troubleshooting troubleshootingand spare parts … · chapter 1: alarms hydrobar express 220 1-3...

MADE IN USA

Seri

al

Nr:

LNS America, Inc.

USA

4621 East Tech Drive

Cincinnati, Ohio 45245

Phone# 513.528.5674

http://www.LNSAmerica.com

Main fax# 513.528.5733

Service fax# 513.528.8320

220220220Hydrobar Express

Hydrobar Express

Hydrobar Express

TROUBLESHOOTING

AND SPARE PARTS

MANUAL

TROUBLESHOOTING

AND SPARE PARTS

MANUAL

TROUBLESHOOTING

AND SPARE PARTS

MANUAL

5

Table of Contents Chapter 1: .........................................................................

Alarms .......................................................................................ALARM HISTORY ..............................................................................................Emergency Stop Line Open .............................................................................Lathe Emergency Stop Line Open...................................................................Bar Feeder Emergency Stop ............................................................................Oil Pressure Failure ..........................................................................................Air Pressure Failure..........................................................................................Main Access Cover Open.................................................................................Bar Feeder Retracted........................................................................................Front Measuring Stop Signal SQ1 Missing.....................................................Front Stopper Cannot Move Up .......................................................................Signal SQ1 For Front Stopper Defective.........................................................Guiding Channel Malfunction During Closing SQ3 .......................................Default Prior to Opening the Guiding Channel...............................................Guiding Channel Malfunction During Opening SQ3 ......................................Guiding Channel Malfunction During Closing SQ4 .......................................Guiding Channel Malfunction During Opening SQ4 ......................................Default Prior to Closing the Guiding Channel ................................................Front Rest Error ................................................................................................Servo Motor Positioning Error.........................................................................Vise Positioning Error ......................................................................................Home Position Proximity Switch SQ7 Missing...............................................Pusher Lost the Bar Stock During its Return to Home Position...................Bar Stock Not Extracted from the Collet.........................................................Vise Coupling Device Malfunction ..................................................................Switch SQ4 Signal Missing ..............................................................................Bar Stock Loading Error...................................................................................Bar Loading Error .............................................................................................Bar Remnant Too Long ....................................................................................Bar Stock Moving Backwards during Headstock Reverse with Collet OpenBar Stock Moving Forward during Headstock Reverse with Collet Open ...Headstock Travel is Shorter Than Programmed Length ...............................Servo Amp/PLC Comm. Fault ..........................................................................Bar Magazine Indexing Motor Faulty...............................................................Bar Stock Insertion Malfunction ......................................................................Servo Drive Alarm.............................................................................................Servo Motor Not Ready ....................................................................................Chuck Closed Prior to Feed Out Complete.....................................................A2 Interrupted During Loading ........................................................................Safety Time for Part Feed Out..........................................................................Software Sequence...........................................................................................Mitsubishi Servo Amplifier Alarm List ............................................................

Chapter 2: .........................................................................

Common Issues.........................................................................Low Voltage / PLC Shutdown ..........................................................................Cannot Change Application Setup Parameters..............................................Multiple Bars have been Loaded into the Channel ........................................Front Rest Issues..............................................................................................Vibration Issues ................................................................................................

Chapter 3: .........................................................................

HYDROBAR E

E108.30.200

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..............2-1

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............................2-4

............................2-5

..............3-1

XPRESS 220

Procedures ..................................................................................................3-1 Adjust Home Position Proximity Switch: SQ7............................................................................3-2 Adjusting the Pusher Support Mechanism.................................................................................3-4 SQ1 Measuring Cell Adjustment..................................................................................................3-6 Front Rest Alignment....................................................................................................................3-9 Chain Tension Adjustment.........................................................................................................3-18 Channel Lid Switches (SQ3 &SQ4) Adjustment .......................................................................3-20 Diameter Adjustment Motor Replacement................................................................................3-23 Enabling the 2mm Option...........................................................................................................3-28 Front Rest Motor Replacement ..................................................................................................3-30 Front Rest Override ............................................................................. Error! Bookmark not defined. Hydraulic Pump Motor Replacement.........................................................................................3-37 Reference Procedure ..................................................................................................................3-41 Remnant Check Device (SQ5) Adjustment ...............................................................................3-43 Setting Channel Lid Cam............................................................................................................3-45 Setting the Remnant Vise Alignment ........................................................................................3-49 Top Limiter Adjustment..............................................................................................................3-53

Chapter 4: ....................................................................................... 4-1

Software Update/Restore ...........................................................................4-1 PLC Fault .......................................................................................................................................4-3 Restore PLC Program From Memory Card to PLC – v1.17a......................................................4-3 PLC Fault .......................................................................................................................................4-6 Restore Bar Feeder Parameters from MMI to PLC – v1.17a ......................................................4-6 Software Update............................................................................................................................4-9 Restore Bar Feeder Parameters From MMI to PLC – v1.17a .....................................................4-9 Software Update..........................................................................................................................4-12 Restore Display Data from Memory Card to MMI – v1.17a ......................................................4-12 Software Update..........................................................................................................................4-16 Restore PLC Program from Memory Card to PLC – v1.17a.....................................................4-16 PLC Fault – v2.08 ........................................................................................................................4-20 Software Update – v2.08.............................................................................................................4-23

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 Collet Reference Chart .................................................................................................................6-3 Guiding Channel Reference Chart...............................................................................................6-4 Parts Order Form ..........................................................................................................................6-5 Electrical Box Components .........................................................................................................6-6 Chain Drive Assembly L/FChain Drive Assembly R/F ...............................................................6-7 Chain Drive Assembly R/F ...........................................................................................................6-8 Servo Motor Assembly Remnant ViseSensor Support AssemblyChannel Cam Cylinder Assembly L/F.................................................................................................................................6-8 Servo Motor Assembly Remnant ViseSensor Support AssemblyChannel Cam Cylinder Assembly L/F.................................................................................................................................6-9 Remnant ViseSensor Support AssemblyChannel Cam Cylinder Assembly L/F ...................6-10 Sensor Support AssemblyChannel Cam Cylinder Assembly L/F ...........................................6-11 Channel Cam Cylinder Assembly L/F........................................................................................6-12 Channel Cam Cylinder Assembly R/F .......................................................................................6-12 Channel Cam Cylinder Assembly R/F .......................................................................................6-13 Hydraulic Pump Assembly.........................................................................................................6-13 Hydraulic Pump Assembly.........................................................................................................6-14 Coding Disc Assembly ...............................................................................................................6-15 Diameter Adjustment Motor Assembly .....................................................................................6-16 Air Regulator and Cable Passage Plate ....................................................................................6-17

HYDROBAR EXPRESS 220

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

Chapter 1: Common Issues


1-2

Designation Description A Remote control station

B Control cabinet

C Optional interface cable outlet

M1 Hydraulic pump motor

M2 Servo motor

M3 Front rest opening/closing motor

M4 Motor for adjusting bar diameter to magazine

M5 2mm motor (option)

QS1 Main disconnect switch

SP1 Pneumatic pressure switch

SP2 Hydraulic pressure switch

SQ1 Positioning stopper proximity switch

SQ2 Bar magazine diameter counting monitor

SQ3 Opening guiding channel control switch

SQ4 Closing guiding channel control switch

SQ5 Remnant check

SQ6 Control switch: mobile vise in forward position

SQ7 Control switch: pusher in rear/park position

SQ8 Front-rest opening monitor

SQ9 Front-rest gap adjuster

SQ10 Retraction system in position switch

SQ11 Main access cover safety switch

Chapter 1: Alarms


1-3

ALARM HISTORY

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

EMERGENCY STOP

LINE OPEN

********************

POSSIBLE CAUSES:

CONNECTION OR WIRING

PROBLEM IN CIRCUITRY

Emergency Stop Line Open

Description: The Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.0). The problem is generated anytime the safety circuit contactor (K1) is not energized and all safety switches are in operating position. (Refer to page 4-17 in the Express 220 Instruction Manual).

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 = 0

MODULE 0

76543210

0

• Verify that the 1/0 connector is plugged into the PLC correctly. • Verify that the circuitry is wired correctly to the electrical diagram

on page 4-17 in the Express 220 Instruction Manual.

2 Bit 0 = 1

MODULE 0

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

Lathe Emergency Stop Line Open

LATHE EMERGENCY

STOP LINE OPEN!

POSSIBLE CAUSES:

- EMERGENCY STOP

PUSHED IN

- WIRING PROBLEM

Description: The Lathe Emergency Stop Line Open alarm occurs whenever the PLC does not detect input (I0.3). 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) twice.


1 Bit 3 = 1

MODULE 0

76543210

1000


2 Bit 3 = 0

MODULE 0

76543210

0

Reset the E-stop push button on the lathe.




1-6

Bar Feeder Emergency Stop

BAR FEEDER

EMERGENCY STOP!

POSSIBLE CAUSES:

- EMERGENCY STOP

BUTTON PUSHED IN

- WIRING PROBLEM

Description: The Bar Feeder Emergency Stop alarm occurs whenever the PLC does not detect input (I0.2). The problem is generated E-stop push button on the remote control station is pressed in.



1 Bit 2 = 1

MODULE 0

76543210

100


2 Bit 2 = 0

MODULE 0

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.

Chapter 1: Alarms


1-7

Oil Pressure Failure

OIL PRESSURE

FAILURE!

POSSIBLE CAUSES:

-PRESSURE SWITCH SP2

DEFECTIVE OR

MIS-ADJUSTED

-PUMP FAILURE

-TANK EMPTY

Description: The Oil Pressure Failure alarm occurs whenever the PLC does not detect input (I0.6 – 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.



1 Bit 6 = 1

MODULE 0

76543210

1000000


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.

Flip the toggle switch on the PLC to the RUN position. 2 Bit 6 = 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

Air Pressure Failure

AIR PRESSURE

FAILURE!

POSSIBLE CAUSES:

-AIR PRESSURE BELOW

3 BAR(45PSI)

-AIR PRESSURE SWITCH

SP1 MIS-ADJUSTED

-AIR PRESSURE SWITCH

DEFECTIVE

Description: The Air Pressure Failure alarm occurs whenever the PLC does not detect input (I0.5 – 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.



1 Bit 5 = 1

MODULE 0

76543210

100000


Raise the incoming air pressure on the air regulator to (recommended) 75 psi. and no higher than 90 psi.

Flip the toggle switch on the PLC to the RUN position. 2 Bit 5 = 0

MODULE 0

76543210

0 Replace the air pressure switch.


Chapter 1: Alarms


1-9

Main Access Cover Open

MAIN ACCESS COVER

OPEN!

CLOSE MAIN COVER TO

RESUME OPERATIONS

Description: The Main Access Cover Open alarm occurs whenever the PLC detects input (I0.4 – 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.



1 Bit 4 = 1

MODULE 0

76543210

10000

Close the main access cover.

2 Bit 4 = 0

MODULE 0

76543210

0





1-10

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

Description: The Bar Feeder Retracted alarm occurs whenever the PLC detects input (I0.1 – SQ10). The problem is generated when the bar feeder is retracted for spindle liner changeover.



1 Bit 1 = 1

MODULE 0

76543210

10

Put the bar feeder back in its working position and lock the latches.

2 Bit 1 = 0

MODULE 0

76543210

0



Chapter 1: Alarms


1-11

Front Measuring Stop Signal SQ1 Missing

FRONT MEASURING STOP

SIGNAL SQ1 MISSING!

POSSIBLE CAUSES:

-FRONT STOPPER DID

NOT MOVE UP

-SIGNAL SWITCH SQ1

DEFECTIVE OR

MIS-ADJUSTED

Description: The Front Measuring Stop Signal SQ1 Missing alarm occurs during the new bar measuring sequence when the front measuring stop is activated but input signal (I0.7) is not detected by the PLC.


Case Input Remote Pendant Solution Check to see if there is a mechanical obstruction preventing the measuring stop from rising up.

Make sure that the SQ1 switch is adjusted to within a sensing distance of 0.5mm-1mm from the measuring stop. 1 Bit 7 = 1

MODULE 0

76543210

10000000 If the input still does not turn on, the problem can be isolated to a defective switch or defective cable. Replace the cable and switch.

2 Bit 7 = 0

MODULE 0

76543210

0




H

1-12

Front Stopper Cannot Move Up

DTp

SP

Ft

FRONT STOPPER

CANNOT MOVE UP!

POSSIBLE CAUSES:

-BAR STOCK PROTRUDES

FROM THE BACK OF

THE SPINDLE

-SQ1 SWITCH

MALFUNCTION

-MECHANICAL OR

PNEUMATIC FAILURE

YDROBAR EXPRESS 220

escription: he Front Stopper Cannot Move Up alarm occurs if, during the loading cycle, the measuring flap does not rise up to be detected by roximity switch SQ1. The alarm is normally generated due to a mechanical obstruction preventing the flap from rising up.

olution: ress the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.

Case Input Remote Pendant Solution Check to see if there is a mechanical obstruction preventing the measuring stop from rising up.

Make sure that the SQ1 switch is adjusted to within a sensing distance of 0.5mm-1mm from the measuring stop.

Check that the air flow restrictor has not cut off the air supply to the cylinder.

1 Bit 7 = 0

MODULE 0

76543210

0

If the input still does not turn on, the problem can be isolated to a defective switch or defective cable. Replace the cable and switch.

2 Bit 7 = 1

MODULE 0

76543210

10000000


or case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset he alarm.

Chapter 1: Alarms


1-13

Signal SQ1 For Front Stopper Defective

SIGNAL SQ1 FOR FRONT

STOPPER DEFECTIVE!

POSSIBLE CAUSES:

-SQ1 SIGNAL SWITCH

FAULTY (ALWAYS ON)

Description: The Signal SQ1 For Front Stopper Defective alarm occurs during remnant measuring or during new bar measuring if input signal (I0.7 – SQ1) does not turn off and the bar feed has already recognized that a bar is inserted in the collet.


Case Input Remote Pendant Solution Check to see if there is a mechanical obstruction preventing the measuring stop from dropping.

Make sure that the SQ1 switch is adjusted to within a sensing distance of 0.5mm-1mm from the measuring stop.

1 Bit 7 = 1

MODULE 0

76543210

10000000

Check the wiring of switch SQ1.

2 Bit 7 = 0

MODULE 0

76543210

0





1-14

Guiding Channel Malfunction During Closing SQ3

GUIDING CHANNEL

MALFUNCTION DURING

CLOSING!

POSSIBLE CAUSES:

-CLOSING MECHANISM

MALFUNCTION

-SIGNAL SWITCH SQ3

DEFECTIVE OR

MIS-ADJUSTED

Description: The Guiding Channel Malfunction During Closing alarm occurs if input (I1.1 – SQ3) does not turn off during the channel closing sequence.



1 Bit 1 = 1

MODULE 1

76543210

10

Check to see if a mechanical obstruction is preventing the channel from closing.

