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ELECTRICAL EQUIPMENT

SERVICE MANUAL – ALPHA SL 65S

Summary of Contents for ALPHA SL65 S

Page 1: ...For CNC machine tool peripherals it s LNS then all the rest ALPHA SL65 S BARFEED Service Manual 9 222 01 01 EN US...

Page 2: ...L SERVICE MANUAL ALPHA SL 65S IMPORTANT READ THIS MANUAL CAREFULLY BEFORE USING AND RETAIN FOR FUTURE REFERENCE Published 08 2020 LNS America 2020 9 222 01 01 EN V00 0 Service manual Printed in LNS Am...

Page 3: ...ANCHORING 23 PUSHER CHANGEOVER 24 SETTING AUTOMATIC MANUAL SEQUENCE 25 BAR FEEDER IN AUTOMATIC MODE 27 SWITCH THE BAR FEEDER INTO MANUAL SEQUENCE 28 MAGAZINE STOPPING FINGERS ADJUSTMENT 28 3 MECHANIC...

Page 4: ...4 INSPECTIONS 84 CHECK THE CONDENSATE COLLECTOR 85 CHECK LUBRICATOR 85 CLEANING 86 9 TECHNICAL CHARACTERISTICS 88 10 DISPOSAL 90 MACHINE 90 11 TROUBLESHOOTING 92 WARNING MESSAGES 92 ERROR MESSAGE MAP...

Page 5: ...GENERAL SERVICE MANUAL ALPHA SL 65S...

Page 6: ...d components from other manufacturers In the case of these components their respective manufacturers have carried out a risk assessment and have declared that their design is fully compliant with the...

Page 7: ...injury CAUTION Type and origin of danger Consequences of non compliance with the warning What to do to avoid danger Warnings of a potentially dangerous situation which if not avoided may cause minor...

Page 8: ...rection of use of the machine COPYRIGHT Any reproduction recording or distribution of all or part of this manual in any form or by any means mechanical photographic audio or other is strictly prohibit...

Page 9: ...interface or inside the electrical cabinet while the bar feeder or the lathe is powered on It is strictly forbidden to bridge or remove circuit breakers and main switches especially safety switches T...

Page 10: ...o the hoist The loading capacity of both the hoist and straps must be larger than 1 ton 3 Raise the hoist to tighten the straps 4 Remove the screws for holding the bar feeder to the pallet during tran...

Page 11: ...behind the spindle for service 1 Remove the safety sensor protector 2 and sensor 1 2 Screw the retraction system toward the bar feeder stand Notice the locking device must be placed toward the front o...

Page 12: ...es more space on the lateral direction 1 Remove the safety sensor protector 2 and sensor 1 2 Screw the retraction system toward the bar feeder stand Notice the locking device must be placed toward the...

Page 13: ...between the lathe and bar feeder should not exceed 20mm A dimension In the other words the bar stock length should not exceed spindle length BAR FEEDER WITHOUT RETRACTION SYSTEM BAR FEEDER WITH RETRAC...

Page 14: ...THOUT RETRACTION SYSTEM 1 Put the level gauge on the bar feeder stand 2 Loose 8 nuts A on the stand 3 Level the bar feeder by adjusting 8 screws B Turn the bolt clockwise until it touches against the...

Page 15: ...YSTEM 1 Verify that nuts A are locked to fixed stand 2 Put the level gauge on the bar feeder stand 3 Loose nuts B on the stand bottom plate 4 Turn screws C clockwise to lift counter clockwise to lower...

Page 16: ...YSTEM 1 Verify that nuts A are locked to fixed stand 2 Put the level gauge on the bar feeder stand 3 Loose nuts B on the stand bottom plate 4 Turn screws C clockwise to lift counter clockwise to lower...

Page 17: ...contacting plate C 2 Open the electrical cabinet Loose nuts A on both sides total 6 nuts 3 Adjust the bar feeder height by turning nuts B on each stand Note that nut D must be always locked and should...

Page 18: ...ould be fed into the center of lathe spindle 2 Move forward pusher out of bar feeder check its center and lathe spindle center carefully and then adjust bar feeder position until pusher center matches...

