As LUL300FO Users Manual

AS LUL300FO Users Manual
Revisions .......................................................................................... 5
Pre-installation instructions .............................................................. 7
Foundation................................................................................................. 7
Electric power and air supply..................................................................... 7
Technical dimensions ................................................................................ 9
Unloading of machine from truck trailer ................................................... 10
Installation ................................................................................................ 13
Safety fences ........................................................................................... 13
General safety Information ............................................................. 15
General .................................................................................................... 15
Safety instructions ................................................................................... 16
Safety system .......................................................................................... 17
Description of function .................................................................... 19
General .................................................................................................... 19
Control ..................................................................................................... 19
Technical data ......................................................................................... 20
Main parts of the AS LUL300FO.............................................................. 21
Storage ................................................................................................ 21
Loading unit ......................................................................................... 21
Sheet separation ................................................................................. 22
Double sheet detector ......................................................................... 23
Unloading unit ..................................................................................... 23
Pallet changer unit ............................................................................... 24
Version 003 1
Pallet lifter............................................................................................ 25
Cutting pallet ....................................................................................... 25
Raw material and unloading pallet ...................................................... 26
Pin table .............................................................................................. 26
Operating console ............................................................................... 27
Function (automatic storage mode) ......................................................... 30
Loading of raw material ....................................................................... 30
Loading of raw material to FO laser (first sheet) ................................. 30
Loading of raw material to FO laser (second sheet) ............................ 30
Unloading/loading of following sheets to FO laser .............................. 30
Unloading of finished machined sheets from storage .......................... 30
Function (Pallet changer mode) ............................................................... 31
Loading of raw material to FO laser .................................................... 31
Unloading of machined sheets ............................................................ 31
Operation ....................................................................................... 33
Starting of the AS LUL300FO .................................................................. 33
Pause, safety/emergency stop and restarting ......................................... 33
Pause .................................................................................................. 33
Safety stop .......................................................................................... 33
Emergency stop................................................................................... 33
Restarting the AS LUL300FO .............................................................. 33
General .................................................................................................... 35
Status bar ................................................................................................ 38
Terminal menus ....................................................................................... 39
2 Version 003
Main menu for AS LUL300 FO ............................................................ 39
Automatic functions ................................................................................. 40
Material handling, get pallet ................................................................. 40
Material handling, edit & leave pallet ....................................................... 41
Loading of the pallets .......................................................................... 42
Job list input ............................................................................................. 44
Running storage mode ............................................................................ 46
Pallet changer mode................................................................................ 47
Ending automatic mode ........................................................................... 48
Manual functions ...................................................................................... 49
Manual main menu .............................................................................. 49
Pallet lifter ................................................................................................ 50
Pallet chain .............................................................................................. 51
Pallet changer .......................................................................................... 52
Loading unit 1/2 ....................................................................................... 53
Loading unit 2/2 ....................................................................................... 54
Unloading unit .......................................................................................... 55
FO laser ................................................................................................... 56
Parameters .............................................................................................. 57
User parameters .................................................................................. 57
Definition of user parameters .............................................................. 57
Autostop function ................................................................................. 58
Phone alarm ........................................................................................ 58
Data base ................................................................................................ 59
Version 003 3
Database check ................................................................................... 59
Edit pallet............................................................................................ 59
Edit position ......................................................................................... 60
Installation parameters ........................................................................ 61
Stopping and shutting down the AS LUL300FO ...................................... 61
Maintenance ................................................................................... 63
Daily check-ups and maintenance .......................................................... 63
Weekly check-ups and maintenance ....................................................... 64
Monthly check-ups and maintenance ..................................................... 64
Twice/year check- ups and mantenance ................................................. 65
Once/year check-ups and maintenance .................................................. 66
Every third year check-ups and maintenance.......................................... 66
Electric cabinet ........................................................................................ 70
Alarms ............................................................................................ 71
General .................................................................................................... 71
Override alarm ..................................................................................... 71
List of alarms ............................................................................................ 72
4 Version 003
AS LUL300FO Users Manual Revisions
Revisions
Edition Modifications Changed pages

Version 001 First version
Ver 002 Job list inbut chapter updated 43-43
User parameter chapter updated
"time idle before job failed" / "Free lifting
before stacking" new 54-55
Auto stop / Phone alarm fuctions new 28, 56
Version 003 Maintenance chapter updated 63, 65, 67
(No 841) Technical table updated 20
Figure text updated, notes new 43
interlockings added 55
Layout changed, note added 59-61
Version 003 5
Revisions AS LUL300FO Users Manual
6 Version 003
AS LUL300FO Users Manual Pre-installation instructions
Pre-installation instructions
1. Foundation
The foundation for the AS LUL300FO (storage) should be made of concrete
and calculated to stand for the weight, and flat (+/- 10 mm / 5 m).
The max. weight of the AS LUL300FO storage in use is 30000 kg divided on
four 99000 mm2 feet gives a pressure under the feet on 0,75 N/mm2. During
run is the weight on the front feet momentarily higher.
2. Electric power and air supply

The AS LUL300FO requires 3 x 400 VAC+N+PE electric power supply. The
connection has to be made only to the main electric cabinet, placed at height
about 1 m.
Compressed air supply
Electric power supply
Figure 2.1: Position of compressed air and electric power connections
The compressed air supply is connected directly to the machine´s air treatment
unit, placed at height about 1 m. A 10 mm (inner diameter) air hose can be used
(not supplied). The compressed air must be clean and dry.
Version 003 7
Pre-installation instructions AS LUL300FO Users Manual
Table 2.1: Air and power supply

Machine type AS LUL300FO
Air supply: pressure 6 bar
flow 1000 l/min
Electric power supply: voltage 3 x 400 VAC+N+PE / 50 Hz
Max. power consumption 15 kW
fuses 3 x 40 A
8 Version 003
3. Technical dimensions
W
W1
L
L1
Figure 3.1: AS LUL300FO dimensions
Table 3.1: dimension and weights of AS LUL300FO parts (main parts)

Base plate+ Gear
Pallets
upper lower service motor
Dimension Total +Pallet
part part platform + (M1)+
elevator
wooden box shaft
Length (L/L1), mm 4450/4630 3710/4200 4430 4050 3040 4200
Width (W/W1), mm 2700/4225 2400 2450 2300 1700 700
Height (H), mm 5100 2530 2570 1600 1200 550
Total weight, kg 30000 * 2500 4400 3200 2000 350
(*) All pallets full loaded in the storage
Version 003 9
4. Unloading of machine from truck trailer

To unload the storage a stacker crane and a forklift truck are needed.
Caution!
It’s important that the machine parts are lifted as illustrated in the fol-
lowing pictures!
Lifting support Fork lift truck

W
L
L1
Figure 4.1: Lifting of "upper part"
10 Version 003
Stacker crane
MIN 60
W
L
Figure 4.2: Lifting of " lower part"
Note
It’s also possible to lift the "lower part" with a fork lift truck
Caution!
If the "lower part" is lifted with a fork lift truck make sure that the forks
are long enough so they reach the frame on the rear side.
Version 003 11
W Forklift truck
Figure 4.3: Lifting of pallets and pallet elevator
L Forklift truck
Figure 4.4: Lifting of base plate + service ladder + wooden box
12 Version 003
5. Installation
The installation should be made by trained personnel from LKI or Amada.
6. Safety fences
For mounting safety fences around the AS LUL300FO, please see the layout
for the machine.
Version 003 13
14 Version 003
AS LUL300FO Users Manual General safety Information
General safety Information
1. General
The following signs are used in the text to mark important information or hints
to facilitate operations.
Warning!
is used to indicate preventive measures to avoid personnel inju-
ries.
Caution!
indicates how to avoid damage to the equipment.
Note
is used to clarify information and to give information about how to man-
age the machine in the most effective way. Overlooking the instructions
provided by these signs will not result in damage to the equipment.
Version 003 15
General safety Information AS LUL300FO Users Manual
2. Safety instructions
Warning!
Only personnel, who has read and understood the operating
instructions, are allowed to operate the system.
When the system is working NOBODY is allowed to be within the

