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LNS Alpha 538, Instruction Manual

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CHAPTER 9: MALFUNCTIONS 

9-6 

 

  ALPHA 538/552 

 
 

AL13: Safety time for part feed out elapsed! 

 
Description 

This alarm is generated when the bar feeder has 
not received any clamping device closing signal 
within the determined timeframe (approx. 30s.). 

 
Solutions 

Check the presence of the closing signal. 
Check the closing of the clamping device. 
Check the wiring of the signal A1. 

 

 

 

 

AL14: Part feed out too long! 

 

Description 

The part feed out is too long. 
 

Solutions 

Check the part length value in parameter P02. 

 

 

 

 

AL15: Part feed out too short! 

 
Description 

The part feed out is too short. 

 
Solution 

Check if a delay is set on the lathe clamping 
device. 
 

 

 

 

 

Summary of Contents for Alpha 538

Page 1: ...For CNC machine tool peripherals it s LNS then all the rest ALPHA 538 552 BARFEED Instruction Manual 9 X51 01 US...

Page 2: ......

Page 3: ...OUT OF THE ELEMENTS 2 4 CHAPTER 3 SETTING INTO OPERATION 3 1 1 TRANSPORTATION 3 2 2 MOUNTING 3 5 3 ANCHORING TO THE GROUND 3 6 4 ELECTRICAL CONNECTIONS 3 7 5 PNEUMATIC CONNECTIONS 3 8 6 HYDRAULIC CONN...

Page 4: ...EMNANT EXTRACTION SYSTEM 7 12 7 PNEUMATIC FRONT REST 7 14 8 RETRACTION DEVICE 7 16 CHAPTER 8 OPERATION 8 1 1 CONTROLS 8 2 2 POWERING ON 8 5 3 EMERGENCY STOP BUTTON 8 6 4 AUTOMATIC SEQUENCE 8 7 5 OPERA...

Page 5: ......

Page 6: ...CHAPTER 1 BASIC NOTIONS 1 1 ALPHA 538 552 CHAPTER 1 BASIC NOTIONS...

Page 7: ...lease refer to the chapter on the device to be set for example see chapter or see point 1 2 Captions Whenever possible the reference numbers contained in the instruction manual are shown with the LNS...

Page 8: ...d its subsidiaries cannot be made responsible for the debts losses expenses or damage incurred or suffered by the buyer of this product or a third party following an accident incorrect use or misuse o...

Page 9: ...2007 Safety of machinery Risk assessment EN 12100 1 2 2004 Safety of machinery Basic concepts principles EN 13857 2008 Safety of machinery Safety distances to prevent hazard zones being reached by up...

Page 10: ...and especially safety switches to conduct normal operation To avoid any harm to persons or damage to components use only the recommended locations points for lifting and moving the machine No one sho...

Page 11: ...ks can come from o machine in which the device ALPHA 538 552 is integrated o its association with other equipment o People s interaction with the machine Evaluate and assess the risks associated by us...

Page 12: ...CHAPTER 2 TECHNICAL DATA 2 1 ALPHA 538 552 CHAPTER 2 TECHNICAL DATA...

Page 13: ...diameter ALPHA 538 42 mm ALPHA 552 52 mm Minimum bar stock length 1000mm Maximum bar stock length 3200 mm 3800 mm 4200 mm Minimum remnant length 90 mm Maximum remnant length 400 mm Pneumatic pressure...

Page 14: ...CHAPTER 2 TECHNICAL DATA 2 3 ALPHA 538 552...

Page 15: ...drive with Smart Power Booster C Remnant retract device D Hydraulic tank with remnant tray E Main switch F Electrical cabinet H Main access cover I Pneumatic front rest J Loading ramp K Bar length mea...

Page 16: ...CHAPTER 3 SETTING INTO OPERATION 3 1 ALPHA 538 552 CHAPTER 3 SETTING INTO OPERATION...

Page 17: ...st be observed in order to prevent any injuries to persons and damages to objects These instructions are stapled to the crate of the bar feeder 1 1 Unpacking For practical and safety reasons the bar f...

Page 18: ...ed as follows A pusher and guiding elements set is mounted in the bar feeder A Depending on the purchase order other sets may be delivered in a separate box The remote control B and the interface plug...

Page 19: ...remove the pallet Ensure that the bar feed system is balanced Move the bar feeder taking care that it remains horizontal and that no one is nearby or under the suspended load Do not knock the bar feed...

