LNS HYDROBAR SPRINT 555 Troubleshooting And Spare Parts Manual Download Page 89 | Manualshive

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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 PCD1 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. 2-2

). 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.

HYDROBAR

SPRINT

555

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Summary of Contents for HYDROBAR SPRINT 555

Page 1: ...513 528 5733 Service fax 513 528 8320 LNS America Inc USA 4621 East Tech Drive Cincinnati Ohio 45245 CNC CNC CNC SPRINT 555 SPRINT 555 SPRINT 555 TROUBLESHOOTING AND SPARE PARTS MANUAL TROUBLESHOOTING...

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Page 5: ...Loading 1 24 A048 Safety Time for Part Feed Out 1 25 A053 Lathe Did Not Resume Its Production Cycle 1 26 A054 Bar Remnant Too Long 1 27 A055 Guiding Channel Malfunction During Closing 1 28 A056 Guidi...

Page 6: ...o remnant retraction 6 3 Guiding Channel Performance Chart with remnant retraction 6 4 Parts Order Form 6 5 Electrical Box Components 6 6 Upper Guiding Channel Support double support 6 7 Lower Guiding...

Page 7: ...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...

Page 8: ...switch optical cell SQ 2 4 391 Guiding elements locked counting proximity switch SQ 3 4 790 Guiding elements open SQ 4 4 790 Guiding elements closed SQ 5 4 391 Feed pusher in home position control SQ...

Page 9: ...s 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...

Page 10: ...n Press the HELP key on the remote control station Press the F4 key Page Down icon three times Case Input Remote Pendant Solution 1 Bit 0 0 MODULE 2 76543210 0 Verify that the 2 16 connector is plugge...

Page 11: ...ed in Solution Press the HELP key on the remote control station Press the F4 Page Down icon three times Case Input Remote Pendant Solution 1 Bit 3 1 MODULE 2 76543210 1000 Alarm needs to be cleared Pr...

Page 12: ...n Solution Press the HELP key on the remote control station Press the F4 Page Down icon three times Case Input Remote Pendant Solution 1 Bit 2 1 MODULE 2 76543210 100 Alarm needs to be cleared Press t...

Page 13: ...not alarm out until the chuck is open Solution Press the HELP key on the remote control station Press the F4 key Page Down icon twice Case Input Remote Pendant Solution 1 Bit 2 1 MODULE 0 76543210 100...

Page 14: ...sure switch Solution Press the HELP key on the remote control station Press the F4 Page Down icon twice Case Input Remote Pendant Solution 1 Bit 1 1 MODULE 0 76543210 10 Alarm needs to be cleared Pres...

Page 15: ...ervice technician needs to perform any work inside the unit Solution Press the HELP key on the remote control station Press the F4 key Page Down icon twice Case Input Remote Pendant Solution 1 Bit 0 1...

Page 16: ...iner changeover Solution Press the HELP key on the remote control station Press the F4 key Page Down icon three times Case Input Remote Pendant Solution 1 Bit 1 1 MODULE 2 76543210 10 Put the bar feed...

Page 17: ...service technician needs to perform any work inside the unit Solution Press the HELP key on the remote control station Press the F4 key Page Down icon three times Case Input Remote Pendant Solution 1...

Page 18: ...om pinching anything in between the magazine protection grid Solution Press the HELP key on the remote control station Press the F4 key Page Down icon twice Case Input Remote Pendant Solution 1 Bit 7...

Page 19: ...o 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...

Page 20: ...A023 Description The Servo Drive Alarm occurs if the Mitsubishi servo amplifier generates an alarm Solution Turn the main power off to the Hydrobar Sprint 555 for 2 seconds and turn the power back on...

Page 21: ...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 am...

Page 22: ...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...

Page 23: ...m occurs if the voltage of the battery drops below the rated power that the absolute encoder inside the servo motor requires Solution Replace the battery inside the Servo amplifier refer to the proced...

Page 24: ...RVO AMPLIFIER FIRMWARE NOT COMPATIBLE WITH PLC REPLACE SERVO AMPLIFIER A028 Description The Servo Amplifier Firmware not Compatible with PLC alarm occurs during power up if the PLC does not recognize...

Page 25: ...E A041 Description The Bar Feeder in Simulation Cycle alarm occurs when the bar feed detects a bar in the guiding channel while operating in simulation mode Solution Exit the simulation operation if p...

Page 26: ...arm needs to be cleared Press the STOP key on the remote control station to clear the message and reset the alarm Check to see if there is a mechanical obstruction preventing the carrier flag from rea...

Page 27: ...ow much material has passed while the pusher is reversing If the calculation is equal to pusher length 0 the bar feed has determined that the remnant has not been brought back and this alarm is genera...

Page 28: ...ce 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 clamping device are aligned and...

Page 29: ...pleting The Feed Out alarm occurs if the input for the clamping device closed is detected before the value of the Input Overall Part Length parameter is reached Solution Verify that the clamping devic...

Page 30: ...7 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...

