In conjunction with each alarm will be a brief description of what the alarm is and a few tips and procedures of how to correct the problem. Figure 1-1 Remote control station HYDROBAR EXPRESS 220...
Page 5
Closing guiding channel control switch Remnant check Control switch: mobile vise in forward position Control switch: pusher in rear/park position Front-rest opening monitor Front-rest gap adjuster SQ10 Retraction system in position switch SQ11 Main access cover safety switch HYDROBAR EXPRESS 220...
LNS America, Inc. for assistance and the message has already been cleared. On certain lathes, once the bar feed sends an alarm to the machine, the machine will in return send an emergency stop alarm to the bar feed which overrides any bar feed alarms.
Bit 0 = 1 control station to clear the message and reset the alarm. For case 1, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 3 = 0 Reset the E-stop push button on the lathe. For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 2 = 0 Reset the E-stop push button on the remote control station. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Flip the toggle switch on the PLC to the RUN position. Replace the oil pressure switch. For case 2, after the solutions have been completed, Press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Flip the toggle switch on the PLC to the RUN position. Replace the air pressure switch. For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 4 = 0 control station to clear the message and reset the alarm. For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 1 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 7 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
10000000 For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 7 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 1 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 1 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Check the channel opening/closing cylinder functionality. Check the adjustment and functionality of the SQ3 switch. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Check the channel opening/closing cylinder functionality. Check the adjustment and functionality of the SQ4 switch. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 2 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Bit 2 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Chapter 1: Common Issues Front Rest Error FRONT REST ERROR! POSSIBLE CAUSES: -BAR DIAMETER DOES NOT CORRESPOND TO ENTERED DIAMETER -SQ9 SIGNAL SWITCH DEFECTIVE OR MIS- ADJUSTED -SQ8 SWITCH (CALIB.) MALFUNCTION See pg. 2-4 Front Rest Issues. HYDROBAR EXPRESS 220...
Check the alignment between the bar feeder and the lathe. The lathe or the bar feeder may have shifted over a long period if either is not lagged to the floor securely. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
MODULE 1 Check the chain coupling device. Check to see if the chain is broken. 76543210 Bit 4 Check SQ6 switch. May be mis-adjusted or defective. Re-reference the bar feed. • Contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
76543210 Bit 5 = 0 distance of 0.5mm-1mm from the measuring stop. If the input still does not turn on, the problem can be isolated to a defective switch or defective cable. Replace the cable and switch. HYDROBAR EXPRESS 220...
Check the adjustment of switch SQ5. • Confirm the lathe chamfers the remnant after cutoff before the bar change cycle begins. • Make sure that PRM30 is not turned off. • Contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Check that the extraction device jaws are not broken. • Check the adjustment of SQ5, the switch should only activate when no bar is present in the collet of the bar feed. • Contact LNS America Inc. for further information. HYDROBAR EXPRESS 220...
1 - 2 6 Chapter 1: Common Issues Vise Coupling Device Malfunction VISE COUPLING DEVICE MALFUNCTION! POSSIBLE CAUSES: -COUPLING DEVICE DEFECTIVE -SQ6 SIGNAL SWITCH DEFECTIVE OR MIS-ADJSUTED -MECHANICAL FAILURE HYDROBAR EXPRESS 220...
Page 30
If the channel is open, and this input is not on, the SQ3 switch is 76543210 Bit 1 = 0 either mis-adjusted or defective. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
If the channel is open, and this input is not on, the SQ4 switch is 76543210 Bit 2 = 0 either mis-adjusted or defective. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 220...
Make sure that the bar stock diameter matches to the value entered for the corresponding parameter. Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Restart the bar feed and lathe in automatic production. HYDROBAR EXPRESS 220...