Page 19: ...osition The user has to prepare it on the bar feeder before installation Please follow the procedures below to install the magazine according to your bar feeder type BAR FEEDER WITHOUT RETRACTION SYST...

Page 20: ...SERVICE MANUAL ALPHA SL 65S 2 Mount the magazine stands Loose nut C Tilt the magazine by adjusting nut D Lock nut C after the adjustment is finished 3 Lock the magazine brackets by tightening screws p...

Page 21: ...PROCEDURES SERVICE MANUAL ALPHA SL 65S BAR FEEDER WITH X AXIS RETRACTION SYSTEM 1 Unlock the magazine brackets by loosing screws pointed Raise the brackets and then lock screws back 2 3 C D...

Page 22: ...llel with the bar feeder stand plates 5 Adjust nut G so that the magazine basement wheels J are able to contact with the ground Then lock nuts H 6 Loose nut C Tilt the magazine by adjusting nut D Lock...

Page 23: ...hor your bar feeder accordingly BAR FEEDER WITHOUT RETRACTION SYSTEM 1 Anchor the bar feeder at location A of each stand and location B of the magazine stands total 6 anchor spots BAR FEEDER WITH X AX...

Page 24: ...annel to lower position 2 Move the pusher to middle of the channel 3 Remove the lock pin 3 Take out the locking mechanism 1 and the pusher 2 from the pusher assembly 4 Insert the lock pin for fixing t...

Page 25: ...L TO 0 IN MANUAL MODE INFORMATION The following conditions must be met to complete this procedure The lathe is not in AUTOMATIC mode Channel at 15 position SQ3 ON Steps to raise the channel to 0 1 Pre...

Page 26: ...roperly set according to pneumatics electrics and mechanics according to bar stock dimension and machining conditions Steps to set automatic sequence 1 Manually move the lathe stopper to TOP CUT posit...

Page 27: ...pper A START signal arises 20 Closes the chuck according to the START signal 21 When postponed time set on P09 Chuck close is up pusher will retract back according to P04 P02 setup Move the stopper ba...

Page 28: ...lose Steps to switch the bar feeder into manual mode 1 Switch the bar feeder into MANUAL mode by pressing button 2 Switch the lathe to MANUAL mode WARNING Never open the lathe chuck when the bar feede...

Page 29: ...PROCEDURES SERVICE MANUAL ALPHA SL 65S...

Page 30: ...loading system consists of bar magazine loading fingers stopping fingers and the loading cylinders This system serves to storage and load bar stocks into the guiding channel In order to load the bar...

Page 31: ...transmission device and TOP CUT measuring switch With this system the servo motor drives the pusher forward and backward hence accomplish bar stock feeding LAYOUT OF THE ELEMENTS Designation Descripti...

Page 32: ...rket It guarantees accurate bar control and prevents them from hitting the turret This is called soft touch positioning Two working modes of Soft Touch positioning 1 Without a bar stop on the turret b...

Page 33: ...tion Note Short pusher First feed The movement inside bar feeder Long pusher TOP CUT The movement outside bar feeder Feeding during production Remnant ejection There are 3 different diameters of pushe...

Page 34: ...sequence 1 First feed 2 The V channel drops down 3 The V channel swings 4 The long pusher is able to move accordingly either in manual or automatic mode RAISE V CHANNEL This position serves to feed a...

Page 35: ...cking handles as shown in counter clockwise rotation 2 Adjust the knob according to bar stock diameter The upper index indicates inch and the lower index indicates mm Turn the knob clockwise to increa...

Page 36: ...he spindle when the spindle inner diameter is larger than the barstock The bar feed system is delivered without spindle liners Spindle liners must be purchased and installed by the customer WARNING A...

Page 37: ...MECHANICAL EQUIPMENT SERVICE MANUAL ALPHA SL 65S...

Page 38: ...ION To guarantee optimal operation of the bar feeder a minimum pressure of 5 bar 75 psi 500 kPa is mandatory LAYOUT OF THE ELEMENTS Designation Description 1 Channel swinging bar stock loading cylinde...

Page 39: ...adjusting knob by pushing it downward SOLENOID VALVE MANIFOLD DESCRIPTION The solenoid valve manifold serves to control the cylinders LAYOUT OF THE ELEMENTS INFORMATION The operating pressure should...

