LNS Hydrobar Express 332 Guide

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]
332332
332
Hydrobar Express
Hydrobar Express
Hydrobar Express
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL

E1
09.09.2005
Table of Contents
Chapter 1: .......................................................................................1-1
Alarms .........................................................................................................1-1
ALARM HISTORY..........................................................................................................................1-3
Emergency Stop Line Open.........................................................................................................1-4
Lathe Emergency Stop Line Open...............................................................................................1-5
Bar Feeder Emergency Stop........................................................................................................1-6
Oil Pressure Failure......................................................................................................................1-7
Air Pressure Failure......................................................................................................................1-8
Main Access Cover Open.............................................................................................................1-9
Bar Feeder Retracted..................................................................................................................1-10
Front Measuring Stop Signal SQ1 Missing...............................................................................1-11
Front Stopper Cannot Move Up.................................................................................................1-12
Signal SQ1 For Front Stopper Defective...................................................................................1-13
Guiding Channel Malfunction During Closing SQ3 .................................................................1-14
Default Prior to Opening the Guiding Channel.........................................................................1-15
Guiding Channel Malfunction During Opening SQ3................................................................1-16
Guiding Channel Malfunction During Closing SQ4 .................................................................1-17
Guiding Channel Malfunction During Opening SQ4................................................................1-18
Default Prior to Closing the Guiding Channel..........................................................................1-19
Front Rest Error..........................................................................................................................1-20
Servo Motor Positioning Error...................................................................................................1-21
Vise Positioning Error ................................................................................................................1-22
Home Position Proximity Switch SQ7 Missing.........................................................................1-23
Pusher Lost the Bar Stock During its Return to Home Position.............................................1-24
Bar Stock Not Extracted from the Collet...................................................................................1-25
Vise Coupling Device Malfunction ............................................................................................1-26
Switch SQ4 Signal Missing........................................................................................................1-28
Bar Stock Loading Error.............................................................................................................1-29
Bar Loading Error .......................................................................................................................1-30
Bar Remnant Too Long ..............................................................................................................1-31
Bar Stock Moving Backwards during Headstock Reverse with Collet Open.........................1-32
Bar Stock Moving Forward during Headstock Reverse with Collet Open .............................1-33
Headstock Travel is Shorter Than Programmed Length.........................................................1-34
Servo Amp/PLC Comm. Fault ....................................................................................................1-35
Bar Magazine Indexing Motor Faulty.........................................................................................1-36
Bar Stock Insertion Malfunction................................................................................................1-37
Servo Drive Alarm.......................................................................................................................1-38
Servo Motor Not Ready ..............................................................................................................1-39
Chuck Closed Prior to Feed Out Complete...............................................................................1-40
A2 Interrupted During Loading..................................................................................................1-41
Safety Time for Part Feed Out....................................................................................................1-42
Software Sequence.....................................................................................................................1-43
Mitsubishi Servo Amplifier Alarm List ......................................................................................1-45
Chapter 2: .......................................................................................2-1
Common Issues...........................................................................................2-1
Low Voltage / PLC Shutdown ......................................................................................................2-2
Cannot Change Application Setup Parameters..........................................................................2-3
Multiple Bars have been Loaded into the Channel ....................................................................2-3
Front Rest Issues..........................................................................................................................2-4
Vibration Issues............................................................................................................................2-5
Chapter 3: .......................................................................................3-1
HYDROBAR EXPRESS 332

