Ke 14

FMB
MA SC H IN E NB A U G E S E LL SC H A F T
turbo 5-42XT
Serie 2
Contents
0. Safety instructions for operating the loading magazine ........................................ 5
0.1 Operation........................................................................................................... 5
0.2 Maintenance and repair ..................................................................................... 6
0.3 Usage to the intended purpose ......................................................................... 6
0.4 Explanation of symbols and notes ..................................................................... 7
0.5 Property rights ................................................................................................... 7
0.6 Safety precautions ............................................................................................. 8
0.7 Safety devices ................................................................................................... 9
0.7.1 Covers.................................................................................................... 9
0.7.2 Guide tube between the loading magazine and the lathe .................... 10
0.7.3 EMERGENCY STOP device ................................................................ 10
0.7.4 Guards on the lathe.............................................................................. 10
1. Technical data and operating resources ............................................................... 11

1.1 Technical data / storage conditions ................................................................. 11
1.2 Electrical connection between loading magazine and machine tool ................ 12
1.3 Oil filling ........................................................................................................... 12
1.4 Requirements for the material bars and their preparation ............................... 13
2. Transportation for erection and dismantling ........................................................ 15

2.1 Preparing the loading magazine for transport.................................................. 15
2.2 Transporting by crane...................................................................................... 16
2.3 Transporting by forklift truck ............................................................................ 18
2.4 Transporting by other means........................................................................... 18
3. Erection .................................................................................................................... 19
3.1 Erection plan ................................................................................................... 19
3.2 Floor characteristics ........................................................................................ 20
3.3 Aligning the loading magazine ......................................................................... 20
3.4 Attachment to the floor .................................................................................... 22
3.5 Compressed air supply .................................................................................... 22
3.6 Electrical connection........................................................................................ 23
3.7 Avoiding hazardous confined spaces .............................................................. 23
3.8 Repairs to the machine tool ............................................................................. 23
4. Notes on the interface ............................................................................................. 24

4.1 Contacts from lathe to FMB loading magazine ................................................ 24
4.2 Contacts from the FMB loading magazine to the lathe .................................... 24
4.3 Program suggestion for lathe .......................................................................... 25
Operating Instructions Edition 04/99 Page 1

turbo 5-42XT
Serie 2 FMBMA SC H IN E NB A U G E S E LL SC H A F T
5. Commissioning the loading magazine ............................................................... 26

5.1 Conditions for commissioning.......................................................................... 26
5.1.1 Fastening the loading magazine - working according to the erection
plan....................................................................................................... 26
5.1.2 Connection to the machine .................................................................. 26
5.1.3 Supply media ....................................................................................... 26
5.1.4 Oil filling ............................................................................................... 26
5.1.5 Mechanical adjustments....................................................................... 27
5.1.6 Staff training / Application of the operating instructions........................ 27
5.2 Switching on the system for the first time ........................................................ 28
5.3 Settings on the controller ................................................................................. 29
5.3.1 Setting the cut-off position (end of initial feed) ..................................... 29
5.3.2 Adjusting the interval feed for processing polygonal material .............. 30
5.3.3 Setting the values for the bar end ........................................................ 31
5.3.4 Setting the "REVERSE ROTATION" value .......................................... 31
5.4 Part length follow-up ........................................................................................ 32
5.4.1 COLLET OPEN FIXED SPEED ........................................................... 32
5.4.2 COLLET OPEN CLUTCH .................................................................... 32
5.4.3 Part length INSIDE (STANDARD OPERATING MODE) ...................... 33
5.4.3.1 Part with 1 follow-up ................................................................. 33
5.4.3.2 Part with 2 follow-ups ............................................................... 33
5.4.3.3 Part with 3 follow-ups ............................................................... 34
5.4.4 Part length OUTSIDE ........................................................................... 34
5.4.5 Part length............................................................................................ 34
5.4.6 Acceleration and stop ramps................................................................ 35
5.4.7 Basic setting when selecting PART LENGTH INSIDE and OUTSIDE . 36
5.4.8 Table for traversing programs .............................................................. 37
5.5 Parameter lists ................................................................................................ 39
5.6 Overview of positions for parameter settings................................................... 41
6. Assembly description.............................................................................................. 42
6.1 Support structure with carriers, supports and oil reservoir............................... 42
6.2 Control Panel / Bedienfeld / Panneau de service ............................................ 43
6.3 Menu levels on the control panel ..................................................................... 44
6.3.1 Switching operating levels.................................................................... 45
6.3.2 Manual operation menu 1 .................................................................... 46
6.3.3 Operation Menu (PART) (SERV) (FORCE) ......................................... 47
6.3.3.1 Menu: PART Standard settings ................................................ 48
6.3.3.2 Menu: PART Special settings ................................................... 49
6.3.3.3 Menu: PART Counter/Timer ..................................................... 51
6.3.4 Menu: SERVICE .................................................................................. 52
6.3.5 Manual operation menu 2 .................................................................... 56
6.3.6 Automatic Menu 1 ................................................................................ 57
6.3.7 Automatic Menu 2 ................................................................................ 58
Page 2 Edition 04/99 Operating Instructions

FMB
turbo 5-42XT
Serie 2
6.4 Switching the system on and off ...................................................................... 59

6.4.1 Switching on the system ...................................................................... 59
6.4.2 Switching off the system ...................................................................... 59
6.4.3 Operation with parts counter ................................................................ 59
6.4.4 Operation with programmed operating time ......................................... 60
6.5 Steady rest ...................................................................................................... 60

6.6 Gripper function and method of operation ....................................................... 62
6.7 Bar support ...................................................................................................... 63
6.7.1 Setting the material diameter ............................................................... 63
6.7.2 Setting the angle .................................................................................. 64
6.8 Drive ................................................................................................................ 65
6.8.1 Clutch ................................................................................................... 65
6.8.2 Motor and servo-amplifier .................................................................... 65
6.8.2.1 Servomotor ............................................................................... 65
6.8.2.2 Servo-amplifier - type BN 6648................................................. 66
6.8.3 Ball screw drive .................................................................................... 68
6.8.4 Crank ................................................................................................... 68
6.9 Feed channel................................................................................................... 68
6.9.1 Feed bar............................................................................................... 68
6.9.2 Clamping sleeves / centring sleeves - function and implementation .... 69
6.9.2.1 Working with the clamping sleeve ............................................ 69
6.9.2.2 Working with the centring sleeve .............................................. 71
6.9.3 Guide tube ........................................................................................... 72
6.9.4 Converting the magazine ..................................................................... 72
6.9.4.1 Replacement of polyurethane inserts ....................................... 73
6.9.4.2 Replacement of feed bar .......................................................... 74
6.9.4.3 Replacement of the front guide tube ......................................... 75
6.9.4.4 Installation example: conversion kit D 42/1150/3200-4200 ...... 76
6.9.4.5 Installation example: conversion kit D 32/1500/3200-4200 ...... 78
6.9.4.6 Sample order for a conversion kit ............................................. 80
6.10 Oil supply....................................................................................................... 80
7. Functional description ............................................................................................ 81

7.1 Method of operation ........................................................................................ 81
7.2 Automatic operation ........................................................................................ 82
7.3 Error messages ............................................................................................... 85
8. Removing a material bar from the feed tube ......................................................... 88
9. Maintenance and adjustment tasks........................................................................ 89

9.1 Maintenance unit ............................................................................................. 89
9.2 Feed clutch -KY1 - maintenance ..................................................................... 90

turbo 5-42XT
9.3 Buffer battery ................................................................................................... 91

9.3.1 Replacing the buffer battery ................................................................. 92
9.3.2 Installing or removing an I/O module.................................................... 93
9.3.3 Removing the terminal strip ................................................................. 93
9.3.4 Removing a module ............................................................................. 94
9.3.5 Installing a module ............................................................................... 94
9.3.6 Installing the terminal strip ................................................................... 94
10. Electrical and pneumatic equipment.................................................................... 95

10.1 Diagram of electrical and pneumatic equipment ............................................ 96
11. Parts list - pneumatic parts ................................................................................... 97

11.1 Pneumatic diagram, page 1........................................................................... 98
11.2 Pneumatic diagram, page 2........................................................................... 99

FMB MA SC H IN E NB A U G E S E LL SC H A F T
turbo 5-42XT
Serie 2
0. Safety instructions for operating the loading

magazine
0.1 Operation
• Safety devices, such as doors, guards and covers may not be removed or rendered
inoperative. They must be closed before operating the machine and must not be
opened during operation.
• Any changes to the machine that are liable to impair safety must be reported
immediately to a supervisor.
• Do not switch off the machine using the master switch while a program is running.
This could result in damage to the machine.
• Only press the Emergency Stop button if there is a risk to personnel or the machine
(and prior to maintenance and repair work).
• When transporting the loading magazine, make sure it is securely fastened down and
sufficiently stabilised (see section 2 of these instructions).
• The loading magazine should be set up in such a way that the feed tube and the
machine spindle are aligned with each other (see section 3 of these instructions).
• Check the electrical interface and the operating voltage before commissioning the
machine (see section 4 of these instructions).
• Before starting the machine, fill up with 80 litres of one of the oil grades recommended
in section 1.3 of these instructions.
• Do not throw any waste into the oil.
• Speed limitations (vibration, noise), resulting from workpiece dimensions and out-of-true
material bars, must be taken into consideration.

turbo 5-42XT
0.2 Maintenance and repair

• Servicing, maintenance and repairs may only be carried out by specially trained
personnel or suitably instructed persons.
• For all work on the loading magazine, particularly if any protective covers are open,
press the Emergency Stop button and close the compressed air valve of the loading
magazine. Switch off the lathe's master switch when carrying out any maintenance or
repair work.
The machine must be depressurised and electrically isolated.
• When carrying out repair works on electrical equipment, the pertinent regulations
must be observed. (VDE 0113, DIN VDE 0160; DIN VDE 0660; Accident Prevention
Regulations of the Health and Safety Executive)
• If the plant needs to be ready for operation in the course of certain repair work,
exercise special care. Ensure that no one is in the vicinity of the danger zone.
• Safety devices removed for the purpose of maintenance or repair work must be
re-installed immediately on completion of the work.
• Use only clean oils of the type recommended under section 1.3 of these instructions.
0.3 Usage to the intended purpose

The loading magazine is intended exclusively for feeding solid and tubular round, square
or hexagonal material to material processing machine tools.
For material diameters, please refer to the section "Technical Data".
Materials with other cross-sections should only be processed after consultation with the
loading magazine manufacturer.
Usage to the intended purpose can also be derived from the Technical Data and the
requirements relating to oil filling and material bars, in particular to their straightness
(see section 1.4). The bar loading magazine will operate below the maximum permissible
noise level if the requirements specified by the manufacturer are satisfied.
Any other use shall be construed as not in accordance with the intended purpose. The
manufacturer shall not be liable for any damage arising from such misapplication; in such
instances, the user shall be solely liable.
Use of the loading magazine is only permitted in dry rooms at an air temperature of +15ºC
to +40ºC and a relative humidity of 30% to 75% (non-condensing). The altitude must not
be more than 1000 m above mean sea level.
Usage in accordance to the intended purpose also includes compliance with the operating,
maintenance and repair conditions specified by the manufacturer.
The loading magazine may only be operated, maintained and repaired by persons who are
familiar with procedures and fully informed of the hazards. The relevant accident
prevention regulations and other generally recognised safety regulations must be
observed. The manufacturer can accept no liability for damage resulting from unauthorised
modifications to the machine.

FMB
turbo 5-42XT
Serie 2
0.4 Explanation of symbols and notes
In these operating instructions, you will find this symbol next to

all notes that draw your attention to industrial safety, where there
is a danger to the life and limb of personnel. These instructions
must be heeded at all times and due care taken when carrying out
such work.
This symbol can be found in these operating instructions

wherever special care is necessary to ensure that guidelines,
Caution ! regulations, notes and the correct sequences of operation are
observed, and in order to prevent damage to and destruction of
the machine.
0.5 Property rights

We reserve the right of ownership to these operating instructions and the attached
documents at all times.
These may not be copied, duplicated, passed on, or made available to third parties,
without our written permission.

turbo 5-42XT
0.6 Safety precautions

Trouble-free and safe operation of the bar loading magazine depends on proper transport,
correct installation and commissioning, and careful operation and maintenance.
Always read and observe these operating instructions before

commissioning!
The loading magazine is designed in accordance with the current level of technology and
is reliable and safe to operate. However, the machine may pose a threat to general safety
if used improperly by untrained personnel, or for purposes other than the intended
purpose.
The machine must only be used, maintained and repaired by

persons who are familiar with the operating instructions and the
currently valid regulations on industrial safety and accident
prevention.
Failure to observe the following points can result in personal injury or damage to property.
It should, therefore, be ensured that the operators read and follow these operating
Instructions.
The following regulations have been taken into account for the loading magazine
construction and documentation:
EC Machine Directive (98/37/EG)
DIN-EN 292
DIN-EN 60 204 Part 1 VDE 0113 Part 1
DIN V 8418
Since 1995, all loading magazines delivered within the EU bear the "CE Symbol" and an
"EC Declaration of Conformity" is enclosed.