Page 31: ...PUT OVERALL PART LENGTH is not reached within 1 minute after the bar feed is commanded to feed out Solution Alarm needs to be cleared Press the STOP key on the remote control station to clear the mess...

Page 32: ...f the value set in INPUT OVERALL PART LENGTH is not reached within 1 minute after the bar feed is commanded to feed out Solution Alarm needs to be cleared Press the STOP key on the remote control stat...

Page 33: ...e remnant chute and will have to be removed of manually and 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...

Page 34: ...l station Press the F4 key Page Down icon twice Case Input Remote Pendant Solution 1 Bit 5 1 MODULE 0 76543210 100000 Check to see if a mechanical obstruction is preventing the channel from closing Ch...

Page 35: ...Press the F4 key Page Down icon twice Case Input Remote Pendant Solution 1 Bit 5 1 MODULE 0 76543210 100000 Alarm needs to be cleared Press the STOP key on the remote control station to clear the mess...

Page 36: ...channel tries to open Solution Press the HELP key on the remote control station Press the F4 key Page Down icon twice Case Input Remote Pendant Solution 1 Bit 5 1 MODULE 0 76543210 100000 The switch m...

Page 37: ...put Remote Pendant Solution 1 Bit 6 1 MODULE 1 76543210 1000000 Alarm needs to be cleared Press the STOP key on the remote control station to clear the message and reset the alarm 2 Bit 6 0 MODULE 1 7...

Page 38: ...ff after the channel opens Solution Press the HELP key Press F4 Page Down icon twice Case Input Remote Pendant Solution 1 Bit 6 1 MODULE 1 76543210 1000000 The switch may be sticking and needs to be r...

Page 39: ...efore the channel before the channel tries to close Solution Case Input Remote Pendant Solution 1 Bit 6 1 MODULE 1 76543210 1000000 The switch may be sticking and needs to be replaced 2 Bit 6 0 MODULE...

Page 40: ...t I1 5 SQ12 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 b...

Page 41: ...ile the collet of the lathe is open and the headstock reverses for regrip Solution Alarm needs to be cleared Press the STOP key on the remote control station to clear the message and reset the alarm C...

Page 42: ...ll hasn t inserted correctly this alarm is generated Solution Alarm needs to be cleared Press the STOP key on the remote control station to clear the message and reset the alarm Make sure that the col...

Page 43: ...scription 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...

Page 44: ...ng Error alarm occurs during the loading of a new bar sequence The chain magazine rack will index 12 times if input signal I2 5 SQ9 does not detect a bar this alarm is generated Solution Alarm needs t...

Page 45: ...of the new pusher does not correspond to a predetermined in the software length This is is generally due to the incorrect assembly of the pushing rod Solution Verify the assembly of the pusher to the...

Page 46: ...ding cycle the output for the M3 motor is active and input signal I2 4 SQ8 does not change states pulse on off after several seconds Solution Make sure that the SQ8 switch is adjusted to within a sens...

Page 47: ...a mechanical obstruction which may be keeping the dropping fingers from rising Check for a pinched air line going to the lifting cylinder 2 Bit 0 0 Bit 1 1 MODULE 1 76543210 10 Alarm needs to be clea...

Page 48: ...ote Pendant Solution 1 Bit 0 1 Bit 1 0 MODULE 1 76543210 1 Alarm needs to be cleared Press the STOP key on the remote control station to clear the message and reset the alarm 2 Bit 0 0 Bit 1 1 MODULE...

Page 49: ...p OK 11 Push forward behind clamping device If profiled material is selected parameter Loading Of Else Seq 12 12 Push forward to top cut position N A 13 Bar stock at top cut position Wait for clamping...

Page 50: ...e 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 i...

Page 51: ...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 A...

Page 52: ...ed 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 cau...

Page 53: ...n 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...

Page 54: ...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 Regenerat...

Page 55: ...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...

Page 56: ...he deviation counter exceeded the encoder resolution 10 pulse 8 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 correc...

Page 57: ...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 S...

Page 58: ......

Page 59: ...d 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...

Page 60: ...rring 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...

Page 61: ...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...

Page 62: ...ing sleeves being a wear item it can inhibit the bar feeder to run as efficiently as it was designed The determining factors indicating whether the rotating sleeve is showing signs of wear are usually...

Page 63: ...acted the collet will eventually lose its ability to grip the bar how it is designed to grip Inserting and extracting an unprepared bar can severely reduce the life expectancy of the collet The follow...

Page 64: ...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...

Page 65: ...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...

Page 66: ......

Page 67: ...aulty 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...

Page 68: ...e 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...

Page 69: ...Press the F3 ENTER function key on the remote station 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...

Page 70: ...INT in the PARAMETERS RELATED TO MISCELLANEOUS FUNCTIONS menu and follow the on screen instructions Step 2 Press the F1 button to select manual mode operation Step 3 Press the F1 button reference icon...

Page 71: ...onditions Main bar feed power on Air pressure set at 6 bar No bar stock in the guiding channel Bar feed in STOP mode Step 1 Press the MENU key on the display Step 2 Press F4 PAGE DOWN until the PARAME...