Check the functionality of the SQ3 switch. The switch may be sticking and needs to be replaced.

2 Bit 1 = 0

MODULE 1

76543210

0



Chapter 1: Alarms


1-15

Default Prior to Opening the Guiding Channel

DEFAULT PRIOR TO

OPENING THE GUIDING

CHANNEL!

POSSIBLE CAUSES:

-SIGNAL SWITCH SQ3

DEFECTIVE OR

MIS-ADJUSTED

-MECHANICAL FAILURE

Description: The Default Prior To Opening The Guiding Channel alarm occurs if the channel is closed and input (I1.1 – SQ3) is on before the channel tries to open to remove the remnant.



1 Bit 1 = 1

MODULE 1

76543210

10

The switch may be sticking and needs to be replaced.

2 Bit 1 = 0

MODULE 1

76543210

0





1-16

Guiding Channel Malfunction During Opening SQ3

GUIDING CHANNEL

MALFUNCTION DURING

OPENING!

POSSIBLE CAUSES:

-OPENING MECHANISM

MALFUNCTION

-SIGNAL SWITCH SQ3

DEFECTIVE OR

MIS-ADJUSTED

Description: The Guiding Channel Malfunction During Opening alarm occurs if input (I1.1 – SQ3) does not turn on when the channel opens up.



1 Bit 1 = 1

MODULE 1

76543210

10


2 Bit 1 = 0

MODULE 1

76543210

0

Check to see if a mechanical obstacle prevents the channel from opening.

Check the channel opening/closing cylinder functionality. Check the adjustment and functionality of the SQ3 switch.


Chapter 1: Alarms


1-17

Guiding Channel Malfunction During Closing SQ4

GUIDING CHANNEL

MALFUNCTION DURING

CLOSING!

POSSIBLE CAUSES:

-CLOSING MECHANISM

MALFUNCTION

-SIGNAL SWITCH SQ4

DEFECTIVE OR

MIS-ADJUSTED

Description: The Guiding Channel Malfunction During Closing alarm occurs if input (I1.2 – SQ4) does not turn on when the channel closes.

Solution:


1 Bit 2 = 1

MODULE 1

76543210

100


2 Bit 2 = 0

MODULE 1

76543210

0

Check to see if a mechanical obstacle prevents the channel from opening.

Check the channel opening/closing cylinder functionality. Check the adjustment and functionality of the SQ4 switch.




1-18

Guiding Channel Malfunction During Opening SQ4

GUIDING CHANNEL

MALFUNCTION DURING

OPENING!

POSSIBLE CAUSES:

-OPENING MECHANISM

MALFUNCTION

-SIGNAL SWITCH SQ4

DEFECTIVE OR

MIS-ADJUSTED

Description: The Guiding Channel Malfunction During Opening alarm occurs if input (I1.2 – SQ4) does not turn off after the channel opens.

Solution: Press the HELP key. Press F4 (Page Down icon) twice.


1 Bit 2 = 1

MODULE 1

76543210

100


2 Bit 2 = 0

MODULE 1

76543210

0



Chapter 1: Alarms


1-19

Default Prior to Closing the Guiding Channel

DEFAULT PRIOR TO

CLOSING THE GUIDING

CHANNEL!

POSSIBLE CAUSES:

-SIGNAL SWITCH SQ4

DEFECTIVE OR

MIS-ADJUSTED

Description: The Default Prior To Closing The Guiding Channel alarm occurs if input (I1.2 – SQ4) is already on before the channel before the channel tries to close to insert the new bar into the collet of the bar feed.

Solution:


1 Bit 2 = 1

MODULE 1

76543210

100


2 Bit 2 = 0

MODULE 1

76543210

0





1-20

Front Rest Error

FRONT REST ERROR!

POSSIBLE CAUSES:

-BAR DIAMETER DOES

NOT CORRESPOND TO

ENTERED DIAMETER

-SQ9 SIGNAL SWITCH

DEFECTIVE OR MIS-

ADJUSTED

-SQ8 SWITCH (CALIB.)

MALFUNCTION

See pg. 2-4 Front Rest Issues.

Chapter 1: Alarms


1-21

Servo Motor Positioning Error

SERVO MOTOR

POSITIONING

FOLLOWING ERROR!

DURNG SEQUENCE

NUMBER [@@]

POSSIBLE CAUSE:

MECHANICAL OBSTACLE

PREVENTS BAR STOCK

TO FEED OUT

Description: The Servo Motor Following Error alarm occurs due to a mechanical obstacle preventing the bar stock from feeding out. The torque on the servo motor will build up when the obstacle prohibits the stock from moving, once the torque reaches a certain limit the PLC instructs the servo amplifier to quit pushing and this alarm message appears on the remote control station.

Solution:

Seq. # Solution

##

Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. • Check for any mechanical obstacles that the bar stock may be hitting. Remove obstacle if this is the case. • Check the bar stock diameter. Make sure that the actual diameter is the same as the value entered in for the

corresponding parameter in the Part Setup menu. • Check the alignment between the bar feeder and the lathe. The lathe or the bar feeder may have shifted over

a long period if either is not lagged to the floor securely.

If the problem persists please contact LNS America, Inc. for further information.



1-22

Vise Positioning Error

VISE POSITIONING

ERROR!

POSSIBLE CAUSES:

-CHAIN COUPLING

DEVICE MALFUNCTION

-DRIVING CHAIN MIS-

ADJUSTED

-MECHANICAL FAILURE

Description: The Vise Positioning Error alarm occurs:

If input (I1.4 – SQ6) does not turn off during the remnant extraction sequence, when the chain cursor reaches the home position and input (I1.5 – SQ7) turns on.

Or

If input (I1.4 – SQ6) does not turn on during the loading sequence, when the vise reaches the mechanical stop at the back of the “H”-channel (at the same time the chain cursor reaches home position) and input (I1.5 – SQ7) turns on.

Solution: Press the STOP key on the remote control station to clear the message and reset the alarm. The bar feed needs to be referenced.

Input Remote Pendant Solution

Bit 4

MODULE 1

76543210

Check the chain coupling device. Check to see if the chain is broken. Check SQ6 switch. May be mis-adjusted or defective. Re-reference the bar feed.

• Contact LNS America, Inc. for further information.

Chapter 1: Alarms


1-23

Home Position Proximity Switch SQ7 Missing

Description: The Home Position Proximity Switch SQ7 Signal Missing alarm occurs if input (I1.5 – SQ7) is not detected by the PLC either during the remnant extraction sequence or re- referencing.

Solution: Press the STOP key on the remote control station to clear the message and reset the alarm. Press the HELP key. Press F4 (Page Down icon) twice.


1 Bit 5 = 1

MODULE 1

76543210

100000


Check to see if there is a mechanical obstruction preventing the carrier flag from reaching the home position.

Make sure that the SQ7 switch is adjusted to within a sensing distance of 0.5mm-1mm from the measuring stop. 2 Bit 5 = 0

MODULE 1

76543210

0 If the input still does not turn on, the problem can be isolated to a defective switch or defective cable. Replace the cable and switch.

HOME POSITION

PROXIMITY SWITCH SQ7

SIGNAL MISSING!

POSSIBLE CAUSES:

-SQ7 SIGNAL SWITCH

DEFECTIVE OR MIS-

ADJUSTED

-CHAIN BROKEN



1-24

Pusher Lost the Bar Stock During its Return to Home Position

PUSHER LOST THE

BARSTOCK DURING ITS

RETURN TO HOME

POSITION!

POSSIBLE CAUSES:

-WRONG SIZE OR

DEFECTIVE COLLET

-EXCESSIVE BURRS

-MECHANICAL FAILURE

Description: The Pusher Lost The Barstock During Its Return To Home Position alarm occurs during the remnant extraction sequence when the remnant check device detects input (I1.3 – SQ5). During the remnant extraction sequence, the pusher travels to the home position and the remnant check device confirms that the remnant is still in the collet of the bar feed before it tries to extract the remnant. If no remnant is detected the bar feed generates this alarm.

Solution: Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm.

• Check that the collet is the correct size for the stock being run and also that the collet is not cracked or broken.

• Check the bar stock for any excessive burrs that may prevent the bar from being properly inserted into the collet.

• Check the adjustment of switch SQ5.

• Confirm the lathe chamfers the remnant after cutoff before the bar change cycle begins.

• Make sure that PRM30 is not turned off.

• Contact LNS America, Inc. for further information.

Chapter 1: Alarms


1-25

Bar Stock Not Extracted from the Collet

BAR STOCK NOT

EXTRACTED FROM THE

COLLET!

POSSIBLE CAUSES:

-EXTRACTION DEVICE

MALFUNCTION

-SIGNAL SWITCH SQ5

DEFECTIVE OR

MIS-ADJUSTED

-MECHANICAL FAILURE

Description: The Bar Stock Not Extracted From The Collet alarm occurs when input (I1.3 – SQ5) is not detected after the bar has been extracted from the collet of the bar feed. Before the guiding channel opens to load a new bar, the remnant check device confirms that the remnant has been extracted from the collet of the bar feed.

Solution: • Check that the extraction device jaws are not broken.

• Check the adjustment of SQ5, the switch should only activate when no bar is present in the collet of the bar feed.

• Contact LNS America Inc. for further information.



1-26

Vise Coupling Device Malfunction

VISE COUPLING DEVICE

MALFUNCTION!

POSSIBLE CAUSES:

-COUPLING DEVICE

DEFECTIVE

-SQ6 SIGNAL SWITCH

DEFECTIVE OR

MIS-ADJSUTED

-MECHANICAL FAILURE

Chapter 1: Alarms


1-27

Switch SQ3 Signal Missing

SWITCH SQ3 SIGNAL

MISSING!

CHANNEL MUST BE OPEN

PRIOR TO PROCESSING

A REFERENCE POSITION

IF CHANNEL IS CLOSED

ACTUATE AIR VALVES

TO OPEN THE CHANNEL

Description: The Switch SQ3 Signal Missing alarm occurs if input (I1.1 – SQ3) is active while the channel is open and the input turns off.

Solution: Open the main access cover and manually activate the YV2A valve to force the channel open. Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.


1 Bit 1 = 1

MODULE 1

76543210

10


2 Bit 1 = 0

MODULE 1

76543210

0

If the channel is open, and this input is not on, the SQ3 switch is either mis-adjusted or defective.




1-28

Switch SQ4 Signal Missing

SWITCH SQ4 SIGNAL

MISSING!

CHANNEL MUST BE OPEN

PRIOR TO PROCESSING

A REFERENCE POSITION

IF CHANNEL IS CLOSED

ACTUATE AIR VALVES

TO OPEN THE CHANNEL

Description: The Switch SQ4 Signal Missing alarm occurs if input (I1.2 – SQ4) is active while the channel is closed and the input turns off.

Solution: Open the main access cover and manually activate the YV2A valve to force the channel open. Press the HELP key on the remote control station. Press the F4 key (Page Down icon) twice.


1 Bit 2 = 1

MODULE 1

76543210

100


2 Bit 2 = 0

MODULE 1

76543210

0

If the channel is open, and this input is not on, the SQ4 switch is either mis-adjusted or defective.


Chapter 1: Alarms


1-29

Bar Stock Loading Error

BAR STOCK LOADING

ERROR!

POSSIBLE CAUSES:

-MAGAZINE EMPTY

-BAR SELECTION

DEVICE MIS-ADJUSTED

-GUIDING CHANNEL

EMPTY DUE TO

MIS-LOADING

Description: The Bar Stock Loading Error alarm occurs during the loading of a new bar sequence. After a new bar has been loaded into the channel and the bar is carried forward for measuring. If there is not a bar present in the channel this alarm is generated.

Solution: • Check to see if there is any bar stock on the loading ramp, and that the bars are rolling parallel to the ramp.

• Make sure that the bar stock diameter matches to the value entered for the corresponding parameter.

Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Restart the bar feed and lathe in automatic production.



1-30

Bar Loading Error

BAR LOADING ERROR!

HEX, SQUARE BARS

POSSIBLE CAUSES:

-LOADING SAFETY TIME

ELAPSED

-BAR STOCK NOT FED

THROUGH THE COLLET

OF THE LATHE

Description: The Bar Loading Error alarm occurs during the top-cut positioning sequence when loading profiled material. During the loading cycle, for profiled material, the bar stock is brought to the back of the clamping device. When this position is reached, the spindle is jogged at a very low rpm and the pusher begins a pecking motion until the profile of the material and the profile of the chuck jaws are aligned and the bar is fed out to the top-cut position. If the top-cut position is not reached after 20 pecking cycles, this alarm is generated.

Solution: Alarm needs to be cleared. Press the STOP button on the remote control station to clear and reset the alarm. Remove the bar from the spindle and restart the top-cut positioning cycle.


Chapter 1: Alarms


1-31

Bar Remnant Too Long

BAR REMNANT

TOO LONG!

POSSIBLE CAUSES:

-END OF BAR POSITION

IMPROPERLY ADJUSTED

-MACHINING VERY LONG

PARTS WITHOUT

OPTIMIZING BAR

LENGTH FOR MINIMUM

REMNANT LENGTH

Description: The maximum remnant that the bar feed can remove is 500mm (19.685”). The Bar Remnant Too Long alarm occurs during the remnant extraction sequence. After machining the last part and the clamping device opens, the pusher reverses to a determined position, the front measuring stop is activated, if signal switch SQ1 is not detected the bar feed continues with the extraction and will stop when it comes time to drop a new bar into the guiding channel, at which point this alarm is generated.

Solution: 1. Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm.

2. Press the F1 key on the remote control station for manual mode.

3. Press the F1 key on the remote control station and remove the long remnant from the channel.

4. After removing the remnant from the channel, press the F1 key (√) to verify that the bar has been manually removed from the channel.

• Check the End of Bar setting in the Parameters Related to Positioning menu.

• If the part length is fairly long, it will be necessary to cut the bar stock to achieve a minimum remnant length.

• If the problem persists please contact LNS America, Inc. for further information.



1-32

Bar Stock Moving Backwards during Headstock Reverse with Collet Open

BAR STOCK

IS MOVING BACKWARDS

DURING

HEADSTOCK REVERSE

WITH COLLET OPEN!

POSSIBLE CAUSES:

-STICKY COLLET

(NOT FULLY OPEN)

-TORQUE MIS-ADJUSTED

Description: The Bar Stock Moving Backwards alarm occurs when the bar feed detects any backward movement of the feeding pusher while the collet of the lathe is open and the headstock reverses for regrip.

Solution: • Check that the collet of the lathe is opening to its maximum allowance.

• Check the pushing torque value in the menu Parameters Related to Servo Drive (Torques) on the bar feed. The value can be increased if necessary.

Chapter 1: Alarms


1-33

Bar Stock Moving Forward during Headstock Reverse with Collet Open

BAR STOCK IS MOVING

FORWARD DURING

HEADSTOCK REVERSE

WITH COLLET OPEN !

