LNS HYDROBAR SPRINT S3 User manual

LNS America, Inc.
4621 East Tech Drive
Cincinnati, OH 45245
Tel: [phone]
Fax: [phone]
www.lnsamerica.com
Instruction Manual

V1.1
12.10.08
TABLE OF CONTENTS
CHAPTER 1 BASIC NOTIONS
Structure 1-2
Rights 1-4
Declaration of compliance 1-5
Safety instructions 1-6
Safety devices 1-7
CHAPTER 2 TECHNICAL DATA
Characteristics 2-2
Floor plans 2-2
Layout of the elements 2-4
CHAPTER 3 SETTING INTO OPERATION
Preparation for installation 3-2
Assembling instructions 3-2
Alignment 3-3
Anchoring 3-3
Loader assembly 3-4
CHAPTER 4 ELECTRICS
Electrical equipment 4-2
Electrical cabinet 4-5
Programmable controller 4-8
Electrical drawings 4-10
Interface 4-18
CHAPTER 5 PNEUMATICS
Air adjustments 5-2
Diagrams 5-5
CHAPTER 6 HYDRAULICS
Hydraulic equipment 6-2
Hydraulic schematic 6-4
SPRINT S3

SPRINT S3
CHAPTER 7 GENERAL DESCRIPTION
Bar stock preparation 7-2
Diameter changeover 7-3
Spindle reduction tubes changeover 7-9
Guiding elements change 7-10
CHAPTER 8 OPERATION
Remote control 8-2
Powering up / down 8-5
Automatic sequence 8-5
Settings 8-6
CHAPTER 9 MALFUNCTIONS
Maintenance 9-2
CHAPTER 10 SPARE PARTS
Spare parts 10-2
APPENDICES
Appendix A : Programming example A-2
Appendix B : Ordering form A-3
Appendix C : LNS agencies A-4

CHAPTER 1: BASIC NOTIONS
SPRINT S3
1-1
CHAPTER 1:BASIC NOTIONS
1. STRUCTURE 1-2
1.1 Cross-references 1-2
1.2 Captions 1-2
1.3 Symbols and terminology 1-3
2. RIGHTS 1-4
3. DECLARATION OF COMPLIANCE 1-5
4. SAFETY INSTRUCTIONS 1-6
5. SAFETY DEVICES 1-7
5.1 Description 1-7
5.2 Layout 1-7

CHAPTER 1: BASIC NOTIONS
SPRINT S3
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 page.
•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 you are 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 instruction manual are shown with the LNS
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.

CHAPTER 1: BASIC NOTIONS
SPRINT S3
1-3
1.3 Symbols and terminology
This sign recommends following the directions very closely avoiding causing an
incident that could result in injury, damage to the equipment, or data loss.
This sign indicates that safety measures must be taken to avoid possible
electrical shocks or mishaps.
The notes stress interesting points or comments, and provide useful advice for
optimal system operation.
This sign points out an advice about environmental protection.

CHAPTER 1: BASIC NOTIONS
SPRINT S3
1-4
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.

CHAPTER 1: BASIC NOTIONS
SPRINT S3
1-5
3. DECLARATION OF COMPLIANCE
(Directive 89/392/EEC, Article 4.2 and Appendix 1, Chapter B)
PROHIBITION OF PUTTING INTO OPERATION
Manufacturer : LNS SA
Address : Route de Frinvillier
CH-2534 Orvin
Declares that:
The HYDROBAR SPRINT S3 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, 23.08.2005
LNS SA
B. Brügger
Sales manager

CHAPTER 1: BASIC NOTIONS
SPRINT S3
1-6
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
feeder 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 completed.
•No servicing should be carried out on
the interface or inside the electrical
cabinet while the bar feeder 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 feeder 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 knock the bar feeder while moving it
as this could damage it.
•Do not move the bar feeder while it is
electrically powered on.
•The work area surrounding the bar feed
system should always be clear of
objects and well lit. The presence of oil
on the ground could cause falls; it is
important to maintain the floor clean on
a regular basis.
•Do not place the machine in a damp
area and make sure that water or oil
does not come into contact with the
electrical equipment.
•Do not open the clamping device (collet
or chuck) of the lathe manually when the
bar feeder is in automatic mode
(Interface).
•Each time the diameter is changed, also
adapt spindle reduction tube. The use of
spindle reduction tubes is highly
recommended for machining bars with
diameters smaller than the maximum
capacity of the spindle.
•Do not attempt to recharge the batteries
of the PLC.
•For the use and maintenance of the bar
feeder, use only parts provided by or
recommended by LNS.
•If it is necessary to move the bar feeder
once it has been originally installed, do
not reinstall it before first contacting LNS
or its local representative.
•The rotating bar should never protrude
the rear of the lathe spindle.
•LNS disclaim all responsibility for
possible accidents or property damage
caused when safety instructions are not
followed.

