LNS HYDROBAR SPRINT 555 Guide

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http://www.LNSAmerica.com
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LNS America, Inc.
USA
4621 East Tech Drive
Cincinnati, Ohio 45245
CNC
CNC
CNC
SPRINT 555
SPRINT 555SPRINT 555
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL
TROUBLESHOOTING
AND SPARE PARTS
MANUAL

E1.1
(02.15.2006)
Table of Contents
Chapter 1: .......................................................................................1-1
Alarms .........................................................................................................1-1
ALARM HISTORY..........................................................................................................................1-3
A001 - Emergency Line Open! .....................................................................................................1-4
A003 - Lathe Emergency Stop Line Open...................................................................................1-5
A004 - Bar Feeder Emergency Stop ............................................................................................1-6
A005 - Oil Pressure Failure ..........................................................................................................1-7
A006 - Air Pressure Failure..........................................................................................................1-8
A007 - Main Access Cover Open.................................................................................................1-9
A009 - Bar Feeder Retracted......................................................................................................1-10
A011 - Magazine Protection Grid Open.....................................................................................1-11
A012 - Bar Magazine Indexing Interrupted! ..............................................................................1-12
A022 - Servo Amp/PLC Comm. Fault ........................................................................................1-13
A023 - Servo Drive Alarm...........................................................................................................1-14
A024 - Servo Motor Not Ready...................................................................................................1-15
A025 - Servo Motor Positioning Error.......................................................................................1-16
A026 - Servo Amplifier Battery is Too Low...............................................................................1-17
A028 - Servo Amplifier Firmware Not Compatible with PLC...................................................1-18
A041 – Bar Feeder in Simulation Cycle.....................................................................................1-19
A042 - Home Position Proximity Switch SQ7 Signal Missing.................................................1-20
A043 - Pusher Lost the Bar Stock During its Return to Home Position.................................1-21
A044 - Bar Loading Error............................................................................................................1-22
A046 - Chuck Closed Prior to Feed Out Complete...................................................................1-23
A047 - A2 Interrupted During Loading ......................................................................................1-24
A048 - Safety Time for Part Feed Out........................................................................................1-25
A053 - Lathe Did Not Resume Its Production Cycle ................................................................1-26
A054 - Bar Remnant Too Long...................................................................................................1-27
A055 - Guiding Channel Malfunction During Closing..............................................................1-28
A056 - Guiding Channel Malfunction During Opening.............................................................1-29
A057 - Default Prior to Opening the Guiding Channel.............................................................1-30
A058 - Guiding Channel Malfunction During Closing..............................................................1-31
A059 - Guiding Channel Malfunction During Opening.............................................................1-32
A060 - Default Prior to Closing the Guiding Channel ..............................................................1-33
Bar Stock Not Extracted from the Collet...................................................................................1-34
A068 - Bar Stock Moving Forward during Headstock Reverse with Collet Open..................1-35
A070 - Bar Stock Insertion Malfunction ....................................................................................1-36
A115 - Bar Stock Moving Backwards during Headstock Reverse with Collet Open.............1-37
A116 - Bar Stock Loading Error.................................................................................................1-38
A124 - Pusher Length Error .......................................................................................................1-39
A126 - Bar Magazine Motor M3 Faulty.......................................................................................1-40
A127 - Problem During Dropping Fingers Rising.....................................................................1-41
A128 - Problem During Dropping Fingers Descent..................................................................1-42
Software Sequence Chart...........................................................................................................1-43
Mitsubishi® Servo Amplifier Alarm List....................................................................................1-44
Chapter 2: .......................................................................................2-1
Common Issues...........................................................................................2-1
Low Voltage / PLC Shutdown ......................................................................................................2-2
Cannot Change Application Setup Parameters..........................................................................2-3
HYDROBAR SPRINT 555

