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I n s t r u c t i o n Ma n u a l L N S A me r i c a , I n c . 4 6 2 1 E a s t T e c h D r i v e C i n c i n n a t i , O H 4 5 2 4 5 T e l : 5 1 3 .
V1.1 12.10.08 TABLE OF CONTENTS CHAPTER 1 BASIC NOTIONS Structure Rights Declaration of compliance Safety instructions Safety devices CHAPTER 2 TECHNICAL DATA Characteristics Floor plans Layout of the elements CHAPTER 3 SETTING INTO OPERATION Preparation for installation Assembling instructions Alignment Anchoring Loader assembly CHAPTER 4...
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CHAPTER 8 OPERATION Remote control Powering up / down Automatic sequence Settings CHAPTER 9 MALFUNCTIONS Maintenance CHAPTER 10 SPARE PARTS Spare parts 10-2 APPENDICES Appendix A : Programming example Appendix B : Ordering form Appendix C : LNS agencies SPRINT S3...
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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 SPRINT S3...
(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.
CHAPTER 1: BASIC NOTIONS 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.
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 HYDROBAR SPRINT S3 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 • once it has been originally installed, do It is strictly prohibited to jump wire or not reinstall it before first contacting LNS remove circuit breakers, main switches, or its local representative. and especially safety switches.
SAFETY DEVICES Description The HYDROBAR SPRINT S3 bar feed system has been designed with a focus on maximum safety during its handling and complies with all IEC requirements. Safety covers an devices make access to the moving parts of the bar feed system impossible. Safety witches keep the bar feed system from operating when these protections are open.
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CHAPTER 2: TECHNICAL DATA CHAPTER 2: TECHNICAL DATA CHARACTERISTICS (*) FLOOR PLAN Hydrobar Sprint S3 Floor Plan LAYOUT OF THE ELEMENTS SPRINT S3...
CHAPTER 2: TECHNICAL DATA CHARACTERISTICS (*) 12 ft Weight [kg / lbs.] 1719 kg / 3790 lbs. Dimensions [mm] 4670 L x 1515 W x 1390 H Min. / Max. diameter ½” / 3 1/8” Min. / Max. bar stock length 70”...
CHAPTER 2: TECHNICAL DATA Designation Description Air control unit Connection box Hydraulic filter Remote control station Control box Loader Loading Ramp Oil recouperator Cover opening arm Upper bearing element Lower bearing element Pneumatic motor Hydraulic pump motor Loader motor Measuring cell Guiding bearings locked prox.
CHAPTER 3: SETTING INTO OPERATION PREPARATION FOR INSTALLATION It is recommended the bar feeder to be installed by LNS or by one of its representatives. To prevent serious damage to the bar feeder, thoroughly follow the hoisting instructions provided with the bar feeder. Do not lift the unit other than at the indicated hoisting points.
CHAPTER 3: SETTING INTO OPERATION Air Requirements and Connections Air pressure is necessary for installation to operate the bar feeder. A minimum pressure of 5 bar (75 psi) is required. Maximum pressure: 6 bar (90 psi). Air must be clean and dry. The Sprint is equipped with a filtering device to provide maximum air cleaning (see chapter 5, point 1.1).
Lift the bar feed system and remove the distance between the lathe and the bar feed system. The distance 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 feed system must be cleared to allow for their maintenance and handling.
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CHAPTER 3: SETTING INTO OPERATION SPRINT S3...
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CHAPTER 3: SETTING INTO OPERATION SPRINT S3...
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CHAPTER 4: ELECTRICS CHAPTER 4: ELECTRICS ELECTRICAL EQUIPMENT Description Layout of the electrical elements Description of the electrical elements of the bar system ELECTRICAL CABINET Layout of the elements in the electrical cabinet Description of the elements in the cabinet PROGRAMMABLE CONTROLLER (PLC) PLC inputs / outputs ELECTRICAL DRAWINGS...
