LNS HYDROBAR SPRINT 542 User manual

LNS America
4621 East Tech Drive
Cincinnati, Ohio 45245
Tel: [phone]
Fax: [phone]
[email protected]
http://www.LNS-america.com
Instruction manual
ENG
9.042.01.ENG

V1.0
Table of Contents
CHAPTER 1 BASIC NOTIONS 1-1
1. STRUCTURE 1-2
1.1. Cross-references 1-2
1.2. Captions 1-2
1.3. Symbols and terminology 1-2
2. RIGHTS 1-3
3. DECLARATION OF COMPLIANCE 1-4
4. SAFETY INSTRUCTIONS 1-5
5. SAFETY DEVICES 1-6
5.1. Description 1-6
5.2. Layout of the safety elements on the bar feed system 1-6
CHAPTER 2 TECHNICAL DATA 2-1
1. CHARACTERISTICS (*) 2-2
2. FLOOR PLANS 2-2
2.1. Left/front loading 2-3
2.2. Left/front loading (2 m) 2-4
3. LAYOUT OF THE MAIN ELEMENTS 2-5
CHAPTER 3 INSTALLATION 3-1
1. TRANSPORTATION 3-2
1.1. Description 3-2
1.2. Unpacking 3-2
1.3. Preparation for mounting 3-3
2. MOUNTING 3-5
2.1. Alignment 3-5
3. ANCHORING TO THE GROUND 3-6
4. CONNECTING 3-6
CHAPTER 4 ELECTRICS 4-1
1. ELECTRICAL EQUIPMENT 4-2
1.1. Description 4-2
1.2. Layout of the electrical elements on the bar feed system 4-3
1.3. Description of the electrical elements of the bar feed system 4-5
2. MAIN ELECTRICAL CABINET 4-6
2.1. Layout of the elements in the electrical cabinet 4-6
2.2. Description of the elements in the cabinet 4-8
3. ELECTRICAL DIAGRAMS 4-15
4. INTERFACE 4-25
4.1. Description 4-25
4.2. Connections 4-26

CHAPTER 5 PNEUMATICS 5-1
1. PNEUMATIC EQUIPMENT 5-2
1.1. Description 5-2
1.2. Layout of the pneumatic elements 5-2
2. AIR FILTERING UNIT 5-3
2.1. Description 5-3
2.2. Layout of the elements 5-3
2.3. Connection 5-3
2.4. Settings 5-3
3. PNEUMATIC VALVE BATTERY 5-5
3.1. Description 5-5
3.2. Layout of the elements 5-5
3.3. Description of the elements 5-6
4. PNEUMATIC DIAGRAMS 5-7
CHAPTER 6 HYDRAULICS 6-1
1. HYDRAULIC EQUIPMENT 6-2
1.1. Description 6-2
1.2. Layout of the elements 6-2
1.3. Setting 6-3
1.4. Filling and draining 6-3
2. HYDRAULIC DIAGRAM 6-4
2.1. Symbols 6-4
2.2. Hydraulic diagram 6-4
CHAPTER 7 GENERAL DESCRIPTION 7-1
1. BAR MAGAZINE 7-2
1.1. Description 7-2
1.2. Layout of the elements 7-2
1.3. Setting 7-2
2. GUIDING ZONE 7-3
2.1. Description 7-3
2.2. Layout of the elements (*) 7-3
2.3. Guiding elements (bearings) 7-4
3. PUSHER 7-5
3.1. Description 7-5
3.2. Layout of the elements 7-5
4. BELT DRIVE 7-8
4.1. Description 7-8
4.2. Layout of the elements 7-8
4.3. Belt 7-8
5. REMNANT EXTRACTION SYSTEM (option) 7-9
5.1. Description 7-9
5.2. Layout of the elements 7-9
5.3. Replacement of the blades 7-10
5.4. Material presence control 7-10
6. RETRACTION SYSTEM (option) 7-11
6.1. Description 7-11
6.2. Operation 7-11