CHAPTER 1: BASIC NOTIONS
SPRINT S3
1-7
5. SAFETY DEVICES
5.1 Description
The HYDROBAR SPRINT S3 bar feed system has been designed with a focus on maximum safety
during its handling and complies with all IEC requirements.
Safety covers an devices make access to the moving parts of the bar feed system impossible. Safety
witches 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 and the electrical box, 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
Designation Description
A Emergency stop push button
B Main access cover
C Outboard support cover
SQ11 Safety switch of the main access cover
BC
A
SQ11

CHAPTER 1
SPRINT S3
1-8 : BASIC NOTIONS

CHAPTER 2: TECHNICAL DATA
SPRINT S3
2-1
CHAPTER 2:TECHNICAL DATA
1. CHARACTERISTICS (*) 2-2
2. FLOOR PLAN 2-2
2.1 Hydrobar Sprint S3 Floor Plan 2-3
3. LAYOUT OF THE ELEMENTS 2-4

CHAPTER 2: TECHNICAL DATA
SPRINT S3
2-2
1. CHARACTERISTICS (*)
12 ft
Weight [kg / lbs.] 1719 kg / 3790 lbs.
Dimensions [mm] 4670 L x 1515 W x 1390 H
Min. / Max. diameter ½” / 3 1/8”
Min. / Max. bar stock length 70” / 149”
Main electrical power (Volt)* 200 – 240 / 400 – 480 V 50/60Hz
Pushing force / torque 150 -760 Nm
Hydraulic oil ISO 100 / 22 gal
Air pressure Min. / Max. 5 bar (75 psi) / 6 bar (90 psi)
*) Depending on the options, these technical data may vary. Please refer to the technical data sheet
2. FLOOR PLAN
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
SPRINT S3
2-3
2.1 Hydrobar Sprint S3 Floor Plan

CHAPTER 2: TECHNICAL DATA
SPRINT S3
2-4
3. LAYOUT OF THE ELEMENTS
D
B
C
A
E
F
G
H
D
I
J
K
M1 M2
M3
SQ
1
SQ4
SQ5
SQ8
SQ3
Y
V1
–
Y
V21
Z13/14
Z19

CHAPTER 2: TECHNICAL DATA
SPRINT S3
2-5
Designation Description
A Air control unit
B Connection box
C Hydraulic filter
D Remote control station
E Control box
F Loader
G Loading Ramp
H Oil recouperator
I Cover opening arm
J Upper bearing element
K Lower bearing element
M1 Pneumatic motor
M2 Hydraulic pump motor
M3 Loader motor
SQ1 Measuring cell
SQ3 Guiding bearings locked prox. switch
SQ4 Guiding bearings closed prox. switch
SQ5 Pusher reference position prox. switch
SQ6 Dropping fingers switch
YV1 – YV21 Air valve assembly
Z13/14 Cylinder bearing blocks open/close
Z19 Cylinder for dropping fingers

CHAPTER 2
SPRINT S3
2-6 : TECHNICAL DATA

CHAPTER 3: SETTING INTO OPERATION 3-1
CHAPTER 3:SETTING INTO OPERATION
1. PREPARATION FOR INSTALLATION 3-2
2. ASSEMBLING INSTRUCTIONS 3-2
2.1 Air Requirements and Connections 3-3
3. ALIGNMENT 3-3
4. ANCHORING 3-3
5. LOADER ASSEMBLY 3-4
SPRINT S3

CHAPTER 3: SETTING INTO OPERATION
3-2
1. PREPARATION FOR INSTALLATION
It is recommended the bar feeder to be installed by LNS or by one of its representatives.
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.
The Sprint S3 will be delivered in two separate crates. Prior to installation the customer must provide the
anchoring bolts, hydraulic oil, air supply and connections.
2. 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 (see chapter 2,
point 2). 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 (see chapter 3, point 4).
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 :
−the threaded rods (1) must be mounted in the lifting plate located in the center of
the main body
−install the rods connecting plate (2)
−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.
SPRINT S3