POSSIBLE CAUSES : -CUT-OFF TOOL BROKEN

OR NOT IN POSITION

-EXCESSIVE PUSHING

TORQUE

Description: The Bar Stock Moving Forward alarm is generated when the bar feed detects any forward movement by the feeding pusher while the collet of the lathe is open and the headstock reverses for regrip.


• Check that the cut-off tool is still intact. If it is broken, it will need to be replaced before putting the bar feed back in automatic production. If this alarm occurs often due to cut-off tools breaking, reduce the pushing torque in the menu Parameters Related to Servo Drive (Torques).




1-34

Headstock Travel is Shorter Than Programmed Length

HEADSTOCK TRAVEL

IS SHORTER THAN THE

PROGRAMMED LENGTH

OR

THE PUSHER LOST THE

BAR STOCK ! VERIFY COLLET SIZE

Description: The overall part length parameter value is too short or the pusher did not travel the distance that was programmed in for the overall part length.

Solution: • Check that the Input Overall Part Length parameter is equal to the travel of the headstock and not the finished part length.

• Check the collet on the pusher. May be broken or worn or the incorrect size.

• Check to see if the pusher got jammed in the channel. Make sure the front guiding channels are seated correctly in the channel (maybe chips fell underneath the guiding channels).


Chapter 1: Alarms


1-35

Servo Amp/PLC Comm. Fault

SERVO AMPLIFIER/PLC

COMMUNICATION FAULT

-TURN OFF MAIN POWER

-WAIT FOR 2 SECONDS

-RESTORE MAIN POWER

IF PROBLEM PERSISTS

VERIFY CONNECTIONS

PLC TO AMPLIFIER

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.




1-36

Bar Magazine Indexing Motor Faulty

BAR MAGAZINE

INDEXING MOTOR

FAULTY !

POSSIBLE CAUSES : -DC MOTOR DEFECTIVE

-LOCKED MECHANISM

-PROXIMITY SWITCH

SQ2 FAULTY

Description: The Bar Magazine Indexing Motor Faulty alarm is generated during the loading sequence when the output for the indexing motor is active and the state of the input (I1.0 – SQ2), bar magazine diameter adjustment proximity switch, does not change.


• Make sure that the SQ2 switch is adjusted to within 0.5mm-1mm from the decoder disc.

• Check that the DC motor is operational.


Chapter 1: Alarms


1-37

Bar Stock Insertion Malfunction

BAR STOCK INSERTION

MALFUNCTION !

POSSIBLE CAUSES : -WRONG SIZE COLLET

-BURRS ON BAR STOCK

-MECHANICAL PROBLEM

Description: The Bar Stock Insertion Malfunction alarm occurs during the loading sequence when the bar is not properly inserted into the collet of the feeding pusher.


• Make sure that the collet is the correct size for the bar stock being ran.

• Check that there are no burrs on the back of the bar stock. LNS recommends that a chamfer be put on the back end of the bar.

• Check the alignment between the feeding pusher and the bar stock while it is doing the insertion. If alignment side-to-side is off make sure that the pusher guiding channel installed has the correct orange head bolts. Refer to pg. 6-4 Guiding Channel Reference chart (the note is in the bottom right hand corner).




1-38

Servo Drive Alarm

SERVO DRIVE ALARM!

-TURN OFF MAIN POWER

-WAIT FOR 2 SECONDS

-RESTORE MAIN POWER

IF PROBLEM PERSISTS

REFER TO INSTRUCTION

MANUAL

Description: The Servo Drive Alarm occurs if the Mitsubishi servo amplifier generates an alarm.

Solution: Turn the main power off to the Express 220 for 2 seconds and turn the power back on.

Note: If the alarm keeps recurring, check the alarm code on the Mitsubishi servo amplifier and refer to Mitsubishi Servo Amplifier Alarm List pg. 1-45.

Chapter 1: Alarms


1-39

Servo Motor Not Ready

SERVO MOTOR

NOT READY!

-VERIFY CN1B

CONNECTOR

-CHECK PLC OUTPUT

Q 4.4 (MUST BE ON)

Description: The PLC outputs a signal (Q4.4) to servo amplifier, which engages the servo motor and puts the servo motor in a “servo lock” condition. If the servo amplifier does not recognize the signal after 3 seconds, this alarm is generated.

Solution: • Verify that the CN1B connector is seated properly in the allotted socket on the servo amplifier.

• Verify that the PLC output (Q4.4) is turning on when the manual or automatic cycle is started.

• Verify that the K1 contactor is activated; input (I0.0) should be on.




1-40

Chuck Closed Prior to Feed Out Complete

CLAMPING DEVICE HAS

CLOSED PRIOR TO

COMPLETING THE

FEED OUT

POSSIBLE CAUSES:

-LATHE PROGRAMMING

ERROR

-CLAMPING SIGNAL

FAULTY (PLC INPUT

A1)

Description: The Clamping Device Has Closed Prior To Completing The Feed Out alarm occurs if the input for the clamping device closed is detected before the value of the Input Part Length parameter is reached.

Solution: Verify that the clamping device is closing properly and that the Clamping Signal Active interface parameter is set in conjunction with how the interface signal is being sent.

Verify that the correct part length has been entered in the PARAMETERS RELATED TO APPLICATIONS menu.

Chapter 1: Alarms


1-41

A2 Interrupted During Loading

SIGNAL A2 (LATHE IN

AUTOMATIC MODE)

INTERRUPTED DURING

LOADING CYCLE!

RESUME AUTOMATIC

CYCLE OF THE LATHE

AND THE BAR FEEDER.

Description: The Signal A2 Interrupted During Loading Cycle alarm occurs whenever PLC input (I3.1) drops out during the loading cycle.

Solution: Alarm needs to be cleared. Press the STOP key on the remote control station to clear the message and reset the alarm. Remove the bar stock from the loading channel and reset the bar feeder and the lathe in automatic cycle.



1-42

Safety Time for Part Feed Out

SAFETY TIME

FOR PART FEED OUT

ELAPSED!

POSSIBLE CAUSES:

-PROGRAMMING ERROR

-MECH. INTERFERENCE

-INTERFACE PROBLEM

Description: The Safety Time For Part Feed Out Elapsed alarm occurs if the value set in OVERALL PART LENGTH is not reached within 1 minute after the bar feed is commanded to feed out.


• Make sure that value for the OVERALL PART LENGTH is correct.

• Check for any mechanical obstruction that will not allow the bar feed to reach the feed out distance.

Contact LNS America, Inc. for further information.

Chapter 1: Alarms


1-43

Software Sequence Seq. 1 (Initialize)

1st time reference Reset graphset

Seq. 2 (Reference) Reference procedure – front rest open to origin position; channel open FC11 reference block Selection (AUTO, MAN.) vise engaged to chain

Seq. 3 (Insertion Cycle)

Front Rest closes; Vise closes; front stopper up Seq. 4 (Insertion Cycle)

Vise runs forward rapidly (measuring) to "H" channel. Brings material forward to within 30mm of front stopper then pauses.


Vise advances forward to bring material in contact with the front stopper, break the switch and pauses. If it doesn’t trip the measuring cell it rapids until front stopper is tripped. Then it stops and reverses

30mm (unless vise at max. stroke then jump to Seq. 10) then goes forward slowly until stopper tripped. This if for recognizing shorter bars.

Memorizes last bar (length) Front rest is closed to bar stock diameter.


Vise is at maximum forward stroke (bar stock is past the back channel). Seq. 7 (Insertion Cycle)

Guiding channel closes Check to see that SQ3 is not ON


Channel is closed Checks to see that SQ4 is not ON


Inserts the bar into the collet Seq. 10 (Insertion Cycle)

If short bar during measuring, insert bar into collet then go slowly to measure Seq. 11 (Profiled material only) (Top-Cut)

Hex material to back of spindle (param) Seq. 12 (Top-Cut)

Go to top-cut with round bar, if not make with hex, then, jump back to Seq. 11 Seq. 13 (Top-Cut)

Top-cut finished Wait for chuck close



1-44

Seq. 14 (Production Cycle)

Production cycle Seq. 15 (Extraction Cycle)

If pusher is more than 500mm from stopper the stopper comes up. If no stock detected the pusher brings the remnant forward to measure size. Then retracts and extracts. If stock detected, then the pusher reverses and extracts remnant. (The load icon is not displayed.)

If pusher is less than 500mm from the stopper the stopper comes up. If no stock detected, it comes forward to measure bar. If stock is short enough the pusher retracts, extracts and displays the load icon. If too long there is no load icon. If stock is detected when less than 500mm the pusher retracts 500mm then checks for remnant.

3-9mm is a different loading cycle with finger than diameter 10mm and above. Safety tolerance for tool breakage or bar push back is 4mm.

Seq. 16 (Extraction Cycle)

After measuring the remnant, pusher retracts to home position and checks the prox. switch. Seq. 17 (Extraction Cycle)

Only (AUTO) checks remnant with SQ5 Does not check in (Man.)


Pusher forward to extraction position (forward 80mm) Jaws close


Pusher home (backward 80mm) for extraction high speed 100% torque Seq. 20 (Extraction Cycle)

Check remnant with SQ5, if not extracted will try for about 45 sec. Seq. 21 (Extraction Cycle)

Verifies channel closed (SQ4 off), then checks SQ3 (off) Channel starts to open (SQ4 on), then checks SQ3 (off)


Channel continues to open then verifies open with switch SQ3 (on) Seq. 23 (Extraction Cycle)

Vise prongs engage chain Seq. 24 (Extraction Cycle)

Vise remnant removal position done by calculation. If remnant is shorter than 320mm the vise is positioned at 820mm. If remnant longer than 320mm position front of remnant about 12mm inside of remnant tray.


Jaws open, vise reverse to remnant stop position then 65mm to stopper. Seq. 26 (Insertion Cycle)

Vise forward to position to receive new bar. (Forward 65mm from limiter.)

Chapter 1: Alarms


1-45

Mitsubishi Servo Amplifier Alarm List

CAUTION • Excessive adjustment or change of parameter setting must not be made as it will make operation instable.

POINT • Using the optional servo configuration software, you can refer to unrotated servo motor reasons,

etc.

The following faults may occur at start-up. If any of such faults occurs, take the corresponding action.

Position control mode (1) Troubleshooting

No. Start-up sequence Fault Investigation Possible cause Reference Not improved if connectors CN1A, CN1B, CN and CN3 2are disconnected.

1. Power supply voltage fault 2. Servo amplifier is faulty.

Improved when connectors CN1A and CN1B are disconnected.

Power supply of CNP1 cabling is shorted.

Improved when connector CN2 is disconnected.

1. Power supply of encoder cabling is shorted. 2. Encoder is faulty.

• LED is not lit. • LED flickers.

Improved when connector CN3 is disconnected.

Power supply of CN3 cabling is shorted.

1 Power on

Alarm occurs. Refer to Section Alarm and warning list and remove cause. Section 11.2

Alarm occurs. Refer to Section Alarm and warning list and remove cause. Section 11.2 2 Switch on servo-on signal. Servo motor shaft is

not servo-locked (is free).

1. Check the display to see if the servo amplifier is ready to operate. 2. Check the external I/O signal indication to see if the servo-on (SON) signal is ON.

1. Servo-on signal is not input. (Wiring mistake) 2. 24VDC power is not supplied to COM.

Section 6.6 of the Mitsubishi Servo Amplifier manual

Rotation ripples (speed fluctuations) are large at low speed.

Make gain adjustment in the following procedure: 1. Increase the auto tuning response level. 2. Repeat acceleration and deceleration several times to complete auto tuning.

Gain adjustment fault Chapter 7 of the Mitsubishi Servo Amplifier manual

3 Gain adjustment

Large load inertia moment causes the servo motor shaft to oscillate side to side.

If the servo motor may be run with safety, repeat acceleration and deceleration several times to complete auto tuning.

Gain adjustment fault Chapter 7 of the Mitsubishi Servo Amplifier manual

4 Cyclic operation Position shift occurs Confirm the cumulative command pulses, cumulative feedback pulses and actual servo motor position.

Pulse counting error, etc. due to noise.



1-46

When alarm or warning has occurred

POINT • Configure up a circuit that will detect the trouble (ALM) signal and turn off the servo-on (SON)

signal at occurrence of an alarm.

Alarms and warning list When a fault occurs during operation, the corresponding alarm or warning is displayed. If any alarm or warning has occurred, refer to Section Alarm definitions and causes and take the appropriate action. Set "1 " in parameter No. 59 to output the alarm code in ON/OFF status across the corresponding pin and SG. Warnings (AL.90 to AL.E9) have no alarm codes. Any alarm code is output at occurrence of the corresponding alarm. In the normal status, the signals available before alarm code setting (CN1B-19, CN1A-18, and CN1A-19) are output.

The alarms marked in the alarm deactivation column can be deactivated by the corresponding operations.

(Note 2) Alarm code Alarm deactivation

Display CN1B-19 pin

CN1A-18 pin

CN1A-19 pin

Name Power OFF→ ON

Press "SET" on current alarm

screen.

Alarm reset (RES) signal

AL.10 0 1 0 Undervoltage AL.12 0 0 0 Memory error 1 AL.13 0 0 0 Clock error AL.15 0 0 0 Memory error 2 AL.16 1 1 0 Encoder error 1 AL.17 0 0 0 Board error AL.19 0 0 0 Memory error 3 AL.1A 1 1 0 Motor combination error AL.20 1 1 0 Encoder error 2 AL.24 1 0 0 Main circuit error AL.25 1 1 0 Absolute position erase AL.30 0 0 1 Regenerative error AL.31 1 0 1 Overspeed AL.32 1 0 0 Overcurrent AL.33 0 0 1 Overvoltage AL.35 1 0 1 Command pulse frequency error AL.37 0 0 0 Parameter error AL.45 0 1 1 Main circuit device overheat AL.46 0 1 1 Servo motor overheat AL.50 0 1 1 Overload 1 (Note 1) (Note 1) (Note 1) AL.51 0 1 1 Overload 2 (Note 1) (Note 1) (Note 1) AL.52 1 0 1 Error excessive AL.8A 0 0 0 Serial communication time-out

error

AL.8E 0 0 0 Serial communication error

Ala

rms

88888 0 0 0 Watchdog AL.90 Home position return incomplete AL.92 Open battery cable warning AL.96 Home position setting warning AL.98 Software limit warning AL.9F Battery warning AL.E0 Excessive regenerative warning AL.E1 Overload warning AL.E3 Absolute position counter warning AL.E6 Servo emergency stop warning

War

ning

s

AL.E9

Main circuit off warning

Removing the cause of occurrence deactivates the alarm automatically.

Note: 1. Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence.

2. 0: Pin-SG off (open)

1: Pin-SG on (short)

Chapter 1: Alarms


1-47

CAUTION

• When any alarm has occurred, eliminate its cause, ensure safety, then reset the alarm, and restart operation. Otherwise, injury may occur.

