LNS Hydrobar Express 220 Installation and operation manual

MADE IN USA
Serial Nr:
LNS America, Inc.
USA
4621 East Tech Drive
Cincinnati, Ohio 45245
Phone# [phone]
http://www.LNSAmerica.com
Main fax# [phone]
Service fax# [phone]
220220
220
Hydrobar Express
Hydrobar Express
Hydrobar Express
START UP
MANUAL
START UP
MANUAL
START UP
MANUAL

START UP MANUAL 1
HYDROBAR EXPRESS 220
E-1
10.12.04
TABLE OF CONTENTS
1. PUTTING THE BAR FEED SYSTEM INTO OPERATION 2
2. SETTINGS RELATED TO INSTALLATION 3
2.1 End of bar position 3
2.2 Top-cut position 6
3. SETTINGS RELATED TO BAR STOCK AND MACHINED PARTS 8
3.1 Parameters settings 8
3.2 Mechanical settings 11
4. PUTTING THE LATHE INTO OPERATION 16
4.1 Spindle reduction tubes 16
4.2 Material 17

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HYDROBAR EXPRESS 220
1. PUTTING THE BAR FEED SYSTEM INTO OPERATION
Prior to handle the followings components, please read the safety instructions
in chapter 1 of the instruction manual.
1.1 Description
Any handling, adjustments and settings required by the bar feed system so that it can
undertake a specific task are part of putting it into operation.
The devicemay be preparedfor a differentrange of diametersby means ofsomevery simple
operations.
The process for putting the bar feed system into operation must be modified when :
CThe diameter of the bars changes
CThe profile of the bars changes
CThe length of the part changes
The procedures to be followed are shown in this chapter. When a setting needs to be done
on one of the devices, it is referenced in the chapter dealing with this subject.

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HYDROBAR EXPRESS 220
Note :
To validate a
new
parameter or
a new value,
keep
[ENTER]
pressed until
the icon
disappears
2. SETTINGS RELATED TO INSTALLATION
2.1 End of bar position
The end of bar position determines the
moment when the bar feed enters the
loading cycle.
Usually, the end of bar position is adjusted
as closely as possible behind the clamping
systemofthe lathe(approximately5 mmor
a 1/4" behind the chuck jaws or collet
pads).
This will provide minimum bar stock
remnant.
Regardless of the length of the bars, or
parts, the end of bar position is always the
same.
In very special cases, a different end of bar
setting needs to be selected.
The length of the remnant may vary :
CThe minimum remnant length (Min) is
obtained when the feeding pusher is just
behind the clamping device while the
last part is being machined.
CThe maximum remnant length (Max) is
obtained when there is not enough
material for machining an additional
part (Lp - 1 mm).
Maximum remnant length =
Lp - 1mm + Min

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End of bar setting :
Important : Before handling the barfeeder, stop the lathe at the end of part cycle.
Procedure
(see conditions, point 5)
1. Press the key [STOP].
2. Press the key [MENU].
The display reads :
PARAMETERS RELATED
TO APPLICATIONS
3. Press twice the key attributed to the icon [PAGE DOWN].
The display reads :
PARAMETERS RELATED
TO POSITIONING
4. Press the key attributed to the icon [ENTER].
The display reads :
END OF BAR POSITION
**** MM
5. Press the key attributed to the icon [SET].
Depending on which sequence the bar feed is in when the parameter is selected, the
available functions and icons can change :
Functions
Conditions By offset correction By teaching
- Guiding channel closed
- No bar stock in the guiding channel icon : [+/-] icon : [TEACH IN]
- Guiding channel open icon : [+/-] ---
[+/-] By offset correction
CPress the key attributed to the icon [+/-].
The display reads the current end of bar position.
CEnter the correction value with the numerical keys. Then, press the key attributed to
the icon [+] to add the value, or the key attributed to the icon [-] to substract it. The
display reads the new end of bar position.
CTo exit the end of bar set mode, press the key attributed to the icon [ESC].
[TEACH IN] By teaching
CPress the key attributed to the icon [TEACH IN].
The display reads the current end of bar position
CPress the key [FWD] and advance the pusher to the desired position (see previous
page).
CTo validate the new end of bar position, keep [ENTER] pressed until the icon
disappears.

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HYDROBAR EXPRESS 220
6. To exit the set mode, press the keys [MENU] or [STOP].

