Page 1
Bar Feeds & Accessories • Chip & Coolant Management • Work Support Systems Alpha ST 320 Instruction Manual LNS America 4621 East Tech Drive Cincinnati, Ohio 45245 Telephone: 513-528-5674 Fax: 513-528-5733 http://www.LNSAmerica.com Email: Sales@LNSAmerica.com Member of the LNS Group...
Safety instructions Safety devices CHAPTER 2 TECHNICAL DATA Characteristics Floor plans CHAPTER 3 SETTING INTO OPERATION Transport Overview Installation CHAPTER 4 ELECTRICS Interface Diagrams Electrics CHAPTER 5 PNEUMATICS Pneumatic equipment CHAPTER 6 HYDRAULICS Hydraulic system Hydraulic schematic ALPHA ST 320...
Page 4
Manual loading system TD-200 display and settings CHAPTER 9 MALFUNCTIONS Alarm messages and troubleshooting CHAPTER 10 SPARE PARTS Spare parts 10-2 APPENDICES Appendix A : Programming example Appendix B : Ordering form Appendix C : LNS agencies ALPHA ST 320...
Page 5
CHAPTER 1: BASIC NOTIONS CHAPTER 1: BASIC NOTIONS STRUCTURE Cross-references Captions Symbols and terminology RIGHTS DECLARATION OF COMPLIANCE SAFETY INSTRUCTIONS SAFETY DEVICES Description Layout ALPHA ST 320...
(see chapter *) or (see point *). 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.
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. ALPHA ST 320...
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.
CH-2534 Orvin Declares that: The ALPHA ST 320 automatic bar feed system Is designed to be incorporated into a machine, or to be assembled with other machines, to create a machine covered by Directive 89/392/EEC amended, and that the following (parts/paragraphs) of the harmonized standards have been applied: EN 292, EN 60 204 1, EN 1088, EN 418, EN 60947, 89/336/EEC, 73/23/EEC.
If it is necessary to move the bar feeder the interface or inside the electrical once it has been originally installed, do cabinet while the bar feeder or the lathe not reinstall it before first contacting LNS is under electrical power. or its local representative. •...
SAFETY DEVICES Description The ALPHA ST 320 bar feed system has been designed with a focus on maximum safety during its handling and complies with all IEC requirements. Safety covers and devices make access to the moving parts of the bar feed system impossible. Safety switches keep the bar feed system from operating when these protections are open.
The following floor space plans indicate the most frequently used dimensions for placing the bar feed system. Details on the dimensions of other parts or elements of the bar feed system will be furnished upon request. All dimensions on the following diagram are listed in millimeters. ALPHA ST 320...
Page 15
CHAPTER 2: TECHNICAL DATA Alpha ST 320 floor plan ALPHA ST 320...
Page 16
CHAPTER 2 : TECHNICAL DATA ALPHA ST 320...
Page 17
CHAPTER 3: SETTING INTO OPERATION CHAPTER 3: SETTING INTO OPERATION TRANSPORT Crate dimension Unpacking OVERVIEW INSTALLATION ALPHA ST 320...
To protect the bar feeder during transportation, the bar feeder is shipped in a wood crate. Please make sure it is not damaged before you open it. Crate dimension Type Total Weight Length Width Height [kg / lbs] [mm] [mm] [mm] 3.7m (12ft) 1459 / 3217 4940 1410 ALPHA ST 320...
Open the crate. Remove the top panel first (Fig 3.1) Fig 3.1 Step 2: To lift the whole machine, use two 30mm bars of 1m length each. Slide them into the stand and use a lifting strap (Fig 3.2 #5) to lift the machine. Fig 3.2 ALPHA ST 320...
For more information about the guiding channel, refer to Chapter 7. Step 4: Collets corresponding to the bar stock size are needed. Fig 3.4 Designation Description Guiding channels Pusher support Feeding pusher ALPHA ST 320...
Page 21
The bar feeder is hydraulic; the oil tank capacity is about 40 liters. (Fig 3.3 #6) Only use ISO 100 quality oil. When filling the tank, check the level with the filling gauge. (Fig 3.5) For more information about the hydraulic system, refer to Chapter 6. Fig 3.5 ALPHA ST 320...
(Fig 3.6 #3 ) feeder using the main screw. (Fig 3.6 #3 ) Fig 3.6 Fig 3.6 Step 5: Remove the front tube and replace it with the alignment bushing. (Fig 3.7 #1) Fig 3.7 ALPHA ST 320...
Page 23
Step 10: Tighten all the locking screws (Fig 3.6 #1, 2, 3) and re-check the alignment. Step 11: Remove the string and bushing and reinstall the connecting parts. On swiss type lathes make sure the headstock can move along the entire travel. ALPHA ST 320...
