Betriebs Anleitung: Attachment Bar Loading Magazine

BETRIEBS
ANLEITUNG
Operating Instructions · Manuel d’opération
Attachment
Bar loading Magazine
INDEX MBL 42
INDEX MBL 65
Part 2
Controls INDEX C 200-4
INDEX C 200-8
Part 1: Steuerungsneutral
Part 2: Steuerungsabhängig
LH1402.10021-01.01
0501/ST
Note on applicability
Some illustrations in this publication may deviate slightly from the product supplied, but this will not detract
from their instructional value.
The right of alteration by reason of technical progress is reserved by INDEX.
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© Copyright by INDEX-Werke GmbH & Co. KG Esslingen 1997

Contents
Commissioning ................................................................................................................................................. 5
Activate Magazine Bar Loader ............................................................................................................................ 5
Determination of bar stop to machine zero point distance ................................................................................ 5
Switch-on magazine bar loader ........................................................................................................................... 6
Setting parameters ............................................................................................................................................. 6
Setting up and Operating ................................................................................................................................ 7

Switch-on magazine bar loader ........................................................................................................................... 7
Feeder data display ............................................................................................................................................. 7
Explanation of motion sequences ...................................................................................................................... 8
Referencing of magazine bar loader ................................................................................................................... 9
1. Referencing in EXTERNAL MBL-mode ....................................................................................................... 9
2 Referencing in MBL REFERENCING mode .................................................................................................. 10
Selection and Deselection of Magazine Bar Loader ........................................................................................... 12
Material bar measurement ................................................................................................................................. 12
Material bar loading ............................................................................................................................................ 13
Loading in "LOAD CYCLE" mode and calling the start-of-bar program ............................................................... 14
Interrupt Loading Procedure ............................................................................................................................... 15
Abort Laoding Procedure .................................................................................................................................... 15
Material bar insertion .......................................................................................................................................... 16
Loading by individual functions and start-of-bar program call ............................................................................ 17
Loading by individual functions without start-of-bar program call ...................................................................... 17
Manual shift of material bar ................................................................................................................................ 18
Remove material bar ........................................................................................................................................... 18
Automatic mode ................................................................................................................................................. 19
Running programs by blocs with open sliding hood .......................................................................................... 20
Start-of-bar program ......................................................................................................................................... 20
Parts program .................................................................................................................................................. 21
End-of-bar program or bar cut-up program ...................................................................................................... 21
General Notes ..................................................................................................................................................... 22
Automatic bar exchange .................................................................................................................................. 22
Material bar recharge ....................................................................................................................................... 22
Magazine bar loader evacuation after end of order ......................................................................................... 22
Optional machine functions ................................................................................................................................ 24
Optional machine data ........................................................................................................................................ 24
Bar loading magazine INDEX MBL42, INDEX MBL65

– 3 –
Contents
Parts Programming .......................................................................................................................................... 25

Used input formats, addresses and commands: ................................................................................................ 25
Programmierung der Nachschubdaten (MBL-Betriebsdaten) ............................................................................ 27
Important machine parameters .......................................................................................................................... 28
Program Examples .............................................................................................................................................. 33
Load feeder data .............................................................................................................................................. 33
Start-of-bar -, End-of-bar -, bar cut-up program: ............................................................................................... 34
Workpiece Program (unique feeding) .............................................................................................................. 35
Double (triple) feeding ..................................................................................................................................... 36
Extended programming for counter spindle work and magazine bar loader...................................................... 42
Material bar is pulled forward exclusively by means of counter spindle ........................................................ 42
Pull forward material bar by counter spindle and simulatneously advance it by feeder ................................. 44
Trouble Shooting C200-8 ................................................................................................................................. 45

Other Register addresses ................................................................................................................................... 46
MBL SINUMERIK Interface ................................................................................................................................ 46

– 4 –
Commissioning
Prior to first commissioning, electrical and hydrualic connections must have been made (see part 1, section
"Hydraulic and electrical connections" in chapter "Transport and installation").
Activate Magazine Bar Loader

Inform the control unit of magazine bar loader installation by setting machine assignment (MAZU) PLC machine data
PLC-MD 8010.2 (bit 2).
Thereafter the magazine bar loader can be activated and deactivated by the machine function (MAFU) "Feeder
active" (MAFU 09/00).
The magazine bar loader can be deactivated only with bar stop in "top" position, otherwise an error message will
result (Note: The spindle must not be accessible from the backside, when the machine is operated without
magazine bar loader).
Determination of bar stop to machine zero point distance
Distance machine-MBL
NC MD 2450
M
Magazine bar loader

H1401.10021/6
material stop
Determine the distance and enter it into NC MD 2450.
At installation and/or commissioning of the machine, the following data must be updated.
MD 2130 Current version of magazine bar loader
MD 2410 Prestop in bar trimming program, i.e. the position, upstream the programmed bar
head position (R6), to be advanced to in function M787 or cycle L185 in order
to assure safe ejection of the remainder in the spindle together with the new bar.
MD 2450 Distance machine zero point to bar stop in magazine bar loader MBL.
MD 2490 Length of used feeder bar.
MD 3330 Maximal bar remainder length that can be ejected to the front side through the spindle
without risc of collision.
After machine data entry , activation by commissioning mode ("COMMISSIONING NC/PLC) is

required. Modified individual machine data too (e.g. entry of determined distance in NC MD
2450) is activated not earlier than in commissioning mode..

– 5 –
Commissioning
Switch-on magazine bar loader

To make the MBL magazine bar loader ready for operation after initial commissioning, it must be "referenced" at the
rear fixed stop. (Select "REFERENCE" mode on the MBL operator panel; press "BACKWARD" key until control light
is flashing for ca. 1 second.)
Thereafter move lattice fence forward, until it catches with it's frontmost support plate the MBL magazine bar loader
front end (select "LATTICE FENCE" mode; press "FORWARD" key).
Setting parameters
Needed R-parameters are to be defined in a workpiece-specific set-up and reset program and must be loaded prior
to workpiece machining start(see chapter "Parts programming", sections "FeederData Programming" and " Program
Examples").
To load (prepare) workpiece-specific data, the MBL MODE SELECTOR SWITCH must first be set to the EXTERNAL
position (closed cycle).
To activate the set-up process, please press the following softkeys in the indicated sequence:
Flow Control -> Reset-> Overall reset
To start the set-up process, press CYCLE START key.
Set-up program data will now be transferred to the MBL magazine bar loader.
During the set-up process, the control unit will check operating and machine data for plausibility.
Not allowed are:
- specified lengths equal to/exceeding 2000 mm (60 inch)

- advance speeds exceeding 24 m/min
- values for feeder bar lengths other than (1242mm), 1344 mm or 1472 mm
(Exception: models with special length feeder bars).
Other values will be indicated by an error message.
The maximum position (end position, expressed in machine coordinates data) attainable by the feeder
bar is evident from the "BAR MAX. POS." in machine operation menu under the softkeys Display
selection ->Bar Feeder -> Programmed Values.
If a higher position value is specified in the reset program under R-parameter "R8",it will be automatically
reduced to the calculated position (MBL mechanical end position) and a message will be edited. Despite
of this, loaded feeder data will be declared valid in contrast to all other messages occuring in the set-
up process. Immediately following machining is therefore possible.

