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. Figure 1-1 Remote control station HYDROBAR EXPRESS 332...
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Closing guiding channel control switch Material presence control switch Control switch: mobile vise in forward position Control switch: pusher in rear/park position Front-rest opening monitor Front-rest gap adjuster SQ10 Retraction system in position switch SQ11 Main access cover safety switch HYDROBAR EXPRESS 332...
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.
Bit 0 = 1 control station to clear the message and reset the alarm. For case 1, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 3 = 0 Reset the E-stop push button on the lathe. For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 2 = 0 Reset the E-stop push button on the remote control station. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Flip the toggle switch on the PLC to the RUN position. 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. HYDROBAR EXPRESS 332...
Flip the toggle switch on the PLC to the RUN position. Replace the air pressure switch. For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 4 = 0 control station to clear the message and reset the alarm. For case 2, after the solutions have been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 1 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 7 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
10000000 For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 7 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 1 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 1 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Check the channel opening/closing cylinder functionality. Check the adjustment and functionality of the SQ3 switch. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Check the channel opening/closing cylinder functionality. Check the adjustment and functionality of the SQ4 switch. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 2 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
Bit 2 = 0 control station to clear the message and reset the alarm. For case 1, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
1 - 2 0 Chapter 1: Alarms 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. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
MODULE 1 Check the chain coupling device. Check to see if the chain is broken. 76543210 Bit 4 Check SQ6 switch. May be mis-adjusted or defective. Re-reference the bar feed. • Contact LNS America, Inc. for further information. HYDROBAR EXPRESS 332...
76543210 Bit 5 = 0 distance of 0.5mm-1mm from the measuring stop. 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. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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If the channel is open, and this input is not on, the SQ3 switch is 76543210 Bit 1 = 0 either mis-adjusted or defective. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
If the channel is open, and this input is not on, the SQ4 switch is 76543210 Bit 2 = 0 either mis-adjusted or defective. For case 2, after the solution has been completed, press the STOP key on the remote control station to clear the message and reset the alarm. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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). If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 332...
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). If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 332...
Verify that the CN3 connector is connected properly on the servo amplifier as well as on the PLC. • Verify the 24VDC supply for the PLC. Any voltage fluctuation can result in poor performance of the PLC. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 332...
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 SQ2 switch is adjusted to within 0.5mm-1mm from the decoder disc. • Check that the DC motor is operational. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 332...
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. •...
Turn the main power off to the Express 332 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. HYDROBAR EXPRESS 332...
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. If the problem persists please contact LNS America, Inc. for further information. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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 HYDROBAR EXPRESS 332...
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820mm. If remnant longer than 320mm position front of remnant about 12mm inside of remnant tray. Seq. 25 (Extraction Cycle) 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.) HYDROBAR EXPRESS 332...
Servo complete auto tuning. Amplifier manual Cyclic operation Position shift occurs Confirm the cumulative Pulse counting error, etc. command pulses, due to noise. cumulative feedback pulses and actual servo motor position. HYDROBAR EXPRESS 332...
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Absolute position counter warning AL.E6 Servo emergency stop warning AL.E9 Main circuit off warning Note: Deactivate the alarm about 30 minutes of cooling time after removing the cause of occurrence. 0: Pin-SG off (open) 1: Pin-SG on (short) HYDROBAR EXPRESS 332...
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2. Encoder fault Change the servo motor. and servo amplifier. 3. Encoder cable faulty Repair or change the cable. (wire breakage or short) 4. Wrong combination of servo Use correct combination. amplifier and servo motor HYDROBAR EXPRESS 332...
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Regenerative 6. Regenerative transistor faulty. transistor fault 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. HYDROBAR EXPRESS 332...
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Parameter setting 1. Servo amplifier fault caused the Change the servo amplifier. is wrong. parameter setting to be rewritten. 2. Regenerative brake option not Set parameter No.0 correctly. used with servo amplifier was selected in parameter No.0. HYDROBAR EXPRESS 332...
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Change the servo motor. 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. HYDROBAR EXPRESS 332...
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88888 Watchdog CPU, parts faulty Fault of parts in servo amplifier Change servo amplifier. Checking method Alarm (88888) occurs if power is switched on after disconnection of all cables but the control circuit power supply cables. HYDROBAR EXPRESS 332...