safety zone.
When dealing with electricity and electronics, consider the follow-
ing:
1. Make sure that the machine is switched off from the mains, and is under
no circumstances reconnected to the mains during the job.
2. Only qualified personnel are allowed to work with the manipulator elec-
tronics.
3. If the job to be done requires voltage to be connected, it must be done by
trained and authorised personnel taking great precaution.
Never adjust, change, shift or remove the safety system and the
safety elements.
Warning!
Never stand under the lifter if there is a pallet on it!
Warning!
Do not climb on the pallets since they are on wheels, they can eas-
ily slide out of the storage!
Caution!
Incorrect handling with a forklift truck, crane, etc. when loading the pal-
lets may damage elements of the AS LUL300FO. The permitted load-
ing height of the pallets must not be exceeded.
Make sure that the sheets are placed evenly.
When loading the pallets manually, the sheets may have

sharp edges. Therefore always use gloves for protection.
Note
The expansion of a sheet handling system to a processing machine
creates a processing system.
Based on our knowledge, the LKI AS LUL300FO storage does not

expose any danger, if correctly installed and operated.
Always keep the operating instructions beside the machine to enable

verification of facts at any time.
16 Version 003
AS LUL300FO Users Manual General safety Information
3. Safety system
The AS LUL300FO is equipped with different kinds of safety systems to pre-
vent personal injuries and damage to the hardware. In spite of this every pre-
caution should be taken when operating the machine.
There are two types of safety devices which protect the operator. A safety
fence and a light guard. Further, there is an emergency stop that will stop the
entire system.
Service platform Safety fence
with safety
switch
FO3015 laser
Pallet elevator
Safety Safety switch

fence
Light guard Stop chain

Figure 3.1: Safety system
Safety fences
The AS LUL300FO is equipped with safety fences around the whole machine
except for the opening in front of the pallet elevator.
Light guard/stop chain
The opening for the pallet elevator is protected with a light guard/stop chain.
The system will stop if the light beam is interrupted by a person or an object
or the stop chains safety switch is activated. The working cycle may be con-
tinued after the safety device has been restored.
The stop chain is used for preventing persons from running through the light
guard straight to the pallet lifter. The use of this extra safety reduce the min.
length from pallet lifter to light guard
Safety switch on service platform
The service platform has an shutter with an safety switch. The system will stop
if the shutter is opened. The working cycle may be continued after the safety
device has been restored.
"Restart after stop" and "Restart after safety stop" - see chapter Operation for
further information.
Version 003 17
General safety Information AS LUL300FO Users Manual
Warning!
Do not operate without the provided fences and light guard.
Emergency stop
The AS LUL300FO emergency stop button is to be connected to the FO3015
laser emergency stop circuit. Therefore both machines will stop at the same
time. For information about restarting after an emergency stop see chapter Op-
eration.
Figure 3.2: Emergency stop on the operating console
18 Version 003
AS LUL300FO Users Manual Description of function
Description of function
1. General
The AS LUL300FO is adapted to take care of automatic loading/unloading of
sheets to Amada FO3015 laser cutting machine, and to store raw material and
finished cut sheets. The use of suction cups enable the AS LUL300FO to han-
dle different kinds of materials such as steel, aluminium, stainless steel and
copper.
Features of the AS LUL300FO
• The storage has positions for both raw material and finished cut sheets.
• Loading of raw material and unloading of finished cut sheets take place
to/from the pallet lifter when the pallet lifter is at the pin-table.
• The sheet to be machined are lifted from the raw material pallet to the
cutting pallet with suction cups. The sheet can then also be postponed
on the cutting pallet.
• If the sheet is between 0,5-6 mm thick is a sheet separation cycle run
and an sheets between 0,5- 10 mm is a double sheet control made.
• The AS LUL300FO automatically load/unload cutting pallets to/from
the FO 3015 laser cutting machine.
• The finished cut sheets are lifted from the cutting pallet with forks with
roller chains and moved to one unloading pallet.
2. Control
When using AS LUL300FO and an Amada FO laser has first the machining
program to be loaded into the FO laser. And the amount of sheets to be ma-
chined is given to the AS LUL300FO.
Signals when to start load/unload and other signals are sent direct between the
AS LUL300FO and the FO laser
AS LUL300FO FO laser
Version 003 19
Description of function AS LUL300FO Users Manual
3. Technical data
Table 3.1: Technical data
AS LUL300FO
Cycle time about 5 min.
Pallet changing time 1) 45 s
Raw material/Unloading pallets 2+4 or 3+3
Load of pallet max: 3000 kg
Sheet size max: 3000 mm x 1500 mm
Sheet size min: 2000 mm x 1000 mm
Sheet thickness 0,5 - 20 mm
Sheet weight max 710 kg
Load on cutting pallet max: 710 kg
Stacking height on raw material pallet max: 150 mm
Stacking height on unloading pallet max: 220 mm
Machined part size max: -
Machined part size min (X x Y) totally free cut: 225 mm x 180 mm
Machined part size min (X x Y) microjoined: -
Double sheet control: On sheets between 0,5-10 mm by
mechanical thickness control
PLC: Siemens S7-300
Operating terminal: Siemens OP170B
Power supply: 3x400 V+N+PE / 40A
Air supply: 6 Bar / 1000 l/min
1) Time from stop of FO laser to new start of FO laser
20 Version 003
4. Main parts of the AS LUL300FO

The AS LUL300FO consist of following main parts
Gear motor for Y-mo-
Sheet separation Suction cup unit ment of loading unit
Storage upper
part
Gear motor for
Z-moment of
loading unit
X-gauge
Double sheet Pallet shelves

detector
Pallets
Separation mag-
nets
Service platform Unloading unit
Cutting pallet
Electric cabinet
Hydraulic unit Storage lower part
Pin table
Pallet changer unit
Figure 4.1: AS LUL300FO overall view
4.1 Storage
The storage (AS LUL300FO frame) consist of two parts: upper part and lower
part.
lower part
The lower part has one pallet shelf position. The unloading unit and the pallet
changer unit are located in the lower part.
upper part
The upper part has 5 shelf positions and on the top is the loading unit where
the sheet separator, double sheet detector and separation magnets are located.
4.2 Loading unit

The loading unit consist of an frame with suction cups beams (with suction
cups) fixed to it. The suction cups are divided into two sections one for lifting
2000x1000 mm sheets and one for lifting 3000x1500 mm sheets (when lifting
3000x1500 mm sheets both sections are active). The loading unit is movable
in Z and X direction.
The Z movement is used when picking up sheets from the raw material pallets
to the cutting pallets, the movement is made by roller chains driven by an in-
verter controlled gear motor.
Version 003 21
The X movement is used when positioning the sheets in X direction, on the

cutting pallets. The movement is made by trapeze bar driven by a gear motor.
Gear motor for Sheet separation Gear motor for Loading unit frame Suction cups
Y-movement with air blow X-movement
X-gauge
Double sheet
detector
Separation
magnets
Figure 4.2: Loading unit in storage upper part
4.3 Sheet separation

To prevent pick-up of several sheets at the same time the AS LUL300FO is
equipped with following devices.
Sheet separation with air blow
The device consist of suction cups mounted on a beam, moved by an pneuma-
tic cylinder, and a air blow nozzle. During the sheet separation is the edge of
the sheet lifted a numbers of times while air is blown in between the sheets.
Note
The sheet separation cycle is only made for sheets with thickness
between 0,5-6 mm.
Sheet separation with magnets

Two powerful permanent magnets are mounted on the side of the storage, in
height with the material shelf. The magnets are moveable to and from the raw
material sheet stack with pneumatic cylinders.
When loading sheets from raw material pallets are the magnets moved against
the raw material sheet stack and the magnetic field helps to separate the sheets
from each other.
Note
The separation magnets works only ferro-magnetic materials.
22 Version 003
4.4 Double sheet detector

The double sheet detector checks the thickness of the uplifted sheet and com-
pares it with the thickness given by the operator. If the measured sheet thick-
ness exceeds the permitted value, the loading unit puts down the sheet on the
stack and makes a new try. If the double sheet detector detects over thick-
ness/or too thin material (< +150% - > -50%) after several tries, the AS
LUL300FO will stop and give an alarm message.
Height adjustment
Sheet
Figure 4.3: Double sheet detector
Adjustment
It is important that the double sheet detector is adjusted to the correct height.
See Figure 4.3
Note
The double sheet control is made for sheets with thickness between
0,5-10 mm.
4.5 Unloading unit

