading magazine into the spindle of the lathe.
Attention!
Mount the telescopic tube in accordance with the drawing
enclosed. By stating the respective order number, this drawing
can be requested from FMB.
Attention!
see section 5.1.5 "Spindle reduction"
The guide tube/telescopic tube bridges the distance between the front end of the loading
magazine and the lathe’s spindle end. It serves as protective cover and prevents rotating
parts from being ejected.
The inner diameter of the guide tube/telescopic tube depends on the feed bar built-in.
Fixed spindle reduction:
Should mounting of a telescopic tube be impossible, the lathe can be operated with a fixed
spindle reduction. For that purpose, the loading magazine guide tube contained in the
capacity adjustment sets slid into the spindle. Hence, the maximum possible bar diameter
is limited.
The following should be noted:
•
•
•
•
The guide tube’s outer diameter must be 1 to 2 mm smaller than the spindle’s inner
diameter.
The length of the guide tube should be fixed such that it bridges the gap between
loading magazine and spindle, whilst excluding any spindle destruction.
The guide tube’s inner diameter must be 2 mm bigger than the diameter of the feed bar
built-in.
The smallest wallthickness of the guide tube should be 2 mm at least.
Following steady (option):
In some lathes it is possible to attach a following steady. Such following steady improves
the material bar’s vibration and guidance behaviour. It is mounted directly at the end of the
spindle stock and guides the material bar during machining.
Since not all lathes are fitted with suitable mounting fixtures, any attachment needs to be
clarified with FMB in advance.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 69
turbo 2-20
series 1
7.6.3.2 Lathe with fixed spindle stock
Before commissioning, the specified guide tube shall be mounted
between lathe spindle and loading magazine. During loading magazine
operation, the guide tube must be present.
The guide tube bridges the distance between the front end of the loading magazine and
the lathe’s spindle end. It serves as protective cover and prevents rotating parts from being
ejected.
The guide tube’s inner diameter depends on the feed bar built-in. When installing the
loading magazine, the length of the guide tube must be taken into account (see sect. 3). It
should be fixed such that there is a gap of 5 mm at maximum between the end of the lathe
spindle and the guide tube’s front end or such that the guide tube projects into the lathe
spindle. This gap must not be within operator’s reach!
7.6.4 Selection and reconstruction, guide channel
The guide channel consists of reducing inserts mounted in support profiles to dampen
vibration during machining. This effect is supported by the oil filling and the feed bar with
its rotating clamping sleeve at the end of the material bar.
After your technical situation has become known, FMB will produce a corresponding
suggestion for equipment.
The loading magazine is fitted and delivered with the guide channel diameter ordered. By
using capacity adjustment sets, it can be converted to other passages as well.
To this effect, the following work steps are necessary:
•
•
•
reducing inserts replacement
feed bar replacement
guide tube replacement/reduction in the telescopic tube
Capacity adjustment set order example:
3200 / 1405 / 13
nominal guide channel passage
(information on insert)
pusher length L
length of lateral material storage
(max. bar length: 3200 mm)
Page 70
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
7.6.5 Removing and fitting of capacacity adjustment set
Unit must be free of any pressure and tension!
The refitting of the loading magazine can be started as follows if there is no material
or remnant in.
1.
2.
3.
4.
Select MANUAL-MENU.
Press the key "ROFF". ("ROFF" = Draw remnant off)
The magazine draws the remnant off.
When no remnant has been withdrawn, the pusher must be moved into the rear limit
position via key
(BACKWARD) in MANUAL-MENU.
5. Swing out pusher and open guide channel.
6. Press emergency stop key and close the compressed air shut-off valve to depressurize
the unit.
7. Open cover, secure guide channel and pusher with safety bolt. (see illustr. section 0.2)
The refitting can be started.
If there is any long bar in the loading magazine it must be removed out of the
channel or clamping sleeve. The following worksteps are necessary:
1.
2.
3.
4.
5.
Select MANUAL-MENU.
Press key "BOFF".
After the REAB-program has been executed, the touchkey changes from black to white.
Swing out the pusher and open the guide channel.
Press emergency stop key and close the compressed air shut-off valve to depressurize
the unit.
6. Open cover, secure guide channel and pusher with safety bolt. (see illustr. section 0.2)
7. Remove material bar out of the guide channel.
The refitting can be started.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 71
turbo 2-20
series 1
7.6.5.1 Replacement of pusher
Attention !
To avoid any problems when pusher swings in, the pusher must
be installed and adjusted in such a way that the flag in the
safety device can be guided exactly.
Cover for
channel front
Cover for
channel rear
Spring cotter pin
Pusher
Lifting plate
front
Lifting plate
rear
Pusher
Safety
flag
1.
2.
3.
4.
Flag
Draw off spring cotter pin, rear and hold pusher.