Alarm needs to be cleared. Press the STOP button on the remote control station to clear and reset the alarm. Remove the bar from the spindle and restart the top-cut positioning cycle. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Check the End of Bar setting in the Parameters Related to Positioning menu. • If the part length is fairly long, it will be necessary to cut the bar stock to achieve a minimum remnant length. • If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Check that the collet of the lathe is opening to its maximum allowance. • Check the pushing torque value in the menu Parameters Related to Servo Drive (Torques) on the bar feed. The value can be increased if necessary. HYDROBAR EXPRESS 220...
Check that the cut-off tool is still intact. If it is broken, it will need to be replaced before putting the bar feed back in automatic production. If this alarm occurs often due to cut-off tools breaking, reduce the pushing torque in the menu Parameters Related to Servo Drive (Torques). If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Check to see if the pusher got jammed in the channel. Make sure the front guiding channels are seated correctly in the channel (maybe chips fell underneath the guiding channels). If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Verify that the CN3 connector is connected properly on the servo amplifier as well as on the PLC. • Verify the 24VDC supply for the PLC. Any voltage fluctuation can result in poor performance of the PLC. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. • Make sure that the SQ2 switch is adjusted to within 0.5mm-1mm from the decoder disc. • Check that the DC motor is operational. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Make sure that the collet is the correct size for the bar stock being ran. • Check that there are no burrs on the back of the bar stock. LNS recommends that a chamfer be put on the back end of the bar. •...
Turn the main power off to the Express 220 for 2 seconds and turn the power back on. Note: If the alarm keeps recurring, check the alarm code on the Mitsubishi servo amplifier and refer to Mitsubishi Servo Amplifier Alarm List pg. 1-45. HYDROBAR EXPRESS 220...
Verify that the PLC output (Q4.4) is turning on when the manual or automatic cycle is started. • Verify that the K1 contactor is activated; input (I0.0) should be on. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Verify that the clamping device is closing properly and that the Clamping Signal Active interface parameter is set in conjunction with how the interface signal is being sent. Verify that the correct part length has been entered in the PARAMETERS RELATED TO APPLICATIONS menu. HYDROBAR EXPRESS 220...
Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Remove the bar stock from the loading channel and reset the bar feeder and the lathe in automatic cycle. HYDROBAR EXPRESS 220...
Make sure that value for the OVERALL PART LENGTH is correct. • Check for any mechanical obstruction that will not allow the bar feed to reach the feed out distance. Contact LNS America, Inc. for further information. HYDROBAR EXPRESS 220...
Seq. 11 (Profiled material only) (Top-Cut) Hex material to back of spindle (param) Seq. 12 (Top-Cut) Go to top-cut with round bar, if not make with hex, then, jump back to Seq. 11 Seq. 13 (Top-Cut) Top-cut finished Wait for chuck close HYDROBAR EXPRESS 220...
Page 47
820mm. If remnant longer than 320mm position front of remnant about 12mm inside of remnant tray. Seq. 25 (Extraction Cycle) Jaws open, vise reverse to remnant stop position then 65mm to stopper. Seq. 26 (Insertion Cycle) Vise forward to position to receive new bar. (Forward 65mm from limiter.) HYDROBAR EXPRESS 220...
Servo complete auto tuning. Amplifier manual Cyclic operation Position shift occurs Confirm the cumulative Pulse counting error, etc. command pulses, due to noise. cumulative feedback pulses and actual servo motor position. HYDROBAR EXPRESS 220...
Page 49
Absolute position counter warning AL.E6 Servo emergency stop warning AL.E9 Main circuit off warning Note: Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence. 0: Pin-SG off (open) 1: Pin-SG on (short) HYDROBAR EXPRESS 220...
Page 50
2. Encoder fault Change the servo motor. and servo amplifier. 3. Encoder cable faulty Repair or change the cable. (wire breakage or short) 4. Wrong combination of servo Use correct combination. amplifier and servo motor HYDROBAR EXPRESS 220...
