LNS HYDROBAR SPRINT S3 Instruction Manual
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LNS HYDROBAR SPRINT S3 Instruction Manual

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Instruction Manual
ENG
HYDROBAR SPRINT S3
LNS America
4621 East Tech Drive
9.014.31.US
Cincinnati, Ohio 45245

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Summary of Contents for LNS HYDROBAR SPRINT S3

  • Page 1 Instruction Manual HYDROBAR SPRINT S3 LNS America 4621 East Tech Drive 9.014.31.US Cincinnati, Ohio 45245...

  • Page 3: Table Of Contents

    V1.05 TABLE OF CONTENTS 1. SAFETY INSTRUCTIONS 2. PREPARATION FOR INSTALLATION 3. ASSEMBLING INSTRUCTIONS 4. AIR REQUIREMENTS AND CONNECTIONS 5. ALIGNMENT 6. ANCHORING 7. ASSEMBLING 7.1. LOADER ASSEMBLING 8. HYDRAULICS 8.1. Hydraulic oil requirements 9. DESCRIPTION OF COMPONENTS 9.1. ELECTRICAL CONTROL COMPONENTS LAYOUT 10.
  • Page 4 19. AUTOMATIC SEQUENCE 19.1. Description 20. SETTINGS 20.1. Description 20.2. Access to the functions 21. AIR ADJUSTMENTS 21.1. MAIN PRESSURE 21.2. AIR MOTOR PRESSURE 21.3. PUSHER FEED RATE ADJUSTMENTS 22. MAINTENANCE 23. AIR CYLINDERS, AIR VALVES 24. INTERFACE ELECTRICAL DIAGRAM 25.

  • Page 5: Safety Instructions

    2. PREPARATION FOR INSTALLATION It is recommended the bar feeder to be installed by LNS or by one of its representatives. The Sprint S3 will be delivered either in two separate crates or on two pallets.

  • Page 6: Assembling Instructions

    3. ASSEMBLING INSTRUCTIONS • Open the crate containing the stands and the bar loader (tall rectangular crate). • Unbolt the loader and other components fastened to the crate for transportation purposes. • Position the stands behind the lathe in approximate alignment with the spindle (refer to floor plan).

  • Page 7: Air Requirements And Connections

    4. 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 point 17.1).

  • Page 8: Alignment

    5. ALIGNMENT • To obtain optimum rpm performance, position the front of the bar feeder as close as possible from the rear of the spindle. • Align the centerline of the bar feeder with the centerline of the spindle by adjusting the height with the nuts (B, see point 3) and sideways by moving the front and rear stands.

  • Page 9: Assembling

    7. ASSEMBLING 7.1. LOADER ASSEMBLING Care must be taken that the bar loader does not topple over. • Remove the bar loader from the crate and position on the side of the Sprintbody. • Install the 4 leveling pads (A) under the 4 leveling screws (B).
  • Page 10 • Adjust the chain tension (3) with screws (D) • Loosen the clamps (H1) and (H2) • Position the lateral supports (G) (F) and pass them through the holes (J) of the supports. Secure with the provided nuts. • Adjust (5) both supports evenly to desired slant with screws (O).
  • Page 11 • Adjust the level (N) on both lateral supports, secure with clamps (H1) and (H2). • Anchor the magazine and the lateral supports to the floor, with anchor bolts through holes (E) and (L). • If unit does not load a heavy bar, friction clutch located inside chain guard can be adjusted manually by tightening to create more friction on toothed sprocket.

  • Page 12: Hydraulics

    8. HYDRAULICS The Sprint 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, see point 9.

  • Page 13: Description Of Components

    9. DESCRIPTION OF COMPONENTS : 3.192 : Air control unit : 4.393 : Pusher home position prox. switch : 4.393 : Loader down prox. switch : 4.393 : Loader up prox. switch : 4.391 : Bearing blocks closed prox. switch : 4.391 : Bearing blocks locked prox.
  • Page 14 9.1. ELECTRICAL CONTROL COMPONENTS LAYOUT Désignation Article No Description 4.887 Programmable controller PCD3 (PLC) Interface terminal blocks (XT3 Power supply terminal block (XT1) Safety terminal blocks (XT2) 4.507 Safety chain control KReset 4.606 Kreset relay (M2 motor encoder reset) 4.606 KM2 relay (hydraulic motor M2 4.606 KM3B relay (bar loader is moving down)

  • Page 15: Electrical Connections

    10. ELECTRICAL CONNECTIONS The necessary conduits and cable for the electrical connections to the lathe are provided. Always refer to the interface electrical diagram located inside the electrical control box. The factory voltage connection is indicated on the cover of the electrical control box.