7. FRONT REST (standard) 7-12
7.1. Description 7-12
7.2. Layout of the elements 7-12
8. PNEUMATIC FRONT REST 2 POSITIONS (option) 7-13
8.1. Description 7-13
8.2. Layout of the elements 7-13
8.3. Setup 7-13
9. AUTOMATIC FRONT REST (option) 7-14
9.1. Description 7-14
9.2. Layout of the elements 7-14
9.3. Setup 7-14
CHAPTER 8 OPERATION 8-1
1. POWERING UP 8-2
2. REMOTE CONTROL 8-3
2.1. Display 8-4
2.2. Softkeys F1 - F4 8-6
2.3. Left / right / up / down direction softkeys 8-6
2.4. Emergency stop button 8-6
2.5. STOP softkey 8-6
3. CONTROL SETTINGS (PARAMETERS) 8-7
3.1. Description 8-7
3.2. Accessing the Control Settings (Parameters) 8-8
3.3. Procedures for setting positioning parameters 8-22
4. BAR FEED PRE-RUN INSPECTION 8-26
4.1. Bar feed mechanical setup 8-26
4.2. Lathe mechanical setup 8-28
4.3. Lathe Bar feed adaptation 8-29
5. AUTOMATIC CYCLE 8-30
5.1. New loading bar stock 8-30
5.2. Part feed out 8-30
5.3. Remnant extraction 8-30
6. POWERING OFF 8-31
CHAPTER 9 MALFUNCTIONS 9-1
1. FACTORS AFFECTING PERFORMANCE 9-2
1.1. Installation 9-2
1.2. Gap between the guiding elements and the bar 9-2
1.3. Gap between the spindle and the bar 9-2
1.4. Material 9-3
2. MAINTENANCE 9-4
2.1. Hydraulics 9-4
2.2. Pneumatics 9-4
2.3. Batteries 9-4
2.4. Mechanics 9-4
2.5. Cleaning 9-4

CHAPTER 10 APPENDICES 10-1
1. APPENDIX B: PROGRAMMING EXAMPLE 10-2
2. APPENDIX B: PUSHER ASSEMBLY (STICKER) 10-3
3. APPENDIX C: ORDERING FORM 10-7
4. APPENDIX D: ADDRESS LNS 10-8

CHAPTER 1: BASIC NOTIONS 1-1
CHAPTER 1
BASIC NOTIONS

1-2
1. STRUCTURE
This manual consists
of various chapters, each containing several points, paragraphs, etc. Lists may be
contained in paragraphs.
•
The page number is indicated in the top outside margin of the page.
•
The chapter number and title are indicated in the top inside margin of the pag
•
The model of the bar feed system is indicated in the bottom outside margin of the page.
1.1. Cross-references
Each chapter generally contains all of the information related to the description and settings of the
devices and elements represented
therein.
Therefore, if a setting must be made while handling the system, please refer to the chapter on the device
to be set, for example: (see chapter *) or (see point *).
1.2. Captions
Whenever possible, the reference numbers contained in the
ordering number of the indicated element.
To make it easier to place an order of supplies, a form has been included in the annex at the end of this
manual.
1.3. Symbols and terminology
This symbol recommends
incident that could result in personal injury, damage to the equipment, or data
loss.
This symbol indicates that safety measures must be taken to avoid possible
electrical shocks or mishaps.
This symbol stresses interesting points or comments, and provides
for optimal system operation.
This symbol advises the strict following of local, state, and federal environmental
guidelines when disposing of certain materials.
CHAPTER 1: BASIC NOTIONS
of various chapters, each containing several points, paragraphs, etc. Lists may be
The page number is indicated in the top outside margin of the page.
The chapter number and title are indicated in the top inside margin of the pag
e.
The model of the bar feed system is indicated in the bottom outside margin of the page.
Each chapter generally contains all of the information related to the description and settings of the
therein.
Therefore, if a setting must be made while handling the system, please refer to the chapter on the device
to be set, for example: (see chapter *) or (see point *).
Whenever possible, the reference numbers contained in the
instruction manual are shown with the LNS
To make it easier to place an order of supplies, a form has been included in the annex at the end of this
This symbol recommends
following the directions very closely to avoid causing an
incident that could result in personal injury, damage to the equipment, or data
This symbol indicates that safety measures must be taken to avoid possible
electrical shocks or mishaps.
This symbol stresses interesting points or comments, and provides
useful advice
for optimal system operation.
This symbol advises the strict following of local, state, and federal environmental
guidelines when disposing of certain materials.
CHAPTER 1: BASIC NOTIONS
of various chapters, each containing several points, paragraphs, etc. Lists may be
The model of the bar feed system is indicated in the bottom outside margin of the page.
Each chapter generally contains all of the information related to the description and settings of the
Therefore, if a setting must be made while handling the system, please refer to the chapter on the device
instruction manual are shown with the LNS
To make it easier to place an order of supplies, a form has been included in the annex at the end of this
following the directions very closely to avoid causing an
incident that could result in personal injury, damage to the equipment, or data
This symbol indicates that safety measures must be taken to avoid possible
useful advice
This symbol advises the strict following of local, state, and federal environmental