FMB
turbo 5-42XT
Serie 2
0.7 Safety devices

0.7.1 Covers
In accordance with current regulations, the loading magazine is equipped with protective
covers to prevent access to moving parts. A form-closed switch with positive opening
operation and safety function monitors the cover above the lateral material support.
During steps 17 to 20 of automatic operation, it is safe to open the cover above the lateral
material support in order to reload bar stock.
The voltage supply of the solenoid valves is switched off via safety function switch -S74
and the contactor with positive action contacts -K20. This excludes valves -Y1.1 (close
feed tube), -Y8.1 (swing in feed bar), -Y10.1 (swing in remnant flap) and -Y7 (steady rest),
which continue to be controlled to ensure safe further processing of any bars inside the
feed channel. The PLC also monitors the open position of the cover.
If the loading magazine is not in automatic mode and not in steps 17 to 20 of automatic
mode, the following error message appears on the control panel display when the covers
are open:
ERROR: COVERS NOT CLOSED
Automatic mode is switched off.
In manual mode it is not possible to trigger any of the solenoid valves with the function
keys on the control panel if the covers are open.
Always follow the sequence of steps specified in the operating

instructions when working on equipment!
Always press the EMERGENCY STOP button and close the

compressed air shut-off valve before opening the cover in order
to ensure that the unit is depressurised (except when reloading
material bars in program steps 17 to 20).
No covers of any kind (access doors, guards, etc.) may be

dismantled or disabled while the loading magazine is in
operation. This also applies to all parts of the covers that are not
electrically monitored or permanently bolted in position.

turbo 5-42XT
0.7.2 Guide tube between the loading magazine and the lathe
The guide tube bridges the gap between the front end of the loading magazine and the
spindle end of the lathe. It serves as a protective cover and prevents the protrusion of
rotating parts.
The inside diameter of the guide tube depends on the feed bar installed. The length of the
guide tube is determined during installation of the loading magazine (see section 3).
It must be set so that the distance between the end of the machine spindle and the front
end of the guide tube does not exceed 5 mm, or so that the feed tube extends into the
machine spindle. This gap must not be accessible to the operator!
The designated guide tube must be installed prior to

commissioning. The guide tube must be mounted for loading
magazine operation.
0.7.3 EMERGENCY STOP device
The bar loading magazine is equipped with an EMERGENCY STOP device as required in
VDE 0113. Pressing the EMERGENCY STOP button -S69 at the control panel switches off
the 24 VDC supply voltage to all PLC outputs. Contactors -K20 and -K21 are also switched
off. The voltage supply to the power supply unit providing the power for the drive motor is
disconnected by -K21 so that the motor, and thus the feed bar, are no longer able to carry
out any movements.
The following message appears on the control panel:
EMERGENCY STOP
The second switch element of the EMERGENCY STOP button also sends an
EMERGENCY STOP signal to the machine where it must be processed according to
regulations.
If an EMERGENCY STOP button is pressed on the machine, the loading magazine

controller must also be switched off.
0.7.4 Guards on the lathe
If the lathe is fitted with a "Guard closed" contact, the voltage supply to the amplifier unit
-N3, which triggers the -KY1 clutch, is switched off when this contact is opened.
This means that it is no longer possible for the material bar to move the feed bar.
This therefore prevents any risk of personal injury from the material bar in the lathe
workshop if the guard is open.

FMB
turbo 5-42XT
Serie 2
1. Technical data and operating resources

1.1 Technical data / storage conditions
Material outlet in the feed tube: max. 42 mm
Power consumption: 1.5 kW
Feed force: max. 750 N (infinitely variable)
Insertion rate: 0 to 700 mm/sec (adjustable)

Feed rate: max.1000 mm/sec (adjustable)
Return rate: 1000 mm/sec
Remnant length: max. 530 mm
Dimensions: see erection plan, page 19
Weight: 3.2 m - 1000 kg

4.2 m - 1200 kg
without oil filling, packaging or material
Loading time: approx. 30 sec. (for 3200 mm bars)
Oil filling: 80 l oil (viscosity: 160 cSt at +40º C)

not included in delivery
Operating conditions :
• Ambient temperature of +15ºC to +40ºC. (depending on oil viscosity)
• Relative humidity 30% to 75% (non-condensing)
• The altitude must not exceed 1000 m above mean sea level.
Storage conditions:
The loading magazine must only be stored in a dry area with an ambient temperature of
-20ºC to +65ºC.
Operating voltage:
400 V / 50 Hz (standard version / 200 V on request).
According to VDE 0113, the continuous operating voltage must be 100% ± 10% of the
mains voltage. The frequency must stay between 0.99 and 1.01 of the rated frequency.
Control voltage: 24 V DC
Compressed air supply: 0.6 MPa (= 6 bar)
Air consumption: approx. 10 litres per loading action and

approx. 0.5 litres per double stroke of steady rest
Noise emission: max. 48 ± 5 dBA (during bar change)

turbo 5-42XT
Serie 2 FMB
1.2 Electrical connection between loading magazine and

machine tool
For further details on the loading magazine's electrical connection and power supply,
please refer to the documentation on electrical equipment.
An authorised electrician must carry out electrical connections; the VDE (German) and
local regulations must be strictly observed, particularly with regard to safety measures.
1.3 Oil filling

Only use the oil types specified in
DIN 51 517-2
DIN 51 506 VBL 150
DIN 451 519 ISO VG 150
We recommend the following oil types:
Oil / Öl / Huile
Manufacturer Type
Hersteller 150 - 160 cSt at +40°C
Fabricant
ARAL Motanol HK 150
ESSO NUTO 150
Mobil Vacuoline 128
SHELL Vitrea 150
TEXACO-DEA URSA P 150
Note:
Results with polygonal material can be improved by using oil with a viscosity of
220 cSt at +40°C. Oil change intervals depend on the degree of soiling. Disposal of
waste oil must be carried out in accordance with statutory regulations.

turbo 5-42XT
Serie 2
1.4 Requirements for the material bars and their preparation

The attainable rotational speed of the material bars depends on the geometric accuracy of
their shape.
The out-of-trueness of the bars strongly influences the attainable

speeds.
The greater the diameter, the more negative the influence if the bar is out-of-true.
As well as out-of-trueness, out-of-roundness and out-of-balance of the bars also affect
the achievable speed.
Out-of-trueness should not exceed a tolerance of 0.5 mm per metre. The stated
"mm per m" refers to an even curvature over a length of 1 metre, and on no account
to a short kink within a length of one metre.
Dial gauge Measuring points

rotated by 90°
• The start of the bar must be burr-free for automatic insertion of the material bar into the
lathe spindle and collet. This is required because the collets only open a few
millimetres.
• The bar end must not be bent or distorted by the cutting process.
• Bars must not be soiled, e.g. with chips, sand or similar.
• However, square or hexagonal bar stock does not require an all-round chamfer for
automatic insertion into the collet, but must have a flat end surface that is sawn, turned
or cleanly sheared off.

turbo 5-42XT
Serie 2 FMB
It is not generally necessary to chamfer or point the bar ends with a circular cross section,
as the gripper lifts the bar onto the guide tube centre and pushes it securely into the
clamping sleeve through the infeed cone.
However, if the material bar diameter is approximately that of the feed bar, so that the thin-
walled clamping sleeve no longer has an infeed cone, we recommend chamfering or
pointing the bar end.
Bar diameter considerably

smaller than feed bar diameter
Feed bar diameter

approximately that of the feed
bar diameter
Bar diameter =
max. nominal capacity
If the feed channel is to be used to its maximum
capacity, the ends of the material bars must be
turned to enable accommodation in the clamping
sleeve. Please note that the feed bar can never be
larger than the maximum material bar diameter to
be processed by the lathe.
Clamping sleeve Turning
Standard feed channels
Bars Suitable bar dimensions

opening D Round ∅ Hexagonal AF Square AF
15 12 (15) AF 10 AF 8
25 22 (25) AF 19 AF 15
32 28 (32) AF 24 AF 20
36 32 (36) AF 28 AF 23
42 38 (42) AF 32 AF 27
() Size in brackets for turning the bar end
Other channels (special types) on request.

FMB
turbo 5-42XT
Serie 2
2. Transportation for erection and dismantling

The manufacturer-supplied loading magazine is originally attached to a wooden pallet for
transport purposes.
For length 3200, see pallet drawing no. 23 D 2123.6000 (ID No. 2023.141), and for length
4200, see drawing no. 23 D 2123.6002 (ID No. 2023.143).
4 hexagonal wood screws 10x80 DIN 571 and 4 washers A10.5 DIN 9021 attach each
support to the pallet. The pallet must not be removed until the loading magazine has been
positioned behind the machine tool.
The lifting and transport equipment used must comply with

Caution ! current regulations. No persons are allowed within their swivel
and operating range.
Only qualified operators should use lifting and rigging
equipment.
Transport equipment and routes must be such that there is no risk of damage to property
or injury to persons. This must be checked before transport, if necessary.
2.1 Preparing the loading magazine for transport

Prepare the magazine as follows:
1. Remove any material bars from the unit (support and channel must be empty).
2. Retract the feed bar as far as possible.
3. Leave the loading magazine to rest for at least 8 hours, to allow the oil to drain
completely into the oil reservoir.
4. Empty the oil reservoir and dispose of the oil according to statutory requirements.
5. Switch off the master switch of the lathe.
6. Disconnect the electrical connection to the lathe (remove connector).
7. Depressurise compressed air supply to the loading magazine
(branch tap, main tap etc.)
8. Bleed the loading magazine by closing the shut-off valve on the maintenance unit.
9. Loosen the floor attachments. (Remove the hexagonal nuts of the UPAT dowels)
10. Attach the parts supplied by the loading magazine manufacturer for crane transport
(see section 2.2) and dismantle all connections between the loading magazine and
fixed parts.
11. Use a crane to lift the loading magazine (see section 2.2).
12. If the loading magazine is to be transported by means other than a crane, it must be
placed on a pallet supplied by the loading magazine manufacturer and firmly attached
to the pallet by at least 8 hexagonal wood screws 10x80 DIN 571 and 8 washers A10.5
DIN 9021 through the existing dowel holes in the support base plates.
13. As soon as the loading magazine is raised, ensure that any dowels protruding above
the floor's surface are removed or cut level with the floor (trip hazard).

turbo 5-42XT
Serie 2 FMB
2.2 Transporting by crane

Only rigging equipment suitable for the specified loads and conforming to regulations may
be used. It must be attached as shown on the transport drawing.
When transporting the magazine with the pallet attached, the increased weight must be
taken into consideration. The pallet must be attached in accordance with section 2.1.
The rigging points for the ropes are shown on the transport sketch.
The manufacturer-supplied transport beams must be mounted in accordance with sketch,

drawing no. 23 E 2123.4008 (ID No. 2023.987).
The oil reservoir and control cabinet must be transported separately. Only qualified
personnel may disconnect the connecting cables of the oil pump and control cabinet.
The connecting hoses for the oil forward and return flow must also be disconnected.
The clamping bolts are non-bearing. The transport beam must lie
firmly on the carrier in accordance with the transport drawing.
Before the magazine is lifted, it must be ensured it has been

prepared in accordance with section 2.1 and that no one is in the
danger zone.
The parts supplied are designed only for the specified load
cases.

FMB
turbo 5-42XT
Serie 2
Transport drawing
Ring bolt M20 DIN 580
M20 DIN 557
Open flap if necessary

M5:1
Transport beam

turbo 5-42XT
2.3 Transporting by forklift truck

If transporting with a forklift truck, the loading magazine must be prepared in accordance
with section 2.1 and, depending on its size, attached to one of the pallets listed under
section 2. The pallets can be obtained from the loading magazine manufacturer.
Position the forks at the load's centre of gravity. If necessary, the centre of gravity must be
redetermined to prevent the load from slipping off. During transport, always first ensure
that there is no one in the danger zone.
The weights to be lifted must be taken into account (see section 1.1).
For transportation, determine the

centre of gravity. If necessary,
attach a weight to the front section.
Secure the magazine with
8 wood screws 10x80 DIN 571 and
8 washers A10.5 DIN 9021
to the pallet.
Pallet
Pallet
Separate the struts as

far as possible.
Always observe the
centre of gravity!
2.4 Transporting by other means

Unless transporting by crane, the loading magazine must be placed on a manufacturer-
supplied pallet and properly secured. Prior to transport, always prepare the loading
magazine in accordance with section 2.1. Any pallets required can be obtained from the
For shipping purposes (e.g. lorry, ship, container), the pallet with the mounted loading
magazine must also be secured against possible inertia forces. During transport,
always ensure that no one is in the danger zone.

turbo 5-42 / 5-42XT / 3200 – 4354 mm
turbo 5-42 / 5-42XT / 4200 – 5354 mm
(Variants A; D)
3. Erection
Operating Instructions
FMB
3.1 Erection plan
Central support only for length 4200
UPAT UKA6-M16 dowel
Edition 04/99
Air connection 6 bar Drill holes during assembly
Bar length 3200
Drilling diagram for

UPAT dowel
only for version 4200
Bar length 4200

Measurements subject to change without notice!
Serie 2
Page 19
turbo 5-42XT
turbo 5-42XT
3.2 Floor characteristics

For machine tool data, please refer to the machine documentation. The building in which
the loading magazine is to be installed must be designed so that it is able to accommodate
the required load capacity. This load capacity must take into account the potential weight
and working load of the loading magazine in conjunction with the machine tool.
The operating weight of the loading magazine is:
• turbo 5-42XT loaded with ∅42 / 3200 long weight approx. 1500 kg
• turbo 5-42XT loaded with ∅42 / 4200 long weight approx. 1800 kg
The building must be suitable for installing the machine. If in doubt, consult an expert
prior to installation. No lines of any kind (electrical, water and others) are to be installed
underneath the loading magazine.
3.3 Aligning the loading magazine

The loading magazine must be set up in such a way that the centre line of the machine
spindle is aligned with the centre line of the feed bar. If these are out-of-true, this may
impair operation of the loading magazine (seizure of the feed bar with the spindle; severe
vibration; damage to the machine spindle).
Carry out the following steps:
1. Lift the loading magazine from the pallet (see section 2).
2. Rough lateral alignment of the loading magazine's centre.
3. Rough height adjustment of the M 20 threaded spindle at the supports (place the delivered
soleplates underneath).
4. Mount the conversion kit (feed channel with feed bar) provided for the machine, if not yet fitted.
5. In longitudinal direction, the loading magazine must be erected as close as possible behind
the machine. It must be ensured that the material bar is pushed out from the loading magazine
by the distance "x" before the feed bar is mounted (turning operation not yet possible).
The material bar must not yet be inserted into the clamping system of the machine and must
not rotate with it, because the gripper blades close in order to mount the feed bar. This could
otherwise lead to damage to the loading magazine and the lathe (see diagram on next page).
6. Fine alignment of the magazine, preferably using an optical instrument by Messrs. Breithaupt,
Kassel. To do this, the feed bar must be precisely aligned at both the front and the rear.
7. Assembly of the guide tube supplied by the loading magazine manufacturer. The length of the
guide tube must be adjusted so that the distance between the front end and the machine
spindle does not exceed 5 mm or, in the case of small bar diameters, the tube extends into the
machine spindle.
Proper alignment of the loading magazine is crucial for correct

Caution ! operation. We recommend that this work is carried out by the
manufacturer's own experienced service technicians.
Commissioning of the loading magazine must be carried out in
accordance with section 5.

