LNS Sprint 545 S2 Instruction Manual Download Page 3

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SPRINT 545/565 S2

V2.0

TABLE OF CONTENTS

CHAPTER 1 : BASIC PRINCIPLES .................................................................. 1-1

STRUCTURE ......................................................................................................................... 1-2

RIGHTS ................................................................................................................................. 1-3

SAFETY REQUIREMENTS ................................................................................................... 1-5

SAFETY DEVICES ................................................................................................................ 1-6

CHAPTER 2 : TECHNICAL DATA .................................................................... 2-1

CHARACTERISTICS............................................................................................................. 2-2

FLOOR PLAN ........................................................................................................................ 2-3

LAYOUT OF THE ELEMENTS ............................................................................................. 2-5

CHAPTER 3 : SYSTEM START UP .................................................................. 3-1

TRANSPORTATION ............................................................................................................. 3-2

ASSEMBLY ........................................................................................................................... 3-5

ANCHORING ......................................................................................................................... 3-6

CONNECTIONS .................................................................................................................... 3-6

CHAPTER 4 : ELECTRICS ................................................................................ 4-1

ELECTRICAL EQUIPMENT .................................................................................................. 4-2

ELECTRICAL CABINET ....................................................................................................... 4-6

INTERFACE DIAGRAM ...................................................................................................... 4-15

INTERFACE ........................................................................................................................ 4-16

CHAPTER 5 : PNEUMATICS ............................................................................ 5-1

PNEUMATIC EQUIPMENT ................................................................................................... 5-2

AIR HANDLING ..................................................................................................................... 5-3

PNEUMATIC BATTERY ....................................................................................................... 5-4

CHAPTER 6 : HYDRAULICS ............................................................................. 6-1

HYDRAULIC EQUIPMENT ................................................................................................... 6-2

HYDRAULIC ELEMENTS ..................................................................................................... 6-4

CHAPTER 7 : GENERAL DESCRIPTION ......................................................... 7-1

BAR MAGAZINE ................................................................................................................... 7-2

GUIDING BLOCKS ............................................................................................................... 7-3

PUSHER ................................................................................................................................ 7-6

BELT DRIVE .......................................................................................................................... 7-9

REMNANT EXTRACTION SYSTEM (option) .................................................................... 7-10

FRONT REST ...................................................................................................................... 7-12

RETRACTION DEVICE (option) ........................................................................................ 7-14

2-POSITION OPTION .......................................................................................................... 7-15

AUTOMATIC FRONT REST (option) ................................................................................. 7-16

10.

2-POSITION PNEUMATIC FRONT REST (option) ........................................................... 7-17

Summary of Contents for Sprint 545 S2

Page 1: ...LNS SA CH 2534 Orvin www LNS group com Instruction Manual ENG Sprint 545 565 S2 9 545 01 ANG...

Page 2: ......

Page 3: ...1 1 ELECTRICAL EQUIPMENT 4 2 2 ELECTRICAL CABINET 4 6 3 INTERFACE DIAGRAM 4 15 4 INTERFACE 4 16 CHAPTER 5 PNEUMATICS 5 1 1 PNEUMATIC EQUIPMENT 5 2 2 AIR HANDLING 5 3 3 PNEUMATIC BATTERY 5 4 CHAPTER 6...

Page 4: ...S LIBRARY 8 23 6 SERVICE 8 24 7 HELP SCREENS 8 25 8 AUTOMATIC CYCLE 8 27 9 END OF BAR POSITION 8 28 10 TOP CUT POSITION 8 30 11 POWERING DOWN 8 31 CHAPTER 9 MALFUNCTIONS 9 1 1 FACTORS AFFECTING PERFOR...

Page 5: ...CHAPTER 1 BASIC PRINCIPLES 1 1 SPRINT 545 565 S2 CHAPTER 1 BASIC PRINCIPLES...

Page 6: ...er 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 ordering...

