LNS Alpha 538 User manual

For CNC machine tool peripherals,
it’s LNS , then all the rest
ALPHA 538 / 552 BARFEED
Instruction Manual
9.X51.01.US

ALPHA 538/552
V2
.
6
TABLE OF CONTENTS
CHAPTER 1 : BASIC NOTIONS ....................................................................... 1-1
1. STRUCTURE .........................................................................................................................1-2
2. RIGHTS..................................................................................................................................1-3
3. DECLARATION OF COMPLIANCE........................................................................................1-4
4. SAFETY INSTRUCTIONS ......................................................................................................1-5
5. SAFETY ANALYSIS FOR A CORRECT INCORPORATION ..................................................1-6
CHAPTER 2 : TECHNICAL DATA .................................................................... 2-1
1. CHARACTERISTICS..............................................................................................................2-2
2. FLOOR PLAN ........................................................................................................................2-2
3. LAYOUT 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 CONNECTIONS................................................................................................3-9
CHAPTER 4 : ELECTRICS................................................................................ 4-1
1. ELECTRICAL EQUIPMENT ...................................................................................................4-2
2. ELECTRICAL CABINET ........................................................................................................4-5
3. ELECTRICAL DIAGRAMS ...................................................................................................4-12
4. INTERFACE.........................................................................................................................4-18
CHAPTER 5 : PNEUMATICS ............................................................................ 5-1
1. PNEUMATICAL EQUIPMENT ................................................................................................5-2
2. F.R.L. UNIT ............................................................................................................................5-3
3. PNEUMATIC VALVE BATTERY ............................................................................................5-4
4. MAINTENANCE .....................................................................................................................5-6
5. PNEUMATIC DIAGRAMS ......................................................................................................5-7

ALPHA 538/552
CHAPTER 6 : HYDRAULICS.............................................................................6-1
1. HYDRAULIC EQUIPMENT .................................................................................................... 6-2
2. DESCRIPTION OF THE ELEMENTS..................................................................................... 6-3
3. MAINTENANCE .................................................................................................................... 6-4
CHAPTER 7 : GENERAL DESCRIPTION.........................................................7-1
1. BAR MAGAZINE ................................................................................................................... 7-2
2. GUIDING ELEMENTS ........................................................................................................... 7-4
3. PUSHER................................................................................................................................ 7-7
4. SYNCHRONIZATION DEVICE .............................................................................................7-10
5. CHAIN DRIVE.......................................................................................................................7-11
6. REMNANT 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. OPERATION PARAMETERS ................................................................................................ 8-8
6. AUTOMATIC CYCLE............................................................................................................8-19
7. POWERING OFF..................................................................................................................8-19
CHAPTER 9 : MALFUNCTIONS .......................................................................9-1
1. ALARMS ............................................................................................................................... 9-2
2. FACTORS AFFECTING PERFORMANCE ...........................................................................9-14
3. MAINTENANCE ...................................................................................................................9-16
CHAPTER 10 : APPENDICES.........................................................................10-1
1. PROGRAMMING EXAMPLE ................................................................................................10-2
2. ORDERING FORM ...............................................................................................................10-3
3. LNS WEB ADRESSES .........................................................................................................10-4

CHAPTER 1: BASIC NOTIONS 1-1
ALPHA 538/552
CHAPTER 1 :
BASIC NOTIONS

CHAPTER 1: BASIC NOTIONS 1-2
ALPHA 538/552
1. STRUCTURE
This manual consists of various chapters, each containing several points, paragraphs, etc. Lists may be
contained in paragraphs.
·Document version #: top-right of the table of content.
·Page #: top right-hand corner of the page.
·# and title of chapter: top left-hand corner of the page.
·Model of the bar feeder: bottom of the page.
1.1. Cross-references
Each chapter generally contains all of the information related to the description and settings of the
devices and elements represented therein.
Therefore, if a setting must be made while you are handling the system, please 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
ordering number of the indicated element.
To make it easier to place an order of supplies, a form has been included in the annex at the end of this
manual.
1.3. Symbols and terminology
This sign recommends following the directions very closely avoiding causing an
incident that could result in injury, damage to the equipment, or data loss.
This sign indicates that safety measures must be taken to avoid possible electrical
shocks or mishaps.
The notes stress interesting points or comments, and provide useful advice for
optimal system operation.
This sign points out an advice about environmental protection.