  • Page 16: Bar Stock Preparation

    Refer to point 12.2 for installation. Please contact LNS or one of its representatives for further information. 11.1. BAR STOCK REQUIREMENTS For optimum results, the bar stock must be straight.

  • Page 17: Diameter Changeover

    12. 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.

  • Page 18: Rotating Sleeve Changeover

    12.1 BEARING ELEMENTS CHANGEOVER Procedure (Open the bearing blocks, remove the pusher. Refer to point 12.1) 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.

  • Page 19: Flag Changeover

    12.4. 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.

  • Page 20: Gear Ratios

    12.6. 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 (refer to 17.2, Pushing force). 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.

  • Page 21: Pushing Force Chart

    12.7. PUSHING FORCE CHART SPRINT S3...

  • Page 22: Diameter Changeover Chart

    12.8. DIAMETER CHANGEOVER CHART SPRINT S3...

  • Page 23: Spindle Reduction Tubes Changeover

    13. 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. of the bearing elements. To remove or to install the spindle liner, the bearing element of the front extended support and the air blast (unscrew screws (D)) must be removed.

  • Page 24: Guiding Elements Change

    14. GUIDING ELEMENTS CHANGE Conditions : No bar stock in the magazine Pusher in home position Barfeed in STOP mode 1. Enter the manual mode by pushing F1 2. Manual mode: Select the pusher changeover procedure.by pushing F4 [SET]. The text " READY TO START PUSHER CHANGEOVER FUNCTION " is displayed on the screen. Start the function.by pushing F1 [START].

  • Page 25: End Of Bar

    15. 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.
  • Page 26 6. [TEACH IN] Apprentissage: • Presser la touche correspondant à l’icône [TEACH IN]. La position de fin de barre actuelle est affichée. • Presser la touche [FWD] et amener le poussoir à la position de fin de barre souhaitée (voir page précédente).

  • Page 27: Mechanical Stop

    16. 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.

  • Page 28: Remote Control

    17. 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.

  • Page 29: Display

    17.1. 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. •...
  • Page 30 Icône Signification Confirm Start sequence Set up Escape Return to previous menu Jump to next menu Load a bar stock in the guiding elements Confirm the unloading of a bar stock out of the guiding elements Validate Cancel Teach data Offset correction Increment data in offset correction mode Decrement data in offset correction mode...
  • Page 31 17.2. 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 to correspond to the circumstance and availability of the bar feed system.

  • Page 32: Powering Up

    18.1. Description The motor of the Hydrobar Sprint S3 bar feed system is equipped with a built-in absolute encoder that continually 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.

  • Page 33: Automatic Sequence

    19. AUTOMATIC SEQUENCE Please read the safety instructions described at the start of this manual before handling the equipment. 19.1. Description The autonomy of the bar feed system is directly connected to the frequency at which the operator feeds the magazine. Each time the automatic sequence of the bar feed system needs to be started up, it is advisable to check the following elements: •...

  • Page 34: Settings

    20. SETTINGS Please read the safety instructions described at the start of this manual before handling the equipment. 20.1. Description The Sprint S3 bar feed system has different parameters and functions allowing the operator to configure it in the manner best adapted to the lathe on which it is installed, and to the mode of production in progress. These parameters permit the positioning of the material in the clamping system of the lathe during the feeding process.

