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BOSS 332-545-551 E
BOSS 332r-545r-551r E

MANUAL FOR USE AND MAINTENANCE

Rel.

Date

24/06/03

Cod.

346005400

S/N

COMPILER:

Ragazzini Gian Luca

ON APPROVAL:

Bevini Claudio

AUTOMATIC BAR FEEDER WITH

HYDRAULIC SUSPENSION

ATTACHMENTS LIST

MANUAL FOR USE AND MAINTENANCE

KEYBOARD INSTRUCTION MANUAL
SPARE PARTS BOOK
SCHEMATICS
EC CONFORMITY DECLARATION FOR MACHINE

Summary of Contents for BOSS 332-545-551 E

Page 1: ... 1 Date 24 06 03 Cod 346005400 S N COMPILER Ragazzini Gian Luca ON APPROVAL Bevini Claudio AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION ATTACHMENTS LIST MANUAL FOR USE AND MAINTENANCE KEYBOARD INSTRUCTION MANUAL SPARE PARTS BOOK SCHEMATICS EC CONFORMITY DECLARATION FOR MACHINE ...

Page 2: ...RER IEMCA division of IGMI S p A ADDRESS Via Granarolo 167 48018 Faenza RA ITALY Tel 0546 698000 Fax 0546 46338 0546 46224 TLX 550879 TYPE OF DOCUMENT MANUAL FOR USE AND MAINTENANCE PRODUCT AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION MODEL BOSS 332 545 551 E BOSS 332r 545r 551r E ...

Page 3: ...551 E volution 4 HANDLING AND INSTALLATION BOSS332 545 551 E volution 5 ADJUSTMENTS AND SETTING UP BOSS 332 545 551 E volution 6 USE AND OPERATION BOSS 332 545 551 E volution 7 BAR FEEDER MAINTENANCE BOSS 332 545 551 E volution 8 TROUBLES CAUSES CURES BOSS 332 545 551 E volution 9 PART REPLACEMENT BOSS332 545 551 E volution 10 LIST OF AFTER SALES CENTERS ...

Page 4: ......

Page 5: ...ERAL INFORMATION BOSS 332 545 551 E volution GB 1 Pag 1 4 INDEX 1 1 TERMS OF WARRANTY 2 1 2 MANUAL PURPOSE 3 1 3 MANUFACTURER AND BAR FEEDER IDENTIFICATION 4 1 4 TECHNICAL ASSISTANCE 4 1 5 ANNEXES ENCLOSED 4 ...

Page 6: ...feeder to lathe In particular before the first start up carry out an accurate check to make sure the bar feeder is correctly aligned with the lathe and fastened with the expansion plugs as shown in section 4 The product warranty is valid only if the bar loader is installed by an authorized technician with Original Installation Certificate Please ask the technician who will make the installation to...

Page 7: ... order to allow a quick search of contents consult the descriptive index Particularly important parts of this manual have been highlighted in bold type and preceded by the following symbols DANGER WARNING shows impending danger which might cause serious injuries exert the maximum caution CAUTION PRECAUTION indicates measures to be adopted to avoid accidents or damages to property INFORMATION techn...

Page 8: ...g diagram T Number of interface wiring diagram INFORMATION Always provide the Manufacturer with the above mentioned specifications when requesting information or ordering spare parts etc 1 4 TECHNICAL ASSISTANCE Whenever necessary please apply to one of the Technical Assistance Centres shown in the attached list INFORMATION when requesting technical assistance for the bar feeder always specify the...

Page 9: ...CATIONS 11 2 6 1 Noise levels 20 2 7 FITTINGS FOREWORD 21 2 7 1 Bush holder device Description 21 2 7 2 Axial displacement device Description 22 2 8 DEVICE FOR SLIDING HEADSTOCK LATHES FOREWORD 23 2 8 1 Bar headstock synchronizing device Description 23 2 8 2 Telescopic nose Description 24 2 9 DEVICES FOR CAM LATHES FOREWORD 25 2 9 1 Headstock return device Description 25 2 9 2 Cam box Description ...

Page 10: ... flow inside the channel creating a hydrodynamic support effect these characteristics allow the bar to rotate at a high r p m number with no vibrations and no surface damaging Thanks to the use of a BRUSHLESS and electronically controlled motor the bar speed thrust value and feeding position may be determined at any time during the working cycle Bar remnant ejection can be caused by bar pusher fee...

Page 11: ...olling bar insertion into the collet and subsequent bar remnant extraction It also drives the bar feeder parts controlling guide opening closing and bar selection H Clamps they hold the bar during bar introduction in and extraction from the bar pusher collet L Facing device it sends a signal at bar passage M Remnant collection box bar remnants are dropped into this box after extraction from the ba...