– 6 –
Setting up and Operating
Switch-on magazine bar loader
1. Switch-on machine (see machine operating instructions).
2. Move to reference point of every machine axis

(see machine operating instructions).
3. Select magazine bar loader, unless already done.

(See section „Select magazine bar loader” on the
following pages).
4. „Position to reference” the magazine bar loader(see section

"Position to reference magazine bar laoder").
After successful positioning to reference points,

the magazine bar loader is ready for operation.
Feeder data display

As comfortable data display of the MBL control unit there are available in control unit's
„MACHINE OPERATION“ menu under the „MENU SELECTION“ softkey via the „BAR FEEDER“ key, the
current actual positions and status conditions ( CURRENT POSITIONS/LENGTHS „ key), and the currently valid
feeder data (R1 to R9) via the „PROGRAMMED VALUES“ key.
Branching into MBL magazine bar loader diagnosis is possible under menu item "i"
(i = Information C200 -4/C200-8/GA2) or "ERROR/MESSAGES/SERVICE" (C200-8/GA1) by means of softkey
"MBL-STATUS" or "SERVICE/STATUS" and the "PLC-2 STATUS" key.

– 7 –
Setting up and operating
Explanation of motion sequences
With opened front or rear protection hoods, all bar feeder functions can be operated only in inching mode, i.e. a motion
is performed only as long as one of the keys FUNCTION FORWARD or FUNCTION BACKWARD is actuated.
This is also true for the load cycle.
Exception: Forward referencing is possible only with closed protection hoods.
With both protection hoods closed, all functions will be executed in cycle mode.It is sufficient to shortly press the
particular key FUNCTION FORWARD or FUNCTION BAKCWARD, and the motion sequence will be performed, until
it reaches the end position, where the function will be shut-off automatically.
By actuating the key for the opposite functional direction, the current function will be stopped and then, after repeated
key actuation, continued in the particular direction. This is true for all functions including those of the bar loader arm
and reference motions.
If feeder error messsages are active on the machine operating panel, the feeder can be moved only via MBL operating
elements with opened protection hoods; the BAR FEEDER FORW/BACKW keys on the machine operating panel are
out of function as well.
Exception: referencing is possible only with error-free feeder.
If functions are to be performed in cycle mode, active feeder errors, indicated at the machine operating panel, must
have been reset before.
If a constellation is reached by external influences, in which neither the bar loader arm nor the
feeder axis are in their rear end positions, both of them cannot be moved any more. In this case
the feeder axis must be moved to the reference switch in the rear end position by means of the
hand crank, before the bar loader arm can be moved again and brought into its end position.
With closed protection hoods and no feeder error message being active, the bar feeder can
voluntarily be moved forward and backward in "JOG, INC or PEF" modes by means of
BARFEEDER FORW/BACKW keys.

– 8 –
Referencing of magazine bar loader

Magazine bar loader referencing is possible in two ways:
1. Referencing in EXTERNAL MBL-mode
Precondition: - The magazine bar loader must be selected.

(See section "Magazine bar loader selection" on the following
pages.)
- A material bar must have been inserted.
- Main spindle bar chuck must be closed or MBL material stop must
still be in its top position.
- MBL magazine bar loader protection hoods must be closed.
This is the normal referencing method between defined switching-off the previously ready machine and its subse-
quent switching-on.
1.1 Automatic referencing in machine axis reference cycle (Referencing against material
bar)
With set MAZU "Automatic referencing allowed", the MBL magazine bar loader will automatically be referenced after
the machine referencing procedure. Thereafter the MBL magazine bar loader is ready for operation so that machining
can be started immediately (automatic cycle start). In case of error message, referencing as of method 2 is required.
1.2 Manual referencing at machine operating panel (Referencing against material bar)
Function and mode selector switch on MBL operator panel set to

EXTERNAL.
79S2
C200-4 and C200-8 GA2 only
Mode selector switch at machine set to REFERENCE POINT.
C200-8 GA1 only

Reference mode selection:
BASIC MENU: 1 MACHINE OPERATION: OPERATING MODES: 7 REFERENCE
Press BAR FEEDER FORWARD key, until there is a short status change of the
red signal light 79H1. (Otherwise referencing as of the method 2 is required.)
Now the magazine bar loader is ready for operation.
S124.2

– 9 –
2 Referencing in MBL REFERENCING mode

2.1 Referencing against material bar
Prior condition: - The magazine bar laoder must have been selected.
(See section„Magazine bar loader selection on the following pages.)
- A material bar must have been inserted.
- The main spindle material chuck must be closed, or material stop must still
be in its top position.
- MBL magazine bar loader proctection hoods must be closed.
Function and mode selector switch on the MBL operator panel must be set to
REFERENCING.
79S2
Shortly depress the FUNCTION FORWARD key on the MBL operator panel.
If the red signal light 79H1 shortly changes its status, the magazine bar loader
has been referenced.
79S5
(Otherwise referencing as of method 2 is required).
Select MBL mode EXTERNAL on the MBL operator panel (Function and mode
selector switch)
79S2
Now the magazine bar loader is ready for operation.

– 10 –
2.2 Referencing against rear reference point
Referencing in this mode is performed only, if method 1 was unsuccessful, i.e. if the material bar position was changed
between machine shut-off and referencing procedures.
a) without inserted material bar:
(Open magazine bar loader front protection hood.)
On the MBL operator panel, select MBL mode REFERENCING (via function
and mode selector switch).
On the MBL operator panel, select MBL mode REFERENCING (via function
and mode selector switch).
79S2
Press FUNCTION BACKWARD key on the MBL operator panel, until the red
signal light 79H1 temporarily changes its status.
79S4
Select MBL functions LATTICE FENCE and FEEDER BAR on the MBL operator
panel (via function and mode selector switch).
79S2
By pressing the FUNCTION FORWARD key on the MBL operator panel, move
feeder bar forward until the lattice fence first support plate engages.
79S5
On the MBL operator panel, select MBL mode EXTERNAL

(via function and mode selector switch).
79S2
The magazine bar loader is now ready for operation.
b) with inserted material bar:

Follow the same procedure as described above under item 2a, but with the following
exception:
By pressing the FUNCTION FORWARD key on the MBL operator panel, move
feeder bar to abut against the inserted material bar end.
In this process the red signal light 79H1 must temporarily change its status
(see item "Material Bar Measurement")

– 11 –
Selection and Deselection of Magazine Bar Loader

The magazine bar loader is being selected and deselected by the machine function FEEDER ACTIVE (MAFU 09/00).
The MBL can be deselected only with material stop in its top position, otherwise an error will be
indicated.
(When operating the machine without magazine bar loader, the spindle must not be accessible
from the rear side.)
Material bar measurement

In every phase of the machining process, the magazine bar loader calculates the still available remaining length of
loaded material bar. For this purpose, control data of the loaded bar initial length must be known. Data is determined
by measuring the material bar, which is usually done automatically. In initial and start situations, however, manual
measurements are required.
These measurements are performed as follows:
Case 1: Material stop in top position

The material stop serves as the measurement reference point.
Select MBL functions LATTICE FENCE and FEEDER BAR on the MBL operator
panel.
79S2 (via function and mode selector switch)
By pressing the FUNCTION FORWARD key on the MBL operator panel, push
feeder bar to abut the material bar end.
Measurement is finished, if the red signal light 79H1 temporarily changes its
79S5 status.
Case 2: Material stop in bottom position

As reference point serves a point, the Z-coordinate of which results from the machine zero point value
plus the distance of the feeder bar from this machine zero point. For the rest the procedure is the same
as in case 1.

