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CHAPTER 5: PNEUMATICS

EXPRESS 220 S2/320 S2

PNEUMATIC EQUIPMENT

Please read the safety instructions provided at the beginning of this manual before handling
the following devices.

1.1. Description

The following automatic movements of the bar feed system are done via pneumatic elements, namely:

Bar stock loading into the guiding channels

Guiding channel /pusher support opening and closing

Material clamping (bar stock insertion/remnant extraction)

Air blast

To guarantee optimal operation of the bar feeder, a minimum pressure of 5 bar (75 psi), and a maximum
pressure of 6 bar (90 psi) is mandatory.

1.2. Layout of the pneumatic elements

Designation Description

Air handling unit with pressure control switch

Monostable solenoid valve

Bi-stable solenoid valve

Pneumatic battery 2 m bar feeder

Pneumatic battery 3 m bar feeder

Pneumatic battery 4 m/12 ' bar feeder

Air blast

Pneumatic cylinders of the clamping of the material

Pneumatic cylinders opening / closing guide zone

Loading bar pneumatic cylinders

Front stopper

Pneumatic pusher cylinder lock to the reference position

Pneumatic cylinders open/close push bracket

Pneumatic cylinders push locked/released

Pneumatic cylinders support guide zone (optional 2 mm)

Содержание Express 220 S2

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Страница 4: ...ENT 24 2 ELECTRICAL CABINET 27 3 INTERFACE 34 CHAPTER 5 PNEUMATICS 37 1 PNEUMATIC EQUIPMENT 38 2 AIR FILTERING UNIT 39 3 PNEUMATIC BATTERY 40 CHAPTER 6 HYDRAULICS 43 1 HYDRAULIC EQUIPMENT 44 2 HYDRAUL...

Страница 5: ...RVICE 84 7 HELP SCREENS 85 8 AUTOMATIC CYCLE 87 9 END OF BAR POSITION 88 10 TOP CUT POSITION 91 11 POWERING DOWN 92 CHAPTER 9 MALFUNCTIONS MAINTENANCE 95 1 FACTORS AFFECTING PERFORMANCE 96 2 ALARMS 98...

Страница 6: ...CHAPTER 1 BASIC PRINCIPLES 3 EXPRESS 220 S2 320 S2 CHAPTER 1 BASIC PRINCIPLES...

Страница 7: ...er 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 number of the i...

Страница 8: ...ponsible 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 or stemming from modifications repairs...

Страница 9: ...electrical power It is strictly prohibited to jump wire or remove circuit breakers master switches and especially safety switches To avoid any harm to persons or damage to components use only the ind...

Страница 10: ...er caused directly or not by any means whatsoever if certain safety devices have not been included 4 1 Safety analysis for a correct incorporation Before considering assembling the machine it is neces...

Страница 11: ...320 S2 4 2 Layout of the safety elements on the barfeed system Designation Description A Main access cover B Emergency stop push button SQ10 Safety switch of the retraction system option SQ11 Safety s...

Страница 12: ...CHAPTER 2 TECHNICAL DATA 9 EXPRESS 220 S2 320 S2 CHAPTER 2 TECHNICAL DATA...

Страница 13: ...emnant length 300 mm 400 mm Pneumatic pressure 5 bar Air consumption 10 l per loading cycle Main electrical power 3x 200 480 V 50 Hz 60 Hz Max current Amps 1 A Pushing force 550 N Maximum feed rate 10...

Страница 14: ...CHAPTER 2 TECHNICAL DATA 11 EXPRESS 220 S2 320 S2 2 1 Left front loading 3 m...

Страница 15: ...12 CHAPTER 2 TECHNICAL DATA EXPRESS 220 S2 320 S2 2 2 Right front loading 3 m...

Страница 16: ...CHAPTER 2 TECHNICAL DATA 13 EXPRESS 220 S2 320 S2 2 3 Left front loading 2 m...

Страница 17: ...14 CHAPTER 2 TECHNICAL DATA EXPRESS 220 S2 320 S2 2 4 Right front loading 2 m...

Страница 18: ...visible C Chain drive D Pneumatic assembly E Air filtering unit F Electrical cabinet G Loading ramp H Retraction system option I Rear stand J Remnant drop tray K Hydraulic tank L Remnant control M Re...

Страница 19: ...16 CHAPTER 2 TECHNICAL DATA EXPRESS 220 S2 320 S2...

Страница 20: ...CHAPTER 3 SYSTEM START UP 17 EXPRESS 220 S2 320 S2 CHAPTER 3 SYSTEM START UP...

