SMW Spacer Barfeed 2003manual PDF

Installation
Operation
& Maintenance
for:
SPACESAVER 2003
SPACESAVER 2003 HD
SMW Part #
43100005
SMW SPACESAVER 2003

CNC Technology manufactures the SMW SPACESAVER, a company located in Czech
Republic. It is distributed in North America exclusively by SMW Systems.
9828 S. Arlee Ave.

SANTA FE SPRINGS
CALIFORNIA 90670
1-800-423-4651
www.smwsystems.com
SMW
SMW SYSTEMS INC. 562-949-7991
Safety recommendations
READ COMPLETE INSTRUCTIONS CAREFULLY
BEFORE OPERATING MAGAZINE BARFEED
Since we are continuously improving the design of our magazine barfeeds, it is possible that
the illustrations may vary from the equipment you received. Concerning the electrical and
pneumatic diagrams, always refer to this manual.
However, some previously accepted shop practices may not reflect current safety regulations
and procedures, and should be reviewed to ensure compliance with the current local safety and
health standards.
We recommend that all shop supervisors, maintenance personnel and machine tool operators
be advised of the importance of safe maintenance, setup and operation of this equipment. Our
recommendations are described below.
Read these safety recommendations before you start working with your
magazine barfeed:
Read appropriate manual or instructions before attempting operation or maintenance of the
barfeed. Make sure you understand all instructions.
Do not operate equipment unless proper maintenance has been regularly performed and
equipment is known to be good working order.
Do not remove any warning or instruction tags from magazine barfeed.
Do not loosen any screws secured by paint.
Do not operate equipment if unusual or excessive heat, noise, smoke or vibration
occur. Report any excessive of unusual vibration, sounds, smoke or heat as well as any
damaged parts.
Make sure equipment is properly grounded. Consult National Electric Code and all
local codes.
Disconnect main electrical power before attempting a repair or maintenance.
Do not reach into any control or power case area unless electrical power is off.
Do not touch electrical equipment when hands are wet or when standing on a wet
surface.
Allow only authorized personnel to repair electrical equipment.
Replace blown fuses with fuses of the same size and type as originally furnished.
Keep the area around the machine well lit and dry.
Have the correct type of fire extinguisher available when machining combustible
material and keep chips clear of the work area.
Do not use a toxic or flammable substance as a solvent cleaner or coolant.
Do not alter the machine to bypass any interlock, overload, disconnect or other safety
device.
Safety recommendations
Remove any loose parts or tools left on the machine or in the work area before operating
machine. Always check machine and work area for loose tools and parts especially after
maintenance personnel have done work.
Before pressing the cycle start push-button, make certain that proper functions are
programmed and that all controls are set in the desired modes.
Know where all stop push buttons are located in case of an emergency.
Check the condition of the barfeed before operating (water trap is empty, the air
pressure and the status of the indicator lights are correct.)
Make certain that all guards are in good condition and are functioning properly before the
cycle is started.
Dont operate the loading mechanism if the gauge on the channel scale (fig. 4.3/3) is set
to a diameter larger than 80 mm. (102 mm on SS2003 HD)
Check setup, tooling and security of workpiece if the machine has been off for any
length of time and its going to work without operator.
Do not take off safety covers when machine is working.
Do not remove or load workpieces while any part of the machine is in motion.
Do not operate any machine wearing rings, watches, jewelry, loose clothing or neckties, or
long hair not contained by net or shop cap.
Do not leave tools, workpieces or other loose items where they can come in contact with
a moving component of the machine.
Do not attempt to brake or slow the machine with your hands.
Any attachments, tools or machine modifications not obtained from our company, must
be reviewed by qualified safety engineer before installation.
Use caution around exposed mechanism and tooling especially when setting up. Be careful
of sharp edges on tools.
Use only a soft-faced hammer.
Do not exceed the rated capacity of machine.
Do not machine bar stock exceeding the length of a lathe spindle.
Use spindle liners inside the spindle.
If it is possible, program the magazine barfeed to retract the pusher fully out of the
spindle before the spindle starts to rotate. Pusher of diameter 6 mm is necessary to pull
all the way out of the spindle every time.
Make certain that the magazine barfeed is properly aligned with the lathe and bolted to the
floor.
If bar stock will not feed properly, carefully diagnose the problem to determine the best
corrective measure. (before continuing to operate the machine)
Do not simply increase air pressure without determining the cause of the problem.
Excessive air pressure is extremely dangerous and must be avoided.
FOR YOUR PROTECTION - WORK SAFELY
Contents
CONTENTS
CONTENTS
1 DESCRIPTION
1.1
GENERAL
1.2
APPLICATIONS
1.3
CONCEPT
1.4
FLOOR PLAN
1.5
MAIN DIMENSIONS
1.6
TECHNICAL CHARACTERISTICS
1.7
OPERATION
1.8
SUPERVISION AND SECURITY
1.9
ELECTRIC SUPPLY
1.10
PNEUMATIC SUPPLY
1.11
INSTALLATION
1.12
IDENTIFICATION
2 TRANSPORTATION AND UNPACKING
9
9
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12
13
15
15
15
15
16
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17
3 INSTALLATION - SET UP
3.1
PREPARATION BEFORE MAGAZINE BARFEED INSTALLATION
3.2
ELECTRICAL AND PNEUMATIC CONNECTIONS
3.3
INSTALLATION - MAGAZINE BARFEED FLOOR MOUNTING
3.3.1
GENERAL
3.3.2
HEIGHT AND SIDE POSITION PRE-ADJUSTMENT
3.3.3
ALIGNMENT
3.3.4
TABLE INSTALATION
4 UTILIZATION
4.1
PRELIMINARY CONDITIONS
4.1.1
FOUNDATION, ALIGNMENT
4.1.2
SAFETY
4.1.3
OPERATOR
4.2
NORMAL (OR STANDARD) PRODUCTION PROCEDURES
4.3
GUIDING TECHNIQUE
4.4
BAR STOCK FEED
4.5
INSTALLATION OR EXCHANGE OF A SPINDLE LINER
4.6
ADJUSTING CHANNEL HEIGHT
4.7
ADJUSTING THE BAR TRAY
4.8
PNEUMATIC CIRCUIT
4.8.1
GENERAL
4.8.2
SETTINGS - MAINTENANCE
4.8.3
ADJUSTING MOVEMENT SPEED
4.9
PUSHER
4.9.1
INSTALLATION OF PUSHER
4.9.2
ASSEMBLY AND DISASSEMBLY OF PUSHER
4.9.3
ADJUSTMENT OF PUSHER LENGTH
4.10
ELECTRICAL PART
4.10.1
OPERATING PANEL
4.10.2
ERROR SIGNALS AND MEANING OF LAMPS H14 AND H15
4.10.3
EXPLANATION AND FUNCTION OF THE SWITCHES
4.10.4
SETTING THE PROXIMITY SWITCHES B24 AND B25
4.10.5
HOW TO PROGRAM THE LATHE
4.10.6
FLOW DIAGRAM OF THE MAGAZINE BARFEED PROGRAM
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30
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47
Contents
4.10.7
GETTING THE AUTO CYCLE STARTED AND STOPPED
4.10.8
INTERFACE
4.10.9
MODIFICATION OF THE PROGRAM CONTROL
4.11
LOADING MECHANISM REVERSE ROTATION
ADDENDUM 1 MAGAZINE BARFEED - LATHE COOPERATION DIAGRAM
49
50
53
54
56
ADDENDUM 2 ELECTRICAL DIAGRAMS
62
ADDENDUM 3 STANDARD INTERFACE DIAGRAMS
74
ADDENDUM 4 PNEUMATIC DIAGRAM
78
ADDENDUM 5 SPARE PARTS
82
ADDENDUM 6 METHODS HOW TO TROUBLESHOOT

6.1
METHODS HOW TO TROUBLESHOOT PLC
6.2
METHODS HOW TO TROUBLESHOOT PUSHER/CHANNEL
6.3
METHODS HOW TO TROUBLESHOOT WARNING SIGNALS
6.4
METHODS HOW TO TROUBLESHOOT VARIOUS PROBLEMS
ADDENDUM 7 INPUTS AND OUTPUTS
7.1
IDENTIFICATION OF ERRORS INPUTS
7.2
IDENTIFICATION OF DEFECTS OUTPUTS
7.3
TROUBLESHOOTING MATRIX ERROR
ADDENDUM 8 CONTROL SHEET FOR INSTALLATION
86
88
88
89
90
92
94
96
97
99
Contents
FIGURE LISTING
Fig. 1.1 - General arangement

Fig. 1.2 - Floor plan
Fig. 1.3 - Main dimensions
Fig. 1.4 - Data tag
Fig. 2.1 - Lifting and locating the magazine barfeed
Fig. 3.1 - Pneumatic and electrical connections
Fig. 3.2 - Look at the opened electrical box
Fig. 3.3 - Elements for height and side alignment and adjustment
Fig. 3.4 - Height and side pre-adjustment
Fig. 3.5 - Centering magnetic gauge - rear view of the spindle
Fig. 3.6 - Alignment kit
Fig. 3.7 - Alignment
Fig. 3.8 - Lagging magazine barfeed to the floor
Fig. 4.1 - Kinds of spindle liners
Fig. 4.2 - The barfeeding
Fig. 4.3 - Setup of the channel height
Fig. 4.4 - The tray (table) setting for correct bar separation
Fig. 4.5 - The pneumatic circuit
Fig. 4.6 - The water trap, regulator and solenoid valve
Fig. 4.7 - Pusher Assembly and disassembly
Fig. 4.8 - Operating panel
Fig. 4.9 - Location of the switches
Fig. 4.10 - Setting the proximity switches B24 and B25
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11
12
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17
20
21
22
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24
25
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Contents
Chapter 1. Description
DESCRIPTION
1.1
GENERAL
The magazine barfeed Spacesaver 2003 has been designed to fit all types of automatic lathes.
The machine head stock length determines the bar length. This allows automatic bar loading
and bar feeding at a low cost to a CNC lathe user, creating a highly efficient and economic
manufacturing process.
The spindle liner centers the bar on lathe center and guides the bar into the spindle. The
spindle liner also prevents damage to the spindle if, during rotation, bar is released from
chucking device in lathe, or when the bar is bent. .
This magazine barfeed was designed for machining round bars, square, hexagonal or shaped
stock. Machining square, hexagonal or shaped bars requires a lathe spindle orientation device.
Machining square bars requires rotating the channels bar guiding block 180 degrees. When
machining bars of special shape it is necessary to install special shaped liner or guide. This
liner is not part of the basic equipment of magazine barfeed.
Its compact design reduces space required behind the lathe.
The bar diameter adjustment is simple and fast, and remnant ejection does not require a
special device.
1.2
APPLICATIONS
The magazine barfeed SS 2003 allows:

