LNS HYDROBAR SPRINT S3 User manual

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

1
SPRINT S3
V1.05
TABLE OF CONTENTS
1. SAFETY INSTRUCTIONS 1
2. PREPARATION FOR INSTALLATION 1
3. ASSEMBLING INSTRUCTIONS 2
4. AIR REQUIREMENTS AND CONNECTIONS 3
5. ALIGNMENT 4
6. ANCHORING 4
7. ASSEMBLING 5
7.1. LOADER ASSEMBLING 5
8. HYDRAULICS 8
8.1. Hydraulic oil requirements 8
9. DESCRIPTION OF COMPONENTS 9
9.1. ELECTRICAL CONTROL COMPONENTS LAYOUT 9
10. ELECTRICAL CONNECTIONS 11
11. BAR STOCK PREPARATION 12
12. DIAMETER CHANGEOVER 13
12.3. ROTATING SLEEVE CHANGEOVER 14
12.4. FLAG CHANGEOVER 15
12.5. LOADER ADJUSTMENT 15
12.6. GEAR RATIOS 16
12.7. PUSHING FORCE CHART 17
12.8. DIAMETER CHANGEOVER CHART 18
13. SPINDLE REDUCTION TUBES CHANGEOVER 19
14. GUIDING ELEMENTS CHANGE 20
15. END OF BAR 21
16. MECHANICAL STOP 23
17. REMOTE CONTROL 24
17.1. Display 25
18. POWERING UP 28
18.1. Description 28

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SPRINT S3
19. AUTOMATIC SEQUENCE 29
19.1. Description 29
20. SETTINGS 30
20.1. Description 30
20.2. Access to the functions 31
21. AIR ADJUSTMENTS 39
21.1. MAIN PRESSURE 39
21.2. AIR MOTOR PRESSURE 40
21.3. PUSHER FEED RATE ADJUSTMENTS 41
22. MAINTENANCE 41
23. AIR CYLINDERS, AIR VALVES 43
24. INTERFACE ELECTRICAL DIAGRAM 44
25. HYDRAULIC DIAGRAM 45
26. PNEUMATIC DIAGRAM 46
27. INPUTS AND OUTPUTS 48
28. ELECTRICAL DIAGRAM 49
29. FLOOR PLANS 57
30. SPARE PARTS 63
This instruction manual is written for a Sprint S3 with left/front loading
system. Drawings and pusher / loading flag control will be opposite for a
rear loading system

1
SPRINT S3
1. SAFETY INSTRUCTIONS
•Follow all operating and safety instructions of the manufacturer.
•Do not override any of the safety switches or devices either on the lathe or the bar
feeder.
•Do not service, perform maintenance or handle any parts of the bar feeder during
automatic cycling.
•Do not touch the bar stock while in rotation or any part in motion.
•Before operating the bar feeder and the lathe in automatic cycle, always close the main
cover of the bar feeder.
•Spindle reduction tubes must be mounted when running barstock of a smaller diameter
than the maximum capacity of the spindle.
•Do not wear any loose fitting clothing near any rotating parts.
Failure to follow the above safety instructions can result in
serious personal injury or bar feeder damage.
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.
To prevent serious damage to the bar feeder, thoroughly follow the hoisting instructions provided with the
bar feeder. Do not lift the unit other than at the indicated hoisting points.
Prior to installation the customer must provide the following :
•Air supply and connections (see point 4)
•Anchoring bolts (see point 6)
•Hydraulic oil (see point 8.1)

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SPRINT S3
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). Remove nuts
(E) and upper seals (D) only.
•Place the 16 leveling pads under the stands and set the
leveling screws to allow 3 mm (1/8") gap between the top of
the leveling pads and the bottom of the base plate (refer to
point 6). Level the stands with the leveling screws maintaining
equal pressure on all leveling screws.
•Loosen the 8 set screws (A) located on the side of the 2
stands. Using the provided spanner wrench (C) raise or lower
the threaded columns by rotating the lock nuts (B) evenly.
Adjust so that the lower seals (lower half of D) are located at
230 mm (9") from the centerline of the spindle.
•Open the long crate by removing the top panel. Remove the
pins of the hinges on the bar feeder main cover. Carefully
remove the main cover of the bar feeder and take out of crate
by hand.
•Remove the 4 screws holding the main body to the bottom of
the crate and located inside the main body. Assemble the
provided hoisting kit :
1: the threaded rods (1) must be mounted in the lifting
plate located in the center of the main body.
2: install the rods connecting plate (2)
3: lock plate with eyed lock nuts (3)
•Carefully raise the main body of the Sprint out of the crate.
The lower part of the body will remain in the crate.
•Remove lower part out of the crate and carefully lower it on
top of the stands verifying that all O'ring (F) remain seated in
their groves.
•Install the 4 upper seals (D) inside the lower part of the body..
•Lower the main body into the lower part of the body.
•Secure with nuts (E) using the provided hexagonal tube
wrench.