Страница 21: ...te Pallet 2 m 3 m 12 4 m 2 m 3 m 12 4 m Weight kg 575 675 725 775 550 650 700 750 Width mm 600 550 Length mm 3500 4400 5000 5400 3500 4400 5000 5400 Height mm 1500 Depending on peak height 1 2 Unpacki...

Страница 22: ...nted 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 are packaged in a separate box with the technical doc...

Страница 23: ...move 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 feeder...

Страница 24: ...If not already done place a levelling plate E under each levelling screw On each foot loosen the locking nuts A of the levelling screws B Then make sure that the weight of the bar feeder is evenly di...

Страница 25: ...lts are tightened check the alignment again and correct it if necessary Tighten the nuts of the levelling screws Remove the 4 2 2 screws C 4 CONNECTIONS When the bar feeder is correctly aligned and an...

Страница 26: ...CHAPTER 4 ELECTRICS 23 EXPRESS 220 S2 320 S2 CHAPTER 4 ELECTRICS...

Страница 27: ...Particular attention should be given to the handling of electrical elements because of risks of electrocution In case of possible electrical malfunctions it is advisable to contact LNS or their local...

Страница 28: ...Q1 Bar length measurement SQ3 Pusher support in open position sensor SQ4 Pusher support in closed position sensor SQ5 Pusher in reference position switch SQ10 Retraction safety switch option SQ10a 2 p...

Страница 29: ...he identification plate If the voltage does not correspond the wiring of the motor must be modified Procedure Turn the bar feeder off trigger QS1 and QM1 Open the main safety cover Unscrew the motor c...

Страница 30: ...utomatic front rest fuse 2 A motor M6 K3 Safety contactor KM1 Hydraulic pump motor M1 relay QF1 Circuit breaker 4 A QM1 Main circuit breaker 2 5 to 4 A QS1 Main switch KS Start relay R1 R6 Interface r...

Страница 31: ...power the circuit breaker activates and push button C STOP is released For safety reasons the power supply to the motor is immediately interrupted After having located and repaired the problem causing...

Страница 32: ...quarter of a turn to the left 2 Remove and replace the fuse with an identical one and put the cap back On the primary side the transformer accepts a voltage of 200 480 V 50 Hz 60 Hz Measure the power...

Страница 33: ...ime 2 3 years it is advisable 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 r...

Страница 34: ...CHAPTER 4 ELECTRICS 31 EXPRESS 220 S2 320 S2 Cover Locking clip Click in to close Open the battery compartment Remove the battery from its housing and replace Close the battery compartment...

Страница 35: ...ation Description A Battery module M1 Slot for software updates M2 Slot for memory expansion in use as standard Battery module Batt The PLC does not need a backup battery on the information module Run...

Страница 36: ...ck I13 Not used O45 YV11 Pusher locked in position I14 Not used O46 Not used I15 Not used O47 Not used I16 K8 Safety line relay O48 KM1 Hydraulic pump relay M1 I17 SP2 Hydraulic pressure O49 Not used...

Страница 37: ...ers are equipped with their own thermal protection systems breakers thermal relays fuses etc The power supply for the bar feeder should be connected to the output of a breaker mounted in the electrica...

Страница 38: ...he 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...

Страница 39: ...roper 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 signal may...

Страница 40: ...CHAPTER 5 PNEUMATICS 37 EXPRESS 220 S2 320 S2 CHAPTER 5 PNEUMATICS...

Страница 41: ...of 5 bar 75 psi and a maximum pressure of 6 bar 90 psi is mandatory 1 2 Layout of the pneumatic elements Designation Description A Air handling unit with pressure control switch B Monostable solenoid...

Страница 42: ...Provide an air hose long enough to allow the complete travel 500 mm of the retraction system When the pipe is connected it should not trail on the ground as it could be damaged 1 Place a clamp A aroun...

Страница 43: ...ontroller connection YV1 Bar loading valve YV2 Valve air blast YV3 Valve material clamping YV4 Valve bar length measurement YV5A Pusher bracket opening valve YV5B Valve pusher support closing YV6A Gui...

Страница 44: ...umatic cylinders activated by 2 solenoid valves Designation Description A Air outlet B Manual activation key 3 4 Pressure control unit To guarantee an optimal work of the bar feed system the service p...

Страница 45: ...42 CHAPTER 5 PNEUMATICS EXPRESS 220 S2 320 S2...

Страница 46: ...CHAPTER 6 HYDRAULICS 43 EXPRESS 220 S2 320 S2 CHAPTER 6 HYDRAULICS...

Страница 47: ...th The hydraulic oil is contained in the machine itself 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...