CHAPTER 1: BASIC NOTIONS 1-3
2. RIGHTS
All rights reserved. Reproduction, recording or transmission of all, or any portion, of this manual, in any
form or through any means whatsoever, whether mechanical, photographic, and sound or other, without
the express written authorization of LNS SA, is prohibited. LNS SA disclaims all responsibility for errors
which may be contained in this manual and the problems which may result therefore.
LNS SA and its subsidiaries cannot be made responsible for the debts, losses, expenses, or damage
incurred, or suffered, by the buyer of this product, or a third party, following an accident, incorrect use, or
misuse, or stemming from modifications, repairs, or transformations not authorized by LNS SA.
LNS SA and its subsidiaries cannot be held responsible for damage and problems arising from the use of
options and products other than LNS products, or products approved by LNS SA.
The names of the products indicated in this manual are registered trademarks.
The instructions found in this manual are only for information; they are subject to change without notice.

1-4 CHAPTER 1: BASIC NOTIONS
3. DECLARATION OF COMPLIANCE
(Directive 89/392/EEC, Article 4.2 and Appendix 1, Chapter B)
Manufacturer: LNS SA
Address: Route de Frinvillier
CH-2534 Orvin
Declares that:
The Hydrobar Sprint 542 automatic bar feed system
- Is designed to be incorporated into a machine, or to be assembled with other machines, to create a
machine covered by Directive 89/392/EEC amended, and that the following (parts/paragraphs) of the
harmonized standards have been applied: EN 292, EN 60 204 1, EN 1088, EN 418, EN 60947,
89/336/EEC, 73/23/EEC.
- And furthermore declares that it is prohibited to put the machine into operation before the machine
into which it is to be inserted, or of which it will become a part, has been examined and declared in
conformity with the provisions of Directive 89/392/EEC and the national laws transposing it, i.e.
forming a whole including the machine to which reference is being made in the present declaration.
Orvin, 07.01.2008
LNS SA
P. Scemama