Draw off lifting device, rear and hold pusher.
Lift pusher out of lifting device, front and remove to the bottom.
Draw off spring cotter pin, front and lifting device.
Page 72
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
7.6.5.2 Replacement of short pusher
Short
pusher
Flag for short
pusher
Fixing screws
1. Loosen the fixing screws for the flag on the carriage and remove short pusher.
7.6.5.3 Replacement of insert at remnant flap
Insert remnant flap
Lever safety insert
1. Tilt lever for safety insert to rear.
2. Push insert appr. 5 mm across the lever.
3. Raise insert out to the top.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 73
turbo 2-20
series 1
7.6.5.4 Replacement of inserts
Attention!
If the inserts are not assemled in an appropiate way a damage of
the loading magazine may be caused.
Attention!
After installing the pusher it is essential to check the safe
actuation of the switch –B1 in the rear limit position. In the rear
limit position of the pusher the current position should be
between 0.0 mm and -1.5 mm.
1. Remove top inserts with insert tool.
2. Release bottom inserts and remove them with insert tool
3. Fit, align and secure the new lifting device, short pusher, inserts and the pusher.The
position of the insert must be ensured. (see Illust.: Refitting the magazine)
4. Remove safety bolt and close cover.
Page 74
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
7.6.5.5 Replacement of guide tube
1. Open clamping piece and remove guide tube.
2. Release the sets screws in the acceptance for the guide tube with sleeve and reducing
ring and remove them.
3. Install the new guide tube with sleeve and the reduction in the reverse order.
7.6.5.6 Replacing the reduction inserts in the telescopic tube
Attention!
Attention!
The possible reduction inserts are included in the telescopic
tube delivery. When replacing, mind the drawing enclosed. This
drawing can be requested from FMB by stating the
corresponding order number.
Install all inserts and parts of the capacity adjustment set in
such a way that the function of the loading magazine is not
limited.
1. Open clamping piece, push the telescoping tube together and mount the reduction in
accordance with the drawing enclosed.
2. Release the emergency stop key and open the compressed air shut-off valve on the
loading magazine to pressurize the unit.
3. Press "CHAN" key. The guide channel closes.
4. Press
key in order to reset the error message "GUIDE CHANNEL NOT CLOSED".
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 75
Page 76
Edition 04/12
RM-Nr. 102068
GB/O
Insert bottom 400
Remnant flap
4200/3800/3200/2200
Insert bottom 1000
4200/3200
Insert bottom 600
3800
Insert top 1137
3800/3200/2200
Insert top 1000
4200
Insert bottom 885
3200/2200
Insert bottom 1000
4200/3800
Insert top 1137
4200/3800/3200/2200
Insert bottom 90
4200/3800/3200/2200
Insert bottom 735
4200/3800/3200/2200
Pusher
Flag pusher
Lifting plate
Insert bottom 600
4200/3800/3200/2200
Insert bottom 90
4200/3800/3200/2200
Tappet/
Flag tappet
Guide jaws/
Insert top 600
3800
Insert top 1137
4200
Guide tube / telescoping nose
Insert bottom 885
4200/3800
Insert top 1137
4200/3800/3200
Insert top 274
2200
turbo 2-20
series 1
7.6.5.7 Illustration: Refitting the magazine
Operating Instructions
turbo 2-20
series 1
7.6.5.8 Installation Example: Capacity adjustment set D13/1405/2200-3200-3800-4200
(other capacity adjustment sets available on request)
Pos.
Designation
pce.
D13/2200
pce.
D13/3200
pce.
D13/3800
pce.
D13/4200
1
Pusher
1
1
1
1
2
Tappet
1
1
1
1
3
Flag pusher
1
1
1
1
4
Flag tappet
1
1
1
1
5
Insert, bottom
600
1
1
2
1
6
Insert, bottom
885
1
1
1
1
7
Insert, bottom
735
1
1
1
1
8
Insert, bottom
90
2
2
2
2
9
Insert, bottom
1000
-
1
1
2
10
Insert
Remnant flap
400
1
1
1
1
11
Insert, top
1137
1
3
3
3
12
Insert, top
1000
1
-
-
1
13
Insert, top
600
-
-
1
-
14
Insert, top
274
1
-
-
-
15
Lifting plate
2
2
2
2
16
Guide jaws
2
2
2
2
17
Guide tube/telescopic tube
1
1
1
1
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 77
turbo 2-20
series 1
7.7 Oil Supply
Refill oil only when loading magazine is switched off and after a
waiting time of 1 hour!
The volume of the inflowing oil can be regulated with the shut-off valve that is mounted at
the submerged pump. The oil should be supplied in the absolutely necessary volume only.
For correct oil volume setting, the shut-off valve is turned roughly into "zero" position and
then opened until smooth running is ensured.