Spindle head fully retracted
Extended material bar before mounting
FMB
Measurement X for 1150 mm feed bar at least 510 mm

Measurement X for 1500 mm feed bar at least 860 mm
Edition 04/99
Serie 2
Page 21
turbo 5-42XT
turbo 5-42XT
3.4 Attachment to the floor

After aligning the loading magazine with the machine spindle (section 3.3) it must be
attached to the floor at the relevant places with 8 heavy-duty M 16 anchor bolts
(UPAT UKA6-16 recommended).
Caution ! The fastening elements are not included in delivery.
If using other fixing methods, these must secure the magazine as effectively as the means
described above.
Ensure that the anchors do not damage load-bearing parts of

building structures or other equipment.
Check the floor for possible supply lines (electrical wiring, water
or gas lines, etc.) before drilling holes for the anchors. These
must not be affected by drilling. Consult an expert, if necessary.
3.5 Compressed air supply

The compressed air supply is connected to a 1/4" hose nozzle on the maintenance unit of
the loading magazine. A shut-off valve must be installed upstream of the loading
magazine.
The compressed air supply must satisfy the following parameters:
• Pressure: 0.6 MPA - 0.8 MPA

• Compressed-air consumption: approx. 10 litres per loading action and
approx. 0.5 litres per double stroke of steady rest
The air must be dry and filtered.
The power supply cable must be installed so that there is no risk

of injury to persons or damage to property.

FMB
turbo 5-42XT
Serie 2
3.6 Electrical connection

The electrical connection between the magazine and the machine tool is illustrated in the
electrical documentation on page 3 (interface). The pin assignment and operating voltage
are determined by the machine tool and are factory-set. In accordance with VDE 0113, the
continuous operating voltage must be 100 % ± 10% of the rated voltage. The frequency
must range between 0.99 and 1.01 of the rated frequency.
Check that the interface complies with the electrical

Caution ! documentation and section 4 of these instructions.
When the machine tool has been prepared for installation of the loading magazine, and
once the electrical connection is established, check the direction of rotation of the oil
pump.
The oil pump must rotate in the direction of the arrow on the
Caution ! ventilator cover. If the oil pump rotates in the wrong direction, no
oil is pumped into the channel. The direction of rotation can be
changed by swapping two wires of the power supply cable.
Always switch the machine off at the master switch before
attempting to swap the wires.
Before commissioning, always first ensure that the emergency

Caution ! stop system and electrically monitored covers are fully functional
(see sections 0.7.1 and 0.7.3).
3.7 Avoiding hazardous confined spaces

The loading magazine must be installed so that it is always accessible
from all sides for maintenance, repair and other work. All control elements must be easy to
access and operate.
It must be possible to open the control cabinet at all times. Any machines and units in
close proximity must be taken into consideration. Take preventitive measures to ensure
that there is no risk of personal injury or damage to property when working on the loading
magazine.
3.8 Repairs to the machine tool

In the event of extensive repairs to the machine, ensure that there is sufficient space to
carry out the work efficiently and without endangering persons or property. This may mean
temporarily moving the loading magazine to another location. In this case, please observe
the transport and installation instructions in sections 2 and 3.

turbo 5-42XT
4. Notes on the interface

The standard connection is customised to the individual
Caution ! machine. Please refer to the electric wiring diagram for details of
relay, contact and plug pin assignment.
4.1 Contacts from lathe to FMB loading magazine

• Clamping device open:
This contact switches on the feed mechanism of the loading magazine.
• End of program cycle, start bar change:
On automatic lathes with program jump, the contact should be in the bar start program,
before "Collet open".
• Automatic lathe ready for operation, automatic mode enabled:
The loading magazine can only be switched to automatic mode if this contact is
available.
• Machine on (optional):
The automatic lathe can use this contact (pulse) to start the automatic mode of the
loading magazine.
• Sliding hood closed:
The magazine can only effect a forward feed stroke if this contact is available.
• Emergency Stop machine:
Isolated contact of automatic lathe. This contact is integrated into the Emergency Stop
circuit of the magazine.
4.2 Contacts from the FMB loading magazine to the lathe

• No fault, bar loading magazine (-K30):
No fault, contact closed. Fault, contact open. If a fault is signalled, the spindle of the
automatic lathe must be locked.
• End of bar change, program start (-K1):
Contact can be transmitted from the magazine as an impulse or as a permanent
contact, depending on the automatic lathe control system. This is a signal to the
automatic lathe that the bar has been inserted into the automatic lathe, or read-in
enable, program start.
• Start bar change, or program stop (-K9):
Contact can be transmitted from the magazine as a make or break contact, depending
on the automatic lathe. This contact is made during processing of the last work piece or
on completion of the last work piece. This is a signal to the automatic lathe indicating
that processing of the material bar is finished.
• Automatic Operation On (-K1M):
The contact is closed if the magazine is in automatic mode.
• Feed OK (-K44):
Signal is output after the part length feed is executed and continues until the feed
signal (collet open) is removed, [output only if: PART LENGTH INSIDE is selected]
• EMERGENCY STOP bar loading magazine:
Isolated contact of the magazine. This contact must also be integrated in the
Emergency Stop circuit of the automatic lathe.

turbo 5-42XT
Serie 2
4.3 Program suggestion for lathe

Parts program
• Positioning turret
• Open the clamping device (signal to the loading magazine)
• Dwell time (bar follow-up). When "PART LENGTH (INSIDE)" is selected, acknowledge
with -K44 (Feed OK)
• Close clamping device
Processing
Query bar end Yes / No (-K9)
Jump - bar start program

Parts program record start
Bar start program
• Positioning turret
• Spindle speed (approx. 50 r.p.m. required for profile material)
• Clamping device open
• Signal start bar change (end of program cycle)
• The machine has to wait until the new material bar has been fed into the automatic
lathe and the signal "-K1" is available.
• Close clamping device
• Cut off the first part of the bar
• Return to the parts program
Caution ! This example is intended for information purposes only!

turbo 5-42XT
5. Commissioning the loading magazine

5.1 Conditions for commissioning
The loading magazine must be in its original condition as delivered by the manufacturer.
All parts required for operation must be correctly fitted. In case of doubt, please contact the
We recommend that commissioning is carried out by the

Caution !
magazine manufacturer's own service personnel.
5.1.1 Fastening the loading magazine - working according to the erection plan
Prior to commissioning, erect and fasten the loading magazine as specified under section 3.
5.1.2 Connection to the machine
Check the alignment and the distance of the loading magazine to the machine
(see section 3). Ensure that the electrical connection cable is properly connected
(see section 3.6).
5.1.3 Supply media
Ensure that the compressed air supply is fully functional (see section 1). Prior to
commissioning, check that the loading magazine's compressed air system is airtight
(soapsuds are suited to this purpose). There must be no pressure loss. Set the pressure of
the maintenance unit to 0.6 MPa (see section 9). The pressure switch -S11 triggers a fault
message at the controller if the pressure falls to less than 0.4 MPa.
5.1.4 Oil filling
Prior to commissioning, the oil reservoir must be filled with 80 l of one of the oil types
specified in section 1.3. Before starting to fill the oil, check the oil reservoir for leaks. The
fitted oil hoses and pipes must not be bent or blocked. There must be no obstructions to
the oil flow. The return lines must be installed with a steep gradient. Prior to
commissioning the oil pump, carry out a trial run (30 min.) to check the following items:
• Check the direction of rotation of the oil pump (reverse electrical connections in
accordance with section 3.6 if required)
• Check the oil flow in the feed channel (must be flooded completely after a short period
of time)
• Once the feed channel is filled with oil, check the loading magazine for leaks,
especially during extension and retraction of the feed bar.
• Check the oil return line to the oil reservoir.
turbo 5-42XT
Serie 2
5.1.5 Mechanical adjustments
Prior to commissioning, the following assemblies must be correctly set to suit the
processing material.
• Feed channel (see section 6.9)
• Steady rest (see section 6.5)
• Lateral material supply (see section 6.7)
5.1.6 Staff training / Application of the operating instructions
The personnel responsible for operation must receive proper training prior to
commissioning.
The operating instructions form the basis for this training.
Every user must study these carefully.
We recommend that staff are instructed and trained by the

Caution ! magazine manufacturer's own service personnel.

turbo 5-42XT
5.2 Switching on the system for the first time

1. Switch on the master switch at the machine tool.
2. It takes a few seconds for the FANUC PLC to start in RUN mode. Until it starts, the red
ERR LED lights up on the control panel. If the LED is off, you need to select Automatic
Menu 2.
3. Since the position of the feed bar may have shifted during transport, initiate a reference
run by pressing F8 "REFF". The reference run is automatically executed. The green
LED lights up in the F8 key.
On completion of the reference run, the yellow LED lights up. Other functions can now
be selected on the control panel.
4. Now set the values for "First insert measure trav.", "Position Front Limit ", "Travel
Interval On" and "Position reverse rotation" under "POSITIONS" in the "SERVICE"
menu. To do this, move the feed bar and clamping sleeve to the appropriate position
using F8 "FORW" or F7 "BACK" in Manual Operation Menu 1. Press the "HLP" key to
display the current position in the top line. This value must be entered under the
"POSITION" menu item.
5. The function of the steady rest can then be selected in the "POSITIONS" menu item.
6. At "PART LENGTH" under "STANDARD SETTINGS" in the "PART" menu, enter the
length of the part produced on the machine in mm. The PLC uses this value to
calculate the bar end (see section 5.3.3).
Enter the "FEED1" in the same menu item.
If the work piece is clamped once, this value corresponds to the part length
(see section 5.4 / 5.4.3.1 etc.).
7. After switching to the automatic menu, depending on the application, you can now
select the steady rest as an insertion aid, or the brake, interval feed or the function
without gripper.
8. Using F3 "S.1" or F4 "S.17", you can now select in which step automatic mode should
start. The selected step appears in the 1st line of the display.
Start at step 1 if there is a remnant or no material at all in the clamping sleeve.
Start at step 17 if a material bar is in the machine spindle and still needs to be finished.
9. F2 "STRT" starts automatic mode.

The green LED in F2 lights up.
10. If the bar change has been started without a remnant, the program continues without
a fault message if the "CLR" key is pressed in steps 1 to 4.
11. After the machine is switched on in the morning for the day's shift, work can be
continued with the last active step at shutdown.

turbo 5-42XT
Serie 2
5.3 Settings on the controller

5.3.1 Setting the cut-off position (end of initial feed)
• In Manual Menu 1, switch over to the SERVICE menu via F6 "SERV".

• Enter measurement E in mm under "First insert measure trav." in the "POSITIONS"
menu item. Measurement E is the distance between the switching flap of the starting
switch -S7 and the cut-off position.
• Now check the cut-off position in automatic mode.
• If the position is incorrect, enter a new value.
• Section 6.2 explains how to enter values at the control panel.
Clamping device of
the machine tool Cut-off tool
-S7
Cut-off length
Long turning automatic lathe
Cut-off length
X = Travelling distance of the spindle head / work piece length

turbo 5-42XT
5.3.2 Adjusting the interval feed for processing polygonal material
To improve the feed of polygonal material into the automatic lathe collet, the forward feed
stroke of the material bar can be controlled in intervals during initial feed. To this end, the
drive unit is switched on and off intermittently. The interval feed function is switched on
with F7 "INTV" in Automatic Menu 1. The travel of the intermittent forward feed stroke is
entered in the "POSITIONS" menu item of the "SERVICE" menu under "TRAVEL
INTERVAL ON".
The PLC calculates the start of the intermittent forward feed stroke by subtracting the
entered value from the cut-off position. The start time and pause time of the forward feed
stroke can be entered under "SPECIAL SETTINGS" in the "Part" menu. The time value is
entered in tenths of a second.
Clamping device of the

machine tool
Start
Interval feed Cut-off tool
-S7
Cut-off length
E = First insert measure travel distance

I = Interval feed

FMB
turbo 5-42XT
Serie 2
5.3.3 Setting the values for the bar end
Caution!: A reference run must first have been carried out before setting the bar end.
Run the feed bar forward into the machine collet with the clamping sleeve. Press the HLP
key to display the current position, and enter this value, minus 3 mm at "Position front limit"
under the "POSITIONS" menu item of the "SERVICE" menu. Then enter the length of the
part to be processed in "Part Length" under "STANDARD SETTINGS" of the "PART" menu.
The PLC subtracts this length from the front limit position and calculates the bar end value.
If the bar end value is reached or exceeded in automatic mode during part follow-up, the
step chain switches to step 18. Relay -K9 signals the bar end to the machine.
"Position front limit" does not need to be changed. The "Part length" value must always be
adapted to the dimensions of the current part.
5.3.4 Setting the "REVERSE ROTATION" value
During a bar change the feed bar moves the remnant at low speed. The motor switches
to a higher speed once the value set for "reverse rotation" is reached.
The position at which the remnant has left the machine spindle must be determined. Once
this value is determined, it is entered in "POSITION REVERSE ROTATION" under
"POSITIONS" in the "SERVICE" menu.

turbo 5-42XT
5.4 Part length follow-up

The turbo 5-42XT offers more than one option for part length follow-up. These options can
be selected in the PART menu under Special Settings.
SELECT PART FEED: COL OPEN FIXED SPEED

OK? Y-ENT N-CLR ABORT-F1 CONT ↑↓
Options: COL OPEN FIXED SPEED

COL OPEN CLUTCH
PART LENGTH INSIDE Standard operating mode
PART LENGTH OUTSIDE
Select by simultaneously pressing + and – until the input field flashes. Then select function
with + or –.
5.4.1 COLLET OPEN FIXED SPEED
Collet open: Motor runs at constant speed with

"SPEED FOR PART FOLLOW-UP"
Clutch on with "FEED FORCE FOR PART FOLLOW-UP"
Collet closed: Motor at standstill

Clutch off when w/o BRAKE selected
Clutch on when with BRAKE selected with "FORCE BRAKE
FUNCTION"
Method of operation: The material bar must be retrieved when this option is selected.
5.4.2 COLLET OPEN CLUTCH
Collet open: Motor runs at constant speed with

Collet closed: Motor runs at constant speed

Clutch off
Method of operation: The material bar must be retrieved when this option is selected.