CHAPTER 1: BASIC NOTIONS 1-5
4. SAFETY INSTRUCTIONS
•
Do not handle the equipment without having
knowledge of the safety instructions and the
instructions for use. Safety instructions for
the bar feed system, as well as the CNC
lathe, must be strictly observed.
• Non-qualified personnel, children, and
persons under the influence of alcohol or
medication should not handle the equipment.
• Loose garments, long hair and jewelry can
be dangerous.
• Do not remove any covers while the bar feed
or the machine is under electrical power.
• Do not conduct any maintenance operations
during the automatic cycle.
• Do not grasp moving or rotating objects, or
nearby elements.
• If certain safety shields or safety covers are
removed to conduct maintenance, they must
be reinstalled as soon as the maintenance
work is complete.
• No servicing should be carried out on the
interface or inside the electrical cabinet while
the bar feed or the lathe is under electrical
power.
• It is strictly prohibited to jump wire or remove
circuit breakers, main switches, and
especially safety switches.
• To avoid any harm to persons, or damage to
components, use only the indicated points
for lifting and moving the bar feed system.
No one should be near the hanging load, or
within the operating range of the overhead
hoist/crane, forklift, or any other means used
for lifting and transportation.
• Do not move the bar feed while it is
electrically powered on.
•
Do not hit the bar feed when moving it, this
could result in damages.
• The work area surrounding the bar feed
system should always be clear of any trip
and/or slip hazards. The presence of oil on
the floor could cause falls; it is important to
maintain a clean floor at all times.
• Do not place the bar feed in a damp area
and make sure that water and/or oil does not
come into contact with any electrical
equipment not rated for such contact.
• Do not open the clamping device—collet or
chuck—of the lathe manually while the bar
feed is in automatic mode (Interface).
• The use of spindle reduction tubes is highly
recommended for machining bar stock with
diameters smaller than the maximum
capacity of the spindle.
• Do not attempt to recharge the PLC or servo
amplifier batteries.
• For the use and maintenance of the bar
feed, use only parts provided by or
recommended by LNS.
• If it is necessary to move the bar feed once it
has been originally installed, do not reinstall
it before first contacting LNS or its local
representative.
• The rotating bar should never protrude from
the rear of the lathe spindle without proper
rotational guiding support and safety devices
in place to eliminate contact with the rotating
material.
• The bar should never extend more than 3
times its diameter beyond the lathe clamping
device without support.
• LNS disclaim all responsibility for possible
accidents or property damage caused when
these safety instructions are not followed.

1-6 CHAPTER 1: BASIC NOTIONS
5. SAFETY DEVICES
5.1. Description
The HYDROBAR SPRINT 542 bar feed system has been designed with a focus on maximum safety
during its handling and complies with all IEC requirements.
Safety covers and devices make access to the moving parts of the bar feed system impossible. Safety
switches keep the bar feed system from operating when these protections are open.
The design of the switches, as well as their insertion into the bar feed system, makes it practically
impossible to bypass them.
By pressing the emergency stop button located on the remote control, the functions of the bar feed
system and the lathe are immediately stopped.
The LNS company, or its local representative, may not be held responsible for possible
accidents or property damage, whether caused directly or not, by any means whatsoever,
if certain safety devices have not been included.
5.2. Layout of the safety elements on the bar feed system
Designation
Description
A Emergency stop push button
B Main access cover
SQ10 Retraction system safety switch (optional)
SQ11 Main access cover safety switch
A
B
SQ11
SQ10