Page 20: ...he weight of the bar feeder is evenly distributed over the 12 support points Loosen the nuts and locking screw D and make sure that the central screws C of the front and rear feet are supported Open t...

Page 21: ...round to make it stable To accomplish this 8 anchorage points A have been provided 8 anchorage bolts B must be furnished by the client min M10 x 100 mm 1 2 x 4 Once the anchoring bolts are tightened c...

Page 22: ...ith their own thermal protection systems breakers thermal relays and fuses etc The power supply for the bar feeder should be connected to the output of a breaker mounted in the electrical control box...

Page 23: ...g enough to allow the complete travel 500 mm of the retraction system When the hose is connected it should not lie on the ground because it could become damaged 1 Insert the hose B in the pneumatic co...

Page 24: ...gs The pressure is constantly monitored by a pressure switch set at the factory at a point of release of 0 5 bar It may be adjusted if necessary Refer to chapter 6 section 2 2 for setting instructions...

Page 25: ......

Page 26: ...CHAPTER 4 ELECTRICS 4 1 ALPHA 538 552 CHAPTER 4 ELECTRICS...

Page 27: ...tive 1 1 Description The electrical parts of the bar feeder as well as the diagrams representing them conform to the CEI 204 1 EN 607 international electrical codes This chapter contains all of the el...

Page 28: ...9 K0 15 Hydraulic pressure switch SQ 1 B18120401 4m Positioned stop SQ 2 B18120400 Home position SQ 3 C11111100 Guiding channel in open position switch SQ 4 C11111100 Guiding channel in closed positio...

Page 29: ...al equipment must only be performed by qualified personnel During the installation ensure that the motor is wired in accordance with the supply voltage available The supply voltage of the bar feeder i...

Page 30: ...4110200 Safety relay CE version DCS version K9 B24110200 Safety relay DCS interface K10 4 932 Additional contactor Optional for DCS version AJ1 B14120101 Servo drive amplifier F3 Reserved KA1 Reserved...

Page 31: ...t breaker QM1 interrupts the 3 phases which power the hydraulic motor If the motor requires excessive power the circuit breaker activates and push button C STOP is released For safety reason the power...

Page 32: ...uption reset the lever B of the circuit breaker 5 Transformer 220 V T1 If the power supplied by the interface cable does not meet the required 220V AC the transformer must be used The incoming power m...

Page 33: ...for the low voltage circuit 7 PCB Printed Circuit Board PCB is a board with circuit printed and electrical components welded on the surface It offers sockets and terminals for electrical components li...

Page 34: ...ither power is connected to the servo drive OR a residual charge is present in the drive s internal power components DO NOT TOUCH ANY ELECTRICAL CONNECTIONS WHILE THIS LED IS LIT B LED display Display...

Page 35: ...y scrutinizes all data from the remote control probes switches cells interface etc The program loaded into the PLC manages this information The PLC then distributes the interface signals controls the...

Page 36: ...pneumatic type X15 SQ4 Guiding channel closed Y15 YV9 Inserting clutch X16 Not in use Y16 YV10 Bar insert extract X17 SQ6 Vice system Y17 YV11 2nd front rest on headstock option X20 SQ11 Main cover sa...

Page 37: ...CHAPTER 4 ELECTRICS 4 12 ALPHA 538 552 3 ELECTRICAL DIAGRAMS...

Page 38: ...CHAPTER 4 ELECTRICS 4 13 ALPHA 538 552...

Page 39: ...CHAPTER 4 ELECTRICS 4 14 ALPHA 538 552...

Page 40: ...CHAPTER 4 ELECTRICS 4 15 ALPHA 538 552...

Page 41: ...CHAPTER 4 ELECTRICS 4 16 ALPHA 538 552...

Page 42: ...CHAPTER 4 ELECTRICS 4 17 ALPHA 538 552 TP04 Asia market...

Page 43: ...feeder and the lathe are provided by LNS The diagram for the interface corresponding to your device essential when making the electrical connection is located inside the electrical cabinet When makin...

Page 44: ...he lathe shall be powered by the 24 V DC of the lathe For the other types of connections please contact LNS S A or their local representative b EMERGENCY STOP signal of lathe XT8 XT9 This signal is pa...

Page 45: ...ode relay This signal is present as soon as the bar feeder is in automatic cycle Aut Start d Emergency stop button of the bar feeder EM1 EM2 When the Emergency Stop button is pressed the contact opens...