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2.2 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.
With this system, the setting is the same for
any bar length.
The setting for the Top-cut position may be
adjusted at any time, in one of two ways :
1. By offset correction
2. By teach in
Top cut position setting :
Important : Before handling the barfeeder, stop the lathe at the end of part cycle.
Procedure
(see conditions, point 6)
1. Press the key [STOP].
2. Press the key [MENU].
The display reads :
PARAMETERS RELATED
TO APPLICATIONS
3. Press twice the key attributed to the icon [PAGE DOWN].
The display reads :
PARAMETERS RELATED
TO POSITIONING
4. Press the key attributed to the icon [ENTER].
The display reads :
END OF BAR POSITION
**** MM

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HYDROBAR EXPRESS 220
5. Press the key attributed to the icon [PAGE DOWN].
The display reads :
TOP-CUT POSITION
**** MM
6. Press the key attributed to the icon [SET].
Depending on which sequence the bar feed is in when the parameter is selected, the
available functions and icons can change :
Functions
Conditions By offset correction By teaching
- Guiding channel closed
- No bar stock in the guiding channel icon : [+/-] ---
- Guiding channel closed
- Bar stock in the guiding channel icon : [+/-] ---
- Guiding channel open
- No bar stock in the guiding channel icon : [+/-] ---
- Guiding channel open
- Bar stock in the guiding channel
- Movable vise in home position icon : [+/-] icon : [TEACH IN]
[+/-] By offset correction
CPress the key attributed to the icon [+/-].
The display reads the current top cut position.
CEnter the correction value with the numerical keys. Then, press the key attributed to
the icon [+] to add the value, or the key attributed to the icon [-] to substract it. The
display reads the new top cut position.
CTo exit the top cut set mode, press the key attributed to the icon [ESC].
[TEACH IN] By teaching
CPress the key attributed to the icon [TEACH IN].
CPress the key attributed to the icon [START].
The movable vise closes and advances the bar stock against the front stopper. The
bar is thus measured. The movable vise continues its travel and positions the bar
inside the spindle of the lathe. The guiding channel closes. The feeding pusher is
now facing the bar. The bar is inserted in the collet.
CPress the key [FWD] and advance the bar stock to the desired position (see previous
page).
CTo validate the new top cut position, keep [ENTER] pressed until the icon
disappears.
7. To exit the set mode, press the keys [MENU] or [STOP].

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Note:
Depending on
lathe
configuration,
there may be
other
parameters
available.
For further
information,
see chapter 8 /
point 5.
3. SETTINGS RELATED TO BAR STOCK AND MACHINED PARTS
IMPORTANT:Prior to changing the bar feed parameters, please make sure
that the guiding channel is open. Parameters will not be accepted with the
channel closed
3.1 Parameters settings
Example 1 : Set-up for round bars
Bar profile round
Bar diameter 20 mm
Guiding channel diamete 23 mm
Length of pieces to be machined 37.0 mm
Press the [MENU]key; the remote command displays the following text :
PARAMETERS RELATED TO APPLICATIONS
Press the [ENTER]key; the remote command displays the following text :
LOADING OF
Select [ROUND]. Press the [ENTER]key twice to store the data.
Inautomaticmode, when thebar is guidedby the front rest, the motor(M3) adjuststhe front-
rest gap according to the setting entered into the [ENTER NEW BAR STOCK DIAMETER]
parameter. Similarly, when the pusher is in the front rest, the motor [M3] adjusts the gap
according to the setting entered into the [ENTER NEW GUIDING CHANNEL NUMBER]
parameter.
Press the [ESC]key to exit the set-up functions.
ENTER NEW BAR STOCK DIAMETER
On the keypad enter [200]
Press the [ENTER]key twice
ENTER NEW GUIDING CHANNEL NUMBER
On the keypad enter [23].
Press the [ENTER]key twice, the remote command displays the following text :
ENTER OVERALL PART LENGTH
On the keypad, enter [370], which represents the sum of the bar length and the thickness of
the cutoff tool.
Press the [ENTER]key twice to store the data. Press the [ESC]key to exit the set-up
functions.