• If an absolute position erase alarm (AL.25) occurred, always make home position setting again. Otherwise, misoperation may occur.

POINT • When any of the following alarms has occurred, always remove its cause and allow about 30

minutes for cooling before resuming operation. If operation is resumed by switching control circuit power off, then on to reset the alarm, the servo amplifier and servo motor may become faulty.

• Regenerative error (AL.30)

• Overload 1 (AL.50)

• Overload 2 (AL.51) • The alarm can be deactivated by switching power off, then on press the "SET" button on the

current alarm screen or by turning on the reset (RES). For details, refer to Alarms and warning list.

Alarm definitions and causes When an alarm occurs, the trouble (ALM) switches off and the dynamic brake is operated to stop the servo motor. At this time, the display indicates the alarm No.

The servo motor comes to a stop. Remove the cause of the alarm in accordance with this section. The optional servo configuration software may be used to refer to the cause.

Display Name Definition Cause Action 1. Power supply voltage is low. 2. There was an instantaneous control power failure of 60ms or longer. 3. Shortage of power supply capacity caused the power supply voltage to drop at start, etc. 4. Power was restored after the bus voltage had dropped to 200VDC. (Main circuit power switched on within 5s after it had switched off.)

Review the power supply. AL.10 Undervoltage Power supply voltage dropped. MR-J2S- CP:160V or less MR-J2S- CP1:83V or less

5. Faulty parts in the servo amplifier

Checking method Alarm (AL.10) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.

Change the servo amplifier.

AL.12 Memory error 1 RAM, memory fault AL.13 Clock error Printed board fault AL.15 Memory error 2 EEP-ROM fault

Faulty parts in the servo amplifier

Checking method Alarm (any of AL.11 to 13 and 15) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.


1. Encode connector (CN2) disconnected.

Connect correctly.

2. Encoder fault Change the servo motor. 3. Encoder cable faulty (wire breakage or short)

Repair or change the cable.

AL.16 Encoder error 1 Communication error occurred between encoder and servo amplifier.

4. Wrong combination of servo amplifier and servo motor

Use correct combination.



1-48

Display Name Definition Cause Action AL.17 Board error CPU/parts fault AL.19 Memory error 3 ROM memory fault

Faulty parts in the servo amplifier

Checking method Alarm (A.17 or A.18) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.


AL.1A Motor combination error

Wrong combination of servo amplifier and servo motor.

Wrong combination of servo amplifier and servo motor connected.

Use correct combination.

1. Encoder connector (CN2) disconnected.

Connect correctly.

2. Encoder fault Change the servo motor.

AL.20 Encoder error 2 Communication error occurred between encoder and servo amplifier. 3. Encoder cable faulty(wire

breakage or shorted) Repair or change the cable.

1. Power input wires and servo motor output wires are in contact at main circuit terminal block (TE1).

Connect correctly.

2. Sheathes of servo motor power cables deteriorated, resulting in ground fault.

Change the cable.

AL.24 Main circuit error

Ground fault occurred at the servomotor outputs (U, V and W phases) of the servo amplifier.

3. Main circuit of servo amplifier failed.

Checking method AL.24 occurs if the servo is switched on after disconnecting the U, V, and W power cables from the servo amplifier.


1. Reduced voltage of super capacitor in encoder

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

2. Battery voltage low

Absolute position data in error

3. Battery cable or battery is faulty.

Change battery. Always make home position setting again.

AL.25 Absolute position erase

Power was switched on for the first time in the absolute position detection system.

4. Super capacitor of the absolute position encoder is not charged

After leaving the alarm occurring for a few minutes, switch power off, then on again. Always make home position setting again.

1. Wrong setting of parameter No. 0

Set correctly.

2. Built-in regenerative brake resistor or regenerative brake option is not connected.

Connect correctly

3. High-duty operation or continuous regenerative operation caused the permissible regenerative power of the regenerative brake option to be exceeded.

Checking method Call the status display and check the regenerative load ratio.

1. Reduce the frequency of positioning. 2. Use the regenerative brake option of larger capacity. 3. Reduce the load.

Review power supply 4. Power supply voltage is abnormal. MR-J2S- CP:260V or more MR-J2S- CP1:135V or more

Change servo amplifier or regenerative brake option.

Permissible regenerative power of the built-in regenerative brake resistor or regenerative brake option is exceeded.

5. Built-in regenerative brake resistor or regenerative brake option faulty.

AL.30 Regenerative alarm

Regenerative transistor fault

6. Regenerative transistor faulty.

Checking method 1) The regenerative brake option has overheated abnormally. 2) The alarm occurs even after removal of the built-in regenerative brake resistor or regenerative brake option.


Chapter 1: Alarms


1-49

1. Input command pulse frequency exceeded the permissible instantaneous speed frequency.

Set command pulses correctly.

2. Small acceleration/deceleration time constant caused overshoot to be large.

Increase acceleration/deceleration time constant.

3. Servo system is instable to cause overshoot.

1. Re-set servo gain to proper value. 2. If servo gain cannot be set to proper value: 1) Reduce load inertia moment ratio; or 2) Reexamine acceleration/deceleration time constant.

4. Electronic gear ratio is large (parameters No. 4, 5)

Set correctly.

AL.31 Overspeed Speed has exceeded the instantaneous permissible speed.

5. Encoder faulty. Change the servo motor. 1. Short occurred in servo amplifier output phases U, V and W.

Correct the wiring.

2. Transistor (IPM) of the servo amplifier faulty.

Checking method Alarm (AL.32) occurs if power is switched on after U, V and W are disconnected.


3. Ground fault occurred in servo amplifier output phases U, V and W.

Correct the wiring.

AL.32 Overcurrent Current that flew is higher than the permissible current of the servo amplifier.

4. External noise caused the overcurrent detection circuit to misoperate.

Take noise suppression measures.

1. Lead of built-in regenerative brake resistor or regenerative brake option is open or disconnected.

1. Change lead. 2. Connect correctly.

2. Regenerative transistor faulty. Change servo amplifier 3. Wire breakage of built-in regenerative brake resistor or regenerative brake option

1. For wire breakage of built-in regenerative brake resistor, change servo amplifier. 2. For wire breakage of regenerative brake option, change regenerative brake option.

4. Capacity of built-in regenerative brake resistor or regenerative brake option is insufficient.

Add regenerative brake option or increase capacity.

AL.33 Overvoltage Converter bus voltage exceeded 400V.

5. Power supply voltage high. Review the power supply. 1. Pulse frequency of the manual pulse generator is too high.

Change the pulse frequency to a proper value.

2. Noise entered the pulses of the manual pulse generator.

Take action against noise.

AL.35 Command pulse frequency error

Input pulse frequency of the command pulse is too high.

3. Manual pulse generator failure Change the manual pulse generator. 1. Servo amplifier fault caused the parameter setting to be rewritten.

Change the servo amplifier. AL.37 Parameter error Parameter setting is wrong.

2. Regenerative brake option not used with servo amplifier was selected in parameter No.0.

Set parameter No.0 correctly.



1-50

Display Name Definition Cause Action 1. Servo amplifier faulty. Change the servo amplifier. 2. The power supply was turned on and off continuously by overloaded status.

The drive method is reviewed. AL.45 Main circuit

device overheat Main circuit device overheat

3. Air cooling fan of servo amplifier stops.

1. Exchange the cooling fan or the servo amplifier. 2. Reduce ambient temperature.

1. Ambient temperature of servo motor is over 40°C.

Review environment so that ambient temperature is 0 to 40°C.

2. Servo motor is overloaded. 1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.

AL.46 Servo motor overheat

Servo motor temperature rise actuated the thermal protector.

3. Thermal protector in encoder is faulty.

Change servo motor.

1. Servo amplifier is used in excess of its continuous output current.

1. Reduce load. 2. Review operation pattern. 3. Use servo motor that provides larger output.

2. Servo system is instable and hunting.

1. Repeat acceleration/ deceleration to execute auto tuning. 2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain adjustment manually.

3. Machine struck something. 1. Review operation pattern. 2. Install limit switches.

4. Wrong connection of servo motor. Servo amplifier's output terminals U, V, W do not match servo motor's input terminals U, V, W.

Connect correctly.

AL.50 Overload 1 Load exceeded overload protection characteristic of servo amplifier. Load ratio 300%: 2.5s or more Load ratio 200%: 100s or more

5. Encoder faulty.

Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway.

Change the servo motor.



Connect correctly.

3. Servo system is instable and hunting.

1. Repeat acceleration/deceleration to execute auto tuning. 2. Change auto tuning response setting. 3. Set auto tuning to OFF and make gain adjustment manually.

AL.51 Overload 2 Machine collision or the like caused max. output current to flow successively for several seconds. Servo motor locked: 1s or more

4. Encoder faulty.

Checking method When the servo motor shaft is rotated with the servo off, the cumulative feedback pulses do not vary in proportion to the rotary angle of the shaft but the indication skips or returns midway.

Change the servo motor.

Chapter 1: Alarms


1-51

Display Name Definition Cause Action 1. Acceleration/deceleration time constant is too small.

Increase the acceleration/deceleration time constant.

2. Internal torque limit 1 (parameter No.28) is too small.

Increase the torque limit value.

3. Motor cannot be started due to torque shortage caused by power supply voltage drop.

1. Review the power supply capacity. 2. Use servo motor that provides larger output.

4. Position control gain 1 (parameter No.7) value is small.

Increase set value and adjust to ensure proper operation.

5. Servo motor shaft was rotated by external force.

1. When torque is limited, increase the limit value. 2. Reduce load. 3. Use servo motor that provides larger output.


7. Encoder faulty Change the servo motor.

AL.52 Error excessive The droop pulse value of the deviation counter exceeded the encoder resolution

10 [pulse].


Connect correctly.

1. Communication cable breakage.

Repair or change communication cable

2. Communication cycle longer than parameter No. 23 setting.

Set correct value in parameter.

AL.8A Serial communication time-out error

RS-232C or RS-422 communication stopped for longer than the time set in parameter No.23. 3. Wrong protocol. Correct protocol.

1. Communication cable fault (Open cable or short circuit)

Repair or change the cable. AL.8E Serial communication error

Serial communication error occurred between servo amplifier and communication device (e.g. personal computer).

2. Communication device (e.g. personal computer) faulty

Change the communication device (e.g. personal computer).

88888 Watchdog CPU, parts faulty Fault of parts in servo amplifier Checking method Alarm (88888) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables.

Change servo amplifier.



1-52

Remedies for warnings If AL.E6 occurs, the servo off status is established. If any other warning occurs, operation can be continued but an alarm may take place or proper operation may not be performed. Use the optional servo configuration software to refer to the cause of warning.

Display Name Definition Cause Action In incremental system: 1. Positioning operation was performed without home position return. 2. Home position return ended abnormally.

1. Positioning operation was performed without home position return. 2. Home position return speed could not be decreased to creep speed. 3. Limit switch was actuated during home position return starting at other than position beyond dog.

1. Perform home position return. 2. Review home position return speed/creep speed/moving distance after proximity dog.

AL.90 Home position return incomplete

In absolute position detection system: 1. Positioning operation was performed without home position setting. 2. Home position setting ended abnormally.

1. Positioning operation was performed without home position setting. 2. Home position setting speed could not be decreased to creep speed. 3. Limit switch was actuated during home position setting starting at other than position beyond dog.

1. Perform home position setting. 2. Review home position setting speed/creep speed/moving distance after proximity dog.

1. Battery cable is open. Repair cable or changed. AL.92 Open battery cable warning

Absolute position detection system battery voltage is low.

2. Battery voltage dropped to 2.8V or less.

Change battery.

1. Droop pulses remaining are greater than the in-position range setting.

Remove the cause of droop pulse occurrence

2. Command pulse entered after clearing of droop pulses.

Do not enter command pulse after clearing of droop pulses.

AL.96 Home position setting warning

Home position setting could not be made.

3. Creep speed high. Reduce creep speed. 1. Software limit was set within actual operation range.

Set parameter No. 48 to 51 correctly.

2. Point table of position data in excess of software limit was executed.

Set point table correctly.

AL.98 Software limit warning

Software limit set in parameter is reached.

3. Software limit was reached during JOG operation or manual pulse generator operation.

Perform operation within software limit range.

AL.9F Battery warning Voltage of battery for absolute position detection system reduced.

Battery voltage fell to 3.2V or less. Change the battery.

AL.E0 Excessive regenerative warning

There is a possibility that regenerative power may exceed permissible regenerative power of built-in regenerative brake resistor or regenerative brake option.

Regenerative power increased to 85% or more of permissible regenerative power of built-in regenerative brake resistor or regenerative brake option. Checking method Call the status display and check regenerative load ratio.

1. Reduce frequency of positioning. 2. Change regenerative brake option for the one with larger capacity. 3. Reduce load.

AL.E1 Overload warning

There is a possibility that overload alarm 1 or 2 may occur.

Load increased to 85% or more of overload alarm 1 or 2 occurrence level. Cause, checking method Refer to AL.50, 51.

Refer to AL.50, AL.51.

1. Noise entered the encoder. Take noise suppression measures.

AL.E3 Absolute position counter warning

Absolute position encoder pulses faulty.

2. Encoder faulty. Change servo motor. AL.E6 Servo

emergency stop warning

EMG-SG is open. External emergency stop was made valid. (EMG-SG opened.)

Ensure safety and deactivate emergency stop.

AL.E9 Main circuit off warning

Servo was switched on with main circuit power off.

Switch on main circuit power.



2-1

Chapter 2:

Common Issues

he Hydrobar Express 220 is designed to be a user-friendly, simple, and reliable bar feeder, covering a range of diameters 0.125” to 1.250” (1.250”-1.375” with bar end preparation). Although easy to use, including extremely quick changeovers and the capability for unmanned operation this unit is not flawless. A list of common issues that have been documented by service technicians and problems relayed back from customers has been compiled in this manual. This chapter discusses the most common problems that have been observed. Along with each problem, a brief description is given as well as

quick reference charts of symptoms/solutions, sequences, and procedures for adjustments, changeovers and alignment.

T



2-2

Low Voltage / PLC Shutdown

Description: The Hydrobar Express 220 uses a SAIA PCD2 controller (PLC) to send/receive inputs/outputs. The PLC is powered by a +24VDC input supplied by a transformer. The input supply voltage must be regulated to ensure proper functioning. The remote control station, which is used to send/receive data back and forth with the PLC, is powered by the +24VDC on the PLC.

Through the remote control station, the user can command the bar feeder to perform different functions by sending data to the PLC. The PLC will then transfer data back to the remote control station to either inform the user the status of what the bar feeder is doing or is waiting for the user to command the next task.