3
SPRINT S3
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).
1/2" standard air hose must be provided by the customer.
Connection :
The connection piece (C) islocated at the rear
of the barfeeder near the support platefor
electrical connection (A) for junction box and
the hydraulic pump (B).
With collar (D) secure hose (E) tightly.
The air hose must be connected and air
present before final alignment of the bar feeder.
Air consumption :
•Production cycle : 9 l / min
•Loading cycle : 20 l

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SPRINT S3
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.
•The alignment can be done by using either a nylon string or an optical unit.
Prior to aligning the bar feeder, the lathe must be leveled.
IMPORTANT : To obtain optimum rpm performance, the bar feeder must be ccurately aligned. Should
the bar feeder not be aligned properly, the bar stock guidance will be affected and
vibrations will result.
6. ANCHORING
After alignment, to secure the bar feeder, it is strongly recommended to anchor the unit to the floor by using
eight M10 x 120 mm (1/2" x 5") wedge type anchors.
Both front and rear stands as well as the loader must be anchored.
1 : Leveling screw
2 : Leveling pad
3 : Anchor bolt
After the bar feeder has been lagged down, the alignment must be checked and eventually
corrected. During anchoring, the stands may have moved and mis-aligned the bar feeder.
Lock the columns in position with set screws (A, see point 3).
Once the bar feeder is secured, the bar loader must be mounted (see point 7).

5
SPRINT S3
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).
•With screws (B), adjust approximatively
the height (1). The bar loader must be
perpendicular.
•Remove the protection sheets on side of
the Sprint.
•Position (2) the bar loader towards the
body of the Sprint.
•Adjust height and level (N) in order to allow
an easy mounting of the support arms with
their respective screws (C).
•Verify the perpendicularity of the loader.
Also an equal pressure of the leveling
screws on their leveling pads must be
present.
•Fasten the small protection sheets on the
loader, then the larges.

6
SPRINT S3
•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).

7
SPRINT S3
•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.
Cross section of clutch is shown at right.

8
SPRINT S3
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.
Description of components).
M2: Hydraulic pump and motor.
A: Flow adjustment.
B: Oil return hose (OUT).
C: Pressure switch.
D: Oil supply hose (IN).
E: Pressure gauge
F: Stop screw
G: Switching point adjustment
The switching points may be set even during operation. Proceed as follows :
1. Loosen stop screw (F) with a screwdriver.
2. Adjust switching points by means of a 5 mm
Hexagon spanner (G). Depending on the
sense of rotation the switching point moves
upwards or downwards Clockwise rotation
means a higher switching value as originaly
set.
Counter clockwise rotation means a lower
switching value as originaly set.
3. Retighten stop screw.
8.1. Hydraulic oil requirements
The Sprint is delivered without oil. 80 liters (22 US gal.) of hydraulic oil must be provided by the
customer. Oil must comply with ISO 100 standards.
Oil will be poured inside the lower part of the SPRINT S3.
List of suppliers and brand names :
BP HLP 100 MOTOREX COREX HLP 100
CASTROL HYSPIN AWS 100 SHELL TELLUS 100
ESSO NUTO 100 STANDARD OIL HL-100
EXXON NUTO H-100 TEXACO RANDO OIL HD 100
GULF ARMONY AW 100 TOTAL AZOLLA 100
MOBIL HEAVY / DTE 27
These oils are just a few of the suppliers that could be used.

9
SPRINT S3
9. DESCRIPTION OF COMPONENTS
A : 3.192 : Air control unit
SQ5 : 4.393 : Pusher home position prox.
switch
SQ8 : 4.393 : Loader down prox. switch
SQ9 : 4.393 : Loader up prox. switch
SQ4 : 4.391 : Bearing blocks closed prox.
switch
SQ3 : 4.391 : Bearing blocks locked prox.
switch
(SQ3/1 : 4.005)
SQ1 : 4.772 : Positioner stop prox. switch
SQ11 : 4.284 : Main cover closed micro -
switches (SQ11/1: 4.005)
SQ6 : 4.005 : Dropping fingers switch
SQ32 : 4.005 : Breaking chain
C : - : Connection box
D : - : Hydraulic filter
E : 4.869 : Remote control station
F : - : Control box
G : - : Loader
H : - : Loading ramp
I : - : Oil recuperator
M1 : 3.160 : Pneumatic motor
M2 : 3.160 : Hydraulic pump motor
M3 : 3.160 : Loader motor
YV1-21 : 3.568 : Air valve assembly
Z1-10 : 3.003 : Cylinders bearing blocks
locking/unlocking
Z13/14 : 3.143 : Cylinder bearing blocks des
opening/closing
Z19 : 3.283 : Vérin doigts dépose-matière
SQ32