CHAPTER 1: BASIC NOTIONS 1-3
ALPHA 538/552
2. RIGHTS
All rights reserved. Reproduction, recording or transmission of all, or any portion, of this manual, in any
form or through any means whatsoever, whether mechanical, photographic, sound or other, without the
express written authorization of LNS SA, is prohibited. LNS SA disclaims all responsibility for errors which
may be contained in this manual and the problems which may result therefore.
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 party, following an accident, incorrect use, or
misuse, or stemming from modifications, repairs, or transformations not authorized by LNS SA.
LNS SA and its subsidiaries cannot be held responsible for damage and problems arising from the use of
options and products other than LNS products, or products approved by LNS SA.
The names of the products indicated in this manual are registered trademarks.
The instructions found in this manual are only for information; they are subject to change without notice.

CHAPTER 1: BASIC NOTIONS 1-4
ALPHA 538/552
3. DECLARATION OF COMPLIANCE
EC DECLARATION OF CONFORMITY
According to annex II A of the directive 2006/42/EC
We declare that the following machinery complies with the next directives :
- Machinery Directive: 2006/42/EC
- Low Voltage Directive: 2006/95/EC
- EMC Directive: 2004/108/EC
Manufacturer : LNS SA
Route de Frinvillier
CH- 2534 Orvin
Suisse
Compiling relevant technical information : Plaseco Kurt De Pauw
Chemin des Petits-Clos 12
CH- 1744 Chénens
Suisse
Description of the machine : BAR FEEDER
Type : ALPHA 552
Serial number : N/A
The following essential requirements of the machine directive 2006/42/EC are applied and fulfilled : 1.1.2,
1.1.3, 1.1.5, 1.1.6, 1.2.1, 1.2.2, 1.2.3, 1.2.4, 1.2.5, 1.2.6, 1.3.1, 1.3.2, 1.3.3, 1.3.4, 1.3.5, 1.3.6, 1.3.7, 1.3.8,
1.3.9, 1.4.1, 1.4.2, 1.4.3, 1.5.1, 1.5.3, 1.5.4, 1.5.8, 1.5.9, 1.6.2, 1.6.3, 1.7.1, 1.7.2, 1.7.3, 1.7.4.
The following transposed harmonized standards have been used :
- Concerning the Machinery Directive :
·EN 14121 - 1 & 2:2007 : 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 upper and lower limbs,
·EN 13850:2006 : Safety of machinery –Emergency stop equipment,
·EN 14120:2009 : Safety of machinery –Conception of movable guards,
·EN 13849-1:2007 : Safety of machinery –Safety related parts of control systems,
·EN 14118:2000 : Safety of machinery –Prevention of unexpected start-up,
·ISO 13855:2008 : Safety of machinery ―Positioning of protective equipment with
respect to the approach speeds of parts of the humanbody
·EN 60204-1:2005 : Safety of machinery –Electrical equipment of machines,
·EN ISO 4414:2011 : Pneumatic Power –Rules and Safety requirements,
·CEI 60812:2006 : Safety of machinery –FMECA Analysis,
- Concerning the Low Voltage Directive :
·IEC 60439-1/3 : Low-voltage switchgear and control gear assemblies
- Concerning the EMC Directive :
·EN 61000-6-4 : Generic emissions standard, Industrial environment
·EN 61000-6-2 : Generic immunity standard, Industrial environment
Place and date : Seal and signature :
Orvin, the 4hDecember 2012 Mrs. Nadia Pellaton
Manager Export department