The following chart discusses possible problems, which may be occurring between the PLC and the remote control station:

Problem Possible Cause/s Solution/s

SPS No response

• The PLC toggle switch is not in the RUN position

• A sudden drop in the supply voltage has caused a communication problem between the PLC and the remote control station

• The battery was either removed or battery voltage was low while the bar feed was powered down which caused the PLC to lose its program

• Flip the toggle switch on the PLC to the RUN position

• Check the supply voltage on the PLC, can be low due to a low incoming 3 phase voltage from the lathe

• Check the battery voltage, if it is low it will need to be replaced with a 3VDC Litium/CD2032 battery and the program will need to be restored (refer to Chapter 4)

No operator action possible on the remote control station

• The PLC toggle switch is not in the RUN position

• Low supply voltage on the PLC

• Flip the toggle switch on the PLC to the RUN position

• Check the supply voltage on the PLC, can be low due to a low incoming 3 phase voltage from the lathe



2-3

Cannot Change Application Setup Parameters In order to change the values of any parameters in the bar feed, it must be in “STOP” mode. To determine whether the bar feed is in “STOP” mode, look at the “STOP” key on the remote control station. When the “STOP” key is pressed, two red LED’s will illuminate on either side of the remote.

In certain cases, as a precaution, the bar feed will not allow the parameters in the PARAMETERS RELATED TO APPLICATION menu to be changed unless a few conditions are met. The following conditions are required to change these parameters:

Guiding channels must be open.

Bar stock (if any) must be removed.

When removing the bar stock, the bar feed must recognize that the bar has been removed. In order for the bar feed to recognize that the bar has been removed follow the steps below:

Step 1: Press the manual mode icon.

Step 2: Press the remove bar stock icon. Note: If the remove bar stock icon is not present, skip the next step and go to Step 4.

Step 3: After pressing the remove bar stock icon, it will ask you to verify if the bar has been removed. Remove the bar from the

channel and pres and hold the confirmation icon. Step 4: Press the “STOP” key on the remote control station and proceed with changing the parameters.

Multiple Bars have been Loaded into the Channel Two bars loaded at a time

Cause Solution Incorrect bar stock diameter. Change the bar stock diameter parameter to the correct

size.

Top limiters are not set correctly and bars are bunching up on the loading ramp.

The top limiters should be set so that the bars can roll freely without the possibility of bars overlapping.

A bar was already in the channel and another was loaded on top

Cause Solution A remnant too long to be dumped into the remnant pan has

been confirmed that it was removed without physically removed. Perhaps during a shift change.

Remove the two bars from the channel and restart the loading process.



2-4

Front Rest Issues How the front rest works? The front rest is used as a guide source for the bar stock to transfer from the bar feed through the headstock. The rest also acts as an extended support for the back of the bar while the spindle is rotating. It operates using an electric motor which drives the “jaws” open and closed. There are three operating positions at which the rest will open/close:

“Home” reference position - this is a constant position at which the rest will open up completely to a zero-position which calibrates the rest. This position is determined by a mechanical setting which is detected by a fixed proximity switch (SQ8).

Bar stock diameter position - this is a variable position at which the rest will close down to approximately (.020”) over the bar stock diameter. This position is automatically calculated when the bar stock diameter parameter is entered in.

Guiding channel position - this is a variable position at which the rest will open up to the I.D. of the guiding channel inserts. The rest opens to this position in order for the pusher (since the pusher O.D. is greater than the bar stock O.D.) to be able to travel through the rest. This position is automatically calculated when the guiding channel parameter is entered in.

Front Rest Opening/Closing Timing Chart

During Loading Sequence During Production Sequence Sequence Rest position

Remnant is being

measured

Remnant is being

extracted

Remnant is dropped into remnant pan

New bar is loaded/ being

measured

Bar has been measured/

passed through front

rest

Feeding part to part (pusher not at front rest open

position)

Feeding part to part (pusher at front rest open

position)

“Home” reference position

Bar stock diameter position

Guiding channel position

Symptoms of front rest mal-functioning Description Cause Solution

Front rest is locked in the “home” ref. position

The front rest has been manually locked open.

Mechanical obstruction has caused a front rest error.

Must be manually closed. Refer to pg. 3-35 Front Rest Override procedure.

Remove any debris which may have caused a mechanical obstruction.

Front rest is closing too tight on bar stock / pusher.

Bar stock diameter / guiding channel size has not been set correctly in the parameters.

SQ9 switch is mis-adjusted or defective.

Front rest is mis-calibrated (SQ8).

Check the bar stock diameter and guiding channel size parameters.

Check the functionality of the SQ9 switch.

Re-calibrate the front rest.

Front rest is not closing enough on the bar stock

Bar stock diameter / guiding channel size has not been set correctly in the parameters.

SQ8 switch is mis-adjusted or defective.

Front rest is mis-calibrated.

Check the bar stock diameter and guiding channel size parameters.

Check the functionality of the SQ9 switch.

Re-calibrate the front rest.



2-5

Vibration Issues

The term “vibration” is being used regarding the Hydrobar Express 220, to indicate that the RPM performance of the lathe is physically deteriorated, to the point of creating an unbalanced rotational oscillation of the bar stock that is detrimental to the machining process.

Various items can cause the bar stock to vibrate, requiring the reduction of the spindle rpm to bring the anomaly back to a normal controlled rotation. These items can be related (but not limited to) the material, the lathe, the spindle reduction tubes, or the bar feed.

Material The material must be reasonably straight. LNS has a specification of .5mm / meter (non-accumulative).

If the material is a hot roll type it will not meet our specifications.

If the material has been “cropped” to length the last 6”-12” of the end of the bar may be unusable due to being bent severely in the process.

Note: Also, there is a possibility to have a severe angle on the end of the bar, which has been cropped. This might cause the mis-loading of a new bar into the collet of the bar feed.

When running profiled material (hex, square, etc.), vibration is more likely to occur due to the physical properties of the material, especially with extremely odd shaped material, in which case a lower rpm is recommended.

The composition of the material also has an effect on the guiding of bar stock. Steel and aluminum bars are relatively easy to guide, but because of the flexibility and specific weight of brass it is generally going to be more difficult to guide at high speeds.

Lathe The lathe should be level and on a solid foundation. LNS recommends that the lathe be bolted to the floor.

Spindle Reduction Tube Ensure that the properly sized spindle liner has been installed (matches guiding channel size).

Ensure that the spindle liner is straight (check total run out).

Ensure that the liner is securely fastened.

Bar Feed The bar feed must be within proper alignment to the spindle of the lathe.

The proper guiding elements should be used to provide minimal gap between the I.D. of the elements and the O.D. of the bar stock diameter. Should not exceed 10mm overall gap (5mm per side). Refer to pg. 6-4 Guiding Channel Reference chart for the recommended guiding elements and ordering numbers.

LNS recommends running ISO 100 hydraulic oil in the bar feed. In certain cases, a thicker oil (ISO 150) may produce better results when guiding profiled material.

Chapter 3: Procedures 3-1


Chapter 3: Procedures

he following chapter includes simple step-by-step procedures for mechanical adjustments, replacing damaged or faulty components and to resolve other issues related to the bar feeder. Along with some of these procedures are video clips which show the actual procedure being performed in case the written procedure is too difficult to follow. The video clips can be viewed on a PC with a compatible video card from the CD-ROM version of this manual.

T

3-2 Chapter 3: Procedures

HYDROBAR EX

Adjust Home Position Proximity Switch: SQ7 This procedure is used to adjust SQ7. Tools List: • Two 13mm combination wrenches Procedure Conditions: • Pusher and channel set up installed Step 1: Confirm that the pusher is in home position. The pin should contact the bracket.

n

Step 2: Loosen the 2 jam nuts on SQ7.

s

Step 3: Set the gap

Loosen jam nut

PRESS 220

between the switch and the fl

SQ7

SQ7

ag to 1mm. Use a 1mm feller gauge to set gap.

h

p

g
Fla
Switc

1mm ga

Home positio


Step 4: Hand-tighten the top jam nut on SQ7 after setting the correct gap.

Hand-tighten

Step 5: Recheck the gap between the switch and the flag.

p

Step 6: Move the switch so that it is 2/3 over

Step 7: Tighten the top jam nut with a 13mm

tighten and damage switch.

e

Procedure complete.

1mm ga

top of the flag and tighten the top jam nut by hand.

combination wrench while holding the bottom nut in position. Be careful not to over

n

Hold in plac

Tighte




Adjusting the Pusher Support Mechanism This procedure is to adjust the pusher support mechanism. Tools List: • 4mm hex key Procedure Conditions: • Pusher and channel setup in machine • Main bar feed power off • Main guiding channel open Step 1: Press the yellow button on the YV2B valve to close the main guiding channels.

Press this yellow button

Step 2: Confirm that the pusher is in its home position. The pin should contact the bracket.

n

Step 3: Confirm that the pusher bracket is tight on the pusher support plate.

Pusher support plate

Pusher support bracket

Home positio


Step 4: Loosen the two bolts on the pusher support plate.

Step 5: Position the bracket so that it is centered on the pusher.

Step 6: While holdin

Procedure com

Bracket and pusher (removed

for clarity)

r
Center the bracket on the pushe

g the bracket in place, tighten the two bolts on the pusher support plate.

plete.



SQ1 Measuring Cell Adjustment This procedure is used to adjust SQ1 measuring cell. SQ1 detects the face of the present bar being loaded and calculates the length of the bar. Tools List: • Small flat screw driver • 2.5mm hex key • 5mm hex key • 7mm combination wrench • One 8 or 11mm guiding channel • Short piece of round material: 1/8” or smaller Procedure Conditions: • Main guiding channel open • Main bar feed power on Step 1: Install an 8 or 11mm guiding channel in the front channel location closest to the lathe.

Step 2: Pull up on the air regulator knob and turn it counter clockwise to drop the air pressure to 0 (zero).

Front channel – closest to the lathe

b

Step 3: Pull up the measuring cell shield.

Measuring cell shield

1

Kno

SQ
1 SQ


HYDR

Step 4: Confirm that the shield is flush against the measuring cell bracket. If not, loosen the split collar with a 5mm hex key and

readjust. When the shield is adjusted correctly, retighten the split collar.

Step 5: Push the measuring cell shield back down.

Split collar Measuring acket cell br

Shield

Shield

Step 6: Adjust the range of the sensor by placing your hand below the channel and adjusting the yellow screw on SQ1. Adjust the

screw until the light on SQ1 illuminates (the sensor will detect your hand and the range has been set).

t

Yellow s

Step 7: Place a short piece of material (8 or 11mm) in the guiding channel. (A straight section of a wir

needed) Place the material so that an inch or more sticks out of the channel and is under SQ1

Bar stock should stick out of the

channel

Ligh

OBAR EXPRESS 220

crew

e coat hanger will work if .



Step 8: Roll the bar stock across the width of the guiding channel and check to see that the sensor is centered over the material.

The light on SQ1 will illuminate if the sensor is centered. If not, continue to the next step. If the sensor is centered, skip to step 11.

Step 9: Using a 2.5mm hex key and 7mm combination wrench, loosen and adjust the fron

up the bar stock and the light on SQ1 illuminates.

Step 10: Retighten the bolt holding the sensor in pl e y repeatin Step 11: Remove the short piece of material. Step 12: Remove the 8 or 11 mm guiding channel and replace the correct guiding channel s Step 13: Pull up on the air regulator knob and turn it clockwise and set the air pressure to th

ace and r check the settings b

Procedure complete.

Roll the bar stock

Light will illuminateif SQ1 is centered

t bolt on SQ1 accordingly so that it picks

Front bolt

g step 8.

ize according to the bar stock used.

e sixth bar (90 psi).

Knob


Front Rest Alignment This procedure is used to align the front rest. This procedure requires special tooling. To receive this tooling, contact LNS America, Inc at 513-528-5674. Some bar feed parts were removed for clarity of the pictures for this procedure. Tools List: • 10mm combination wrench • 13mm combination wrench • 3mm hex key • 4mm hex key • 5mm hex key • Rest alignment tooling (loaned from LNS factory)

Procedure Conditions: • Main guiding channel open • No bar stock in the channel • Main bar feed power off Step 1: Remove the three guiding channels closest to

eAlignment blocks

Remove guiding channels

Step 2: Remove the front rest cover by loosening the fo

Thumb sc

Alignment tub

the front rest.

r

45m

75mm alignmentbushing

ur thumb screws (two on either

ws re

Alignment ba

Tube alignmentbushing


m alignment bushing

side of the cover).



Step 3: Loosen the 2 thumb screws on the oil shield and remove the shield.

Loosen thumb screws

d

Step 4: Remove the t-tube mounting plate by removing the four bolts on the pla

Step 5: Tap the air blast ring out.

Step 6: Insert an alignment block in the front of the first channel and set it direc

Oil shiel

te.

T-tube mounting plate

g
Air blast rin
tly behind the first pin.


Step 7: Place the second alignment block at the end of the second channel.

Step 8: Insert the alignment bar through the front rest and into the blocks so that the bar is just inside of the bar feed. Note: Make sure that the blocks stay in place.

Step 9: Pull up on the air regulator knob and turn it counter clockwise to drop the air pressure to two bars (30psi).

b

Step 10: Close the channels by pressing the yellow button on the YV2B air v

y n

Kno

alve.

e
Press this ellow butto
YV2B valv




Step 11: Insert the large 75mm alignment bushing on the end of the alignment bar.

Step 12: Slide the alignment bar through the front rest feed approximately 3”.

until it is out of the bar

Step 13: Loosen the four front rest mounting bolts with a 13mm combination wrench.

Step 14: Slide the 75mm alignment bushing into the rest and retighten the 4 mounting bolts so that the 75mm alignment bushing

moves freely in and out of the front rest.

3”

75mm alignment bushing

Loosen

Tighten


Step 15: Install the 45mm alignment bushing onto the front of the alignment bar.

Step 16: Adjust the four set screws until the alignment bushing mov Note: You may need to loosen one of the four bolts at a ti

Adjust set screws

Step 17: Confirm that both of the alignment bushings move in and o Step 18: Remove the 45mm alignment bushing from the front of the

Step 19: Reinstall the air blast ring. Note: Make sure that the air blast holes on the inside of th blast holes on the outside of the ring are facing away from

Insert air blast ring

45mm alignmentbushing


es freely in and out of the front rest. me in order to adjust. (Some set screws are not visible.)

Adjust set screws until it moves

freely in and out of the front rest

ut freely of the front rest. Adjust if needed.

bar.

Remove

e ring are facing towards the front rest rubber inserts. The air the front rest rubber inserts.



Step 20: Reinstall the t-tube mounting plate. Do not tighten the four bolts yet. Note: Make sure that the plate is installed with the largest hole on top.

Step 21: Open the channel by pressing the yellow button on the YV2A a

ir valve.

T-tube mounting plate

Step 22: Pull the alignment bar forward until it hangs out of the bar feed approximately 2 ft.