The area where the oilpump shall be switched on in the automatic mode, can be entered in
"PART SPECIAL" (page 2) menu under "POSITION OIL PUMP ON" and "POSITION OIL
PUMP OFF". The "POSITION OIL PUMP ON/OFF" refers to the position of the pusher.
For smooth running of the loading magazine, oil viscosity is decisive, too (see Technical
Data).
Page 78
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
8. Functional Description
8.1 Mode of Operation
The magazine is loaded from the lateral storage through bar separation up to the guide
channel.
When the feed bar is swung out and the guide channel opened, the material bar falls into
the guide channel, which will close then.
With the feed bar still swung out the short pusher moves forward and positions the bar end
in the gripper position. The feed bar swing in once the short pusher has moved to its rear
limit position again.
The gripper blades close, the feed bar moves forward and the clamping sleeve is pushed
onto the end of the material bar. (Clamping mandrels are used to clamp tubes internally.)
Forward feeding begins.
When the pusher reaches the cut-off position, it stops and a signal is sent to the lathe.
Machining begins.
The precise bar positioning required for machining is guaranteed by an oil-filled guide
channel and a guide steady rest between the lathe and the guide channel.
The bearings integrated in the pusher allow high-speed operation. The guide
tube/telescopic tube fixed to the front part of the magazine also acts as a spindle reducer.
The loading magazine is synchronised with the lathe. After the last possible workpiece has
been machined, the operation of the lathe is stopped with its clamping device open.
The pusher moves back to remove the remnant. If the remnant is under the gripper blades,
the pusher stops. The gripper blades close and the pusher returns to its rear limit position.
This allows the remnant to be withdrawn from the clamping sleeve. If no remnant has been
brought back, an error message is given and the unit switches itself off. After the remnant
has fallen into the remnant bin, a remnant check is carried out using the gripper and switch
-B13. If no fault is indicated, the guide channel opens to accept a new material bar. The
cycle then begins again.
If a fault occurs in automatic mode, automatic operation is suspended. The error message
is passed on to the lathe. The relay -K30 drops out. The error message is shown in the
display of the control panel.
The error messages are listed in the following section.
When the fault has been remedied and the error message cleared by pressing the key
,
the current step is displayed again and automatic operation can be resumed by pressing
key
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 79
turbo 2-20
series 1
8.2 Automatic Workflow
Hereinafter, automatic operation with switched-on gripper function is depicted.
If the gripper function is disabled, the conditions for continued processing differ slightly at
some steps.
Display Information
AUTO STEP 1:
RETURN
AUTO STEP 2:
STOP, CLOSE GRIPPER BLADES
AUTO STEP 3:
GRIPPER BLADES CLOSED, RETURN
AUTO STEP 4:
STOP, OPEN GRIPPER BLADES
AUTO STEP 5:
CLOSE REMNANT FLAP
AUTO STEP 6:
CLOSE GRIPPER BLADES
AUTO STEP 7:
OPEN GRIPPER BLADES
Page 80
Step Function
Slow return run ("SPEED FOR RETURN FROM
SPINDLE") of the pusher with the remnant up to the
lower deviation of the set "POSITION REVERSE
ROTATION".
Return run with "SPEED FOR RETURN HIGH".
From "POS. REVERSE ROTATION CHANGE OVER
SLOWLY" set in the PLC the pusher moves at low speed
to "POSITION MATERIAL DRAW OFF".
Once this position is reached the system switches to
step 2.
The motor is switched off.
The brake is switched on. Remnant flap opens.
Gripper blades close and grip the remnant. The no
longer actuated -B14, -B17 switches and a transfer time
switches into step 3.
Gripper blades remain closed.
Remnant flap is opened.
The pusher moves back to its rear limit position.
Switch -B1 switches to step 4.
Remnant flap is opened.
The motor is switched off.
The brake is switched on. The gripper blades open. The
remnant falls into the remnant bin. Switch -B14 and a
transfer time switch to step 5.
The remnant flap closes.
Switches -B14, -B17 and a transfer time switch into
step 6.
A check is carried out to see whether the remnant has
fallen out of the gripper blades into the remnant bin.
The gripper blades close and switch -S13, actuated in
closed position, switches to step 7.
The gripper blades open. Switch -B14 is actuated.
-B14 and a transfer time switch into step 8.
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions
turbo 2-20
series 1
Display Information
AUTO STEP 8:
OPEN GUIDE CHANNEL, PUSHER
AUTO STEP 9:
CLOSE GUIDE CHANNEL
Step Function
The pusher is swung out. The guide channel is opened.
This causes a new material bar to fall from the side
support into the open guide channel. Switches -B5,
-B22 and a transfer time switch to step 9.
The pusher remains swung out.
The guide channel closes again. Switch -B6 switches to
step 10.
