LNS Sprint 545 S2 User manual

LNS SA
CH-2534 Orvin
www.LNS-group.com
®
Instruction Manual ENG
Sprint 545 / 565 S2
9.545.01.ANG

SPRINT 545/565 S2
V
2.0
TABLE OF CONTENTS
CHAPTER 1 : BASIC PRINCIPLES ..................................................................1-1
1.STRUCTURE......................................................................................................................... 1-2
2.RIGHTS ................................................................................................................................. 1-3
3.SAFETY REQUIREMENTS................................................................................................... 1-5
4.SAFETY DEVICES................................................................................................................ 1-6
CHAPTER 2 : TECHNICAL DATA ....................................................................2-1
1.CHARACTERISTICS............................................................................................................. 2-2
2.FLOOR PLAN........................................................................................................................ 2-3
3.LAYOUT OF THE ELEMENTS............................................................................................. 2-5
CHAPTER 3 : SYSTEM START UP ..................................................................3-1
1.TRANSPORTATION ............................................................................................................. 3-2
2.ASSEMBLY........................................................................................................................... 3-5
3.ANCHORING......................................................................................................................... 3-6
4.CONNECTIONS .................................................................................................................... 3-6
CHAPTER 4 : ELECTRICS................................................................................4-1
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 : HYDRAULICS.............................................................................6-1
1.HYDRAULIC EQUIPMENT ................................................................................................... 6-2
2.HYDRAULIC ELEMENTS..................................................................................................... 6-4
CHAPTER 7 : GENERAL DESCRIPTION.........................................................7-1
1.BAR MAGAZINE................................................................................................................... 7-2
2.GUIDING BLOCKS ............................................................................................................... 7-3
3.PUSHER................................................................................................................................ 7-6
4.BELT DRIVE.......................................................................................................................... 7-9
5.REMNANT EXTRACTION SYSTEM (option).................................................................... 7-10
6.FRONT REST...................................................................................................................... 7-12
7.RETRACTION DEVICE (option) ........................................................................................ 7-14
8.2-POSITION OPTION.......................................................................................................... 7-15
9.AUTOMATIC FRONT REST (option)................................................................................. 7-16
10.2-POSITION PNEUMATIC FRONT REST (option) ........................................................... 7-17

SPRINT 545/565 S2
CHAPTER 8 : HANDLING.................................................................................8-1
1.POWERING ON.....................................................................................................................8-2
2.REMOTE CONTROL.............................................................................................................8-3
3.SET-UP..................................................................................................................................8-7
4.SOFTWARE SETTINGS......................................................................................................8-12
5.PARTS 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 PERFORMANCE...........................................................................9-2
2.MAINTENANCE.....................................................................................................................9-6
CHAPTER 10 : APPENDICES.........................................................................10-1
1.PROGRAMMING EXAMPLE...............................................................................................10-2
2.ORDERING FORM ..............................................................................................................10-3
3.LNS ADDRESSES...............................................................................................................10-4

CHAPTER 1: BASIC PRINCIPLES 1-1
SPRINT 545/565 S2
CHAPTER 1 :
BASIC PRINCIPLES

1-2 CHAPTER 1: BASIC PRINCIPLES
SPRINT 545/565 S2
1. STRUCTURE
This manual consists of various chapters, each containing several points, paragraphs, etc. Lists may be
contained in paragraphs.
the page number is shown at the top of the page;
the chapter number and title are shown at the top of the page;
the bar feeder model is shown at the top 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 to avoid 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 indicates advice concerning environmental protection.

CHAPTER 1: BASIC PRINCIPLES 1-3
SPRINT 545/565 S2
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, audio or other, without the
express written authorization of LNS SA, is prohibited. LNS SA accepts no responsibility for errors which
may be contained in this manual 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 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.