Page 72: ...ushing This position will give you the shortest remnant length Certain applications may require different settings Step 6 Press and hold the F key corresponding to the pusher forward icon until the pu...

Page 73: ...r stock in the magazine rack Clamping device of the lathe open Bar feed is in STOP mode By offset correction Step 1 Press the STOP key Step 2 Press the MENU key Step 3 Press F4 twice PAGE DOWN till th...

Page 74: ...on Step 8 Enter the correction value with the numerical keys Then press the F1 key to add the value or press the F4 key to subtract it The display will read the new top cut position Step 9 To exit the...

Page 75: ...5 Press F4 twice PAGE DOWN till the Parameters Related to Positioning is displayed Step 6 Press F3 ENTER to enter into the Parameters Related to Positioning menu Step 7 Press F4 PAGE DOWN until the T...

Page 76: ...r The bar is thus measured The movable vise continues its travel and positions the bar inside the spindle of the lathe The guiding channel closes The feeding pusher is now facing the bar The moveable...

Page 77: ...r 3 Procedures 3 11 Step 12 To validate the new top cut position keep F3 ENTER pressed until the ENTER icon disappears Step 13 To exit the set mode press the STOP key Procedure complete HYDROBAR SPRIN...

Page 78: ......

Page 79: ...emote control station The Smart Media Card holds a backup program for the Hydrobar Sprint 555 if at anytime there has been a power failure or any error has occurred in the user program In addition it...

Page 80: ...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 ha...

Page 81: ...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...

Page 82: ...meter 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...

Page 83: ...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 s...

Page 84: ...ght 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...

Page 85: ...rent 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...

Page 86: ......

Page 87: ...ful 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...

Page 88: ...ergent 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 compresse...

Page 89: ...lowly discharge and an alarm message will appear on the remote control station Low PLC Battery pg 2 2 The following chart shows the average life expectancy of the battery Use of Automation Avg Life Ex...

Page 90: ......

Page 91: ...hen 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 d...

Page 92: ...ting sleeve 1 6E40 025 015 015 814 015 015 814 25MM Rotating sleeve 1 0552 024 013 052 024 013 052 024 013 36MM Rotating sleeve ELECTRICAL 1 6 102 A 6 102 A N A R1 R5 Relay 1 4 391 4 391 N A SQ2 SQ5 S...

Page 93: ...Chapter 6 Spare Parts 6 3 Guiding Channel Performance Chart w o remnant retraction HYDROBAR SPRINT 555...

Page 94: ...6 4 Chapter 6 Spare Parts Guiding Channel Performance Chart with remnant retraction HYDROBAR SPRINT 555...

Page 95: ...one 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 complet...

Page 96: ...ments opening motor M4 relay KA3 4 606 Guiding elements locking motor M5 relay KA4 4 606 Guiding elements unlocking motor M5 relay KM1 4 507 Hydraulic pump motor M1 KM2 4 507 Magazine motor M3 going u...

Page 97: ...Chapter 6 Spare Parts 6 7 HYDROBAR SPRINT 555 Upper Guiding Channel Support double support...

Page 98: ...6 8 Chapter 6 Spare Parts HYDROBAR SPRINT 555 Lower Guiding Channel Support double support...

Page 99: ...Chapter 6 Spare Parts 6 9 HYDROBAR SPRINT 555 Lower Guiding Channel Support single support...

Page 100: ...6 10 Chapter 6 Spare Parts HYDROBAR SPRINT 555 Upper Guiding Channel Support single support w pusher locking tabs...

Page 101: ...Chapter 6 Spare Parts 6 11 HYDROBAR SPRINT 555 Upper Guiding Channel Support single support...

Page 102: ...6 12 Chapter 6 Spare Parts HYDROBAR SPRINT 555 Guiding Channel Locking Mechanism L F...

Page 103: ...Chapter 6 Spare Parts 6 13 HYDROBAR SPRINT 555 Upper Guiding Channel Locking Paw...

Page 104: ...6 14 Chapter 6 Spare Parts HYDROBAR SPRINT 555 Guiding Channel Actuator Shaft L F...

Page 105: ...Chapter 6 Spare Parts 6 15 HYDROBAR SPRINT 555 Guiding Channel Actuating Cylinder...

Page 106: ...6 16 Chapter 6 Spare Parts HYDROBAR SPRINT 555 Guiding Channel Actuator Shaft R F...

Page 107: ...Chapter 6 Spare Parts 6 17 HYDROBAR SPRINT 555 Cam Locking Mechanism Drive Motor...

Page 108: ...6 18 Chapter 6 Spare Parts HYDROBAR SPRINT 555 Outboard Support Sub Assembly...

Page 109: ...Chapter 6 Spare Parts 6 19 HYDROBAR SPRINT 555 Chain Magazine Rack...

Page 110: ...6 20 Chapter 6 Spare Parts HYDROBAR SPRINT 555 Pusher Locking Mechanism Sub Assembly...

Page 111: ...Chapter 6 Spare Parts 6 21 HYDROBAR SPRINT 555 Belt Drive Sub Assembly...

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