Page 7: ...anual and any problems which may result LNS SA and 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 part...

Page 8: ...he Machinery directive EN ISO 12100 2010 Safety of machinery General principles for design ISO TR 14121 2 2013 Safety of machinery Risk assessment EN ISO 13857 2008 Safety of machinery Safety distance...

Page 9: ...or within the operating range of the overhead hoist crane forklift or any other means used for lifting and transportation Do not knock the bar feeder while moving it as this could damage it Do not mo...

Page 10: ...ing the emergency stop button located on the remote control the functions of the bar feeder and the lathe are immediately stopped The LNS Company or its local representative may not be held responsibl...

Page 11: ...CHAPTER 2 TECHNICAL DATA 2 1 SPRINT 545 565 S2 CHAPTER 2 TECHNICAL DATA...

Page 12: ...mm mm mm mm 65 60 38 46 Minimum authorised bar length mm 1500 Maximum authorised bar length mm 3200 3800 4200 Minimum authorised remnant length mm 110 Maximum authorised remnant length mm 450 Pneumati...

Page 13: ...R PLAN The plans below are for the SPRINT 545 and SPRINT 565 S2 respectively showing the most frequently used dimensions for positioning the bar feeder Details on the dimensions of other parts or elem...

Page 14: ...2 4 CHAPTER 2 TECHNICAL DATA SPRINT 545 565 S2...

Page 15: ...control E Guiding blocks F Remnant recovery device G Remote control H Main access cover I Front rest J Interface connector not shown K Air blast L Measure path probe M Front stand N Retraction device...

Page 16: ...2 6 CHAPTER 2 TECHNICAL DATA SPRINT 545 565 S2...

Page 17: ...CHAPTER 3 SYSTEM START UP 3 1 SPRINT 545 565 S2 CHAPTER 3 SYSTEM START UP...

Page 18: ...der to prevent any injuries to persons or damage to objects These instructions are stapled to the crate of the bar feeder Crate Pallet Type 3m 4m 12 3m 4m 12 Width 1150 mm 90 mm Length 4700 mm 4800 mm...

Page 19: ...llows 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 C are p...

Page 20: ...t 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 feeder as you move it this may d...

Page 21: ...der is evenly distributed over the 12 support points Loosen the locking nuts D and make sure that the central screws C of the front and rear feet are supported Open the guiding blocks and place the le...

Page 22: ...alignment again and correct it if necessary Tighten the nuts of the levelling screws Remove the 2 support plates from the bar magazine Remove the 4 retaining screws C behind the rear foot 4 CONNECTIO...

Page 23: ...CHAPTER 4 ELECTRICS 4 1 SPRINT 545 565S2 CHAPTER 4 ELECTRICS...

Page 24: ...eir local representative 1 1 Description Electrical equipment and schematics comply with international electrical rules contained in ISO IEC 204 1 617 This chapter contains all of the elements regardi...

Page 25: ...CHAPTER 4 ELECTRICS 4 3 SPRINT 545 565S2 1 2 Layout of the electrical elements on the bar feeder A B SP1 SQ3 SQ4 SQ6 SQ7 SQ12 SQ8 M3 SQ1 SQ16 SQ9 M2 SQ11 M1 SP2 SQ5 SQ15 SQ10 SQ17 SQ18 SQ19 SQ13 SQ14...

Page 26: ...5 4 391 Pusher switch in park position SQ 6 4 790 Material deposit sensor bottom SQ 7 4 790 Material deposit sensor top SQ 8 4 391 Bar loader indexing sensor SQ 9 4 772 Material check on the bar loade...

Page 27: ...hat the motor is wired in accordance with the supply voltage available The supply voltage of the bar feeder is indicated on the identification plate point 4 If the voltage does not correspond the wiri...

Page 28: ...st motor K3 4 932 Safety contactor K8 4 931 Safety control relay KA5 4 925 Automatic front rest motor opening relay M6 option KA6 4 925 Automatic front rest motor closing relay M6 option KM1 4 507 Hyd...