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EMG-SG is open. External emergency stop was made Ensure safety and emergency stop valid. (EMG-SG opened.) deactivate emergency stop. warning AL.E9 Main circuit off Servo was switched on Switch on main circuit warning with main circuit power power. off. HYDROBAR EXPRESS 332...
Chapter 2: Common Issues he Hydrobar Express 332 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.
Description: The Hydrobar Express 332 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.
A remnant too long to be dumped into the remnant pan has Remove the two bars from the channel and restart the been confirmed that it was removed without physically loading process. removed. Perhaps during a shift change. HYDROBAR EXPRESS 332...
Check the functionality of the SQ9 Front rest is not closing enough on the bar parameters. switch. stock SQ8 switch is mis-adjusted or Re-calibrate the front rest. Refer to defective. pg. 3-30 Calibration Procedure for Front rest is mis-calibrated. Front Rest. HYDROBAR EXPRESS 332...
Vibration Issues The term “vibration” is being used regarding the Hydrobar Express 332, 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.
Disconnect the telescopic tube from the lathe adapter. Lathe adapter Telescopic tube Figure 1-1 Figure 1-2 • Use a 4mm hex key to loosen the 2 bolts securing the clamp to the telescopic tube. Figure 1-3 Loosen bolts HYDROBAR EXPRESS 332...
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Remove the three 5mm bolts on the t-tube mounting ring (Figure 1-8) and remove it from the front mounting plate of the bar feed. (Be sure not to lose the 3 standoffs in the gasket (Figure 1-9)) Gasket Remove t-tube mounting Standoffs ring Figure 1-8 Figure 1-9 HYDROBAR EXPRESS 332...
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Remove the air blast ring and mounting bracket assembly by removing the 2 bolts located on the base of the mounting bracket. Remove mounting bracket Remove bolts Figure 3-1 Figure 3-2 Step 8: Remove the front 2 channels and channel adapter inserts. Remove channels Figure 4-1 HYDROBAR EXPRESS 332...
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(Figure 7-2). If there isn’t a front “L” bracket and the front plate was originally installed, use the original plate rather than the tooling supplied. The square front plate bolts must be left loose at this point for alignment. Remove “L” bracket Remove if equipped mounting bolts Figure 7-1 HYDROBAR EXPRESS 332...
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Figure 8-1 Figure 8-2 Tighten bolts Figure 8-3 Step 13: Confirm the front rest is open. Position the alignment bar so that it sticks out the front of the bar feed 4-6 inches. 4-6” Figure 9-1 HYDROBAR EXPRESS 332...
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Step 17: Loosen the 4 base plate mounting bolts out with an 8mm allen socket and ratchet approximately 1/8” so the rest can move freely for alignment. Loosen base plate mounting bolts Figure 13-1 Step 18: Slide the bushing into the front plate to support the bar. Figure 14-1 HYDROBAR EXPRESS 332...
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Confirm that the bushing is still in the front plate and the plate bolts are tight. Touch the Figure 16-1 set screws Figure 16-2 Step 21: Give all four 4mm set screws another ¼ turn down to preload. HYDROBAR EXPRESS 332...
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Step 25: If the bar feed is equipped with front “L” bracket continue to the next step, otherwise skip to step 25. Step 26: Remove front plate only if used for tooling by removing the four 5mm bolts. Remove front plate if used for tooling Figure 22-1 Figure 22-2 HYDROBAR EXPRESS 332...
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Step 31: Reinstall rubber front rest inserts with the four 5mm bolts (2 on each side). (This would be a good time to replace the rest inserts if worn severely and to do procedure to set front rest gap.) Reinstall rest Tighten inserts screws Figure 27-1 Figure 27-2 HYDROBAR EXPRESS 332...
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Loosely install the telescopic tube clamp onto the ring. Do not completely tighten the 3 mounting screws. Snug mounting screws Figure 29-2 • Insert the telescopic tube into the clamp. Be sure the back of the tube fits all the way back to the mounting ring. Figure 29-4 Figure 29-3 HYDROBAR EXPRESS 332...
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On the lathe adapter, make sure the nylon bushing is present if needed. Nylon bushing Figure 29-7 • Connect the telescopic tube to the lathe adapter. Figure 29-8 Figure 29-9 Step 34: Replace the front rest cover and any lathe safety covers that were removed. Procedure complete. HYDROBAR EXPRESS 332...