On selection special insert on:
AUTO STEP 9:
CHANNEL OPEN
AUTO STEP 10:
SHORT PUSHER FORWARD / BACKWARD
On selection special insert on:
:AUTO STEP 10:
SHORT PUSHER FORWARD / BACKWARD /
CHANNEL OPEN
AUTO STEP 11:
CLOSE GRIPPER / PUSHER
On selection special insert on:
AUTO STEP 11:
CLOSE CHANNEL / PUSHER
AUTO STEP 12:
RUN FORWARD / PRESS UPON
AUTO STEP 13:
STOP, OPEN GRIPPER BLADES
Operating Instructions
The pusher remains swung out.
The guide channel remains opened. Switches –B5 and
–B22 switch to step 10.
The pusher moves at the set "SPEED F. SHORT
PUSHER RUN FORWARD" to the position specified in
the PLC at which point the speed is switched to
"SPEED FOR FIRST INSERT LOW". The material bar
is pushed forward at this speed up to the position
calculated by the PLC where the bar end is positioned
underneath the gripper blades. Once this position is
reached, the pusher stops and, after a short delay time,
moves to the limit position. Switch –B1 switches to
step 11.
The gripper blades close on the new material bar. The
guide channel closes. The pusher is swung in. In this
position switch -B23 is actuated.
Switches -B6, -B23 and the non-actuated switch -B14
start a time which switches to step 12.
The gripper blades close on the new material bar. The
guide channel closes.
The pusher is swung in. In this position switch -B23 is
actuated.
Switches -B6, -B23 and the non-actuated switch -B14
start a time which switches to step 12.
Gripper blades remain closed.
The pusher moves forward, and the clamping sleeve is
pushed onto the end of the material bar.
The pusher travels forward by at least 22.0 mm,
specified in the PLC. On reaching or passing 22.0 mm
and the non-actuated switch –B14, a time is started,
which switches to step 13.
The pusher stops. The brake is switched on. The
gripper blades open.
Switches -B6, -B14, -B17 and -B23 switch to step 14.
Edition 04/12
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GB/O
Page 81
turbo 2-20
series 1
Display Information
AUTO STEP 14:
FIRST INSERT
AUTO STEP 15:
START LATHE
AUTO STEP 16:
MATERIAL CUT OFF
AUTO STEP 17:
PART PRODUCTION
Page 82
Step Function
The oil pump is switched on and remains active until
step19. Pusher pushes material bar into lathe spindle
until bar’s front is in cut-off position.
This position is computed out of the value entered
under "FIRST INSERT TRAVEL". (The first insert travel,
which is entered at the control panel, is added to the
current position when switch –S7 is reached.) The bar
is pushed forward at the set speed "SPEED FOR
FIRST INSERTION" to the "INTERVAL FEED" position.
From this position onwards, the speed is switched to
"SPEED FOR FIRST INSERT LOW".
If the "INTERVAL FEED" function is selected, the motor
moves the preset distance forward with the set clock
interval. When the cut-off position is reached, the
system switches to step 15.
OPTION:
When "STANDARD" is selected in menu PART
SELECT under "SELECT FIRST INSERT", and upon
reaching the cut-off position step 15 is switched into.
When "TO STOP" is selected in menu PART SELECT
under "SELECT FIRST INSERT", and upon reaching
the cut-off position the material bar will be pushed
forwards onto the stop. When reaching the cut-off
position and on the expiry of the dwell-time of 0,5 sec.
step 15 is switched into.
Via the –K1 relay, the message "BAR CHANGE END –
PROGRAM START" is communicated to the lathe.
Upon lathe collet closing, the contact "collet open"
releases and switches into step 16.
The bar’s front is cut-off. After cut-off, step 17 is
switched into via the "collet open" contact.
The material bar is machined. Current bar length is
shown in the display. When the message "collet open" is
applying from the lathe, the motor, with the clutch being
switched on, pushes the material bar forward. If, during
parts follow-up, the value computed in the PLC for the
bar end ("POSITION FRONT LIMIT" less "PART
LENGTH") is exceeded, step 18 will be switched into.
Edition 04/12
RM-Nr. 102068
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Operating Instructions
turbo 2-20
series 1
Display Information
AUTO STEP 18:
INSERT LAST PART
AUTO STEP 19:
MACHINE LAST PART
AUTO STEP 20:
STOP LATHE / START BAR CHANGE
Operating Instructions
Step Function
The last material is fed into the lathe. Via the releasing
contact "collet open", step 19 is switched into.
The last work piece is machined. Through the -K9 relay,
the message "BAR END – PROGRAM STOP" is
communicated to the lathe. When the last part is
machined completely, the lathe uses contact "cycle
end" to switch into step 20.
Relay -K9 is switched on. A transfer time switches into
step 1.
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Page 83
turbo 2-20
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9. Faults/Error messages
9.1 Faults display
Current faults are displayed in the MANUAL-MENU and the AUTO-MENU.