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SPRINT S3
9.1. ELECTRICAL CONTROL COMPONENTS LAYOUT
Désignation
Article No
Description
A
4.887
Programmable controller PCD3 (PLC)
B
-
Interface terminal blocks (XT3
C
-
Power supply terminal block (XT1)
D
-
Safety terminal blocks (XT2)
K1
4.507
Safety chain control
KReset
4.606
Kreset relay (M2 motor encoder reset)
KM2
4.606
KM2 relay (hydraulic motor M2
M3B
4.606
KM3B relay (bar loader is moving down)
M3H
4.606
KM3H relay (bar loader is moving up)
QF1
4.815
Circuit breaker 2 x 2A
QM1
4.503
Circuit breaker 2.5 to 4 A
QS1
4.380
Main disconnect switch
RC1
4.352
RC1 relay (filtre)
RC2
4.352
RC2 relay (filtre)
R1
4.194
Alarm relay
R2
4.194
Bar feeder loading cycle relay
R3
4.194
End of bar relay
R4
4.194
Headstock release relay
R5
4.194
Headstock release relay
T1
4.769
Transformer with 24 VDC power supply
T2
4.779
24 VDV Power supply 150W

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SPRINT S3
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.
Electrical income power must be checked before turning the power on.
Bar feeder arrangements may need to be changed accordingly.
Any damaged components due to mis-connections will not be covered by the factory's warranty.
Should the bar feeder electrical arrangements be changed, the following steps must be taken :
Control box
At the transformer terminal block
connect the wire according to the
income voltage
A : Fuse (3.15 A)
Electric motors
The hydraulic pump motor as well the bar loader motor can be arranged to receive 3x200-220V
or 3x380-480V, 50/60 Hz. Refer to the electrical diagram located in the motor connection box.
Hydraulic motor :
200 - 220 V 50/60 Hz 1,07 A
380 - 480 V 50/60 Hz 0,62 A
Bar loader motor :
200 - 220 V 50/60 Hz 1,4 A
380 - 480 V 50/60 Hz 0,8 A

12
SPRINT S3
11. BAR STOCK PREPARATION
SOLID BARS
LNS recommends to chamfer the back end of the bar
stock with a 30 degrees concentric chamfer (60
degrees included). This will provide a concentric
rotation of the pusher and a safe contact bar
stock/pusher cone after the bar stock leaves the bar
feeder.
The front of the bar stock must be free of burrs to feed
smoothly through the clamping system and the spindle
of the lathe.
TUBING
To prevent any mixing between the hydraulic oil and
the coolant of the lathe, a sealed plug must be
mounted at the rear of the tubing.
HEXAGONAL- SQUARE BAR STOCK
To allow the feeding of the material through the profile of the collet, an adapter bushing will be mounted
in the collet of the lathe. The inside hole of the adapter must be identical to the profile of the bar stock +
0.2 mm (+ .0078").
When loading a new bar stock, the spindle of the lathe must rotate at low rpm (30 rpm). Spindle inching
or orientation will also allow a correct functioning.
IMPORTANT: To improve RPM performance when running profiled bar stock (hex., square), a
rotating element (with I.D. = barstock dia. across the corners+0,2mm/+.0078") can be
installed in the front outboard support, as well as elongated bearing elements must be
mounted. 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.
Should the bar stock exceed 0.5 mm/m (.020" / 3Ft) straightness, RPM performance may decrease
depending on the material type, length, etc...
Bar stock must be preferably clean to minimize maintenance and free of burrs.