Page 12: ...elow The bar pusher A feeds bar B in the lathe by following lathe impulses until bar end The bar pusher A and remnant C are in their forwards limit stop position The bar pusher A and remnant C reach their backwards limit stop position The clamps D close and the bar pusher moves back the remnant is extracted from the collet The clamps open and the remnant is dropped into the box E ...

Page 13: ... inserted in the bar pusher collet the feeder stops otherwise it continues its cycle Upper guides H open together with bar pusher A the bar selection device F moves upwards thereby raising the first bar and withholding the remaining bars Bar G drips into the guide channel Bar selection device F is lowered The small pusher truck M starts its stroke ...

Page 14: ...d for bar pusher insertion The small pusher truck executes its return stroke The upper guides H are closed the bar pusher A is positioned along the spindle axis The clamps D close the bar pusher A moves forwards the bar G is inserted into the bar pusher collet The bar pusher A and bar G execute their facing stroke A new automatic work cycle is started ...

Page 15: ...ions are manual cycle when the guard is opened the feeder will be stopped if the guides are not closed when the guard is opened if the guide channels are closed the feeder functions are not disabled because no operator risks are present automatic cycle during the bar feeding phase guard opening may be necessary for the purpose of restocking the magazine Even if the feeder functions are not disable...

Page 16: ...ixed guard it prevents accidental access to the drive area G Fixed guard it prevents accidental access to the drive belt area H Remnant collection tank it also acts as a fixed guard to prevent accidental access to moving parts L Fixed guard it prevents accidental access to the bush holder device M Main switch cuts out the electric energy source during interventions in the electric switchboard and ...

Page 17: ... 2 Pag 9 26 2 4 SAFETY PLATES LOCATION AND DESCRIPTION A Danger of upper limb crushing B Caution Moving parts C Do not remove the safety barriers D Wear safety gloves and shoes E Caution Danger of electric contact F Warning fix the bar feeder to the ground ...

Page 18: ...5 VERSION DESCRIPTION Table 1 Maximum bar length Model Version Max length mm ft 21 2080 6 8 32 3200 10 5 37 3740 12 2 BOSS 332 BOSS 545 BOSS 551 44 4400 14 4 Table 2 Max bar pusher extension Model Version A Max extension mm N 937 L 1267 BOSS 332 BOSS 545 BOSS 551 LL 1597 ...

Page 19: ...6 2 6 TECHNICAL SPECIFICATIONS Without axial displacement device the minimum dimension can be reduced to 850 mm Table 3 Overall dimensions Model Version A mm B mm 21 2603 32 3802 1220 37 4342 1760 BOSS 332 BOSS 332r BOSS 545 BOSS 545r BOSS 551 BOSS 551r 44 5002 2420 ...

Page 20: ...ed Max 1000 mm sec Max 750 mm sec Adjustable return speed Max 1800 mm sec Max 1200 mm sec Remnant length standard version 400 mm Mod 21 295 mm 400 mm Remnant length oversize version 700 mm 700 mm Bar change over time with 3000 mm bar Version 32 30 sec 30 sec Input voltage 230 400 Volt 230 400 Volt Mains frequency 50 Hz 60 Hz 50 Hz 60 Hz Control voltage 24 Volt D C 24 Volt D C Installed power 2 kW ...

Page 21: ... axis height Model Upper screws position X mm Working axis height Y mm Max loading height Y 1 900 940 1090 2 935 975 1125 3 970 1010 1160 4 1005 1045 1195 5 1040 1080 1230 6 1075 1115 1265 7 1110 1150 1300 8 1145 1185 1335 9 1180 1220 1370 BOSS 332 BOSS 545 BOSS 551 10 1215 1255 1405 ...

Page 22: ...rs for any guide channel are only given as an example A barstock diameter approximately 10 mm smaller than the guide channel diameter may cause vibration and failure to the bar feeder Therefore it may be necessary to slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application CAUTION the collet outside diameter should ...

Page 23: ...x Largest tube diameter mm 10 5 8 10 13 12 5 10 12 15 5 13 15 17 16 5 14 16 18 5 16 18 19 5 17 19 21 20 5 18 20 23 8 21 23 26 25 8 23 25 25 8 23 25 28 27 8 25 27 30 8 27 30 31 8 28 31 33 32 8 29 32 32 8 29 32 36 35 8 32 35 38 37 8 34 37 40 10 37 40 43 42 10 39 42 42 10 39 42 46 45 10 42 45 BOSS 545 52 51 12 45 45 valid also for prepared bars or normal bars machined with front remnant ejection ...