FMB
turbo 5-42XT
Serie 2
5.4.3 Part length INSIDE (STANDARD OPERATING MODE)

Please refer to section 5.4.7 for further information on the basic setting
5.4.3.1 Part with 1 follow-up
Input in PART menu e.g.:

PART LENGTH: 100.00 FEED1: 100.00
FEED2: 0:00 FEED3: 0:00
Collet open: After cut-off, the material bar is fed forward 100 mm each time
the Collet Open signal (push) is output.

FUNCTION"
Method of operation: There is no limit stop during operation when this option is selected.
5.4.3.2 Part with 2 follow-ups

FEED2: 20:00 FEED3 0.00
Collet open: After cut-off, the material bar is fed forward 80 mm the first time the
Collet Open signal (push) is output. The second time the Collet Open
signal is output, the material bar is fed forward 20 mm.
Collet Open counter repeats 1-2-1-2, etc.

FUNCTION"

turbo 5-42XT
Serie 2 FMB MA SC H IN E NB A U G E S E LL SC H A F T
5.4.3.3 Part with 3 follow-ups

FEED2: 20.00 FEED3: 30.00
Collet open: After cut-off, the material bar is fed forward 50 mm the first time the
Collet Open signal (push) is output. After the second Collet Open
signal, the material bar is fed forward 20 mm and a further 30 mm
after the third signal.
Collet Open counter repeats 1-2-3-1, etc.
Clutch on when with BRAKE selected with "FORCE BRAKE FUNCTION"
Note: The Collet Open counter can be reset to FEED1 by simultaneously

pressing + - and 0
5.4.4 Part length OUTSIDE

(Only possible when the automatic lathe signal is available!)
Please refer to section 5.4.7 for further information on the basic setting
Multiple part follow-up:

FEED2: 20.00 FEED3: 30.00
Collet open: When the signals "Collet Open" and "FEED1 On" are output
simultaneously, the material bar is fed forward 50 mm.
When the signals "Collet Open" and "FEED2 On" are output
When the signals "Collet Open" and "FEED3 On" are output
Clutch on when with BRAKE selected with "FORCE BRAKE FUNCTION"
5.4.5 Part length
The part length to be entered in the "PART" menu corresponds to the part length plus the
cut-off width. In the case of "Part length INSIDE", the part length must correspond to the
sum of the feed values 1 to 3. In the case of "Part length OUTSIDE", the part length must
correspond to the sum of the externally controlled feed values per part.

FMB
turbo 5-42XT
Serie 2
5.4.6 Acceleration and stop ramps
The acceleration ramps can be entered in the "PART" menu under "STANDARD SETTINGS"
and in the "SERV" menu under "SPEED". Depending on the load (material), you can enter
acceleration ramps of up to 2000 mm/s².
Round material
Diameter (mm) max. acceleration (mm/s²)

10 – 34.9 2000
35 – 39.9 1800
40 – 42 1300
Square material
AF (mm) max. acceleration (mm/s²)

10 – 29.9 1600
Hexagonal material
AF (mm) max. acceleration (mm/s²)

10 – 34.9 1600
35 – 36 1200
The accelerations specified in the table can only be set with

Caution ! XT clamping sleeves. Failure to use XT clamping sleeves may
result in tool breakage or damage to the machine tool.

turbo 5-42XT
5.4.7 Basic setting when selecting PART LENGTH INSIDE and OUTSIDE
FEED FORCE FOR PART FOLLOW-UP: 100%

SPEED FOR PART FOLLOW-UP: min. 400 mm/s
ACCELERATION PART FOLLOW-UP: between 400 - 2000 mm/s²
(In the case of larger material bars and clamping sleeves with less holding power - setting:
400 mm/s²)
MIN. PART LENGTH FOLLOW-UP:

Part length minus 0.1 mm
e.g. part length 100 mm: 99.9 mm
In the case of multiple part length follow-up per part: enter the shortest
value minus tolerance.
e.g. FEED1: 50; FEED2: 20;
FEED3: 30 INPUT: 19.9 mm
MAX. PART LENGTH FOLLOW-UP:

Part length plus 0.2 - 0.3 mm
e.g. part length 100 mm: 100.2 mm
In the case of multiple part length follow-up per part: enter the longest
value plus tolerance.
e.g. FEED1: 50; FEED2: 20;
FEED3: 30 INPUT: 50.2 mm
Note:
- If the error message "PART FOLLOW UP TOO SHORT " is displayed during part follow-up,
the follow-up time value may be too low.
Remedy: Push signal on the automatic lathe needs to be output for longer (enter dwell time)
- If clamping sleeves with low axial holding power are used for material bars with large
diameters, the material bar may slip from the clamping sleeve if the acceleration ramp is too
high.
Remedy: use XT clamping sleeves with high holding power or lower

acceleration ramp.
The following tables contain the traversing times for "PART LENGTH FOLLOW-UP".
Example: Part length: 100 mm

Feed rate: 400 mm/s
Acceleration: 400 mm/s²
Traversing time in the table is:
1 second plus response time 0.1 second = 1.1 seconds
For this example, the push signal from the automatic lathe (Collet Open)
must be output for 1.1 seconds for part follow-up.

FMB
turbo 5-42XT
Serie 2
5.4.8 Table for traversing programs

PART LENGTH INSIDE AND OUTSIDE
Table for traversing programs

(traversing time only, without response time of controller, response time approx. 0.1sec)
Feed rate: 400 mm/sec
Distance Traversing time in sec. for acceleration:
traversed
in mm 400mm/sec² 600mm/sec² 800mm/sec² 1000mm/sec²
10 0.32 0.26 0.22 0.2
20 0.45 0.36 0.32 0.28
30 0.55 0.44 0.39 0.35
40 0.63 0.51 0.45 0.4
50 0.71 0.57 0.5 0.45
60 0.77 0.63 0.55 0.49
70 0.84 0.68 0.59 0.63
80 0.89 0.72 0.63 0.57
90 0.95 0.77 0.67 0.6
100 1 0.81 0.71 0.63
110 1.05 0.85 0.74 0.66
120 1.1 0.89 0.77 0.69
130 1.14 0.92 0.81 0.72
140 1.18 0.96 0.84 0.75
150 1.22 0.99 0.87 0.77
160 1.26 1.02 0.89 0.8
170 1.3 1.06 0.92 0.82
180 1.34 1.09 0.95 0.85
190 1.38 1.12 0.97 0.88
200 1.41 1.15 1 0.9
220 1.48 1.2 1.05 0.95
240 1.55 1.25 1.1 1
260 1.61 1.31 1.15 1.05
280 1.73 1.36 1.2 1.1

turbo 5-42XT
Serie 2 FMB
Table for traversing programs

(traversing time only, without response time of controller, response time approx. 0.1sec)
Feed rate: 600 mm/sec
Distance Traversing time in sec. for acceleration:
traversed
in mm 400mm/sec² 600mm/sec² 800mm/sec² 1000mm/sec²
10 0.32 0.26 0.22 0.2
20 0.45 0.36 0.32 0.28
30 0.55 0.44 0.39 0.35
40 0.63 0.51 0.45 0.4
50 0.71 0.57 0.5 0.45
60 0.77 0.63 0.55 0.49
70 0.84 0.68 0.59 0.63
80 0.89 0.72 0.63 0.57
90 0.95 0.77 0.67 0.6
100 1 0.81 0.71 0.63
110 1.05 0.85 0.74 0.66
120 1.1 0.89 0.77 0.69
130 1.14 0.92 0.81 0.72
140 1.18 0.96 0.84 0.75
150 1.22 0.99 0.87 0.77
160 1.26 1.02 0.89 0.8
170 1.3 1.06 0.92 0.82
180 1.34 1.09 0.95 0.85
190 1.38 1.12 0.97 0.87
200 1.41 1.15 1 0.89
220 1.48 1.2 1.05 0.94
240 1.55 1.25 1.1 0.98
260 1.61 1.31 1.14 1.02
280 1.73 1.36 1.18 1.06

FMB
turbo 5-42XT
Serie 2
5.5 Parameter lists

These lists specify the standard parameters.
After installing the loading magazine as described in section 5.5, determine the values
marked *, and enter them in the control panel and in the following list.
Section 6.2 explains how to enter values at the control panel.

turbo 5-42XT
Serie 2 FMB

FMB
turbo 5-42XT
Serie 2
5.6 Overview of positions for parameter settings

Variants A; D
Travel interval on
Position front limit
Initial feed
Position reverse rotation
Position close steady

Position open steady
Pos. approach clamping sleeve
with front edge
Feed bar length
Position material draw off
Position slide front

Gripper blades
Position support
Pos. approach slide
with front edge
Position slide
at limit stop
0 point approached
during reference run
Position rear limit
Limit stop

turbo 5-42XT
6. Assembly description
6.1 Support structure with carriers, supports and oil reservoir
The carrier, supports and oil reservoir form the support structure. All parts of the loading
magazine are mounted onto the carrier. Similarly, this carrier is bolted to the height-
adjustable supports.
4 setscrews (M 16 x 60 DIN 916) on each support allow adjustment in all directions.
The screws must be located in the supplied soleplates.
After alignment, the supports are fastened to the floor using heavy-duty M 16 anchors
(see section 3).
The oil reservoir is positioned separately under the magazine. The oil inlet and outlet must
be connected to the carrier, and the oil pump must be connected to the power supply.
For transport purposes, the control cabinet is secured to the carrier and the front support.
When the magazine is set up, this is placed on the floor.

FMB
turbo 5-42XT
Serie 2
6.2 Control Panel / Bedienfeld / Panneau de service

turbo 5-42XT
6.3 Menu levels on the control panel

MANUAL operation menu 1
MANUAL OP. MENU1 MENU2 ↓ COL:OPEN Display Collet OPEN/CLOSED
-A- ROFF BRON SEPA PART SERV BACK FORW
F1 F2 F3 F4 F5 F6 F7 F8
Run forward (fast forward F8 and + key)

Return run (fast return F7 and + keys)
Service menu, see section 6.3.4
Part menu, see section 6.3.3
Separate material
Remove the remnant and draw up a new bar
Remove and eject the remnant
Automatic Menu 1, see section 6.3.6
MANUAL operation menu 2

MANUAL OP. MENU2 MENU1 ↓ COL:OPEN Display Collet OPEN/CLOSED
-A- GRIP BOFF TUBE REMN STDY OILP PSWG
F1 F2 F3 F4 F5 F6 F7 F8
Lift out feed bar / close with gripper, remnant check

Oil pump ON in manual mode
Steady rest ON in manual and automatic mode
Open remnant flap
Open tube
Return bar and withdraw from clamping sleeve
Close gripper blades
Automatic Menu 1
Automatic Menu 1
Display of current step
AUTO STEP1 RETURN COL:OPEN Display Collet OPEN/CLOSED

-M- STRT S.1 S.17 S.ST STDY INTV FORCE
F1 F2 F3 F4 F5 F6 F7 F8
Feed force for part follow-up menu

Interval feed ON/OFF
Steady rest ON in manual and automatic mode
Step selection, incremental
Preselect step 17 (parts production)
Preselect step 1 (return run)
Start Automatic mode
Manual operation MENU 1
Automatic Menu 2
Display of current step
AUTO STEP1 RETURN COL:OPEN Display Collet OPEN/CLOSED

-M- STRT INHE W-OG BRAK REFF
F1 F2 F3 F4 F5 F6 F7 F8
Reference run
Brake ON (hold position) (Switching is only possible by simultaneously pressing + and –)

With or without gripper (green LED active - without gripper - switching only possible by simultaneously pressing + and –)
Steady rest as insertion aid (green LED = Yes)
Start Automatic mode
Manual operation MENU 1

FMB
turbo 5-42XT
Serie 2
6.3.1 Switching operating levels
a) Press cursor key ↓ to switch from Manual Operation Menu 1 to Manual Operation
Menu 2.
b) Press cursor key ↑ to switch from Manual Operation Menu 2 to Manual Operation
Menu 1.
c) Press function key F1 (-A-) in Manual Menu 1 or 2 to switch from Manual Menu 1 to
Automatic Menu 1.
d) Press cursor key ↓ to switch from Automatic Menu 1 to Automatic Menu 2.
e) Press cursor key ↑ to switch from Automatic Menu 2 to Automatic Menu 1.
f) Press function key F1 (-M-) in Automatic Menu 1 or Automatic Menu 2 to switch from
Automatic Menu to Manual Menu.
Pressing the HLP function key in the Manual Menus outputs the following message in
the first line of the display:
CURRENT POSITION +_____.__mm.
The text of the abbreviation is contained in the second line and can be read via by
pressing function key F1. If you continue to press the HLP key, the text can be scrolled
using cursor keys ↑ or ↓.
Pressing the HLP in the AUTOMATIC Menus causes the following message to appear:
↑ AUTO-MENU 1 ↓ AUTO-MENU 2 COL: OPEN/CLOSED

ZAEHLER/COUNTER:_____ ZEIT/TIMER:__.__
The current values are displayed.
As in the Manual menus, the cursor keys can be used to select the text relating to the
abbreviations above the function keys.

turbo 5-42XT
6.3.2 Manual operation menu 1
-A- Switch to Automatic Menu 1

F1
ROFF Remove remnant. Feed bar is retracted. The remnant is pulled out of the
F2 clamping sleeve and ejected.
BRON Remove the remnant and draw up a new bar. The feed bar is retracted,
F3 the remnant ejected, the new bar separated and pushed into the clamping
sleeve.
SEPA Separates a new material bar. Only active when the feed tube is closed.
F4
PART Jumps to the Part menu

F5
Standard setting - with cursor key ↓
PART • These parameters can be modified by the user at any time
(see section 6.3.3.1)
Special setting - with cursor key →

• Selects specific additional functions. Must be enabled, see
operation menu (see section 6.3.3.2)
Counter/timer - with cursor key ←

(see section 6.3.3.3)
SERV Jumps to the Service menu (see section 6.3.4)

F6
These parameters should only be modified during installation or
SERV
by service personnel!
BACK The feed bar is slowly retracted. For fast retraction, simultaneously press
F7 F7 and +.
FORW The feed bar advances at slow speed. For fast forward run, simultaneously
F8 press F8 and +.