YV2A

2’

Step 23: Relocate the back alignment block to the end of the bar in the channel


Step 24: Close the channels by pressing the yellow button on the YV2B air valve.

e

y n

Step 25: Place the alignment tube onto the alig

Step 26: Mount the alignment tube to the t-tube

Step 27: Tighten the four mounting bolts on the

Press this ellow butto

nment bar.

mounting plate with the t

s

t-tube mounting plate to t

YV2B valv

Alignment tube

hree bolts. (Third bolt is not visible)

Mount with bolt


he rest.



Step 28: Insert the tube alignment bushing on to the bar and against the tube.

Step 29: Using the 3mm hex key, tighten the set screws so that the tube alignment bushing moves freely in and out of the tube. (The

fourth set screw is not visible)

Step 30: Tighten the 10mm nuts on the set scr nto position.

ews to lock them i

Step 31: Remove the tube alignment bushing and the alignment tube. Step 32: Open the channel by pressing the yellow button on the YV2A air valve.

Step 33: Remove the tooling from the inside of the channel: alignment blocks, alignment bar, and 75mm alignment bushing.


YV2A

Adjust set screws

Tighten nuts on the set screws

Tube alignment bushing


Step 34: Replace the oil shield and tighten the thumb screws.

Tighten thumb screws

d

Step 35: Replace the front rest cover and tighten the four thumb screws (two on

ws Thumb scre

Procedure complete.

Oil shiel


either side of the cover).



Chain Tension Adjustment This procedure is used to adjust the chain tension. Tools List: • Two 10mm combination wrenches Procedure Conditions: • Main guiding channel open Step 1: Loosen the bolt and nut on the chain idler.

Step 2: Loosen jam nut on tensioner.

Step 3: Back the tensioner bolt out of the block to tighten t

he chain.

t

t

r

Loosen chain Tighten chain

Loosen bolt

Loosen nut

Loosen jam nu

Tensioner bol

Chain idle

Bolt Direction


Step 4: The chain should be tensioned so that pushing down on the chain so that it will just touch the idler. (Located by the servo

motor) Adjust the tensioner bolt to reach this condition.

Idler

Idler

Step 5: Once the chain tension is set correctly, tighten the bolt and nut on the chain idler.

t

Step 6: Recheck the chain tension setting by the servo motor.

t

Step 7: Retighten the jam nut.

Procedure complete.

Tighten bol

Tighten nu

t
Tighten jam nu



Channel Lid Switches (SQ3 &SQ4) Adjustment The purpose of this procedure is to adjust SQ3 and SQ4 switches.

Tools List: • 5mm hex key Procedure Conditions: • Main guiding channels open • Turn main bar feed power off. Step 1: Loosen the split collar that is closes

Step 2: Set the gap to 0.5 - 0.6mm with a fe

SQ3

t to SQ3 with a 5mm hex key.

4

eler gauge between SQ3 and th

Split Co

e

SQ

SQ3

e plate.

llar

0.5 - 0.6 gap

Plat


Step 3: Set the plate so that it covers two-thirds of the switch space and then tighten the split collar.

Step 4: Confirm that there is still a 0.5 - 0.6mm gap between SQ3 and t Step 5: Press the yellow YV2B valve to close the main guiding channels.

he plate.

button on the

Step 6: Loosen the split collar located next to SQ4 with the 5mm hex key.


Step 7: Move the plate inwards towa

barely visible)

rd the sw

Loosen split collar

itch until the gold arm o

SQ4


n the roller is lined up with the switch. (Gold arm becomes

Gold arm on roller

Line up against the edge of the switch

Move plate inward



Step 8: Rotate the plate downwards until the edge of the plate just contacts the roller on the switch while holding its position just set

from the previous step.

Step 9: Tighten the split collar into place.

Step 10: Press the yellow button on the YV2A v

Procedure complete.

Rotate plate downwards

Roller just contacts the plate
Tighten splitcollar
alve to reopen the main guiding channels.




Diameter Adjustment Motor Replacement This procedure is used to replace the diameter adjustment motor. Tools List: • 2mm & 4mm hex key • 4mm hex key socket w/ ratchet • 6” drive extension • Flat blade screw driver (for coder disc removal) • Small electrical flat blade screw driver (for motor wire removal) • 10mm open end wrench • 15mm open end wrench Procedure Conditions: • Main bar feed power off. • Coder disc at reference position. (SQ2 at first hole and the pin in the down position).

SQ2 at first hole

Pin in down position

Step 1: Remove the bolt from the pin on the dr

ive shaft.

Drive shaft

Remove bolt

Step 2: Loosen the two bolts with a 6” drive socket and a 4mm hex socket on the base of the drive shaft that is attached to the split

collar. Note: Be careful when removing the drive shaft or the coder disc. The guide wheel is not attached and may fall off.



Step 3: Remove the coder disc by holding the screw on the disc in place and removing the nut on the other side.

Step 4: Remove the gear on the motor by loosening the set screw with a 2mm hex key.

Step 5: Remove all four bolts on the diameter adjustment motor. (Fourth bolt not visible)

Step 6: Remove the cover from the junction box.

Coder disc

t

Set screw

r

Junction box

Hold screw in place

Nu

Gea



Step 7: With a 15mm open end wrench, loosen the cable grip on cable M4.

Step 8: Disconnect the brown wire from terminal KA3-13 and disconnect the blue wire 0V terminal. Note: You will need to trace the blue wire from the M4 cable to find which terminal it is in.

Step 9: Extract the M4 cable out of the junction box.

Step 10: Pull the cable and motor completely out of the bar feed. Step 11: Insert the new motor and route the cable back to the junction box. Step 12: Insert the cable through the cable grip.

M4 cable grip

M4 cable grip

Step 13: Connect the brown wire to KA3-13 terminal and connect the blue wire to the 0V terminal.



Step 14: Tighten the cable grip on cable M4. Note: Be careful not to over-tighten the cable grip nut. It is capable of striping very easily.

Step 15: Replace the cover on the junction box and tighten shut.

Step 16: Mount the diameter adjustment motor with the four bolts and tighten. (Fourth bolt not visible)

Step 17: Place the new gear and position it so that the gear is flush with the end of the motor shaft. Once the gear is positioned

correctly, tighten the set screw with a 2mm hex key.

M4 cable grip

r
Gea
Set screw


HYDROBAR EXPR

Step 18: Place the coder disc so that it meshes with the motor gear and is in reference position. (The first hole in the disc is lined up

with the switch and the pin is in the down position.) Tighten the nut when the coder disc is in place.

Coder disc

tSwitch lined up to the first hole

n

Make sure that the gears mesh

together Step 19: Place the drive shaft onto the guide wheel and tighten the bolt. Note: If the guide wheel fell off, make sure that it is replaced before putting the drive shaft back on.

Replace

Tighten bolt

Step 20: Once the drive shaft is in place, tighten the two bolts on the base of the drive shaft attached to the split collar.

Procedure complete.

Nu

Pin in down positio

ESS 220



Enabling the 2mm Option This procedure is used to enable to 2mm option on the Express 220. Make sure that when using the 2mm option that the bar stock is still aligned against the rear limiter. Tools List: • 10mm wrench Procedure Step 1: Press the MENU button on the remote station. Step 2: Press F4 (PAGE DOWN) function key to Additional Parameters Related to Applications. Press the F3 (ENTER) function key

on the remote station.

ADDITIONALPARAMETERS RELATEDTO APPLICATIONS

-CLAMPING DEVICE OPENINGS-FEED OUT W/WO TURRET-CLAMPING MODE-AUX. END OF BAR-BAR MOTION CONTROL

tep 3: Press F4 (PAGE DOWN) function key to Small Diameter Bars Loading Rack. S

Step 4: Press ‘2’ to change the option. Then press and hold the F3 (ENTER) function key to enable it.



Step 5: Loosen the two 10mm bolts on the adjustable tooth plate.

Adjustable tooth plate

Loosen bolts

Step 6: Raise the loading rack up and tighten the two 10mm bolts.

Raise up

Step 7: Repeat steps 5 and 6 for the remaining loading racks. Step 8: Make sure that all of the top limiters should be raised to their highest setting.

Raised to its highest setting

Procedure complete.



Front Rest Motor Replacement The purpose of this procedure is to replace the front rest motor.

Tools List: • 2.5mm and 3mm allen wrench • 4mm allen socket bit and ratchet wrench • 15mm open-end wrench • Diagonal cutters • Flat-blade electrical screwdriver • Philips-head screwdriver Procedure Conditions: • Main bar feed power off. • Loading fingers in upper position. Step 1: Remove the cover off of the electrical junction box inside the coffin at the rear of the bar feed.

Step 2: With the 3mm allen wrench, remove the four screws that mount the junction box to the coffin. (Located down in the holes next to the cover screw holes).

Remove the brown wire in terminStep 3: al KA2-22 and the blue wire in terminal KA1-21.



Step 4: Lift up the junction box to get to the cable grip for the M3 cable. With the 15mm open-end wrench, loosen the cable grip. (It will be the 2nd one down on the right-hand column of cable grips).

Step 5: Once the cable grip is loose, extract the cable from the junction box.

r.

Step 7: With the ratchet wrench and 4mm allen socket, remove the two screws for the front rest motor mounting bracket.

Step 6: Loosen the thumb screws for the front rest cover and remove the cove



Step 8: With the 2.5mm allen wrench, loosen the setscrew for the motor drive gear.

Step 9: Remove the four bracket mounting screws from the bottom of the motor and take off the bracket.

le through the bar feed

tep 11: eed; attach the motor mounting bracket to the new motor.

Step 12: Attach the drive gear to the motor shaft. The gear should butt-up against the mounting bracket.

Step 10: Pull the motor and motor cable out of the bar feed. Take the replacement motor and route the cabexactly how the original was routed.

With the new motor routed through the bar fS



Step 13: Attach the motor bracket to the front rest. Make sure that the drive gear mesh’s with the ball screw gear.

Step 14: Place the front rest cover back on and tighten the thumb screws.

grip on the cable.

Step 16: Mount the junction box to the coffin.

Step 15: Insert the motor cable through the cable grip and tighten the cable



Step 17: Hook the brown wire up to terminal KA2-22 and the blue wire to terminal KA1-21.

Step 18: Put the junction box cover back on and tighten down.

rocedure complete.

P



Front Rest Override

Overriding the front rest can be used as a temporary solution if a problem should ever arise with calibration or misalignment. The front rest override parameter locks the front rest in the open position and allows the user to run any operation with the bar feeder until the problem can be corrected properly. However, there are disadvantages to running production with the front rest locked open. Excess vibration can occur during machining due to the absence of stabilization that the front rest would normally provide. Also, when loading a new bar, depending on how sturdy the bar stock is, there is a possibility of sagging or drooping between the end of the guiding channel and the back of the spindle. This creates a problem with transferring the bar from the bar feeder to the lathe because the front rest also aids in supporting and guiding the bar into the spindle. Disable Procedure Conditions: • The bar feeder must be in STOP mode. • The guiding channels must be open. Step 1: Press the MENU button on the remote station. Step 2: Press F4 (PAGE DOWN) function key to Parameters Related to Miscellaneous Functions. Press the F3 (ENTER) function

key on the remote station.

PARAMETER RELATEDTO MISCELLANEOUS

FUNCTIONS

-LANGUAGE-INCH/METRIC-FRONT REST OPERATION-DRY RUN-MAGAZINE ADJUSTMENT-HOME REFERENCING

Step 3: Press F4 (PAGE DOWN) function key to Front Rest Opening and Closing Control to Replace Rest Guiding Insert or Rest

Calibration (Service Only) menu. Press the F3 (ENTER) function key on the remote station.

FRONT REST OPENINGAND CLOSING

CONTROL TO REPLACEREST GUIDING INSERT

ORREST CALIBRATION(SERVICE ONLY)

Step 4: To override the front rest, press the F4 (PAGE DOWN) function key. The remote station should appear like the second

figure below and is should say that it is enabled. Press and hold the “X” until the front rest becomes disabled, as shown in the third figure.




THE FRONT ENABL

REST ISED

PRESS F3 TO DISABLE

THE FRONT REST ISDISABLED

PRESS F3 TO ENABLE



Note: After having completed Step 4, the front rest is now locked in the open position. The front rest will remain in the open position during any operation of the bar feeder until the override has been deactivated. The front rest is now disabled. Step 5: Press STOP to exit and return to the main menu. Enable Procedure Conditions: • The bar feeder must be in STOP mode. Step 1: Press the MENU button on the remote station. Step 2: Press F4 (PAGE DOWN) function key to Parameters Related to Miscellaneous Functions. Press the F3 (ENTER) function

key on the remote station.


FUNCTIONS


Step 3: Press F4 (PAGE DOWN) function key to Front Rest Opening and Closing Control to Replace Rest Guiding Insert or Rest

Calibration (Service Only). Press the F3 (ENTER) function key on the remote station.




Step 4: To deactivate the override, press the F4 (PAGE DOWN) function key. The remote station should appear like the second

figure below and is should say that it is disabled. Press and hold the “ ” until the front rest becomes enabled, as shown in the third figure.

FRONT REST OPENINGTHE FRONT REST IS

DISABLEDTHE FRONT REST IS

ENABLEDAND CLOSING

CONTROL TO REPLACE PRESS F3 TO ENABLE PRESS F3 TO DISABLEREST GUIDING INSERT

REST CALIBRATIONLY)

OR

(SERVICE ON

Note: After having completed Step 4, the front rest is no longer locked in the open position. The front rest is now enabled. Step 5: Press STOP to exit and return to the main menu. Procedure complete.



Hydraulic Pump Motor Replacement The purpose of this procedure is to replace the hydraulic pump motor.

Tools List: • 5mm allen wrench • 13mm open end wrench (or socket) • 7mm & 8mm nut driver • Philips-head screwdriver • Hydraulic jack and 2 (2”x4”s @ 12” long) Procedure Conditions: • Main bar feed power off. Step 1: Remove the oil pressure switch (SP2) and the pump motor cover.

Oil pressure switch (SP2)

Pump motor cover

Step 2: Disconnect the 3-legs going to the motor windings (wire #1-U1, #2-V1, and #3-W1) and ground wire.

Step 3: Loosen the hose clamp on the 90° fitting and disconnect the hydraulic hose.



Step 4: Place the 2”x4”s on the jack and set the jack underneath the hydraulic tank. Raise the jack, so that the hydraulic tank is

sitting on the 2”x4”s.

Step 5: Remove the four tank mounting screws.

rain the cables running into the tank that are strapped to the bottom of the coffin).

Step 7: Remove the four motor mounting bolts and remove the pump motor from the tank.

Step 6: Drop the tank down. (Be careful not to st

The two bolts in the back are not shown.



Step 8: Put the new pump motor in the tank and fasten with the four bolts.

The two bolts in the back are not visible.

Step 9: Raise the jack back up in place and mount the tank to the coffin with the four mounting bolts.

Step 10: Reattach the hydraulic hose and tighten the hose clamp.