The unloading unit consist of 41 pcs forks, with roller chains, fastened in a
beam. The whole unit moves up and down by two hydraulic cylinders. The
roller chains, on the forks, are driven by an inverter controlled gear motor.
When unloading a finished cut sheet the cutting pallet is moved in to the un-
loading unit. The forks are in such height that they are moved in under the
sheet. The forks are lifted up and the cutting pallet will be replaced with a un-
loading pallet. When the pallet is in position the chain fingers start to move the
finished machined sheet outwards. At the same time the pallet starts to move
outward, and the finished machined sheet will fall down on the pallet.
Version 003 23
Beam
Forks with roller chains

Gear motor
Hydraulic cylinder
Figure 4.4: Unloading unit
4.6 Pallet changer unit

The pallet changer unit consist of a frame with two shelves for cutting pallets.
Two hydraulic cylinders and roller chains move the frame in Z direction, two
positions. (loading/unloading off upper or lower shelf to FO laser).
The pallet changer also have four bellow cylinders per shelf. These are lifted
up when the cutting pallets shall move in X direction, when loading/unloading
of cutting pallets to the FO laser.
Roller chains
Hydraulic lifting cyl-

inders
Pallet rails Pneumatic bellow cyl-

inders
Figure 4.5: Pallet changer unit, in storage lower part
24 Version 003
4.7 Pallet lifter

The pallet lifter moves the pallets between different positions in the storage.
The Z-movement is made by roller chains driven by an inverter controlled gear
motor. The pallet lifter is guided directly on the storage frame with track roll-
ers.
Two roller chains, one per side, with attachment pieces moves the pallets in
Y-direction. The roller chains are driven by an inverter controlled gear motor.
Gear motor for Roller chain

Z-movement
Gear motor for
Y-movement
Roller chain with

attachment piece
Track rollers
Pallet lifter
frame
Figure 4.6: Pallet lifter
Warning!
Never move in under the pallet lifter if the lifter is not in lowest
possible position.
4.8 Cutting pallet

The cutting pallet consist of a frame, protection sheets and changeable sheet
carrier.
The cutting pallets are movable in both X- and Y-direction.
Version 003 25
Sheet carrier
Wheels for Wheels for Frame

X-movement Y-movement
Figure 4.7: Cutting pallet
4.9 Raw material and unloading pallet

The raw and unloading pallets are similar and consist of an frame with five
base stoppers. The pallets are movable in Y-direction on four wheels. The pal-
let frame has two hooks that hook on the pallet lifter roller chain attachment
pieces when the pallets are moved.
Max load on the pallets are 3000 kg.
The Unloading pallets have an additional base plate that secure that the ma-
chined sheets hold on the pallets.
4.10 Pin table

The pin table is positoned under the pallet lifter and consist of an frame with
poles. When the pallet lifter goes to the input/output station is the poles raised
so they goes trough the pallets and lifts the material from the pallet. This
makes it possible to load/unload material on the pallet without wooden pallet
26 Version 003
4.11 Operating console

The operating console consist of a Siemens OP170B type operating terminal,
push buttons and switches.
Function keys
Figure 4.8: Operating console
Buttons and switches on the console

•
Switch for controller ON / OFF

•
Start button
•
Stop button
•
Emergency stop button

•
Switch for pallet changer, manual or automatic mode
Version 003 27
Reset of safety button

•
Key switch for maintenance or operating mode. Switching to mainte-

nance-mode enables key to be taken away for preventing machine to be
accidently started during maintenance and service.
Buttons on the terminal
• Function keys (Function indicated on the screen)
• NEXT/PREV
- Takes you to next/previous menu
• AUTO OFF
-For activating the automatic power off function. Can be used in both
pallet changer and storage mode.
• PHONE LARM
-For activating the phone alarm function. Can be used in both pallet
changer and storage mode.
• PALLET INFO
- Not in use
• PARAMETER
- Opens User parameter page
• ALARM
-Open alarm list page
• EVENT
- Not in use
• RESET
- Open reset page, where it’s possible to reset the ongoing sequence
• DIAGNOSTIC
- For service only
• ESC
- Cancel field inputs provided that they haven’t been terminated by
pressing "ENTER"
- Cancel display of help text
• Enter
- Enter and terminate your input
• ACK
- Acknowledge of command.
• Help (If the led is on)
- If the help LED linked with this key comes on, you can open a con-
text-sensitive Help text specifically about the screen currently dis-
played
•
Buttons for moving the cursor on the menus.
28 Version 003
Note
For further information see Appendix.
Version 003 29
5. Function (automatic storage mode)
5.1 Loading of raw material

• The operator orders a raw material pallet to the input/output station
from the operating terminal.
• The raw material is lifted and positioned on to the pallet with a forklift
truck.
• The operator input the amount and type of sheets on the operating ter-
minal and the pallet is returned to the storage.
5.2 Loading of raw material to FO laser (first sheet)

• The cutting program is loaded to the FO laser
• The working sequence is programmed on the AS LUL300FO operating
terminal.
• The AS LUL300FO is started.
• The raw material pallet to be used is moved from its storage position to
the material shelf.
• One raw material sheet is lifted up with suction cups. The sheet separa-
tion cycle and the double sheet control are made. At the same time is
the first cutting pallet picked up from the pallet changer and moved in
under the up lifted sheet.
• The sheet is positioned (if selected) and lowered down onto the cutting
pallet.
• The cutting pallet with raw material is moved into the pallet changer
and further into the FO laser.
5.3 Loading of raw material to FO laser (second sheet)

• When the cutting of the first sheet in the FO laser has started is the sec-
ond raw material sheet moved onto the second cutting pallet in the
same way as for the first sheet.
• The second cutting pallet is moved to the pallet changer to wait until
the cutting of the first sheet is ready.
5.4 Unloading/loading of following sheets to FO laser

• The FO laser gives signal to AS LUL300FO when the cutting is ready
• The pallet changer unit takes out the cutting pallet with the worked
sheet and moves the second cutting pallet with raw material into the
FO laser.
• The cutting pallet with the worked sheet is moved to the unloading unit
where the worked sheet is removed from the pallet with the forks.
• The cutting pallet is after that loaded with a new raw material sheet and
moved back to the pallet changer.
• A unloading pallet is collect to the unloading unit and the worked sheet
is moved onto the pallet from the forks.
• The unloading pallet is moved back to its storage position
5.5 Unloading of finished machined sheets from storage

• The operator orders the unloading pallet to the input/output station
from the operating terminal.
30 Version 003
• The worked sheets is unloaded from the pallet with a forklift truck.
• The operator input data about unloading to the operating terminal.
6. Function (Pallet changer mode)
6.1 Loading of raw material to FO laser

• The cutting program is loaded to the FO laser
• The operator order one cutting pallet to the input/output station from
the operating terminal
• The raw material sheet is manually lifted and positoned on the cutting
pallet
• The operator input the type of sheet on the operation terminal
• The operator send the cutting pallet back to the pallet changer
• The cutting pallet will automatically be moved into the FO-laser for
machine and automatically moved back to the ballet changer when the
machining is ready.
• The second cutting pallet can be loaded on the same way during
machining of the first one.
6.2 Unloading of machined sheets

• The operator order the cutting pallet with machined sheets from the
pallet changer to the input/output station, from the operation console
• The machined sheet is removed from the cutting pallet manually
• A new raw material sheet is loaded or the empty cutting pallet is sent
back to the pallet changer.
Version 003 31
32 Version 003
AS LUL300FO Users Manual Operation
Operation
1. Starting of the AS LUL300FO

• Turn on the AS LUL300FO using the main switch located on the elec-
trical cabinet.
• Turn on the air supply.
• Switch on the operating console on the controller ON/OFF switch.
• Check that the emergency stop button is not depressed.
2. Pause, safety/emergency stop and restarting
2.1 Pause
When the stop push button, located on the operating console is pressed, the AS
LUL300FO is set to PAUSE. This is indicated in the machine status field on
the operating console. The PAUSE function can be used e.g. in following sit-
uations.
• To pause the machine during inspection. Without interrupting the light
guard or opening safety platform shutter
• To check that no collisions or dangerous situations arise, or to prevent
such things.
Note
If the FO laser goes into safety stop and the door between the AS
LUL300FO and the FO laser is open AS LUL300FO will go to Pause.
Note
If the light guard is interrupted or the service platform shutter opened
the AS LUL300FO will go to safety stop.
2.2 Safety stop