Page 51
Regenerative 6. Regenerative transistor faulty. transistor fault Checking method 1) The regenerative brake option has overheated abnormally. 2) The alarm occurs even after removal of the built-in regenerative brake resistor or regenerative brake option. HYDROBAR EXPRESS 220...
Page 52
Parameter setting 1. Servo amplifier fault caused the Change the servo amplifier. is wrong. parameter setting to be rewritten. 2. Regenerative brake option not Set parameter No.0 correctly. used with servo amplifier was selected in parameter No.0. HYDROBAR EXPRESS 220...
Page 53
Change the servo motor. Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway. HYDROBAR EXPRESS 220...
Page 54
88888 Watchdog CPU, parts faulty Fault of parts in servo amplifier Change servo amplifier. Checking method Alarm (88888) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. HYDROBAR EXPRESS 220...
Page 55
EMG-SG is open. External emergency stop was made Ensure safety and emergency stop valid. (EMG-SG opened.) deactivate emergency stop. warning AL.E9 Main circuit off Servo was switched on Switch on main circuit warning with main circuit power power. off. HYDROBAR EXPRESS 220...
Chapter 2: Common Issues he Hydrobar Express 220 is designed to be a user-friendly, simple, and reliable bar feeder, covering a range of diameters 0.125” to 1.250” (1.250”-1.375” with bar end preparation). Although easy to use, including extremely quick changeovers and the capability for unmanned operation this unit is not flawless.
Description: The Hydrobar Express 220 uses a SAIA PCD2 controller (PLC) to send/receive inputs/outputs. The PLC is powered by a +24VDC input supplied by a transformer. The input supply voltage must be regulated to ensure proper functioning. The remote control station, which is used to send/receive data back and forth with the PLC, is powered by the +24VDC on the PLC.
A remnant too long to be dumped into the remnant pan has Remove the two bars from the channel and restart the been confirmed that it was removed without physically loading process. removed. Perhaps during a shift change. HYDROBAR EXPRESS 220...
Front rest is not closing enough on the bar parameters. Check the functionality of the SQ9 stock SQ8 switch is mis-adjusted or switch. defective. Re-calibrate the front rest. Front rest is mis-calibrated. HYDROBAR EXPRESS 220...
Vibration Issues The term “vibration” is being used regarding the Hydrobar Express 220, to indicate that the RPM performance of the lathe is physically deteriorated, to the point of creating an unbalanced rotational oscillation of the bar stock that is detrimental to the machining process.
Step 2: Loosen the 2 jam nuts on SQ7. Loosen jam nuts Step 3: Set the gap between the switch and the flag to 1mm. Use a 1mm feller gauge to set gap. Switch 1mm gap Flag HYDROBAR EXPRESS 220...
Page 64
Move the switch so that it is 2/3 over top of the flag and tighten the top jam nut by hand. Step 7: Tighten the top jam nut with a 13mm combination wrench while holding the bottom nut in position. Be careful not to over tighten and damage switch. Tighten Hold in place Procedure complete. HYDROBAR EXPRESS 220...
Confirm that the pusher is in its home position. The pin should contact the bracket. Home position Step 3: Confirm that the pusher bracket is tight on the pusher support plate. Pusher support plate Pusher support bracket HYDROBAR EXPRESS 220...
Page 66
Position the bracket so that it is centered on the pusher. Bracket and pusher (removed for clarity) Center the bracket on the pusher Step 6: While holding the bracket in place, tighten the two bolts on the pusher support plate. Procedure complete. HYDROBAR EXPRESS 220...
Step 2: Pull up on the air regulator knob and turn it counter clockwise to drop the air pressure to 0 (zero). Knob Step 3: Pull up the measuring cell shield. Measuring cell shield HYDROBAR EXPRESS 220...
Page 68
Place a short piece of material (8 or 11mm) in the guiding channel. (A straight section of a wire coat hanger will work if needed) Place the material so that an inch or more sticks out of the channel and is under SQ1. Bar stock should stick out of the channel HYDROBAR EXPRESS 220...