Page 24
Step 12: Anchor the bar feeder to the floor. (Fig 3.10) Fig 3.10 Step 13: Connect the interface cable. Step 14: Fill the oil tank (through the remnant evacuation slot). Step 15: Turn the bar feeder on and set the parameters. ALPHA ST 320...
Page 25
CHAPTER 4: ELECTRICS CHAPTER 4: ELECTRICS ELECTRICS Layout of the electrical elements Layout of the elements in the control cabinet PCB Layout 4-11 Symbols 4-13 Electric diagrams 4-15 INTERFACE 4-27 Power 4-27 Signal 4-27 DIAGRAMS 4-28 ALPHA ST 320...
Measuring device proximity switch 9A30-001 Pusher home position switch (proximity switch) 9A30-002 Guiding channel closed verification switch 9A30-003 Remnant extraction verification switch 9A30-004 Guiding channel open verification switch 4.050 Oil pressure switch SQ11 4.763 Main access cover switch ALPHA ST 320...
Page 27
9A05-009 Main disconnect switch 9A05-005 Power supply Supply Hydraulic pump motor 9A05-010 PCB Board 9A05-003 Printed circuit board overload protection 9A05-007 Main power circuit breaker 705-025 Safety circuit contactor Analog output EM223 9A05-011 I/O expansion module EM232 9A05-012 expansion module ALPHA ST 320...
Page 28
After having located and repaired the problem reset the lever (B) of the circuit breaker. The factory setting of the breaking current is 2.5 Amperes. Designation Description Power in connecting terminal Lever off/on Power out connecting terminal ALPHA ST 320...
Page 29
Lever off/on Power out connecting terminal 1.2.2 +24 VDC Power supply The power supply module provides DC 24V voltage for various modules of the PLC, PCB switches, solenoid electrovalves, etc. Designation Description Input AC200/220V Output DC 24V ALPHA ST 320...
Page 30
230 V + ground power supply Power output to SERVO motor Battery (not used) Battery plug Emergency stop contact Encoder connecting plug Programmable controller / SERVO amplifier communication connecting plug Alarm and codes display of amplifier Cover 220 Vac Input ALPHA ST 320...
Page 31
The PLC program manages this information. The PLC sets the interface signals, controls the servo drive as well as the pneumatic valves and displays the appropriate messages on the text display. Designation Part No Description 9A05-001 CPU module I/O extension module Analog module (for SERVO control) ALPHA ST 320...
Page 32
Interface connecting to TD200 Output terminal Q0.0~Q1.7 Expansion module Input terminal I0.0~I2.7 Port, Stop/Run, PR0/PR1 selectors provided inside expansion module PR0 for analog signal adjustment PR1 for analog signal adjustment Flexible ribbon cable connecting to expansion module ALPHA ST 320...
Page 33
CHAPTER 4: ELECTRICS (b) Module 1 Designation Description Output Q2.0~Q2.3 Input I3.0~I3.3 Flexible ribbon cable connecting to expansion module (c) Module 2 Designation Description Analog Signal Output (for servo drive control). Main power I/P terminal ALPHA ST 320...
Page 34
Designation Description Main power I/P(From QF1) Main power O/P(To servo amplifier) Motion help contact(To PLC) Contactor control main power Operating State (I = energized / O = De-energized) ALPHA ST 320...
Page 35
Interface relay – Barfeed Alarm Interface relay – Load Cycle Complete Interface relay – End of Bar Interface relay – Spindle Interlock Interface relay – Servo Amp “ON” relay Servo Amp Alarm relay Not used Not used ALPHA ST 320...
Page 36
4-12 CHAPTER 4: ELECTRICS (a) Interface signals from the CNC-lathe (b) Interface signals from the bar feeder ALPHA ST 320...
Page 37
CHAPTER 4: ELECTRICS 4-13 Symbols Symbol Description Designation Main disconnect switch Main circuit Circuit-breaker Contactor mains Transformer Bridge rectifier Fuse Fuse Servo motor Hydraulic pump motor ALPHA ST 320...
Page 38
4-14 CHAPTER 4: ELECTRICS Symbol Description Designation Emergency stop Safety switch Indicator lamp Relay Valve solenoid Diode Select switch Proximity switch Limit switch Air pressure switch Momentary switch Function switch ALPHA ST 320...
Page 39
CHAPTER 4: ELECTRICS 4-15 Electric diagrams ALPHA ST 320...
R2:Loading cycle completed signal R3:End of bar R4:Automatic mode R5:Bar loader empty alarm There are several parameters to configure the interface (authorized personnel only). The recommended parameter settings are given on the interface diagram in the electrical cabinet. ALPHA ST 320...