If the light guard is interrupted, the service platform shutter opened or the
maintenance/operation switch turned to maintenance position the AS
LUL300FO will go to SAFETY STOP.
2.3 Emergency stop

If any of the emergency stop buttons, on the whole line is pressed will the hole
line stop and go to SAFETY STOP.
2.4 Restarting the AS LUL300FO

Restarting the AS LUL300FO from PAUSE
• Press the start button on the AS LUL300FO operating console
Restarting the AS LUL300FO from SAFETY STOP
• Attend to the cause of SAFETY STOP
• Press the reset safety button on the operating terminal.
Version 003 33
Operation AS LUL300FO Users Manual
Restarting the AS LUL300FO from EMERGENCY STOP

• Attend to the cause of EMERGENCY STOP
• Reset the emergency stop button
• Restart the FO laser
• Press the reset safety button on the operating terminal.
34 Version 003
3. General
The AS LUL300FO menus are related as follows
Figure 3.1: Menu structure 1/3
Version 003 35
36 Version 003
Version 003 37
4. Status bar
The status bar in the upper part of the terminal window is the same in all men-
us:
Figure 4.1: AS LUL300FO status bar
Current mode - The selected mode:

• Manual mode
• Storage mode
• Pallet changer mode
Menu name - Name and number of the current menu
Machine status Current status of the machine:
• Emergency stop
• Safety stop
• Pause
• Normal
FO status - Current status of the FO laser:
• FO working (in AOP and not Z-origin)
• FO waiting (giving M707)
• FO in stop
• FO off-line (not in MDI or Memory mode)
• FO idle (in Z-origin and not AOP)
Password level - Current password level
• Level 1 = user/operator
• Level 6 = Amada
• Level 9 = LKI
38 Version 003
5. Terminal menus
5.1 Main menu for AS LUL300 FO
Figure 5.1: Menu: 5, Main menu
To select automatic mode first you have to turn the mode selection switch to
wanted position; left for pallet changer mode or right for storage mode. In the
middle position manual mode is active. The current mode is shown in the sta-
tus bar.
For selecting any of the other functions, the machine must be in manual mode.
Version 003 39
6. Automatic functions
6.1 Material handling, get pallet
Figure 6.1: Menu: 30, Material handling
For manual loading or unloading of a pallet, it can be ordered to the output sta-
tion. This can be done from two menus; the “Material handling” menu found
in the main menu or in the storage mode menu. The functions are similar.
The pallet number to get can be either selected by pressing keys + or -, or by
entering the pallet number into the field found at “Pallet”.
When a pallet is selected, the data about it is shown in the menu. Press key on
right side to get the pallet.
Another menu is shown while the lifter gets the pallet to the output station.
If the function was selected from storage mode, the pallet is fetched when the
pallet lifter has nothing else to do.
Note
A cutting pallet cannot be selected.
Caution!
Be careful when loading/unloading material to and from the pallets so
that the roller chain or attachment pieces are not damaged.
40 Version 003
7. Material handling, edit & leave pallet
Figure 7.1: Menu: 32 Material handling
When the pallet is at the output station, the data of the pallet can be edited.
If the pallet is a raw material pallet, the following data is essential:
Status
If the pallet is empty or not empty.
Sheet amount
How many sheets on is pallet
Sheet thickness
Thickness of sheet [1/100 mm]. If left as 0, the sheet is assumed to be thick, so
no separation or thickness measuring is performed by the loading unit.
Sheet length
Need to know how many suction cups to use on suction cup unit. If longer than
2000 mm all suction cups are used. If left as 0, the sheet is assumed to be long,
so all suction cups are used.
Sheet width
For same purpose as the length. Limit for to use all suction cups is 1000 mm.
Sheet type
User can select type of sheet. Information is not used in program.
If the pallet is a unloading pallet, the following data is essential:
Status
If the pallet is full or not full.
Sheet amount
How many sheets have been unloaded onto the pallet.
Version 003 41
The rest of the data is unessential.

Press key to right to leave the pallet back to storage.
7.1 Loading of the pallets

Check that the raw material sheet stack is even at bode sides and max 20 mm
from the base stopper in X-direction and max 10 mm from the base stoppers
in Y-direction.
Max 20 mm
Max 10 mm
Figure 7.2: Sheets correctly placed
Figure 7.3: Sheet incorrectly placed
42 Version 003
Max stacking height on raw material pallets is 220 mm and max load is
3000 kg.
Max 150 mm
Figure 7.4: Max stacking height
If using any kind of support between the pallets and the sheet stack make sure
that the support are placed even so the sheets have a flat surface.
Figure 7.5: Sheets evenly placed
Figure 7.6: Sheets unevenly placed
Note
It’s not recommended to have support under the sheet stack
To secure the function is it recommended to equip the raw material pal-
lets with an additional sheet separation magnet (option) if using sup-
ports under the sheet stack
Version 003 43
8. Job list input
Figure 8.1: Menu: 200, Automatic run
Here you make the job schedule for the machine. Max. 5 jobs can be given.
The schedule is accomplished from top to bottom.
FROM
From what pallet to take the raw material (the pallet must be configured as a
raw material pallet).
AMOUNT
How many sheets to load from the pallet.
TO
To what pallet to unload the ready worked sheets (the pallet must be config-
ured as a unloading pallet).
By pressing “Start auto” a check of the schedule you wrote will be performed,
and if it is valid the machine starts. Otherwise an alarm is generated with fault
codes that tells you which job is fault.
Note
When unloading a worked sheet onto a pallet, the height on the pallet
can grow with 3-4 times the sheet thickness. Therefore if running many
sheets from a pallet, it can be possible that not all sheets fits onto the
unloading pallet. Then you can split the order into two orders with half
of the sheets on each job from the same material pallet, but to be
unloaded on different unloading pallets.
If the job list not is empty, press “Clear list” to empty all fields.
44 Version 003
Note
Always press "Clear list" before entering a new job list. don’t just write
over the old values. This because the fields "Loaded" and "Unloaded"
may retained their previous values.
If starting with a sheet left on the forks, the machine will start with unloading
of the forks before any sheet is loaded. The sheet is unloaded to the first un-
loading pallet found in the schedule
When you have some sheets (raw material or worked) already on the cutting
pallet at start, those sheets will be added to the "Loaded" field in the schedule.
This way only the amount of sheets you have entered in the schedule will be
run.
If you of some reason interrupted the previous automatic run, and now want to
continue it, press the key "Continue". Then the field "Loaded" is not changed.
Version 003 45
9. Running storage mode
Figure 9.1: Menu: 210, Automatic run
When started storage mode the schedule you wrote is shown, but you cannot
change it. Two additional columns are added which shows the amount of load-
ed and unloaded sheets in each job.
When a job is ready, the fields gets gray. E.g, when the loading is ready the
fields “From” and “Loaded” gets gray and when unloading is ready the rest of
the fields.
The thickness of currently loaded sheet is shown in right corner.
If you want to load or unload a pallet during automatic run, you can press the
first key. Then the menu for material handling is shown and the functions are
the same as in earlier described menu. When ordering a pallet to the output sta-
tion, the pallet is brought there when the pallet lifter has time for it. When the
pallet is at the output station, of course no other pallet movements can be
made, which means that the schedule must wait.
If there are some problems with the FO cutting program and FO must be re-
started, this will lead to that the pallet is exchanged. To avoid this the key “Ig-
nore FO” can be pressed. When the function is selected no automatic pallet ex-
change will be performed. Remember to disable the function when isn’t
needed.
The “Master reset” key can only be selected when machine is in stop. The
function resets all sequences and stop axis when “START” button is pressed
again. Use this function if you have some problem which demands restart of
the schedule/machine.
If you need to end the run, but first finish the ongoing sequence, press “Un-
load&stop”. Then no more loading of sheets is performed, but the already
loaded sheets will be cut in FO and unloaded onto pallet.
46 Version 003
10. Pallet changer mode
Figure 10.1: menu:20, Automatic run
Only one menu is found in pallet changer mode. The content of each cutting
pallet is shown in the box:
EMPTY
No sheet on pallet.
RAW SHEET
Contains a sheet that not has been cut.
WORKED SHEET
A ready cut sheet.
The pallet changer mode is a semi-automatic mode with manual loading and
unloading of sheets to the cutting pallets. As soon a a pallet with raw sheet is
inside the pallet changer, and the FO is empty and ready to receive a pallet, the
pallet is automatically moved to FO and the program is started. When the cut-
ting is ready the pallet is brought back to the changer. During cutting of one
sheet, the second pallet can be loaded.
To move an empty pallet or pallet with worked sheet out onto the pallet lifter,
press the first key. A pallet with raw sheet cannot be moved back onto lifter.
Only machine with foldable pin-table type:
When you have an empty pallet on the lifter and wants to load a new raw sheet
onto the pallet, you can use the pin-table. By pressing the second key, the lifter
moves up, the pins on the tables rises, and the lifter moves down with the pallet
onto the pins. When moving the pallet back to the changer, the machine auto-
matically moves the lifter up and lowers the pins.
To move a emptied pallet (without sheet) back into the pallet changer, press
the third key (‘ø’).
If the pallet has been loaded with a new raw sheet, press the fourth key (‘1’) to
move it back.
Version 003 47
11. Ending automatic mode
Figure 11.1: Menu: 19, Confirmation
If in pallet changer or storage mode, and turning the MODE-selection switch