– 12 –
Material bar loading

Preparations:
- Adjust material bar support brackets.
- Adjust V-blocks and hinged supports.
- Exchange guiding sleeves and guide ring.
- Exchange feeder bar, if necessary.

After feeder bar exchange, referencing in MBL mode REFERENCING is absolutely mandatory.
Load cycle
Material bars are automatically loaded by the load cycle .
The load cycle can be run continuously (MBL mode LOAD CYCLE) or in individual steps.
The load cycle comprises the following steps:
- Move feeder bar back behind material stop, move material stop to top position and feeder
bar to its most rear position.
- Insert material bar.
- Move lattice fence over material bar and measure bar.

The load cycle is completed by measuring the material bar.

– 13 –
Loading in "LOAD CYCLE" mode and calling the start-of-bar program
Case 1: Material stop in bottom position, magazine bar loader selected, feeder bar in front most position.
Select MBL mode LOAD CYCLE via function and mode selector switch on the
MBL operator panel.
79S2
By pressing the FUNCTION BACKWARD key on the MBL operator panel, the
load cycle is being started and at the same time the start-of-bar program is
called.
79S4
Select MBL EXTERNAL mode via mode and function selectro switch on the
MBL operator panel.
79S2
Case 2: Material stop in top position, feeder bar immediately in front of material stop, magazine bar loader
deselected.
Same procedure as in case 1.
If the coordination channel of control unit C200-4/C200-8 is in

RESET condition(i.e. the control unit was switched-on anew or
program flow was interrupted by RESET key depression), the
start-of-bar program must be manually activated at this point
by pressing the softkeys Sequence control -> Bar work ->Start-
of-bar.
Further notes: - If both magazine bar loader protection hoods are closed, the load cycle will run automatically.
- The load cycle will be interrupted, if one protection hood is being opened. It can be continued
by permanent depression, or with closed protection hoods momentary depression, of the
FUNCTION BACKWARD key.

– 14 –
Interrupt Loading Procedure

There are several ways to interrupt the load procedure:
Depression of FUNCTION FORWARD key.

Load cycle continuation by FUNCTION BACKWARD key depression.
Opening of protection hood.

Load cycle continuation by closing protection hood(s) and depressing the FUNCTION
BACKWARD key on the MBL operator panel.
Change of MBL mode.

In this case any magazine bar loader motions will be stopped.
Load cycle continuation:
Select MBL mode LOAD CYCLE via mode and function selector switch on the
MBL operator panel.
79S2
Depress FUNCTION BACKWARD key the MBL operator panel.
79S4
If an interruption was performed prior to material bar insertion, and the material bar was inserted
in individual steps, the load cycle must be completed with individual functions.
If this point is not observed, the control unit will assume that a material bar has not yet been
inserted ,and will try to insert another bar.
Abort Laoding Procedure
Abort loading procedure.
Remove material bar (manually or by means of load arm).
Select MBL functions LATTICE FENCE and FEEDER BAR via mode and function
selector switch on the MBL operator panel.
79S2
Move feeder bar to the front most position by depressing the FUNCTION
FORWARD key on the MBL operator panel. Not before now the MBL control
unit will register material bar removal, and it will abort the load cycle.
79S5

– 15 –
Material bar insertion
Select MBL functions LATTICE FENCE and FEEDR BAR via

mode and function selector switch on the MBL operator panel.
79S2
Move lattice fence and feeder bar to their rearmost end positions
by depressing the BACKWARD FUNCTION key on the MBL operator panel.
79S4
Insert material bar manually on hinged supports V-blocks
or
select MBL function LOAD ARM on the MBL operator panel
and
insert material bar by depressing the FORWARD FUNCTION key on the MBL
operator panel.
79S5

– 16 –
Loading by individual functions and start-of-bar program call
Precondition: Material sto p in top position.
Insert material bar.
Measure material bar (see section „Material bar measurement“).

The start-of-bar program is simultaneously called thereby.
This completes the load process.
Select MBL mode EXTERNAL via mode and function selector switch on the
MBL operator panel.
79S2
If the coordination channel of C200-4/C200-8 control unit is in RESET

condition (i.e. the control unit was just switched-on or program run was
interrupted by RESET key depression), the start-of-bar program must be
manually activated at this point by depressing softkeys Sequence control
-> Bar work -> Start-of-bar.
Loading by individual functions without start-of-bar program call
Precondition: Material stop in bottom position.
Insert material bar into guide tube or workspindle resp. and

position it to the "start-of-bar position" (machine coordinates) (see "parts
programming" section).
Chuck material bar.
Measure material bar (See section „Material bar measurement“.)
This completes the load process.

– 17 –
Manual shift of material bar

If an already measured material bar is being shifted manually, it must be re-measured subsequently (see section
"Material bar measurement").
Remove material bar
Select MBL functions LATICE FENCE and FEEDER BAR via the mode and
function selector switch on the MBL operator panel.
79S2
Move lattice fence and feeder bar to their rearmost end positions by pressing
the BACKWARD FUNCTION key on the MBL operator panel.
79S4
Remove material bar by hand
or
select the MBL function LOAD ARM on the MBL operator panel
and
79S2
remove material bar by depressing the BACKWARD FUNCTION key on the

MBL operator panel (with heavy bars).
79S4
79S2
Bring feeder bar into its frontmost end position by depressing the FORWARD
FUNCTION key on the MBL operator panel.
By this step the control unit realizes that the material bar has been removed.
79S5
If there is no motion to the frontmost position after material bar removal, start-of-bar, end-of-
bar and bar cut-up programs remain called so that it is impossible to enter a different program
number at the machine operator panel or to branche to a different sequence in the program
coordination.

– 18 –
Automatic mode
Preparations:
Select magazine bar loader.
Select MBL mode EXTERNAL via mode and functions selector switch on the
MBL operator panel.
79S2
Reference magazine bar loader.

(See section „Referencing of magazine bar loader“.)
Load material bar.
Close magazine bar loader protection hoods.
Now the parts program can be started.
Hints to automatic mode

In the EXTERNAL mode the FORWARD FUNCTION and BACKWARD FUNCTION keys on the MBL operator panel
are blocked.
Instead of this the keys BARFEEDER FORWARD and BARFEEDER BACKWARD on the machine operator panel are
effective, if machine setting mode (i.e. JOG, INC or REF modes) is selected.
If the magazine bar loader reloads another bar in automatic mode,the keys BARFEEDER FORWARD and BARFEEDER
BACKWARD will be blocked, until the load process is completed.
In automatic mode, the front protection hood can be opened at any time to reload material bars. In this process any
bar feeder function will be stopped momentarily and will be discontinued unless the protection hood is closed again.
Machine spindle rotation continues during this period.
Not allowed are:

Magazine bar loader mode change with running cycle.
In case of non-observance an error will be signalled.

– 19 –
Running programs by blocs with open sliding hood

The start-of-bar, end-of-bar, bar cut-up program, or any other parts program can also be run by blocs with open machine
sliding hood
Start-of-bar program
Set key switch to SETTING position.