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turbo 5-42XT
Serie 2
6.3.3 Operation Menu (PART) (SERV) (FORCE)
a) Call up the menu with the appropriate key.
b) Select appropriate menu item with arrow keys.
c) If the parameter is flashing, it can be overwritten. If not, it must be enabled. Enable by

simultaneously pressing + and - .
d) Enter the values.
e) If a wrong value is entered, use the CLR key to restore the old value.
f) Several parameters can be entered successively.
g) If the entered parameters are OK, quit the menu using the ENT key for the changed
parameters to be accepted by the controller.
h) If the menu is aborted by pressing F1, the modified parameters are ignored and the old
parameters remain valid.
i) By enabling the Select Steady and Synchronization Clutch parameters using the + and
- keys, you can select a different type of steady rest or synchronisation clutch. (See
section 6.3.4 Menu: Service: Positions)
Note:
The SERV menu parameters should only be modified during installation by the
magazine manufacturer's own service personnel.

turbo 5-42XT
Serie 2 FMB
6.3.3.1 Menu: PART standard settings
MENU_PART STANDARD SETTINGS ↓

← COUNTER/TIMER SPECIAL SETTINGS →
↓ Standard Settings
PART LENGTH: ________mm FEED1:__________mm

FEED2: ________mm FEED3:__________mm
FEED FORCE FOR PART FOLLOW-UP: _____%

FEED FORCE FOR FIRST INSERTION: _____%

FEED FORCE FOR PRESSING: _____%

SPEED FOR PART FOLLOW-UP: _____mm/SEC

ACCELERATION PART FOLLOW UP:________

YES-ENT ABORT-F1 NO →

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6.3.3.2 Menu: PART Special settings
→ Special settings
CORRECTION VALUE AF.AUTO/DOOR ON: _______mm After automatic mode has been
stopped or the sliding door of the
OK? Y-ENT N-CLR ABORT-F1 CONT ↑↓ automatic lathe is opened, the
brake function is disabled, thus
relieving the pressure on the
system. As a result, execution of
the next part length follow-up
was too short. To prevent this, a
correction value can be entered
for the first part length follow-up
after autostart or the closing of
the sliding door.
EXTENSION OF INITIAL INSERT: _______.____mm

e.g.: Part length 100,00 mm

Input 99,99 mm
MIN. PART LENGTH FOLLOW-UP: _______.____mm
In the case of multiple part
OK? Y-ENT N-CLR ABORT-F1 CONT ↑↓ length follow-up per part, enter
the shortest value minus
tolerance.
e.g.: Part length 100,00 mm

Input 100,2 mm
MAX. PART LENGTH FOLLOW-UP: _______.____mm In the case of multiple part
OK? Y-ENT N-CLR ABORT-F1 CONT ↑↓ length follow-up per part, enter
the longest value plus tole-
rance, plus correction value.
• COL OPEN FIXED SPEED

• COL OPEN CLUTCH
SELECT PART FEED: PART LENGTH (INSIDE) • • PART LENGTH INSIDE
OK? Y-ENT N-CLR ABORT-F1 CONT ↑↓ • PART LENGTH OUTSIDE
Select by pressing + and –
together. Input field flashes.
Then select function
with + or –.
COLLET OPEN DELAY: __________10/SEC

Continued on the next page!

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Serie 2 FMB
Continued
COLLET CLOSED DELAY: __________10/SEC

CYCLE TIME INTERVAL ON : __________10/SEC

CYCLE TIME INTERVAL OFF: _______10/SEC

CYCLE TIME SPINDLE ON: _______10/SEC

CYCLE TIME SPINDLE OFF: _______10/SEC

MONITOR COLLET OPENED _______10/SEC

MONITOR COLLET CLOSED _______10/SEC


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6.3.3.3 Menu: PART Counter/Timer
← Counter/Timer
PARTS COUNTER DESIRED: _____ACTUAL: _______ see also section 6.4
max. setpoint value:
OK? Y-ENT ABORT-F1 ACTUAL: 0=CLR ↑↓ 9999999
OPERATING TIME: ____.__H ACTUAL: ____.__H see also section 6.5

max. setpoint value:
OK? Y-ENT ABORT-F1 ACTUAL: 0=CLR ↑→ 60.60
__.__H The 2 fields flashing to the left of the point in the input field indicate where to
enter the hours. Press cursor key → to jump to the 2 fields to the right of the
point and enter the minutes.

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Serie 2 FMB
6.3.4 Menu: SERVICE
M-SERVICE: SPEED ← FEED FORCE →

POSITIONS ↓ CURRENT POSITIONS ↑
↓ Positions
FIRST INSERT MEASURE TRAV: _______.____mm
POSITION FRONT LIMIT _______mm

POSITION REAR LIMIT _______mm

POSITION MATERIAL DRAW OFF _______mm

POSITION OPEN STEADY: _______mm

POSITION CLOSE STEADY: _______mm

TRAVEL INTERVAL ON: _______mm

POSITION REVERSE ROTATION: _______mm

LIMIT POSITION SLIDE FRONT: _______.____mm

Continued on the next!

page!
FMB
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Serie 2
Continued
MATERIAL POSITION: _______mm

PUSHER LENGTH: +______mm

• ROLLER STEADY
• ROLLER STEADY OPEN
SELECT STEADY: GUIDE STEADY • AT PUSHER
OK? Y-ENT N-CLR ABORT-F1 CONT ↑↓ Select by simultaneously pressing +
and –. Input field flashes. Then select
function with + or –.
• WITH SYNCHRO
SYNCHRONIZATION CLUTCH: W/O SYNCHRO • • FOLLOW-UP
OK? Y-ENT N-CLR ABORT-F1 CONT → • SPECIAL
For selection see above.
→ FEED FORCE
FEED FORCE FOR RETURN: ______%

FEED FORCE FOR PART FOLLOW-UP ______%

FEED FORCE FOR FIRST INSERTION: ______%

FEED FORCE FOR PRESSING: ______%

OK? Y-ENT N-CLR ABORT-F1 CONT →
FORCE BRAKE FUNCTION: ______%

-S1 -S12
↑ CURRENT POSITION
-S7
CURRENT POS: ±_______.____mm 00000000_00000000 for service

Continued on the next page!

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Serie 2 FMB
Continued
POSITION INTERVAL ON: _______.____mm

POSITION INTERVAL OFF: _______.____mm

POSITION END INITIAL INSERT: _______.____mm

POSITION BAR END: _______.____mm

BAR LENGTH: _______.____mm

← SPEED
SPEED FOR RETURN FROM SPINDLE: ______mm/SEC

SPEED FOR RETURN HIGH: ______mm/SEC

SPEED FOR SLIDE FOLLOW-UP: ______mm/SEC

SPEED FOR FIRST INSERTION: ______mm/SEC

SPEED FOR FIRST INSERT LOW: ______mm/SEC

Continued on next page!

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Continued
ACCELERATION RETURN F.SPINDLE: _________

ACCELERATION FOR RETURN: _________

ACCELERATION SLIDE FOLLOW UP: _________

ACCELERATION FIRST INSERTION _________

ACCELERATION FIRST INSERTION: LOW: _______

ACCELERATION PART FOLLOW UP: _______


turbo 5-42XT
6.3.5 Manual operation menu 2
-A- Switch to Automatic Menu 1

F1
GRIP Close / open gripper blades

F2
BOFF Retract feed bar with material bar, close gripper blades, material bar is
F3 withdrawn.
TUBE Open / close feed tube

F4
REMN Open / close remnant flap

F5
STDY Switch steady rest function on / off in manual/automatic mode

F6
OILP Switch oil pump on/off in manual mode

F7
Close gripper blades. If there is no remnant or material bar in the clamping

PSWG sleeve, the feed bar is disengaged. The disengaged feed bar is engaged
F8 again the next time F8 is pressed. The feed bar must be at its rear limit
position.

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Serie 2
6.3.6 Automatic Menu 1
-M- Switch to Manual Menu 1

F1
STRT START automatic mode

F2
S.1 Select step1: return run of the feed bar from the machine spindle.
F3
S.17 Select step 17: parts production

F4
S.ST Move on step by step from Step 1 - 20

F5
STDY Switch steady rest function on / off in manual / automatic mode

F6
INTV Switch interval feed on

F7
FORCE Option of altering feed force for parts follow-up.

F8 Feed force can be altered whether automatic mode is on or off.
The setting is explained in section 6.3.3 (operating menu).

turbo 5-42XT
6.3.7 Automatic Menu 2
-M- Switch to Manual Menu 1

F1
STRT START automatic mode

F2
STOP Stop automatic mode

F2
INHE Steady rest as insertion aid. The steady rest closes when the first part of the bar
F3 enters the jaws of the steady rest during initial feed. This lifts the first part of the
bar to the middle of the spindle.
W-OG Select: with or without gripper function

F4 (yellow LED with gripper - green LED without gripper)
The function can only be switched by simultaneously pressing the + and - keys.
BRAK Brake on. The feed bar is held in position. Function can only be switched by
F5 simultaneously pressing the + and – keys.
REFF Before automatic operation commences, the reference run can be enabled. As
F8 long as the function is active, the green LED in the F8 key lights up. When the
reference run is completed, the yellow LED lights up (see also section 6.2).

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6.4 Switching the system on and off

6.4.1 Switching on the system
First ensure that the master switch on the machine tool is switched on. When the machine
is ready for operation, automatic loading magazine operation can be started with the F2
key in Automatic Menu 1.
The loading magazine then continues its operation at the point where it was switched off. If
any changes are made during shutdown, start-up must follow a specific sequence as
explained under section 5.2.
6.4.2 Switching off the system
The system is switched off at the machine tool.
Shut down automatic operation with the F2 "STOP" key,

Caution ! preferably after a bar change and several parts have been
produced with closed clamping device.
Automatic operation is automatically shut down once all available bar stock is exhausted,
or if any of the protective equipment at the machine tool or loading magazine is triggered.
If the unit is shut down while the clamping device is open or while the motor is still turning,
the reference run must be carried out after start-up by pressing F2.
The following text appears on the control panel:
CARRY OUT REFERENCE RUN

STRT
6.4.3 Operation with parts counter
Select manual operation menu 1 via F1 "-M-". Select the Part menu with the F5 key
"PART" and switch to the "PARTS COUNTER" menu item with the cursor key ←. Enter
the setpoint and exit the menu with the "ENT" key. Start automatic operation. The counter
shuts down automatic operation when the setpoint is reached and the yellow LED flashes
above the F2 key. Automatic operation cannot be restarted unless the actual value, or both
setpoint and actual value are reset.
Press the "CLR" key in the "PARTS COUNTER" menu item to reset the actual value. Enter
"0" or a new setpoint (0 = counter off) in the "PARTS COUNTER" menu item to reset the
setpoint.

turbo 5-42XT
Serie 2 FMB
6.4.4 Operation with programmed operating time
Select Manual Operation menu 1 via key F1 "-M-",. Select the Part menu with the F5 key
"PART" and switch to the menu item "PARTS COUNTER" with the cursor key ←. Select
the "OPERATING TIME" menu item with the cursor key ↓. Enter the setpoint and quit the
menu by pressing the "ENT" key. Start automatic operation. The operating time shuts
down automatic operation when the setpoint is reached and the yellow LED flashes above
the F2 key. Automatic operation cannot be restarted unless the actual value or both
setpoint and actual value are reset.
Press the "CLR" key in the "OPERATING TIME" menu item to reset the actual value. To
reset the setpoint in the "OPERATING TIME" menu, enter "0" for hours and minutes, or
enter a new setpoint (for hours and minutes 0 = operating time off). Use the cursor key →
to switch from hours to minutes.
6.5 Steady rest

The steady rest guides the material bar immediately behind the lathe spindle and opens to
admit the feed bar, which usually has a larger diameter than the material bar itself.
If the steady rest is in the closed position, the guide jaws are pressed together.
The open position of the steady rest must be set so that the feed bar can pass through but
is still lightly guided by the guide jaws. The adjusting screw (Fig.) is fitted for this purpose.
Changing the guide jaws
The guide jaws of the steady rest must be matched to the diameter of the material.
You need to select guide jaws whose diameter is no greater than the machine spindle
diameter, but 1 mm to 2 mm greater than the diameter of the processing material.
The jaws are replaced by loosening the hexagonal nuts on the clamping pieces.
Guide jaws made of polyamide are available in the following sizes:
Guide jaws Order No. Diameter of processing material

D7 2021.764 from 5 to 6 mm
D10 2021.765 from 6 to 9 mm
D15 2021.766 from 9 to 14 mm
D16 2027.704 from 14 to 16 mm
D20 2021.767 from 16 to 19 mm
D22 2027.705 from 19 to 21 mm
D25 2021.768 from 21 to 24 mm
D28 2030.119 from 24 to 27 mm
D30 2021.769 from 27 to 29 mm
D32 2023.714 from 29 to 31 mm
D34 2024.758 from 31 to 33 mm
D35 2021.770 from 33 to 34 mm

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turbo 5-42XT
Serie 2
D36 2024.970 from 34 to 36 mm

D40 2024.717 from 36 to 39 mm
D42 2021.771 from 39 to 41 mm
D44 2029.328 from 41 to 42 mm

compressed air shut-off valve before opening the cover in order
to ensure that the unit is depressurised.
Adjusting screw
Clamping piece
Guide jaw
Diameter of jaws
1mm to 2mm larger than material diameter

turbo 5-42XT
6.6 Gripper function and method of operation

The gripper allows the loaded material bar to be pushed into the clamping sleeve of the
feed bar and any remnant to be removed before processing.
The gripper is operated via pneumatic cylinder.
A lever system closes the gripper and the bar stock is automatically lifted to the spindle
centre.
To push in the material bar or to pull off the remnant, the stock or remnant is transported to
the gripping position between the gripper blades. The grippers close and a main drive unit
either pushes or pulls the clamping sleeve of the feed bar, depending on whether a
material bar is being inserted or a remnant drawn off.