Page 40: ...ful during tests or maintenance When the key is released the pneumatic cylinder returns to its resting position except for pneumatic cylinders activated by double effect solenoid valve AIR PRESSURE SW...

Page 41: ...PNEUMATIC EQUIPMENT SERVICE MANUAL ALPHA SL 65S...

Page 42: ...that you believe is electrical contact LNS or a local representative SAFETY COMPONENTS These components are installed to ensure safe use of the bar feeder LAYOUT OF ELEMENTS Designation Description 1...

Page 43: ...sed NO contact will be engaged When the gird is open NO contact will be disengaged and e01 will arise Besides NC contact will be engaged sending signal to PLC input contact X27 and e32 will arise Once...

Page 44: ...n 3 Electrical cabinet QS1 Main disconnect switch M1 Servo motor M2 Motor for setting the diameter SQ1 Bar length measurement optical cell not shown SQ2 Pusher in reference position switch SQ3 Guiding...

Page 45: ...ELECTRICAL CABINET Designation Description PCB Printed Circuit Board PCB PLC Programmable Logic Controller PLC SA Servo amplifier K8 K9 Safety relay KS Relay QF2 24V DC power supply breaker PS 24V DC...

Page 46: ...ch power the transformer Designation Description 1 Input terminal block 2 Release power on button 3 Output terminal block K1 ELECTROMAGNETIC SWITCH K1 is energized by the emergency stop loop When the...

Page 47: ...d numerical keys SIGNAL DISPLAY AREAPLAY AREA CHUCK Indicates the lathe chuck is open closed when the LED is ON OFF START Indicates the START signal is ON OFF when the LED is ON OFF End of Bar Indicat...

Page 48: ...ameter setup page without changing the setting Use this key to validate a new parameter setting NUMERICAL KEY PADS Shown as and They serve to enter numbers or execute functions attributed to them 1 Wh...

Page 49: ...ency stop Rightward Move pusher rightward Only available when the bar feeder is in MANUAL mode Slow Rightward Move the pusher rightward with10 of the general forward speed Only available when the bar...

Page 50: ...vo motor status After powering up the screen shown left is displayed Press key to switch to the parameter screen as shown on the right In the parameter screen 3 selections are available 1 To access th...

Page 51: ...et Designation Description 1 I O connector 2 Encoder connector 3 Serial connector 4 1 phases 220 V input for controller invisible 5 3 phases 220 V input invisible 6 3 phases 220 V output for motor inv...

Page 52: ...0V AC to 480V AC see drawing below Then it can be transformed to 230 V AC shown on the secondary terminal Designation Description 1 Primary terminal block 2 Secondary terminal block ANALOG MODULE The...

Page 53: ...ddition the PLC powers HMI with 24V DC Designation Description 1 Input terminal All connected wires are labelled 2 Input terminal notation 3 Input signals indication LED Indicate the status of inputs...

Page 54: ...VICE MANUAL ALPHA SL 65S PCB PRINTED CIRCUIT BOARD PCB is a board with circuit printed and electrical components soldered on the surface It offers sockets and terminals for electrical components like...

Page 55: ...RY COMPONENTS These components carry out the instructions that are given by the control components motors hydraulic pump etc SERVO MOTOR The Servo motor controls the drive of the notched belt SENSORS...

Page 56: ...to the same position Wire connection 24 brown wire M blue wire 105 white wire Designation Description 1 Bar length measurement sensor SQ1 CONNECTIONS POWER SUPPLY Voltage 200 480 V 50 60 Hz Ground 10...

Page 57: ...s signal initiates feeding and bar change process of bar feeder by itself as well as combination with other signals The signal logic could be inverted by MODE 2 setup d Lathe alarm PLC input X12 termi...

Page 58: ...FIRST FEED The moment that SHORT pusher returns to the home position 2 The moment when the LONG pusher leaves the home position for TOP CUT The moment the LONG pusher stopped after arriving at TOP CU...

Page 59: ...ELECTRICAL EQUIPMENT SERVICE MANUAL ALPHA SL 65S...