13
SPRINT S3
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. of the bearing elements. 1 mm (.04") provides ideal guidance.
To order supplies, please use the following ordering numbers.
Ordering Nr
Ref.(*) Element Diameter 3m 12' 4m
I Bearing elements 14 - 81 014.011.253/
+ Diameter 014.011.263/ + Diameter 014.011.273/ + Diameter
II Pusher 13 - 80 014.011.223 / + Diameter
III Rotating sleeve 13 014.011.103
III Rotating sleeve 18 014.011.113
III Rotating sleeve 25 014.011.243
III Rotating sleeve 36 014.011.133
III Rotating sleeve 50 014.011.143
IV Flag 13 GAV - 014.011.513 GAR - 014.011.543
IV Flag 18 GAV - 014.011.523 GAR - 014.011.553
IV Flag 36 GAV - 014.011.533 GAR - 014.011.563
(*) Please refer to the chart (point 12.8) to ensure correct part selection.
In addition, a spindle reduction tube (spindle liner) must be mounted in the spindle of the lathe. Its I.D. must
be identical to the I.D. of the bearing elements. The bar loader must be adjusted for different bar stock
diameters to select one bar stock at a time (see point 12.5).
12.1 PUSHER CHANGEOVER
The pusher will always match the I.D. of the bearing elements - 1 mm (.040").
Procedure:
Refer to point 15.2/7, DIAMETER CHANGEOVER
•Manually open the main cover.
•Remove the pusher.
•Change the bearing elements (point 12.2)
•If required, change the rotating sleeve (point 12.3)
•If required, change the flag (point 12.4)
•Install new pusher (verify correct overall length which must correspond to all other
pushers).
Close the main cover.
Refer to point 12. DIAMETER CHANGEOVER

14
SPRINT S3
12.1 BEARING ELEMENTS CHANGEOVER
Procedure (Open the bearing blocks, remove the pusher. Refer to point 12.1)
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. Install new elements. When installing
elongated bearing blocks to run profiled material (hex., square,
etc...), a special care must be taken due to the dissimilarity of the
bearing elements. Please refer to the indication on each element
(note : block #1 is located at the rear of the Sprint S2) (The upper
elongated elements are secured with a screw).
2: Lower half bearing element
Using a standard screw driver, pop-out the lower bearing element
(2) to extract them from their location.A locating pin will seat the new
bearing element into the correct position.
3: Outboard support bearing element
Loosen set screw (C), remove bearing element (D), place new
element into the front extended guiding support and secure with set
screw (C).
4: Pusher supports bearing element
Identical to 3.
12.3. ROTATING SLEEVE CHANGEOVER
Each rotating sleeve covers a pusher diameter range (refer to chart point 12.8).
Sleeves for dia. 13mm (1/2") to 35 mm (1-3/8")
1. Remove lock pin 3. Install new pusher
2. Remove pusher 4. Secure with lock pin
Sleeves for dia. 36mm (1-3/8") to 80 mm (3-1/8")
1. Remove set screws (A) 3. Install new pusher
2. Remove pusher 4. Secure with set screws

15
SPRINT S3
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. Select appropriate flag
(B) and install on chain. Secure with
lock screws (A).
C : Chain guiding rail.
12.5. LOADER ADJUSTMENT
Place three to six bars (same diameter) on the magazine ramp (2).
Adjust slant of the ramp (1) with
adjusting screws (refer to point 7.1)
so that the bars roll down (2)
towards the elevator.
Excessive slant will cause loading
problems.
Loosen lock nuts (B) and adjust (3)
bar stoppers (D) with knob (C) so
that only one bar stock (A) is being
selected by the lifting fingers (E).
Secure with lock nuts (B)

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SPRINT S3
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.
To prevent small diameter bar stock to bent due to an excessive pushing force, the gear ratio 1/4 (standard
ratio) is recommended.
An excessive pushing force could also cause bearing failures (refer to point 12.7).
RATIO PUSHING FORCE in Newton PUSHING FORCE in LBS (US)
2,5 3 BAR 3,5 4BAR 3,5 5 BAR 31.5 45 PSI 52.5 60 PSI 67.5 75 PSI
1 : 4
(014.08.244)
150 220 280 350 420 480 31.20 45.76 58.24 72.80 87.36 99.84
1 : 6
(014.08.164)
260 360 460 560 660 760 54.08 74.88 95.68 116.48 137.28 158.08
The air motor is located at the rear of the SPRINT S3.
Changing the gear ratios :
1: Loosen the bolt (A).
2: Swing up the motor mounting plate to
free the ratio gear (B).
3: Lock in position with bolt (A).
Loosen the gear set screw (C).
•Remove gear and install new gear.
•Align (by sight) the new ratio gear with
motor gear.
•Secure with set screw (C).
•Loosen the bolt (A) and swing the motor
mounting plate down into position.
Secure with bolt (A). To prevent gear
binding, Position the mounting plate to
allow a small play between the gears.