Page 24: ...ow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application CAUTION the collet outside diameter should be at least 0 5 mm smaller than the bar pusher outside diameter INFORMATION The bar feeder is normally provided with a bar pusher with a diameter equal to the maximum barstock guide channel offered by the lathe Sometime...

Page 25: ...x Largest tube diameter mm 10 5 8 10 13 12 5 10 12 15 5 13 15 17 16 5 14 16 18 5 16 18 19 5 17 19 21 20 5 18 20 23 8 21 23 26 25 8 23 25 25 8 23 25 28 27 8 25 27 30 8 27 30 31 8 28 31 33 32 8 29 32 32 8 29 32 36 35 8 32 35 38 37 8 34 37 40 10 37 40 43 42 10 39 42 42 10 39 42 46 45 10 42 45 BOSS 551 52 51 12 47 51 valid also for prepared bars or normal bars machined with front remnant ejection ...

Page 26: ...ow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application CAUTION the collet outside diameter should be at least 0 5 mm smaller than the bar pusher outside diameter INFORMATION The bar feeder is normally provided with a bar pusher with a diameter equal to the maximum barstock guide channel offered by the lathe Sometime...

Page 27: ...olna 100 Fina Solna 150 IP IP Hermea 100 IP IP Hermea 150 Klüber Crucolan 100 Klüber Crucolan 150 Mobil Vectra Oil Heavy Mobil Vectra Oil Heavy Olio FIAT Daphne LPN 100 Olio FIAT Daphne LPN 150 Roloil Arm V 100 Roloil Arm V 150 Shell Vitrea 100 Tellus C 100 Shell Vitrea 150 Tellus C 150 Tamoil Industrial Oil 100 Tamoil Industrial Oil 150 Texaco Omnis 100 Texaco Omnis 150 Total Cortis 100 Azolla ZS...

Page 28: ...uide channel diameter spindle rotation speed suitable for the material to be machined as to the bar feeder use of oil having features suitable for the diameter of the bar to be machined all bar feeder panels must be closed Should the above mentioned conditions be met the noise level emitted during bar rotation into the guide channel measured in compliance with the international standards will be w...

Page 29: ...lf bushes A which are coupled to form a round channel with a diameter just slightly larger than that of the bar being machined In many cases this device can be used by only changing the diameter of the half bushes to greatly extend the range of diameters which can be machined without having to replace the guide channel Operation When the bar is dropped into the guide channel the two half bushes ar...

Page 30: ...device Description It allows the feeder to be moved away from the lathe to allow maintenance cleaning or any other servicing of the lathe Table 12 Overall dimensions Model Version A mm B mm 21 1880 800 32 3170 900 37 3770 900 BOSS 332 BOSS 332r BOSS 545 BOSS 545r BOSS 551 BOSS 551r 44 4370 900 ...

Page 31: ...g headstock lathes too To do this special devices are available which are listed and then described below 2 8 1 Bar headstock synchronizing device Description 2 8 2 Telescopic nose Description 2 8 1 Bar headstock synchronizing device Description It is used to connect the bar pusher and consequently the bar to the lathe headstock to obtain their synchronized forwards backwards movement ...

Page 32: ...2 Telescopic nose Description It is used to optimize bar guiding between the bush holder device and the lathe spindle Table 13 Max stroke and overall dimensions Model Max stroke A mm Overall dimensions B mm 200 270 210 270 230 300 280 430 BOSS 332 BOSS 545 BOSS 551 330 480 ...

Page 33: ...bed below 2 9 1 Headstock return device Description 2 9 2 Cam box Description 2 9 3 Camshaft release device Description 2 9 1 Headstock return device Description Necessary when the lathe headstock return spring size hinders feeder installation The original lathe spring A is then installed inside the feeder 2 9 2 Cam box Description Used to synchronize the feeder and cam lathe movements The cams lo...

Page 34: ...2 545 551 E volution 2 Pag 26 26 2 9 3 Camshaft release device Description Used to release and engage the camshaft during bar changeover A radial version and an axial version of this device are available A Axial version B Radial version ...

Page 35: ...RMATIONBOSS 332 545 551 E volution GB 3 Pag 1 4 INDEX 3 1 GENERAL SAFETY PRESCRIPTIONS 2 3 2 HANDLING AND INSTALLATION Safety 3 3 3 ADJUSTMENTS AND SETTING UP Safety 3 3 4 USE AND OPERATION Safety 4 3 5 BAR FEEDER MAINTENANCE Safety 4 ...

Page 36: ...nstructions in this manual is a guarantee of protection against injury The operator and skilled engineer must perform only their specified duties Do not tamper with the safety devices for any reason whatsoever Comply strictly with the work health and safety regulations issued by the relevant authorities in the country of installation of the machine IEMCA declines any liability whatsoever for injur...