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Serie 2
6.7 Bar support

The bar support is used for storing the material bars and separating them for bar changes.
The separating device consists of an ejector and a limit stop, distributed over the length of
the bar.
Example: polygonal material
Ejector
Limit stop
Limit stop
Clamping piece M8-DIN912

Ejector
Hand lever
Clamping
Adjusting shaft
Material diameter
Eccentric shaft
6.7.1 Setting the material diameter
To set the required material diameter, mount a bar of the processing material and loosen
the M 8 DIN 912 bolt (Allen key size 6) of the clamping piece.
Use the M 20 hexagon nut (AF 30), located on the right-hand side at the end of the
adjusting shaft, to turn the limit stop until the distance X between the front edge of the
ejector and the front edge of the stop is approx. 2/3 of the material diameter
(round and square material).
For polygonal material, set the limit stop so that the ejector only lifts a maximum of the
surface area of the polygonal material (see Fig.). Then retighten the bolt of the clamping
piece.

turbo 5-42XT
6.7.2 Setting the angle
The angle of the bar support depends on the size and shape of the mounted material. The
rule is:
Small polygonal material - largest angle
Large round material - smallest angle
To adjust the angle of the bar support, release the clamping device of the eccentric shaft
using the two hand levers. First make sure there is no material on the bar support. Using
the M 20 hexagon nut (AF 30) located on the right-hand side at the end of the eccentric
shaft, adjust the eccentric shaft until the bar support has the required angle. Both hand
levers of the eccentric shaft are clamped again, and a bar should be mounted to check
that the required material runs smoothly. If necessary, repeat the procedure.

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Serie 2
6.8 Drive
A ball screw drive moves the feed bar and the linked material bar. This drive is powered by
a servomotor over a toothed belt drive with interconnected clutch. The incremental,
toothed belt-driven shaft encoder is located at the rear, parallel to the ball screw drive, and
informs the PLC of the position of the feed bar.
6.8.1 Clutch
The feed clutch -KY1 (electromagnetic single-disk clutch) transmits the motion from the
feed motor -M1 to the ball screw drive. It limits the transmission torque. The clutch is
actuated by the PLC via an amplifier module (-N3).
The feed force of the clutch depends on the direct voltage applied and can be set on the
control panel with the F8 key (FORCE) in Automatic Menu 1 or in Manual Menu 1 under
"FEED FORCE" of the "SERVICE" menu ". The exact setting options can be found in the
"Control Panel" section.
If the function "Brake On" (F5, BRAK) is selected on the control panel in Automatic Menu
2, the clutch is actuated with the value set in the FEED FORCE menu item "FORCE
BRAKE FUNCTION". Actuation is active during parts production while the collet is closed.
6.8.2 Motor and servo-amplifier
6.8.2.1 Servomotor
Description
The servomotor is mounted on the carrier, parallel to the ball-screw spindle.

In order to ensure sufficient cooling, the motor must be installed in such a way that the air
can circulate freely around it. Optimum service life is only achieved if the motor is
protected from dust and splashing.
Mechanical installation for repair work
The service life of the roller bearings depends largely on the care taken during installation.
• Check that any clutch elements without adjusting spring are correctly balanced, as the
servomotor has been balanced with a complete adjusting spring (only applies to motors
with adjusting spring).
• Carefully check the alignment of the servomotor shaft to the machine shaft to ensure
that vibrations, imbalance or excessive loads on the shaft are avoided.
• Avoid any impact against the shaft, as this could adversely affect the roller bearings,
clearance or the machined surfaces of the shaft.

turbo 5-42XT
Serie 2 FMB
6.8.2.2 Servo-amplifier - type BN 6648
The servo-amplifier serves to control the integral brushless servomotor with resolver.
In the integral version with front connection, all connections are located on the front panel,
as are the trimming potentiometer and the LEDs. The control signals are connected via a
15-pin SUB-D socket and the connections for the motor and operating voltage are via a
7-pin Combicon connector. The resolver is connected via a 9-pin SUB-D socket.
Trimming Potentiometer
Openings on the front panel of the amplifier provide access to the 4 trimming potentiometers.
The sequence of the trimming potentiometers from top to bottom is as follows:
Designation on the Des. in circuit Description Effect with clockwise

front panel diagram rotation
Return P1 Amplification Increase in amplification

setting
Speed P2 Speed setting Increase in speed
Zero point P3 Zero setting
Current P4 Current setting Increase in current
During commissioning, the trimming potentiometers are factory-

Caution ! set by the loading magazine manufacturer and should not be
readjusted on site!

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turbo 5-42XT
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LEDs
The following three LEDs are located on the front panel of the amplifier above the trimming
potentiometers:
Meaning Colour Display
Fault red Lights up when the fault is stored,

flashes as long as the thermostat is open.
Ready green Lights up when ready,
flashes when ready but not enabled.
Overload yellow Lights up when switched from pulse current to
continuous current.
The red "Fault" LED lights up if a fault has occurred or is stored. It flashes if the safety
thermostat of the heat sink has switched the amplifier to fault and the temperature has not
dropped enough to allow the unit to be switched on again.
The green LED lights up if the unit is ready for operation, i.e. if the controller enable is
closed and no fault has occurred. It flashes if the operating voltage is connected but the
output stage is disabled because either the controller enable is not available or a fault has
occurred.
The yellow LED lights up if the I²²t circuit switches back to continuous current due to
overloading.
When the mains voltage is switched on, the amplifier remains disabled until all voltages
are stabilised. The red LED lights up during this time, which lasts for a few tenths of a
second.

turbo 5-42XT
6.8.3 Ball screw drive
The feed bar is moved by the ball screw drive.

The motor, complete with clutch and incremental shaft encoder, is mounted at the rear
end. The ball screw drive is maintenance-free. Make sure that the ball screw drive does
not impact with any fixed limit stops during movement as this can lead to damage.
6.8.4 Crank
The hand crank provided can be inserted for maintenance and adjustment work by
removing the end wall at the rear on the end of the ball screw drive.

compressed air valve on the loading magazine before fitting the
hand crank in order to depressurise the unit. To prevent
interference of the servo controller, the hand crank must only be
used if the master switch is on.
Caution ! Always use electrical manual feed if possible.

Only use the hand crank if absolutely necessary.
Caution ! After using the hand crank, always start a reference run.
Caution ! The ball screw drive must not be allowed to impact with limit
stops!
6.9 Feed channel

The feed channel is made of flexible, semi-cylindrical shells mounted in aluminium profiles
to dampen vibration during processing. This effect is reinforced by the oil filling and the
feed bar with its rotating clamping sleeve at the end of the bar stock.
Depending on their straightness, material bars with differences in diameter of up to 20 mm

can be processed without replacing the channel (conversion).
6.9.1 Feed bar
The feed bar enables the bar end to be moved behind the collet of the lathe. The tip of the
feed bar is fitted with a bearing insert on which a clamping sleeve is mounted with
setscrews. This sleeve may need to be changed, depending on the processing material.
A coupling piece connects the rear end of the carriage to the ball screw drive.

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6.9.2 Clamping sleeve / centring sleeves - function and implementation
Clamping sleeves (1) or centring sleeves (2) are required on the feed bar for the
purpose of guiding the bar end.
Clamping sleeve
Feed bar
Bar
Centring sleeve
Bar
Feed bar length with clamping sleeve
Feed bar length with centring sleeve
6.9.2.1 Working with the clamping sleeve
The material bars are externally clamped with clamping sleeves. The clamping sleeve is
mounted onto the revolving journal of the feed bar with DIN 914 setscrews. The outside
diameter of the clamping sleeve must be equal to the nominal diameter of the fitted
conversion kit.
If the guide tube is to be utilised up to the full nominal capacity of the conversion kit, a
journal needs to be turned into the end of the material bar in order to accommodate the
clamping sleeve.
Bar diameter
Clamping sleeve = max. nominal capacity
Turning
As the holding powers of the clamping sleeve are graded, round

Caution ! material may be turned to at least 10 mm smaller than the outside
diameter, and square and hexagonal material at least 5 mm
smaller than the width across flats (A.F.) in order to ensure
secure clamping.
turbo 5-42XT
Sample order:
Clamping sleeve XT SHT G D42 / 30.0
Clamping diameter
Specifications in 1/10 mm (in this case, 30.0 mm)
Specifications for square bars: 27.0 4-kt
Specifications for hexagonal bars: 32.0 6-kt
Outside diameter of the clamping sleeve

(in this case 42.0 mm)
= Nominal diameter of conversion kit
Available clamping sleeves:
Clamping sleeve XT SHK SHT SHT SHT SHT G

D15 D25 D32 D36 D42
Material diameter (mm) 5 to 13 5 to 20 5 to 27 5 to 32 5 to 36
Square material (mm) 5 to 9 5 to 14 5 to 19 5 to 22 5 to 25
Hexagonal material (mm) 5 to 11 5 to 17 5 to 23 5 to 27 5 to 30
Caution! The SHK clamping sleeve must be used for feed bar diameter 15.
Further channels and clamping sleeve diameters on request.
All XT clamping sleeves have a proven high holding power. They

Caution ! are marked by an "XT" on their circumference. Failure to use XT
clamping sleeves may lead to tool breakage or damage to the
machine tool due to the high acceleration values of the loading
magazine.
When working with tubes with an inside diameter greater than 20 mm, a ring must be
inserted in the clamping sleeve to expand the limit stop in order to achieve the same initial
setting as for solid material. The length of this ring is adjusted in such a way that it is in
contact with the base of the clamping sleeve hole and is flush with the journal. The ring is
secured with a setscrew inserted through the lateral drilled holes in the clamping sleeve.
DIN916 setscrew
Existing drill holes of Ring for increasing limit

the clamping sleeve with outside diameter = tube diameter
Adjusted to
Tube with inside diameter
journal
<journal diameter Ø20

turbo 5-42XT
Serie 2
6.9.2.2 Working with the centring sleeve
Centring sleeves are implemented when bar stock with a diameter approximately that of
the feed bar diameter (channel diameter) needs processing and it is not possible to turn
the bar stock so that it fits in the clamping sleeve. In this case, the remnant cannot be
pulled backwards.
It is pushed into the machine when the bar is changed. The bar end must have a centred
chamfer on the guide side which fits into the centring sleeve.
When working with the centring sleeve, it is not possible to position the material bar to part
length.
When working with centring tapers, always work with limit stops,
Caution !
whereby the limit stop must retrieve the material bar for part
follow-up.
Caution ! The spindle must be protected from hard impacts at all times.
When working with the centring taper, the remnant must be

Caution ! removed by pulling forward (through the automatic lathe)! A
significant difference between the material diameter and the
implemented channel diameter is likely to result in a reduction of
the maximum possible speed.
Settings at the control panel
• Switch on the "W-0G" function (without gripper, the remnants are pushed forward and
removed) in Automatic Menu 2 (see section 6.3.7).
• Switch on the "BRAK" (brake) function in Automatic Menu 2 (see section 6.3.7)
• Determine the extension of the feed bar due to implementation of the centring taper
according to the drawing on page 69.
• Enter the new feed bar length in the "Feed bar length" menu item under "Positions" in
the Service menu. (Before changing the value, the + and - keys must be pressed
simultaneously until the value flashes). Exit menu by pressing the "ENT" key.
• "SELECT PART FEED" in the "PART" menu under "SPECIAL SETTINGS" and set to
"COLLET OPEN FIXED SPEED" (see section 6.3.3.2).

turbo 5-42XT
Serie 2 FMB
6.9.3 Guide tube
The guide tube bridges the gap between the front end of the loading magazine and the
spindle end of the lathe. It serves as a protective cover and prevents the protrusion of
rotating parts.
The inside diameter of the guide tube depends on the installed feed bar. The length of the
guide tube is determined when the loading magazine is installed (see section 3). It must be
set so that the distance between the end of the machine spindle and the front end of the
guide tube does not exceed 5 mm, or so that the feed tube extends into the machine
spindle.
The designated guide tube must be installed prior to

commissioning. The guide tube must be mounted during
operation of the loading magazine.
6.9.4 Converting the magazine
The plant must be depressurised and electrically isolated.
On delivery, the loading magazine is fitted with the ordered guide tube diameter. It can be
converted to accommodate other diameters using conversion kits.
To do this, you need to carry out the following:
• Replace the polyurethane linings

• Replace the feed bar
• Replace the front guide tube
• Replace the material guide jaws of the steady rest

FMB
turbo 5-42XT
Serie 2
6.9.4.1 Replacement of polyurethane inserts
Before the inserts are replaced, any bars or remnants must be removed from the channel
or the clamping sleeve of the feed bar. To do this, switch the magazine to manual mode,
open the collet of the lathe, run the feed bar to the rear limit position and draw the material
out of the feed bar. The feed bar is then swung out and the feed tube opened.
Caution ! Prior to swinging out the feed bar, check that the material really
has been withdrawn!
The above actions are only possible if the cover is closed !

compressed air shut-off valve on the magazine before opening
the cover, in order to ensure that the unit is depressurised!
Once the bolted connections are opened, the inserts can be pried out from the plate
sections using a large screwdriver. The new inserts are fitted in the same way (see Fig. on
pages 77 and 79).

turbo 5-42XT
Serie 2 FMB
6.9.4.2 Replacement of feed bar
Each conversion kit includes a special feed bar with its swivel plate.
The following steps must be carried out to replace the feed bar:
1. Switch the magazine to manual mode and open the lathe's collet.
2. Run the feed bar to its rear limit position.
3. Clear the channel of any material.
4. After removing the material, swing out the feed bar.
5. Hit the EMERGENCY STOP button and close the magazine's compressed air shut-off
valve to bleed the unit.
6. Open the access cover.
7. Remove the material bar.
8. Loosen and remove the clamping bolts of the swivel plates and remove the latter
together with the feed bar.
9. Insert and align the new feed bar with the corresponding swivel plates.
10. Replace the tappets.
11. Check that the installed parts can be swung back in.
Check to ensure that:
• the inserts fit snugly
• the carriage is in the rear limit position
• there is no material is in the channel
• the feed bar lug is in the guide.
12. Close cover, release EMERGENCY STOP button, open compressed air shut-off valve
and clear error message.
13. In manual mode, swing in the feed bar.
14. Press the EMERGENCY STOP button and close the compressed air shut-off valve to
depressurise the system, then open the cover.
15. Check the position of the swivel plates to ensure that the feed bar can pass easily;
adjust if necessary. To do this, you will need to remove the clamping bolts.
16. Close cover, release EMERGENCY STOP button, open compressed air shut-off valve
and clear error message.
17. Set steady rest in accordance with section 6.5.