Page 46: ...CHAPTER 5 PNEUMATICS 5 1 ALPHA 538 552 CHAPTER 5 PNEUMATICS...

Page 47: ...ch engaging Smart booster additional force at material insertion and extraction Front rest opening closing with Air blast To guarantee an optimal operation of the bar feeder a minimum pressure of 5 ba...

Page 48: ...ossible clean and dry 2 2 Layout of the elements 2 3 Settings 1 Unlock the adjusting knob by pulling it upward 2 To increase the pressure turn it clockwise To decrease it turn it in the opposite direc...

Page 49: ...evice YV2A C11110210 Guiding channel opening YV2B Guiding channel closing YV3 C11110100 Guiding Channel locking YV4 C11110100 Material clamping YV5 C11110100 Material loading bar selection YV6 C111101...

Page 50: ...e range on screw B 17 Valves Contact your LNS agent for further safety information before proceeding to any operation on the valves By pressing the button A the cylinders can be activated manually Thi...

Page 51: ...he condensate is found inside the collector drain the condensate by pushing the plug upward and check the humidity control system 2 Check lubricator The oil consumption varies with the bar feed system...

Page 52: ...CHAPTER 5 PNEUMATICS 5 7 ALPHA 538 552 5 PNEUMATIC DIAGRAMS...

Page 53: ...CHAPTER 5 PNEUMATICS 5 8 ALPHA 538 552...

Page 54: ...CHAPTER 5 PNEUMATICS 5 9 ALPHA 538 552...

Page 55: ...CHAPTER 5 PNEUMATICS 5 10 ALPHA 538 552...

Page 56: ...CHAPTER 6 HYDRAULICS 6 1 ALPHA 538 552 CHAPTER 6 HYDRAULICS...

Page 57: ...s contained in the machine itself Aspirated by a pump motor it is injected into the front rest and the guiding blocks A pressure switch measures the pressure at the outlet of the pump A level allows t...

Page 58: ...B By turning clockwise the release of the pressure switch will take place at a pressure higher than the original setting Turning in the opposite direction will produce the reverse PLC input X12 will...

Page 59: ...will be pumped into the hydraulic system These substances will damage the pump the guiding channel or even bar stock Therefore depends on the bar feed system running status it is recommend to drain a...

Page 60: ...CHAPTER 7 OPERATION 7 1 ALPHA 538 552 CHAPTER 7 GENERAL DESCRIPTION...

Page 61: ...er the stopper rolls over the dropping fingers while the fingers move down The bar is placed into the guiding elements ready to be moved into the spindle 1 2 Layout of the elements Designation Descrip...

Page 62: ...etting the loading ramp handle to the correct diameter 1 Unlock the side handle A completely so that the setup handle B can be moved 2 Move the setup handle B to the desired diameter range correspondi...

Page 63: ...uiding zone The bar is pushed into the spindle then the system closes and is locked in closed position The system will remain until a remnant is evacuated or a new bar is loaded Hydraulic oil is injec...

Page 64: ...1 A004A xx 6x X51 31 A005A xx 4M Left to Right X51 31 A215A xx Right to Left X51 31 A215A xx 10x X51 31 A004A xx 7x X51 31 A005A xx Long pusher 1834mm Barfeed Length Kit of Guiding Elements Separated...

Page 65: ...ng them up B Remove all the upper elements by pressing the button of the Quick Change system C Turn the locks in the way shown on the picture then slide the upper and lower elements out of the front r...

Page 66: ...ed into the guiding zone The loading flag A which is connected to the servo drive through the chain moves the bar stock into the spindle When the bar is out of interference the loading flag retracts t...

Page 67: ...031 174 15053 22 xx xx 23 052 015 264 052 015 1354 015 031 013 15 24 052 015 274 052 015 1364 015 031 013 15 25 052 015 284 052 015 1374 015 015 814 052 015 994 052 015 984 15053 25 xx xx 26 052 015 2...

Page 68: ...fixed type lathe 3 6 Telescopic tube sliding headstock The telescopic tube can extend and retract It s designed specifically for Swiss type lathe since the spindle is sliding during the part feed out...

Page 69: ...of the sliding headstock and replicate them to the pusher This prevents the small bar stock to be bent during the spindle movements 4 1 Layout of the elements Designation Article No Description A B16...