to manual (middle) position, you are asked if you really want to end automatic
mode.
48 Version 003
12. Manual functions
12.1 Manual main menu
Figure 12.1: Menu: 50, Manual main
Main menu for manual control.

The interlockings written for the manual functions are only some of the inter-
lockings. There are so many and complex interlockings so there for not all are
written down.
Note
No pallet movements made by manual functions will update the pallet
and position database. Therefore you are always asked when leaving
the manual main menu, if you want to edit the database.
Version 003 49
13. Pallet lifter
Figure 13.1: Menu: 51, Pallet lifter man
The keys on the left side jogs the lifter up and down.
The key on the right side is to toggle the pin-table up and down. The lifter may
not be at down position to do this.
The lifter can also be moved to a certain height by entering the position in the
field “TO” and pressing “Start” key. Pressing “Cancel” stops the movement.
The actual position is shown in the field “AT”.
The lifter can also be moved to one of the pre-programmed position (shelves);
move the cursor with the arrow keys to the selection field (above “AT”). Press
“Enter” and a list of position is shown. Select wanted position and press
“Start” (in lower right corner) to start the positioning.
50 Version 003
14. Pallet chain
Figure 14.1: Menu: 52, Pallet chain man
Manual control of the pallet chain.

The keys on the left side jogs the chain inwards and outwards.
By pressing the key on right side on the same time as the chain is moving, the
chains on the unloading unit also rotates in the same direction. This to enable
manual unloading of the unloading unit (forks).
The three symbol key in the bottom move the chain to pre-programmed posi-
tions:
Get material/unloading pallet out of the shelf
Get cutting pallet out of the shelf/pallet changer
Leave pallet to shelf (all types of pallets)
Interlocking: the chain cannot be moved if the pallet lifter not is at a position
(shelf).
Version 003 51
15. Pallet changer
Figure 15.1: Menu: 55, Pallet changer man
Manual control of the pallet changer.

The keys on the left side move the changer up and down.
The keys on the right side lifts and lowers the pallet rails for the upper and the
lower shelf in the changer.
Text beside the symbols shows current state of the parts.
Interlockings: the FO chain must be at forward or backward end to move the
changer.
52 Version 003
16. Loading unit 1/2
Figure 16.1: Menu: 53, Loading unit man
Manual control of the loading unit.

The keys on the left side jogs the suction cup unit up and down.
The first key on the right side is for the separation magnets. When both mag-
nets are out (away from the sheets) and you press the key, the first magnet
moves towards the sheet. Pressing a second time moves the second magnet to-
wards the sheet. When both magnets are towards the sheet, they move away
when pressing the key again.
The second key on the right side toggles the vacuum on and off.
More functions are found under the key “More”.
By pressing the origin key in the left down corner, the suction cup unit moves
to its home position (height) and the X-origin setter to its backward position.
Interlockings: you cannot move up or down if the double sheet detector or
X-origin senor is out.
Version 003 53
17. Loading unit 2/2
Figure 17.1: Menu: 57 Loading unit man
Manual control of the loading unit, second menu.

The first two keys on the left side jogs X-origin setter forwards and backwards.
The next key moves the X-origin senor outwards.
The first key on the right side is for manual test of the sheet separator.
For testing the double sheet detector, press the next key. It moves then out-
wards and the measured thickness is shown (in mm and pulses).
Interlockings: the X-origin sensor must be out to enable the X-origin setter to
be move forwards.
54 Version 003
18. Unloading unit
Figure 18.1: Menu:54 Unloading unit man
Manual control of the unloading unit.

Lift and lower the forks with the keys on the left side. The movement down
will automatically stop if the stacking detector under the forks is interrupted.
The chains on the forks rotates by pressing the keys to the right.
Interlockings:
The forks cannot be lowered of the stacking detector is interrupted
Version 003 55
19. FO laser
Figure 19.1: Menu: 56, FO laser manual
Manual control of the FO laser.

The pallet can be move to and from the FO with the keys to the left.
Interlockings: The FO door must be open and the FO index pin unlocked to
enable the chain to be moved. Also the pallet changer must be either up or
down, the pallet rails lifted, and the pallet lifter may not be in front of the pallet
changer.
The first key on the right side locks/unlocks the pallet at FO.
The FO shuttle door is opened/closed with the next key.
56 Version 003
20. Parameters
20.1 User parameters

From the "User parameter" menu can following parameters be changed.
Enter password 7290 to change the user parameters
Table 20.1 shows the users parameters. Note the column for user settings
changes in the right column for future references.
Table 20.1: User parameters
New user
Factory
User parameters Value range setting
default
value
Y-origin position 2240
Separation cycles 1-9 3
Separation time active 0,5-9,9 s 1,0
Separation time pause 0,5-9,9 s 0,5
Do separation Yes-No Yes
Do measuring Yes-No Yes
Do X-origin setting of sheet Yes-No Yes
Do Y-origin setting of sheet Yes- No No
Use magnets 1, 2 Yes-No Yes
Time idle before job failed 0-60 min 30
Free lift before stacking Yes/No Yes
20.2 Definition of user parameters

Definition of Y-origin position:
If Do Y-origin setting of sheet is NO this is the Y-position where the cutting
pallet is moved to when loading sheet (automatic mode).
Defining of Separation cycles:
How many cycles the sheet separation unit is making.
Defining of Separation time active:
Time for separator to be in upper position.
Defining of Separation time pause:
Time for separator to be in lower position.
Defining of Do separation:
If to make sheet separation (not on > 6 mm sheets).
Defining of Do measure:
If to measure the sheet thickness (not on > 10 mm sheets).
Defining of Do X-origin setting of sheet:
If the X-origin positioning of sheet, on cutting pallet, is made.
Version 003 57
Defining of Do Y-origin setting of sheet:

Not in use
Defining of Use magnets:
If the separation magnets shall be used.
Defining of Time idle before job failed:
The time before the machine (AS LUL or FO) must be in idle before it is as-
sumed to be something wrong with the machine.
Defining of Free lift before stacking
When the forks are lowered down onto a unloading pallet, you can select if it
should lift until the stacking detector is free again.
Using "No" will give better stacking but risk that already stacked parts, on the
unloading pallet, and the forks collide.
20.3 Autostop function

The ASLUL300FO has an autostop function
The autostop time is set by the parameter "Time idle before job failed". The
function is activated from the operating terminal "AUTO OFF" button. The led
in the button starts to shine when the function is on and starts to flash when
count down has started.
If the autostop function is activated, then the autostop time must be longer
than the cutting pallet exchange time. The automatic shut-off causes the
ASLUL300FO to shut down the FO laser as well as itself when the pro-
grammed time has passed. Automatic shut-off also occurs after a disturbance
in the ASLUL300FO or the FO-laser. The purpose of this function is to reduce
the power consumption during unattended operation.
20.4 Phone alarm