automatic low cost CNC lathe operation
utilization of limited floor space due to its small footprint and its lateral loading.
accurate job at high speed, not affected by the magazine barfeed.
continuous operation, avoiding changeovers in setup.
solves problems due to bent bars or geometry faults.
the automatic change of bar stock, by a pre-programmed PLC.
1.3
CONCEPT
The concept and function is very simple, the magazine barfeed SS 2003 is very viable with a
long lasting life and requires minimum maintenance. Its operation is simple even for an inexperienced operator.
The operation panel (1.1/1) displays all of the rotary switches, emergency stop and indicator
lights useful to the operator. Only the main switch (1.1/8) is located on the frame. The bar
stock to be machined is stored on an inclined tray (1.1/2) with a threaded rod height
adjustment.
(1.1/5) and introduced to the lathe spindle by rotating claws (1.1/12), fixed channel (1.1/10)
and pusher (1.1/11).
The rear side of the magazine barfeed includes air inlet (1.1/3). On the bottom are holes for
electrical connection (1.1/7). The operation height of frame (1.1/4) is adjustable with screws
(1.1/9) located in 2 adjustable legs (1.1/6).
2
12
11
8
10
1
5
6
Fig. 1.1 - General arangement
10
1.4
FLOOR PLAN
Fig. 1.2 - Floor plan
11
1.5
MAIN DIMENSIONS
Fig. 1.3 - Main dimensions
12
1.6
TECHNICAL CHARACTERISTICS
Barstock range
Round bar diameter
Hexagonal bar stock
Square bar stock
SS 2003
6 to 80 mm
8 to 68 mm
8 to 55 mm
SS 2003 HD
6 to 102 mm
8 to 85 mm
8 to 70 mm
Length of bar stock

Length is limited to the total length of the spindle (including cylinder and chucking device)
and not to exceed the length of the magazine barfeed 60 inches or 1524 mm.
Capacity of material rack
bar diameter - 102 mm (SS 2003 HD only)
bar diameter - 80 mm
bar diameter - 6 mm
3 bars (due to weight limit of 500 lbs)

22 bars
Over 100 bars
Guiding technology
Bar is guided (centered) in the spindle with a spindle liner and pushed by the pusher to a turret
stop (see chapter 1.7).
Speed rotation
According to the RPM rating of the lathe and quality of the spindle liner.
Material advancement
By pneumatic pusher, adjustable feeding speed up to 1170 inch/min or 30 m/min.
Straightness of bar stock
No specific recommendations for bar preparation. The bar must go easily into spindle liner
with clearence defined in chapt.4.3. Bar straightness recommended at 0.5 mm/meter or .006
per foot.
Time of automatic reload cycle
About 25 seconds from tray into spindle.
Set-up time
About 2 minutes to go from one diameter to another + a spindle liner change time
Application, Adaptation
On most CNC lathes equipped with a barfeed interface
Electrical equipment
PLC driven by 24VDC
Power supply 200-575VAC 50/60Hz max. 4Amp.
Electrical cabinet according to VDE standards.
13
Compressed air connections
Air pressure requirement - 58 psi to 14.5 psi (4 - 10 bar)
The magazine barfeed is equipped with a pressure regulator and water trap. A supply hose
with an inside diameter of at least 8-mm is required. The air consumption per full stroke is 1,2
l of compressed air, it means approximately 20 l/hour, if machining 5-6 bars is machined.
Equivalent noise level
Noise level, caused by magazine barfeed in its work area does not reach 70 dB due to bar
cushioning loading mechanism. Improper manual loading of bigger bars to the rack may
cause noise (when the bar hits the rack or when the bar is moving on the rack).
Weight
360 kg
Packing
Magazine barfeed is packed in water-resistant plastic cover and transported inside wooden
crate.
14
1.7
OPERATION
The magazine barfeed SS2003 feeds barstock into the lathe according to the following
sequence:
a. The bar stock is loaded into to channel by the electrical loading mechanism. The channel
locates the bar on the spindle center.
b. The flag advances the bar stock into the spindle. Then the flag fully retracts.
c. Pusher is lowered onto the spindle axis.
d. The pusher advances the bar stock into the open collet (or chuck) against turret stop.
e. The collet (or chuck) is closed and the pusher retracts.
f. The lathe machines part.
g. The next bar is fed to the turret after spindle stops rotation and the chuck opens (or when
the lathe gives appropriate signal).
h. The signal end of bar (EOB) is given during the last feeding when bar stock length is
sufficient to machine still one part but no more. EOB starts the NC part program which
finishes last part and gives signal to eject the remnant.
i. The pusher ejects the remnant.
j. When the remnant is ejected pusher retracts and a new bar is loaded
1.8
SUPERVISION AND SECURITY
The magazine barfeeder is equipped with a programmable logic controller (PLC) that controls
all functions and binary signals are processed.
1.9
ELECTRIC SUPPLY
The magazine barfeed is equipped with an input transformer, primary from 200 to 575 VAC,
50/60 Hz (2. Fuses till 240 V 4A, for higher voltage 2A), and secondary 24 VDC after
rectifier for PLC input and output circuits and bar loading motor.
Its consumption is 0.25 kW. The connections between the lathe and the magazine barfeed are
illustrated in Addendum 3 Interface. (Modified diagrams exist for specific lathes)
1.10
PNEUMATIC SUPPLY
The pneumatic circuit of the magazine barfeed requires a supply of filtered (not oiled)
compressed air between 4 and 10 bars (60 - 120 psi). Inside diameter supply hose is 8 mm. Its
average consumption is 0.7 cubic feet per hour. (Supposing 5-6 bars is machined). A relief
valve avoids all excess pressure problems and assures total security.
15
1.11
INSTALLATION
The magazine barfeed installation is assured by the SMW service engineers or by agreed
agents. The presence of a lathe engineer during the installation is required.
1.12
IDENTIFICATION
The serial number for each magazine barfeed is shown on the data tag, which is located at the
rear side of the unit. Include this number in all correspondence regarding this magazine
barfeeder.
Fig. 1.4 - Data tag
16
Chapter 2. Transportation and unpacking
TRANSPORTATION AND UNPACKING
The magazine barfeed is packed in plastic cover and transported in wooden crate (see
dimensions in chapter 1 - technical specifications).
It is bolted to the bottom of the crate by screws.
- the weight of a crate is 140 kg
WARNING
In order to prevent damage of the magazine barfeed during unpacking, the
following recommendations must be strictly observed. SMW cannot accept any
responsibility for unpacking and installation carried out by untrained personnel.
To unpack magazine barfeed:

Place the crate containing magazine barfeed in the area near lathe.
Remove the top and sides of the crate.
Check if everything is in good condition and complete (according to packing list).
WARNING
The magazine barfeed must be lifted using only the bottom part of the frame.
Never use any other part of the magazine barfeed for lifting, otherwise this could
cause permanent damage to the unit. Use strong enough lifting straps. If there is
not enough space (under the frame) for the lifting straps, use the height adjustable
legs to lift the unit. You can also use forklift. Lifting forks must be placed only
under the frame.
- Place the magazine barfeed at the rear end of the machine, as shown in fig. 2.1, note the
distance A (50 mm max.) measured between the rear of the spindle and the cover of the
magazine barfeed. If this distance is bigger, it may cause problems with loading shorter bars
Fig. 2.1 - Lifting and locating the magazine barfeed
17
Chapter 2. Transportation and unpacking

Standard accessories supplied with the magazine barfeed
Accessories required for the alignment, operation and maintenance are supplied with each
magazine barfeed SS2003. During unpacking, check for the following:
Qty
Designation
5
5
1
1
2
1
1
Floor lag bolts

Flat washers for lag bolts
Alignment kit
Operators manual
Touch-up paint
Hexagonal channel adjusting key
Handle for opening electrical box
Other non standard accessories would be defined in the packing list.
18
INSTALLATION - SET UP
3.1
PREPARATION BEFORE MAGAZINE BARFEED

INSTALLATION (SUMMARY)
WARNING
In order to guarantee quick and trouble free installation, the assembly and
operation must be undertaken by SMW technicians or its agreed representatives.
It is in the customers interest that the maintenance supervisor and operator are
present during installation in order to receive proper training in the use of this
magazine barfeed.
Furthermore, it is recommended to respect the following points:

a) The lathe
It must be equipped with an automatic chucking device.
It must be ready for production via NC program and equipped with proper tools.
At installation day it must be available (no production or programming).
It must be prepared with proper electrical interface.
Note: It is strongly recommended to bolt the lathe to the floor in order to avoid lathe
movement.
b) Spindle liners for lathe spindle
It is customers responsibility to ensure that all necessary spindle liners for lathe spindle are
available for the type and size of bar stock that is going to be machined during the first month
of production. The explanations regarding spindle liners are given in chapter 4.3 figure 4.1.
c) Compressed air supply
An air supply hose must be available for the magazine barfeed installation (pressure 4 to 10
bars). Inside diameter of the hose should be 8 mm.
d) Bar stock
To perform tests during the installation, the customer will furnish prepared bar stock.
e) Foundation
The floor foundation for the magazine barfeed must be made of high quality concrete. The
legs of the magazine barfeed will be anchored to the concrete using the lag bolts provided.
The foundation should be of sufficient strength and size to support the magazine barfeed and
the lathe without vibration.
WARNING
A complete description of the pre-installation requirements is provided to the
customer at ordering time to guard against last minute installation problems.
19
3.2
ELECTRICAL AND PNEUMATIC CONNECTIONS
The magazine barfeed must be connected to the shops compressed air system.
Connect the magazine barfeed with compressed air. Adjust the pressure reducing valve of
horizontal cylinder (fig. 3.1/5) to pressure from 2 to 6 bars (pressure depends on size of
the bars). Adjust relief valve (fig. 3.1/6) to a pressure approximately 0.5 bar higher.
Connect the power cable to the lathe by selecting the proper tap on the barfeeds
transformer (acceptable voltages are: 200, 240, 400, 440, 480, 575, AC single phase) and
interface cable to proper positions on terminal strip.
Note: Some types of lathes require two separated cables for the interface and power
connection, some use just one cable.
5
4
2
1
3
6
Fig. 3.1 - Pneumatic and electrical connections