Page 37: ...ar feeder adequate lighting and a clean working environment are of the utmost importance as far as personal safety is concerned The electric system connection must be made exclusively by skilled electricians Make sure the electrical system is connected to an efficient earth circuit by means of a dedicated wire 3 3 ADJUSTMENTS AND SETTING UP Safety Carry out the adjustments as described in the user...

Page 38: ...ention regulations in force in the country in which the machine is installed Inform maintenance personnel of all operating anomalies that come to your attention Before starting the bar feeder make sure that there are no personnel engaged in servicing or cleaning the machine 3 5 BAR FEEDER MAINTENANCE Safety Do not allow unauthorized persons to carry out maintenance Read this manual carefully befor...

Page 39: ...5 Levelling and alignment 12 4 4 6 Feeder fastening 16 4 4 7 Installation If the feeder 17 4 5 FEEDER WITH AXIAL DISPLACEMENT DEVICE INSTALLATION 18 4 5 1 Preliminary operations 18 4 5 2 Height Adjustment 18 4 5 3 Preliminary positioning 19 4 5 4 Sleeve Installation 19 4 5 5 Levelling and alignment 20 4 5 6 Feeder fastening 22 4 5 7 Telescopic nose Installation 22 4 6 DEVICE FOR SLIDING HEADSTOCK ...

Page 40: ...amshaft release device 26 4 8 LUBRICATING OIL FILLING 28 4 9 ELECTRIC CONNECTION 29 4 9 1 THREE PHASE POWER SUPPLY 29 4 9 2 SAFETY SIGNALS 29 4 9 2 1 EMERGENCY STOP 30 4 9 2 2 COVER SAFETY STOP WHEN PROVIDED 30 4 9 3 FUNCTION SIGNALS 30 4 10 PNEUMATIC CONNECTION 32 4 11 SOFTWARE PARAMETRING 32 ...

Page 41: ...d on a pallet and wrapped in protective film C WITH CRATE the feeder is placed in a crate wrapped in protective film 4 2 LIFTING DANGER WARNING handling and lifting operations should be carried out with suitable equipment see weight table in paragraph 2 6 by specially trained and experienced personnel According to the packaging choice lifting is carried out as shown in the next page ...

Page 42: ...266 M20 Use a hook type lifting device of suitable capacity LIFTING WITH PALLET Use a hook or fork type lifting device or of suitable capacity see information on packaging LIFTING WITH CRATE Use a hook or fork type lifting device of suitable capacity see information on packaging ATTENTION never use any different lifting system or device from the ones above ...

Page 43: ...d any handling equipment or transport vehicles travelling near the bar feeder The selected bar feeder setting should be suitably lit and provided with an electric power and air outlets During operation the feeder will release small amount of oil vapors Make sure that the premises where the feeder is installed are suitably ventilated The feeder has not been designed and built for use in an explosiv...

Page 44: ...ATION Before carrying out feeder installation check lathe stability make sure that it is firmly fastened to the ground and with a horizontal spindle axis 4 4 1 Support plates and feet Installation Position the feeder next to the lathe Keep it lifted and install the plates A and feet B in the positions shown in the figure ...

Page 45: ... Adjustment The feeder is normally factory preset to have a working axis height adjusted to lathe height However if feeder height needs adjustment proceed as follows tighten the lifting chains and remove the 16 screws A lift the feeder according to the required dimension X see table ...

Page 46: ...r screws position X mm Working axis height Y mm Max loading height Y 1 900 940 1090 2 935 975 1125 3 970 1010 1160 4 1005 1045 1195 5 1040 1080 1230 6 1075 1115 1265 7 1110 1150 1300 8 1145 1185 1335 9 1180 1220 1370 BOSS 332 BOSS 545 BOSS 551 10 1215 1255 1405 Tighten the A screws and remove the B eyebolts ...

Page 47: ...on A 1 Fixed headstock or steady rest lathe 2 Sliding headstock N C lathe 3 Sliding headstock cam lathe INFORMATION it is not always necessary to control the bar pusher all the way out In fixed headstock lathes its stroke can be reduced to 100 mm to allow the feeder to be brought as close as possible to the lathe contact IEMCA After sales Service for more information Table 3 Max bar pusher extensi...

Page 48: ...Pag 10 32 Roughly adjust the working axis height to obtain alignment with the lathe by turning the feet screws 4 4 4 Sleeve Installation BOSS 332 Install the sleeve A in the bush holder device Install the oil recovery device B Connect the drain pipe to the tank ...

Page 49: ... HANDLING AND INSTALLATION BOSS332 545 551 E volution GB 4 Pag 11 32 BOSS 545 BOSS 551 Install the sleeve A in the bush holder device Install the oil recovery device B Connect the drain pipe to the tank ...