Procedures..................................................................................................3-1
Alignment Procedure for Front Rest...........................................................................................3-2
Alignment Procedure for Mobile Vise .......................................................................................3-13
Alignment Procedure for Pusher Support Guiding Channel...................................................3-18
Calibration Procedure for Front Rest........................................................................................3-30
Front Rest Override ....................................................................................................................3-33
Modified Upper Limiter Bracket Installation.............................................................................3-35
Pump Motor Splash Guard Assembly.......................................................................................3-41
Reference Procedure..................................................................................................................3-43
Replacement of the Front Rest Diameter Adjustment Motor and Installation of the Modified
Spacer Bracket............................................................................................................................3-45
Adjustment Procedure for End of Bar.......................................................................................3-51
Replacement of the Loading Finger Diameter Motor...............................................................3-53
Top Cut Positioning....................................................................................................................3-55
Chain Tension Adjustment.........................................................................................................3-60
Pusher Changeover ....................................................................................................................3-64
Chapter 4:.......................................................................................4-1
Software Update/Restore ...........................................................................4-1
PLC Fault .......................................................................................................................................4-3
Restore PLC Program From Memory Card to PLC – v1.17a......................................................4-3
PLC Fault .......................................................................................................................................4-6
Restore Bar Feeder Parameters from MMI to PLC – v1.17a......................................................4-6
Software Update............................................................................................................................4-9
Restore Bar Feeder Parameters From MMI to PLC – v1.17a.....................................................4-9
Software Update..........................................................................................................................4-12
Restore Display Data from Memory Card to MMI – v1.17a......................................................4-12
Software Update..........................................................................................................................4-16
Restore PLC Program from Memory Card to PLC – v1.17a.....................................................4-16
PLC Fault – v2.08 ........................................................................................................................4-20
Software Update – v2.08.............................................................................................................4-23
Chapter 5:.......................................................................................5-1
Preventative Maintenance..........................................................................5-1
Daily Maintenance.........................................................................................................................5-2
Weekly Maintenance.....................................................................................................................5-2
Monthly Maintenance....................................................................................................................5-2
Annual Maintenance.....................................................................................................................5-3
Chapter 6:.......................................................................................6-1
Spare Parts..................................................................................................6-1
Recommended Spare Parts List..................................................................................................6-2
Collet Reference Chart .................................................................................................................6-3
Guiding Channel Reference Chart...............................................................................................6-4
Parts Order Form ..........................................................................................................................6-6
Electrical Box Components .........................................................................................................6-7
Front Rest Air Blast Assembly.....................................................................................................6-8
Magazine Adjustment Decoder Disc Assembly..........................................................................6-9
Main Access Cover Switch Assembly.......................................................................................6-10
Hydraulics Assembly..................................................................................................................6-11
Material Presence Cylinder ........................................................................................................6-12
Pusher Locking Device – L/F Load............................................................................................6-13
Pusher Locking Device – R/F Load ...........................................................................................6-14
Front Rest Assembly – L/F Load ...............................................................................................6-15
Front Rest Assembly – R/F Load...............................................................................................6-16
Measuring Bracket – L/F Load...................................................................................................6-17
Measuring Bracket – R/F Load...................................................................................................6-18
Vise Assembly – L/F Load..........................................................................................................6-19
Vise Assembly – R/F Load .........................................................................................................6-20
Vise Assembly – Extraction Jaws..............................................................................................6-21
Chain Drive – Sub-assembly......................................................................................................6-22
Chain Drive – Servo Motor .........................................................................................................6-23
Chain Drive – Sprocket...............................................................................................................6-24
HYDROBAR EXPRESS 332

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-1
Chapter 1:
Alarms
n error has occurred during setup or cycling of the bar feeder. When an error occurs, an alarm message is generated on
the remote control station. Also provided are some possible causes as to why the error has occurred. This
troubleshooting guide discusses every alarm that the bar feed may generate. 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.
A
Figure 1-1 Remote control station

1-2 Chapter 1: Alarms
HYDROBAR EXPRESS 332
Desi
g
nation Descri
p
tion
A Remote control station
B Control cabinet
C Optional interface cable outlet
M1 Hydraulic pump motor
M2 Servo motor
QS1 Main disconnect switch
SP1 Pneumatic pressure switch
SP2 Hydraulic pressure switch
SQ1 Positioning stopper proximity switch
SQ2 Bar magazine diameter counting monitor
SQ3 Opening guiding channel control switch
SQ4 Closing guiding channel control switch
SQ5 Material presence control switch
SQ6 Control switch: mobile vise in forward position
SQ7 Control switch: pusher in rear/park position
SQ8 Front-rest opening monitor
SQ9 Front-rest gap adjuster
SQ10 Retraction system in position switch
SQ11 Main access cover safety switch

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-3
MOST RECENT
ALARMS
ALARM HISTORY
Description:
The Most Recent Alarms feature allows the user to view the 20 most recent alarms that have occurred on the bar feed. This
is helpful when determining what to look at as far as troubleshooting problems that have recently taken place, especially when the
troubleshooting involves contacting 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. Once the bar feed alarm is overridden the only way to pinpoint the original
bar feed alarm is to enter into the alarm history.
This menu is located HELP menu, to locate the alarm history follow the steps below:
Step 1: Press the HELP key on the remote control station at any time.
Step 2: Press the PAGE DOWN key 6 times.
Use the PAGE UP and PAGE DOWN keys to scroll through alarms. The alarms are are listed with the most recent alarm being the
first to appear to the 20th most recent alarm being listed last.

1-4 Chapter 1: Alarms
HYDROBAR EXPRESS 332
EMERGENCY STOP
LINE OPEN
********************
POSSIBLE CAUSES:
CONNECTION OR WIRING
PROBLEM IN CIRCUITRY
Emergency Stop Line Open
Description:
The Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.0). The problem is generated anytime the
safety circuit contactor (K1) is not energized and all safety switches are in operating position. (Refer to page 4-17 in the Express 332
Instruction Manual).
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 0 = 0
MODULE 0
76543210
0
•Verify that the 1/0 connector is plugged into the PLC correctly.
•Verify that the circuitry is wired correctly to the electrical diagram
on page 4-17 in the Express 332 Instruction Manual.
2 Bit 0 = 1
MODULE 0
76543210
1
Alarm needs to be cleared. Press the STOP key on the remote
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.