1.
2.
3.
4.
5.
Water trap on air inlet unit

Interface cable
Power cable
Compressed air supply hose
Air inlet unit with Water trap (filter/valve reducing pressure of horizontal
movement/pressure gauge)
6. Relief valve
20
To access electrical equipment after installation, open the door on the magazine barfeeder
frame and unscrew the top of electrical box.
WARNING:
Turn off main power BEFORE opening electrical box.
S12
Fig. 3.2 - Look at the opened electrical box
21
Chapter 3. Installation - set up
3.3
INSTALLATION - MAGAZINE BARFEED FLOOR

MOUNTING
3.3.1
GENERAL
The alignment of the magazine barfeed relative to the lathe is the most important operation of
the installation and must be carried out with extreme care. The time spent is insignificant
when compared to the possible damage to the lathe or magazine barfeed of misalignment
(axes of lathe and magazine barfeed are not in the correct position).
Accurate alignment of the barfeed is critical to correct operation.
Refer to the installation plans and follow the indicated distances as precisely as possible (see
chapter 2 fig. 2.1).
Locking nut on height

adjustment screw
Height adjustment screw
Screws for height position

fixing (4x)
Stud bolt for clamping of

leg and leg pad (2x)
Screws for height
adjustment (2x)
Leg pad
Fig. 3.3 - Elements for height and side alignment and adjustment
22
3.3.2
HEIGHT AND SIDE POSITION PRE-ADJUSTMENT
For the height pre-adjustment to the magazine barfeed refer to the following procedure:
Check with water level, that the barfeed magazine is correctly leveled (with no body
torsion) if not, correct the position with screws for the height adjustment on the leg pads.
Both leg pads must firmly lay on the floor.
Install the pusher
Loosen 4 screws on both legs
To the holes for stud bolts (fig. 3.4/1), insert appropriate spacer tubes (between stud bolts
and holes), which secure clearance for light side alignment later.
Using the 4 screws for height adjustment, lift the magazine barfeed legs upon the leg pad
with clearance for light alignment (about 5 mm). Check horizontal position of the frame in
both directions. Tighten the stud bolts.
Using the height adjustment screw, adjust the magazine barfeed approximately to the
height position. Tapping the pad, adjust the magazine barfeed approximately to the correct
side position.
The pusher should be on centerline with the spindle liner.
Continue with alignment according to chapter 3.3.3
Fig. 3.4 - Height and side pre-adjustment
23

3.3.3
ALIGNMENT
a) Preparation
To properly align the magazine barfeed to the lathe, an alignment kit including ring inserted
into lathe clamping device (3.6/1) and rear carrier of alignment cord (3.6/4) a centering gauge
(3.6/3) and an alignment cord (3.6/2), is supplied with each magazine barfeed.
To perform the alignment, proceed as follow:
Remove the pusher
Install the alignment kit supplied (fig. 3.6)
1. part 3.6/1 in the lathes clamping device
2. part 3.6/3 in the pusher front carrier
3. part 3.6/4 in the pusher rear carrier
Fix flag at the rear (using the mechanical stopper)
Pass the alignment cord 3.6/2 through rings 3.6/1, 3.6/3 and 3.6/4.
In the ring 3.6/4 secure the cord with a knot.
Tie the alignment cord between 40 to 60 kg and fasten it to the ring 3.6/1 on the front of
clamping device.
Place the centering magnetic gauge on the rear of the spindle with the point toward the
center of the spindle bore, where the alignment cord goes through 3.6/2. The centering
gauge must be made from a piece of flexible magnetic strip.
WARNING
When performing the alignment operations, make sure that the alignment cord
does not touch any metallic part at the front of the magazine barfeed or at the rear
of the spindle.
Fig. 3.5 - Centering magnetic gauge - rear view of the spindle

1. Centering magnetic gauge
2. Alignment cord
24
Fig. 3.6 - Alignment kit
25

b) Rough alignment before lagging to floor
All vertical and horizontal adjustments necessary to align the magazine barfeed to the lathe
are made with the adjustable front and rear leg (fig. 3.3 and 3.4)
Adjusting the rear legs (furthest from the lathe) will affect the alignment string relative to the
gauge (3.5/1) on the back of the spindle.
Adjusting the front legs (nearest the lathe) will affect the centering ring (3.6/3) relative to the
alignment string.
Always adjust the rear legs, then the front legs, as the rear adjustment alters the front centering
ring by a large amount, while the front adjustment alters the rear only minimally.
To get the correct height, use again the height adjustment screws in the legs. Check the height
with the centering ring (3.6/3) and the magnetic centering gauge (3.5/1) on the back of the
spindle. The general tolerance of final position is +/- 0.2 mm. The alignment tolerance before
anchoring to the floor should be +/- 0.5 mm.
WARNING
If the final positioning tolerance of 0.2 mm is not respected, it risks damage to
the lathe or the magazine barfeed during the automatic functioning, pusher could
touch the spindle liners in the spindle. SMW declines all responsibilities in case of
damage to the machines (lathe or magazine barfeed) due to the misalignment.
26

1. Check for any interference between cord and any part of the lathe or magazine barfeed
2. Rough align the magazine barfeed.
3. Center cord on spindle back by adjusting rear legs of the magazine barfeed. Once again
check for any interference of the wire.
OK
4. Center cord on front pusher guide by adjusting the front legs of the magazine barfeed.
Once again check for any interference of the wire.
OK
5. Carefully block adjusting screws (se chapter 3.3.1 and 3.3.2). Recheck the cord for
alignment and start again point 3 to 5 if necessary (if you did not get necessary tolerance).
Fig. 3.7 - Alignment
27

c) Anchoring the magazine barfeed to the floor
When the alignment is correct, bolt the magazine barfeed to the floor with the expansion bolts
(2 per each leg and 1 for table support) supplied.
Drill one hole per leg, using a masonry drill bit, to a depth of at least 110-120 mm
(preferably all the way through the floor)
Insert an expansion bolt before drilling the second hole.
The expansion bolts should not touch the bottom of the drilled holes.
Make sure that all expansion bolts are in place and tightened use the supplied washers (the
washers used to bolt the magazine barfeed to the wooden crate).
Fig. 3.8 - Lagging magazine barfeed to the floor

d) Final alignment
Fine adjustment may be necessary to complete the magazine barfeed alignment. Take out the
spacers from the holes around the stud bolts connecting the leg with pad and repeat operations
described in point b) on previous page, but move the magazine barfeed only on the leg pad.
When the magazine barfeed is adjusted in the correct position tighten all locking nuts and
fixing screws, then re-check the magazine barfeed alignment. The final positioning tolerance
is 0.2 mm. When the magazine barfeed is perfectly aligned, remove the alignment kit and
store it for future use.
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3.3.4 TABLE INSTALATION

To finish installation is necessary to install the table.
Remove the table switch from transport position inside the low machine cover and let
it hang freely on the cable at the back of barfeed.
Remove the right screw for table installation at the end distant from the lathe.
Disconnect table tray (4.4/3) from table frame (Loose 4 screws securing the top on the
frame at the bottom of the material tray and remove the top out by unscrewing the
central screw 4.4/1 for setting the position of the material tray.
Install the table frame by inserting the frame on left screw, insert the second screw
(right) and check, that the frame is roughly in center. If not, remove some spacers
under table fixing screws and finally tighten these screws.
Fix the table leg by expansion screw to the floor.
Install table tray 4.4/3 on the frame and center it in such way, that the claws will be in
center of the slots in table tray.
Check, if the table is parallel to the channel.
Last two items can be reach by correct setting 4 screws under table tray. At the end fix
these screws to allow free movement of table tray on table frame activated by screw
4.4/1.
Install the table cover using two screws on the side of it. Insert necessary number of
spacers to keep free movement up and down in grooves at basic barfeed body.
Install the table switch. SS2003 has switch completed with lever, which must be turn
from the barfeed body. SS2003 HD has switch on special mounting assembly. In all
cases check correct function of the switch. Opening the table cover must disconnect
PLC input 24. (Check it in manual mode, pushing Start, when this Input is displayed
on Output 14). To see the function of this switch, you must have the channel in
production position (not in the red field).
29
Chapter 4. Utilization
UTILIZATION
4.1
PRELIMINARY CONDITIONS
4.1.1
FOUNDATION, ALIGNMENT
The magazine barfeed must be carefully installed referring to the instructions in chapter 3.
4.1.2
SAFETY
The interface and the safety connections between the lathe and the magazine barfeed must be
correctly connected and systematically checked.
SMW declines all responsibilities if the interface wiring is not installed correctly (refer
to addendum 3)!
4.1.3
OPERATOR
A complete understanding of the lathe and magazine barfeed is essential for correct
functioning of the equipment and operator safety.
4.2
NORMAL (or STANDARD) PRODUCTION PROCEDURES
When changing bar stock (type, material, shape, size) a few adjustments of the magazine
barfeed and the lathe is required:
When changing the diameter of the bar stock:
1. Change spindle liners
2. Adjust correct height of channel (channel loader height)
3. Adjust loading bar tray position to separate 1 bar only
4. Change pusher
For large size bar stock:
1. Change pusher size
2. Adjust loading table angle
3. Adjust air pressure on the magazine barfeed
4. Adjust pusher speed
When you change the length of the part:
1. Adjust End of Bar switch B24, always place the front part of the bar in a position so that
the bar will actuate the switch B27 (material available)
When changing the clamping device type
1. Set the switch B25 (remnant ejection), with the end of the pusher 3-5 mm in front of the
chucking device.
2. Set the mechanical stop of the pusher so that the pusher doesnt go behind this point and
the switch B25 is activated.
3. Set switch B24. The position of B24 depends on position of B25 and length of the
machined part.
When changing diameter
1. If possible retract the pusher all the way from the lathe spindle.
2. If the pusher comes in contact with the spindle during machining set the PLC to retract the
pusher all the way.
30
4.3
GUIDING TECHNIQUE
The bar stock is guided into the lathe by a spindle liner. The inside diameter of the spindle
liner should be about 0.75 mm (0.030) larger than the diameter of the bar. This allows very
accurate guiding of the bar stock in the spindle, providing optimal speed and performance.
Spindle liner - made of a steel tube
Diameter
- spindle liner inside diameter = bar diameter + (min. 0.5 - max. 2.5)
mm
Concentricity
- spindle liner with spindle = 0.1 mm maximum (.004 inch)
Cone
- spindle liner max. 3 x 30
Straightness
- of pushed bar max. 0.5 mm/meter
Maximum clearance from the end of spindle liner to the back of the clamping device - 30 mm
(1.18 inch)
The bar diameter is much smaller than spindle inside diameter
The bar diameter is a little smaller than spindle inside diameter
Fig. 4.1 - Kinds of spindle liners
31
4.4
BAR STOCK FEED
The pusher assembly feeds bar stock to the previously adjusted turret stop. The spindle must
not be rotating as the stock is being loaded.
Fig. 4.2 - The barfeeding
4.5
INSTALLATION OR EXCHANGE OF A SPINDLE LINER