Страница 48: ...he opposite direction will produce 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 A minimum quantity of h...

Страница 49: ...C DIAGRAM 2 1 Symbols The following table represents the hydraulic symbols used and their description Symbol Description Designation Hydraulic pump motor M1 Hydraulic pressure control unit SP2 Hydraul...

Страница 50: ...CHAPTER 7 GENERAL DESCRIPTION 47 EXPRESS 220 S2 320 S2 CHAPTER 7 GENERAL DESCRIPTION...

Страница 51: ...a new production job The inclination of the plane is always the same regardless of the diameter the profile or the material of the bars to be loaded 1 Enter the new diameter of the bar stocks to load...

Страница 52: ...e bar forth and back Hydraulic oil is injected into the channels and distributed all along the bar stock An oil bath is created around the rotating bar pusher which is thus kept at the center of the g...

Страница 53: ...on all Front rest element for round bar Front rest element for profiled bar Guiding element shape Use For round bar stocks the standard guiding elements are automatically set to the best position For...

Страница 54: ...20 S2 2 4 Connecting parts to the lathe 1 Telescopic tube depending on the maximum spindle stroke 2 Adaptation parts depending on the spindle back design 3 Guiding bushing depending on the guiding red...

Страница 55: ...and backward movements of the pusher the insertion and extraction movements of the bar in the collet 3 2 Layout of the elements Designation Description A Pinion helical gear drive B Gear driven screw...

Страница 56: ...notched toothed wheel are misaligned the motor will lose its reference points If this occurs please contact technical support Procedure Switch the bar feed system to STOP mode on the remote control Op...

Страница 57: ...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 do no...

Страница 58: ...ose again 9 Set the air pressure to 5 bar 10 Switch the main power on QS1 Designation Description A Clamping plate B Truncated clamping plate C Platelet attachment screws D Locating Pins E Pneumatic c...

Страница 59: ...blast A located just before the exit pushes away the resting oil The rest opening is actuated by an electrical motor C and controlled by the PLC Designation Description Cover not shown A Air blast B F...

Страница 60: ...g During machining of small diameter 2 to 5 mm forces and counter forces from the lathe spindle and of the pusher acting on the bar may cause deformation of it The synchronization system allows for si...

Страница 61: ...guarantees perfect alignment when the bar feeder is in working position A safety switch impedes any handling as long as the bar feed system is not in operational position 7 2 Operation Conditions Bar...

Страница 62: ...escription This option is designed to change the following parts 1 Lid A with guide bearings cylinders B for closed guiding area and prevent the bars of small diameter to come out of the guiding area...

Страница 63: ...ESCRIPTION EXPRESS 220 S2 320 S2 10 LOADING SYSTEM INCREASED BY 100 mm option 10 1 Description This option is designed to increase the loading capacity of the bar feeder by adding guides A according t...

Страница 64: ...CHAPTER 8 HANDLING 61 EXPRESS 220 S2 320 S2 CHAPTER 8 HANDLING...

Страница 65: ...on 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 the...

Страница 66: ...reducing 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...

Страница 67: ...urrent parameter Access 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 machini...

Страница 68: ...Confirm manual extraction 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...

Страница 69: ...DE 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 S...

Страница 70: ...wing parameters change 1 Bar stock diameter 2 Bar stock shape 3 Part length 3 1 BARFEED MECHANICAL SETUP 3 1 1 Adjusting the bars magazine The upper limiters should be set to each support The inclinat...

Страница 71: ...he magazine Pusher in home position Bar feed system in STOP mode Procedure On the remote control use the manual functions to move back the pusher to its reference in lifted position 1 STOP Press the S...

Страница 72: ...hange parameters such as the bar diameter feeding length etc See this chapter section SETTINGS for further information 3 2 1 Changing the access panel elements Automatic front rest if required In case...

Страница 73: ...the great advantage 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 thi...

Страница 74: ...the spindle 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 inse...

Страница 75: ...hese 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 with preci...

Страница 76: ...ing 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 mod...

Страница 77: ...er 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 p...

Страница 78: ...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...

Страница 79: ...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...

Страница 80: ...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 used...

Страница 81: ...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 p...

Страница 82: ...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 ba...

Страница 83: ...st 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 rest...

Страница 84: ...d applied this time to loading Couple for compensation of friction during machining with tailstock Machine This torque must be sufficient so that the bar does not have to pull the pusher when the head...

Страница 85: ...r 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...

Страница 86: ...arts 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 n...

Страница 87: ...thout 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 Feed rate factory values min max 100 3000 min 1 6 Torque without bar stock...

Страница 88: ...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...

Страница 89: ...P 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 bo...