With the Touchkey
or
enables changing over to the menu page FAULTS.
‘Current faults’ display:
‘Position of the fault on the loading magazine’ display:
Clearing the faults
Call up the position of the fault on the loading magazine
Call up the fault archive of the cleared error messages.
Page 84
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Operating Instructions
turbo 2-20
series 1
9.2 Error Messages
display information
Cause of trouble, remedy
FAULT:
GUIDE CHANNEL NOT CLOSED
Solenoid valve –KK01 must be switched on.
-KK01/B6
FAULT:
NO AIR PRESSURE!
MIN 4 BAR
–B11
Pressure switch -B11, check whether compressed air shut-off valve is open.
FAULT:
MOTOR PROTECTION -F1 TRIPPED! -M1/F1
Switch motor protection switch -F1 on again.
FAULT:
MOTOR PROTECTION -F2 TRIPPED!-M2/F2
Switch motor protection switch –F2 on again.
FAULT:
SWITCH -B7 NOT IN HOME POSITION
- -KK9/B7
Actuation flap for switch -B7 is not in its initial position or switch -B7 is not actuated.
FAULT:
NO RETURN OF REMNANT
-B13
During enquiry in steps 3 and 4, switch -B13 was actuated.
FAULT:
MONITORING TIME BAR CHANGE
The bar change in step 20 as well as in steps 1 to 15 did not run correctly.
FAULT:
EMERGENCY STOP LATHE
Emergency stop key on the lathe is pressed.
FAULT:
NO NEW BAR IN GUIDE CHANNEL -B13
During material feed in steps 9 and 10, the switch -B13 has been actuated.
FAULT:
NO STOP IN THE LATHE
If "SELECT FIRST INSERT: TO STOP" is selected, the material bar is pushed still forwards
after moving the first insert travel.
If thereby the material bar is not stopped via a bar stop, this error message is given.
Operating Instructions
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RM-Nr. 102068
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Page 85
turbo 2-20
series 1
FAULT:
COLLET IN THE LATHE CLOSED
If "SELECT BRON MODE: WITH FIRST INSERT" is selected the material bar having been
pressed upon is pushed forwards only when the lathe collet is opened. If the lathe collet is
closed, this error message is given.
FAULT:
EMERGENCY STOP LOADING MAGAZINE -S69
Emergency stop key on the control panel of the loading magazine is pressed.
FAULT:
POSITIONS BACKWARD
An input value: "POS. REVERSE ROTATION RETURN" or "POSITION MATERIAL
DRAW-OFF" is not correct.
FAULT:
POSITIONS FORWARD
An input value under positions: "TRAVEL INTERVAL ON", "FIRST INSERT TRAVEL" or
"POSITION FRONT LIMIT" is not correct.
FAULT:
REMNANT FLAP NOT CLOSED
-KK10/-KK010/B17
Solenoid valve –KK10 is not switched on or switch - B17 was not actuated.
FAULT:
PUSHER NOT SWUNG IN CORRECTLY
-KK8/-KK08/-B22/-B23
Pusher is not swung in correctly, solenoid valve –KK8 is not switched on, or switch –B23
was not actuated.
FAULT:
OPENING – CLOSING OF GUIDE CHANNEL
-KK1/KK01/B5/B6
When the guide channel is open, switch -B5 must be actuated. In case of closed guide
channel, switch -B6 must be actuated.
FAULT:
REMNANT JAMMED IN CLAMPING SLEEVE -B13
During remnant fall-out check in step 6, switch -B13 was not actuated.
FAULT:
MOTOR RUN FORWARD
In step 10, 13 or 14 the monitoring time is expired.
FAULT:
MOTOR RETURN
In step 1 - 4 the monitoring time is expired.
FAULT:
PART FOLLOW-UP TOO SHORT
Active only, if in the "PART SPECIAL" menu a value >0 is entered at: "MIN. PART
LENGTH FOLLOW-UP". When the entered value is not reached during "PART FOLLOWUP", a fault message will be released
Page 86
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Operating Instructions
turbo 2-20
series 1
FAULT:
PART FOLLOW-UP TOO LONG
Active only, if in the "PART SPECIAL" menu a value >0 is entered at: "MAX. PART
LENGTH FOLLOW-UP". When the entered value is exceeded during "PART FOLLOWUP", a fault message will be released.
FAULT:
BAR WAS RETRACTED
Active only, if in the "PART SPECIAL" menu a value >0 is entered at: "MAX. BAR
RETURN". With "COLLET OPEN", if the pusher is retracted above this value, the error
message is triggered.
FAULT:
COVER NOT CLOSED -B74/B75/B76/K20
Covers not closed. Switch -B74 or -B75 is not actuated, or the loading magazine is not in
basic position, switch -B76 is not actuated.