(WHEN CHANGING DIAMETER OF THE BAR STOCK)
It is the customers responsibility to ensure that spindle liners are available for the required
type and size of bar stock. The clearance between bar stock and spindle liner must be about
0.75 mm (0.030) (refer to chapter 4.3).
To install a spindle liner proceed as follows:
Raise the pusher to the top position (using the button on operators console in MANUAL
mode)
After opening of top cover loosen 2 locking screws 4.3/1 and lower the channel to the
lowest position by rotating handle 4.3/2 (off the scale 4.3/3 into the red field)
Remove the spindle liner from the lathe spindle
Install the new spindle liner into the spindle
Adjust channel height to suit the new bar stock diameter and tighten the locking screws
4.3/1.
WARNING
If the channel is out of permitted range of diameter (max. 80 mm), and the red
field on the scale 4.3/3 is displayed, operating the loading mechanism may cause
damage to the loading mechanism or other parts.
32
4.6
ADJUSTING CHANNEL HEIGHT - When changing bar stock

diameter
Raise the pusher to the top position (using the button on the operators console in
MANUAL mode)
After lifting the top cover loosen three fixing screws of the channel loader 4.3/1
Using the setting nut 4.3/2 set the channel loader to the position according to the bar stock
diameter, using the scale 4.3/3.
Put a new bar into the channel and manually move the bar into the spindle, check
alignment of the bar and of the spindle liner. If necessary, lightly re-adjust the channel
height.
Tighten the locking screws of the channel 4.3/1.
1
Fig. 4.3 - Setup of the channel height
4.7
ADJUSTING THE BAR TRAY - When changing bar stock

diameter
To ensure proper selection of one bar at a time, the table must be correctly positioned for the
bar stock.
Using the button S7 on the operators console in MANUAL mode move the loading
mechanism up into a position so that the claws are just bellow the bar stock tray.
Put bars (minimum 2) on the tray
Loosen nut 4.4/1 of setting screw 4.4/2 and use this screw to set the tray 4.4/3 to a position
so that the claws separate first bar and do not push second bar away. Try bar loading
sequence in MANUAL mode.
Check if the side distance screws under the table are tightened. If necessary use these
screws to set the table to right position according to the claws. For round bars, 3 to 10
degrees tray angle is advised according to the bar stock diameter.
For hexagonal and square bars over 20 degrees angle is advised.
WARNING
When the bar is loading, the channel must be empty. No other bar or tool is
allowed to be in channel at the time of loading a new bar. This is to prevent
damage or personal injury that may result.
33
4
3
2
1
Fig. 4.4 - The tray (table) setting for correct bar separation
Note: Bar stock must be cut to a proper length so that the bar is still supported by the
channel when being loaded into the spindle. The minimal length of the bar is determined by
the distance between the end of the channel and the end of the spindle. The bars center of
gravity must be still in the channel, and the front of the bar already in the spindle liner to
prevent bar falling to floor or becoming lodged between spindle liner and channel during
reloading process.
Note: The lathe must be equipped with a spindle orientation to load hexagonal or square
bar stock. When machining square bar stock a 90 adapter must be placed on front of the
channel loader.
34
4.8
PNEUMATIC CIRCUIT
4.8.1
GENERAL
The Pneumatic circuit controls the movement of the pusher with solenoid valves (see
pneumatic diagram in addendum 4)
The air supply unit (fig. 4.5/3) located on the rear side of the magazine barfeed secures
cleaning and drying of air and pressure adjustment.
Fig. 4.5 - The pneumatic circuit

1.
2.
3.
4.
5.
Horizontal pneumatic rod-less cylinder for flag and pusher motions

Solenoid valve (see - fig. 4.6)
The water trap and regulator unit (see - fig. 4.6)
Pressure switch
Relief valve
35
4.8.2
SETTINGS - MAINTENANCE
A
Y23
Y22
D
Fig. 4.6 - The water trap, regulator and solenoid valve

Settings
With relief valve (A) set pressure indicated on pressure gauge (B) to range from 1 bar for
light bars to max. 6 bar for heavy bars. This setting determines per application bar pushing
force. Too much pressure may cause damage to pusher mechanism or bar stock.
Set relief valve (C) pressure to 0.5 bar higher than the pressure setting on gauge (B).
Note: To guarantee correct function of the pneumatic components (especially speed of
movement) it is necessary to have an air flow rate of at least 17 to 20 liter/minute at the inlet
to the barfeed.
Maintenance
The air supply unit is equipped with a water trap (D), so check at least once a week or when
changing air pressure (changing size of bar stock.) Also check the tightness of the pneumatic
circuit and if the water trap bowl is empty.
4.8.3
ADJUSTING MOVEMENT SPEED
Setting is performed on the screws 4.6/E located on the solenoid valves in the magazine
barfeed.
Speed decreases when you turn the setscrews clockwise (use 4-mm hex key.)
Y22 Solenoid valve moves pusher forward.
Y23 Solenoid valve retracts pusher.
Speed should be set to the point, when the time of movement is:
a) movement of pusher forward 4.5 sec
b) movement of pusher retraction 3.5 sec
36
4.9
PUSHER
4.9.1
INSTALLATION OF PUSHER
One pusher (10 mm) is delivered with the magazine barfeed Spacesaver 2003.
1 pusher of diameter 10 mm for bar stock of diameter 15 - 80 mm - with solid tip
1 pusher of diameter 18 mm for bar stock of diameter 40mm and higher with solid tip
(SS2003 HD only)
4.9.2
ASSEMBLY AND DISASSEMBLY OF PUSHER
Loosen 2 hexagonal screws 4.7/2 on the lock of rear pusher holder and pusher 4.7/1 with
rear holder pull out from front bushing 4.7/3.
Change bushing in front holder for bushing adequate to size of the new pusher.
Insert pusher into the front bushing, rear holder put to the lock of pusher and tighten using
the 2 hexagonal screws.
Check and adjust position of pusher mechanical stop.
4.9.3
ADJUSTMENT OF PUSHER LENGTH
Loosen the pusher mechanical stop.

Move the pusher forward by hand until it passes through the collet by 0.25 in.
Move the mechanical stop of the pusher forward until it touches the front support.
Tighten the mechanical stop.
Check if the switch B25 gives signals in this position. Adjust the switch, if necessary.
Fig. 4.7 - Pusher Assembly and disassembly

1. pusher
3. front bushing
2. hexagonal screw on the pusher lock

4. mechanical stop guide bar
37
4.10
ELECTRICAL PART
4.10.1
OPERATING PANEL
Q1
Main switch (located on left side of the frame)

0 = OFF, 1 = ON
S7
S9
S3
S5
H14
H15
S1
Fig. 4.8 - Operating panel

S1
Emergency (total) stop Immediately switches off the magazine barfeed and sends
error signal to the lathe, which should also stop.
S3
Operation mode selector switch

CHUCKING this allows the lathe to operate without magazine barfeed.
These conditions on the unit are necessary:
1. Main switch on the magazine barfeed is ON
2. Pusher is fully retracted (out of the spindle)
MANUAL
This allows to operate the unit manually. When the pusher is in the
highest or the lowest position the flag (pusher) can be operated forward or backward.
When the flag is fully back, the loading mechanism can move (the loading claws can
rotate) and at the same time the pusher raise or lower.
AUTO
This allows fully automatic barfeeding/machining cycle.
COUNT
This has the same function as AUTO but it stops the unit, when the
selected number of bars has been completed. To select the number of bars to be
machined, push the switch S9 forward (each push for one bar). If you select just
function COUNT the unit will stop when machining bar is completed. The count setting
is not dependent on the condition of lathe. When re-selecting AUTO mode, the counter
will be reset (the number on the bar counter will be reset).
38
S5
Start switch
To activate AUTO mode push START button. The unit is now ready for automatic
cycle.
S7
Pusher up and down

Permits pusher up or down travel. You can select this operation, only when the
magazine barfeed is set in the manual mode and the flag is fully retracted.
S9
Pusher forward and backward

This allows the movement of the pusher or flag backward and forward depending on if
the pusher is in up or down position. This movement is operational only when the
magazine barfeed is set in the manual mode and the pusher is in limit up/down position.
S11 Pusher fully retracted