Страница 90: ...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 t...

Страница 91: ...m bar stock remnant In the case of a Swiss style lathe the setting will be done with the lathe headstock at the part off position Regardless of the length of the bars or parts the end of bar position...

Страница 92: ...isplays the following text END OF BAR POSITION Tap the value displayed on the screen Depending on which sequence the bar feed is in when the parameter is selected the available functions and icons can...

Страница 93: ...TEACH IN The display shows the current end of bar position Press the key FWD and advance the pusher to the desired position see previous page Correct if necessary with the key REW To validate the new...

Страница 94: ...position can be adjusted at any time in one of two ways By offset correction By teaching Teach In 10 2 Setting Before handling the bar feeder stop the lathe at the end of part cycle To edit these para...

Страница 95: ...el raises and grasps a bar as it passes by 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 P...

Страница 96: ...CHAPTER 8 HANDLING 93 EXPRESS 220 S2 320 S2...

Страница 97: ...94 CHAPTER 8 HANDLING EXPRESS 220 S2 320 S2...

Страница 98: ...CHAPTER 9 MALFUNCTIONS MAINTENANCE 95 EXPRESS 220 S2 320 S2 CHAPTER 9 MALFUNCTIONS MAINTENANCE...

Страница 99: ...f the channel with the axis of 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 1 1 3 Spindle length In so...

Страница 100: ...ugs must be fitted at the rear of each tube Profiled 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 a...

Страница 101: ...onnection AL02 MAIN ACCESS COVER OPEN Description The PLC does not detect the input I2 SQ11 of the safety switch on the main access cover The problem is generated when the main access cover on the bar...

Страница 102: ...ing mechanism has a fault Solutions Check or replace the sensor SQ3 check the operation of the closing and locking mechanism AL13 PROBLEM WHEN SHELLS OPENS Description This alarm is activated when the...

Страница 103: ...8 SENSORS SQ17 OU SQ18 ADJUSTMENT PROBLEM Description Sensor SQ17 and or SQ18 incorrectly adjusted or defect Solutions Check the sensors adjustment or replace if defect AL19 SQ1 SENSOR INACTIVE Descri...

Страница 104: ...outs this alarm is generated Solutions Remove the bar out of the spindle Start the top cut cycle again If the problem persists please contact LNS AL24 SAFETY TIME FOR PART FEED OUT ELAPSED Descriptio...

Страница 105: ...pper It could be worn broken or of incorrect size Check if the pusher was seized in the channel Check that the channels are well sit and remove any chips If issue persists please contact LNS AL29 THE...

Страница 106: ...e gripper of the pusher Solutions Check the operation of the extraction device and whether the jaws are not broken Check the settings of SQ12 the sensor must be activated only when there is the materi...

Страница 107: ...front rest motor Check relays KA5 and KA6 AL40 AUTOMATIC BAR SELECTOR ISSUE Description Problem with the automatic bar selector Solutions Check or replace sensor SQ20 Check or replace motor M7 Check o...

Страница 108: ...Solutions Search for a mechanical obstruction such as a bar loaded incorrectly tools forgotten in the apparatus an incompatibility between the diameters of the plunger and pin reduction Check the alig...

Страница 109: ...106 CHAPTER 9 MALFUNCTIONS MAINTENANCE EXPRESS 220 S2 320 S2 3 SERVO AMPLIFIER ALARMS...

Страница 110: ...CHAPTER 9 MALFUNCTIONS MAINTENANCE 107 EXPRESS 220 S2 320 S2...

Страница 111: ...108 CHAPTER 9 MALFUNCTIONS MAINTENANCE EXPRESS 220 S2 320 S2...

Страница 112: ...CHAPTER 9 MALFUNCTIONS MAINTENANCE 109 EXPRESS 220 S2 320 S2...

Страница 113: ...110 CHAPTER 9 MALFUNCTIONS MAINTENANCE EXPRESS 220 S2 320 S2...

Страница 114: ...echanics 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 sturdy and reliable i...

Страница 115: ...112 CHAPTER 9 MALFUNCTIONS MAINTENANCE EXPRESS 220 S2 320 S2...

Страница 116: ...CHAPTER 10 APPENDICES 113 EXPRESS 220 S2 320 S2 CHAPTER 10 APPENDICES...

Страница 117: ...ould 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 Descri...

Страница 118: ...RAM 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 PART N N PAR...

Страница 119: ...116 CHAPTER 10 APPENDICES EXPRESS 220 S2 320 S2 3 LNS ADRESSES LNS Europe www lns europe com LNS America www lns america com LNS Asia www lns asia com...

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