S122.7
Control units C200-4 and C200-8 GA2

Set mode selector switch at the machine to AUTOMATIC mode.
Control unit C200-8 GA1
Select AUTOMATIC mode.
Control units C200-4 and C200-8 GA2

INDIVIDUAL BLOC ON
S123.0
Control unitC200-8 GA1
Select individual bloc
Run start-of-bar program by blocs, until the message„PLEASE CONFIRM

MOTION” is displayed on the monitor.
Press key FEEDERBAR FORWARD.

The magazine bar loader will feed, until the lattice fence engages.
S124.2
Press the CYCLE START key.

Message „PLEASE CONFIRM MOTION” will disappear.
Workspindle oscillates, as far as this was programmed
S120.1
Message „PLEASE CONFIRM MOTION” appears again.
Press key BARFEEDER FORWARD.

The magazine bar loader will feed to end position - 10mm.
S124.2
Press key CYCLE START.

Message „PLEASE CONFIRM MOTION” will disappear.
S120.1

– 20 –
Press BAR FEEDER FORWARD key.

The magazine bar loader feeds forward up to the programmed end position.
S124.2
Continue with CYCLE START.

S120.1
Parts program
Set key switch to SETTING UP.
beschrieben
wie vorher
INDIVIDUAL BLOC ON.
Run parts program by blocs until the message „PLEASE CONFIRM MOTION”
is displayed on the monitor.
Press BARFEEDER FORWARD key until the message„PLEASE CONFIRM

MOTION” disappears.
S124.2

S120.1
End-of-bar program or bar cut-up program
Key switch to SETTING position..

beschrieben
wie vorher
INDIVIDUAL BLOC ON
Run program by blocs until the message „PLEASE CONFIRM MOTION” appears
on the monitor .
Depress BARFEEDER FORWARD key, until the message„PLEASE CONFIRM

MOTION” disappears.
S124.2

S120.1

– 21 –
General Notes
Automatic bar exchange

After the last advance step in the parts program, the program checks whether one more workpiece can be
produced. If this is not possible, bar exchange will be initiated.
Work on the workpiece in process will be completed. The start-of-bar program will be called by the magazine bar
loader.
Material bar recharge
Open magazine bar loader front protection hood.

All motions of the magazine bar loader will be suspended thereby.
Work spindle rotation is continued!
Insert material bars.
Close front protection hood.

Suspended motions will be released again.
Magazine bar loader evacuation after end of order
Case 1: All material bars are used up. The machine stops with error message "material end".
Material stop is in top position. The initiated load cycle must be aborted.
79S2
Move feeder bar to material stop by depressing the FORWARD FUNCTION

key on the MBL operator panel.
79S5
The magazine bar loader is now evacuated, and the material stop can be moved
up and down.

– 22 –
Case 2: The material bar is not used up. The material bar is in bottom position. In this case proceed as follows:
Remove material bar.
Select MBL function LATTICE FENCE and FEEDER BAR via mode and function
selector switch on the MBL operaotr panel.
79S2
By depressing the FORWARD FUNCTION key on the MBL operator panel,

move feeder bar to its frontmost position.
79S5
Move feeder bar back behind the stop bolt by depressing the BACKWARD
FUNCTION key on the MBL operator panel.
The magazine bar loader is now evacuated, and the material stop can be moved
79S4 up and down.
If the magazine bar loader operating hints given above are not observed or any troubles occur, an adequate adequate
error message is being displayed on the monitor.
These messages (NC-, PLC-errors and missing start preconditions) are described in detail in the „Trouble Shooting“
chapter and the associated appendix of machine operating instructions.
If there was no motion to the frontmost end position after load cycle abortion, the start-of-bar
program remains in requested status, and it is impossible to enter a different program number
at the machine operator panel, or to branch to a different sequence in the program coordination.

– 23 –
Optional machine functions

The MAFU „NO AUTOMATIC LOADING“ (MAFU 09/02) selects the functions of the INDEX MBL magazine bar
loader:
After material end, the feeder carriage moves back to the rearmost position and stays there, until
another material bar is being inserted manually.
Subsequenly the load cycle and thus the automatic sequence can be continued by depressing the
„CYCLE START“ key on the machine operator panel (or the „BACKWARD“ key on the MBL
operator panel).
By additional selection of MAFU „RESET AT MATERIAL END“ (MAFU 09/03) in this mode, the
load cycle will be automatically aborted in this rearmost position (replacement spindle end
magazine).
In this process the material stop is directly moved downward for manual work spindle charge
with a short material bar from the backside.
Return to automatic working sequence is possible, after the material bar has been positioned,
chucked in the work spindle and manually measured by the bar feeder.
MAFU „MATERIAL BAR CONTROL“ (MAFU 09/04) activates an optionally attachable ultrassonic
sensor that monitors the correct position of the material bar on the material supports during the
lattice fence threading process. (By additionally setting NC machinen data (NC-MD) NC-MD 2130
to 1x, material bar control by the ultrasonic emitter can be extended to the bar load arm too).
With activated MAFU „RETRACTION MODE“ (MAFU 09/01), the MBL magazine bar loader will
retract the feeder bar back behind the spindle after each feeding action in the work spindle.
Thereby a break of thin feeder bars due to co-oscillation in the work spindle is prevented.
Optional machine data

By setting NC machine data NC-MD 2130 to 2x, the pressure reduction for all traversing zones be activated to
reduce its power in case of axis blockage.
By setting NC machine data NC-MD 2130 to 4x, a special feeder bar length can be activated and its length (in
mm) can be entered in NC machine data NC-MD 2490.

– 24 –
Parts Programming
Used input formats, addresses and commands:

Input format
(Syntax = weighted digit before / after the decimal point)
Metric: Travel specifications in mm as 4.1-values (—> xxxx.x mm)

Feeding speed in m/min as 2.0-values (—> xx m/min)
Inch: Travel specifications in inch as 3.2-values (—> xxx.xx inch)
Feeding speed in foot/min as 2.0-values (—> xx foot/min)
Adresses
The addresses given here are directly programmed in the particular working program and
function to call the described parts functions.
General: Fxxxx Advance value (mm/min, inch/min)
G94
M03/M04 work spindle RIGHT/LEFT HAND ROTATION
M05 work spindle STOP
M68 work spindle chuck closed
M69 work spindle chuck open
Nxxxx block number
Sxxxx work spindle speed(with M03/M04)
Xxxx traversing travel in X-direction
Zxxx traversing travel in Z-direction
Special: M187 1. Push feed in parts program (Length R1)
M287 2. Push feed in parts program (Length R2)
M387 3. Push feed in parts program (Length R3)
1)
M487 Push feed function OFF - only used when pulling material
bar forward with counter spindle (R19=x00L127). Otherwise
no need for explicit programming.
M687 Prepare insertion on new material bar into spindle

(material stop down- lock lattice fence in front position)
M787 Insert new material bar into spindle; floating function
contained in subroutine used for work spindle (L 185) !
1)
M987 Move feeder bar without reader stop to the end of material
bar in parallel to the working process.