Page 69
Step 12: Remove the 8 or 11 mm guiding channel and replace the correct guiding channel size according to the bar stock used. Step 13: Pull up on the air regulator knob and turn it clockwise and set the air pressure to the sixth bar (90 psi). Knob Procedure complete. HYDROBAR EXPRESS 220...
Front Rest Alignment This procedure is used to align the front rest. This procedure requires special tooling. To receive this tooling, contact LNS America, Inc at 513-528-5674. Some bar feed parts were removed for clarity of the pictures for this procedure.
Page 71
Remove the t-tube mounting plate by removing the four bolts on the plate. T-tube mounting plate Step 5: Tap the air blast ring out. Air blast ring Step 6: Insert an alignment block in the front of the first channel and set it directly behind the first pin. HYDROBAR EXPRESS 220...
Page 72
Pull up on the air regulator knob and turn it counter clockwise to drop the air pressure to two bars (30psi). Knob Step 10: Close the channels by pressing the yellow button on the YV2B air valve. YV2B valve Press this yellow button HYDROBAR EXPRESS 220...
Page 73
Step 13: Loosen the four front rest mounting bolts with a 13mm combination wrench. Loosen Step 14: Slide the 75mm alignment bushing into the rest and retighten the 4 mounting bolts so that the 75mm alignment bushing moves freely in and out of the front rest. Tighten HYDROBAR EXPRESS 220...
Page 74
Note: Make sure that the air blast holes on the inside of the ring are facing towards the front rest rubber inserts. The air blast holes on the outside of the ring are facing away from the front rest rubber inserts. Insert air blast ring HYDROBAR EXPRESS 220...
Page 75
Step 22: Pull the alignment bar forward until it hangs out of the bar feed approximately 2 ft. 2’ Step 23: Relocate the back alignment block to the end of the bar in the channel HYDROBAR EXPRESS 220...
Page 76
Step 26: Mount the alignment tube to the t-tube mounting plate with the three bolts. (Third bolt is not visible) Mount with bolts Step 27: Tighten the four mounting bolts on the t-tube mounting plate to the rest. HYDROBAR EXPRESS 220...
Page 77
Step 32: Open the channel by pressing the yellow button on the YV2A air valve. YV2A Press this yellow button Step 33: Remove the tooling from the inside of the channel: alignment blocks, alignment bar, and 75mm alignment bushing. HYDROBAR EXPRESS 220...
Page 78
Step 34: Replace the oil shield and tighten the thumb screws. Oil shield Tighten thumb screws Step 35: Replace the front rest cover and tighten the four thumb screws (two on either side of the cover). Thumb scre Procedure complete. HYDROBAR EXPRESS 220...
Chain idler Loosen bolt Step 2: Loosen jam nut on tensioner. Loosen jam nut Step 3: Back the tensioner bolt out of the block to tighten t he chain. Tensioner bolt Bolt Direction Tighten chain Loosen chain HYDROBAR EXPRESS 220...
Page 80
Once the chain tension is set correctly, tighten the bolt and nut on the chain idler. Tighten nut Tighten bolt Step 6: Recheck the chain tension setting by the servo motor. Step 7: Retighten the jam nut. Tighten jam nut Procedure complete. HYDROBAR EXPRESS 220...
Loosen the split collar that is closest to SQ3 with a 5mm hex key. Split Collar Step 2: Set the gap to 0.5 - 0.6mm with a feeler gauge between SQ3 and the plate. 0.5 - 0.6 gap Plate HYDROBAR EXPRESS 220...
Page 82
(Gold arm becomes barely visible) Move plate Gold arm inward on roller Line up against the edge of the switch HYDROBAR EXPRESS 220...