1-4 CHAPTER 1: BASIC PRINCIPLES
SPRINT 545/565 S2
"CE" DECLARATION OF CONFORMITY
As per annex II A of directive 2006/42/EC
We hereby declare that the following machinery is manufactured in compliance with the
following 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
Switzerland
Technical Dossier Compiled by: Plaseco Kurt De Pauw
Chemin des Petits-Clos 12
CH- 1744 Chénens
Switzerland
Description of the machine Automatic bar loader
Type Sprint 545 / 565 S2
Delivery serial no. XXXXXX / 2015
The machine meets the following essential requirements applicable as per directive 2006/42/EC:
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 harmonised standards have been used as a basis:
- Concerning the 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 distances,
EN ISO 13855:2010 : Safety of machinery – Positioning of safeguards,
ISO 14120:2002 : Safety of machinery – Design of movable guards,
EN ISO 13850:2008 : Safety of machinery – Emergency stop function,
EN ISO 13849-1:2008 : Safety of machinery – Safety-related parts of control systems,
ISO 14118:2000 : Safety of machinery – Prevention of unexpected start-up,
EN 60204-1:2005 : Safety of machinery – Electrical equipment of machines,
EN ISO 14119 :2013 : Safety of machinery – Interlocking devices associated with guards,
EN ISO 4414:2011 : Pneumatic fluid power - General rules and safety requirements,
IEC 60812:2006 : Safety of machinery – FMECA analysis
- Concerning the Low voltage directive:
EN 61439-1/3 :2013 : Low voltage switchgear and controlgear assemblies,
- Concerning the EMC directive:
EN 61000-6-4 : Emission standard for industrial environments,
EN 61000-6-2 : Immunity for industrial environments
Location and date: Stamp and signature:
Orvin, xx xxxx 2015 Nadia Pellaton
Export Department Manager

CHAPTER 1: BASIC PRINCIPLES 1-5
SPRINT 545/565 S2
3. SAFETY REQUIREMENTS
Do not handle the equipment without having
knowledge of the safety instructions and the
instructions for use. Safety instructions for the
bar feeder, as well as the CNC lathe, must be
strictly observed.
Non-qualified personnel, children, and persons
under the influence of alcohol or medication
should not handle the equipment.
Loose garments, long hair and jewellery can
be dangerous.
Do not remove any covers while the bar
feeder or the machine is under electrical
power.
Do not conduct any maintenance operations
during the automatic cycle.
Do not grasp moving or rotating objects, or
nearby elements.
If certain safety shields or safety covers are
removed to conduct maintenance, they must
be reinstalled as soon as the maintenance
work is completed.
No servicing should be carried out on the
interface or inside the electrical cabinet while
the bar feeder or the lathe is under 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 indicated points for
lifting and moving the bar feeder. 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.

Do not knock the bar feeder while moving it as
this could damage it.
Do not move the bar feeder while it is electrically
powered on.
The work area surrounding the bar feeder should
always be clear of objects and well lit. The
presence of oil on the ground could cause falls; it
is important to keep 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.
Do not open the clamping unit (collet or chuck) of
the lathe manually when the bar feeder is in
automatic mode (Interface).
Each time the diameter is changed, also adapt
the 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.
Do not attempt to recharge the batteries of the
PLC.
For the use and maintenance of the bar feeder,
use only parts provided by or recommended by
LNS.
If it is necessary to move the bar feeder after it
has been commissioned, LNS or its local
representative must be contacted before any
attempt to restart it.
The bar should never extend beyond the lathe's
clamping unit more than 3 times its diameter.
LNS accepts no responsibility for possible
accidents or property damage caused when
safety instructions are not followed.

1-6 CHAPTER 1: BASIC PRINCIPLES
SPRINT 545/565 S2
4. SAFETY DEVICES
4.1. Description
This bar feeder has been designed with the aim of ensuring it offers maximum safety during use; it meets
all EC requirements.
Safety covers and devices make access to the moving parts of the bar feeder impossible. Safety switches
keep the bar feeder from operating when these protections are open. The design of switches, and their
integration on the bar feeder, makes their exclusion almost impossible.
By pressing 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 responsible for possible
accidents or property damage, whether caused directly or not, by any means whatsoever,
if certain safety devices have not been included.
4.2. Layout of the elements on the bar feeder
Designation Description
A
Emergency s
t
op button
B Main access cover
C Protective grille
SQ10 Safety switch for the retraction system (option)
SQ11 Safety switch of the main access cover
SQ15 Safety switch for the protective grille
SQ16 Safety switch for the bar magazine
A
B
SQ11
SQ10
SQ15
C
SQ16