Step 36: Disconnect YV7A and YV5 valve pack connectors from their valves by unscrewing them. After unscrewing, pull the connectors off of the valves. Unscrew YV7A Remove Step 37: Remove the first guiding channel and adapter. Remove the first guiding channel and adapter HYDROBAR EXPRESS 332...
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Step 40: Place the vise tooling onto the vise. Center the jaws on the vise to the center of the tooling. Vise tooling “H” channel tooling (block) Step 41: BE CLEAR OF THE VISE. THIS STEP WILL CLAMP THE VISE JAWS. Connect the YV7A valve pack connector onto the YV5 valve. HYDROBAR EXPRESS 332...
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“H” channel and vise toolings are aligned properly. Once the desired height is reached, tighten all of the screws. Loosen all of the screws on the vertical base except the last screw on the right. Do NOT loosen this screw. HYDROBAR EXPRESS 332...
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2 screws on the right. Do NOT loosen these screws. Front screw Step 47: Once all of the screws are tightened, remove the YV7A valve pack connector from the YV5 valve. Remove Step 48: Remove the “H” channel and vise tooling. HYDROBAR EXPRESS 332...
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Chapter 3: Procedures 3 - 1 7 Step 49: Attach the YV7A and YV5 valve connectors back to their proper valves and screw to place. YV7A Step 50: Replace the guiding channel and adapter. Procedure complete. HYDROBAR EXPRESS 332...
Assemble the matching pusher assembly for the bar stock size. • Install the correct collet onto the pusher assembly. Insert pin • Confirm that the pusher channel adapter is attached to the pusher channel tightly by tightening the six 3mm screws. Pusher channel Pusher channel adapter HYDROBAR EXPRESS 332...
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Step 5: Confirm that part or all of the collet is exposed out of the end of the pusher channel. This will confirm that the pusher was assembled correctly and that the collet adapter is not missing, etc. HYDROBAR EXPRESS 332...
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Press F4 (ENTER) to proceed to the following screens. When the correct screens are displayed, enter in the new value and press F4 to enter the new value and press F4 again to move to the next screen. When all of the correct values are entered, press F1 to ESC. HYDROBAR EXPRESS 332...
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STOP key after the channel closes and before the collet is inserted onto the bar stock. At this point the bar stock will be clamped into the remnant vise and is now ready to align pusher to the bar stock position. Press STOP when this position is reached HYDROBAR EXPRESS 332...
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Step 15: Loosen the two 6mm bolts with a 5mm hex key on the front pusher channel support mounting bracket. This will allow the pusher channel to move freely for adjustment. HYDROBAR EXPRESS 332...
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Step 19: Recheck the collet alignment to the bar stock. If the alignment is still off, repeat steps 14 through 17. Step 20: Use a screw driver to push the chain backwards until it hits the mechanical stop by the servo drive motor. HYDROBAR EXPRESS 332...
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Step 23: Adjust the rear pusher support channel left or right so the flag is centered over the pins. Pins Flag Step 24: Once adjusted left to right, tighten the two 6mm bolts and lock nuts on the rear pusher support channel mounting bracket with a 5mm hex key and a 10mm open end wrench. HYDROBAR EXPRESS 332...
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If the channel comes down smooth with no popping sound and it is not contacting the pins, the channel is aligned correctly and skip to step 32. Press top Channel closed yellow button HYDROBAR EXPRESS 332...
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If the alignment is correct, continue on to the next step. If the alignment is still off, repeat the steps 20 through 31 depending if alignment is needed from front to back or from left to right. HYDROBAR EXPRESS 332...
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Step 35: Pull the chain forward again and recheck the alignment between the bar stock and collet. Step 36: Push down the vise mechanical stop and tighten in place so the vise has no movement. Tighten with a 4mm hex key and a 7mm open wrench. HYDROBAR EXPRESS 332...
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Step 39: Check to make sure that the remnant check cylinder tip is installed and tight. Remnant check cylinder (removed for clarity) Remnant check Remnant check cylinder tip cylinder tip HYDROBAR EXPRESS 332...
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Step 41: On the display, press STOP. Then press F1 to insert into manual mode and press F1 or F4 (depending on if the bar feed is a left front or a right front) to extract the bar stock. Left front Right front Procedure complete. HYDROBAR EXPRESS 332...