Please read the safety instructions provided at the beginning of this manual before handling the following devices. 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 representative. Description The electrical parts of the bar feed system, as well as the diagrams representing them, conform to the ISO/IEC 204-1, 617 international electrical codes.
CHAPTER 4: ELECTRICS Layout of the electrical elements SQ11/1 SQ11 Designation Part No Description 3.569 Pneumatic motor control valves (YV 16 – 18) 3.569 Air valve battery (YV 1-9, 13 – 14, 19, 21) Electrical connection box 4.875 Remote control station Electrical control box (not shown) 680-000 Positioning encoder...
Hydraulic pump motor 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 representative. It is strictly prohibited to make adjustments as long as the bar feed system is under electrical power.
CHAPTER 4: ELECTRICS ELECTRICAL CABINET Layout of the elements in the electrical cabinet Designation Part No Description 4.887 Programmable controller PCD3 (PLC) Interface terminal blocks (XT3) Power supply terminal block (XT1) Safety terminal blocks (XT2) 705-025 Safety chain control KReset 501-255 KReset relay (M2 motor encoder reset) 501-255...
CHAPTER 4: ELECTRICS Description of the elements in the cabinet 2.2.1 Main disconnect switch QS1 In accordance with the requirements of the international IEC standards, when the main disconnect switch is at 0 off, it interrupts the input of the three phases in the control cabinet of the bar feed system.
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CHAPTER 4: ELECTRICS 2.2.4 Transformers 230 V (T1) and 24 VDC (T2) The transformers T1 and T2 power the entire low voltage network of the bar feed system, as well as a portion of the interface signals. To replace the fuse: Remove the orange fuse compartment;...
CHAPTER 4: ELECTRICS PROGRAMMABLE CONTROLLER (PLC) The programmable controller (PLC) continuously scrutinizes all data from the remote control, probes, switches, cells, interface, etc. The program loaded into the PLC manages this information. The PLC then distributes the interface signals, controls the SERVO drives as well as the pneumatic valves, and displays the appropriate messages on the remote control station.
4-18 CHAPTER 4: ELECTRICS INTERFACE Before turning the power on, ensure that the voltage of the bar feed system corresponds to that of the lathe. The voltage of the bar feed system is indicated on the identification plate located inside the bar feed on the rear main rail. Description 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 located inside the electrical cabinet.
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Hydraulic pump motor Bar stock magazine motor The LNS bar feed systems are equipped with their own thermal protection systems (breakers, thermal relays and fuses, etc.). The power supply for the bar feed system should be connected to the output of a breaker mounted in the electrical control box of the lathe (10 A max.).
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4-22 CHAPTER 4: ELECTRICS Lathe clamp signal (PLC input A1) This signal is for checking the mode of the lathe clamping device (open), and is mainly used for the feeding of a part, which takes place each time the clamp opens. For safety reasons, wire a normally open contact, coming from the signal of the lathe clamp.
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5.3.4 Options The options described below are an integral part of the standard equipment of the LNS bar feed systems. These signals, however, are not required for the proper operation of the devices, or the safety locking for protecting persons and materials. The options are available only to optimize production conditions.
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CHAPTER 5: PNEUMATICS CHAPTER 5: PNEUMATICS AIR ADJUSTMENTS Main pressure Air motor pressure Pusher feed rate adjustments Air cylinders, air valves DIAGRAMS SPRINT S3...
Please read the safety instructions provided at the beginning of this manual before handling the following devices. Main pressure For trouble free operation of the Hydrobar Sprint S3, a minimum of 5 bar (75 PSI) is required but should not exceed 6 bar (90 PSI) Should an adjustment be necessary: Procedure: •...
CHAPTER 5: PNEUMATICS Pusher feed rate adjustments The feed rate can be adjusted by adjusting valves (F) and (G). An average feed rate is factory adjusted. Should an adjustment be necessary : Pusher fast forward • To increase the feed rate turn adjusting valve (F) counterclockwise. •...