Page 50: ...nt between the feeder and lathe is the most critical installation phase therefore this operation should be carried out by experienced personnel with the greatest accuracy CAUTION bad alignment can be the main cause of feeder malfunction and resulting damage PRELIMINARY PROCEDURE Open the upper guard Open rear guard A ...

Page 51: ... 545 551 E volution GB 4 Pag 13 32 LEVELLING Insert the templates in the specially provided holes in the beam Check levelling by positioning the level crosswise and lengthwise Carry out the required connections by turning the feet screws ...

Page 52: ...nd move the bar pusher to its backwards limit stop Move the crank to the guide opening screw shaft and open the upper guides To obtain alignment lead a ø 1 mm nylon thread between the lathe collet and the feeder rear plate then proceed as follows place a drilled bush A in the lathe collet stretch out the wire to the hole in the rear plate ...

Page 53: ...ce the bar in the guide and cause it to slide forwards and backwards in the spindle until almost reaching the lathe collet area POSITIONING ADJUSTMENTS After checking alignment of the feeder with either the thread or the bar any required corrections should be carried out Adjust height by turning the screws in the support feet carry out lateral adjustment with calibrated mallet blows on the sides o...

Page 54: ...ods A and lock with nuts B Perform another levelling and alignment check Remove all the equipment used for levelling and alignment and restore initial feeder conditions FASTENING TO THE LATHE Wherever possible the feeder should be fastened to the lathe through the suitable coupling unit according to lathe make and type The figure shows a general example of fastening contact IEMCA service departmen...

Page 55: ...ould not turn If it does a bearing or another similar device should be mounted to prevent telescopic nose turning after it has been installed Move the headstock to its all the way back position and measure the dimension L Take out the grub screw C compress the telescopic nose to its limit stop minus 5 mm and cut the pipe D to the measured dimension Move the headstock to its all the way forwards po...

Page 56: ...the stability make sure that it is firmly fastened to the ground and with a perfectly horizontal spindle axis 4 5 1 Preliminary operations Roughly position the feeder behind the lathe Screw out nuts A and screws B 4 5 2 Height Adjustment See paragraph 4 4 2 remember that the mentioned dimension X will not change when the feeder is equipped with an axial displacement device ...

Page 57: ...paragraph 4 4 3 Roughly adjust the working axis height to obtain alignment with the lathe by turning the feet screws Place four plates under the axial sliding frame in the positions shown in the figure and screw down the cone end grub screws A Check frame levelling crosswise and lengthwise adjust if required through the screws A Roughly restore working axis height and alignment with the lathe if r...

Page 58: ...ulting damage Preliminary procedure See paragraph 4 4 5 Levelling See paragraph 4 4 5 Alignment See paragraph 4 4 5 Positioning adjustment After checking alignment of the feeder with either the thread any required corrections should be carried out Adjust height by turning the screws in the support feet carry out lateral adjustment with calibrated mallet blows on the sides of frame A During this ph...

Page 59: ...ING AND INSTALLATION BOSS332 545 551 E volution GB 4 Pag 21 32 Position the remaining eight plates under the axial sliding frame in the positions indicated in the figure then tighten the cone end grub screws B ...

Page 60: ...l sliding frame with expansion plugs Perform a levelling and alignment check Tighten nuts A and screws B Perform another levelling and alignment check Remove all the equipment used for levelling and alignment and restore initial feeder conditions Fastening to the lathe See paragraph 4 4 6 4 5 7 Telescopic nose Installation See paragraph 4 4 7 ...

Page 61: ...upper guard INFORMATION the figure shows a general example of installation contact IEMCA service department for more information Screw out the screw A Install the bar B and tie rod C and make sure that the headstock D can run freely throughout its stroke together with shaft E Position the support F in such a way as not to hinder the headstock stroke and tighten the screw A ...

Page 62: ...s a general example of installation contact IEMCA service department for more information Remove the original headstock return unit from the lathe Loosen the screw A Install the bar B and tie rod C and make sure that the headstock D can run freely throughout its stroke together with shaft E Position the support F in such a way as not to hinder the headstock stroke and tighten the screw A ...

Page 63: ...l lathe spring G and adjust its tension through the ring nut H 4 7 2 Cam box INFORMATION the figure shows a general example of installation contact IEMCA service department for more information Install the sleeve A on the lathe camshaft B Connect the shaft C to the sleeve through the pin D ...

Page 64: ... 4 7 3 Camshaft release device INFORMATION the figures show a general example of installation contact IEMCA service department for more information Radial version Mount the articulation A in the flange B Mount the joint C in the articulation D and in the lathe control E ...