Remove the front rest cover. Step 2: Verify that the front rest inserts are not worn. Replace if needed. Rubber inserts Step 3: In the menu, enter in the current bar stock diameter loaded in the magazine rack. HYDROBAR EXPRESS 332...
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If this is not the case, then loosen the jam nut on the mechanical setting (see figure below) and adjust to proper setting (rotate CW if the rest is too tight or CCW if the rest is too loose). Make small 1/8 or 1/4 turn increments at a time. Mechanical setting HYDROBAR EXPRESS 332...
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Once adjusted properly, hold the mechanical setting securely with the 2.5mm hex key and tighten the jam nut. Open and close the front rest a few more times to confirm that the rest is consistent at closing to the correct setting. Step 10: Press STOP to exit menu. Procedure complete. HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
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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. HYDROBAR EXPRESS 332...
Attach the new upper limiter bracket to the split collar with the two 5mm bolts and cupped washers, but leave the bolts loose. Upper limiter bracket Split collar Step 3: Confirm that the bar diameter adjustment finger is flush against the mechanical home position (zero contact). Bar diameter adjustment finger Mechanical home position HYDROBAR EXPRESS 332...
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Tighten the black handled wing nut and check for a gap. If there is a gap, retighten against the stop. Black handled wing nut Bolt head Stop Step 7: Tighten the two 5mm bolts on the limiter mount. Tighten bolts on the limiter mount HYDROBAR EXPRESS 332...
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Step 10: Check again to make sure that the lower limiter is aligned with the magazine rack. Adjust if needed. Lower limiter Magazine rack Step 11: Once again, loosen the two 5mm bolts attaching the limiter mount to the split collar. Loosen HYDROBAR EXPRESS 332...
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Then tighten the orange handled wing nut. Step 15: Once the lower limiter bracket and the magazine rack are horizontally aligned using the tooling, tighten the two 5mm bolts for the limiter mount to the split collar. Tighten bolts on the limiter mount HYDROBAR EXPRESS 332...
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Step 19: Turn the main power of the bar feeder on. Step 20: The SWING-OUT UPPER LIMITERS parameter must be enabled. • Press MENU and then press F4 (PAGE DOWN) to the PARAMETERS RELATED TO SERVICE menu. HYDROBAR EXPRESS 332...
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Once in this menu, press F4 (PAGE DOWN) until the very last parameter, which is the SWING-OUT UPPER LIMITERS INSTALLED parameter. Press 2 to select YES. • Press STOP. Procedure complete. Follow this procedure for each of the upper limiter brackets. HYDROBAR EXPRESS 332...
Remove the four mounting bolts that hold the pump motor on. Step 2: Lift the pump motor out of the hydraulic tank. Step 3: Move the O-ring down 2-3 inches. Step 4: Snap the splash guard for the pump motor around the shaft of the pump. HYDROBAR EXPRESS 332...
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3 - 4 2 Chapter 3: Procedures Step 5: Place the motor back into the hydraulic tank and tighten down the four mounting bolts Procedure complete. HYDROBAR EXPRESS 332...
The purpose of this procedure is to reset the pusher and moveable vise into home position. Procedure Conditions: • Channels open • Bar stock extracted Step 1: Select REQUEST FOR REFERENCE POINT and follow the on screen instructions. Step 2: Pusher is in home position (vise disengaged). HYDROBAR EXPRESS 332...
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The vise will engage again and then reverse approximately 40mm. The vise will move forward in slow feed rate against the “H” channel and then it will return to a new bar load position. Procedure complete. HYDROBAR EXPRESS 332...
(F3) to close the rest. DO NOT PRESS STOP ON DISPLAY AFTER CLOSING REST. Close rest Step 3: Turn off the main power on the bar feed. Step 4: Remove the 4 screws on the small front junction box, and remove the cover. HYDROBAR EXPRESS 332...
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Note: DO NOT loosen the 6mm bolts that mount the base plate to the front rest box or tooling will be required to realign. Step 8: Remove the two 4mm motor bracket mounting screws and remove the motor. HYDROBAR EXPRESS 332...
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Step 11: Place the motor bracket onto the new motor and tighten the four 2.5 bolts. Be careful not to over tighten the bolts as they may strip in the plastic. Step 12: Reinstall the bevel gear. Set the face of the gear flush with the shaft end. Tighten the set screw securely. HYDROBAR EXPRESS 332...