4-28 CHAPTER 4: ELECTRICS DIAGRAMS The interface diagram below is provided an example. The diagram corresponding to your bar feed system is located in the electric cabinet, with the electric diagram. ALPHA ST 320...
Page 53
CHAPTER 5: PNEUMATICS CHAPTER 5: PNEUMATICS PNEUMATIC EQUIPMENT Description Weekly maintenance Pneumatic System Diagram ALPHA ST 320...
Please read the safety precautions described at the beginning of this manual before handling the following devices. Description The following automatic movements of the Alpha ST 320 bar feeder system are done via pneumatic elements, namely: The locking of the feeding pusher...
The oil pump starts running when the bar feeder is in auto mode. It stops when the pusher reaches the anti-vibration or if the lathe is not running for more than 5 minutes. (Collet signal absent) ALPHA ST 320...
(pusher diameter = channel diameter – 1 mm). Anti- vibration needs to be adjusted to pusher size. Fig 7.1 Designation Description Feeding pusher Loading flag PU channel PE channel Support ALPHA ST 320...
Page 63
Step 4: Replace the channels (# 5 & # 6). Step 5: Lock in place the new support pusher (# 4) and the new flag (# 2). Step 6: Insert the new pusher (# 3). Fig 7.2 ALPHA ST 320...
The vise is actuated by a pneumatic cylinder (Fig 7.4 #1). It does not need to be adjusted for each bar diameter. The sensor LED (Fig 7.4 #2) is only ‘ON’ when the vise is closed without bar between the jaws (Fig 7.4 #3). Fig. 7.4 ALPHA ST 320...
Each time a new bar is loaded, the plate (Fig 7.7 #1) is brought to the upright position and obstructs the guiding channel. When the bar hits the plate, the switch (Fig 7.7 #2) is activated and plate (Fig 7.7 #1) flips downward. Fig. 7.7 ALPHA ST 320...
Loosen the nuts (Fig 7.10 #3, #4). Tighten nut (Fig 7.10 #4) until it touches the main support (Fig 7.10 #5). From there, tighten 1 more turn to release the material and lock nuts (Fig 7.10 #4, #3) together. ALPHA ST 320...
The bar feeder is equipped with a remnant drawer (Fig 7.11). It may be removed to empty it and slide it back into position when the bar feeder is in operation. Max remnant length: 400 mm / 15.748 in Min remnant length: 50 mm / 1.968 in Fig 7.10 ALPHA ST 320...
Page 68
CHAPTER 7 : GENERAL DESCRIPTION ALPHA ST 320...
Page 69
CHAPTER 8: OPERATION REMOTE CONTROL MANUAL OPERATION Guiding Channel Closed Guiding Channel Open Automatic Operation TD-200 DISPLAY AND SETTINGS Parameter F1~F8 display and description P0 & P1 Setting Message Display MANUAL mode display AUTO mode display 8-10 ALPHA ST 320...
REMOTE CONTROL Designation Description Emergency Stop push button Manual mode Pusher forward Guiding channels open Guiding channels closed Pusher reverse Auto mode Auto Start Alarm indicator Spindle inching End of bar Lathe push command Collet signal status ALPHA ST 320...
The function of the manual operation keys depends on the status of the guiding channel cover (open or close). Guiding Channel Closed Move pusher forward Move pusher forward with reduced speed. Move pusher backward Move pusher backward with reduced speed Open channel. Condition: Pusher in home position (SQ2 activated) No Function ALPHA ST 320...
Guiding Channel Open Move loading flag forward Move loading flag forward with reduced speed. Move loading flag backward Move loading flag backward with reduced speed Length measurement device on (SQ1) Close channel and insert bar into chuck ALPHA ST 320...
The bar is moved forward to the Top Cut position. Step 4: The lathe makes the Top Cut and starts producing parts. Step 5: When the ‘End of bar’ position is reached the clamping device opens and the pusher retracts with the remnant. ALPHA ST 320...
To select Functions 1 – 4 (F1 – F4): Step 1: Press F1 , F2 , F3 or F4 Step 2: Enter Step 3: Press ▲ or ▼ to change parameter Step 4: Press Enter to confirm the change ALPHA ST 320...
= 22mm. With every work piece the remaining bar length is reduced by 22mm. 3.1.3 F3 : Guiding Channel Diameter Guiding channel size:This value affects the pushing force. It should correspond to the actual channel size (the channel size is marked on the channel). ALPHA ST 320...
Page 76
Too Short: “0”, no underfeeding (too short) alarm. “1”, alarm will occur in case of underfeeding. F7: Too Long: “0”, no overfeeding (too long) alarm. “1”, alarm will occur in case of overfeeding. ALPHA ST 320...