Page 83
Roller just contacts the plate Step 9: Tighten the split collar into place. Tighten split collar Step 10: Press the yellow button on the YV2A valve to reopen the main guiding channels. Press this yellow button Procedure complete. HYDROBAR EXPRESS 220...
Loosen the two bolts with a 6” drive socket and a 4mm hex socket on the base of the drive shaft that is attached to the split collar. Note: Be careful when removing the drive shaft or the coder disc. The guide wheel is not attached and may fall off. HYDROBAR EXPRESS 220...
Page 85
Remove the gear on the motor by loosening the set screw with a 2mm hex key. Gear Set screw Step 5: Remove all four bolts on the diameter adjustment motor. (Fourth bolt not visible) Step 6: Remove the cover from the junction box. Junction box HYDROBAR EXPRESS 220...
Page 86
Step 11: Insert the new motor and route the cable back to the junction box. Step 12: Insert the cable through the cable grip. M4 cable grip Step 13: Connect the brown wire to KA3-13 terminal and connect the blue wire to the 0V terminal. HYDROBAR EXPRESS 220...
Page 87
Step 17: Place the new gear and position it so that the gear is flush with the end of the motor shaft. Once the gear is positioned correctly, tighten the set screw with a 2mm hex key. Gear Set screw HYDROBAR EXPRESS 220...
Page 88
Note: If the guide wheel fell off, make sure that it is replaced before putting the drive shaft back on. Replace Tighten bolt Step 20: Once the drive shaft is in place, tighten the two bolts on the base of the drive shaft attached to the split collar. Procedure complete. HYDROBAR EXPRESS 220...
-BAR MOTION CONTROL tep 3: Press F4 (PAGE DOWN) function key to Small Diameter Bars Loading Rack. Step 4: Press ‘2’ to change the option. Then press and hold the F3 (ENTER) function key to enable it. HYDROBAR EXPRESS 220...
Page 90
Raise up Step 7: Repeat steps 5 and 6 for the remaining loading racks. Step 8: Make sure that all of the top limiters should be raised to their highest setting. Raised to its highest setting Procedure complete. HYDROBAR EXPRESS 220...
With the 3mm allen wrench, remove the four screws that mount the junction box to the coffin. (Located down in the holes next to the cover screw holes). Step 3: Remove the brown wire in termin al KA2-22 and the blue wire in terminal KA1-21. HYDROBAR EXPRESS 220...
Page 92
Once the cable grip is loose, extract the cable from the junction box. Step 6: Loosen the thumb screws for the front rest cover and remove the cove Step 7: With the ratchet wrench and 4mm allen socket, remove the two screws for the front rest motor mounting bracket. HYDROBAR EXPRESS 220...
Page 93
With the new motor routed through the bar f eed; attach the motor mounting bracket to the new motor. Step 12: Attach the drive gear to the motor shaft. The gear should butt-up against the mounting bracket. HYDROBAR EXPRESS 220...
Page 94
Step 14: Place the front rest cover back on and tighten the thumb screws. Step 15: Insert the motor cable through the cable grip and tighten the cable grip on the cable. Step 16: Mount the junction box to the coffin. HYDROBAR EXPRESS 220...
Page 95
3 - 3 4 Chapter 3: Procedures Step 17: Hook the brown wire up to terminal KA2-22 and the blue wire to terminal KA1-21. Step 18: Put the junction box cover back on and tighten down. rocedure complete. HYDROBAR EXPRESS 220...
Press and hold the “X” until the front rest becomes disabled, as shown in the third figure. THE FRONT REST IS THE FRONT REST IS FRONT REST OPENING ENABL DISABLED AND CLOSING CONTROL TO REPLACE PRESS F3 TO DISABLE PRESS F3 TO ENABLE REST GUIDING INSERT REST CALIBRATION (SERVICE ONLY) HYDROBAR EXPRESS 220...