Page 60: ...he bar feeder when it s in AUTOMATIC mode All the operation parameters could be changed according to the machining requirement To achieve the best performance It is strongly recommended to read this c...

Page 61: ...ut setup TOP Cut position measured from Top Cut measuring device SQ1 F0 P06 End of Bar setup The forward limit pusher moves to gauge the bar stock length left is enough for a complete workpiece accord...

Page 62: ...s an alarm if the feeding distance is smaller than this value when collet is open Safety setup Too long The maximum allowed feeding distance The bar feeder arises an alarm if the feeding distance is l...

Page 63: ...this setup on a value smaller than 5 00mm 0 20inch Part setup Chuck opens Ranging from 1 to 3 if a complete part must be divided into multiple feedings you can use this parameter to set chuck opening...

Page 64: ...is no rotating adapter between the pusher and the bar stock the pusher tip must not contact any rotating component or it will be damaged Below is the summary for those cases and their solutions Situat...

Page 65: ...f not Mode 8 1 bar will be positioned at the Top cut setup value INFORMATION TOP CUT is the process which cuts few millimeters off from a new bar stock tip for creating a precise positioning reference...

Page 66: ...ually push the pusher forward until it no longer move 4 Read the current position value showed on HMI 5 Use the value showed from HMI and minus a safety value 10 mm to set up on P06 6 Return to the or...

Page 67: ...must be set to 1620 and should never be changed Loading flag rapid distance The distance between short pusher and limiter This setup can shorten the time of FIRST FEED Move short pusher forward to loa...

Page 68: ...uring dry run state If conditions pusher is at home position with SQ2 ON guiding channel is at 15 position with SQ3 ON Top cut sensor SQ1 is OFF are satisfied set P10 dry run ON So bar feeder will swi...

Page 69: ...e bar stock will be pushed to and waits that the bar feed has pushed the material to this point 1 The turret is moving to position The turret comes to the bar stock end the bar feed starts pushing aga...

Page 70: ...protected Please contact LNS or its official agent in your country for getting technical support in case any modification is needed ACCESSING After selecting the service parameters by pressing F1 as s...

Page 71: ...the START signal MODE 11 Y06 EOB Signal Output Type Define when will output the End of Bar signal MODE 12 Application Setup Eject with pusher Define when the remnant will be ejected by pusher MODE 13...

Page 72: ...gnal A2 is ON when lathe is in auto mode i e receiving A2 for allowing all pushing forward actions 1 Lathe in auto signal A2 is OFF when lathe is in auto mode i e receiving A2 for not allowing all pus...

Page 73: ...other words receiving A4 signal for not allowing pusher to feed bar stock forward Note If there s no A4 signal from Lathe please set the Mode to 1 MODE 6 This parameter intentionally left blank MODE 7...

Page 74: ...ot Once the check is activated bar feeder will count the times of chuck signal If the chuck signal is turned ON OFF for 3 cycles but bar feeder is still in manual mode alarm e11 will arise This setup...

Page 75: ...signal Start 1 After sending the End of Bar signal push forward to touch lathe stopper bar feeder will send Start signal to inform the lathe move backward the stopper Start 2 Similar to Start1 after...

Page 76: ...open until a new bar is fed into the lathe End of Bar 2 When lathe chuck is close calculate and keep sending the End of Bar signal until pusher returns to the home position SQ2 End of Bar 3 When lath...

Page 77: ...is open Eject with new bar New bar stock pushes remnant out of lathe chuck After sending the End of Bar signal and loading a new bar the new bar will push out remnant when lathe chuck is open Sub Spin...

Page 78: ...ivated range 100 2500 RPM The FIRST FEED speed to P08 forward limit when TOP CUT switch SQ1 detects the bar The speed which long pusher feeding bar stock from home position to P05 Speed 3 Default 3000...

Page 79: ...e struggle to push them through the lathe chuck To solve this problem the bar feeder offers a function called INCHING The function INCHING consists of 2 actions 1 Move the pusher back and forth repeat...

Page 80: ...in the lathe and press auto ready and auto start keys to enter the automatic mode delay Too short checking after how many parts are completed when feeding to TOP CUT position in automatic mode This n...