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-5
Lathe Emergency Stop Line Open
LATHE EMERGENCY
STOP LINE OPEN!
POSSIBLE CAUSES:
- EMERGENCY STOP
PUSHED IN
- WIRING PROBLEM
Description:
The Lathe Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.3). The problem is generated when
the lathe E-stop push button is pressed in.
Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 3 = 1
MODULE 0
76543210
1000
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
2 Bit 3 = 0
MODULE 0
76543210
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.

1-6 Chapter 1: Alarms
HYDROBAR EXPRESS 332
Bar Feeder Emergency Stop
BAR FEEDER
EMERGENCY STOP!
POSSIBLE CAUSES:
- EMERGENCY STOP
BUTTON PUSHED IN
- WIRING PROBLEM
Description:
The Bar Feeder Emergency Stop alarm occurs whenever the PLC does not detect input (I0.2). The problem is generated E-stop push
button on the remote control station is pressed in.
Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 2 = 1
MODULE 0
76543210
100
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
2 Bit 2 = 0
MODULE 0
76543210
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.

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-7
Oil Pressure Failure
OIL PRESSURE
FAILURE!
POSSIBLE CAUSES:
-PRESSURE SWITCH SP2
DEFECTIVE OR
MIS-ADJUSTED
-PUMP FAILURE
-TANK EMPTY
Description:
The Oil Pressure Failure alarm occurs whenever the PLC does not detect input (I0.6 – SP2) while the hydraulic pump is running. The
problem is generated after 30 seconds when oil pressure is not sufficient, below the factory setting of point of release of 0.5 bars, to
activate the oil pressure switch. The bar feed does not alarm out until the chuck is open.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 6 = 1
MODULE 0
76543210
1000000
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
Check the oil level indicator on the side of the hydraulic tank and
make sure there is sufficient oil. Recommended 80 liters of ISO 100
type oil.
Flip the toggle switch on the PLC to the RUN position.
2 Bit 6 = 0
MODULE 0
76543210
0
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.

1-8 Chapter 1: Alarms
HYDROBAR EXPRESS 332
Air Pressure Failure
AIR PRESSURE
FAILURE!
POSSIBLE CAUSES:
-AIR PRESSURE BELOW
3 BAR(45PSI)
-AIR PRESSURE SWITCH
SP1 MIS-ADJUSTED
-AIR PRESSURE SWITCH
DEFECTIVE
Description:
The Air Pressure Failure alarm occurs whenever the PLC does not detect input (I0.5 – SP1) after a period of 5 seconds. The problem
is generated anytime air pressure is not sufficient, below 45psi, to make the air pressure switch.
Solution:
Press the HELP key on the remote control station. Press the F4 (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 5 = 1
MODULE 0
76543210
100000
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
Raise the incoming air pressure on the air regulator to
(recommended) 75 psi. and no higher than 90 psi.
Flip the toggle switch on the PLC to the RUN position.
2 Bit 5 = 0
MODULE 0
76543210
0
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.

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-9
Main Access Cover Open
MAIN ACCESS COVER
OPEN!
CLOSE MAIN COVER TO
RESUME OPERATIONS
Description:
The Main Access Cover Open alarm occurs whenever the PLC detects input (I0.4 – SQ11). The problem is generated, as a safety
precaution, when the main access cover is opened to prevent any movement in the bar feeder if the operator or service technician
needs to perform any work inside the unit.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 4 = 1
MODULE 0
76543210
10000
Close the main access cover.
2 Bit 4 = 0
MODULE 0
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
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.

1-10 Chapter 1: Alarms
HYDROBAR EXPRESS 332
Bar Feeder Retracted
BAR FEEDER RETRACTED
OR NOT LOCKED IN ITS
WORKING POSITION!
SIGNAL SQ10 MISSING
SECURE BAR FEEDER
IN ITS WORKING
POSITION TO RESUME
OPERATIONS
Description:
The Bar Feeder Retracted alarm occurs whenever the PLC detects input (I0.1 – SQ10). The problem is generated when the bar
feeder is retracted for spindle liner changeover.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 1 = 1
MODULE 0
76543210
10
Put the bar feeder back in its working position and lock the latches.
2 Bit 1 = 0
MODULE 0
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
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.