The machine may be equipped with a phone alarm, which may be used during
unattended operation. The alarm signals are given by the PLC. The PLC out-
puts used for this purpose are found in the electric drawings.
There are two possible signals:
• Job done
The signal "Job done" is given when the schedule is ready
• Job failed
Should there be a problem with e.g. the loading of a new sheet into the
FO-laser and the "Time idle before job failed" time has passed, then the
alarm "Job failed" is triggered.
The function is activated from the operating terminal "PHONE ALARM" but-
ton. The led in the button starts to shine when the function is on
Note
To activate the functions "AUTO STOP" and "POHONE LARM" has the
buttons on the operating terminal to be pressed for two seconds
58 Version 003
21. Data base
21.1 Database check

The database can be checked in the menu Parameters/Database.
Press key "Check database", if no alarm is generated, the database is valid.
21.2 Edit pallet

If some pallet has been moved manually has the pallets data to be updated in
the database. The data can be updated from "Edit pallet data" menu that is
found under Parameters/Database/Edit pallet data.
Figure 21.1: Menu: 141, Data base
The pallet type Raw material / Unloading pallet can not be changed by the us-
er. Contact closest Amada service office if you want to change pallet type
Version 003 59
21.3 Edit position

The height for the positions (shelves and system positions) have been set at
factory. If, however, they needs to be adjusted this is the procedure:
Under Parameters/Database/Edit position data this menu is found.
Figure 21.2: Menu: 140, Data base
The position to set can be reached by pressing +/-, or entering the value into
the field.
The new height is entered at field "Height".
Set the "Content" to correct status for the position (select field and press "En-
ter" key).
Note
If changes have been made to a position, remember to save the new
setting before leaving the selected position by pressing the symbol in
left down corner.
Table 21.1: System positions
Mark on
Position Description
storage
1-5 1-5 Pallet shelves
51 M Material shelf
52 Not used
53 L Loading shelf
54 Output station
55 U Unloading shelf
56 FO laser
57 Pallet lifter
58 C Pallet changer, upper shelf
60 Version 003
Table 21.1: System positions

Mark on
Position Description
storage
59 C Pallet changer, lower shelf
Note
Remember to save changes!
21.4 Installation parameters

Contact you closest Amada service office if you need to change some of the
installation parameters.
22. Stopping and shutting down the AS LUL300FO

• Run all pallets to their positions in the AS LUL300FO storage
• Shout down the FO laser

• Switch of the AS LUL300FO on the operating console on the control-
ler ON/OFF switch
Note
If the AS LUL300FO is stopped for more than one week is it recom-
mended to turn OFF the AS LUL300FO main switch and air supply.
Version 003 61
62 Version 003
AS LUL300FO Users Manual Maintenance
Maintenance
All maintenance information is based on the experience of the manufacturer.
A more frequent and thorough maintenance may be necessary when the spe-
cific prerequisites of the application are considered.
Note
Use the service ladder to get to the service platform when making serv-
ice to the storage upper part
Warning!
Make sure that the service ladder is fastened to the hooks on the
service platform
1. Daily check-ups and maintenance

Table 1.1: Daily check-ups and maintenance
Part Description Action Note
Operating console Clean
Figure 6.1 Cutting pallets Clean from
scrap
Figure 6.1 Sheet carrier on cutting pallets Check if worn
out and
replace if
needed
Figure 6.1 Pallet shelves Clean from
scrap
Figure 6.4 Pallet rail on pallet changer Clean from
unit scrap
Figure 6.2 Suction cups Check that
they aren’t
worn out
Figure 6.2 Air hoses Check that
they don’t
hang down
P1 Figure 6.1 Air pressure for cylinders Check Pressure regula-
tor (P1= 6 bar)
P2 Figure 6.1 Air pressure for suction cups Check Pressure regula-
tor (P2 = 5 bar)
Version 003 63
Maintenance AS LUL300FO Users Manual
2. Weekly check-ups and maintenance

Table 2.1: Weekly check-ups and maintenance
Figure 6.2 Separation magnets Check that
they are prob-
ably fastened
and clean
from scrap
P1,P2 Figure 6.1 Water separation tank on the Empty and
air pressure regulator clean
Figure 6.1 Protection sheets under Clean from Clean more fre-
unloading unit scrap quently if needed
Figure 6.4 Protection sheets under pallet Clean from Clean more fre-
changer unit scrap quently if needed
3. Monthly check-ups and maintenance

Table 3.1: Monthly check-ups and maintenance
C Figure 6.2 Roller chains on loading unit Lubricate
with oil4)
C Figure 6.3 Roller chains in unloading unit Check ten-
sion, check if
they are worn
and lubricate
with oil4)
C Figure 6.4 Roller chains on pallet changer Lubricate with
unit oil4)
C Figure 6.1 Roller chains on pallet lifter Check tension
Figure 6.5 and
lubricate with
oil4)
Figure 6.1 Brake resistor on top of elec- Clean from Clean more fre-
trical cabinet dust quently if needed
4) Recommended viscosity VG 150 (SAE 40)
Warning!
Never stand under the lifter if there is a pallet on it!
Warning!
Do not climb on the pallets since they are on wheels, they can eas-
ily slide out of the storage!
64 Version 003
4. Twice/year check- ups and mantenance

Table 4.1: Twice/year check-ups and maintenace
M Figure 6.1 Gear motor Check oil
Figure 6.2 level fill up is
Figure 6.3 necessary 3)
Figure 6.5 Check work- 0.25-0.6 mm
ing air gap in
the motor
brake5)
B Figure 6.1 Bearing units Lubricate with
Figure 6.2 vaseline1)
Figure 6.3
Figure 6.4
Figure 6.5
H Figure 6.1 Hydraulic unit check oil level
and fill up if
necessary 2)
Figure 6.1 Hydraulic houses Check if worn
Figure 6.2 Double sheet detector Check height
C Figure 6.2 Roller chain Check that the
loading unit is
horizontal and
adjust the
roller chain
length if nec-
essary
C Figure 6.4 Roller chain Check that the
loading unit is
horizontal and
adjust the
roller chain
length if nec-
essary
Figure 6.1 Toothed belt for encoder Check tension
and that not
worn
C Figure 6.5 Chain for encoder check tension
and lubricate
with oil4)
1) Recommended Vaseline to DIN 51825 K2K and consistency class NLGI 2.

2) Oil quality 46 hydraulic oil.
3) Oil quality DIN CLP, viscosity VG 220.For more information please refer to the manufacturer’s manual (SEW).
4) Recommended viscosity VG 150 (SAE 40)
5) For more information please refer to the manufacturer’s manual (SEW).
Version 003 65
5. Once/year check-ups and maintenance

Table 5.1: Once/year check-ups and maintenace
Filter Figure 6.1 Return filter Change FRA31B06NCD
01W
Pressure filter FPM21B06CNF
IC03X
R Figure 6.2 Runner block on separation Lubricate with
magnets vaseline 1)
R Figure 6.2 Runner blocks on X-gauge and Lubricate with
double sheet detector vaseline 1)
R Figure 6.3 Runner block on unloading Lubricate with
unit vaseline 1)
R Figure 6.4 Runner block pallet changer Lubricate with
unit vaseline 1)
6. Every third year check-ups and maintenance

Table 6.1: Every third year check-ups and maintenace
M Figure 6.1 Gear motor Change oil 3)
Figure 6.2 and renew the
Figure 6.3 anti-friction
Figure 6.5 bearing
grease1)

3) Oil quality DIN CLP, viscosity VG 220.For more information please refer to the manufacturer’s manual (SEW).
66 Version 003
M B (C) Roller chain for

pallet lifter
Hooks for serv-
ice ladder
P1, P2
Brake Pallet shelves

resistor
Hydraulic Protection
houses sheets under
unloading unit
Cutting pallet
Sheet carrier
Hydraulic unit
Filter
Electrical cabinet Toothed belt