Page 29: ...CHAPTER 4 ELECTRICS 4 7 SPRINT 545 565S2 2 2 LAYOUT OF THE ELEMENTS A D B C AJ1 A D B C AJ1...

Page 30: ...ton C STOP is released For safety reasons the power supply to the motor is immediately interrupted After having located and repaired the problem causing this interruption reset the circuit breaker by...

Page 31: ...ted in a support To replace the fuse 1 Unscrew the cap a quarter of a turn to the left 2 Remove and replace the fuse with an identical one and put the cap back Although fuses seldom need replacing is...

Page 32: ...visable to keep spares on hand When a battery becomes low the amplifier signals this through a control light The battery is not rechargeable and must be replaced right away The replacement must be don...

Page 33: ...CHAPTER 4 ELECTRICS 4 11 SPRINT 545 565S2 Cover Locking clip Click in to close Open the battery compartment Remove the battery from its housing and replace Close the battery compartment...

Page 34: ...r software updates M2 Slot for memory expansion in use as standard Although the batteries last for a relatively long time 2 3 years it is advisable to keep spares on hand When a battery becomes low th...

Page 35: ...t rest I15 SP1 Pneumatic pressure O47 YV12 Profiled guide I16 K8 Safety line relay O48 KM1 Hydraulic pump relay M1 I17 SP2 Hydraulic pressure O49 KM2 Bar loader motor relay M3 I18 SQ10 Retraction safe...

Page 36: ...4 14 CHAPTER 4 ELECTRICS SPRINT 545 565S2...

Page 37: ...CHAPTER 4 ELECTRICS 4 15 SPRINT 545 565S2 3 INTERFACE DIAGRAM...

Page 38: ...e lathe is are provided by LNS Although an example of an interface diagram is provided the diagram for the interface corresponding to your device essential when making the electrical connection is loc...

Page 39: ...o the bar feeder Always refer to the electrical diagrams shipped with the bar feeder and placed in the electrical cabinet All the wires for the interface connections are numbered All LNS bar feeders a...

Page 40: ...e mode of the lathe collet As long as this signal is present the signal of the foot switch to open and close the lathe collet must be locked The lathe should not start up in automatic cycle until the...

Page 41: ...the proper operation of the devices or the safety locking for protecting persons and materials The options are available only to optimize production conditions R5 auxiliary end of bar relay This sign...

Page 42: ...4 20 CHAPTER 4 ELECTRICS SPRINT 545 565S2...

Page 43: ...CHAPTER 5 PNEUMATICS 5 1 SPRINT 545 565 S2 CHAPTER 5 PNEUMATICS...

Page 44: ...e bar feeder a minimum pressure of 5 bar 75 psi 500 kPa and a maximum pressure of 6 bar 90 psi 600 kPa are mandatory 1 2 Layout of the pneumatic elements Designation Article no Description A 3 636 3 6...

Page 45: ...mm Provide an air hose long enough to allow the complete travel 250 mm of the retraction system to be used When the pipe is connected it should not trail on the ground as it could be damaged 1 Place a...

Page 46: ...connections C Silencer D Controller connection YV1 Bar loading valve YV 2 Valve air blast YV 3 Valve remnant device clamping YV 4 Valve protection SQ1 Pusher lock in reference position YV 5A Pusher b...

Page 47: ...ept for cylinders activated by two solenoid valves A B VQC 5 1 2 3 4 5 SMC Designation Description A Air outlet B Manual activation key 3 3 2 Pressure control unit To guarantee optimal operation of th...

Page 48: ...5 6 CHAPTER 5 PNEUMATICS SPRINT 545 565 S2 3 4 PNEUMATIC DIAGRAMS...

Page 49: ...CHAPTER 5 PNEUMATICS 5 7 SPRINT 545 565 S2...

Page 50: ...5 8 CHAPTER 5 PNEUMATICS SPRINT 545 565 S2...