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HYDROBAR EXPRESS 220
Note:
Depending on
lathe
configuration,
there may be
other
parameters
available.
For further
information,
see chapter 8 /
point 5.
Example 2: Small-diameter profiled bars / standard elements in the front rest.
Bar profile hexagonal
Bar diameter (across edges) 5mm
Guiding channel diameter 8 mm
Length of pieces to be machined 15.0 mm
Press the [MENU]key; the remote command displays the following text :
PARAMETERS RELATED TO APPLICATIONS
Press the [ENTER]key; the remote command displays the following text :
LOADING OF
Select [ROUND / PROFILED] then, to save, press [ENTER]twice.
As the guide elements have not been replaced, when this parameter is selected, the front rest
is adjusted as for round stock. In automatic mode, when the bar is guided by the front rest,
the motor (M3) adjusts the front-rest gap to the setting entered into the [ENTER NEW BAR
STOCK DIAMETER]. Similarly, when the pusher is in the front rest, the motor (M3) adjusts
the gap according to the setting entered into the [ENTER NEW GUIDING CHANNEL
NUMBER] parameter.
However, the positioning cycle (Top Cut) is adapted to load profiled stock.
Press the [ESC]key to exit the set-up functions.
ENTER NEW BAR STOCK DIAMETER
On the keypad enter [50] (barstock diameter across edges)
Press the [ENTER]key twice, the remote command displays the following text :
ENTER NEW GUIDING CHANNEL NUMBER
On the keypad enter [8]
Press the [ENTER]key twice, the remote command displays the following text :
ENTER OVERALL PART LENGTH
On the keypad, enter [150], which represents the sum of the bar length and the thickness of
the cutoff tool.
Press the [ENTER]key twice to store the data.
Press the [ESC]key to exit the set-up functions.

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HYDROBAR EXPRESS 220
Note:
Depending on
lathe
configuration,
there may be
other
parameters
available.
For further
information,
see chapter 8 /
point 5.
Example 3: Large-diameter profiled bars / special elements in the front rest.
Bar profile hexagonal
Bar diameter (acrossedges) 17 mm
Guiding channel diameter 20 mm
Length of pieces to be machined 44.0 mm
Press the [MENU]key; the remote command displays the following text :
PARAMETERS RELATED TO APPLICATIONS
Press the [ENTER]key; the remote command displays the following text :
LOADING OF
Select [PROFILED] then, to save, press [ENTER] twice.
Remember – the standard guiding elements have been replaced by elements especially
adapted to the stock to be loaded.
When selecting this parameter, the front-rest adjustment will be so effected asto ensure that
the elements are touching when the front rest is closed (see point 3.2.5 of this manual).
The positioning cycle (Top Cut) is also adapted to profiled stock.
Press the [ESC]key to exit the set-up functions.
ENTER NEW BAR STOCK DIAMETER :
On the keypad enter [170] (barstock diameter across edges)
Press the [ENTER]key twice, the remote command displays the following text :
ENTER NEW GUIDING CHANNEL NUMBER
On the keypad enter [20]
Press the [ENTER]key twice, the remote command displays the following text :
ENTER OVERALL PART LENGTH
On the keypad, enter [440], which represents the sum of the bar length and the thickness of
the cutoff tool.
Press the [ENTER]key twice to store the data.
Press the [ESC]key to exit the set-up functions.

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Note :
For bars
larger than 12
mm in
diameter, the
upper limiter
is superfluous.
3.2 Mechanical settings :
• Setting of the bar magazine point 3.2.1
• Replacement of the guiding elements point 3.2.2
• Replacement of the feeding pusher point 3.2.3
• Replacement of the collet point 3.2.4
• Replacement of the clamping jaws of the front rest (shaped bars) point 3.2.5
3.2.1 Setting
The loading diameter is set by a motor.
On the other hand, the upper limiters must be adjusted on every support.
The inclination of the surface stays the same, independently of the diameter, the profile, or
the material of the bars to be loaded.
Procedure :
1. Loosen the locking handles (D) and raise the upper limiters (A)
2. Place a few bars of the desired diameter on the inclined surface (B), resting on the
adjustable endstops (C).
Lower the upper limiters (A) to obtain a clearance of around 1-mm with the bars
positioned on the inclined surface.
Tighten the locking handles (D).

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Note :
The elements
of the cover
must only be
replaced when
they are worn
or damaged
3.2.2 Replacement of the guiding elements
As previously indicated only the elements of the guiding channel may or must be replaced
depending on the diameter of the bars.
CMove each element horizontally until the locking pin is aligned on the slot.
CWith a screwdriver, lift the guiding elements upward to remove them, and to clean them.
CEnsure that the guiding channel is clean; if it is not, clean it.
CInsertthenewelementsintotheguidingchannel,makingsurethatthepinsoftheguiding
channel are seated in the slots of the guiding elements. Push the elements horizontally
so that they are held in position by the pins.
NB: On 4-meter bar feed systems, the short elements must be installed in the rear. The
order of the other elements is not important.
The guiding channels are sensitive to corrosive products. Please do not wipe
or cleanthechannelswithany corrosivedetergent.Useadry cloth onlytowipe
theoil off the channels.
Note: The channels can be stored inside the body of the bar feeder underneath
the rack.