CHAPTER 1: BASIC NOTIONS 1-5
ALPHA 538/552
4. SAFETY INSTRUCTIONS
Only qualified personal, instructed about the product, may install, set in operation, maintain and,
where necessary, repair the product.
The customer must ensure that the provisions regarding internal monitoring, the events logbook,
the organization of work, the staff training are available, as well as the installation / instructions
manuals.
All persons who perform work on this machine must have read and understood the instructions
and installation notice.
LNS disclaim all responsibility for possible accidents or property damage caused when safety
instructions are not followed.
·
Do not handle the machine without having
knowledge of the safety instructions and the
instructions for use. Safety instructions for the
bar feeder system, as well as the CNC lathe,
must be strictly observed.
·Non-qualified personnel, children, and persons
under the influence of alcohol or medication
should neither handle nor use the machine.
·Loose garments, long hair and jewelry can be
dangerous when operating/maintaining the
machine.
·Do not conduct any maintenance operations
during the automatic cycle.
·Do not grasp moving or rotating objects, or
nearby elements.
·While it is powered on, the machine should not
be moved, no servicing should be carried out on
the interface or inside the electrical cabinet, no
maintenance should be performed, no cover
should be removed or disassembled.
·If any safety shield, cover or device is to be
removed to conduct maintenance, it must be
reinstalled as soon as the maintenance work is
completed.
·It is strictly prohibited to jump wire or remove
circuit breakers, main switches, 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 should be near the hanging
load, or within the operating range of the
overhead hoist/crane, forklift, or any other
means used for lifting and transportation.
·For the use and maintenance of the machine,
use only parts provided by or recommended by
LNS.
·
Don’t hit the machine when moving it, this could
result in damages.
·The work area surrounding the machine should
always be clear of objects and well lit. The
presence of oil on the ground could cause falls;
it is important to maintain the floor clean on a
regular basis.
·Do not place the machine in a damp area and
make sure that water or oil does not come into
contact with the electrical equipment.
·If it is necessary to move the machine once it
has been originally installed, do not reinstall it
before first contacting LNS or its local
representative.
·LNS disclaim all responsibility for possible
accidents or property damage caused when
safety instructions were not followed.
Special notes in case of an LNS bar feeder
system :
·Do not open the clamping device (collet or
chuck) of the lathe manually when the bar
feeder is in automatic mode (Interface).
·Each time the diameter is changed, also adapt
spindle reduction tube. The use of spindle
reduction tubes is highly recommended for
machining bars with diameters smaller than the
maximum capacity of the spindle.
·The rotating bar should never protrude the rear
of the lathe spindle.
·Do not attempt to recharge the batteries of the
PLC.
·The maximum length (max. L) the bar feeder
system is allowed to load is given by the length
of the lathe spindle. The bar should never
extend without support more than 3 times its
diameter beyond the lathe clamping device.

CHAPTER 1: BASIC NOTIONS 1-6
ALPHA 538/552
5. SAFETY ANALYSIS FOR A CORRECT INCORPORATION
Before considering assembling the machine, it is necessary to consider the following points:
·Consider safety strategies that reduce risks to an acceptable level;
·Define the tasks required for applications to predict and assess the need of access and / or for
the approach;
·Identify sources of risks, including failures and failure modes associated with each task. Risks
can come from:
omachine in which the device ALPHA 538/552 is integrated;
oits association with other equipment,
oPeople’s interaction with the machine.
·Evaluate and assess the risks associated by using the machine ALPHA 538/552:
oprogramming risks
ooperation risks
orisks of use
omaintenance risks
·Choose methods of protection :
othe use of protective devices
othe introduction of signals
ocompliance with safe work procedures
Once the bar feeder has been aligned and anchored to the ground, the bar feeder must be connected to
the interface of the lathe and compressed air needs to be connected. At this stage, the hydraulic tank
may be filled.

CHAPTER 2: TECHNICAL DATA 2-1
ALPHA 538/552
CHAPTER 2 :
TECHNICAL DATA

CHAPTER 2: TECHNICAL DATA 2-2
ALPHA 538/552
1. CHARACTERISTICS
NOTE: Depending on the options, these technical data may vary. Please refer to the technical
data sheet.
3 meter 12 feet 4 meter
Weight 2450 lbs (1100 kg) 2550 lbs (1150 kg) 2650 lbs (1200 kg)
Dimensions
See Floor Plan, page 2-3
Minimum diameter
(profiled: on flats)
5 mm
(square: 4 mm)
(hex: 5 mm)
5 mm
(square: 4 mm)
(hex: 5 mm)
5 mm
(square: 4 mm)
(hex: 5 mm)
Maximum 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 5 bar
Air consumption < 10 liter / loading cycle
Main electrical power 3x 208 –480 V 50 Hz –60 Hz
Max. 6A
Pushing force Nominal: 464N
Max. electrical: 1160N (0,5 seconds) + 630N with mechanical booster
Maximum feed rate >1m/min
Loading cycle 35 - 40 seconds
Hydraulic oil ISO 100 / 14 gallons ISO 100 / 14 gallons ISO 100 / 14 gallons
2. FLOOR PLAN
Left to right bar feeder (L to R) Right to left bar feeder (R to L)
Lathe
Lathe