– 25 –
Parts Programming
M1187 Push feed in end-of-bar program(Length R4).
M1287 Position new material bar at material bar stop.
M1387 Push feed in material bar cut-up program

(length R5 of loaded feeder data).
M1487 Position new material bar without material bar stop

(in start-of-bar program instead of M1287).
1)
M1587 Shift new material bar for first treatment (after facing)
in Z-plus direction ("Zero point offset" with material bar).
1)
These functions are available starting with MBL software level <MBL A.3-00>.

– 26 –
Parts Programming
Feeder Data Programming (MBL Operatin Data)

The R-parameters deseribed below are being defined in a workpiece-specific tooling or retooling
program (%MPF 52xx) and must be loaded by calling the "TOOLING" function prior to machinig start
of the particular workpiece or after a parameter modification (see also programming instructions
for C200-4, C200-8).
By R50 = 4 L150 select feeder data loading procedure
R1 = xxxx.xx 1st feed length (M187)

R2 = xxxx.xx 2nd feed length (M287)
R3 = xxxx.xx 3rd feed length (M387)
R4 = xxxx.xx Feed length in end-of-bar-program.

(< > 0: → branch to end-of-bar program → M1187,
feeding length in end-of-bar program)
R5 = xxxx.xx Feed length in bar cut-up program

(< > 0: → branch to bar cut-up program → M1387,
feeding length in bar cut-up program)
R6 = xxxx.xx Start-of-bar position specified in machine coordinates
R7 = xxxx.xx Length of wear in start-of-bar program (→ M1287)
R8 = +/- xxxx.xx Feeder bar final or maximum position

(→ provides workpiece clamping length)
R9 = xx Feeding speed
All dimensions given in "mm", except feeding speed which is given in "m/min"
(max. 24m/min).
The values specified for parameters "R4" and "R5" define the procedure at bar
material end as follows:
R4 = 0: Branch to start-of-bar program
R4 < > 0: Branch to end-of-bar program
R5 < > 0: Branch to bar cut-up program

– 27 –
Parts Programming
Important machine parameters

NC-MD 2130: MBL magazine bar loader version:
1st digit: („x“ stands for the value in 2nd digit)

x0 = old serial versions until 8/1989
x1 = rear bed extension by 100 mm
x2 = front lattice fence extension by 152 mm
x3 = new serial version starting with 8/1989
(including rear bed extension by 100 mm and front lattice fence extension by 150
mm).
2nd digit: („y“ stands for the value in 1st digit)

1y = material bar control(MAFU 09/04) affects bar load arm too
2y = pressure reduction permanently active
4y = special feeder bar active
NC-MD 2410: Prestop distance in start-of-bar program(mm):

This dimension defines the position ahead of the programmed start-of-bar position
(R6) in the M787 function (in cycle L185 for work spindle floating), to which advance
is made to assure definite (!) ejection of the old material bar remainder from the
work spindle.
NC-MD 2450: Distance machine zero point to magazine bar loader material bar stop (mm):
This dimension is for balancing machine coordinates and must be entered after machine
installation individually and as exactly as possible.
NC-MD 2490: Length of used feeder bar(mm):
Allowed lengths are (1242mm), 1344mm, 1472mm, (special lengths)
NC-MD 3330: Maximal remainder length< (mm):

The specified value characterizes the bar remainder length that can be ejected to
the front through the spindle without any collision in the workspace and demolition
of the chip conveyor (depends on particular machine, usually an approximate value
in the order of 500 - 1000 mm).
During set-up procedure the control unit checks operating and machine data for plausibility. Not
allowed are:
- length specifications equal to or exceeding2000 mm (60 inch)
- advance speeds exceeding 24 m/min (89 foot/min)
- feeder bar lengths other than (1242 mm), 1344 mm or 1472 mm (except special feeder
bar length versions), that will be quitt with an error message.
The feeder bar maximal position (expressed in machine coordinates)is evident from the „MASCHINE
OPERATION“ key MENU SELECTION“, key „MATERIAL BAR FEEDER“ and key „PROGRAMMED
VALUES“under the designation „BAR MAX.POS.:“. If in R8 a position is being entered that exceeds
the calculated position in Z-direction, the entered value is automatically reduced to the calculated
value (mechanical bar feeder end stop), and a message is edited.
In contrast to all other messages occuring during the set-up procedure, inspite of this loaded feeder
data will be declared valid and thereby immediately following machining enabeld.

– 28 –
Parts Programming
Desription of MBL feeder data, addresses and displays

Feed parameters
R1 = xxxx.xx 1st feed length in parts program (mm); called by M187.

R2 = xxxx.xx 2nd feed length in parts program (mm); called by M287.
R3 = xxxx.xx 3rd feed length in parts program (mm); called by M387.
The M187 function serves to feed the material bar after finished part cut-off. Feeding is against a fixed
stop, positioned in the work space by tool carrier (turret) one or two. After the material bar chuck has
been opened, feeding is performed by the length previously loaded in the retooling program in
parameters(n) R1 (R2,R3). With R2 = 0 and/or R3 = 0 a second and/or third feed operation and thus
a call of M287 and/or M387 in the parts program do not apply.
1 2
1 Material bar immediately before

feeding
R06 R01 2 Material bar stop
H1401.10021/1
R4 = xxxx.xx Feed length in end-of-bar program (mm); called by M1187.
The end-of-bar program functions to dipose of the material bar remainder from the work spindle after
complete machining of the last workpiece. Optionally the end-of-bar program can also be dropped,
and instead the material bar remainder can be ejected by the new material bar in the start-of-bar
program.
R4 = 0 —> After production of the last workpiece no end-of-bar program will follow.
R4 > 0 —> After machining the last workpiece
an end-of-bar program will follow to dispose of the material bar end. For safe disposal at least the feed
length specified for the end-of-bar program will be reserved, so that this value can necessarily still
be fed (special case: R4 = 1 —> end-of-bar program is to follow, but a minimum length has not to
be reserved).

– 29 –
Parts Programming
If no material bar stop is provided in the end-of-bar program, feeding is performed until the feeder
bar has reached its programmed end position (R8). Thereafter another material bar will be loaded
automatically. If a material stop is realized before the feeder bar has arrived at its end position
(feeder bar hits a block, i.e. axis is blocked), feeding in the end-of-bar program will be finished at
this point, and loading another material bar will be initiated.
R5 = xxxx.xx Feed length in material bar cut-up program (mm); called by M1387.
If disposal of the bar remainder in its full length through the work spindle to the front is not possible
due to remainder's dimensions, the remainderr can be cut-up.
R5 = 0 —> No material bar cut-up program is

following the last workpiece production.
R5 > 0 —> Following the last produced workpiece, a cut-up cycle is to be inserted,
if the remainder in the work spindle exceeds the dimension defined in
R5.
If no material stop is provided in the abr cut-up program, free advance will be performed for the
maximum lenth defined in R5. If a shorter feed length is sufficient to reach the length of the
remainder in the work spindle, that is defined in R5, advance is made for this shorter length only
(feed length, however, always amounts to at least 7 mm to enable cut-off without any danger).
Thereafter programmed program branching will be continued.
If the remainder exceeds the value in R5, the bar cut-up program is called repeatedly.
By positioning the material stop to a position ahead of the position specified in R5, bar cut-up in
shorter partial lengths can be enforced.If the length of the remainder in the work spindle,
programmed in R5, is not reached in this process, the bar cut-up program will be called
repeatedly.
The final remainder in the work spindle nevertheless always has necessarily the length defined in
R5.