FAULT:
PRESS UPON NOT CORRECT.
When the clamping sleeve was pressed upon the new material bar, the "POSITION
MATERIAL DRAW-OFF" has not been reached.
FAULT:
COLLET CLOSED TOO LONG
Active only, if in the menu "PART" under "SPECIAL SETTINGS" a value >0 is entered at:
"MONITORING COLLET CLOSE". The time value is entered in tenths of a second.
FAULT:
COLLET OPENED TOO LONG
Active only, if in the menu "PART" under "SPECIAL SETTINGS" a value >0 is entered at:
"MONITORING COLLET OPEN". The time value is entered in tenths of a second.
FAULT:
LOADING MAGAZINE NOT IN AUTOMATIC MENU
The loading magazine is not visualised in the automatic menu, when the signal
"AUTOMATIC-START" has been released from the machine.
FAULT:
PART COUNTER DESIRED-VALUE REACHED
see sect. 5.3.3
FAULT:
OPERATION TIME DESIRED-VALUE REACHED
see sect. 5.3.4
FAULT:
STARTING SWITCH –B7 SWITCHES SEVERAL TIMES
The starting switch –B7 has switched serveral times between step 10 and 14. Switch -B7
can only be activated in step 10 or 14.
Operating Instructions
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Page 87
turbo 2-20
series 1
FAULT:
ENTERED INSERT TRAVEL NOT CORRECT (MIND:750)
The entering in menu "SERVICE POSITIONS" "FIRST INSERT TRAVEL" amounts to at
least 750 mm.
FAULT:
NO BASIC POSITION
-B6/B14/B17/B23
When starting the automatic mode BOFF, ROFF oder BRON the magazine is not in basic
position.
Switches –B6, -B14, -B17 and –B23 are not activated.
WARNING:
PLC-BATTERY EMPTY!
see sect. 11.4
OPTION:
FAULT:
MAGAZIN NOT IN START POSITION: STEP 1,15,17 OR 19
The loading magazine only can be started in step 1, 15, 17 or 19.
Page 88
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Operating Instructions
turbo 2-20
series 1
9.3 Display status of the CPU
POWER
(green)
RUN
(green)
ERR/ALM
(red)
lights
OFF
lights
OFF
lights
flashes
INH
(yellow)
PRPHL
(yellow)
BKUP
(yellow)
OFF
lights
OFF
flashes
OFF
lights
OFF
Operating Instructions
Power is ON.
Power is OFF.
The CP1L is executing a program in either RUN or MONITOR
mode.
Operation is stopped in PROGRAM mode or due to fatal error.
A fatal error (including FALS execution) or a hardware error (WDT
error) has occurred. CP1L operation will stop and all outputs will
be turned OFF.
A non-fatal error has occurred (including FAL execution). CP1L
operation will continue.
Operation is normal.
The Output OFF bit (A500.15) has turned ON. All outputs will be
turned OFF.
Operation is normal.
Communications (either sending or receiving) are in progress
through the peripheral USP port.
Other than above.
• A user program, parameters, or Data Memory is being
written or accessed in the built-in flash memory (backup
memory).
• A user program, parameters, Data Memory, DM initial
values, or comment memory is being written or accessed
in a Memory Cassette.
• The BKUP indicator also lights while user programs,
parameters, and Data Memory are being restored when
the PLC power supply is turned ON.
Note: Do not turn OFF the PLC power supply while this indicator
is lit.
Other than above.
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10. Removing a Material Bar from Guide Channel
For removing a long material bar from the guide channel, the following work steps are
necessary:
1. Select MANUAL-MENU.
2. Press key "BOFF".
(BOFF = Draw off long bar).
3. After the REAB-program has been executed, the touchkey changes from black to
white.
4. Press emergency stop key and close the compressed air shut-off valve to depressurize
the unit.
5. Open cover.
6. Push material bar towards the lathe that the gripper blades can close without material
bars.
7. Close cover.
8. Unlock EMERGENCY STOP key and open compressed air shut-off valve at the
loading magazine in order to aerate the unit.
9. Press key "PUSH", and the pusher will be swung out.
10. Press key "CHAN". The guide channel opens.
11. Press EMERGENCY STOP key.
12. Shut off the compressed air supply by turning the pneumatic shut-off valve to
depressurize the unit.
13. Open cover, and secure pusher and guide channel with safety bolt.
14. Draw material bar to the rear into the direction of the magazine’s end.
15. Empty the lateral material storage.
16. Raise material bar via lateral storage out of the guide channel.
17. Convert magazine, if necessary, and re-load material bars as requested.
18. Remove safety bolt and close cover.
19. Connect compressed air supply again.
20. Unlock EMERGENCY STOP key.
21. Press key "CHAN" The guide channel closes.
22. Press the key
in order to delete the "GUIDE CHANNEL NOT CLOSED" fault
message.