When the switch is in one of positions (I0,21 is active) the pusher will move fully back
(out of spindle), after it has pushed material and the material has been clamped. When
the switch is in the other position (I0,21 is not active), the pusher will move back about
50 mm from end of material after the material has been clamped.
Note 1: There are two reasons to use the full retraction of the pusher:
1. When there is vibration problem (magazine barfeed or pusher).
2. When there is danger of contact of the pusher with the spindle liner (when
using pusher and its outside diameter is close to inside diameter of the
spindle liner).
Note 2: It is recommended, to fully retract pusher out of the spindle.
S12 Reversing of the loading motor direction
Reversing of the motor is possible only in the manual mode and it is used if collision or
binding of loading device occurs. The switch is located on side of the electric box. If the
reversion is activated in auto mode an error is signaled. . This reverse movement can be
also used for changing spindle liners or testing channel position setup for huge bars. In
all this cases the table must be free.
39
4.10.2
ERROR SIGNALS AND MEANING OF LAMPS H14 AND H15
Lamps H14 (green) and H15 (red) are basic indicators of the magazine barfeed condition. If
the magazine barfeed is OK the green lamp is on. When an error occurs, the red lamp is on.
Basic rules:
If the red lamps is flashing fast (period 0.1 s) without stopping or with 1-sec intervals, the
magazine barfeed is in some error situation, refer to error signals on the next page. You
can stop this situation when you switch to manual mode.
If the red lamp is flashing slowly (period 1 s) the magazine barfeed is doing the start
sequence, or its signaling that the lathe is not ready for the automatic operation (signal
lathe in AUTO is missing), refer to Basic meaning of the lamps on the next page.
If the red lamp is ON all the time, the magazine barfeed correctly finished operation
because the set number of bars was machined or there is no material, refer to basic
meaning of the lamps on the next page. If the green lamp is flashing (period 1 s) and the
red lamp is not ON, the pusher is pushing forward (to working area of the lathe) or its
loading a bar, refer to Basic meaning of the lamps on the next page.
Motor reversal:
If the motor reversal (S12) is selected, the red and green lamps are
flashing alternately (period 1 s) in all modes.
Emergency stop:
If any of the emergency stop buttons is pressed, or the top cover of the
magazine barfeed is open an error is caused Emergency stop. But this also causes
disconnection of power supply to the part of PLC output. PLC so both the lamps are OFF.
After the top cover is closed, power is supplied again to the PLC outputs, and both lamps
being on indicate the error.
All errors of magazine barfeed are indicated by PLC output LEDs, when MD LED is
ON (O0.8, O0.9, O0.14 and O0.15; see next page).
Interruption of power supply:
This interruption in automatic mode will cause canceling
of the auto mode, when the supply returns, it will signal fault emergency stop. Any fault
condition (caused before power supply interruption) is preferred to emergency stop signal
caused by power supply interruption. So just turning the barfeed ON/OFF wont remove any
AUTO mode fault. You need to reset the barfeed, using the S3 mode selector switch by
switching it to MANUAL mode, to remove any fault.
Note: In MANUAL mode when the start button is pressed, adequate outputs O0.14 and
O0.15 to inputs I0.24 (input from tray hood switch) and I0.25 (input from K1R relay indication of loading mechanism rotation direction).
40
Bit number
H15 red
(O0.5)
H14 green
(O0.6)
Alarm 4 (O0.15)
Alarm 3 (O0.14)
Alarm 2 (O0.9)
Alarm 1 (O0.8)
Value from SS2003_2E, SS2003_3E (HD) version

Explanatory note:
OFF ............. Switch off
ON; l .......... Is ON permanently
OFF/0.1 ....... Switch off/ flashing in interval 0.1 sec
0.1 ............... Flashing in interval 0.1 sec
1; ............. Flashing in interval 1 sec
MBF............. Magazine barfeed
Basic meaning of lamps H14 and H15 in automatic mode of MBF

1
OFF
ON
ON
1
ON
OFF
1
1
1
OFF
OFF
ON
ON
B47
MBF is starting
MBF is in starting position and lathe is not in AUTO mode
Channel is in the low limit position loading impossible
MBF in AUTO or COUNT mode all is OK
MBF is loading or pushing bar
Number of bars are finished COUNT mode
Bar is not available
Error signals of MBF in automatic mode (MD mode activated MD LED is ON)
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
1
OFF
OFF
OFF
OFF
OFF
OFF
0.1
1
OFF/0.1
0.1/OFF
OFF
OFF
OFF/0.1
0.1
0.1
0.1
0.1
0.1
OFF/0.1
OFF/0.1
0.1
0.1
0.1
0.1
0.1
OFF/0.1
0.1
0.1
OFF/0.1
0.1
0.1
B42
B41
B36
B37
B38
B39
B40
B45
B46
B34
B57
B48
B49
B50
B60
B59
M-function during controlled ejection of bar remnant

Slow controlled ejection of bar remnant (max. 8 sec)
Slow movement (- 4 s, 1.5 s, 8 s; HD:- 7 s, 2.5 s)
The error of vertical movement switch
The error of horizontal movement switch
The error of material available switch B27.
The chuck closed during bar loading
The Lathe AUTO mode signal is lost during loading
M-function is not finished
Open chuck/collet during starting
Motor reversal
Undefined starting position of pusher
Low input air pressure
Emergency stop (I0.0=OFF)
Loading impossible B28 is not active
NK1, B20 or B21 signals lost
User error identification

When AUTO or COUNT mode of BF is active:
When is not any fatal error of BF, all output LEDs mean the states of the PLC outputs.
When is any fatal error of BF present, the PLC is changing regularly the meaning of the
output LEDs:
MD LED is ON
Output LEDs are showing any fatal error (see the error
matrix on this page).
MD LED is OFF
Output LEDs are showing the states of the PLC outputs.
Note:
MD LED (MD mode) is permanently SET after the PUSHER UP button pressing.
MD mode is permanently RESET after the PUSHER DOWN button pressing.
MD mode is regularly changing after the PUSHER BACK button pressing.
Note:
MD LED is next to output LEDs of PLC.
41
4.10.3
EXPLANATION AND FUNCTION OF THE SWITCHES
B25
B20
B24
B21
S20
B28
B27
ENCODER (NK1, NK2, B26)
SQ23
Fig. 4.9 - Location of the switches

B20
Pusher up
Input 12 on the PLC is activated if the pusher is its highest position
B21
Pusher down
Input 13 on the PLC is activated if the pusher is in its lowest position
Note: The end switches B20 and B21 can activate only when the claws are rotating in
normal direction. If the claws rotate against this direction, lever end switches B20 and B21
are not activated refer to chapter 4.11.
NK1 Pusher/flag backward
Input 14 on the PLC is activated if the pusher or flag is fully backward.
NK2 Flag forward
Signal from the magnetic lever end switch located in measuring strip. Input 15 on the
PLC is activated if the flag is fully forward. The front of the flag is in the same
position as the front of the channel, so the bar left the channel.
42
B24
End of bar
Input 16 on the PLC is activated if the pusher is in position when there is not enough
material to machine another part. (flag passed proximity switch B 24).
B25
Remnant ejected
Input 17 on the PLC is activated if the pusher is stopped by the mechanical stop. The
proximity switch confirms that the remnant has been successfully ejected. In this
position the front end of the pusher little bit further than the front end of the chucking
device (3-5 mm).
B26
Pusher/flag in motion
Signal from the movement detector in measuring strip. As the flag is moving the input
18 on the PLC alternately activates and de-activates. This is used to find out if the flag
is moving.
S20
Pressure switch
The input 19 on the PLC is activated, if the air pressure is OK. If the air pressure
coming in the unit is lower than 2,5 bars and the magazine barfeed is pushing material
using the flag/pusher, an error of the magazine barfeed is signaled.
B27
Material available
Input 20 on the PLC is activated as the loading mechanism is loading the bar into the
channel. If there is no bar on the claw, when loading, input 20 is not activated and an
error of the magazine barfeed is signaled.
B28
Loading possible
Input 24 on the PLC is activated as the material channel is in loading position. Input 24
is not activated as the material channel is in down position for spindle liner change
(the loading is impossible).
43
4.10.4
SETTING THE PROXIMITY SWITCHES B24 AND B25
B25
B24
H ..... Length of machined part

I....... Thickness of the cutting tool
J ...... Machining safety zone
K ..... Length of chuck jaws
Fig. 4.10 - Setting the proximity switches B24 and B25

B24 End of bar
This switch is set in a distance A behind the switch B 25. This distance is sum of
distance of part (H), thickness of the cutting tool (I) and clamping length of jaws of the
clamping device (K). This setting will ensure that there is always enough material to
clamp the bar, while the last part is being machined (see fig. 4.10). Although safety
zone (J) influences length of the remnant, it has no influence on distance A between
proximity switches B 24 and B 25.
B25 Remnant ejected
When the pusher is on mechanical stop (D) the proximity switch must be set above the
metal strip of the flag. Mechanical stop of the pusher is activated if the front end of the
pusher exceeds (0.25-in.) the front of the jaws (see fig. 4.10).
Note: The proximity switches should be set so there is 1 mm between the switch and the
surface that activates it.
44
4.10.5
HOW TO PROGRAM THE LATHE
FEEDING PROGRAM - the lathe must analyze signal end of bar, which is input of PLC and
it may be checked by parameter PLC, M-code or by mode /.
EOB controlled with a / command
(EOB = end of bar)
Spindle stop
/ command
no EOB:
go to the next line
with EOB: call the loading program or sub-program
Move the turret stop to the front end of the bar (2 mm distance between bar and stopper).
Open the collet/chuck jaws. (Possible M-code as another order for the magazine barfeed to
push bar).
Time to push the bar out
(Max 4 seconds for pusher fully out, Max 1 seconds when pusher is left in the spindle)
The pusher will push the bar to the turret stop.
Move the stop in position to machine a new part (max. speed 5m/min).
Close the collet/chuck jaws.
Time for pusher to leave the part (about 0.5 seconds - pusher stays in the spindle)
(Max 4 seconds for the pusher fully out, Max 1 s when pusher is left in the spindle)
Machine the part.
EOB controlled with a M function
Spindle stop
M code
no EOB:
go to the next line
with EOB: call the loading program or sub-program
Move the turret stop to the front end of the bar (2 mm distance between front of the
clamping device and stopper).
Open the collet/chuck jaws. (Possible M-code as another order for the magazine barfeed to
push bar).
Time to push the bar out
(Max 4 seconds for the pusher fully out, Max 1 second when pusher is left in the spindle)
Magazine barfeed push the bar to the turret stop.
Time for pusher to leave the part.
Machine the part.
45
RE-LOAD CYCLE PROGRAM
Spindle stop
Move the turret head stopper to the front end of the bar (2 mm distance between bar and
stopper).
Open the collet/chuck jaws.
M-code (to eject the remnant - start loading cycle)
Dwell 2 seconds (if does not need to be programmed, if the magazine barfeed cancels the
static M - code)
Move the turret stop in Z+ so that you get distance between collet/chuck jaws and the stop.
This distance must be big enough to eject the remnant. Max speed 5m/min.
Dwell 8 sec. This dwell will ensure that the magazine barfeed can send out an alarm
before the lathe moves in Z- if the remnant has not been ejected.
Move the turret stop to the front of collet/chuck (2 mm between front of the clamping
device and the stopper)
M-code (to push a new bar to the lathe turret stop)
Time for pusher to leave the part.
Go back to the main program
WARNING
It is unconditionally necessary to enter 8-second dwell after the remnant ejection!
If this dwell is shorter, a collision of turret head and remnant can occur, if the
remnant has not been ejected because it is blocked. This dwell does not influence
the time to load a new bar, because the magazine barfeed during this dwell is
loading a new bar. It is possible to shorter other time dwells after testing. Test only
the last bar (pusher all the way out).
46
4.10.6
FLOW DIAGRAM OF THE MAGAZINE BARFEED PROGRAM