Page 51: ...CHAPTER 6 HYDRAULICS 6 1 SPRINT 545 565S2 CHAPTER 6 HYDRAULICS...

Page 52: ...ntained in the chassis of the device Aspirated by a pump motor it is injected into the front rest and the guiding blocks A pressure control unit measures the pressure at the outlet of the pump A level...

Page 53: ...e the reverse 3 When the adjustment is completed retighten the clamping screw D 1 4 Filling and draining The bar feeder is supplied without oil Depending on the length of the bar feeder 80 3M 90 12 or...

Page 54: ...TER 6 HYDRAULICS SPRINT 545 565S2 2 HYDRAULIC ELEMENTS M2 Symbol Description Designation M2 Hydraulic pump motor M2 Hydraulic pressure control unit SP2 Device chassis A Guiding block B Front rest C SP...

Page 55: ...CHAPTER 7 GENERAL DESCRIPTION 7 1 SPRINT 545 565S2 CHAPTER 7 GENERAL DESCRIPTION...

Page 56: ...magazine if something breaks its beam A retractable guard secured by a sensor SQ15 controls access to the inside of the bar feeder When they are on the magazine the bars must be against the rear limi...

Page 57: ...are available Hydraulic oil is injected into the cover and distributed along the guiding shells Thanks to this oil bath the bar which is rotating is held in the centre of the guide block 2 2 Layout of...

Page 58: ...E1 auto front rest round shell E2 Sprint 545 3m 6 055 031 114 2 023 31 114C 1 023 31 114C 12 8 055 031 124 4m 10 055 031 134 Sprint 565 S2 3m 6 055 031 114 2 023 31 114C 1 023 31 114C 12 8 055 031 12...

Page 59: ...otating shell Max permitted hexagonal bar 46 mm across flats Max permitted square bar 38 mm across flats The internal diameter of the rotating shell is always adapted to the diameter on the points of...

Page 60: ...connection with the chain is re established and the lock is deactivated Adaptor parts C F can be used to equip each rotating sleeve E with different diameters of pusher body D and collets G see table...

Page 61: ...4 65 62 055 015 114 65 57 055 015 114 60 015 15 053 65 65 56 015 15 053 60 60 51 60 61 G Av 052 015 094 D Av 052 015 154 014 021 023C 65 66 G Av 052 015 094 D Av 052 015 154 014 021 023C 028 031 104 0...

Page 62: ...013 200 015 031 013 200 052 015 234 052 015 254 052 015 244 052 015 274 Convertibilit N C ne non Adaptation c ne embout oui 028 031 104 052 15 474D 10 052 15 474D 11 052 15 474D 12 052 15 474D 13 052...

Page 63: ...ioning During the intervention the belt must remain tensioned If the belt and the notched pulley are misaligned the motor will lose its reference points If this occurs please contact technical support...

Page 64: ...t when loading a new bar and to extract it from the collet of the bar feeder during remnant extraction Irrespective of the material the diameter or the bar profile the jaws are invariably the same and...

Page 65: ...l presence check Depending on the sequence of the bar feed system and in order to prevent damages to material a control system verifies that there is no material in the collet Bar presence check consi...

Page 66: ...ith hydraulic oil during the entire automatic cycle via the fitting B At the front rest outlet some of the hydraulic oil which is on the bar is recovered using a centrifugal effect A blast of air C em...

Page 67: ...flow rate of the front rest and the pneumatic flow rate of the air gun are adjusted using the two flow reducers at the rear of the front rest The factory settings are adjusted so that the two reducers...

Page 68: ...nance To facilitate these tasks the bar feeder can be equipped with a retraction device which allows the operator to move it by 250mm The rigidity of the system guarantees perfect alignment when the b...

Page 69: ...precision in the direction of the lathe so that it can be connected directly to the spindle The software takes the position into account and saves the End Of Bar EOB and the Top Cut positions in a sep...