Page 70: ...hile adjusting the Chain remains under tension in order not to lose the reference point Should the reference point be lost call for service assistance Procedure Switch the bar feeder to STOP mode remo...

Page 71: ...ar feeder Independently of the material the diameter or the bar profile the clamping jaws are invariably the same and do not require any adjustment The vise of the ALPHA 552 bar feeder allows the extr...

Page 72: ...ng screws and remove the worn out clamping blades A 2 Install the new blade according to the drawing below and secure them with the fastening screws Designation Article No Description A X51 22 P010C R...

Page 73: ...ntains 2 guiding elements C The pneumatic front rest is supplied with oil during the whole automatic cycle At the front the oil is collected by centrifugal effect An air blast B located just before th...

Page 74: ...ir blast position because it hits the guiding elements open the front rest by activating the front rest in manual mode Parameters User F0 Functions F3 PgDn Down activate function F0 Now you can easily...

Page 75: ...aintenance To facilitate these tasks the ALPHA 538 552 can be equipped with a retraction system which allows the operator to move the bar feeder The rigidity of the system guarantees a perfect alignme...

Page 76: ...CHAPTER 8 OPERATION CHAPTER 8 OPERATION...

Page 77: ...CHAPTER 8 OPERATION 8 2 ALPHA 538 552 1 CONTROLS 1 1 Remote control The remote control offers a touch screen display and buttons for operating the bar feed system when it s in MANUAL mode 1 2 Display...

Page 78: ...mode To switch to AUTOMATIC ready mode one of the following conditions must be fulfilled The channel is closed and the pusher is NOT at home position OR The channel is open and the pusher is at home p...

Page 79: ...ial and the pusher retracts hence the material is removed from the finger chuck The channel opens To operate this button the following conditions must be fulfilled The bar feeder is in MANUAL mode The...

Page 80: ...m the beginning The PLC reads signals from sensors and gives the operator allowable operations only Notice Do not change the pusher position when bar feeder is powered OFF If it s found the position r...

Page 81: ...y The 3 phases 220V AC to servo amplifier is interrupted All the output signals of PLC are interrupted except Y20 input signal of relay R1 An alarm e01 is arising at HMI When the emergency situation i...

Page 82: ...he channel open button Press the channel close button to measure the bar The bar feeder advances the bar stock to TOP CUT position Switch the bar feeder into AUTOMATIC mode Switch the lathe into AUTOM...

Page 83: ...on 5 1 Accessing and editing parameters After selecting the operation parameters the following screen will be displayed 5 2 Part setup parameters Part setup Diameter Length Bar diameter This parameter...

Page 84: ...nings during the machining of one part Used to prevent undesired part feed out during clamping opening Part setup Alarm headstock reverse If the bar stock goes backwards when the lathe clamping device...

Page 85: ...is adjusted as closely as possible behind the clamping system of the lathe approximately 5 mm or a 1 4 behind the chuck jaws or collet pads This will provide minimum bar stock remnant Regardless of t...

Page 86: ...uxiliary end of bar Depending on the lathe and its options the auxiliary end of bar may be used in several ways for example for the opening of an external rest The procedure is the same as this for th...

Page 87: ...sc parameters Misc Unit Allows to choose units of measure Misc Functions Unload bar stock Dry run and front rest setup functions are available on this screen Misc Function Unload bar stock Unload bar...

Page 88: ...sed positions 5 8 Service parameters Password protected only for trained technician Service Main screen Main screen SERVICE Bar feeder setup Defines the Bar feeder length and loading position SERVICE...

Page 89: ...rest on the pusher during machining Front rest opening is synchronized with lathe clamping device opening This parameter reduces vibrations SERVICE Bar feeder setup Feed out safety tolerance Tolerance...

Page 90: ...5 ALPHA 538 552 SERVICE Feed rate Feed rate values SERVICE Feed rate 2 Feed rate values SERVICE Options setup Defines the front rest type if the bar feeder uses a synchronization system and allows to...

Page 91: ...pulsed for 2 seconds PI16 R2 to confirm top cut only top cut M code PI17 R3 signal latches at End Of Bar yes no PI18 R3 turns on at EOB and turns off at Loading Start Clamping Opening PI19 R3 turns o...

Page 92: ...ode for machining Simulation Only for shows Simulate machining process without bar stock Test interface mode Cycle to test the interface 5 9 HELP To reach the Help menu press the STOP button then pres...