– 30 –
Parts Programming
R6 = xxxx.xx start-of-bar position in machine coordinates (mm).
This value defines the material bar start position immediately before a parts program feed operation
(i.e. after finished part cut-off). This position of material bar start must also be met after start-of-bar
program run (i.e. after cutting off the length of wear in the start-of-bar program,the start-of-bar must
be in the same position as after cutting off a finished part.
(To meet this position precisely when positioning freely with function M1487, the exact definition and
input of MD2450 "Machine zero point/MBL distance" is a precondition!)
R7 = xxxx.xx Length of wear in start-of-bar program (mm).
This value being effective in the start-of-bar program only specifies the travel by which the material
is to positioned beyond the start-of-bar position (R6). This excessive length will then be cut-off from
the newly loaded material bar in the start-of-bar program facing procedure (i.e. in the start-of-bar
program,the newly loaded material bar will be shortened by the amount specified in R7, and will
subsequently be in the start-of-bar position (R6)!).
1 2
M 1 Material bar
2 Material bar stop
R06 R07
H1401.10021/2
R8 = +/- xxxx.xx Feeder bar end or maximal position in machine coordinates (mm).
This date defines the extent to which the the feeder bar (and thus the end of the bar) may be
pushed into the spindle to still assure a safe material bar clamping .This value therefore
defines the minimum material chuck clamping length and thus cannot be exceeded in any
magazine bar loader mode. Negative and positive input values are allowed.
The mechanically absolutely possible maximal position of the feeder bar is limited by the
magazine bar loader end stop and displayed on the screen in form of machine coordinates
under condsideration of MD 2450 „Machine zero point/MBL distance“ (selection menu:key
„BAR LOADER“ - key „PROGRAMMED VALUES“).
If inspite of this a feeder bar end positon, exceeding this mechanical end stop, is being programmed,
this value will automatically be reduced and an error message will be edited. Transferred data,
however, will be accepted as being valid.
(Precondition for exactly meeting this position is the precise definition and input of MD 2450
„Machine zero point/MBL distance"!)

– 31 –
Parts Programming
X+
M
Z+
1 2
R08 H1401.10021/3
negativ R8 = – xxxx.x
Figure: Feeder bar end point is behind machine zero point
X+
1 Nachschubstange
2 Werkstoffstange
3 3 Spannzange
M
Z+
1 2
R08
H1401.10021/4
positiv R8 = + xxxx.x
Figure: Feeder bar end position is ahead of machine zero point
R9 = xx Feeder speed for work spindle advance (m/min).
The speed entered here becomes effective as maximal feed value in the different programs (maximal
values are 24 m/min or 89 foot/min).(Speeds effective during the load cycle are being defined and
modified by means of machine data).

– 32 –
Parts Programming
Program Examples
Note: When programming feeder functions, wait times are not required. It only must be
assured that the porgram run time after completed feeding is not shorter than the
minimal length of three seconds!
The feeder will advance the material bar, after the adequate function has been called
and „material chuck released“ has been signalled. Program processing by the
control unit will be suspended by a „Read-in interrupt“ (reader stop) caused by the
material bar feeder, until the feeder has reached the predetermined feed length.
Load feeder data

%MPF 5201
R50=4 L150 Select load process feder data
R1=40 R2=20 R4=20 R5=50 R6=20 R7=5 R8= - 40 R9=24 L151 Load feeder data
...
... possibly load more workpiece data
...
M30

– 33 –
Parts Programming
Start-of-bar -, End-of-bar -, bar cut-up program:

%MPF1701
L100
L421
@100 R50
N1 (Start-of-bar program)
M1=69 M4=5 Chuck open, spindle stop
M687 Prepare bar insertion
(bolt up, fence in front position)
. (possibly position pick-off tray for bar
remainder)
R10=100 R11=1.5 L185 Spindle floating an inserting
(comprises M787)
... (possibly pick-off tray back)
Tx=? D=? stop tool
Xx=0 at first approach X
Zx=?? then approach turret Z stop position
M1287 position to start-of-bar + length of wear
M1=68 chuck closed
...
... cut bar to length of wear
@100 K9999 skip to the end
N2 (bar cut-up program)

... (poss. approach turret as stop, X then Z)
M1=69 chuck open
M1387 feed cut-up length (R5) or stop feeding when
hitting a stop
M1=68 chuck closed
... (possibly remove turret)
... cut-off bar (and possibly dispose)
@100 K9999 skip to the end

– 34 –
Parts Programming
N3 (end-of-bar program)
... (poss. approach turret as stop, X then Z)
M1=69 chuck open
M1187 feed to feeder bar end position (R8) or stop
feeding when hitting the stop
M1=68 chuck closed
... (possibly remove turret)
... cut-off bar and/or dispose
N9999 M30 End
Workpiece Program (unique feeding)

%MPF1001
L100
Tx=? D=? Stop tool
Xx=0 at first approach X
Zx=?? then approach turret Z stop position
M1=69 chuck open
M187 feed 1st feed length (R1)
M1=68 chuck closed
... workpiece machining
M30

– 35 –
Parts Programming
Double (triple) feeding

%MPF 1001
Tx=? D=? change to stop tool
Xx=0 turret in X,
Zx=?? and approach to stop position in Z
M1=69 material bar chuck open
M187 feed 1st feed length (value in R1)
M1=68 material bar chuck closed
.
. workpiece machining

Xx=0 approach turret in X and in Z
Zx=?? to stop position
M287 feed 2nd feed length (value in R2)
For triple feeding only

Xx=0 approach turret in X and Z
Zx=?? to stop position
M387 feed 3rd feed length (value in R3)
M30 end of program

– 36 –
Parts Programming
Example for a bar program from channels 1 and 2.
%MPF 5260 (Retooling program)

N5 R50=4 L150 (Select load program type)
N10 R1=75 R2=75 R3=75 R4=40 R5=30
R6=111 R7=2 R8=35 R9=20 L151 (Load feeder data)
N15 M30
%MPF1760 (Bar program channel 1)

L100 (Program home position)
L421 (Read coordinates subgroup)
@100 R50 (Unconditional skip to block R50)
N1 Start-of-bar program, Identif. block no.: N1)
N10 G0 G53 X200 Z400 D0 M4=42 (Start point)
N15 G59 X=R901 Z=R902 (Zero point offset)
N7011 [ WAIT M,711,1,2 ] (Synchronisation channels 1 with 2)
N20 M4=33 M4=26 (Select main spindle actual & nominal values)
N25 M1=69 M4=5 (Chuck open, spindle stop)
N30 M687 (To prepare insertion, move MBL stop down
- have lattice fence locked in front pos.)
N35 T1 D1 (Select material bar stop)
N40 G0 X0 (First approach in X-axis)
N45 Z-74 (Approach in Z-axis)
N50 R10=100 R11=1 R16=0 L185 (Have main spindle floating with 100 rpm in
seconds cycle and insert material bar).
N55 M1287 (Feeding to start-of-bar, position R6 + Abbutzlänge R7 in
machine coordinates)
N60 M1=68 (Chuck closed)
N65 G0 Z100 (Lift material bar stop)
N70 G53 X200 Z400 D0 (Traverse to start point)
N7012 [ WAIT M,712,1,2 ] (Synchronisation channels 1 with 2)
N7013 [ WAIT M,713,1,2 ] (Synchronisation channesl 1 with 2)
N75 @100 K9999 (Unconditional skip to end of program)