  • Page 35: Access To The Functions

    20.2. Access to the functions The functions are structured as follows : 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.). Part setup Total part feed out length Note :...
  • Page 36 20.2.1. Part setup Note : The manipulations, adaptations, and settings, specific to the machining of a part, and To validate a 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 parameter or in the Start Up manual.
  • Page 37 1.3. 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 to a value (Z) 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.
  • Page 38 SPRINT S3...
  • Page 39 20.2.2. Positions 2.1. End of bar The end of bar position determines the moment when the bar feed enters theloading cycle. Usually, the end of bar position is adjusted as closely as possible behind the clamping system of the lathe (approximately 5 mm or a 1/4" behind the chuck jaws or collet pads).
  • Page 40 2.2. Top Cut brake position In order to save time, the bar is first moved in high speed; then the pusher switches to low speed when approaching the optical cell or Top Cut position. This switching point is defined by this parameter 2.3.
  • Page 41 20.2.3. Misc. functions 3.1. Language Note : To validate a This parameter allows to adapt the language in which the messages will appear, depending on the country of destination of the bar feed system (for practical reason, parameter or a it is not necessary to stop the bar feeder to select a language).
  • Page 42 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.

  • Page 43: Air Adjustments

    21. AIR ADJUSTMENTS 21.1. MAIN PRESSURE For trouble free operation of the Sprint, a minimum of 5 bar (75 PSI) is required but should not exceed 6 bar (90 PSI). Procedure : Should an adjustment be necessary : Pull up the knob (1) and turn clockwise to increase the pressure.

  • Page 44: Air Motor Pressure

    21.2. AIR MOTOR PRESSURE The pushing force (torque) can be adjusted with knob (7). Maximum pressure allowed, 5 bar (75 PSI). To secure the connection between the bar stock and the pusher and to increase the life time of the rotating sleeves of the pusher as well as to prevent small diameter bar stock to bent, the pushing force must be adjusted accordingly.

  • Page 45: Pusher Feed Rate Adjustments

    21.3. PUSHER FEED RATE ADJUSTMENTS The feed rate can be adjusted with adusting valves 6 and 7. An average feed rate is factory adjusted. Should an adjustment be necessary : Pusher fast forward • To increase the feed rate turn adjusting valve 6 counterclockwise. •...

  • Page 46: Maintenance

    22. MAINTENANCE The bar feeder requires minimum maintenance. Howewer, the following needs to be regularly checked : 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. Procedure : Install plug (1) in bottom of the reservoir.

  • Page 47: Air Cylinders, Air Valves

    23. 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.

  • Page 48: Interface Electrical Diagram

    24. INTERFACE ELECTRICAL DIAGRAM The following interface drawings are examples only. Always refer to the electrical diagram sent with the bar feeder and located in the electrical control box. SPRINT S3...

  • Page 49: Hydraulic Diagram

    25. HYDRAULIC DIAGRAM M1 / Motor 0,18 kw B 34 / Pressure switch 0,5 Bar (12PSI) Pump 15 l/min 4 Gal/min Oil supply to bearing blocks Flow adjustment Oil filter Pressure gauge SPRINT S3...

  • Page 50: Pneumatic Diagram

    26. PNEUMATIC DIAGRAM SPRINT S3...
  • Page 51 SPRINT S3...

  • Page 52: Inputs And Outputs

    27. INPUTS AND OUTPUTS Inputs Outputs Safety line relay (K1) Guiding element 1 (YV1) Main access cover safety (SQ11) Guiding element 2 (YV2) Measuring cell (SQ1) Guiding element 3 (YV3) Guiding bearings locked (SQ3) Guiding element 4 (YV4) Guiding bearings closed (SQ4) Guiding element 5 (YV5) Pusher in referencing position (SQ5) Guiding element 6 (YV6)

  • Page 53: Electrical Diagram

    28. ELECTRICAL DIAGRAM SPRINT S3...
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  • Page 61: Floor Plans

    29. FLOOR PLANS SPRINT S3...
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  • Page 67: Spare Parts

    30. SPARE PARTS When ordering parts, always indicate the part number and the fabrication number of the bar feeder. The fabrication number is printed on a tag located inside the SPRINT on the chassis. The main cover must be opened to access to the tag. SPRINT S3...
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