Step 11: Hook up the M1 cable to the motor and put the motor cover back on. (Ground wire goes to the chassis of the motor, wire #1 goes to U1, wire #2 goes to V1, and wire #3 goes to W1).

Wire #1

Wire #2

Wire #3

Ground wire

Step 12: Hook up the SP2 cable to the oil pressure switch.

Procedure complete.



Reference Procedure This procedure is used for resetting the home position of the Hydrobar Express 220. Procedure Conditions: • Main bar feed power on • Air pressure set at 5 bar (75psi) • Main guiding channels open • No bar stock in the channel • Bar feed in STOP mode Step 1: At the HOME PAGE, press the MENU key on the remote control station.

THE CHANNEL IS OPEN

PRESS F1 TO SELECTMANUAL MODE

AND TO CONTINUEOPERATION

Step 2: Press the F4 (PAGE DOWN) key on the remote control station until Parameters Related to Miscellaneous Functions appears. Step 3: Press the F3 (ENTER) key on the remote control station to open this menu.


FUNCTIONS


Step 4: Press the F4 (PAGE DOWN) key on the remote control station until the “Request for Reference Point Settings” option appears.

REQUEST FORREFERENCE POINT

PRESS F3 KEY FOR2 SECONDS TO CONFIRM

ANDFOLLOW INSTRUCTIONS



Step 5: Press and hold the F3 (ENTER) key until the screen returns to the Home Page.

THE CHANNEL IS OPEN

PRESS F1 TO SELECTMANUAL MODE

AND TO CONTINUEOPERATION

Step 6: Press the F1 key on the remote control station for Manual Mode and a Positioning Error! will occur on the screen.

POSITIONING ERROR!

ENCODER LOST ITSREFERENCE POINT…

RESET REFERENCEPOINT (ZERO POINT)

Step 7: Press the F1 key on the remote control station to begin the self-referencing sequence.

REFERENCE POINTPOSITIONING

IN PROGRESS...

Sequence: The carrier flag retracts toward the home position. The PLC waits to detect the proximity switch-SQ7 (input I1.4) and the servo amplifier looks for the torque to build up after hitting the mechanical stop simultaneously.

Procedure complete.



Remnant Check Device (SQ5) Adjustment The purpose of this procedure is to adjust the SQ5 switch.

Tools List: • 5mm allen wrench • Small jewelers flat-blade screwdriver Procedure Conditions: • Guiding channel covers open. • Main bar feed power on. Step 1: Loosen the split collar so that the switch can be rotated by hand but not too loose so that the switch will fall down.

nnel, if it

tep 3: Rotate the switch until the red sensing beam is centered on the bar.

Split collar

Step 2: Place a piece of the smallest diameter bar available inside the channels. The bar should lie in the center of the chaappears to be off center the entire adjustment can be thrown off; move the bar to the center.

S

3mm bar stock

Red sensing beam



Step 4: The gain adjustment is found on the side of the switch. With the small screwdriver, turn the gain adjustment CCW until it will

no longer turn, this is the “zero” position. Now, slowly turn the gain adjustment CW until the bar is detected and continue with another ½ turn. (Detection is verified by a solid yellow LED found above the gain adjustment).

Note: With the beam centered on the bar and the yellow LED on, pull the bar out of the channel and place it on the loader rack; the yellow LED should turn off. Perform a bar load from the remote operators pendant and the beam should detect the bar once it has been dumped into the channel. Repeat this task a couple of times and make sure the sensing beam consistently detects the bar once it has settled.

Yellow LED

Gain adjustment

Step 5: Tighten the split collar and recheck the consistency of the beam detection to make sure the switch did not shift when tightening the split collar.

Procedure complete.


Setting Channel Lid Cam This procedure is used to set and adjust the channel lid cam Tools List: • 2mm hex key • 3mm hex key • 5mm 3/8 drive hex socket • 3/8 extention • 3/8 ratchet • Pry bar • 8mm t-handle or a large phillips screw driver Procedure Conditions: • Main bar feed power off • Main guiding channel open • No bar stock in channel Step 1: Remove the rear cover plate.

r

Step 2: Using a 2mm hex key, measure the ga

measure 2mm. If the gap is 3mm or gr

Gap shoumeasure 2

Step 3: Loosen the two 17mm hex bolts and s

You may need to raise the channel lids

Rear cove

p between the follower plate and the back of the guiding channel. The gap should eater, continue to the next step. If the gap is set correct, skip to step 5.

ld mm

l

lide the cam cylinder ove slightly in order to mov

s

Follower plate

Guiding channe

r towards the guiding channel until the 2mm gap is reached. e the cam cylinder.

p

Loosen bolt

2mm ga

r
Slide cam ove



Step 4: Tighten the 17mm hex bolts and recheck the setting.

Step 5: Using a 3mm hex key check the spacing between the end of the cam cylinder and the cam roller. The gap should measure

3mm. If the gap is not 3mm, continue to the next step. If the gap is set correct, skip to step 8.

Step 6: Loosen both split collars that lock the position of the cam. One is located by the first guiding channel by the front rest, and

the other split collar is located by the pusher support. Using a pry bar, shift the cam bar and cam to reached the 3mm setting.

Step 7: Once the setting is reached, retighten both split collars up against the nylon flanges to lock the cam bar in position. Step 8: Pull up on the air regulator knob and turn it counter clockwise to drop the air pressure to 0 (zero).

b

s

Gap should measure 2mm

Gap should measure 3mm

Cam roller

Split collar located by Split collar located by

the pusher support the 1st guiding channel

Kno

Tighten bolt

Cam cylinder


Step 9: Insert an 8mm t-handle in the gap between the air cylinder clevis and follower plate and pull in back forcing the channels to

close.

s

Step 10: Confirm that the bolt is lined up verticallids.

Step 11: Check to see if the channel lids are clos Step 12: To adjust the channel lids so that they a

lid so that it is in a closed position and r

Step 13: Confirm that the cam cylinder is still in i

Follower plate

Cylinder clevi

ly with the end of the linear rail. This is the reference position to set all of the channel

t

ed or ope

re closedetighten t

ts correct

Ver

Linear rail

n. If all channe

, loosen both she split collars.

s

position as in s

tically aligned

Bol

l lids are closed, skip to step 14.

plit collars on each channel lid section. Position the channel Repeat this step for the remaining open channel lids.

arSplit coll


tep 10.



Step 14: Pull up on the air regulator knob and turn it clockwise and set the air pressure to the sixth bar (90 psi). This will cause the

channels to open.

Step 15: Complete the Adjustment of the Pusher Su Step 16: Complete the Channel Lid Switches (SQ3 Step 17: Replace the rear cover plate.

Procedure complete.

Knob

pport Mechanism procedure.

& SQ4) Adjustment procedure.

Rear cover


Setting the Remnant Vise Alignment This procedure is used for setting the alignment of the remnant vise. Tools List: • 6mm allen socket and ratchet • 3mm hex key or T-handle • Unchamferred remnant that matches pusher collet Procedure Conditions: • Main guiding channel open • Preferred channel size installed: 14 – 21 mm Step 1: Loosen the two thumb screws located on the pusher support brackets.

s

Step 2: Remove the pusher support brackets

Step 3: Press STOP on the remote to clear a Step 4: Remove the YV7A and YV5 plugs fro

Thumb screw

HY

s

s

and place the pusher assembly directly into the pu

ny alarms.

m the valves.

A 5

Thumb screw

Pusher support bracket

sher channel.

Remove brackets

YV7
YV
DROBAR EXPRESS 220


HYDROBAR EXPRES

Step 5: Hold a remnant that matches the pusher collet size in front of the pusher collet and over the vise. While holding the remnant

in position, install the YV7A plug on the YV5 valve. This will cause the vise jaws to clamp up on the remnant. CAUTION: Be sure that your hands are clear from the vise blades.

t

Step 6: After the remnant is

Step 7: Loosen the hold-dow

remnant runs straigsame time to keep t

Step 8: Move the vise left to

Remnan

S 220

in place, check to

n bolts (one on eht with the top of thhe vise leveled.

right to align it so

YV7A plug onYV5 valve

5

see if the remnant runs straight

ach side of the vise) until there ise channel. Once the level is set

that the remnant is center with t

t

Center remwith col

YV

with the top of the channel.

light tension and adjust the set screws until the , only adjust both set screws on either side at the
Hold-down bolts
Set screws

he pusher collet.

Colle

nant let


Step 9: If the height needs to be adjusted, adjust all the set screws at the same increment so that the bar stays parallel with the

channel.

Adjust all set screws on both sides of the vise

Step 10: Once the correct height is maintained. Tighten the hold-down bolts.

Step 11: Verify the remnant alignment to the pu

Step 12: Remove YV7A plug from the YV5 valv

Hold-down bolts

sher collet and readjust if necessary.

t

e.

Colle

Center remnant with collet

A
Remove YV7



Step 13: Replace the YV7A and YV5 plugs back on the correct valve and tighten.

Step 14: Reinstall the pusher support brackets

Procedure complete.

A 5
YV7
and tighten them with the thumb

b

t

YV

screws.

r

Replace brackets on oth ends of the pushe

Tighten withhumb screws


Top Limiter Adjustment The purpose of this procedure is to adjust the top limiters.

Tools List: • 7mm combination wrench • .01 feeler gauge or a piece of shim • Business card or a small piece of paper Procedure Conditions: • Main guiding channel open • Magazine rack empty • Main bar feed power on Step 1: Confirm that the coder disc is at the referencing position (SQ2 at first hole and the pin in the down position). If the coder disc

is not in position, go to manual mode and press the bar out icon and press and hold the check mark or press the bar in icon.

Step 2: Press the yellow button on the

Step 3: Turn the main bar feed power o Step 4: Raise the top limiter by looseni

is raised.

SQ2 at first hole

Bar out icon Bar in icon

Pin in down position

YV7A valve to raise the bar dropping finders to set a reference point for the top limiters.

ff.

ng the orange handle and pulling up on the limiter. Tighten the orange handle once the limiter


YV7A

Orange handle




Step 5: Confirm that the diameter adjustment fingers are set even with the bar dropping fingers.

Diameter adjustment finger

Bar dropping finger

Step 6: Loosen the black handle and push down on the top limiter and tighten the black handle.

Step 7: Lay the business card or small piece of paper on the maga Step 8: Holding onto the top limiter, slowly drop the limiter down on

directly in line with the diameter adjustment finder.

Step 9: Loosen the two 7mm nuts on the top limiter.

e
Black handl
zin

th

Push down here

e ramp.

e ramp and paper. The back of the top limiter should be

two nutsLoosen the


Step 10: Slide the limiter so that it is even with the diameter adjustment finger and the bar dropping finger. Tighten the orange handle

once the top limiter is in place.

Step 11: Insert the feeler gauge or shim behind the top pin on the top limiter and tighten the top 7mm nut.

Step 12: Insert the feeler gauge or shim in front of the bottom pin on the top limiter and tighten the bottom 7mm nut.

Step 13: Loosen the orange handle and raise the limiter up. Remove the business card or piece of paper.

Orange handle




Step 14: Holding the top limiter, slowly drop the limiter down onto the ramp. Check to see if the contact is even. If the contact is not

even, repeat steps 6 – 14.

Step 15: Repeat the procedure on the remaining 7 limiters. Procedure Complete.

Chapter 4: Software Update/Restore 4-1

Chapter 4:

Software Update/Restore

ith the help of the latest technological innovations, it is possible to update new software and restore lost data through the use of Smart Media. Smart Media, which is mainly used in photography, has been integrated for use with the user-friendly remote control station. The Smart Media Card holds a backup program for the Hydrobar Express 220 if at anytime there has been a power failure or any error has occurred in the user program. In addition, it automatically backs up any application/interface parameters that have been set for the most recent application being ran. Following

a few systematic procedures is all it takes to be up and running with the most up to date software or restoring lost PLC programs and/or parameters.

W


4-2 Chapter 4: Software Update/Restore

To ensure that the right procedure is used to perform a Software Update or to restore software, check the display on the bar feed to determine its firmware version: 1.17a or 2.08. In order to check the version of the firmware, turn the main bar feed power off and then back on again. During the power up, the first screen will show the firmware version of the display.

Firmware v 1.17a Firmware v 2.08 Firmware v 2.08 (No card is present or the card is blank) If the display has firmware version 1.17a, proceed to page 4-3. If the display has firmware version 2.08, proceed to page 4-20.



PLC Fault Restore PLC Program From Memory Card to PLC – v1.17a This procedure is used due to a defective battery or a new PLC was installed. Procedure Step 1: Turn off the power to the bar feed. Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position. Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

Step 4: Once the 2 halves are separated insert the Smart Media card (solid back side facing up and chamfered edge away from

you) into the slot.

Black side

facing up Chamfered edge away from you



Step 5: Press and hold the menu button while turning on the bar feed. You may release the menu button when the following screen appears.

A a r t e c A G

K o n s o l e

K 8 3 1 D

P a s s w o r d

Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.) Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The run light indicator will turn off) Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 9: There are 4 menu choices on this screen, press the F3 key for PLC Fault.



Step 10: When the PLC fault screen appears (seen below) press the F3 key (ENTER).

Step 11: Press F3 (ENTER) on the first screen that displays to Restore PLC Program from Memory Card to PLC.

Step 12: The PLC program will now be saved from the memory card to the PLC. This may take several minutes.

Step 14: Turn off power to bar feeder. Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder. Procedure complete.

Step 13: Press F4 (OK).



PLC Fault Restore Bar Feeder Parameters from MMI to PLC – v1.17a Procedure Step 1: Turn off the power to the bar feed. Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position. Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.


you) into the slot.

Black side facing up

Chamfered edge away from you




Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

he run light indicator will turn off)

tep 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

tep 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP positioS n. (T

S




Step 10: Press F4 (PAGE DOWN) until Restore Bar Feeder Parameters from MMI to PLC screen is displayed. Press F3 (ENTER).

Step 11: The parameters will then be restored from the MMI to the PLC.


Step 13: Turn off power to bar feeder. Step 14: Move the RUN/STOP switch to RUN position. Step 15: Restore power to the bar feeder.

Procedure complete.



Software Update Restore Bar Feeder Parameters From MMI to PLC – v1.17a Procedure Step 1: Turn off the power to the bar feed. Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position. Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.


you) into the slot.






Step 6: Wait until the PLC run light indictor goes from a flashing to a solid state. (This may take a few seconds.)

n light indicator will turn off)

Step 8: A password is required at this point using the number buttons on the pendant enter 3; 1; 4; 1; 5.

Step 7: Once the light is in a solid state, flip the RUN/STOP switch to STOP position. (The

ru

Step 9: There are 4 menu choices on this screen, press the F2 key for Software Update.



Step 10: When you reach the Update PLC screen, press F3 (ENTER).

Step 11: Press F4 (PAGE DOWN) until you reach the screen to Restore Bar Feeder Parameters From MMI to PLC, and press F3 (ENTER).

Step 12: The bar feeder parameters will now be saved from the display to the PLC.