Multiple Bars have been Loaded into the Channel ....................................................................2-3
Rotating Sleeves...........................................................................................................................2-4
Collets............................................................................................................................................2-5
Front Rest Issues..........................................................................................................................2-6
Vibration Issues ............................................................................................................................2-7
Chapter 3:.......................................................................................3-1
Procedures..................................................................................................3-1
Front Rest Override ......................................................................................................................3-2
Reference Procedure....................................................................................................................3-4
Adjustment Procedure for End of Bar.........................................................................................3-5
Top Cut Position Adjustment.......................................................................................................3-7
Chapter 4:.......................................................................................4-1
Software Update/Restore ...........................................................................4-1
PLC Fault – v2.08 ..........................................................................................................................4-2
Software Update – v2.08...............................................................................................................4-5
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
Guiding Channel Performance Chart (w/o remnant retraction) ................................................6-3
Guiding Channel Performance Chart (with remnant retraction)...............................................6-4
Parts Order Form ..........................................................................................................................6-5
Electrical Box Components .........................................................................................................6-6
Upper Guiding Channel Support (double support)....................................................................6-7
Lower Guiding Channel Support (double support)....................................................................6-8
Lower Guiding Channel Support (single support) .....................................................................6-9
Upper Guiding Channel Support (single support w/ pusher locking tabs)............................6-10
Upper Guiding Channel Support (single support) ...................................................................6-11
Guiding Channel Locking Mechanism (L/F)..............................................................................6-12
Upper Guiding Channel Locking Paw .......................................................................................6-13
Guiding Channel Actuator Shaft (L/F).......................................................................................6-14
Guiding Channel Actuating Cylinder.........................................................................................6-15
Guiding Channel Actuator Shaft (R/F).......................................................................................6-16
Cam Locking Mechanism Drive Motor ......................................................................................6-17
Outboard Support Sub-Assembly .............................................................................................6-18
Chain Magazine Rack .................................................................................................................6-19
Pusher Locking Mechanism Sub-Assembly.............................................................................6-20
Belt Drive Sub-Assembly ...........................................................................................................6-21
HYDROBAR SPRINT 555

Chapter 1: Alarms 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
HYDROBAR SPRINT 555

1-2 Chapter 1: Alarms
A
SQ10
B
SQ11 SP1
SQ2
M5
HYDROBAR SPRINT 555
Designation Ordering no. Description
A 4.551 /
6.0 , 7.0
Remote control station
B (*) Electrical cabinet
C 4.068/4.074 Optional interface cable outlet (not shown here)
M 1 2.230 Hydraulic pump motor
M 2 4.706 Servo motor
M 3 4.796 Magazine motor
M 5 4.798 Guiding elements locking motor
QS 1 4.242 Main disconnect switch
SP 1 3.329 Air pressure switch
SP 2 4.050 Hydraulic pressure switch
SQ 1 4.772 Positioning proximity switch (optical cell)
SQ 2 4.391 Guiding elements locked counting proximity switch
SQ 3 4.790 Guiding elements open
SQ 4 4.790 Guiding elements closed
SQ 5 4.391 Feed pusher in home position control
SQ 6 4.790 Bar stock laying fingers up position control
SQ 7 4.790 Bar stock laying fingers down position control
SQ 8 4.391 Bar stock magazine indexing
SQ 9 4.772 Bar stock presence proximity switch
SQ 10 4.484 Retraction system in position switch
SQ 11 4.484 Main access cover safety switch
SQ 12 4.772 Remnant check (option)
SQ 15 4.763 Magazine protection safety switch
SQ 16 4.773 Magazine safety switch (optical cell)
M1
M2 SQ3/SQ4 SQ6/SQ7 SQ12
SQ8
M3
SQ1
SQ15SP2
SQ16
SQ9
SQ5

Chapter 1: Alarms 1-3
ALARM HISTORY
HYDROBAR SPRINT 555
MOST RECENT
ALARMS
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
A001 - Emergency Line Open!
HYDROBAR SPRINT 555
EMERGENCY
LINE OPEN!
POSSIBLE CAUSES:
-CONNECTION
-PROBLEM IN
CIRCUITRY
A001
Description:
The Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I2.0). The problem is generated anytime the
safety circuit contactor (K1) is not energized and all safety switches are in operating position. (Refer to Chapter 4 in the Hydrobar
Sprint 555 Instruction Manual).
Solution:
Press the HELP key on the remote control station. Press the F4 key (Page Down icon) three times.
Case Input Remote Pendant Solution
1 Bit 0 = 0
MODULE 2
76543210
0
•Verify that the 2/16 connector is plugged into the PLC correctly.
•Verify that the circuitry is wired correctly to the electrical diagram
in Chapter 4 of the Hydrobar Sprint 555 Instruction Manual.
2 Bit 0 = 1
MODULE 2
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.