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Step 15: Install the motor onto the modified spacer bracket with the two 4mm bolts. Step 16: Set the gear mesh so that there is a minimal amount of play, but not enough to cause and binding. HYDROBAR EXPRESS 332...
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Step 20: Pull the wires back through strain relief and reconnect the blue and brown wires to terminals 9 and 10 (M3). After tightening the wires, pull on them to confirm that they are securely tightened on the terminal block. Terminal 9 (blue) Terminal 10 (brown) HYDROBAR EXPRESS 332...
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Chapter 3: Procedures Step 21: Replace the cover onto the small front junction box and tighten the screws. Step 22: Turn on the main power to the bar feed. Step 23: Replace the front rest cover. Procedure complete. HYDROBAR EXPRESS 332...
Press the MENU key on the display. Step 2: Press F4 (PAGE DOWN) until the PARAMETERS RELATED TO POSITIONING screen is displayed and press F3 (ENTER). Step 3: On the first screen displayed, END OF BAR POSITION, press F3 (SET). HYDROBAR EXPRESS 332...
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Press and hold the F-key corresponding to the pusher forward icon until the pusher is ½” behind the main collet. Step 7: Once the desired position is reached, press and hold F3 (ENTER) to set the end of bar position. Step 8: Press F2 (ESC) to exit the menu. Procedure complete. HYDROBAR EXPRESS 332...
XS10 to the motor wires according to picture below. Blue – Red; Brown – Black. Step 6: Slide the heat shrink tubing over the two connectors so that the connectors are no longer exposed. HYDROBAR EXPRESS 332...
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3 - 5 4 Chapter 3: Procedures Step 7: Using the proper heating device, apply heat to the heat shrink tubing so that it shrinks to fit the connection. Procedure Complete. HYDROBAR EXPRESS 332...
Press F3 (ENTER) to enter into the Parameters Related to Positioning menu. Step 5: Press F4 (PAGE DOWN) until the Top Cut Position is displayed. Step 6: Press F3 (SET) to set or make changes to top cut position. HYDROBAR EXPRESS 332...
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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 top cut set mode, press F2 (ESC). By Teach In: Step 1: On a clear screen, press F1 (MANUAL MODE). HYDROBAR EXPRESS 332...
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Press F3 (ENTER) to enter into the Parameters Related to Positioning menu. Step 7: Press F4 (PAGE DOWN) until the Top Cut Position is displayed. Step 8: Press F3 (SET) to set or make changes to top cut position. HYDROBAR EXPRESS 332...
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The feeding pusher is now facing the bar. The moveable vise moves back and positions the material inside the collet of the bar feed system. Step 11: Press the F1 (FWD) key and advance the bar stock to the desired position. HYDROBAR EXPRESS 332...
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Chapter 3: Procedures 3 - 5 9 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 EXPRESS 332...
Push the locking paw down on the vise. Step 2: Push the vise forward by hand up to the guiding channel. Step 3: Remove the front rest cover. Unscrew the four screws located on the sides of the cover. HYDROBAR EXPRESS 332...
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Back the bolt out just far enough to set the tightness of the chain so that it just touches the nylon guide. This should give approximately a 1 ½” space between the chain and the bottom of the bar feed. Chain should just touch the nylon guide Approx. 1 ½” HYDROBAR EXPRESS 332...
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Step 10: Reinstall the front rest cover. Step 11: Close the main lid of the bar feed. Step 12: Turn the main power of the bar feed power on. Step 13: On the display, press F1 to enter into MANUAL mode. HYDROBAR EXPRESS 332...
Slide the rear pusher channel over so that orange head screws can slide through the slots on the pusher support and remove the pusher. Remove Step 3: Remove the five front guiding channels. Check to make sure that there are no chips or debris in the “H” channel. Remove Front guiding channels HYDROBAR EXPRESS 332...
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Collet Collet Adapter • If the collet can be threaded onto the collet adapter (Collet size 7mm OD), thread the collet onto the collet adapter using two 6mm wrenches to tighten. Collet adapter and rotating Collet sleeve HYDROBAR EXPRESS 332...
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Flag Insert pin • If the flag can be threaded on (flag size 7), thread the flag onto the end of the pusher tightly using a 6mm wrench to hold the pusher. Pusher Flag HYDROBAR EXPRESS 332...