Figure 6.1: Maintenance positions on storage
B C
Suction cups
M Air houses
Double sheet
detector
Separation
magnets
Figure 6.2: Maintenance positions on loading unit
Version 003 67
R
R
B
C M
Figure 6.3: Maintenance positions on unloader unit
B C
Protection sheets Pallet rail R
Figure 6.4: Maintenance positions on pallet changer unit
68 Version 003
B C (Chain for encoder)
Tension unit
Figure 6.5: Maintenance positions on pallet lifter
Version 003 69
7. Electric cabinet
Inspect and serve as follows at least once a year:
• check that no dust, dirt or oil exist in the cabinet. Clean with cloths or
vacuum cleaner.
• check in particular that inverters and the PLC are free from dirt and
dust.
• check if there are any loose screws or nuts. Tighten if necessary.
• check the isolation and the sockets. Improve the insulation and the
sockets if necessary.
• check that the parts are not discoloured, damaged or a cable breakdown
has occurred due to high temperature.
Warning!
Only qualified personnel are authorised to carry out maintenance,
measuring and adjustments. There is highly dangerous voltage in
the electric cabinet. Before any engagement of the electric cabi-
net, the voltage must be switched off. Check that there is no cable
breakdown or insulation failure on live cables. In case of any fail-
ure, the defective component must be replaced or repaired.
70 Version 003
AS LUL300FO Users Manual Alarms
Alarms
1. General
When an alarm is active, a symbol is displayed in the top centre of the window.
By pressing the short-cut key “ALARM” the alarm page is shown. Here are
the active alarms listed.
To acknowledge an alarms, select the alarm and press key “ACK”. If there is
help text available for the current alarm, the led at the key “HELP” is lit and
the text can be viewed by pressing the key.
The alarm can have three different states shown in column “State”:
• An active alarm indicated as “A”
• When acknowledged it is shown as “Q”
• An alarm been on but now not more active shown as “C”
Example: If the air pressure has been too low but is now ok, it is
indicated in “State” as “AC”. When pressing “ACK” for the
alarm, the “State” goes to “ACQ” and the alarm disappear
from the list.
The number in the alarm symbol shows how many alarms are active. As long
as there are some unacknowledged alarms, the symbol flashes. When all
alarms have been acknowledged, the symbols stops flashing.
Note
Before acknowledging an alarm, find out the reason to the alarm.
1.1 Override alarm

All alarms set the machine in stop, but with some alarms it is possible to set
machine in run again. Those alarms are at least the Easy Motion Control
alarms.
If such an alarm is active as stops the machine, and you must do some move-
ments from a manual menu to continue, it can be done as follows:
• When pressing the key for manual function, at the same time also press
the “STOP”-button on the machine. This way it is possible to override
the stop command.
Version 003 71
Alarms AS LUL300FO Users Manual
2. List of alarms
1.“Suction cup unit: Lower hardware overtravel”

Meaning: The suction cup unit has reached the lower overtravel position.
Action: Lift the suction cup unit in manual menu.
2. “Database fault: Error code=## Return value=##”

Meaning: Error in database, error codes:
• 01 Pallet at unknown position. A pallet is at an unknown position.
(return value=pallet number)
• 02 Pallet in position but position is free. A pallet is configured to be in
a position, but the position it selves is configured to be free (return
value=position number).
• 03 Another pallet at same position. Two or several pallets are config-
ured to be at the same position(return value=position number).
• 04 Pallet usage not configured. The usage of the pallet is not config-
ured (return value=pallet number).
Action: Edit the database.
3. “Cannot start with pallet on lifter”

Meaning: A pallet exists on pallet lifter.
Action: Move the pallet into its shelf and remember to update the database.
4. “Cannot start with pallet in loading shelf”

Meaning: A pallet exists in the loading shelf.
Action: Move the pallet into its own shelf and remember to update the data-
base.
5. “Job order fault: Error code=##”

Meaning: Error in job list (schedule), error codes:
• 01 First order is 0
There are empty fields in the first job order
• 02 FROM pallet not a material pallet
One of the pallets in the FROM column is not an material pallet
• 03 TO pallet not a unloading pallet
One of the pallets in the TO column is not an unloading pallet
• 04 AMOUNT is 0
The AMOUNT field is 0 even if the FROM field is used
• 05 TO pallet is left empty
The TO field is left empty
72 Version 003
• 06 FROM pallet is empty

The FROM field is left empty
• 07 TO pallet is full
One of the pallets in the TO column is assumed to be full
Action: Correct the job list.
6. Alarm not used
7. Alarm not used
8. "Sheet left on forks"

Meaning: A worked sheet is left on the forks
Action: Remove the sheet from the forks. If there is no sheet there, goto the
database-menu and set that there is no sheet on forks.
9. "Low air pressure"

Meaning: The air pressure is too low for the machine to work
Action: Find out the reason to the low air pressure.
10. "Motor protection/inverter failure (not axis 1-2-3)"

Meaning: Some of the motor protections or the inverters (not for axis; pallet
lifter, pallet chain or suction cup unit) have a fault.
Action: Find out the reason fault and reset the device.
11. "Forks collision detected"

Meaning: A pallet has collided with the unloading unit so it has been pushed
backwards.
Action: Go to manual menu and move the pallet away from the forks, find out
the reason to alarm.
12. "Pallet lifter: Upper hardware overtravel"

Meaning: The pallet lifter has reached the upper overtravel position.
Action: Lower the pallet lifter in manual menu.
13. "Pallet lifter: Lower hardware overtravel"

Meaning: The pallet lifter has reached the lower overtravel position.
Action: Lift the pallet lifter in manual menu.
Version 003 73
14. "Pallet chain: Inward hardware overtravel"

Meaning: The pallet chain has reached the inward overtravel position.
Action: Move the pallet chain outwards in manual menu.
15. "Pallet chain: Outward hardware overtravel"

Meaning: The pallet chain has reached the outward overtravel.
Action: Move the pallet chain inwards in manual menu.
16: "Suction cup unit: Upper hardware overtravel"

Meaning: The suction cup unit has reached the upper overtravel position.
Action: Lower the suction cup unit in manual menu.
The following alarms are for the Easy Motion Control (positioning system).
The alarms 17-32, 33-48 and 49-64 are similar but for different axis. Therefore
only the alarms 33-64 are described here.
For more information, see manual
“Siemens Easy Motion Control; Position-controlled positioning with soft-
ware”.
17. "Pallet lifter: Min. SW limit switch exceeded"

Meaning: The actual position is outside the working range.
Action: Set machine in “START” drive and drive in opposite direction.
18. "Pallet lifter: Max. SW limit switch exceeded"

Meaning: The actual position is outside the working range.
Action: Set machine in “START” drive and drive in opposite direction.
19. "Pallet lifter: Target beyond travel range"

Meaning: The target lies outside the software overtravel limit
Action: Check position to mode to.
20. "Pallet lifter: Axis not synchronized"

Meaning: A movement was tried without first synchronize the axis.
Action: Calibrate axis in calibration menu.
74 Version 003
21. "Pallet lifter: Motion not allowed in direction entered"

Meaning: One movement further into a software limit switch is
inadmissible.
Action: Start a travel order away from the software limit switch.
22. "Pallet lifter: Invalid Motion-FB parameter"

Meaning: Acceleration <= 0, deceleration <= 0, or the entered or calculated
target coordinate lies outside the numerical range.
Action: Check acceleration or deceleration vaules.Or PLC program error.
23. "Pallet lifter: Start not possible in current axis state"

Meaning: On a travel FB, the execute input was set at a time when the axis
was in an error status or was active during an FB MoveStop. Or the FB Move-
Home was not started when the axis was at a standstill.
Action: PLC program error.
24. "Pallet lifter: Reference point motion is too far"
Meaning: The reference point lies outside the system working range.
25. "Pallet lifter: Axis is in stop, must be acknowledged"

Meaning: The axis is in stop status requiring acknowledgement.
Action: -
26. "Pallet lifter: Drive enable missing"

Meaning: "EnableDrive" is not set at FB MoveControl.
Action: Set machine in “START”.
27. "Pallet lifter: Max. following distance exceeded"