Turn off power to bar feeder. Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder.

Procedure complete.

Step 14:



Software Update Restore Display Data from Memory Card to MMI – v1.17a This procedure is used to update the PLC software. Procedure Step 1: Turn off the power to the bar feed. Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position. Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.


you) into the slot.

Black side

facing up Chamfered edge away from you



Step 10: When you reach the Update PLC screen, press F3 (ENTER).

Step 11: Press F3 to restore data from memory card to the display (text and icons).

Step 12: The registers will then be restored from the memory card to the display.

tep 13: Press F4 (OK). S

Step 14: Turn off power to bar feeder.



Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder.

re complete.

roceduP



Software Update Restore PLC Program from Memory Card to PLC – v1.17a

YOU WILL NEED TO RECORD YOUR PARAMETERS BEFORE PERFORMING THIS PROCEDURE. ram has been

d

Step 1: Turn off the power to the bar feed. Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position. Step 3: ws on the b a front half.

*The current parameter settings will not be saved. The parameters will need to be reprogrammed after the PLC progestored.r Proce ure

Remove the 9 scre ack of the pendant, and then carefully separate the b ck half from the


you) into the slot.





Step 5: Press and hold the menu button while turning on the bar feed.

rs. You may release the menu button when the following screen appea





the Update PLC screen, press F3 (ENTER).

Step 10: When you reach

Step 11: Press F4 (PAGE DOWN) until you reach the screen to Restore PLC Program from Memory Card to PLC, press F3

(ENTER).

Step 12: The PLC program will now be saved from the memory card to the PLC. This may take several minutes.




ff power to bar feeder.

position.

Procedure complete.

Step 14: Turn o Step 15: Move the RUN/STOP switch to RUN Step 16: Restore power to the bar feeder.



PLC Fault – v2.08

his procedure is used due to a defective battery or a new PLC was installed. Procedure Step 1: Turn off the power to the bar feed. Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position. Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

T


you) into the slot.





tep 10: When the PLC fault screen appearsS (seen below) press the F3 key (ENTER).

Step 11: The current parameter settings will be saved. The display will then restore the PLC program to the PLC and the parameters will then be restored to their previous settings.

Step 12: Press F4 (OK). Step 13: Turn off power to bar feeder Step 14: Move the RUN/STOP switch to RUN position. Step 15: Restore power to the bar feeder. Procedure complete.



Software Update – v2.08 T

his proce

Procedure Step 1: Turn off the power to the bar feed. Step 2: Make sure the RUN/STOP switch on the PLC is in the RUN position. Step 3: Remove the 9 screws on the back of the pendant, and then carefully separate the back half from the front half.

dure is used to update the PLC software.


you) into the slot.




Chapter 4: Software Update/Restore 4-25 Chapter 4: Software Update/Restore 4-25


Step 10: When you have reached the Update PLC screen press the F3 key (ENTER).

Step 11: The current parameter settings will be saved. The PLC program will then be updated and the parameters will then be

restored to their previous settings.

Step 12: Press F4 (OK). Step 13: Turn off power to bar feeder Step 14: Move the RUN/STOP switch to RUN position. Step 15: Restore power to the bar feeder. Procedure complete.


Chapter 5: Preventative Maintenance 5-1


Chapter 5: Preventative Maintenance

eriodic maintenance of the Hydrobar Express 220 bar feeding system can only serve to improve the operation and prolong its useful life. Following a few simple steps can be extremely helpful and takes relatively no time at all. The list of maintenance procedures has been broken down into four groups determined by the frequency with which each procedure should be followed, however, some items should be checked more often depending on the operating environment that the equipment is exposed. P

5-2 Chapter 5: Preventative Maintenance


Daily Maintenance Verify the Air Pressure The recommended setting for operation with optimum performance should be at a minimum pressure of 5 bar (75 psi.) and a maximum pressure of 6 bar (90 psi.).

Weekly Maintenance Verify that the Air Decanter is Empty The air-filtering device is equipped with and automatic drainage valve, but depending on how much water is in the pneumatic circuit of the building, the water that is recuperated can build up faster than it can be drained. Excess water in the air lines can cause pneumatic cylinders to become defective. The water causes the o-rings inside the cylinder to swell up and no longer function correctly.

Hydraulic Oil Level When checking the level of the hydraulic oil, allow the bar feed to set idle for at least one hour so that the oil inside the coffin has time to drain back into the tank. If the oil is not allowed this time to drain back into the tank, the tank may look low, and if the oil is added it may cause an overflow.

Monthly Maintenance

Cleaning of the bar feeder Wipe down the outside of the bar feeder with a cloth and any regular detergent, for cleaning the inside of the bar feed use a cloth or brush. However, do not use the detergents on any of the guiding channels or any other parts made of synthetic materials. The use of compressed air for cleaning is not advisable, because chips and other particles can become lodged in sensitive areas and can impede the proper operation of the bar feeder.

Hydraulics Check the cleanliness of the hydraulic oil. It is important to wipe down the bars (even briefly) before loading them on the magazine rack. The bar feed recirculates the oil; excessive dirt and metal chips can form a deposit at the base of the coffin which can slow the oil return. The metal chips can also become lodged in the hydraulic pump causing the pump to lock up and/or the pump motor to overheat.

Rotating sleeves In order to guarantee the correct operation of the bar feeder, the rotating sleeve must function perfectly. Although the construction of the sleeve is very sturdy and reliable, it is recommended to verify periodically that it rotates without friction. If a defect should be present, please contact your local agent. This is a wear item and it is recommended to keep spares on hand, refer to Recommended Spare Parts List pg. 6-2.

Drive chain Over time, it is possible that the tension of the drive chain may loosen up. To tighten the chain, refer to Chain Tension Adjustment pg. 3-58.

Chapter 5: Preventative Maintenance 5-3


Annual Maintenance Check the PLC battery The PLC backup battery saves the PLC program in case of any power failure. The battery used in the SAIA PCD2 is a non-rechargeable 3VDC Lithium/ CD2032 battery. Over time, the battery will slowly discharge and an alarm message will appear on the remote control station (Low PLC Battery pg. 1-22). The following chart shows the average life expectancy of the battery:

Use of Automation Avg Life

Expectancy: 25°C

Avg Life Expectancy:

55°C 100% off 0% on 3 years 6 months

0% off 100% on 5 years 4 years

30% off 70% on 4 years 1 year

Verify the alignment of the bar feeder Check alignment of bar feeder to lathe spindle to make sure neither have shifted.

Chapter 6: Spare Parts 6-1


Chapter 6: Spare Parts

Note: When ordering parts the following information will be needed to ensure better customer support:

• Bar feeder type

• Bar feeder Serial Number (found on the hydraulic tank next to the air regulator)

• Bar stock diameter

• Lathe type (make and model)

6-2 Chapter 6: Spare Parts


Recommended Spare Parts List

As an extended courtesy, a list of recommended spare parts has been compiled for the end user. The list consists of mechanical and electrical parts that over time may become faulty due to everyday wear on the item. For machines that are running production during multiple shifts or even 24/7, keeping an inventory of these spare parts can vastly minimize downtime. Keeping an inventory can also be very cost effective since shipping costs can escalate immensely, especially in cases where rush delivery is necessary.

Qty. Order # Part # Drawing # Description MECHANICAL

1 6E40-007 7mm rotating sleeve

1 6E40-010 10mm rotating sleeve

1 6E40-015

Refer to pg. 6-4 Guiding Channel Reference chart

15mm rotating sleeve

2 028.29.023-A 028.29.023-A Inserts for front rest

1 04B Chain master link

2 EA. 034.05.064-A 034.05.094-A

034.05.064-A 034.05.094-A Jaws for extracting device

ELECTRICAL 1 6S05-009.A 2 amp fuse

1 6S05-009.B 5 amp fuse

1 4.391 4.391 Proximity switch

1 4.772 4.772 Photo eye

1 6E30-001.A 6E30-001.A Servo amplifier battery When ordering parts, to ensure better customer support, please specify the following information; Type of bar feeder, bar feeder serial number, bar stock diameter, and lathe type (refer to Parts Order Form pg. 6-6)

Spindle Liners Ensure that the properly sized spindle liner has been installed (matches guiding channel size).

Ensure that the spindle liner is straight (check total run out).

Ensure that the liner is securely fastened.



Collet Reference Chart The Express 220 is able to run up to a 10mm gap between the guiding channel I.D. and the bar stock O.D. There is a set of collet adapters which comes with each set of guiding channels. These collet adapters are used so you can accomplish the full range of the channel set. See Express 220 Guiding Channel Reference chart.

LNS makes collets every tenth of a millimeter, from 2 millimeter I.D. to 20 millimeter I.D. The collet O.D. is based on your guiding channel I.D. The collet O.D must be at least 1 millimeter smaller than the guiding channel I.D. See chart below for collet part numbers.

Barstock Diameter Range (Round) Guiding Channel

Inside Diameter Collet Outside

Diameter Min. Max. *Part Number 8mm 7mm 2mm 5mm 632-007.xxxx

7mm 2mm 5mm 632-007.xxxx 11mm

10mm 4mm 8mm 632-010.xxxx

10mm 4mm 8mm 632-010.xxxx 14mm

12mm 6mm 10mm 632-012.xxxx

12mm 6mm 10mm 632-012.xxxx 17mm

16mm 10mm 14mm 632-016.xxxx 12mm 8mm 10mm 632-012.xxxx 16mm 10mm 14mm 632-016.xxxx 19mm

18mm 12mm 16mm 632-018.xxxx

16mm 11mm 14mm 632-016.xxxx 18mm 12mm 16mm 632-018.xxxx 21mm

20mm 14mm 18mm 632-020.xxxx

18mm 13mm 16mm 632-018.xxxx 20mm 14mm 18mm 632-020.xxxx 23mm

22mm 16mm 20mm 632-022.xxxx

*XXXX = BARSTOCK O.D. IN MILLIMETERS

PART NUMBER EXAMPLE METRIC CONVERSION

632 - 010.0635

632 = references an Express collet

010 = is the O.D. of the collet (10mm )

0635 = is the I.D. of the collet ( 6.35mm )

To convert Inches to Millimeters Multiply by 25.4

To convert Millimeters to Inches Divide by 25.4



A B

Guiding Channel Reference Chart

C D E F G Bar Stock Diameter

Guiding Channel

Size Part No.

Loading Flag Part No.

Pusher Flag # Part No.

Pusher Body

Part No.

Pusher Support Channel Part No.

Rotating Sleeve Part No.

Adapting Part

Part No.

Pusher Lifting

Fingers (2 per set)

Part No. 2mm-5mm

.0781"-.2031" 8mm

6E20-008

7mm 034-031-014 (LF) 034-031-024 (RF)

7mm 034-31-184

8mm 034-011-043.08

7mm 6E40-007 N/A 7mm

034-11-254.07

10/M5 6E32-010.0007 2mm-8mm

.0781"-.3125" 11mm

6E20-011

10mm 034-031-114 (LF) 034-031-124 (RF)

10mm 034-31-174

11mm 034-011-043.11 10/7

6E32-010.1008

10mm 034-11-254.10

12/7 6E32-012.1008 4mm-10mm

.1563"-.3906" 14mm

6E20-014

12mm 034-031-034 (LF) 034-031-044 (RF)

7-12mm 034-031-054 (LF)

034-031-064 (RF)

12mm 034-31-164

13mm 034-011-043.13

10-12mm 6E40-010

12/8 6E32-012-1210

12mm 034-11-254.12

16/7 6E32-016.1008

16/8 6E32-016.1214

7mm-14mm .2813"-.5469"

17mm 6E20-017

16mm 034-031-134 (LF) 034-031-144 (RF)

16mm 034-31-154

17mm 034-011-043.17

16/11 6E32-016.1614

16mm 034-11-254.16

18/M5 6E32-018.0007

18/7 6E32-018.1008

18/8 6E32-018.1214

9mm-16mm .3594"-.625"

19mm 6E20-019

18mm 034-031-154 (LF) 034-031-164 (RF)

18mm 034-31-144

19mm 034-011-043.19

18/11 6E32-018.1618

18mm 034-11-254.18

20/8 6E32-020.1214

20/11 6E32-020.1618

11mm-18mm .4375"-.6875"

21mm 6E20-021

20mm 034-031-174 (LF) 034-031-184 (RF)

20mm 034-31-124

21mm 034-011-043.21

20/14 6E32-020.2018

20mm 034-11-254.20

22/8 6E32-022.1214

22/11 6E32-022.1618

13mm-20mm .5156"-.7813"

23mm 6E20-023

22mm 034-031-094 (LF) 034-031-104 (RF)

16-22mm 034-031-074 (LF)

034-031-084 (RF)

22mm 034-31-104

23mm 034-011-043.23

16-22mm 6E40-015

22/14 6E32-022.2022

22mm 034-11-254.22



Parts Order Form

LNS America, Inc. Date:

P.O. # Phone #:

Bill to: Ship to:

Contact: Attn:

Ship via:

Model of Bar feeder: Serial # of Bar feeder:

Model of Lathe: Bar stock diameter:

Qty. Part # Description

Note: To place an order, this form should be photocopied, completed, and faxed to (513) 528-8320.

Please call (513) 528-5674 for price and availability of parts.



Electrical Box Components

Designation Part # Description A - Interface terminal blocks (X2)

AJ1 4.705 Mitsubishi servo amplifier C - Emergency Stop circuit (X3) D - LNS PCD2 (PLC) E - 24VDC terminal blocks (X1)

FU 1 4.416 Fused terminal / 2Amp for motor protection K1 4.507 Main contactor

KM1 4.507 Hydraulic pump motor contactor KA1 4.606 Relay: Motor “M3” close rest KA2 4.606 Relay: Motor “M3” open rest KA3 4.606 Relay: Loading finger diameter adjust. Motor “M4” KA4 4.606 M5 motor relay (2mm option)

QF1/2 4.138 Main circuit breaker (5A) QS1 4.242 Main disconnect switch QM1 4.503 Main circuit breaker

R1-R5 4.606 Interface relays T1 4.769 3 Amp Transformer T2 4.779 5 Amp, 24 VDC power supply

XS10-XS13 4.629 Connection terminal box

Chapter 6: Spare Parts Spare Parts 6-7


Chapter 6: 6-7


Chain Drive Assembly L/F

6-8 Chapter 6: Spare Parts Spare Parts


6-8 Chapter 6:


Chain Drive Assembly R/F



Servo Motor Assembly



6-10 Chapter 6:


Remnant Vise



Chapter 6: 6-11


Sensor Support Assembly



6-12 Chapter 6:


Channel Cam Cylinder Assembly L/F



Chapter 6: 6-13


Channel Cam Cylinder Assembly R/F



Hydraulic Pump Assembly



Chapter 6: 6-15


Coding Disc Assembly



Diameter Adjustment Motor Assembly



Air Regulator and Cable Passage Plate

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