Page 65: ...GB 4 Pag 27 32 Axial version Cut a hole and thread in the lathe casing to fix the transmission unit F and mount the disk G in the control H Insert the shaft L in the joint M and lock with a pin insert the other end of shaft L in joint N and lock with a pin ...

Page 66: ...rsion Loosen the screws move the slides Q retighten the screws P 4 8 LUBRICATING OIL FILLING CAUTION wear personal protections according to the regulations in force Open the rear base door and pour oil into the machine Check the level by means of the A indicator Table 4 Guide lubricating oil characteristics Model Oil type Quantity l BOSS 332 Classe C CKB 100 57 BOSS 545 551 Classe C CKB 150 57 See...

Page 67: ... one ore more multiple plugs to plug into the special lathe outlets The interface signals are wired to these outlets and can be classified into three types Three phase power supply Safety signals Function signals 4 9 1 THREE PHASE POWER SUPPLY The bar feeder must be provided with three phase voltage and with a suitable earthing connection The three phase supply line should also be protected by mea...

Page 68: ...ar feeder informs the lahte that the covers are closed all lathe operations as well as indexing are now allowed Whenever one of bar feeder covers is open the signals are stopped in this case all dangerous operations on the lathe i e on multispindle machines spindle drum indexing must be stopped immediately in agreement with safety class 3 As soon as the contacts are closed the lathe operation can ...

Page 69: ...ar feeder to lathe The signals that have been implemented are the result of our long experience and allow the application of the bar feeder on every lathe type it is therefore possible that some of them are not used IMPORTANT for any other information you may need please refer to the interface wiring plan or contact us our Customer Service and Engineering Department are always at your disposal ...

Page 70: ...as shown in the figure after connecting a three way valve to adjust and release pressure With knob E adjust the pressure at 6 bar Check air lubrication 1 12 drops per 1000 l of air adjust by turning the screw F IMPORTANT Air must be filtered 4 11 SOFTWARE PARAMETRING There should be an adequate parametring of the bar feeder software according to the working needs and to the type of lathe To obtain...

Page 71: ...5 2 GENERAL ADJUSTMENTS FOREWORD 3 5 2 1 Feeding chain Adjustment 3 5 2 2 Setting the pressure switch 3 5 3 SET UP ACCORDING TO THE BAR TO BE MACHINED 4 5 3 1 Guides half bushes bar pusher and collet Replacement 11 5 3 2 Clamps Replacement 25 5 3 3 Bar guide plates and bar selectors Adjustment 27 5 4 CAM BOX TIMING 30 ...

Page 72: ...uested in the manual In addition to normal adjustments throughout its service life this bar feeder also needs set up according to the type of operation According to bar size and type of machining setting up may also include replacement of a few components These operations are listed and then described below 5 2 General adjustments Foreword 5 3 Set up according to the bar to be machined 5 4 Cam box...

Page 73: ...on of bar feeder chain tension has to be checked If bush B of chain tension is still fast against rear plate then no chain extension took place If on the contrary bush B moved away of 1 2 mm from rear plate then a chain extension took place which is harmful for a trouble free operation of bar feeder So it is necessary to tighten screw A as long as bush B is clamped fast to end plate 5 2 2 Setting ...

Page 74: ...O BE MACHINED According to the new bar diameter a few or several operations must be carried out based on the diameter of the previously machined bar The table shows the available guide diameters with the corresponding range of bar pushers to be mounted and the range of diameters of the bars to be machined ...

Page 75: ...ters for any guide channel are only given as an example A barstock diameter approximately 10 mm smaller than the guide channel diameter may cause vibration and failure to the bar feeder Therefore it may be necessary to slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application CAUTION the collet outside diameter shoul...

Page 76: ...Max Largest tube diameter mm 10 5 8 10 13 12 5 10 12 15 5 13 15 17 16 5 14 16 18 5 16 18 19 5 17 19 21 20 5 18 20 23 8 21 23 26 25 8 23 25 25 8 23 25 28 27 8 25 27 30 8 27 30 31 8 28 31 33 32 8 29 32 32 8 29 32 36 35 8 32 35 38 37 8 34 37 40 10 37 40 43 42 10 39 42 42 10 39 42 46 45 10 42 45 BOSS 545 52 51 12 45 45 valid also for prepared bars or normal bars machined with front remnant ejection ...

Page 77: ...slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application CAUTION the collet outside diameter should be at least 0 5 mm smaller than the bar pusher outside diameter INFORMATION The bar feeder is normally provided with a bar pusher with a diameter equal to the maximum barstock guide channel offered by the lathe Someti...