23. Press key "PUSH", and the pusher will be swung in again.
Page 90
Edition 04/12
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GB/O
Operating Instructions
turbo 2-20
series 1
11. Maintenance Works and Settings
11.1 Maintenance to be carried out regularly
Attention!
•
•
•
•
•
•
As a function of the strain on the loading magazine by vibrations,
it may be possible that the maintenance intervals stated are
shortened.
Every month, the screw connections at the gripper, steady and channel of the loading
magazine are to be checked and tightened if necessary.
Every half year, all the screw connections are to be tightened.
Every year, the alignment of the loading magazine to the lathe spindle is to be checked
and readjusted if necessary.
Every year, the alignment of the steady rest and guide tube is to be checked and
readjusted if necessary.
If the maintenance intervals stated are not complied with, the output of the loading
magazine can be limited.
The loading magazine may not be operated if screw connections are loose.
Operating Instructions
Edition 04/12
RM-Nr. 102068
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Page 91
turbo 2-20
series 1
11.2 Maintenance unit
Id.Nr.: 2058-273
Consisting of:
E
V
1. Starting valve
2. Filter-regulator valve
3. Plug-in screwing
4. Pressure switch
5. Connecting plate
6. Plug-in screwing
7. Double nipple
8. Manometer
9. Condensate glass
The filter- regulator valve (2) is factory-set to an operating pressure of 0.6 MPA (6 bar). To
regulate or reset it, the adjusting knob (2.1) is released (E) and turned to the right with inlet
pressure on until the pressure gauge shows the required outlet pressure. The pressure
setting is kept constant by locking (V) the adjusting knob (2.1).
Condensate drainage: Manual condensate drainage with the drain screw (9.1) is only
possible under pressure.
Page 92
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Operating Instructions
turbo 2-20
series 1
11.3 -Q1 Feed Clutch Maintenance
Attention!
For rotor draw-off from the shaft, the rotor hub is provided with
bores having internal threads. No pressure must be exerted on
the outer thin-walled area of the rotor!
Check, in certain time intervals, whether the air gap a equals 0.2 mm. After a longer
service time, air gap readjustment by removal of spacer washers becomes necessary.
rotor
anchor part
Do not exert any
pressure here!
magnet part
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 93
turbo 2-20
series 1
11.4 Battery
The CPU of the CP1L control units contains a battery set which must be replaced when it
reaches the maximum life span. The life under normal conditions is about 5 years, but is
reduced at higher temperatures.
With dropping battery voltage a battery error is indicated, the ERR/ALM flashes and the
warning
WARNING:
PLC-BATTERY EMPTY!
is output on the display of the control panel.
The warning will be cleared after the battery has been replaced and the controller of the
loading magazine switched-off and -on.
Page 94
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Operating Instructions
turbo 2-20
series 1
11.4.1 Replacing the battery
Attention!
The battery must be changed within 5 minutes after switching off
the CP1L power supply to ensure memory backup.
Never throw any lithium battery into fire and never try to recharge
a lithium battery. The battery may explode or release hazardous
vapors!
Used batteries shall be treated as hazardous waste!
Proceed as follows to change the battery:
1. Switch off the CP1L power supply. If the CP1L power supply has not yet been
switched on, switch it on for at least one minute and then back off.
If a power supply has not been switched on for at least one minute before changing the
battery the capacitor used for memory backup after removing the battery is not completely
charged and the contents of the memory may be lost before a new battery is inserted.
2. Open the battery chamber on the top left side of the CPU and carefully pull out the
battery.
3. Pull off the battery connector.
4. Connect the new battery, push it into the battery chamber and close the cover.
The warning "PLC-BATTERY EMPTY!" will be automatically cleared after inserting a new
battery and switching off and –on the controller.
Operating Instructions
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Page 95
turbo 2-20
series 1
11.5 Disassembling, respectively assembling the CPU or one
of the I/O-modules
Before assembling, respectively disassembling the CPU or one
of the modules, always switch-off the voltage supply. Ignoring
this instruction, the PLC may changeover to STOP, the module
gets damaged or even staff members injured.
Observe the below guideline for assembling and disassembling the CPU and modules.
Attention !
The process wiring is connected through terminal blocks. The terminal blocks of the CPUmodule can be screwed-off.
The CP1L-controller consists of the CPU-module, analogue output module and digital one.
The modules are electrically connected among each other through plugs with flat flex cables
located on the side. Before disassembling any module, pull-off the respective plugs and re-fit
them after termination of replacement.
1. For disassembling, pull the CPU or module
to the front and remove it from the subbase.
Pull out the slide for the DIN-subbase.
2. For assembling the CPU or module,
hook the back onto the subbase as
shown in the below illustration.
3. Push the slide for the subbase to top in
order to lock the CPU or the module.