Page 81: ...eck Magazine empty TOP CUT position 4 During automatic mode and each time chuck opens the pusher will stop moving forward after feeding a workpiece and send out START signal to lathe 5 During automati...

Page 82: ...er forward before switching bar feeder to automatic mode by pressing button AUTO START When bar feeder is in automatic mode the rear end position of bar stock is read from the current position of push...

Page 83: ...TERS SERVICE MANUAL ALPHA SL 65S MODE 25 A7 Door Invert Define lathe door action when receiving lathe door signal 0 Lathe door signal is ON when lathe door is open 1 Lathe door signal is OFF when lath...

Page 84: ...plug and shut off the air supply before removing the cover Never operate the machine without having reinstalled the safety guards in terms of the maintenance work INSPECTIONS Component Maintenance op...

Page 85: ...nsumption varies with the bar feeder applications The oil height should not exceed half of the oil cup It is recommended to use oil ISO VG 32 only When the oil is less than 30 follow the procedures be...

Page 86: ...nd the rollers and other elements made of synthetic material Also take care to avoid any contact between the cleaning products and electrical components NOTICE Risk of damage to the machine It is stro...

Page 87: ...MAINTENANCE SERVICE MANUAL ALPHA SL 65S...

Page 88: ...s Option 23 6 in 600mm Minimum diameter 0 236 in 6 mm Maximum diameter 2 625 in 67 mm Minimum bar stock length 12 in 300 mm Maximum bar stock length 61 0 in 1550 mm Maximum permitted bar weight 95 lb...

Page 89: ...TECHNICAL CHARACTERISTICS SERVICE MANUAL ALPHA SL 65S...

Page 90: ...er disposal of the machine can cause serious harm to the environment Deposit the machine at a recycling collection point Also inquire about local departments in charge of recycling Procedure 1 Clean t...

Page 91: ...DISPOSAL SERVICE MANUAL ALPHA SL 65S...

Page 92: ...y close main cover Magazine cover CE switch SQ11 is separated from sensor block Manually close magazine protection cover Optional retraction device does not lock Lock retraction device After powering...

Page 93: ...ill open Close lathe chuck and then switch to auto mode Press before moving pusher forward to exceed P08 forward limit Push forward to exceed P08 setup position and return to home position Then press...

Page 94: ...TROUBLESHOOTING SERVICE MANUAL ALPHA SL 65S Status remind when the feeder is at 0 for loading a new bar stock and Mode 7 1...

Page 95: ...he P07 e23 No Yes Pusher returns to home position e 10 e18 Load a new bar e15 First feed e2 e7 e9 e10 e17 e25 Send R5 to CNC optional Short pusher returns to home position e14 e18 Long pusher feeds to...

Page 96: ...ut only K9 is OFF bar feeder does not receive lathe door close signal If both K8 and K9 are both OFF check the circuit 3 Check if the emergency stop on remote control STP1 was pressed If it is please...

Page 97: ...and test the signal again Check if start loading signal on the lathe is activated If not activate it 10 Lathe collet is not open This alarm is activated either one of the followings The chuck signal...

Page 98: ...Forward Limit The pusher fails to advance bar stock at a part length when the chuck is opened during machining Check the pushing force and adjust P03 Torque accordingly if the bar stock is not advance...

Page 99: ...Check if ejection position is too small and adjust it 23 Remnant ejection time exceeded After chuck is open pusher fails to exceed remnant ejection position in 15 seconds Check if the remnant blocked...

Page 100: ...king position The retraction is not locked This alarm only is available when installing retraction device safety switch Lock retraction device If retraction device is already locked check if the switc...

Page 101: ...TROUBLESHOOTING SERVICE MANUAL ALPHA SL 65S SEQUENCE LISTING...

Page 102: ...TROUBLESHOOTING SERVICE MANUAL ALPHA SL 65S...

Page 103: ...over high AL017 Memory error EE PROM write in and read out is in error AL018 Encoder output error The encoder output exceeds the rated output frequency AL019 Serial communication error RS232 485 commu...

Page 104: ...manual to reconnect wiring IGBT error Heat sink overheated Please contact your distributor for assistance or contact with Delta Control parameter setting error Check if the setting value exceeds the f...