Meaning: The axis does not follow the setpoint values or is too slow in fol-
lowing.
Action: Check why the axis does not follow the setpoint outputted from the
positioning system.
28. "Pallet lifter: Outside standstill range"

Meaning: Axis has moved out of "standstill range" without travel order.The
axis was at standstill, it was by external force move outside its standstill
range”.
Action: -
Version 003 75
29. "Pallet lifter: Target approach error"

Meaning: The actual value has not reached the "target range" within the
"monitoring time for target approach".
Action: Check the axis for mechanical limitations.
30. "Pallet lifter: Encoder error"

Meaning: The encoder outputs no pulses or unreliable pulses.
Action: Check encoder mechanical and electrical connections.
31. "Pallet lifter: Output driver error"

Meaning: At the output driver, input "OutErr" was set.
32. "Pallet lifter: Axis data incorrectly configured"
Meaning: Parameters in axis DB are defective.
65. "Suction cup unit: Sheet too thick or double sheet. Press F1 to retry"
Meaning: The measured sheet thickness is more than 150% of the given thick-
ness.
Action: Check the given thickness. By pressing key F1 the loading unit does
the sheet separation and thickness measuring again.
66. "Suction cup unit: Sheet too thin. Press F1 to retry"

Meaning: The measured sheet thickness is less than 50% of the given thick-
ness.
Action: Check the given thickness. By pressing key F1 the loading unit does
the sheet separation and thickness measuring again.
67. "Suction cup unit: Sheet dropped. Press F1 to retry"

Meaning: The suction cup unit has dropped the sheet, or no sheet was picked
up.
Action: Check why the sheet was dropped. By pressing key F1 the loading
unit tries to pick-up the sheet again.
76 Version 003
68. "Sheet from FO wrinkled"

Meaning: The pallet moved to or from the FO is too high, probably the sheet
is wrinkled.
Action: Check why the pallet is too high and correct it.
69. "Pallet too high for shelf"

Meaning: The pallet is too high to fit in the shelf.
Action: Find out why the pallet is too high.
70. "Lifter safety"

Meaning: One pallet is sticking out of the storage when trying to move the
pallet lifter up or down.
Action: Check why the pallet is sticking out and push it back in. Also a sheet
sticking out can activate this alarm.
71. "Pallet lifter: Chain is slack"

Meaning: The pallet lifter lifting chain is slack due to that the lifter is not
hanging freely.
Action: Find out what is causing the lifter to hang. Lift the pallet lifter in man-
ual menu
72. "Pallet lifter: Overload"

Meaning: Torque limit exceeded on pallet lifter = too much load.
Action: Check weight of the pallet lifted!
73. "Pallet chain: Overload"

Meaning: Torque limit exuded on pallet chain.
Action: Find out what is causing the overtorque.
74. "Suction cup unit: Overload"

Meaning: Torque limit exceeded on suction cup unit = too much load.
Action: Check weight of the sheet lifted!
75. "Error on operation GET PALLET: Error code=##"

Meaning: Error when getting a pallet, error codes:
• 01 No pallet found in front of lifter
The position was found empty.
• 02 Pallet not moved onboard lifter
Version 003 77
Either the sensor which indicates that a pallet is on the lifter is not
active, OR the sensor which indicates that a pallet is in front of the
lifter is still active.
• 03 Not used
• 04 No pallet exists at selected position
Position is configured as free in the database.
Action: -
76. "Error on operation LEAVE PALLET: Error code=##"

Meaning: Error when leaving a pallet, error codes:
• 01 Pallet move order not valid
The pallet moving order given is not valid.
• 02 A pallet already exists at position
A pallet already exists at position the position to where we want to
move the pallet.
• 03 Pallet not moved from lifter

Either the sensor which indicates that a pallet is on the lifter is still
active, OR the sensor which indicates that a pallet is in front of the
lifter is not active.
Action: -
77. "Unloading pallet is full"

Meaning: The unloading pallet currently used is full.
Action: The pallet must be emptied before further use.
78. Alarm not used
79. "Emergency stop"

Meaning: Emergency stop pressed.
Action: -
78 Version 003
The following alarms are for the inverters. The alarms 80-89, 90-99 and
100-109 are similar but for different axis. Therefore only the alarms 80-89 are
described here.
The most likely cause of the alarm is described here. For more information,
see manual “Siemens MicroMaster 440; Operating instructions".
80. " Pallet lifter inverter: General alarm=####"

Meaning: The pallet lifter inverter has an alarm other that those specified
hereafter. The alarm code refers to the Siemens inverter fault code list.
Action: Find out alarm meaning. See inverter manual.
81. "Pallet lifter inverter: Over current F0001

Meaning: The motor takes more current than specified in parameter P307.
Action: Check acceleration and current load on axis.
82. "Pallet lifter inverter: Over voltage F0002"

Meaning: Main supply voltage too high or a too fast deleleration.
Action: Check voltage and deceleration value.
83. "Pallet lifter inverter: Under voltage F0003"

Meaning: Main supply voltage too low or a shock load applied to the drive.
Action: Check voltage and current load on axis.
84. "Pallet lifter inverter: Powerstack fault F0022"

Meaning: Shock load applied to the drive.
Action: Check current load on axis.
85. "Pallet lifter inverter: CB setpoint fault F0070"

Meaning: No setpoint value from PLC even if “Enable” signal received.
Action: PLC <> inverter communication problems or PLC program error.
86. Alarm not used

87. Alarm not used
88. Alarm not used
89. Alarm not used
Version 003 79

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Pre-installation instructions .............................................................. 7

Electric power and air supply..................................................................... 7

Technical dimensions ................................................................................ 9

Unloading of machine from truck trailer ................................................... 10

Safety fences ........................................................................................... 13

General safety Information ............................................................. 15

Safety instructions ................................................................................... 16

Safety system .......................................................................................... 17

Description of function .................................................................... 19

Technical data ......................................................................................... 20

Main parts of the AS LUL300FO.............................................................. 21

Loading unit ......................................................................................... 21

Sheet separation ................................................................................. 22

Double sheet detector ......................................................................... 23

Unloading unit ..................................................................................... 23

Pallet changer unit ............................................................................... 24

Cutting pallet ....................................................................................... 25

Raw material and unloading pallet ...................................................... 26

Pin table .............................................................................................. 26

Operating console ............................................................................... 27

Function (automatic storage mode) ......................................................... 30

Loading of raw material ....................................................................... 30

Loading of raw material to FO laser (first sheet) ................................. 30

Loading of raw material to FO laser (second sheet) ............................ 30

Unloading/loading of following sheets to FO laser .............................. 30

Unloading of finished machined sheets from storage .......................... 30

Function (Pallet changer mode) ............................................................... 31

Loading of raw material to FO laser .................................................... 31

Unloading of machined sheets ............................................................ 31

Starting of the AS LUL300FO .................................................................. 33

Pause, safety/emergency stop and restarting ......................................... 33

Safety stop .......................................................................................... 33

Restarting the AS LUL300FO .............................................................. 33

Status bar ................................................................................................ 38

Terminal menus ....................................................................................... 39

Main menu for AS LUL300 FO ............................................................ 39

Automatic functions ................................................................................. 40

Material handling, get pallet ................................................................. 40

Material handling, edit & leave pallet ....................................................... 41

Loading of the pallets .......................................................................... 42

Job list input ............................................................................................. 44

Running storage mode ............................................................................ 46

Pallet changer mode................................................................................ 47

Ending automatic mode ........................................................................... 48

Manual functions ...................................................................................... 49

Manual main menu .............................................................................. 49

Pallet lifter ................................................................................................ 50

Pallet chain .............................................................................................. 51

Pallet changer .......................................................................................... 52

Loading unit 1/2 ....................................................................................... 53

Loading unit 2/2 ....................................................................................... 54

Unloading unit .......................................................................................... 55

User parameters .................................................................................. 57

Definition of user parameters .............................................................. 57

Autostop function ................................................................................. 58

Phone alarm ........................................................................................ 58

Data base ................................................................................................ 59

Database check ................................................................................... 59

Edit position ......................................................................................... 60

Installation parameters ........................................................................ 61

Stopping and shutting down the AS LUL300FO ...................................... 61

Daily check-ups and maintenance .......................................................... 63