Page 97
Note: After having completed Step 4, the front rest is no longer locked in the open position. The front rest is now enabled. Step 5: Press STOP to exit and return to the main menu. Procedure complete. HYDROBAR EXPRESS 220...
Oil pressure switch (SP2) Pump motor cover Step 2: Disconnect the 3-legs going to the motor windings (wire #1-U1, #2-V1, and #3-W1) and ground wire. Step 3: Loosen the hose clamp on the 90° fitting and disconnect the hydraulic hose. HYDROBAR EXPRESS 220...
Page 99
Step 7: Remove the four motor mounting bolts and remove the pump motor from the tank. The two bolts in the back are not shown. HYDROBAR EXPRESS 220...
Page 100
The two bolts in the back are not visible. Step 9: Raise the jack back up in place and mount the tank to the coffin with the four mounting bolts. Step 10: Reattach the hydraulic hose and tighten the hose clamp. HYDROBAR EXPRESS 220...
Page 101
Step 11: Hook up the M1 cable to the motor and put the motor cover back on. (Ground wire goes to the chassis of the motor, wire #1 goes to U1, wire #2 goes to V1, and wire #3 goes to W1). Wire #1 Ground wire Wire #2 Wire #3 Step 12: Hook up the SP2 cable to the oil pressure switch. Procedure complete. HYDROBAR EXPRESS 220...
Chapter 3: Procedures 3 - 4 1 Reference Procedure This procedure is used for resetting the home position of the Hydrobar Express 220. Procedure Conditions: • Main bar feed power on • Air pressure set at 5 bar (75psi) •...
Page 103
Sequence: The carrier flag retracts toward the home position. The PLC waits to detect the proximity switch-SQ7 (input I1.4) and the servo amplifier looks for the torque to build up after hitting the mechanical stop simultaneously. Procedure complete. HYDROBAR EXPRESS 220...
3mm bar stock tep 3: Rotate the switch until the red sensing beam is centered on the bar. Red sensing beam HYDROBAR EXPRESS 220...
Page 105
Step 5: Tighten the split collar and recheck the consistency of the beam detection to make sure the switch did not shift when tightening the split collar. Procedure complete. HYDROBAR EXPRESS 220...
Loosen the two 17mm hex bolts and slide the cam cylinder over towards the guiding channel until the 2mm gap is reached. You may need to raise the channel lids slightly in order to move the cam cylinder. 2mm gap Loosen bolts Slide cam over HYDROBAR EXPRESS 220...
Page 107
Once the setting is reached, retighten both split collars up against the nylon flanges to lock the cam bar in position. Step 8: Pull up on the air regulator knob and turn it counter clockwise to drop the air pressure to 0 (zero). Knob HYDROBAR EXPRESS 220...
Page 108
Repeat this step for the remaining open channel lids. Split coll Step 13: Confirm that the cam cylinder is still in its correct position as in step 10. Vertically aligned HYDROBAR EXPRESS 220...
Page 109
Knob Step 15: Complete the Adjustment of the Pusher Support Mechanism procedure. Step 16: Complete the Channel Lid Switches (SQ3 & SQ4) Adjustment procedure. Step 17: Replace the rear cover plate. Rear cover Procedure complete. HYDROBAR EXPRESS 220...
Remove the pusher support brackets and place the pusher assembly directly into the pusher channel. Remove brackets Step 3: Press STOP on the remote to clear any alarms. Step 4: Remove the YV7A and YV5 plugs from the valves. YV7A HYDROBAR EXPRESS 220...
Page 111
Set screws Hold-down bolts Step 8: Move the vise left to right to align it so that the remnant is center with the pusher collet. Collet Center remnant with collet HYDROBAR EXPRESS 220...
Page 112
Step 10: Once the correct height is maintained. Tighten the hold-down bolts. Hold-down bolts Step 11: Verify the remnant alignment to the pusher collet and readjust if necessary. Collet Center remnant with collet Step 12: Remove YV7A plug from the YV5 valve. Remove YV7A HYDROBAR EXPRESS 220...