Page 70: ...emaining oil The front rest opening is actuated by an electric motor C and controlled by the PLC A cover not shown protects the mechanism while the oil recovery device not shown protects the underneat...

Page 71: ...e hydraulic oil which is on the bar is recovered using a centrifugal effect A blast of air A emitted just before the bar feeder outlet dispenses with the remaining oil The front rest opening is actuat...

Page 72: ...7 18 CHAPTER 7 GENERAL DESCRIPTION SPRINT 545 565S2...

Page 73: ...CHAPTER 8 HANDLING 8 1 SPRINT 545 565S25 CHAPTER 8 HANDLING...

Page 74: ...n the value saved is immediately taken into account thus avoiding any referencing position The status parameters saved in the PLC prior to powering off are then checked by the PLC which analyses them...

Page 75: ...ducing the access time to the necessary functions The screen continuously and clearly shows the status of the bar feeder and the production allowing the functions diagnostics and error signals to be c...

Page 76: ...ss to the main menu Access to the help menu Referencing position Change of the guiding elements Switch to automatic mode Exit the current function back to start Stop after machining one bar Back to pr...

Page 77: ...tion of a bar from the guiding elements Automatic Top Cut positioning in manual mode picture may be reversed Teach data Remove the material from the lathe s spindle the image can be reversed to match...

Page 78: ...buttons 2 5 1 MENU key The MENU key allows access to the main menu where the parameters concerning production the interface and the general settings can be reviewed and changed 2 5 2 STOP key The STO...

Page 79: ...following devices All handling adaptations and settings required by the bar feeder to carry out a specific job are part of the set up A few simple operations are necessary to prepare the device to ha...

Page 80: ...a soft cloth to clean them Conditions Guiding channel opened No bar stock in the magazine Pusher in home position Bar feed system in STOP mode Procedure On the remote control use the manual functions...

Page 81: ...e the loading finger B if necessary according to the new diameter of the elements 5 Install the new pusher and place it in the guiding elements 6 Validate the pusher modification 4 Enter the manual me...

Page 82: ...dvantage of holding the bar at two points separated by about 1 5 the diameter with clamping 2 times 350 degrees over about 0 5 times the diameter Efficiency excellent 3 jaws chuck With this type of cl...

Page 83: ...e bore and the rotating bar The greater the clearance the more frequent the vibrations Using reduction tubes helps to reduce this clearance Guiding is thus improved but in addition the insertion of th...

Page 84: ...nks to these parameters when feeding the material can be positioned in the lathe s clamping unit Then during the production cycle each time the clamping unit is opened the material is moved forward wi...

Page 85: ...ng length Number of collet openings Feeding length for the auxiliary part remnant machining Application Used to quickly set the working mode by selecting the desired application Following working mode...

Page 86: ...r or the lathe jaws The precision of the positioning is also ensured by a procedure specially dedicated to profiled bars Introduce the diameter of the bar to be loaded It is important that for each pr...

Page 87: ...ber of times the collet must open for the machining of a part The bar feed system only carries out the first positioning for a single part The following positioning if any must be done by the turret D...

Page 88: ...supply length and the number of openings of the jaws must also be introduced The supply length comprises the length of the piece to be realized and the thickness of the cutting tool Top cut position m...

Page 89: ...f bar setting needs to be selected More information in section 9 of this chapter Auxiliary end of bar position may be not visible Depending on the lathe and its options the auxiliary end of bar may be...

Page 90: ...l maintaining the bar stock pressure against the turret Feeding without turret The bar feeder feeds the part When the collet opens the pusher pushes the bar according to the value entered in the total...

Page 91: ...e end of bar position is always the same In very special cases a different end of bar setting needs to be selected 9 Refer to the Start up manual for the settings Top cut position During feeding the b...

Page 92: ...rest installed at the rear of the lathe spindle The procedure is the same as this for the end of bar signal Front rest opening position This parameter makes it possible to determine when the front res...