FMB
turbo 5-42XT
Serie 2
6.9.4.3 Replacement of the front guide tube
A guide tube is fitted in the space between the steady rest and the lathe spindle.
Depending on the conversion kit implemented, the guide tube can project into the spindle
as a permanent spindle reducer, or stop just before the spindle. The latter is the case if the
spindle diameter and the feed bar diameter do not permit a fixed spindle reduction.
To replace the guide tube carry out the following steps:
1. Switch the magazine to manual mode, open the collet of the lathe and move the feed
bar to the rear limit position.
2. Withdraw any bar stock and remove from the channel (see section 8).
3. Press the EMERGENCY STOP button and close the compressed air shut-off valve to
depressurise the system.
4. Dismantle the cover at the draining container.
5. Open clamping piece and remove the entire holding fixture for the guide tube
(aluminium part).
6. Loosen the setscrews in the holding fixture for the guide tube with sleeve and reducer
ring and remove parts.
7. Install the new guide tube with sleeve and reducer ring in the reverse order.
8. Replace the cover.
9. Release the EMERGENCY STOP button, open the compressed air shut-off valve and
clear the error message

turbo 5-42XT
6.9.4.4 Installation example: conversion kit D 42/1150/3200-4200

(Other conversion kits on request)
Item Designation Number Number

D42/3200 D42/4200
1 Feed bar 1 1
2 Rear swivel plate 1 1
3 Front swivel plate 1 1
4 Tappet 1 1
5 Bottom insert, rear 1295 1 1
6 Bottom insert 900 - 2
7 Bottom insert 800 2 1
8 Bottom insert 440 (remnant flap) 1 1
10 Top insert 900 - 2
11 Top insert 800 2 1
15 Material guide jaw 2 2
16 Guide tube 1 set 1 set

FMB
turbo 5-42XT
Serie 2
Diagram of conversion kit
Conversion kit D42/1150/4200


turbo 5-42XT
6.9.4.5 Installation example: conversion kit D 32/1500/3200-4200

(Other conversion kits on request)
Item Designation Number Number

D32/3200 D32/4200
1 Feed bar 1 1
2 Rear swivel plate 1 1
3 Front swivel plate 1 1
4 Tappet 1 1
5 Bottom insert, rear 1645 1 1
6 Bottom insert 900 - 2
8 Bottom insert 440 (remnant flap) 1 1
9 Top insert 900 - 2
13 Material guide jaw 2 2
14 Guide tube 1 set 1 set

FMB
turbo 5-42XT
Serie 2
Diagram of conversion kit


turbo 5-42XT
6.9.4.6 Sample order for a conversion kit
3200 / 1500 / 32
Nominal capacity of the channel

(specification for insert)
Feed bar length L
Length of the lateral material support

(max. bar length 3200 mm)
6.10 Oil supply

The quantity of inflowing oil can be regulated using the shut-off valve mounted on the
submerged pump. Ensure that no more oil is supplied than is absolutely necessary.
In order to set the correct quantity of oil, the shut-off valve is turned approximately to the
"Zero" position and then opened until the motor runs smoothly.
Top up with oil only after the machine is switched off and after a
1-hour cooling-off period.
The viscosity of the oil is also crucial to the smooth running of the loading magazine
(see Technical Data).

FMB
turbo 5-42XT
Serie 2
7. Functional description
7.1 Method of operation
The bars are loaded into the magazine from the side support into the bar separator and
from there into the guide channel.
With the feed bar swung out and the top part of the feed bar open, the material bar falls
into the guide channel and the top part of the feed bar closes. (Optionally, a bar lift can be
supplied for storage).
The slide now pushes the material bar forwards until the bar end is in reach of the gripper.
The slide returns and the feed bar swings in. The gripper closes, the feed bar moves
forwards and pushes the clamping sleeve over the end of the bar. (Clamping mandrels are
used to clamp tubes internally). Forward feeding begins.
When the feed bar reaches the cut-off position, it stops and a signal is sent to the lathe.
Processing begins.
The oil-filled guide tube and the guiding steady rest, fitted between the machine tool and
the feed channel, guarantee the precise bar positioning required for processing.
The bearings integrated in the feed bar allow high-speed operation. The guide tube fixed
to the front section of the magazine also acts as a spindle reducer.
Operation of the loading magazine and the machine tool is synchronised. After the last
work piece available has been processed, operation of the machine tool is stopped with its
clamping device open.
The feed bar moves back to remove the remnant. The feed bar stops if the remnant is
currently under the gripper blades. The gripper blades close and the feed bar returns to its
rear limit position. The remnant is withdrawn from the clamping sleeve. If no remnant was
fed back, an error message is issued and the unit switches off. After the remnant has been
ejected into the remnant bin through the remnant failure flap, the gripper and switch -S13
are used to carry out a further remnant removal check. If no fault is indicated, the feed bar
swings out, opening the feed tube to accept a new bar. The cycle then begins again.
If a fault occurs in automatic mode, automatic operation is suspended (yellow LED in the
F2 key on the control panel lights up). The error message is forwarded to the machine tool.
The relay -K30 is released and the error message flashes in the first line of the control
panel display.
The error messages are listed in the following section.

After the fault is eliminated and the error message is cleared by pressing the "CLR" key,
the current step is displayed again and automatic operation can be resumed via F2
"STRT".

turbo 5-42XT
7.2 Automatic operation

This description applies to automatic operation with the gripper function enabled.
Display
1st line-control panel Stepping function
AUTO STEP:1 RETURN COL:OPEN Return from machine spindle at low speed. From the
preset value in "POSITION REVERSE ROTATION"
the motor returns at high speed to "Position material
draw off". The system switches to step 2 when it
reaches this position.
AUTO STEP:2 CLOSE GRIPPER BLAD. COL:OPEN The gripper blades close on the remnant. A transfer
time and the inactive switch -S14 both switch to step 3.
AUTO STEP:3 WITHDRAW REMNANT COL:OPEN The gripper blades remain closed. The feed bar moves
back to its rear limit position. Switch –S21 switches to
step 4.
AUTO STEP:4 OPEN GRIPPER / OPEN TUBE Feed tube opens. Gripper blades open. Remnant falls
onto remnant flap. Switch -S14 switches to step 5.
AUTO STEP:5 REMNANT FLAP OPEN The feed tube is open. The remnant flap swings out.
The remnant falls into the remnant bin. A transfer time
and the inactive switch -S17 both switch to step 6.
AUTO STEP:6 CLOSE GRIPPER/CLOS.REMN.FLAP The feed tube is open. The remnant flap swings into
initial position. The gripper blades close and switch
S13, actuated in closed position, switches to step 7.
AUTO STEP:7 LIFT PUSHER OUT The feed tube is open. The feed bar is lifted out. The
material separator is lowered. The switching flap of
starting switch -S7 is lowered. Switches -S17 and -S22
switch to step 8.

FMB
turbo 5-42XT
Serie 2
Display
AUTO STEP:8 SEPARATE MATERIAL The feed tube is open. The feed bar is lifted out. The
material separator is raised, lifting a new material bar
from the side support in the process and dropping it into
the open feed tube. A transfer time and switches -S5
and -S22 switch to step 9.
AUTO STEP:9 CLOSE TUBE The feed bar remains raised. Feed tube closes.
Switches -S22, -S6 and -S14 switch to step 10.
AUTO STEP:10 SLIDE FORWARDS / BACKWARDS The feed bar remains raised. The slide moves forwards
-M- STRT S.1 S.17 S.ST STDY INTV FORCE and pushes the bar end into the position entered in the
control panel under "Limit position slide front". The
gripper blades close on the new bar. The slide then
moves back to its rear limit position. Switch –S21
switches to step 11.
AUTO STEP:11 PUSHER SWING IN The feed bar swings into the channel. The gripper
blades are closed. Switch -S23, a transfer time and the
inactive switch -S14 switch to step 12.
AUTO STEP:12 FORWARD / PRESS BAR IN COLLET

The gripper blades remain closed. The feed bar moves
-M- STRT S.1 S.17 S.ST STDY INTV FORCE forwards to "Position Material Draw Off". The reached
position and switch -S23 both switch to step 13.
AUTO STEP:13 OPEN GRIPPER BLADES The gripper blades open. Switch -S14 switches to
step 14.
AUTO STEP:14 INITIAL INSERTCOL:OPEN The oil pump is activated and remains switched on until
step 19. The feed bar pushes the material bar into the
machine spindle until the beginning of the bar is in cut-
off position. This position is calculated using the value
entered under "First insert measure trav.". If the
"Interval Feed" function is selected, the motor moves
the preset distance forwards for the preset clock time.
When the cut-off position is reached, the system

turbo 5-42XT
Display
AUTO STEP:15 START LATHE(S12) COL:OPEN1 Relay -K1 on the lathe signals: "Bar change end -
Program start". When the machine collet closes, the
"Collet open" contact is released and the system
AUTO STEP:16 PART MATERIAL COL:CLOSE The beginning of the bar is cut. After cutting, the "Collet
open" contact causes the system to switch to 17.
AUTO STEP:17 PART MAN. BAR L C:OPEN 1 The material bar is processed. The current bar length is
-M- STRT S.1 S.17 S.ST STDY INTV FORCE shown on the display. When the machine gives the
message "Collet open", the clutch engages and the
motor pushes the material bar forwards. If the bar end
value (as calculated by the PLC - "Position front limit"
minus "Part length") is exceeded while parts are being
pushed, the system switches to step 18.
AUTO STEP:18 INSERT LAST PART COL:OPEN1 The last bar is inserted into the machine. When the
"Collet open" contact is released, the system switches
to step 19.
AUTO STEP:19 MACHINE LAST PARTCOL:CLOSE The last work piece is being processed. Relay -K9
signals "Bar end - program stop" to the machine. When
the last part is finished, the "End of cycle" contact
switches the machine to step 20.
AUTO STEP:20 STOP LATHE/BAR CH. COL:OPEN Relay -K9 is triggered. A transfer time switches the
system to step 1.

FMB
turbo 5-42XT
Serie 2
7.3 Error messages
Displayed message Cause and remedy
FAULT: EMERGENCY STOP The EMERGENCY STOP button on the control panel
has been pressed.
FAULT: NO AIR PRESSURE: Pressure switch -S11, check whether air shut-off valve
CHECK AIR PRESSURE MIN: 4 BAR
is open.
FAULT: MOTOR PROT. Q1 TRIPPED Switch motor circuit breaker -Q1 back on.
CHECK MOTOR M1, SWITCH Q1 ON
FAULT: MOTOR PROT. Q2 TRIPPED Switch motor circuit breaker -Q2 back on.
CHECK OIL PUMP, SWITCH Q2 ON
FAULT: FEEDER TUBE NOT CLOSED Solenoid valve -Y1.1 must be actuated.
CHECK FEEDER TUBE BACK FORW
FAULT: OPEN FEEDER TUBE Switch -S5 must be actuated when the feed tube is
CLOSING NOT CORRECT
open, switch -S6 when the feed tube is closed.
FAULT: BAR IN CLAMPING SLEEVE NOT The position "Material draw off" was not reached when
CORRECT
the clamping sleeve was pushed onto the new bar.
FAULT: NO RETURN OF REMNANT Switch -S13 was actuated while the query for steps 3
and 4 was in progress.
FAULT: NO NEW BAR IN FEEDER TUBE Switch -S13 was actuated while the bar was being
pressed into the feed tube in steps 11 and 12.
FAULT: MONITORING TIME BAR CHANGE The bar change in step 20 and steps 1 to 15 was not
EXPIRED
successfully executed.
FAULT:PUSHER IS NOT CORRECT IN FEED TUBE The feed bar is not in the channel correctly. Switch –S23
must be actuated while the feed bar is swung in.

turbo 5-42XT
Displayed message Cause and remedy
FAULT: MONITORING TIME-MOTOR EXPIRED A motor program has run too long; e.g. the
"Collet open" contact on the lathe was activated for
longer than 5 minutes.
FAULT: PART FOLLOW-UP TOO SHORT Only active if a value > 0 has been entered for "MIN.
PART LENGTH FOLLOW-UP" under "SPECIAL
SETTINGS" in the "PART" menu. The error message is
output if the entered value is not reached during part
follow-up.
FAULT: PART FOLLOW-UP TOO LONG Only active if a value > 0 has been entered for "MAX.
PART LENGTH FOLLOW-UP" under "SPECIAL
SETTINGS" in the "PART" menu. The error message is
output if the entered value is exceeded during part
follow-up.
FAULT: COLLET OPEN TOO LONG: Only active if a value > 0 has been entered for
"MONITOR COLLET OPEN" under "SPECIAL
SETTINGS" in the "PART" menu. The time value
is entered in tenths of a second.
FAULT: COLLET CLOSED TOO LONG Only active if a value > 0 has been entered for
"MONITOR COLLET CLOSED" under "SPECIAL
SETTINGS" in the "PART" menu. The time value is
entered in tenths of a second.
FAULT: SERVO CONTROLLER / MOTOR

The servo controller issues an error message.
(Fault can only be cancelled by switching the operating
voltage on and off).
FAULT: SERVOMOTOR OVERFLOW The servo controller/motor has been overloaded for
some time.
FAULT: REMNANT JAMMED IN CLAMPING SLEEVE Switch -S13 was not actuated during the remnant
removal check in step 6.