Page 78: ...Max Largest tube diameter mm 10 5 8 10 13 12 5 10 12 15 5 13 15 17 16 5 14 16 18 5 16 18 19 5 17 19 21 20 5 18 20 23 8 21 23 26 25 8 23 25 25 8 23 25 28 27 8 25 27 30 8 27 30 31 8 28 31 33 32 8 29 32 32 8 29 32 36 35 8 32 35 38 37 8 34 37 40 10 37 40 43 42 10 39 42 42 10 39 42 46 45 10 42 45 BOSS 551 52 51 12 47 51 valid also for prepared bars or normal bars machined with front remnant ejection ...

Page 79: ...slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application CAUTION the collet outside diameter should be at least 0 5 mm smaller than the bar pusher outside diameter INFORMATION The bar feeder is normally provided with a bar pusher with a diameter equal to the maximum barstock guide channel offered by the lathe Someti...

Page 80: ...lf bushes bar pusher and bar pusher collet must be replaced and the magazine and clamps must be adjusted Example 3 The previous machining cycle had been carried out under these conditions Guide diameter mm Bar pusher diameter mm Bar diameter mm 17 15 8 The new machining cycle requires feeding of 25 mm bars In this case the guides half bushes bar pusher and bar pusher collet must be replaced and th...

Page 81: ...uction clamps unit you can move the bar pusher from the keyboard in manual mode with the guard open and the guides closed Close the upper guard On the keyboard press the blue buttons and the guides opening button simultaneously now open the feeder guides Open the upper guard Remove the feeding motor protection so that you can fit the crank Use the crank to bring the bar pusher to its backwards lim...

Page 82: ...E volution 5 Pag 12 33 Move the small pusher truck forwards until the flag reaches the opening then remove the truck from its seat Disassemble the lower guides Proceed disassembling the upper guides 1 Fastening screw version 2 Quick fastening version ...

Page 83: ...5 ADJUSTMENTS AND SETTING UP BOSS 332 545 551 E volution GB 5 Pag 13 33 Remove the bar pusher support A Guides with Ø 13 46 B Guide with Ø 52 1 Support 2 Spacer ...

Page 84: ...ion 5 Pag 14 33 Remove the nose in the following way Fixed nose Remove the oil recovery device A and nose B Telescopic nose Remove the nose C Remove the front half bushes in the following way BOSS 332 Remove the cover and manually extract the two half bushes ...

Page 85: ...open the two half bushes by manually turning the shaft A and extract the lower bush Close the remaining half bush by working the shaft A again and extract it For BOSS 332 only Remove the internal sleeve If necessary remove the lathe spindle liner and install another one suitable for the diameter of the guides ...

Page 86: ...s suitable for the bar in the following way BOSS 332 Insert the two half bushes and place the cover BOSS 545 551 Insert the upper half bush turn the shaft A and insert the lower half bush Fully close the half bushes and place the cover For BOSS 332 only Install a nose suitable for the guide channel ...

Page 87: ... only a few components supplied as a spare part kit need to be changed Compress the intermediate stage to the end of its stroke and remove the ring C Extract the bush D the spring E the bush F the spring G and the sleeve H Remove the ring L replace the bushing M with another one suitable for the bar and replace the ring L Replace the nose H the spring G the bushing F the spring E and the bushing D...

Page 88: ...Pag 18 33 Place the sleeve back into its seat For BOSS 332 only If the new guide diameter is 13 mm the intermediate flag should be changed as follows Remove the two rings A the spring B and the flag Mount the 13 mm guide flag then replace the spring and two rings ...

Page 89: ...e that the lower guide screws have an oil inlet hole Choose the right collet for the bar refer to the manual GUIDE CHANNELS BAR PUSHERS REVOLVING TIPS COLLETS Selection manual INFORMATION contact IEMCA After Sales service for more information Legend 1 IEMCA collet for pipes 2 IEMCA collet for bars 3 IEMCA collet for machined bars with remnant front ejection 4 SCHLENKER collet for bars 5 Ring 6 Col...

Page 90: ...USTMENTS AND SETTING UP BOSS 332 545 551 E volution 5 Pag 20 33 CAUTION PRECAUTION At every collet change modell 381p 381p 011 381p 021 e 386p it is necessary to install the grub screw H and the counter screw L ...

Page 91: ...ter Install the collet in the bar pusher and make sure that the rings are riveted in their special recesses to prevent accidental collet unscrewing from its connection INFORMATION The picture shows a generic example of collet assembly Install a suitable bar pusher support in relation to the diameter of the bar pusher A Guides with Ø 13 46 B Guide with Ø 52 1 Support 2 Spacer ...