Page 105: ...estarting the servo drive Potential Cause Checking Method Corrective Actions Encoder is damage Check Encoder for the damage Repair or replace the motor Encoder is loose Examine the Encoder connector I...

Page 106: ...eed Clearing Method Turn ARST DI signal ON to clear the fault or restart the servo drive Potential Cause Checking Method Corrective Actions Speed input command is not stable too much fluctuation Use s...

Page 107: ...otential Cause Checking Method Corrective Actions The wiring of encoder is in error 1 Check if all wiring is correct 2 Check if the users conduct the wiring by the wiring information in the user manua...

Page 108: ...Modify parameter setting and re estimate motor capacity AL015 Forward CCWL limit switch error Clearing Method Turn ARST DI signal ON to clear the fault This fault message can be removed when the servo...

Page 109: ...of hidden parameter is in error Press SHIFT key on the drive keypad and examine if E100X is displayed on LED display If this fault occurs when resetting the parameter settings it indicates that the s...

Page 110: ...cable is loose or broken Tighten the communication cable make sure the communication cable is not damaged and ensure all wiring is correct AL021 Reserve AL022 Input power phase loss Clearing Method Tu...

Page 111: ...g Method This fault message can be removed by restarting the servo drive Potential Cause Checking Method Corrective Actions The internal memory of the encoder is in error An encoder counter error occu...

Page 112: ...does not clear after all the above actions are done please contact your distributor for assistance or contact with Delta AL027 Motor internal error Clearing Method This fault message can be removed by...

Page 113: ...s not clear after all the above actions are done please contact your distributor for assistance or contact with Delta AL029 Motor internal error Clearing Method This fault message can be removed by re...

Page 114: ...llow the wiring steps in the user manual to reconnect the wiring and ground the servo drive and motor properly The ground connection is loose or not conducting properly Check if the ground connection...

Page 115: ...the environment temperature is too high Try to reduce environment temperature AL099 DSP firmware upgrade Clearing Method This fault message can be removed after setting P2 08 to 30 first and then 28 n...

Page 116: ...TROUBLESHOOTING SERVICE MANUAL ALPHA SL 65S PLC INPUTS OUTPUTS...

Page 117: ...TROUBLESHOOTING SERVICE MANUAL ALPHA SL 65S...

Page 118: ...ded you have DropBox downloaded to your smartphone If you do not have the DropBox app it s a free app and can be downloaded on your Smartphone quickly Below are steps to retrieve information from the...

Page 119: ...select Go Point your smartphone at the QR code to be recognized STEP 2 STEP 3 When you hit Go you will see this screen Tap on the file name in the box STEP 4 Select the arrow in the top right hand cor...

Page 120: ...OUBLESHOOTING SERVICE MANUAL ALPHA SL 65S AFTER SALES SERVICE Customer Service Service BFsupport LNS northamerica com Customer Service Parts BFparts LNS northamerica com Phone 513 528 5674 Fax 513 528...

Page 121: ...TROUBLESHOOTING 121 SERVICE MANUAL ALPHA SL 65S...

Page 122: ...PLC controls the machine s operation Shaft Steel bar for supporting rotating elements or to transfer power SD card Removable memory card Secure Digital Informed persons Persons sufficiently informed o...

Page 123: ...APPENDICES 123 SERVICE MANUAL ALPHA SL 65S WIRING DIAGRAM BSL65 A8...

Page 124: ...124 APPENDICES SERVICE MANUAL ALPHA SL 65S...

Page 125: ...APPENDICES 125 SERVICE MANUAL ALPHA SL 65S...

Page 126: ...126 APPENDICES SERVICE MANUAL ALPHA SL 65S...

Page 127: ...APPENDICES 127 SERVICE MANUAL ALPHA SL 65S...

Page 128: ...128 APPENDICES SERVICE MANUAL ALPHA SL 65S PNEUMATIC DIAGRAM...

Page 129: ...m fill it out in its entirety and send it back to your nearest LNS reseller or retailer Company name Person in charge Address ZIP City Country Phone Fax Type of device Serial number Qty Ordering no De...

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