FMB
turbo 5-42XT
Serie 2
Display Cause and remedy
FAULT: AXIS CONTROLLER The APM module issues an error message. The values
CODE 1 CODE 2:
of CODE 1 and Code 2 are for service purposes.
FAULT: COVERS NOT CLOSED Switch -S74 was not actuated.
FAULT: LIMIT SWITCH S7 NOT IN HOME POSITION Actuating flap for switch -S7 is not in initial position, or
switch -S7 has not been actuated.
FAULT: REMNANT FLAP NOT CLOSED Solenoid valve -Y10.1 is not switched on, or switch
-S17 has not been actuated.
FAULT: NEG.SOFTWARE ENDPOSITION! MAN. Negative software end position overrun. Use Manual
FUNCTION FORW. TO RELEASE
Menu 1 "FORW" to release.
FAULT: POS.SOFTWARE ENDPOSITION! MAN. Positive software end position overrun. Use Manual
FUNCTION BACK TO ENABLE
Menu 1 "BACK" to release.
FAULT: NEG.HARDWARE ENDPOSITION! MAN. Negative hardware switch (-S1) overrun. Use Manual
FUNCTION FORW. TO RELEASE
Menu 1 "FORW" to release.
FAULT: PUSHER OUT OF POSITION The feed bar was pushed backwards or forwards while
there was no feed signal. Check that the "BRAKE"
function in Automatic Menu 2 is activated.
FAULT: ENCODER NOT OK OR PUSHER IS The feed bar (material bar) is blocked or the encoder is
BLOCKING
faulty.
Possible causes:
• Feed force set too low
• Collet of automatic lathe opens too late
• Material jammed in collet
• Encoder faulty (G3)
• Toothed belt to encoder faulty
• Clutch to encoder faulty

turbo 5-42XT
8. Removing a material bar from the feed tube

The following steps must be carried out to remove a long bar of material from the feed tube.
• Select manual operation menu 2.

• Press key F3 "BOFF", green LED in the F3 key lights up
(BOFF = pull long bar off).
• The yellow LED in F3 lights up when the BOFF program is finished.
• Hit the EMERGENCY STOP button and close the compressed air valve on the loading
magazine to bleed the unit.
• Open the cover.
• Push the material bar in the direction of the lathe to allow the gripper blades to close
without material.
• Close the access cover.
• Release the Emergency Stop button and open the compressed air valve on the loading
magazine to pressurise the system.
• Press F8 key "PSWG", the feed bar is swung out.
• Press F4 key "TUBE", the feed tube is opened.
• Hit the EMERGENCY STOP button.
• Shut off the compressed air supply by turning the pneumatic shut-off valve to
depressurise the system.
• Open the cover.
• Pull the material bar towards the rear in the direction of the magazine end.
• If there are any bars on the support, empty the support
• Move material ejectors (separators) downwards by turning the shaft.
• Lift the material bar out of the feed channel over the side material support.
• If necessary, re-equip magazine and load the required material bar.
• Close the access cover.
• Reconnect the compressed air supply.
• Release the EMERGENCY STOP button.
• Press F4 key "TUBE". The feed tube is closed.
• Press "CLR" to cancel the error message "Feed tube not closed".
• Press F8 key "PSWG". The feed bar is swung in again.

FMB
turbo 5-42XT
Serie 2
9. Maintenance and adjustment tasks

9.1 Maintenance unit
ID No. 2035.709
Consisting of:
1. Filter for compressed air control valve
2. Shut-off valve (ball cock)
3. Distributor
4. Pressure switch -S11
The filter for the compressed air valve (1) is factory-set to an operating
pressure of 0.6 MPA (6 bar). To readjust or reset the adjusting knob
(1.1), unlock it (E) and turn it clockwise under primary pressure until
the pressure gauge shows the required secondary pressure. The
pressure setting is kept constant by locking (V) the adjusting knob
(1.1).
Condensate drainage: Semi-automatic
The drain screw (1.4) must be removed to make the semiautomatic
drain valve ready for operation. The drain valve closes when the
pressure exceeds 0.5 bar. As soon as the filter is relieved of pressure,
the valve (1.4) opens to drain off any accumulated condensed water. It
is only possible to drain condensed water manually with the drain
screw when under pressure.

turbo 5-42XT
Serie 2 FMB
9.2 Feed clutch -KY1 - maintenance
Check the air gap at specific intervals and ensure that a = 0.2 mm. After prolonged
machine operation, the gap will need adjusting. This is done by removing the spacer
washers.
Rotor
Anchor washer
Magnetic part
The rotor hub is fitted with threaded holes to facilitate removal of the
Caution ! rotor from the shaft. The thin outer parts of the rotor must not be
subjected to pressure.
Do not apply pressure

FMB
turbo 5-42XT
Serie 2
9.3 Buffer battery

The buffer battery keeps the contents of CPU memory intact when the system is switched
off. If the battery voltage falls too low to guarantee reliable buffering, the red LED "BATT"
lights up on the power supply unit of the PLC. The following message appears on the
display of the control panel:
"Warning: Battery dead!

Do not switch off mains voltage until battery has been changed."
The message will reappear after a short time if the message is cancelled via the "CLR" key
without changing the battery.
POWER SUPPLY
RS-485 PORT
BATTERY CONNECTIONS
LITHIUM BATTERY

turbo 5-42XT
9.3.1 Replacing the buffer battery
It is not necessary to disconnect the voltage supply in order to replace the battery (FMB
ID No. 2024.608). The battery is replaced as follows:
• Remove the battery compartment cover at the bottom of the front panel of the power
supply unit.
• Take the battery out of the retaining clip.
• Insert the new battery in the retaining clip on the battery compartment cover.
• Insert the plug of the new battery in the socket in the power supply unit.
• Pull the plug of the old battery out of the socket in the power supply unit.
• Press the battery compartment cover back into the front panel of the power supply unit.
Take care to ensure that the two leads are not trapped.
• Press the "CLR" key on the control panel if the message: "Battery empty!" is still
displayed.
• Switch the mains power supply off and then on again. The red LED "BATT" on the
power supply unit is no longer on.
• The PLC is ready for operation again.
Caution ! Once the old battery is removed, the new battery must be
connected within 20 minutes; if not, the contents of the memory
will be lost in the event of a power cut!
Never throw a lithium battery into the fire, or attempt to recharge

it. The battery might explode or emit dangerous fumes!
Used batteries must be disposed of as

hazardous waste!

turbo 5-42XT
Serie 2
9.3.2 Installing or removing an I/O module
Please observe the following recommendations when installing/removing an I/O-module.
Removable terminal strips are delivered with each I/O-module which provide the
connection for the interface wiring. This makes it easy to wire the process terminals in
advance or to change modules without mixing up the terminals.
Always disconnect the mains power supply before fitting or

Caution !
removing a module. Failure to do so may cause the PLC to switch
to STOP, or even lead to module damage or personal injury.
9.3.3 Removing the terminal strip
• Open the plastic cover of the terminal strip

• Press the lever upwards to release the terminal strip block
• Grasp the loop on the terminal strip block and pull it forwards to free the contacts.
• Remove the entire terminal strip block
LEVER
LOOP

turbo 5-42XT
9.3.4 Removing a module
• Press the release lever at the bottom of the module upwards against the module.
• Keeping the release lever pressed, swing the module upwards.
• Lift the module up and away from the front panel.
PRESS LEVER
9.3.5 Installing a module
• Hold the module with the terminal strip facing towards the front and the release lever
facing downwards.
• Tilt the module and insert the hook on the top corner at the back into the slot on the
chassis.
• Press the module downwards until the release lever at the bottom of the module snaps
into the notch on the chassis.
9.3.6 Installing the terminal strip
• Insert the hinge at the bottom of the terminal strip block into the slot at the bottom of
the module.
• Press the terminal strip block against the module until it snaps home.

FMB
turbo 5-42XT
Serie 2
10. Electrical and pneumatic equipment

-S1 Negative hardware limit switch
-S5 Feed tube open
-S6 Feed tube closed
-S7 Initial feed start
-S11 Pressure switch
-S12 Reference switch
-S13 Gripper blades closed
-S14 Gripper blades open
-S17 Remnant failure flap swung in
-S21 Feed bar rear limit position/swing-out position
-S22 Feed bar lifted out
-S23 Feed bar swung in, in channel
-S74 Cover of side support closed
-Q1 Motor circuit breaker for M1 (feed motor)
-Q2 Motor circuit breaker for M2 (oil pump)
-M1 Drive motor
-T3 Resolver
-M2 Oil pump
-KY1 Feed clutch
-G3 Shaft encoder
Solenoid valves
-Y1 Open feed tube
-Y1.1 Close feed tube
-Y2 Close gripper blades
-Y5 Separate material
-Y7 Close steady rest
-Y8 Lift out feed bar
-Y8.1 Swing in feed bar
-Y10 Swing out remnant flap
-Y10.1 Swing in remnant flap
Pneumatic cylinder
-ZY1 Open / close feed tube
-ZY2 Open / close gripper blades
-ZY5 Separate material
-ZY7 Close / open steady rest
-ZY8 Lift out, swing in feed bar
-ZY9 Swing in switching flap of starting switch
-ZY10 Swing out, swing in remnant flap
turbo 5-42XT
Serie 2 FMB
10.1 Diagram of electrical and pneumatic equipment

FMB
turbo 5-42XT
Serie 2
11. Parts list - pneumatic parts
Item Quantity Designation/Type ID section
1 1 Double-action cylinder - ADVU-5080-P-A 2035.474
2 1 Double-action cylinder - ADVU-4030-A-P-A 2035.475
3 3 Double-action cylinder - DNC-5080-PPV-A 2034.712
6 1 Single-action cylinder - ESN-12-25-P 2030.646
7 3 5/2-way valve - 1/8 - 0820 038 126 2035.699
8 3 5/3-way valve - 1/8 - 0820 039 116 2035.698
9 1 Connecting plate, 6-fold - 1825 503 897 2035.700
10 2 Silencer - 1827 000 001 2035.702
11 1 Filter for pressure regulating valve G 1/4 - 0821 300 756 2035.788
12 1 Shut-off valve G 1/4 - 0821 300 773 2035.787
13 1 Pressure switch 0.5-8 bar - 0821 100 015 2035.791

turbo 5-42XT
Serie 2 FMB
11.1 Pneumatic diagram, page 1
Page 2
Ø63/20x80 stroke
closed open
Gripper
-ZY2
Ø50/20x80 stroke Ø50/20x80 stroke

closed open
-ZY1.1
Feed tube
closed open
-ZY1

-ZY5 -ZY9 -ZY7 -ZY8 -ZY10
Separation Starting switch Steady rest Feed bar Remnant flap
down up down closed open down up closed open
Ø50/20x80 stroke Ø50/16x80 stroke

FMB
Ø40/16x30 stroke Ø12/6x25 stroke Ø40/16x25 stroke
11.2 Pneumatic diagram, page 2
Edition 04/99
Page 1
Serie 2
Page 99
turbo 5-42XT

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1. Technical data and operating resources ............................................................... 11

2. Transportation for erection and dismantling ........................................................ 15

4. Notes on the interface ............................................................................................. 24

Operating Instructions Edition 04/99 Page 1

5. Commissioning the loading magazine ............................................................... 26

Page 2 Edition 04/99 Operating Instructions

6.4 Switching the system on and off ...................................................................... 59

6.5 Steady rest ...................................................................................................... 60

7. Functional description ............................................................................................ 81

8. Removing a material bar from the feed tube ......................................................... 88

9. Maintenance and adjustment tasks........................................................................ 89

Operating Instructions Edition 04/99 Page 3

9.3 Buffer battery ................................................................................................... 91

10. Electrical and pneumatic equipment.................................................................... 95

11. Parts list - pneumatic parts ................................................................................... 97

Page 4 Edition 04/99 Operating Instructions

0. Safety instructions for operating the loading

• Do not throw any waste into the oil.

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0.2 Maintenance and repair

0.3 Usage to the intended purpose

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0.4 Explanation of symbols and notes

In these operating instructions, you will find this symbol next to

This symbol can be found in these operating instructions

0.5 Property rights

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0.6 Safety precautions

Always read and observe these operating instructions before

The machine must only be used, maintained and repaired by

EC Machine Directive (98/37/EG)

DIN-EN 60 204 Part 1 VDE 0113 Part 1

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0.7 Safety devices

ERROR: COVERS NOT CLOSED

Automatic mode is switched off.

Always follow the sequence of steps specified in the operating

Always press the EMERGENCY STOP button and close the

No covers of any kind (access doors, guards, etc.) may be

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The designated guide tube must be installed prior to

0.7.3 EMERGENCY STOP device

If an EMERGENCY STOP button is pressed on the machine, the loading magazine

0.7.4 Guards on the lathe

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1. Technical data and operating resources

Power consumption: 1.5 kW

Feed force: max. 750 N (infinitely variable)

Insertion rate: 0 to 700 mm/sec (adjustable)

Remnant length: max. 530 mm

Dimensions: see erection plan, page 19

Weight: 3.2 m - 1000 kg

Loading time: approx. 30 sec. (for 3200 mm bars)

Oil filling: 80 l oil (viscosity: 160 cSt at +40º C)

Compressed air supply: 0.6 MPa (= 6 bar)

Air consumption: approx. 10 litres per loading action and

Noise emission: max. 48 ± 5 dBA (during bar change)

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1.2 Electrical connection between loading magazine and

1.3 Oil filling

We recommend the following oil types:

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