Page 93: ...PERATION 8 18 ALPHA 538 552 HELP Inputs Shows Inputs and their status Grey not active Red active HELP Outputs Shows Outputs and their status Grey not active Red active HELP End of bar Cycles Number of...

Page 94: ...he loading finger moves forward and pushes the bar stock in measuring position The bar length is measured 3 The loading finger goes on to maximal forward position and inserts the bar stock in the spin...

Page 95: ...CHAPTER 8 OPERATION 8 20 ALPHA 538 552...

Page 96: ...CHAPTER 9 MALFUNCTIONS 9 1 ALPHA 538 552 CHAPTER 9 MALFUNCTIONS...

Page 97: ...e STOP button on the remote control to reset the alarm AL02 Main cover access open Description The PLC does not detect input X20 SQ11 The problem is generated when the main access cover on the bar fee...

Page 98: ...OP button on the remote control to reset the alarm AL05 Air pressure failure Description The PLC does not detect input X11 SP1 after a period of 5 seconds The problem is generated anytime air pressure...

Page 99: ...hanism Press the STOP button on the remote control to reset the alarm AL08 SQ4 switch failure during the channel closing Description This alarm is generated whenever the PLC does not receive the signa...

Page 100: ...he AL12 Safety time for loading elapsed Description This alarm is used for the bar stock move in top cut position The profiled bar stock moves until the back of the clamping device Then the spindle ru...

Page 101: ...ned timeframe approx 30s Solutions Check the presence of the closing signal Check the closing of the clamping device Check the wiring of the signal A1 AL14 Part feed out too long Description The part...

Page 102: ...parameter is equal to the travel of the headstock and not the finished part length Check the collet on the pusher May be broken or worn or the incorrect size Check to see if the pusher got jammed in t...

Page 103: ...25 SQ16 is not detected after the bar has been extracted from the collet of the bar feed Before the guiding channel opens to load a new bar the remnant check device confirms that the remnant has been...

Page 104: ...feeder AL23 Remnant too long Description This alarm is generated whenever the remnant is too long to be ejected Solution Check the bar feed parameters and adjust the remnant length AL24 Top cut posit...

Page 105: ...2 AL25 Automatic front rest failure Description Automatic front rest failure Solutions Check SQ13 AL26 Loading or unloading cycle interrupted Description Loading or unloading cycle interrupted AL27 Le...

Page 106: ...OFF SQ15 X24 ON AL31 Booster clutch failure during disengagement Description Default during decoupling SQ14 signal is missing Solutions Check that there s no mechanical problem and check the SQ14 prob...

Page 107: ...m the collet of the bar feed Before the guiding channel opens to load a new bar the remnant check device confirms that the remnant has been extracted from the collet of the bar feed Solutions Check th...

Page 108: ...P button on the remote control to reset the alarm Verify any mechanical obstacle preventing the bar stock to feed out Verify the bar stock diameter It must correspond to the entered value in the param...

Page 109: ...perfect It is essential that the alignment of the bar feeder is done in accordance with the instructions indicated in Chapter 3 Setting into operation Spindle length In some cases the length of the sp...

Page 110: ...material It is recommended to install a bushing inside the clamping device with the same inside profile 0 2 mm as the bar The rear of this collet and the front of the bars should be flat During the l...

Page 111: ...to the SERVO amplifier 3 4 Mechanics Rotating sleeves In order to guarantee the correct operation of the bar feeder the rotating sleeve must function perfectly Although the construction of the sleeve...

Page 112: ...CHAPTER 10 APPENDICES 10 1 ALPHA 538 552 CHAPTER 10 APPENDICES...

Page 113: ...TURRET TO FEED OUT POSITION N CLOSE COLLET N END OF BAR CHECK PROGRAM JUMP N START SPINDLE N CLOSE COLLET N COLLANT ON N CLEAR TURRET N TOP CUT MATERIAL N N N PART PROGRAM N END OF SUB PROGRAM N X Z...

Page 114: ...be photocopied duly filled out and returned to your retailer or nearest LNS agent Company name Person in charge Address ZIP City Country Phone Fax Type of device Serial number Qty Ordering no Descript...

Page 115: ...DICES 10 4 ALPHA 538 552 3 LNS WEB ADDRESSES Please find an always up to date list of your representatives for your region under LNS Europe www lns europe com LNS America www lns america com LNS Asia...

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