CHAPTER 2: TECHNICAL DATA 2-1
SPRINT 545/565 S2
CHAPTER 2 :
TECHNICAL DATA

2-2 CHAPTER 2: TECHNICAL DATA
SPRINT 545/565 S2
1. CHARACTERISTICS
Unit 3 m 12’ 4 m
Weight kg 900 970 1100
Dimensions See p. 2-3
Retraction distance (option) mm SPRINT 545: 500 /
SPRINT 565 S2:350
min. Ø round bar
min. Ø profiled bar (size on flat sides) mm 5 square: 4 - hexagonal: 5
Sprint 545:
max. Ø mm 45
Sprint 565 S2:
max. Ø round bar
max. Ø round bar (without bar prep.)
max. Ø square profiled bar (size on flat
sides)
max. Ø hexagonal profiled bar (size on
flat sides)
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
Pneumatic supply pressure bar
(kPa) 5 (500)
Air consumption litres < 10 / loading cycle
Supply voltage (at 50 or 60Hz) Volts 3x 220 – 480
Maximum pushing force (60% motor
torque: maximum possible value) daN SPRINT 545: 235 / SPRINT 565 S2: 120
Maximum feed rate m/min >60
Loading cycle seconds 30 – 40
Quantity of hydraulic oil (ISO100) kg 80 90 100
Depending on the country and the applicable standards, some of the technical data, such as the supply
voltage, may vary.

CHAPTER 2: TECHNICAL DATA 2-3
SPRINT 545/565 S2
2. FLOOR 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 elements of
the bar feeder will be provided upon request.

2-4 CHAPTER 2: TECHNICAL DATA
SPRINT 545/565 S2

CHAPTER 2: TECHNICAL DATA 2-5
SPRINT 545/565 S2
3. LAYOUT OF THE ELEMENTS
Designation Description
A
Pusher (not visible)
B Belt drive
C Vice
D Remnant control
E Guiding blocks
F Remnant recovery device
G Remote control
H Main access cover
I Front res
t
J Interface connector (not shown)
K
A
ir blas
t
L Measure path probe
M Front stand
N Retraction device (option)
O Rear stand
P Bar magazine
Q
A
ir handling
R Electrical cabinet
S Pneumatic assembl
y
T Protective grille
B
C
D
E
F
G
H
I
K
L
M
N
O
P
Q
R
S
T

2-6 CHAPTER 2: TECHNICAL DATA
SPRINT 545/565 S2

CHAPTER 3: SYSTEM START UP 3-1
SPRINT 545/565 S2
CHAPTER 3 :
SYSTEM START UP

3-2 CHAPTER 3: SYSTEM START UP
SPRINT 545/565S2
1. TRANSPORTATION
Please read the safety instructions provided at the beginning of this manual before
handling the following devices.
1.1. Description
Depending on its destination, the bar feeder may be delivered either on a pallet, or packed in a wooden
crate. When transported by sea or 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 or damage to objects. These instructions are stapled to the crate of the
bar feeder.
Crat
e
Pallet
Type 3m, 4m, 12
’
3m, 4m, 12
’
Width 1150 mm 90 mm
Length 4700 mm 4800 mm
Height 1750 mm ---
1.2. Unpacking
For practical and safety reasons, the bar feeder must be unpacked in a spacious, well-lit location.
Check that the hoisting crane or lift truck has sufficient lifting capacity before starting
handling of the merchandise. Ensure that no one is in the vicinity of the suspended load, or
within the operating range of the hoisting crane.
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.
1
2
3

CHAPTER 3: SYSTEM START UP 3-3
SPRINT 545/565 S2
From this point on, the bar feeder is unpacked in the same way as when delivered on a pallet.
The 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.
Take out the parts and place them in an easily accessible area for mounting the bar feeder.
A
B
C
D

3-4 CHAPTER 3: SYSTEM START UP
SPRINT 545/565S2
1.3. Preparation for assembly
For assembly and installation of 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 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.
I
N
T
E
R
D
I
T
!
F
O
R
B
I
D
D
E
N
!
V
E
R
B
O
T
E
N
!
P
R
O
I
B
I
T
O
!
B
A
B