program of version SS2003_xx
mode without M-function
inputs and
outputs
Waiting
I 0.03
Chuck open
Pusher forward
no
End of bar
?
O 0.02
yes
I 0.16
Chuck closed
Chuck closed
Pusher retract
Pusher retract
I 0.03
O 0.03
25 mm retraction or full
retraction
depends on S11 switch
Waiting
Chuck open & M-function
Continue from end of next

page
Push remnant to
turret stop
(optional)
Remnant on stop (B26)
Ejecting of
remnant by
pusher and Mfunction finish
Remnant ejected (B25)
Pusher
backward
47
I 0.03
I 0.09
O 0.02
I 0.18
O 0.02
O 0.12
I 0.17
O 0.03
inputs and
outputs
I 0.14
Pusher back
O 0.00
Loadnew bar
I 0.12
Pusher up (SQ20)
no
Pusher
down
Material
available
(B27)
yes
I 0.20
Push new bar by

flag
Flag in front (NK2)
Pusher down (SQ21)
Flag backward
Flag back (NK1)
End
Pusher down
O 0.02
I 0.15
O 0.03
I 0.14
O 0.1
Pusher down (SQ21)
I 0.13
M-function
I 0.09
Waiting
Shift of new bar to

stop of tool head
by pusher
Bar on stop (B26)
M-function finish
pusher is still
pushing
Chuck closed
Continue on midle of
previous page
48
O 0.02
I 0.18
O 0.12
O 0.02
I 0.03
4.10.7
GETTING THE AUTO CYCLE STARTED AND STOPPED
a. Before starting work and turning the lathe ON check:

1. That pusher is fully back and down (out of spindle).
2. That magazine barfeed is connected with the air supply and its main switch is
turned ON.
3. That mode selector switch on magazine barfeed is in mode Chucking, which
allows independent work of the lathe.
b. Start the lathe and prepare the magazine barfeed for auto cycle.
1. After turning the lathe on, reach references and do all steps to start auto cycle. The
magazine barfeed when in Chucking mode wont influence your work. Clamp a
bar in the clamping device by hand, after you have done all preparation steps. Set
the requirement to pull the pusher out of the spindle using the switch S11.
2. Put the magazine barfeed into Auto mode and press Start button.
Operations:
a. Choose Auto mode using the switch S3.
Activate Start using button S5.
Spacesaver will now check position of material using the pusher. Green (H14) and red
(H15) lamp is flashing in 1-s intervals. If this process is successfully finished, some of
these conditions will stabilize.
1. Green lamp (H14) is ON.
Lathe and magazine barfeed are ready to machine.
2. Red lamp (H15) is flashing in 1-s intervals.
Lathe is not set in auto mode (input I0.11 is not activated)
Conditions necessary for lathe to start automatic operation of lathe and magazine
barfeed:
1. Collet/Chuck jaws are closed (input 10.3 is not activated)
2. Lathe in auto mode and magazine barfeed operation allowed.
3. Magazine barfeed is ON.
Conditions necessary for magazine barfeed to start automatic operation of lathe and
magazine barfeed:
1. Pusher is fully down and back (inputs I0.13 and I0.14 activated)
c. To start Automatic operation of lathe with magazine barfeed, start lathe Automatic
cycle.
d. Finish the combined operation of lathe and magazine barfeed as follows:
Choose the Count mode on magazine barfeed (with number of bars to be finished, if
necessary). After the set number of bars is finished, no more bars are loaded and
automatic operation of lathe will be stopped by alarm - both lamps (green and red) are
ON (not flashing). Then switch the magazine barfeed into Chucking mode and do all
finishing steps of the lathe alone. Do not turn the magazine barfeed off using the
main switch (this switch is just for service purposes).
49
4.10.8
INTERFACE
FROM THE LATHE TO THE MAGAZINE BARFEED

These signals on the lathe side are carried out by relay contacts or by switches. Signals are
supplied 24 VDC from the magazine barfeed.
Emergency (Total) stop on the lathe
pin 4 and 5 on X1 - input I0.00 on PLC indicates status.
Immediately stops magazine barfeed and lathe.
Lathe in AUTO mode
pin 11 on X1 - input I0.11 on PLC signals status.
Allows magazine barfeed to run in automatic mode. After the magazine barfeed is started, the
green lamp is ON (continuous). If signal from the lathe is not active, the green lamp is OFF
and the red lamp is flashing in 1-second intervals.
Signal activated
- lathe auto cycle
Signal not activated
- lathe manual cycle only
Note: This is a safety signal from the lathe, proper operation requires this signal at I0,11
prior to the receipt of I0,03 or the barfeed will fault. This signal can be accomplished though
either an AUTO output from the lathe, or (preferably) a Lathe door closed signal. This
input is allowed to drop out (opening lathe door) under the condition that the pusher is not
requested to perform forward motion, otherwise a fault will occur.
Clamping device open (collet)
Pin 12 on X1 - Input I0.03 on PLC signalizes status.
The signal to the magazine barfeed to feed bars.
Signal activated
- collet open
- collet closed (the logic of this signal can be also reversed,
see input I0.22)
Note: When the collet is closed, the pusher stays 0.5 or 3 seconds under pressure.(See
4.10.9.)
Note: By choosing mode of the magazine barfeed, it is possible to complete the condition to
push with M-code (for signal collet open).
50
M-code
Pin 9 on X1 - Input I0.09 on PLC signals status.
It can be pulsing (after certain amount of time the signal vanishes without magazine barfeed
initiative) or latching which requires a finish signal provided by the barfeed to confirm end of
M-function. The latching signal is preferred. The lathe is programmed according to type of
M-code. In loading cycle the first M-code is used as a signal to eject remnant and load a new
bar into the spindle. A second occurrence of the same M-code is the order to push the new bar
to the lathe stop.
FROM MAGAZINE BARFEED TO THE LATHE

These signals are carried out by relay contacts on magazine barfeed side.
Signals are supplied 24 VDC from the lathe.
Emergency stop on the lathe
pin 21 and 22 on X1 - Immediately stops magazine barfeed and lathe.
Magazine barfeed OK
pin 14 on X1 - Output O0.07 on PLC
Safety signal from magazine barfeed informs lathe that magazine barfeed is OK and it is ready
for function.
Signal activated
- no errors on magazine barfeed
- magazine barfeed signals error
Note: This signal is also activated when the main switch on magazine barfeed is ON,
magazine barfeed is in CHUCKING mode and pusher is fully back (I0.14 is activated). This
allows lathe function without using the magazine barfeed.
Note: This signal always reports an error when in MANUAL mode.
51
End of bar - EOB
Pin 16 on X1 - PLC output O0.10 signals status.
Signal activated
- end of bar reached
- end of bar not reached (enough material to clamp)
This signal will be sent to the lathe during feeding cycle, when pusher passes proximity switch
B24 (end of bar) and is canceled on beginning of loading cycle. Position of proximity switch
B24 is set per application.
Setting proximity switch B24 during testing EOB before machining:
Set the pusher tip 3 - 5 mm in front of the lathe-chucking device and mark position of
flag activating the proximity switch. If the EOB is checked in NC program before
feeding, move the EOB proximity switch to distance that equals to length of the part
plus length of clamping device jaws in direction from the lathe. If normal NC program
is running (see chapter 4.10.5) and signal EOB is not sent, the bar is normally moved to
distance that equals to length of the part. If this movement activates the proximity
switch program for machining last piece is called. The lathe should check for END OF
BAR at the beginning of the program before it signals the barfeed to push out another
part.
Checking EOB signal - EOB after loading cycle for part production:
Move the EOB proximity switch to the marked position that is shorter of clamping
distance. If you pass this position while pushing bar, it will signal that there is not
enough material for next clamping. So the EOB test is made after machining.
Spindle inhibit
Pin 17 on X1 - Output O0.11 on PLC signals status.
Signal tells to lathe that it can start spindle rotation.
Signal is activated
- authorizes spindle rotation
Signal is not activated - forbids spindle rotation
Note: In CHUCKING mode, the signal is active if the flag is in rear position.
M-code finish
Pin 18 on X1 - Output O0.12 on PLC signals status.
M-code finished.
Signal is activated
- M-code canceled (finished)
Signal is not activated - M-code not canceled (finished)
Signals to the lathe that the M-code command has been satisfied...
52
4.10.9
MODIFICATION OF THE PROGRAM CONTROL
Function of the SS2003 can be modified using inputs I0.10, I0.22 and I0.23.
I0.10 Bar pushing after CHUCKING device opens.
This PLC input defines if the bar should be pushed when the clamping device opens, or if
special order (M - code) to load bar is necessary.
I0.10 not active
push when clamping device opens and M-code is present
I0.10 active
push when clamping device opens
I0.22 Change of logic of signal Clamping device opens (I0.03)
This PLC input defines polarity of the signal Chucking device open.
I0.22 not active
clamped when I0.03 in not active
I0.22 active
clamped when I0.03 is active
I0.23 Time switch - chuck delay
This PLC input defines the pushing time backward after collet closing
I0.23 not active
pushing time is 0,5 sec.
I0.23 active
pushing time is 3 sec.
53
4.11
LOADING MECHANISM REVERSE ROTATION
You can use this mode only on a barfeed equipped with the option of choosing the direction of
loader rotation.
You will use this mode just for special situation.. For example when adjusting the machine
and you may need to unload the bar from the channel back on the tray.
Steps
1.
Remove bar from the tray or secure them so the claws do not push them back during the
reverse rotation.
2.
Using the mode switch S3 choose Manual mode.
3.
Switch the rotation direction switch S12 on the electric box of the magazine barfeed (see
fig. 3.2).
The magazine barfeed signals the reverse movement of the loading mechanism with
the red and green lamps. The lamps will alternate, one on while the other lamp is off.
(see chapter 4.10.2)
4.
With any button S7 for vertical movement of the pusher unload the bar from the channel
on the tray.
If one button S7 does not work, the other one S7 will work.
5.
Now the claws are close to their down lower limit position. With maximum caution
continue moving the claws in the reversed direction until there are close to their upper
limit position. Here stop before the claws hit the bar we just unloaded.
6.
Using the switch S12 choose normal direction of rotation of loading mechanism.
The magazine barfeed signals normal movement of the loading mechanism using the
lamps. The flashing of the lamps stops (see point 3).
7.
If everything is all right press the button S7 for pusher movement down (not up) and
hold it until the claws stop in position under the tray.
The loading claws will move in normal direction under the tray and pusher will be in
its lower limit position. In this position the loading mechanism stops to react on
signals from button S7.
Note: Lever switches B20 and B21 are activated only when the loading mechanism rotates
in normal direction. When the loading mechanism rotates in reversed direction, these two
lever switches are not active.
WARNING
If free movement of the claws through the tray is not addressed (see point 1), you
risk damage to the loading mechanism. Damage caused by not following the steps
on this page (chapter 4.11) is not covered under warranty.
54
55
Addendum 1
ADDENDUM 1
MAGAZINE BARFEED - LATHE
COOPERATION DIAGRAM
(Mode without M-function)
56
Addendum 1
57
Addendum 1
Addendum 1 Magazine barfeed lathe sequence diagram