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Install the correct pusher channel onto the bar feed. Once the pusher channel is locked into place, tighten the seven 4mm orange head screws. Be careful not to over tighten the screws. Slide pusher Lock into place channel over and tighten HYDROBAR EXPRESS 332...
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Press F3 (ENTER) on the first screen displayed, PARAMETERS RELATED TO APPLICATIONS. On the first screen, LOADING OF, enter in the number that corresponds with the shape of the bar stock being loaded. After entering in the number, press F4 (ENTER). HYDROBAR EXPRESS 332...
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Press F4 (ENTER) after entering in the guiding channel size. On the last screen, ENTER OVERALL PART LENGTH, enter in the length of the bar that must be fed for the next part to be machined. Press F4 (ENTER) to exit the menu. Procedure complete. HYDROBAR EXPRESS 332...
Smart Media. Smart Media, which is mainly used in photography, has been integrated for use with the r-friendly remote control station. The Smart Media Card holds a backup program for the Hydrobar Express 332 if at a nytime there has been a power failure or any error has occurred in the user program.
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. HYDROBAR EXPRESS 332...
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 Chamfered edge facing up away from you HYDROBAR EXPRESS 332...
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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. HYDROBAR EXPRESS 332...
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Step 12: The PLC program will now be saved from the memory card to the PLC. This may take several minutes. Step 13: Press F4 (OK). 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. HYDROBAR EXPRESS 332...
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 Chamfered edge facing up away from you HYDROBAR EXPRESS 332...
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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. HYDROBAR EXPRESS 332...
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Step 11: The parameters will then be restored from the MMI to the PLC. 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. HYDROBAR EXPRESS 332...
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 Chamfered edge facing up away from you HYDROBAR EXPRESS 332...
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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 F2 key for Software Update. HYDROBAR EXPRESS 332...
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Step 12: The bar feeder parameters will now be saved from the display to the PLC. Step 13: Press F4 (OK). 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. HYDROBAR EXPRESS 332...
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 Chamfered edge facing up away from you HYDROBAR EXPRESS 332...
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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 F2 key for Software Update. HYDROBAR EXPRESS 332...
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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. Step 13: Press F4 (OK). Step 14: Turn off power to bar feeder. HYDROBAR EXPRESS 332...
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Chapter 4: Software Update/Restore 4- 15 Step 15: Move the RUN/STOP switch to RUN position. Step 16: Restore power to the bar feeder. Procedure complete. HYDROBAR EXPRESS 332...
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 Chamfered edge facing up away from you HYDROBAR EXPRESS 332...
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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 F2 key for Software Update. HYDROBAR EXPRESS 332...
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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. HYDROBAR EXPRESS 332...
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Chapter 4: Software Update/Restore 4- 19 Step 13: Press F4 (OK). 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. HYDROBAR EXPRESS 332...
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 Chamfered edge facing up away from you HYDROBAR EXPRESS 332...
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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. HYDROBAR EXPRESS 332...
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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. HYDROBAR EXPRESS 332...
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 Chamfered edge facing up away from you HYDROBAR EXPRESS 332...
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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 F2 key for Software Update. HYDROBAR EXPRESS 332...
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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. HYDROBAR EXPRESS 332...
Maintenance erio dic maintenance of the Hydrobar Express 332 bar feeding system can only serve to improve the operation and prolong its u seful life. Following a few simple steps can be extremely helpful and takes relatively no time at all. The list of...
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. HYDROBAR EXPRESS 332...
Check alignment of bar feeder to lathe spindle to make sure neither have shifted. In case the bar feeder or lathe has shifted. After certain periods of time, the drive chain may need to be tightened, refer to Chain Tension Adjustment pg. 3-58. HYDROBAR EXPRESS 332...
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) HYDROBAR EXPRESS 332...
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. HYDROBAR EXPRESS 332...
Multiply by 25.4 632 = references an Express collet 010 = is the O.D. of the collet (10mm ) To convert Millimeters to Inches 0635 = is the I.D. of the collet ( 6.35mm ) Divide by 25.4 HYDROBAR EXPRESS 332...
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27 – 34mm Pusher Support Channel Orange Head Bolts Size 8-29mm use M5x7.5 bolts with adapter (6E21- *Collet determined by bar stock size 000). **LF – Left F ront Loader; RF – Right Front Size 30-37mm use M5x10 bolts. HYDROBAR EXPRESS 332...
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 or price and availability of parts. HYDROBAR EXPRESS 332...
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