CHAPTER 5: PNEUMATICS Air cylinders, air valves An air cylinder can be manually activated by rotating the screw "A" located on its corresponding air valve. The screw "A" must be returned to its original position (B) to prevent any malfunction of the electro-valve and the Sprint. The feed rate of the piston can also be adjusted by turning the air regulators (1) and (2).
Description The HYDROBAR SPRINT S3 is equipped with a hydraulic pump to provide oil pressure to the bearing elements. This oil will allow ideal guidance and support of the bar in rotation. A flow adjusting valve is located inside the body of the Sprint next to the hydraulic pump motor (rear of the bar feeder).
Oil must comply with ISO 100 standards. Oil will be poured inside the lower part of the HYDROBAR SPRINT S3. To follow is a list of just a few oils and suppliers that could be used.
BAR STOCK PREPARATION Solid bars LNS recommends to chamfer the back end of the bar stock with a 30 degrees concentric chamfer (60 degrees included). This will provide a concentric rotation of the pusher and a safe contact bar stock/pusher cone after the bar stock leaves the bar feeder.
CHAPTER 7: GENERAL DESCRIPTION DIAMETER CHANGEOVER For optimum performance, it is recommended to equip the Sprint with the corresponding accessories to each bar stock diameter. These elements are also designed to operate in a certain diameter range. To obtain optimal rpm performance, it is recommended not to exceed 6 mm (.23") gap between the O.D. of the bar stock and the I.D.
CHAPTER 7: GENERAL DESCRIPTION Bearing elements changeover Procedure (Open the bearing blocks, remove the pusher. (see chapter 7, point 2.1) • Upper half bearing element The upper elements (1) are secured in the upper half of the bearing blocks by a quick disconnect system (A). To remove them, push down the bearing elements.
CHAPTER 7: GENERAL DESCRIPTION Flag changeover Each flag covers a range and can be used for different size of rotating sleeves. The range is indicated on each flag. Before replacing the flag, remove the pusher and the rotating sleeve. Unscrew lock screws (A) and remove flag. Select appropriate flag (B) and install on chain.
CHAPTER 7: GENERAL DESCRIPTION GEAR RATIOS The pushing force of the pusher must be adjusted according to the bar stock diameter. The pushing force can be adjusted with the air adjusting valve (see chapter 7, point 2.7). For more flexibility and for wider adjusting range, the motor gear ratio can be changed. The gear ratio 1/6 is recommended for bar stock over 58mm (2") diameter.
CHAPTER 7: GENERAL DESCRIPTION SPINDLE REDUCTION TUBES CHANGEOVER To allow proper feeding of the bar stock through the clamping cylinder and the headstock, it is recommended to mount spindle reduction tubes (spindle liners). Ideally, the I.D. of the spindle liner must correspond to the I.D.
7-10 CHAPTER 7: GENERAL DESCRIPTION GUIDING ELEMENTS CHANGE Conditions : No bar stock in the magazine Pusher in home position Barfeed in STOP mode Procedure : • Enter the manual mode by pushing F1. • Manual mode: Select the pusher changeover procedure.by pushing F4 [SET]. The text "READY TO START PUSHER CHANGEOVER FUNCTION"...
CHAPTER 7: GENERAL DESCRIPTION 7-11 End of bar Principle : In automatic cycle, when the pusher reaches the end of bar position, the remaining material is too short to machine another part and the lathe will hold its production cycle and a new bar is loaded. The production cycle (program) will resume once the new bar has reached the top-cut position.
7-12 CHAPTER 7 : GENERAL DESCRIPTION Mechanical stop To prevent damage to the pusher and to the tools of the lathe, a mechanical stop is mounted in front of the bar feeder. This stop must be adjusted during initial installation. It must be positioned so that the front of the pusher cannot reach the inside of the collet of the lathe.
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CHAPTER 8: OPERATION CHAPTER 8: OPERATION REMOTE CONTROL Display Function keys F1 - F4 Emergency stop switch STOP key POWERING UP / DOWN Description AUTOMATIC SEQUENCE Description SETTINGS Description Access to the functions SPRINT S3...
