LNS HYDROBAR SPRINT 555 Guide

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LNS America, Inc.
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4621 East Tech Drive
Cincinnati, Ohio 45245
CNC
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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.

Chapter 1: Alarms 1-5
A003 - Lathe Emergency Stop Line Open
LATHE EMERGENCY
STOP LINE OPEN!
POSSIBLE CAUSES:
-EMERGENCY STOP
PUSHED IN
-WIRING PROBLEM
A003
Description:
The Lathe Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I2.3). 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) three times.
Case Input Remote Pendant Solution
1 Bit 3 = 1
MODULE 2
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 2
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.
HYDROBAR SPRINT 555

1-6 Chapter 1: Alarms
A004 - Bar Feeder Emergency Stop
BAR FEEDER
EMERGENCY STOP!
POSSIBLE CAUSES:
- EMERGENCY STOP
BUTTON PUSHED IN
-WIRING PROBLEM
A004
Description:
The Bar Feeder Emergency Stop alarm occurs whenever the PLC does not detect input (I2.2). 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) three times.
Case Input Remote Pendant Solution
1 Bit 2 = 1
MODULE 2
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 2
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.
HYDROBAR SPRINT 555

Chapter 1: Alarms 1-7
A005 - Oil Pressure Failure
OIL PRESSURE
FAILURE!
POSSIBLE CAUSES:
-PRESSURE SWITCH SP2
DEFECTIVE OR
MIS-ADJUSTED
-PUMP FAILURE
-TANK EMPTY
A005
Description:
The Oil Pressure Failure alarm occurs whenever the PLC does not detect input (I0.2 – 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 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.
HYDROBAR SPRINT 555
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.
2 Bit 2 = 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
A006 - Air Pressure Failure
AIR PRESSURE
FAILURE!
POSSIBLE CAUSES:
-AIR PRESSURE BELOW
3 BAR(45PSI)
-AIR PRESSURE SWITCH
SP1 MIS-ADJUSTED
-AIR PRESSURE SWITCH
DEFECTIVE
A006
Description:
The Air Pressure Failure alarm occurs whenever the PLC does not detect input (I0.1 – 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 1 = 1
MODULE 0
76543210
10
Alarm needs to be cleared. Press the STOP key on the remote
control station to clear the message and reset the alarm.
HYDROBAR SPRINT 555
Raise the incoming air pressure on the air regulator to
(recommended) 75 psi. and no higher than 90 psi.
2 Bit 1 = 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 1-9
A007 - Main Access Cover Open
MAIN ACCESS COVER
OPEN!
CLOSE MAIN COVER TO
RESUME OPERATIONS
A007
Description:
The Main Access Cover Open alarm occurs whenever the PLC detects input (I0.0 – 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 0 = 1
MODULE 0
76543210
1
Close the main access cover.
2 Bit 0 = 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 solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.
HYDROBAR SPRINT 555

1-10 Chapter 1: Alarms
A009 - 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
A009
Description:
The Bar Feeder Retracted alarm occurs whenever the PLC detects input (I2.1 – 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) three times.
Case Input Remote Pendant Solution
1 Bit 1 = 1
MODULE 2
76543210
10
Put the bar feeder back in its working position and lock it in place.
2 Bit 1 = 0
MODULE 2
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.
HYDROBAR SPRINT 555

Chapter 1: Alarms 1-11
A011 - Magazine Protection Grid Open
MAGAZINE PROTECTION
GRID OPEN!
CLOSE GRID TO RESUME
OPERATIONS
A011
Description:
The Magazine Protection Grid Open alarm occurs whenever the PLC detects input (I2.6 – SQ15). The problem is generated, as a
safety precaution, when the magazine protection grid 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) three times.
Case Input Remote Pendant Solution
1 Bit 6 = 1
MODULE 2
76543210
1000000
Close the magazine protection grid.
2 Bit 6 = 0
MODULE 2
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 solutions have been completed, press the STOP key on the remote control station to clear the message and
reset the alarm.
HYDROBAR SPRINT 555

1-12 Chapter 1: Alarms
A012 - Bar Magazine Indexing Interrupted!
BAR MAGAZINE
INDEXING
INTERRUPTED!
POSSIBLE CAUSES:
-REFLECTIVE SENSOR
OBSTRUCTED
-REFLECTIVE SENSOR
MISALIGNED
-REFLECTIVE SENSOR
DEFECTIVE A012
Description:
The Bar Magazine Indexing Interrupted alarm occurs whenever the PLC does not detect input (I2.7 – SQ16) while the chain rack is
loading a new bar into the channels. The problem is generated, as a safety precaution, when the reflective sensor is blocked, to
prevent the chain fingers from pinching anything in between the magazine protection grid.
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 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.
HYDROBAR SPRINT 555
Check to make sure there is nothing obstructing the beam reflector.
Check the cleanliness of the reflector plate.
2 Bit 7 = 0
MODULE 0
76543210
0 Check the alignment of the reflector 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 1-13
A022 - Servo Amp/PLC Comm. Fault
SERVO AMPLIFIER/PLC
COMMUNICATION FAULT
-TURN OFF MAIN POWER
-WAIT FOR 2 SECONDS
-RESTORE MAIN POWER
IF PROBLEM PERSISTS
REFER TO INSTRUCTION
MANUAL A022
Description:
The Servo Amplifier/PLC Communication Fault alarm occurs when the PLC sends a message to the servo amplifier and the message
is not confirmed by the servo amplifier via a checksum or vice versa. This is generated if one of three conditions is not met:
1. The data sent did not match the data received.
2. After 10 seconds, no response from the Servo Amplifier.
3. On power up, the amplifier and PLC parameters do not match.
Solution:
•Verify that the CN3 connector is connected properly on the servo amplifier as well as on the PLC.
•Verify the 24VDC supply for the PLC. Any voltage fluctuation can result in poor performance of the PLC.
If the problem persists please contact LNS America, Inc. for further information.
HYDROBAR SPRINT 555

1-14 Chapter 1: Alarms
A023 - Servo Drive Alarm
SERVO DRIVE ALARM!
-TURN OFF MAIN POWER
-WAIT FOR 2 SECONDS
-RESTORE MAIN POWER
IF PROBLEM PERSISTS
REFER TO INSTRUCTION
MANUAL
A023
Description:
The Servo Drive Alarm occurs if the Mitsubishi® servo amplifier generates an alarm.
Solution:
Turn the main power off to the Hydrobar Sprint 555 for 2 seconds and turn the power back on.
Note: If the alarm keeps recurring, check the alarm code on the Mitsubish® servo amplifier and refer to Mitsubishi® Servo
Amplifier Alarm List pg. 1-44.
HYDROBAR SPRINT 555