Page 113
Step 13: Replace the YV7A and YV5 plugs back on the correct valve and tighten. YV7A Step 14: Reinstall the pusher support brackets and tighten them with the thumb screws. Tighten with thumb screws Replace brackets on both ends of the pusher Procedure complete. HYDROBAR EXPRESS 220...
Step 3: Turn the main bar feed power off. Step 4: Raise the top limiter by loosening the orange handle and pulling up on the limiter. Tighten the orange handle once the limiter is raised. Orange handle HYDROBAR EXPRESS 220...
Page 115
Holding onto the top limiter, slowly drop the limiter down on the ramp and paper. The back of the top limiter should be directly in line with the diameter adjustment finder. Step 9: Loosen the two 7mm nuts on the top limiter. Loosen the two nuts HYDROBAR EXPRESS 220...
Page 116
Step 12: Insert the feeler gauge or shim in front of the bottom pin on the top limiter and tighten the bottom 7mm nut. Step 13: Loosen the orange handle and raise the limiter up. Remove the business card or piece of paper. Orange handle HYDROBAR EXPRESS 220...
Page 117
Step 14: Holding the top limiter, slowly drop the limiter down onto the ramp. Check to see if the contact is even. If the contact is not even, repeat steps 6 – 14. Step 15: Repeat the procedure on the remaining 7 limiters. Procedure Complete. HYDROBAR EXPRESS 220...
Smart Media. Smart Media, which is mainly used in photography, has been integrated for use with the user-friendly remote control station. The Smart Media Card holds a backup program for the Hydrobar Express 220 if at anytime there has been a power failure or any error has occurred in the user program. In addition, it automatically backs up any application/interface parameters that have been set for the most recent application being ran.
Firmware v 2.08 Firmware v 2.08 (No card is present or the card is blank) If the display has firmware version 1.17a, proceed to page 4-3. If the display has firmware version 2.08, proceed to page 4-20. HYDROBAR EXPRESS 220...
Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half. Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you) into the slot. Black side Chamfered edge facing up away from you HYDROBAR EXPRESS 220...
Page 121
A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5. Step 9: There are 4 menu choices on this screen, press the F3 key for PLC Fault. HYDROBAR EXPRESS 220...
Page 122
Step 12: The PLC program will now be saved from the memory card to the PLC. This may take several minutes. Step 13: Press F4 (OK). Step 14: Turn off power to bar feeder. Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder. Procedure complete. HYDROBAR EXPRESS 220...
Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half. Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you) into the slot. Black side Chamfered edge facing up away from you HYDROBAR EXPRESS 220...
Page 124
A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5. Step 9: There are 4 menu choices on this screen, press the F3 key for PLC Fault. HYDROBAR EXPRESS 220...
Page 125
Step 11: The parameters will then be restored from the MMI to the PLC. Step 12: Press F4 (OK). Step 13: Turn off power to bar feeder. Step 14: Move the RUN/STOP switch to RUN position. Step 15: Restore power to the bar feeder. Procedure complete. HYDROBAR EXPRESS 220...
Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half. Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you) into the slot. Black side Chamfered edge facing up away from you HYDROBAR EXPRESS 220...
Page 127
A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5. Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update. HYDROBAR EXPRESS 220...
Page 128
Step 12: The bar feeder parameters will now be saved from the display to the PLC. Step 13: Press F4 (OK). Step 14: Turn off power to bar feeder. Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder. Procedure complete. HYDROBAR EXPRESS 220...
Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half. Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you) into the slot. Black side Chamfered edge facing up away from you HYDROBAR EXPRESS 220...
Page 130
A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5. Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update. HYDROBAR EXPRESS 220...
Page 131
Step 11: Press F3 to restore data from memory card to the display (text and icons). Step 12: The registers will then be restored from the memory card to the display. tep 13: Press F4 (OK). Step 14: Turn off power to bar feeder. HYDROBAR EXPRESS 220...