CHAPTER 8: OPERATION REMOTE CONTROL The ergonomic and user-friendly remote control with a clear built-in display facilitates the handling of the bar feed system. Depending on the sequence under way, the bar feed system gives access only to those functions which are available, thus avoiding any incorrect handling, and reducing the access time to the necessary functions.
CHAPTER 8: OPERATION Display The liquid crystal display provides the operator with all the necessary data, both for handling the bar feed system and for maintenance. • The upper portion of the display has eleven lines and is reserved for the reading of text. Error messages are usually displayed with their diagnostics.
CHAPTER 8: OPERATION Function keys F1 - F4 These keys are located right below the display. The functions attributed to them are indicated on the display by icons. As the operator advances in the handling, the functions of the keys are automatically reattributed. The risk of error in handling is therefore virtually reduced given that the proposed functions always correspond to the circumstance and availability of the bar feed system.
Description The motor of the HYDROBAR SPRINT S3 bar feed system is equipped with a built-in absolute encoder that continuously controls the position of the carrier. When the bar feed system is powered down or there is a power failure, this position is kept in the memory by the PLC.
Description The HYDROBAR SPRINT S3 has several parameters and functions allowing the operator to configure it so that it adapts as closely as possible to the lathe on which it is installed, as well as to the production mode under way.
CHAPTER 8: OPERATION Access to the functions By pressing the MENU key, it is possible to visualize the values of the settings, regardless of the position of the bar feed system (automatic sequence, manual sequence, etc.). To change or modify any parameters, the bar feed must be in STOP mode. MAIN MENU [@] 1:PART SETUP 2:POSITION/TORQUE...
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CHAPTER 8: OPERATION 4.2.1 Part setup The manipulations, adaptations, and settings, specific to the machining of a part, and which must be made to the bar feed system are part of the start-up. The mechanical settings which must performed on the bar feed system are presented in the Start Up manual.
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CHAPTER 8: OPERATION • Top Cut position During the loading cycle, the bar is automatically loaded and positioned into the spindle, outside the clamping device of the lathe (chuck or actuator). This positioning corresponds value programmed by the operator, which is equal to the distance between the measuring cell and the position of the material in the lathe clamping device.
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8-10 CHAPTER 8: OPERATION • Top Cut position During the loading cycle, the bar is automatically loaded and positioned into the spindle, outside the clamping device of the lathe (chuck or actuator). This positioning corresponds value programmed by the operator, which is equal to the distance between the measuring cell and the position of the material in the lathe clamping device.
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The service parameters allow to configure the bar feed system in its environment and to adapt the interface connected to the lathe. These parameters are protected with a password, because only LNS (or certified) technician is authorized to modify them. SPRINT S3...
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CHAPTER 9 : MALFUNCTIONS MAINTENANCE Please read the safety instructions provided at the beginning of this manual before handling the following devices. Hydraulic filter / hydraulic oil The oil filter must be maintained clean and requires cleaning once a month. The hydraulic oil may need to be replaced once a year depending on the cleanness of the bar stock.
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CHAPTER 10: SPARE PARTS 10-1 CHAPTER 10: SPARE PARTS SPARE PARTS 10-2 Bearing block 10-2 Pusher support 10-3 Cover opening lever 10-4 Outboard support 10-5 Oil filter 10-6 Chain drive 10-7 Loading rack 10-8 Lifting finger 10-9 Floor rack 10-10 1.10 Stock stop adjuster 10-11 SPRINT S3...
APPENDICES APPENDIX A: PROGRAMMING EXAMPLE MAIN PROGRAM N... ”M” CODE “LATHE IN AUTOMATIC CYCLE” N... SPINDLE STOP N... COOLANT OFF N... TURRET TO FEED IN POSITION N... COLLET OPEN N... TURRET TO FEED OUT POSITION N... END OF BAR CHECK >...
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 :...
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