Seq. Region --- PLC software status (for technician only). – Sequence number Speed Region --- Motor speed percentage. Torque Region --- Motor torque percentage. Pusher Region --- Current pusher position P0 Region --- see chapter 8 4.2 P1 Region --- see chapter 8 4.2 ALPHA ST 320...
‘*OFF’ Chuck closed and servo OFF. Seq. Region --- PLC software status (for technician only). – Sequence number Speed Region --- Motor speed percentage. Torque Region --- Motor torque percentage. Pusher Region --- Current pusher position ALPHA ST 320...
Page 79
Alarm 31 – Position Error 1.24 Alarm 32 – Loading Safety Time Elapsed 1.25 Alarm 33 – Lathe Did Not Resume Start Cycle 1.26 Alarm 34 – Pusher Drive Error 1.27 Alarm 35 – Alarm Signal From the Lathe ALPHA ST 320...
Alarm3: Description : An obstacle has prevented the servo drive from moving. Solution : Power down the bar feed for 2 sec. and power back on. Check for a mechanical obstruction. Check for burrs on bar stock. ALPHA ST 320...
Alarm 7 – Bar Stock Cannot Extracted Collet Alarm7: Description : Pusher can not retract back to home position when attempting to extract the bar Solution : Chamfer/cut off burrs on the bar end. Check collet size. ALPHA ST 320...
Only applies to fix type lathes. Occurs when the feeding distance is bigger than the defined part length (parameter F2). Solution : Check parameter F2. Check the timing of the ‘chuck open’ interface signal (PLC input I3.1). Check that turret stop tool is not broken. ALPHA ST 320...
Alarm 15 – Bar Feeder is Not in Auto Alarm15: Description : If the lathe chuck is opened and closed more than three times while the bar feeder is in manual mode this alarm will occur. Solution : Select bar feeder Auto Mode. ALPHA ST 320...
Limit switches SQ5 (open position) and SQ3 (close position) are both activated at the same time. Solution : Check the adjustment of the limit switches. Check that the switches function. Replace if necessary. Check wiring of limit switches to PLC. ALPHA ST 320...
Alarm 23 – Default Prior to Open Guiding Channel Alarm23: Description : The open position limit switch gives a signal before the channel open. Solenoid (YV2A) is activated Solution : Check position and function of limit switch SQ5. ALPHA ST 320...
This alarm occurs if the newly loaded bar does not reach the top-cut position within a predetermined time limit. Solution : Clean burrs/chamfer bar end. Check for a mechanical obstacle preventing the loading flag from traveling forward. Check value of parameter F5. ALPHA ST 320...
Solution : Check the mechanical power transmission from motor to the pusher (chain broken? chain too loose?). 1.27 Alarm 35 – Alarm Signal From the Lathe Alarm35: Description : Alarm signal from lathe. Solution : Check the lathe. ALPHA ST 320...
Page 88
9-10 CHAPTER 9 : MALFUNCTIONS ALPHA ST 320...
Page 89
Rack Cover 10-4 Extraction Device 10-5 Chassis Assembly 10-7 Cover 10-8 Hydraulic Tank 10-9 Chain Drive Assembly 10-10 Bar Measuring 10-11 Pusher Lifting System 10-12 1.10 Front Rest 10-13 1.11 Upper Channel 10-15 1.12 Guiding Elements 10-17 ALPHA ST 320...
CHAPTER 10: SPARE PARTS 10-17 1.12 Guiding Elements ALPHA ST 320...
Page 106
10-18 CHAPTER 10: SPARE PARTS ALPHA ST 320...
Page 107
CHAPTER 10: SPARE PARTS 10-19 ALPHA ST 320...
Page 108
10-20 CHAPTER 10: SPARE PARTS ALPHA ST 320...
Page 109
CHAPTER 10: SPARE PARTS 10-21 ALPHA ST 320...
Page 110
10-22 CHAPTER 10: SPARE PARTS ALPHA ST 320...
Page 111
CHAPTER 10: SPARE PARTS 10-23 ALPHA ST 320...
Page 112
10-24 CHAPTER 1 0: SPARE PARTS ALPHA ST 320...
Page 113
APPENDICES APPENDICES APPENDIX A: PROGRAMMING EXAMPLE APPENDIX B: ORDERING FORM APPENDIX C: LNS AGENCIES ALPHA ST 320...
Page 114
N... X, Z, G, F, T, S, M, ... N... N... END OF PROGRAM (LOOP) Important : The above is an example only. Programming may change according to the interface between the lathe and the bar feed. ALPHA ST 320...
Page 115
APPENDICES APPENDIX B: ORDERING FORM This form should 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 :...