– 37 –
Parts Programming
N2 (Bar cut-up program, ident. block no.: N2)

N7021 [ WAIT M,721,1,2 ] (Synchronisation channel 1 to 2)
N90 M1=69 (Chuck open, prepare MBL)
N95 M1387 (Feed length R5 from loaded feed data)
N100 M1=68 (Chuck closed, finish feeding)
.
. Cut-up material bar
.
N110 @100 K9999 (Unconditional skip to program end)
N3 (End-of-bar program, ident. block no.: N3)

N125 G59 X=R901 Z=R902 (Zero point offset)
N130 T1 D1 (Select material bar stop)
N135 G0 X0 (At first approach X-axis)
N140 Z-64 (Approach Z-axis)
N145 M1=69 (Chuck open, prepare MBL)
N150 M1187 (Feed length R4 in end-of-bar program)
N155 M1=68 (Chuck closed, finish feeding)
N160 G0 Z100 (Lift material bar stop)
N165 X200 (Lift material bar stop X-axis)
.
. Machining end-of-bar
.
N270 M1=69
N275 M1=68 Remainder disposal
.
.
N300 G0 G53 X200 Z400 D0 (Start point)
N9999 M30 (Program end)

– 38 –
Parts Programming
%MPF 2760 (Material bar program channnel 2)

L100 (Program home position)
L421 (Read coordination subgroup)
@100 R50 (Unconditional skip to block R50)
N1 (Start-of-bar program, ident. block no.: N1)

N10G0 G53 X410 Z200 D0 M4=42 (Start point)
N15G59 X=R901 Z= R902 (Zero point offset)
N20T2 D32 (Select facing tool)
N25M4=26 M4=33 (Select main spindle act. and nominal values)
N30 M4=3 S4=1500 (Main spindle sense of rot. and speed)
N35 M4=8 (Main spindle coolant ON)
N40G0 X65 Z-74 (Approach facing tool)
N45 G1 X-1 F0.2 (Start-of-bar facing)
N50 G0 X100 Z-60 (Lift off facing tool)
N55 M4=9 (Main spindle coolant OFF)
N2 (Bar cut-up program, ident. block no.: N2)

N75G0 G53 X410 Z200 D0 (Start point)
.
. Cut-up material bar
.
N3 (End-of-bar program, ident. block no.: N3)

N90G0 G53 X410 Z200 D0 (Start point)
N95G59 X=R901 Z=R902 (Zero point offset)
N100 T12 D42 (Select turning tool)
N105 G0 Z-70 (Approach turning tool, at first in Z-axis)

– 39 –
Parts Programming

.
. End-of-bar machining
.
N9999 M30 (Program end)

– 40 –
Parts Programming
Feeder bar frontmost positione (=R8)

the MBL mayfeed to in order to assure safe
clamping
Distance MBL bar stop /machine zero point

G59 Z=R902
R8+
R6 R7
Cut-up length - R5 R5 R5 3
Z+
smallerthan
partlength
4 (R1+R2+R3) 2
R4 1
5 shortest attainable remainder
length R1 (R2, R3)
Feed length 1 ( 2or. 3)

Sum corresponds to partial
length
H1401.10021/5
Actual remainder length.If it exceeds the cut-up length, with

1Material bar stop
R5 not = the program branches to cut-up program 2Material bar
(The maximum remainder length is saved in machine data. 3Collet chuck
If the atained remainder length exceeds this value, an error
message will be edited and the machine will be stopped. 4Feeder bar
5MBL material bar stop
R4 = Remainder length for end-of-bar program

R6 = Bar position for machining the nextpart.
Position after cutting-off the last part(relative to machine zero point)
R7 = FAcing wear length of new material bar
R8 = Feeder bar ftontmost position
R9 = Feeding speed (max. 24 m/min)

– 41 –
Parts Programming
Extended programming for counter spindle work and magazine bar

loader
Material bar is pulled forward exclusively by means of counter spindle
Starting with MBL software version MBLA.3-00 the following new M-functions are available for
counter spindle machining:
M487: Feed OFF. For internal use only, must not be programmed explicitely!
M987: Move feeder bar to the end of material bar without reader stop in parallel to the machining process (New
measurement of material bar and new definition of material bar end psoition; precondition: chuck is
closed.)
By means of these functions the material bar can be pulled forward and machined independent on the feeder. The
feeder remains at the position it had reached at last.
If the feeder is to abut again the rear end of the pulled-forward material bar and the material bar is to be measured
and balanced anew relative to the remainder length (decision for program branching to bar cut-up, end-of-bar or start-
of-bar), this can be done by function M987 in parallel to another process.To assure safe control of program branching,
the particular parts program must be active at least for 10 - 15 seconds after function M987 edition, before it will be
finished by M30!
All feeder monitoring functions(„nominal position not reached/overshot“) are suspended; the max. traversing travel
is limited to a single workpiece length (1.+ 2.+ 3.feed length),otherwise error „nominal position overshot“ will be
signalled.
Note: If the material bar is pulled forward by the counter spindle without the feeder following it, the
material bar can leave the last support plate of the guide grid. With thin material bars and high
machining speeds the unsupported end of the bar can be snapped off and can damage the feeder.
When machining without abutting feeder bar it must therefore be assured that the material bar
can not be snapped off with the speed selected, or the feeder must be moved to abut the bar by
means of function M987 before machining with higher speeds!
If above requirement cannot be met, the feeder must be advanced at the same time the counter
spindle pulls forward the material bar (see following section)!
Programming example
%MPF1001
…
… L127 Pull forward material bar
… Machining
X0 Z100 M987 Put feeder against bar (in parallel to machining)
… Machining
M30

– 42 –
Parts Programming
M1587: Shift material bar for first machining step (after wear length cut-off) in start-of-bar program.
This function serves to plane the new material bar as close as possible to the spindle, and to to advance it to the
position required for the following machining process in the parts program. The value specified in parameter „Start-
of-bar position“ (R6) is set anew with every loaded material bar and is being increased for further machining by the
value of the material bar advanced to the material stop by means of function M1587.
All feeder monitoring functions („nominal position not reached/overshot“) are suspended; the max. traversing travel
is limited to a single workpiece length ( 1. + 2 . + 3 . feed length), otherwise error „nominal position overshot“ is
signalled.
Programming example:
%MPF 2701
N1 (start-of-bar program)
M1=69 M4=5
M 687
R10=100 R11=1. 5 L185
Tx=? D=?
Xx= 0
Zx=? ?
M1287 Material bar thread-up
and positioning
M1=68 Material bar chuck closed
Cut-off bar wear length,
machine head-of-bar if necessary
Tx=? D=?
Xx= 0
Zx=?? Material stop to position
start-of-bar for machining
in parts program
M1=69 Material bar chuck open
M1587 Shift material bar and take-over

new position for start-of-bar
(material bar zero-point-offset!)
M1=68 Material bar chuck closed
M30

– 43 –
Parts Programming
Pull forward material bar by counter spindle and simulatneously advance it by feeder
When calling cycle L127 (clamp and pull forward material by counter spindle - comp. C200 programming instrucitons!)
parameter R10 is to be programmed as follows:
R16 =1xx: Pull forward material bar by counter spindle and in parallel thereto advance it by
1st feed length by means of feeder.
R16 = 2xx: Pull forward material bar by counter spindle and in parallel thereto advance it by 2nd
feed length by means of feeder.
R16 = 3xx: Pull forward material bar by counter spindle and in parallel thereto advance it by 3rd
feed length by means of feeder.
Thereby the associated M-function for advancing the bar feeder (M187, M287, M387) is edited in cycle L127 too! The
bar feeder generates an advance stop signal, untio it has been moved to, and moves from its cancellation in parallel
to the counter spindle with included material bar . All bar feeder control functions are active during the advance
process. A maximum of three feed lengths, to be programmed in the tool program under parameters R1, R2 and R3
is allowed.