CHAPTER 2: TECHNICAL DATA 2-1
CHAPTER 2
TECHNICAL DATA

2-2 CHAPTER 2: TECHNICAL DATA
1. CHARACTERISTICS (*)
2 m
3 m
12’
4 m
Weight - - - -
Dimensions See p. 2-3 See p. 2-3 See p. 2-3 See p. 2-3
Retract travel (option) 500 mm 500 mm 500 mm 500 mm
Minimum stock diameter
(profiled: dia. across flats)
5 mm
(square: 4 mm)
(hex: 5 mm)
5 mm
(square: 4 mm)
(hex: 5 mm)
5 mm
(square: 4 mm)
(hex: 5 mm)
5 mm
(square: 4 mm)
(hex: 5 mm)
Maximum stock diameter
(profiled: dia. across flats )
42 mm
(square: 30
mm)
(hexagonal:
36 mm)
42 mm
(square: 30
mm)
(hexagonal:
36 mm)
42 mm
(square: 30
mm)
(hexagonal:
36 mm)
42 mm
(square: 30
mm)
(hexagonal:
36 mm)
Minimum bar stock length 1300 mm 1300 mm 1300 mm 1300 mm
Maximum bar stock length 2200 mm 3200 mm 3800 mm 4200 mm
Minimum remnant length 100 mm 100 mm 100 mm 100 mm
Maximum remnant length 300 mm 420 mm 420 mm 420 mm
Pneumatic pressure 5 bar 5 bar 5 bar 5 bar
Air consumption < 10 l / loading cycle
Main electrical power (Volt) * 3x 220 – 480
50 Hz – 60 Hz
3x 220 – 480
50 Hz – 60 Hz
3x 220 – 480
50 Hz – 60 Hz
3x 220 – 480
50 Hz – 60 Hz
Pushing force / torque 55 Nm 55 Nm 55 Nm 55 Nm
Maximum feed rate >100 m/min >100 m/min >100 m/min >100 m/min
Loading cycle 30 – 40 sec. 30 – 40 sec. 30 – 40 sec. 30 – 40 sec.
Hydraulic oil ISO 100/70 kg ISO 100/80 kg ISO 100/90 kg ISO 100/100 kg
*) Depending on the options, these technical data may vary. Please refer to the technical data sheet.
2. FLOOR PLANS
The following floor space plans indicate the most frequently used dimensions for placing the bar feed
system. Details on the dimensions of other parts or elements of the bar feed system will be furnished
upon request.

CHAPTER 2: TECHNICAL DATA 2-3
2.1. Left/front loading

2-4 CHAPTER 2: TECHNICAL DATA
2.2. Left/front loading (2 m)

CHAPTER 2: TECHNICAL DATA 2-5
3. LAYOUT OF THE MAIN ELEMENTS
Designation
Description
A Belt drive
B Pneumatic control valve assembly
C Main access cover
D Guiding zone
E Remnant extraction device with material presence control (option)
F Auxiliary electrical junction box
G Air filtering unit
H Main electrical cabinet
J Rear stand
K Retraction system (option)
L Remnant collection / hydraulic oil reservoir
M Material loading system cylinder
N Front stand
P Remote operator’s control
R Front rest (several options available ; see sections 7.6, 7.8, and 7.9 for further
details)
A
E
L
P
R
N
K
J
G
H
B
D
F
M
C

2-6 CHAPTER 2: TECHNICAL DATA

CHAPTER 3: SETTING INTO OPERATION 3-1
CHAPTER 3
INSTALLATION

3-2 CHAPTER 3: SETTING INTO OPERATION
1. TRANSPORTATION
Please read the safety precautions described at the beginning of this manual before
handling the following devices.
1.1. Description
Depending on its destination, the HYDROBAR SPRINT 542 bar feed system may be delivered either on a
pallet, or packed in a wooden crate. When sea or air transports it, the second solution is recommended.
Regardless of the type of packaging, the uncrating and lifting instructions recommended by LNS must be
observed in order to prevent any injuries to persons and damages to objects. These instructions are
stapled to the crate of the bar feed system.
Crate Pallet
2 meter 3 meter 12 ‘ 4 meter 2 meter 3 meter 12 ‘ 4 meter
Width --- 1100 mm --- 1100 mm --- 1000 mm --- 1000 mm
Length --- 4500 mm --- 5400 mm --- 4500 mm --- 5400 mm
Height --- 1750 mm --- 1750 mm --- --- --- ---
1.2. Unpacking
For practical and safety reasons, the bar feed system must be unpacked in a spacious, well-lit location.
Check to see that the lifting capacity of the hoisting crane, or lift truck, is adequate before
proceeding with the handling of the merchandise. No one should be near the hanging load,
or within the operating range of the overhead hoist/crane, forklift, or any other means used
for lifting and transportation.
1) If the bar feed system is received in a crate,
start by unscrewing the front panel.
2) Remove the top.
3) Remove the side-walls.
1
2
3