Page 132
Chapter 4: Software Update/Restore 4- 15 Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder. rocedu re complete. HYDROBAR EXPRESS 220...
Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you) into the slot. Black side Chamfered edge facing up away from you HYDROBAR EXPRESS 220...
Page 134
A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5. Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update. HYDROBAR EXPRESS 220...
Page 135
Step 11: Press F4 (PAGE DOWN) until you reach the screen to Restore PLC Program from Memory Card to PLC, press F3 (ENTER). Step 12: The PLC program will now be saved from the memory card to the PLC. This may take several minutes. HYDROBAR EXPRESS 220...
Page 136
Chapter 4: Software Update/Restore 4- 19 Step 13: Press F4 (OK). Step 14: Turn o ff power to bar feeder. Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder. Procedure complete. HYDROBAR EXPRESS 220...
Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half. Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you) into the slot. Black side Chamfered edge facing up away from you HYDROBAR EXPRESS 220...
Page 138
A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5. Step 9: There are 4 menu choices on this screen, press the F3 key for PLC Fault. HYDROBAR EXPRESS 220...
Page 139
Step 12: Press F4 (OK). Step 13: Turn off power to bar feeder Step 14: Move the RUN/STOP switch to RUN position. Step 15: Restore power to the bar feeder. Procedure complete. HYDROBAR EXPRESS 220...
Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half. Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from you) into the slot. Black side Chamfered edge facing up away from you HYDROBAR EXPRESS 220...
Page 141
A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5. Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update. HYDROBAR EXPRESS 220...
Page 142
Step 12: Press F4 (OK). Step 13: Turn off power to bar feeder Step 14: Move the RUN/STOP switch to RUN position. Step 15: Restore power to the bar feeder. Procedure complete. HYDROBAR EXPRESS 220 HYDROBAR EXPRESS 220...
Maintenance eriodic maintenance of the Hydrobar Express 220 bar feeding system can only serve to improve the operation and prolong its useful life. Following a few simple steps can be extremely helpful and takes relatively no time at all. The list of...
This is a wear item and it is recommended to keep spares on hand, refer to Recommended Spare Parts List pg. 6-2. Drive chain Over time, it is possible that the tension of the drive chain may loosen up. To tighten the chain, refer to Chain Tension Adjustment pg. 3-58. HYDROBAR EXPRESS 220...
0% off 100% on 5 years 4 years 30% off 70% on 4 years 1 year Verify the alignment of the bar feeder Check alignment of bar feeder to lathe spindle to make sure neither have shifted. HYDROBAR EXPRESS 220...
Note: When ordering parts the following information will be needed to ensure better customer support: • Bar feeder type • Bar feeder Serial Number (found on the hydraulic tank next to the air regulator) • Bar stock diameter • Lathe type (make and model) HYDROBAR EXPRESS 220...
Parts Order Form pg. 6-6) Spindle Liners Ensure that the properly sized spindle liner has been installed (matches guiding channel size). Ensure that the spindle liner is straight (check total run out). Ensure that the liner is securely fastened. HYDROBAR EXPRESS 220...
See Express 220 Guiding Channel Reference chart. LNS makes collets every tenth of a millimeter, from 2 millimeter I.D. to 20 millimeter I.D. The collet O.D. is based on your guiding channel I.D. The collet O.D must be at least 1 millimeter smaller than the guiding channel I.D. See chart below for collet part numbers.
Serial # of Bar feeder: Model of Lathe: Bar stock diameter: Qty. Part # Description Note: To place an order, this form should be photocopied, completed, and faxed to (513) 528-8320. Please call (513) 528-5674 or price and availability of parts. HYDROBAR EXPRESS 220...
Need help?
Do you have a question about the Hydrobar Express 220 and is the answer not in the manual?
Questions and answers
A023 alarm not really sure where to start.