CHAPTER 2: TECHNICAL DATA 2-3
ALPHA 538/552

CHAPTER 2: TECHNICAL DATA 2-4
ALPHA 538/552
3. LAYOUT OF THE ELEMENTS
Designation Description
A Pusher (not visible)
B Chain 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 measuring device (not visible)
L Front stand
M Retraction system
N Rear stand
P Pneumatic assembly
A
B
C
D
E
F
H
I
J K
L
N
M
P

CHAPTER 3: SETTING INTO OPERATION 3-1
ALPHA 538/552
CHAPTER 3 :
SETTING INTO OPERATION

CHAPTER 3: SETTING INTO OPERATION 3-2
ALPHA 538/552
1. TRANSPORTATION
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
Depending on its destination, the ALPHA 538/552 bar feeder may be delivered either on a pallet or
packed in a wooden crate. When transported by sea or by air, the second solution is recommended.
Regardless of the type of packaging, the uncrating and lifting instructions recommended by LNS must 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 feeder must be unpacked in a spacious, well-lit location.
Check that the lifting capacity of the hoisting crane, or lift truck, is adequate before
proceeding with the handling of the merchandise. No one should be near the hanging load,
or within the operating range of the overhead hoist/crane, forklift, or any other means used
for lifting and transportation.
1) If the bar feeder is received in a crate, start
by unscrewing the front panel.
2) Remove the top.
3) Remove the side-walls.

CHAPTER 3: SETTING INTO OPERATION 3-3
ALPHA 538/552
From this point on, the bar feeder is unpacked in the same way as when delivered on a pallet.
The ALPHA 538/552 bar feeder is always delivered 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 (C) are packaged in a separate box (D), with the
technical documentation and the accessories. (D).
Take out the parts and place them in an easily accessible area for mounting the bar feeder.
A
B
C
D

CHAPTER 3: SETTING INTO OPERATION 3-4
ALPHA 538/552
1.2. Preparation for mounting
For mounting and installing the bar feeder, it is advisable to contact LNS or
one of its agents. The latter cannot be held responsible for any malfunction
resulting from an incorrect installation in which they did not take part.
·Insert the two lift bars (B) delivered with the bar feeder into the holes of
the lifting plates.
·Place the hoist vertically above the bar feeder.
·Place the straps over the ends of the bars (B), then attach them to the hoist.
·Raise the hoist to tighten the straps.
·Remove the screws (A) holding the bar feeder to the pallet during transportation.
·Lift the bar feeder and 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 feeder as you move it; this may damage it.
·Place the bar feeder behind the lathe, as close as possible and in approximate alignment with the
spindle. For the placement, the stationary and mobile space requirements for the lathe and the bar
feeder should be taken into account. When placing the bar feeder insert levelling plates under the
feet.
The distance between the lathe and the bar feeder should not exceed 20 mm. Should
an obstacle impose a greater distance, contact LNS or their local representative.
The area around the lathe and the bar feeder must be cleared to allow for their
maintenance and handling. It should remain clear after the installation is completed.
A
B
B

CHAPTER 3: SETTING INTO OPERATION 3-5
ALPHA 538/552
2. MOUNTING
The ALPHA 538/552 bar feeder is delivered completely assembled. Because of this, it is possible to
proceed directly to its alignment when in place behind the lathe.
2.1. Alignment
Before proceeding with the alignment of the bar feeder, ensure that the lathe is stable
and preferably levelled.
During the alignment, ensure that there is no reduction unit in the spindle (spindle
liner).
The alignment may be carried out using a nylon string, an optical tool, etc. If you do not have any
alignment tools, please contact LNS or their local representative so they may take care of the bar feeder
installation.
·On each foot, loosen the lock nuts (A) of the leveling screws (B). Then, make sure that the 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 the guiding channel and place the level crosswise on
the lower part. Adjusting the screws (B), set the lateral level
of the bar feeder.
·Adjusting the central screws (C), set the height of the bar
feeder. Normally, when the reference point is known, this
adjustment is done at the factory.
·Together with the vertical alignment, proceed with the lateral
alignment, by shifting the apparatus. If you don't have the
needed material to perform this operation, please contact
LNS SA or your local representative.
·When the alignment is satisfactory, tighten all locking
screws (D). Check the alignment and, if necessary, correct it
with the screws (B).
The lock nuts of the leveling screws should only be tightened after the bar feeder is
anchored to the ground.
D
B
A
C