Page 93: ...the clamp Depending on the bar diameter the feeder suggests a suitable thrust torque Torque rate during loading according to bar diameter Same principle as for the couple fast forward applied this tim...

Page 94: ...deactivating the front rest symbol close then symbol open Two icons allows for opening and closing of the front rest thus easing the possible replacement of the elements The protection cover must be...

Page 95: ...rts library into the parts parameters by calling its part ID ADD PART OVERWRITE EXISTING PART This screen allows adding a new part to the Parts Library by storing all the current parameters under a ne...

Page 96: ...during loading cycle factory values min max 100 3000 min 1 3 Feed rate without bar stock factory values min max 1000 4000 min 1 4 Feed rate for part feed out factory values min max 100 3000 min 1 5 P...

Page 97: ...about the software and components Software This screen displays the current software running the bar feeder and its version Interface This screen shows the current signals being sent received through...

Page 98: ...addresses Alarms list This screen shows the history of the last 10 alarms Memory list This screen helps entering and monitoring specific bits status in green red and register values value in left box...

Page 99: ...magazine is loaded using the cylinder loading into the guiding elements The pusher is in the fully retracted rear position and the pusher guide is open 2 The loading finger moves forward and pushes th...

Page 100: ...ined when the feeding pusher is just behind the clamping device while the last part is being machined The maximum remnant length Max is obtained when there is not enough material for machining an addi...

Page 101: ...int 7 6 by offset correction Press the key corresponding to the icon The display shows the current end of bar position Press the icon to add the value or the icon to subtract it The new value is store...

Page 102: ...parameters the bar feeder must be in STOP mode To validate a new parameter or a new value keep ENTER pressed until the icon disappears 1 STOP Press the key STOP 2 MENU Press the key MENU 3 POSITIONS...

Page 103: ...The feeding pusher inserts the bar into the lathe spindle The feeding pusher returns to its reference position The feeding pusher is now facing the spindle Press the key FWD and advance the pusher to...

Page 104: ...8 32 CHAPTER 8 HANDLING SPRINT 545 565S2...

Page 105: ...CHAPTER 9 MALFUNCTIONS 9 1 SPRINT 545 565S2 CHAPTER 9 MALFUNCTIONS...

Page 106: ...the spindle must be perfect It is essential that the bar feeder is aligned in accordance with the instructions indicated in Chapter 3 Start up Spindle length In some cases the length of the spindle m...

Page 107: ...relatively easy to guide Square bars or special profiles increase the risk of the film of oil rupturing Bar straightness Performances may vary depending on the material machined the length of the bar...

Page 108: ...5 to 7 times the diameter Efficiency good to very good B Bi conical collet Clamping over 1 or 2 x 350 degrees over an approximate length of 1 2 times the diameter Efficiency very good to excellent C...

Page 109: ...Hard grips Wrong The radius of the grip is greater than the radius of the bar The jaws press against only 3 points at 120 degrees Correct Modify the centers of the jaws to obtain 2 times 6 support cl...

Page 110: ...rvo amplifier 2 4 Mechanics Rotating sleeve In order to guarantee the correct operation of the bar feeder the rotating sleeve must function perfectly Although the construction of the sleeve is very st...

Page 111: ...CHAPTER 10 APPENDICES 10 1 SPRINT 545 565S2 CHAPTER 10 APPENDICES...

Page 112: ...AR CHECK PROGRAM JUMP SUB PROGRAM N CLOSE CLAMPING UNIT N TURRET HOME N TURRET HOME M CODE FEED OK N N CLOSE CLAMPING UNIT N START SPINDLE PART PROGRAM N COOLANT ON N X Z G F T S M N TOP CUT N MACHINE...

Page 113: ...ld 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 Order no Descript...

Page 114: ...10 4 CHAPTER 10 APPENDICES SPRINT 545 565S2 3 LNS ADDRESSES LNS Europe www lns europe com LNS America www lns america com LNS Asia www lns asia com...

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