– 44 –
Trouble Shooting C200-8
Branching to MBL magazine bar loader diagnosis is possible under item "i" (i = Information C200 -4/C200-8/GA2)
or "ERROR/MESSAGES/SERVICE" (C200-8/GA1) by means of softkey "MBL-STATUS" or "SERVICE/STATUS" and
key "PLC-2 STATUS".
After machine switch-on, data words to be displayed will be set in such a way that inputs/outputs of the magazine
bar loader will be displayed (otherwise the particular specified addresses have to be entered by segment and offset):
By overwriting the values (contents) of displayed addresses ,the magazine bar loader can be
mechanically destroyed!
MBL OUTPUT PORT A Address SEG:OFF —> 32768:512 (right byte only)
Bit 0: output bar load arm forward
Bit 1: output bar load arm backward
Bit 2: ouput bar stop up
Bit 3: output bar stop down
Bit 4: ouput lattice fence release
Bit 5:output pressure reduction off
Bit 6: output light on
MBL SW CONTROL REGISTER Address SEG:OFF —> 32:94

Bit 0: output positive motion sense
Bit 1: output negative motion sense
MBL INPUT PORT B Address SEG:OFF —> 32768:514 (right byte only)
Bit 0: input rear hood open
Bit 1: input front hood open
Bit 2: input stop not in top position
Bit 3: input stop in bottom position
Bit 4: input bar load arm in rear position
Bit 5: input lattice fence not in front position
Bit 6: input 2nd reference point
Bit 7: input material support occupied
MBL INPUT PORT C Address SEG:OFF —> 32768:516 (right byte only)
Bit 0: input ultrasonic sensor occupied
Bit 1: input hardware fuse 24V not in circuit
Bit 2: input key forward/up (MBL operator panel)
Bit 3: input key backward/down (MBL operator panel)
Bit 4: input mode selector switch Bit 0 (MBL operator panel)
Bit 7: input 24V available internal in module
For more error information see control unit error tabels.

– 45 –
Trouble Shooting C200-8
Other Register addresses
MBL software date Address SEG:OFF —> 57344:83

MBL software version Address SEG:OFF —> 57344:76
Nominal position Address SEG:OFF —> 32:188
IActual position Address SEG:OFF —> 32:190
End-of-bar position Address SEG:OFF —> 32:238
Start-of-bar position Address SEG:OFF —> 32:314
Rem. travel still to be moved Address SEG:OFF —> 32:184

Already moved travel Address SEG:OFF —> 32:182
Final speed Address SEG:OFF —> 32:174

Nominal speed Address SEG:OFF —> 32:176
Actual sped Address SEG:OFF —> 32:178
Constant speed Address SEG:OFF —> 32:180
MBL SINUMERIK Interface
PLC transfer to MBL interface(DB59 DW67-73):
PLCSM_PGL_MBL —> DB59 DW67
PLCSM_BTR_MBL —> DB59 DW68
PLCSM_BIT_MBL —> DB59 DW69
PLCSM_DAT_MBL —> DB 59 DW70
PLCSM_HSDW1_MBL —> DB59 DW71
MBL transfer to PLC interface(DB59 DW74,DW75):
SMPLC_PGL_MBL —> DB59 DW74
SMPLC_BTR_MBL —> DB59 DW75

– 46 –
INDEX-Werke GmbH & Co. KG
Hahn & Tessky
Postfach 10 03 54
D-73726 Esslingen
Fax (0711) 3191 - 587
E-Mail TED@INDEX-Werke.de

Betriebs Anleitung: Attachment Bar Loading Magazine

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Betriebs Anleitung: Attachment Bar Loading Magazine

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BETRIEBS

Bar loading Magazine

© Copyright by INDEX-Werke GmbH & Co. KG Esslingen 1997

Setting up and Operating ................................................................................................................................ 7

Bar loading magazine INDEX MBL42, INDEX MBL65

Parts Programming .......................................................................................................................................... 25

Trouble Shooting C200-8 ................................................................................................................................. 45

Bar loading magazine INDEX MBL42, INDEX MBL65

Activate Magazine Bar Loader

Determination of bar stop to machine zero point distance

Magazine bar loader

Determine the distance and enter it into NC MD 2450.

MD 2130 Current version of magazine bar loader

MD 2490 Length of used feeder bar.

After machine data entry , activation by commissioning mode ("COMMISSIONING NC/PLC) is

Bar loading magazine INDEX MBL42, INDEX MBL65

Switch-on magazine bar loader

Flow Control -> Reset-> Overall reset

To start the set-up process, press CYCLE START key.

- specified lengths equal to/exceeding 2000 mm (60 inch)

Other values will be indicated by an error message.

Bar loading magazine INDEX MBL42, INDEX MBL65

Switch-on magazine bar loader

1. Switch-on machine (see machine operating instructions).

2. Move to reference point of every machine axis

3. Select magazine bar loader, unless already done.

4. „Position to reference” the magazine bar loader(see section

After successful positioning to reference points,

Feeder data display

Bar loading magazine INDEX MBL42, INDEX MBL65

Explanation of motion sequences

Exception: Forward referencing is possible only with closed protection hoods.

Bar loading magazine INDEX MBL42, INDEX MBL65

Referencing of magazine bar loader

1. Referencing in EXTERNAL MBL-mode

Precondition: - The magazine bar loader must be selected.

- A material bar must have been inserted.

- MBL magazine bar loader protection hoods must be closed.

Function and mode selector switch on MBL operator panel set to

C200-4 and C200-8 GA2 only

Mode selector switch at machine set to REFERENCE POINT.

C200-8 GA1 only

Bar loading magazine INDEX MBL42, INDEX MBL65

2 Referencing in MBL REFERENCING mode

- A material bar must have been inserted.

- MBL magazine bar loader proctection hoods must be closed.

Bar loading magazine INDEX MBL42, INDEX MBL65

2.2 Referencing against rear reference point

a) without inserted material bar:

(Open magazine bar loader front protection hood.)

On the MBL operator panel, select MBL mode EXTERNAL

b) with inserted material bar:

Bar loading magazine INDEX MBL42, INDEX MBL65

Selection and Deselection of Magazine Bar Loader

Material bar measurement

Case 1: Material stop in top position

Case 2: Material stop in bottom position

Bar loading magazine INDEX MBL42, INDEX MBL65

Material bar loading

- Adjust V-blocks and hinged supports.

- Exchange guiding sleeves and guide ring.

- Exchange feeder bar, if necessary.

Material bars are automatically loaded by the load cycle .