Proximity switches
End of bar (EOB) B24 B25 Remnant ejected

Step
Barfeed
Lathe
1a
Waiting.
Brings turret head

stopper to the
clamping device.
Check EOB.
If no EOB continue.
2a
Pusher forward.
3a
Pusher forward.
4a
Pusher
backward.
Opens the collet.
Sets the stopper to

the length of the part
Closes the collet.
5a
Waiting.
Machining the part.
6a
Waiting.
Cuts off the part.
58
Addendum 1

Proximity switches

Step
Barfeed
Lathe
1b
Waiting.
Brings turret head

stopper to the
clamping device.
Check EOB.
If no EOB continue.
2b
Pusher forward.
3b
EOB B24
Pusher forward.
4b
Pusher
backward.
Opens the collet.
Sets the stopper to

the length of the
part.
Closes the collet.
5b
Waiting.
Machining the part.
6b
Waiting.
Cuts off the part.
59
Addendum 1

Proximity switches

Step
Barfeed
Lathe
Waiting.
Brings turret head

stopper to the
clamping device.
Check EOB.
CALL subprogram.
8
Pusher forward.
Opens the collet.

Send M-code.
9
Pushing out
the remnant.
End of M-function.
10
Remnant ejected B25
At B25 pusher moved

away.
11
Loading a new bar

into the channel.
12
Flag forward to
introduce a new bar
Into the spindle.
60
Turret moves away

to eject the remnant.
Turret moves away
to eject the remnant.
Dwell 8 s.
Turret moves into

the position to receive
new bar to departure
position (in front of
clamping device).
Addendum 1

Proximity switches

Step
Barfeed
13
Pusher forward
(loading the new bar).
14
As the new bar is

against the turret end of M-code.
15
Pusher backward.
16
Waiting.
Lathe
Sends M-code.
Closes the collet.
Machinig new bar

face.
Go back to the 1a step.
61
Addendum 2
ADDENDUM 2
ELECTRICAL DIAGRAMS
62
Addendum 2
63
Addendum 2
64
Addendum 2
65
Addendum 2
66
Addendum 2
67
Addendum 2
68
Addendum 2
69
Addendum 2
70
Addendum 2
71
Addendum 2
72
Addendum 2
73
Addendum 3
ADDENDUM 3
STANDARD INTERFACE DIAGRAMS
74
Addendum 3
75
Addendum 3
76
Addendum 3
77
Addendum 4
ADDENDUM 4
PNEUMATIC DIAGRAM
78
Addendum 4
79
Addendum 4
80
Addendum 4
81
Addendum 5
ADDENDUM 5
SPARE PARTS
82
Addendum 5
83
Addendum 5
Basic spare parts for SS2003:

a) Mechanical parts
Group/part No.
1-01
Drawing No.
09 38 002
09 38 008
09 38 004
1-02
1-03
1-04
08 38 100
09 24 000
09 24 003
09 24 005
1-05
1-06
1-07
1-08
1-09
09 27 000
09 27 003
09 27 005
09 16 100
09 38 005
08 38 004
09 23 000
09 23 004
09 27 005
1-10
1-11
1-12
Name, description
Alignment kit
Centering ring D 20/19
Cord holder
Bushing with screw M4
Alignment cord D 1,5
Adjusting key
Expansion screw
Complete pusher D 6
Pusher D 6
Bushing D 6
Holder D 6
Complete pusher D 10
Pusher D 10
Bushing D 10
Holder D 10
Proximity switch holder
Side alignment accessory kit
Spacer tubes
Complete pusher D 18
Pusher D 18
Bushing D 18
Holder D 10
Single-row ball bearing 6004 2ZR
Roller chain 081-1
Chain coupler 081
b) Pneumatic parts
Group/part No.
2-01
2-02
2-03
2-04
2-05
2-06
Drawing No.
Name, description
Rod-less cylinder D 32 L 1660
type M/46132/1660
Air water trap & regulator
Solenoid valve unit
Relief valve
Pressure switch
Hose D 8
84
Addendum 5
c) Electrical parts
Group/part No.
3-04
3-05
3-06
3-10
3-11
3-12
3-13
3-17
3-18
3-19
3-20
3-21
3-22
3-23
3-25
3-26
3-27
3-28
3-31
3-32
3-33
3-34
3-35
3-36
Drawing No.
Name, description
Start button (T10 ACE)
Proximity switch (XS1N12PA340D)
Proximity switch cable with connector
(XZCP1241 L5)
Relay 24VDC (RP700PC-P)
Relay ZT 4P 5A 24VDC (ZT570024)
PLC (TSX-1724012E)
EEPROM (TSX MC70E38)
Power module 24VDC
Main switch (S25JU1102A6)
Measuring strip ESSA (LRC 1660B)
Limit switch for loading - kit
Switch S11
Switch up/down, FWD/BWD
Mode overswitch
Cover switch XCK-T511
Power supply - rectifying board TRU-SU 06
Power supply - transformer TRONIC 000 4354
Motor 122194
Fuse T 8A
Fuse AL 15A
LED signal lamp red (XB5 AVB 3)
LED signal lamp green (XB5 AVB 4)
Fuse GT 4A (200-240 V)
Fuse GT 2A (400-575 V)
85
Addendum 6
ADDENDUM 6
METHODS HOW TO TROUBLESHOOT
86
Addendum 6
87
Addendum 6
6.1
METHODS HOW TO TROUBLESHOOT PLC
All lamps are off, PLC does not responding

Check the fuses F1, F2, F3. Location of fuses shown in Addendum 2 on page 63.
Check also fuse connections.
Green lamp on PLC RUN/STOP is on but PLC is not responding
Check Input 0 on the PLC unit. If the LED is off, the Emergency-stop circuit of the lathe or
magazine barfeed is open. Check the wiring on pins 4 and 5 of X1 connector.
Also check the connections and relay for Emergency-stop on the lathe and the magazine
barfeed.
Green lamp RUN/STOP is flashing
The PLC is stopped (program is not running). To repair Re-Initialize PLC
Green (RUN/STOP) and red (I/O) lamps are flashing alternately
There is no program in PLC memory. To repair Re-Initialize PLC
Red I/O lamp is on
I/O Fault - Possible short-circuit on input or output side.
Red I/O lamp is flashing
RAM memory fault. To repair Re-Initialize PLC
Note:
6.2
The BATT (battery) lamp is normally on.
METHODS HOW TO TROUBLESHOOT

PUSHER/CHANNEL
Pusher drifting backward or forward/ Flag is not stopping immediately after forwardbackward button is released.
The solenoid valve does not work correctly.
Check guiding of flag carrier on horizontal pneumatic cylinder.
When checking solenoid valve first check if its electrical control works (lights PLC output
and valve solenoid is operated). If you identify the fault to be in the electrical part of the valve,
it is necessary to change this valve. If the electrical part is OK, check the mechanical part.
First remove electrical connector and try to control the valve by hand (manual over-ride
yellow control button). If the valve does not move, remove the inlet hose and spray lubricant
into the valve (for example WD. 40). If the function does not get any better its necessary to
change the valve.
88
Addendum 6
The pusher is moving slowly
First check the air pressure which must be set according to the size of the bar (2 5 bars). You
should also check the airflow that is adjustable by screw on the outlet of the solenoid valves.
Cause of the problem can be also partially blocked silencer (exhaust muffler) of the solenoid
valve. You can remove the valve and clean in degreasing agent. If you have very dirty air you
can see plenty of sediment in the supply hoses. The sediment may not cause immediate
problem, but it can later cause blockages throughout the system.
Pusher moves in the opposite direction when collet opens or closes
It is necessary to change logic of input I0.03, see chapter 4.10.9.
Pusher vibration
Magazine barfeed may not be aligned with the lathe spindle center (see Installation). Remove
the vibration by retracting pusher fully out of the spindle before machining part. To retract the
pusher out of the spindle put the switch S11 (located under operators panel) in position when
input 21 on PLC is active. The cause of the vibration can also be worn-out bearings of the
pusher, the front carrier or bent bar of the pusher. 6 mm pusher is necessary to pull fully out
of the spindle after any pushing of bar. Use the largest diameter pusher when possible and
optimal working pressure.
6.3
METHODS HOW TO TROUBLESHOOT WARNING