Page 96
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Operating Instructions
turbo 2-20
series 1
11.6 New program for PLC
The PLC program is permanently stored in an internal memory which is located in the CPU
module. If the loading magazine is to be put into operation with a modified program, the
central processing unit (CPU) must be replaced, as described in section 11.5.
The current PLC program must of course have been installed in the new CPU, or must be
installed in it after replacement.
Operating Instructions
Edition 04/12
RM-Nr. 102068
GB/O
Page 97
turbo 2-20
series 1
12. Electric and Pneumatic Parts
-B1
-B5
-B6
-B7
-B11
-B13
-B14
-B17
-B22
-B23
-B74
-B75
-B76
Pusher, rear limit position
Guide channel opened
Guide channel closed
First insert start
Pressure switch
Gripper blades closed
Gripper blades opened
Remnant flap closed
Pusher swung out
Pusher swung in, within guide channel
Cover closed, rear
Cover closed, front
Shifting device in basic position (Option)
-M1
Drive motor
-M2
Oil pump
-Q1
Feed clutch
-Q6
Synchronized clutch
-QL3
Brake
-B3
Encoder
Control panel
-S69
EMERGENCY STOP key
Solenoid valve
-KK1
Open guide channel
-KK01
Close guide channel
-KK2
Close gripper blades
-KK7
Close steady rest
-KK8
Swing pusher out
-KK08
Swing pusher in
-KK10
Open remnant flap
-KK010
Close remnant flap
-KK14
Steady rest lathe close
-KK9
Reset starting switch
-KH1
Valve block
Pneumatic cylinder
-MM1
Open/close guide channel
-MM2
Open/close gripper blades
-MM7
Open/close steady rest
-MM8
Swing out/in pusher
-MM9
Reset starting switch
-MM10
Close, open remnant flap
Terminal box and connections
-X4
Actor-Sensor-Box
-X5
Terminal box motor, clutch, brake
-X6
Actor-Sensor-Box
-X7
Terminal box synchronous clutch (Option)
-X12
Plug-in connection for valve block –KH1
-X15
Connector for lathe
Page 98
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Operating Instructions
turbo 2-20
series 1
- X1 Terminal strip on switch cabinet
PE-Lead
to beam
Connecting lead
for
* Option
Steady rest built
in the machine
12.1 Arrangement of electrical and pneumatic equipment
Operating Instructions
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GB/O
Page 99
turbo 2-20
series 1
13. Parts list of pneumatic parts
Pos.
Bezeichnung/Typ
Ident-Nr.
Cylinder (double action) ADN 32-50 A-P-A
Length 2200
Length 3200, 3800, 4200
Cylinder (double action) ADN 32-50-A-P-A
2059-378
2
2
3
1
3
1
Cylinder (double action) ADN-25-20-A-P-A
2067-941
4
1
Cylinder (single action) EGZ 10-15
2031-086
5
1
Cylinder (double action) DSNU 25-50 PA
2030-551
6
1
Maintenance unit consist of:
2058-273
7
1
Filter regulator valve LFR-1/4-DB-7
2058-322
8
1
Valve HE-D-MINI
2058-323
9
1
Pressure switch
2058-325
10
1
Manometer
2058-328
11
1
Valve block
2072-059
12
3
Directional control valve 5/3
2057-808
13
3
Directional control valve 5/2
2057-809
14
3
Valve kit
2057-807
15
8
One-way restrictor
2057-797
16
1
Blank plug B 1/8"
2007-149
17
2
Spare plate
2058-684
18
1
Silencer SZ 640012 1/2"
2067-009
19
1
Silencer U-1/8-B
2057-802
1
Page 100
Menge
Edition 04/12
RM-Nr. 102068
GB/O
2059-378
Operating Instructions
close
Operating Instructions
close
Ø32x50stroke
open
close
Edition 04/12
RM-Nr. 102068
GB/O
Ø32x50stroke
Place of valve from right to left on LED-Display
Ø32x50stroke
swing in – swing out
-MM8
Pusher
swing in – swing out
Ø32x50stroke
open
2200 - 2 Cylinder
3200/3800/4200 – 3 Cylinder
–
Ø32x50stroke
open
-MM1
Guide channel
Page 2
close
Ø25x50stroke
open
-MM10
Remnant flap
turbo 2-20
series 1
13.1 Pneumatic diagram, Page 1
Page 101
Page 102
Page 1
Ø32x50Hub
-MM2
Gripper
open
close
Ø10x15Hub
-MM9
Starting switch
Ø25x20Hub
-MM7
Steady rest
open
close
-MM14
Spindle stock steady
open
close
-MM15
Oil blow-off device
Options for place of valve positions 7 & 8
turbo 2-20
series 1
13.2 Pneumatic diagram, Page 2
Edition 04/12
RM-Nr. 102068
GB/O
Operating Instructions