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Note :
Chart of
diameters :
Instructions
Manual,
chapter 7 /
point 3.3.
3.2.3 Replacement of the pusher support
Conditions: - Guiding channel open
Procedure :
CSwing up the two bar limiters (A)
CRemove the pusher pulling out towards the
front of the bar feeder (B)
CRemove the two pusher supports (C)
CRemove the loading finger by unscrewing
its mounting screw
CRemove the pusher guiding channel (E)
CInstall new pusher guiding channel
CInstall new loading finger
CInstall new pusher supports
CInstall new pusher
CSwing down the two bar limiters
CAdjust limiters to bar diameter
3.2.4 Replacement of the elements
Pushers 7 - 12 mm
On the 7 to 12 mm diameter pushers, the flag is fastened to the body of the pusher with a
headless screw (B). On the 7 mm diameter pusher, all elements are screwed together. To
replace them, first unscrew (1), then take them apart (2).
Pushers 16 - 22 mm
On the 16 to 22 mm diameter pushers, the elements are assembled with pins (A). To
replace them, extract (1) the pins (A), then take them apart (2).

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3.2.5 Replacement of the clamping jaws of the front rest (shaped bars)
When the shape of the bars is changed, in addition to the aforementioned adjustments for
round bars, the following modifications should be made, if necessary :
When the bars to be guided are profiled,
the standard jaws will have to be
replaced.
Their internal diameter (d) must be
approximately 0.5mm greater than the
outside diameter across the corners
Conditions : - Guiding channel open
- Guiding channel empty
Procedure :
1. Press the [STOP] key.
2. Press the [MENU] key.
The remote command displays the
following text :
PARAMETERS RELATED TO
APPLICATIONS
3. Press 4 times the key attributed to the
icon [PAGE DOWN].
The remote command displays the
following text :
PARAMETERS RELATED TO
MISCELLANEOUS FUNCTIONS
4. Press the key attributed to the icon [ENTER].
5. Press 2 times the key attributed to the icon [PAGE DOWN].
The remote command displays the following text :
FRONT REST OPENING AND
CLOSING
6. Press the key attributed to the icon [ENTER].
7. Press the icon button for two seconds.
The jaws close
8. Unscrew the fixing screws (B)
9. Press the icon button for two seconds.
The jaws open.
10. Lift the jaws (C) out.
11. Drop the new jaws in and secure with the screws (B).
12. Press the [MENU] or [STOP] keys to exit the set-up functions.
Designation Article No Description
A6E50-002.A Clamping jaws with round profile

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4. PUTTING THE LATHE INTO OPERATION
4.1 Spindle reduction tubes
The efficiency of the bar guiding while in rotation in the lathe is determined by the
clearance between the spindle reduction tube and the rotating bar. The greater the
clearance is, the more frequent the vibrations are.
Using reduction tubes helps to decrease this clearance. Guiding is thus improved, but, in
addition, the insertion of the bar into the clamping device of the lathe is made much
easier.
The inside diameter of the reduction tubes should be chosen in terms of the diameter of
the bar (diameter of the bar + 1 mm), but should always be larger than that of the
diameter of the feeding pusher.
For inserting and removing the spindle reductions, move the bar feed system using the
retraction device (Chapter 7/ Point 8).
Spindle reduction tubes are available from LNS, upon request.

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4.2 Material
4.2.1 Round bars
To guarantee a perfect insertion of the bars inside the
collet of the bar feed system, it is recommended to
chamfer them in the rear at 30o.
Likewise, to avoid possible catching during the
introduction in the spindle, the bars must be well
deburred at the front.
In some cases, when the diameter of the bar is close to
the external diameter of the collet (see Chapter 7, point
3.3 - Assembly of the pushers), the rear of the bars
must be machined to the inside diameter (D) of the
collet. The length of the machining (L) must be at
least 30 mm
4.2.2 Tubes
When loading tubes, in order to avoid mixing the bar
feed system oil and the cutting oil, it is recommended
to make plugs. These plugs must be installed at the
rear of every tube.
4.2.3 Shaped bars (hex and square)
It is recommended to install a bushing, inside the clamping device, with the same inside
profile (+ 0.2 mm) as the bar.
The rear of this collet and the front of the bars should be flat.
During the loading cycle, a slight rotation of the spindle (about 30 RPM) is desirable.