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-11
Front Measuring Stop Signal SQ1 Missing
FRONT MEASURING STOP
SIGNAL SQ1 MISSING!
POSSIBLE CAUSES:
-FRONT STOPPER DID
NOT MOVE UP
-SIGNAL SWITCH SQ1
DEFECTIVE OR
MIS-ADJUSTED
Description:
The Front Measuring Stop Signal SQ1 Missing alarm occurs during the new bar measuring sequence when the front measuring stop
is activated but input signal (I0.7) is not detected by the PLC.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
Check to see if there is a mechanical obstruction preventing the
measuring stop from rising up.
Make sure that the SQ1 switch is adjusted to within a sensing
distance of 0.5mm-1mm from the measuring stop.
1 Bit 7 = 1
MODULE 0
76543210
10000000
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.
2 Bit 7 = 0
MODULE 0
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
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.

1-12 Chapter 1: Alarms
HYDROBAR EXPRESS 332
Front Stopper Cannot Move Up
FRONT STOPPER
CANNOT MOVE UP!
POSSIBLE CAUSES:
-BAR STOCK PROTRUDES
FROM THE BACK OF
THE SPINDLE
-SQ1 SWITCH
MALFUNCTION
-MECHANICAL OR
PNEUMATIC FAILURE
Description:
The Front Stopper Cannot Move Up alarm occurs if, during the loading cycle, the measuring flap does not rise up to be detected by
proximity switch SQ1. The alarm is normally generated due to a mechanical obstruction preventing the flap from rising up.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
Check to see if there is a mechanical obstruction preventing the
measuring stop from rising up.
Make sure that the SQ1 switch is adjusted to within a sensing
distance of 0.5mm-1mm from the measuring stop.
Check that the air flow restrictor has not cut off the air supply to the
cylinder.
1 Bit 7 = 0
MODULE 0
76543210
0
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.
2 Bit 7 = 1
MODULE 0
76543210
10000000
Alarm needs to be cleared. Press the STOP key on the remote
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.

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-13
Signal SQ1 For Front Stopper Defective
SIGNAL SQ1 FOR FRONT
STOPPER DEFECTIVE!
POSSIBLE CAUSES:
-SQ1 SIGNAL SWITCH
FAULTY (ALWAYS ON)
Description:
The Signal SQ1 For Front Stopper Defective alarm occurs during remnant measuring or during new bar measuring if input signal (I0.7
– SQ1) does not turn off and the bar feed has already recognized that a bar is inserted in the collet.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
Check to see if there is a mechanical obstruction preventing the
measuring stop from dropping.
Make sure that the SQ1 switch is adjusted to within a sensing
distance of 0.5mm-1mm from the measuring stop.
1 Bit 7 = 1
MODULE 0
76543210
10000000
Check the wiring of switch SQ1.
2 Bit 7 = 0
MODULE 0
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
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.

1-14 Chapter 1: Alarms
HYDROBAR EXPRESS 332
Guiding Channel Malfunction During Closing SQ3
GUIDING CHANNEL
MALFUNCTION DURING
CLOSING!
POSSIBLE CAUSES:
-CLOSING MECHANISM
MALFUNCTION
-SIGNAL SWITCH SQ3
DEFECTIVE OR
MIS-ADJUSTED
Description:
The Guiding Channel Malfunction During Closing alarm occurs if input (I1.1 – SQ3) does not turn off during the channel closing
sequence.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 1 = 1
MODULE 1
76543210
10
Check to see if a mechanical obstruction is preventing the
channel from closing.
Check the functionality of the SQ3 switch. The switch may be
sticking and needs to be replaced.
2 Bit 1 = 0
MODULE 1
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
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.

Chapter 1: Alarms
HYDROBAR EXPRESS 332
1-15
Default Prior to Opening the Guiding Channel
DEFAULT PRIOR TO
OPENING THE GUIDING
CHANNEL!
POSSIBLE CAUSES:
-SIGNAL SWITCH SQ3
DEFECTIVE OR
MIS-ADJUSTED
-MECHANICAL FAILURE
Description:
The Default Prior To Opening The Guiding Channel alarm occurs if the channel is closed and input (I1.1 – SQ3) is on before the
channel tries to open to remove the remnant.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 1 = 1
MODULE 1
76543210
10
The switch may be sticking and needs to be replaced.
2 Bit 1 = 0
MODULE 1
76543210
0
Alarm needs to be cleared. Press the STOP key on the remote
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.

1-16 Chapter 1: Alarms
HYDROBAR EXPRESS 332
Guiding Channel Malfunction During Opening SQ3
GUIDING CHANNEL
MALFUNCTION DURING
OPENING!
POSSIBLE CAUSES:
-OPENING MECHANISM
MALFUNCTION
-SIGNAL SWITCH SQ3
DEFECTIVE OR
MIS-ADJUSTED
Description:
The Guiding Channel Malfunction During Opening alarm occurs if input (I1.1 – SQ3) does not turn on when the channel opens up.
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.
Case Input Remote Pendant Solution
1 Bit 1 = 1
MODULE 1
76543210
10
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
2 Bit 1 = 0
MODULE 1
76543210
0
Check to see if a mechanical obstacle prevents the channel from
opening.
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.