SIGNALS
Error signal of the lathe when magazine barfeed is not being used
Main switch of the magazine barfeed is not on, the mode selector switch of the magazine
barfeed is not in CHUCKING mode or pusher is not fully back.
You can clearly identify the error of the magazine barfeed in AUTO mode using the outputs
O0.08, O0.09, O0.14 and O0.15 on PLC of the magazine barfeed (see chapter 4.10.2).
89
Addendum 6
6.4
METHODS HOW TO TROUBLESHOOT VARIOUS

PROBLEMS
The magazine barfeed signals no material although the bar was loaded
Loaded bar must activate signal of proximity switch B27. Bars must be placed on the tray so
they will activate the proximity switch on the claw. The metal strip that activates the
proximity switch, must freely movable and it must activate the switch. If the switch does not
activate, check if the sensing distance between the switch and the metal strip is 1 mm, if
neccessary, replace the proximity switch.
90
Addendum 6
91
Addendum 7
ADDENDUM 7
INPUTS AND OUTPUTS
92
Addendum 7
93
Addendum 7
7.1
IDENTIFICATION OF ERRORS INPUTS
With S3 mode switch in CHUCKING position check function of all proximity switches. Input
I0.00 must be activated.
I0.00 Emergency stop - Must be active to turn on barfeed. If not check pins 4 and 5 of the
X1 connector.
I0.01 Input from mode switch S3 from MANUAL-AUTO-COUNT
I0.02 Input from mode switch S3 from MANUAL-AUTO-COUNT
I0.03 Input from lathe indicated collet status
signal not active - collet closed,
signal active - collet opened
(if input I0.22 is not active)
I0.04 Input from S5 switch Start
I0.05 Input from S7 button pusher up
I0.06 Input from S7 button pusher down
I0.07 Input from S9 button pusher forward
I0.08 Input from S9 button pusher backward
I0.09 Input (order) from lathe for feeding bar stock (M-function)
I0.10 Input from mode switch
signal not active - mode with M-function,
signal active - mode without M-function
I0.11 Input AUTO from the lathe

signal active - lathe in AUTO
I0.12 Input from B20 end switch
signal active - pusher up
I0.13 Input from B21 end switch
signal active - pusher down
I0.14 Input from NK 1 magnetic switch in measuring strip
signal active - pusher back
I0.15 Input from NK 2 magnetic switch in measuring strip
signal active - pusher forward
I0.16 Input from B24 proximity switch
signal active - end of bar
94
Addendum 7
I0.17 Input from B25 proximity switch
signal active - remnant ejection confirmed
I0.18 Input from movement encoder
If the pusher moves, this input should be flashing.
I0.19 Input from S20 pressure switch
signal active - air supply is OK
I0.20 Input from B27 proximity switch for material available
signal active - bar is being loaded into the channel
I0.21 Input from S11 lever toggle switch
signal active - pusher fully out of the spindle after each feeding
I0.22 Input chuck reversal mode
reversal of logic of input I0.03 (see chapter 4.10.9)
I0.23 Input for 3 sec chuck delay
Increase the pusher dwell to 3 seconds to allow the chuck to close
I0.24 Input from the loading possible switch B28
signal is not active - channel in down position (loading impossible)
I0.25 Input from S12 direction of movement of the loading claws toggle switch
signal active - normal direction of claws movement
95
Addendum 7
7.2
IDENTIFICATION OF DEFECTS OUTPUTS
O0.00 Output for K1 relay - pusher up

O0.01 Output for K1 relay - pusher down
O0.02 Output for Y22 valve - pusher forward
O0.03 Output for Y23 valve - pusher backward
O0.04 Output for K4 relay - Top Cut Interlock
O0.05 Output for H15 - red lamp on panel ON
O0.06 Output for H14 - green lamp on panel ON
O0.07 Output for K2 relay - barfeed OK
O0.08 Output for K5 relay - Long EOB
Diagnostic when MD LED is ON - ALARM 1 (see chapter 4.10.2)
O0.09 Output for K5 relay - Mazak EOB
Diagnostic when MD LED is ON - ALARM 2 (see chapter 4.10.2)
O0.10 Output for K5 relay - Short EOB
O0.11 Output for K6 relay - spindle rotations authorized
O0.12 Output for K7 relay - M-function finished
O0.13 Output for K5 relay - Standard EOB
O0.14 Diagnostic when MD LED is ON - ALARM 3 (see chapter 4.10.2)
O0.15 Diagnostic when MD LED is ON - ALARM 4 (see chapter 4.10.2)
Note: In MANUAL mode when START button is pressed inputs I0.24 and I0.25 are
displayed at outputs O0.14 and O0.15
96
Addendum 7
7.3
TROUBLESHOOTING MATRIX ERROR
Bit number
H15 red
(O0.5)
H14 green
(O0.6)
Alarm 4 (O0.15)
Alarm 3 (O0.14)
Alarm 2 (O0.9)
Alarm 1 (O0.8)
Value from SS2003_2E, SS2003_3E (HD) version

Explanatory note:
OFF ............. Switch off
ON; l .......... Is ON permanently
OFF/0.1 ....... Switch off/ flashing in interval 0.1 sec
0.1 ............... Flashing in interval 0.1 sec
1; ............. Flashing in interval 1 sec
MBF............. Magazine barfeed
Basic meaning of lamps H14 and H15 in automatic mode of MBF

1
OFF
ON
ON
1
ON
OFF
1
1
1
OFF
OFF
ON
ON
B47
MBF is starting
MBF is in starting position and lathe is not in AUTO mode
Channel is in the low limit position loading impossible
MBF in AUTO or COUNT mode all is OK
MBF is loading or pushing bar
Number of bars are finished COUNT mode
Bar is not available
Error signals of MBF in automatic mode (MD mode activated MD LED is ON)
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
l
1
OFF
OFF
OFF
OFF
OFF
OFF
0.1
1
OFF/0.1
0.1/OFF
OFF
OFF
OFF/0.1
0.1
0.1
0.1
0.1
0.1
OFF/0.1
OFF/0.1
0.1
0.1
0.1
0.1
0.1
OFF/0.1
0.1
0.1
OFF/0.1
0.1
0.1
B42
B41
B36
B37
B38
B39
B40
B45
B46
B34
B57
B48
B49
B50
B60
B59
M-function during controlled ejection of bar remnant

Slow controlled ejection of bar remnant (max. 8 sec)
Slow movement (- 4 s, 1.5 s, 8 s; HD:- 7 s, 2.5 s)
The error of vertical movement switch
The error of horizontal movement switch
The error of material available switch B27.
The chuck closed during bar loading
The Lathe AUTO mode signal is lost during loading
M-function is not finished
Open chuck/collet during starting
Motor reversal
Undefined starting position of pusher
Low input air pressure
Emergency stop (I0.0=OFF)
Loading impossible B28 is not active
NK1, B20 or B21 signals lost
User error identification

When AUTO or COUNT mode of BF is active:
When is not any fatal error of BF, all output LEDs mean the states of the PLC outputs.
When is any fatal error of BF present, the PLC is regularly changing the meaning of the
output LEDs:
MD LED is ON
Output LEDs are showing any fatal error (see the error
matrix on this page).
MD LED is OFF
Output LEDs are showing the states of the PLC outputs.
Note:
MD LED (MD mode) is permanently SET after the PUSHER UP button pressing.
MD mode is permanently RESET after the PUSHER DOWN button pressing.
MD mode is regularly changing after the PUSHER BACK button pressing.
Note:
MD LED is next to output LEDs of PLC.
97
Addendum 8
ADDENDUM 8
CONTROL SHEET FOR INSTALLATION
, they will proceed as follows:
If the installation is being done by
99
Addendum 8
man2003us_V4.doc
100

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Installation

SMW SPACESAVER 2003

9828 S. Arlee Ave.

SMW SYSTEMS INC. 562-949-7991

FOR YOUR PROTECTION - WORK SAFELY

ADDENDUM 2 ELECTRICAL DIAGRAMS

ADDENDUM 3 STANDARD INTERFACE DIAGRAMS

ADDENDUM 4 PNEUMATIC DIAGRAM

ADDENDUM 5 SPARE PARTS

ADDENDUM 6 METHODS HOW TO TROUBLESHOOT

Fig. 1.1 - General arangement

The magazine barfeed SS 2003 allows:

Fig. 1.1 - General arangement

Fig. 1.2 - Floor plan

Fig. 1.3 - Main dimensions

Length of bar stock

3 bars (due to weight limit of 500 lbs)

SUPERVISION AND SECURITY

Fig. 1.4 - Data tag

Chapter 2. Transportation and unpacking

TRANSPORTATION AND UNPACKING

To unpack magazine barfeed:

Fig. 2.1 - Lifting and locating the magazine barfeed

Chapter 2. Transportation and unpacking

Floor lag bolts

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

PREPARATION BEFORE MAGAZINE BARFEED

Furthermore, it is recommended to respect the following points:

ELECTRICAL AND PNEUMATIC CONNECTIONS

Fig. 3.1 - Pneumatic and electrical connections

Water trap on air inlet unit

Fig. 3.2 - Look at the opened electrical box

Chapter 3. Installation - set up

INSTALLATION - MAGAZINE BARFEED FLOOR

Locking nut on height

Screws for height position

Stud bolt for clamping of

Chapter 3. Installation - set up

HEIGHT AND SIDE POSITION PRE-ADJUSTMENT

Fig. 3.4 - Height and side pre-adjustment

Chapter 3. Installation - set up

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

Chapter 3. Installation - set up

Fig. 3.6 - Alignment kit

Chapter 3. Installation - set up

Chapter 3. Installation - set up

2. Rough align the magazine barfeed.

Chapter 3. Installation - set up

Fig. 3.8 - Lagging magazine barfeed to the floor

Chapter 3. Installation - set up

3.3.4 TABLE INSTALATION

NORMAL (or STANDARD) PRODUCTION PROCEDURES

The bar diameter is a little smaller than spindle inside diameter

Fig. 4.1 - Kinds of spindle liners

BAR STOCK FEED

Fig. 4.2 - The barfeeding

INSTALLATION OR EXCHANGE OF A SPINDLE LINER

ADJUSTING CHANNEL HEIGHT - When changing bar stock

Fig. 4.3 - Setup of the channel height

ADJUSTING THE BAR TRAY - When changing bar stock

Fig. 4.5 - The pneumatic circuit

Horizontal pneumatic rod-less cylinder for flag and pusher motions