Page 92: ...ING UP BOSS 332 545 551 E volution 5 Pag 22 33 Install the 1st feeding carriage into its seat Bring the 1st feeding carriage to its backward stroke limit and fit the bar pusher Move the bar pusher forwards past the clamps area ...

Page 93: ...ing button simultaneously now close the guides Bring the bar pusher to its backward limit stop by means of the keyboard The upper surface of the intermediate flag must be flush with the lower guides proceed as follows to obtain adjustment Open the guides by means of the keypad pressing the two blue buttons and the guides opening button simultaneously ...

Page 94: ...E volution 5 Pag 24 33 Open the guard and proceed as follows Loose the screw adjust the flag position and tighten the screw Close the upper guides Move the bar pusher forwards and backwards in the flag area to make sure that its stroke is not hindered ...

Page 95: ...y machined bars e g when changing over from round bars to square or hexagonal bars Contact IEMCA after sales service for more information Proceed as follows to replace the clamps With the feeder powered off and the compressed air supply disconnected close the clamps manually Open the upper guides Manually lift the lower lever and replace the clamp Remove the intermediate flag if necessary see para...

Page 96: ...GB 5 ADJUSTMENTS AND SETTING UP BOSS 332 545 551 E volution 5 Pag 26 33 Unscrew screws A and change the clamp Restore the initial conditions of the bar feeder ...

Page 97: ... 33 5 3 3 Bar guide plates and bar selectors Adjustment Preliminary procedure Open the upper guard Close the upper guides sensor A must be energized Make sure that the bar selectors are lower than the magazine surface Prepare two bar remnants having a length of 1200 mm ...

Page 98: ...ghten the handle A repeat this operation on all the plates Feed two bars to the magazine loosen the handle A and drop the plates which will stop against the bars If the bars are round or hexagonal make sure that a little clearance is left between the plate and the bars The clearance must be 3 8 mm for square bars Tighten the screws A on all plates ...

Page 99: ... selectors Make the adjustment as follows Use screw B to adjust the transverse position of bar stop A so that selectors C lift just one bar Open the upper guides the first bar must be dropped into the guides while the second bar should be retained in the magazine until the next bar closure ...

Page 100: ... opening In addition it also controls operation of the bar headstock synchronizing device S91 Bar change over enabling It signals lathe collet opening closing to the feeder It determines the camshaft stop position at bar end S92 Feed stop enabling Only used in sliding headstock lathes It disables the feeding thrust during any operations requiring headstock return with a closed collet S99 Camshaft ...

Page 101: ...YCLE PHASE HEADSTOCK PHASE COLLET LATHE FEEDER CAM COMPLETE CYCLE PHASE MICROSWITCH S90 PHASE MICROSWITCH S91 PHASE MICROSWITCH S92 A STROKE G CLOSED B FEED H OPEN C FORWARD STOP L CLOSED D RETURN M DISABLED E BACKWARD STOP N ENABLED F HEADSTOCK RETURN WITH CLOSED COLLET IF REQUIRED FOR SPECIAL OPERATIONS ...

Page 102: ...B is released Turn shaft A until the collet opens Turn S91 microswitch cam to release the wheel Rotate shaft A until the collet closes Turn the cam to lift S91 microswitch cam Rotate shaft A of 10 approx then lift S90 microswitch wheel INFORMATION S90 and S91 microswitch wheels must lower when the headstock is in a forward position and lift when the headstock is backwards in any case before the fo...

Page 103: ...s return stroke lower S99 microswitch wheel and lift it before the stroke is over Should microswitch S99 be fitted on lathe setting adjustments are to be performed on lathe cam GENERAL REMARKS Microswitch activation can be either delayed or advanced through screw C Whenever servicing the camshaft disconnect the cam box according to the following procedure loosen clamp D and unscrew sleeve E servic...

Page 104: ...IC CYCLE START 11 6 5 1 Bar magazine Filling 12 6 5 2 Lubrication oil Flow adjustment 13 6 5 3 Automatic cycle start 14 6 5 4 Guide channel opening closing procedure 15 6 5 5 Cycle actuation mode in the STEP BY STEP function 16 6 6 FEEDER STOP 16 6 7 AUTOMATIC CYCLE START AFTER MANUAL CYCLE OPERATIONS 17 6 8 AUTOMATIC CYCLE START RESUMING WORK AFTER POWER OFF 17 6 9 MACHINING CHANGE QUICK GUIDE 18...

Page 105: ...rd it is possible to start automatically the bar feeder even when lathe MAN AUT signal is in Manual mode INFORMATION When Automatic mode is on the bar feeding is possible only when lathe MAN AUT signal is in Automatic mode INFORMATION Pressing Manual mode button it is possible to prevent the bar feeder automatic start by the lathe ...

Page 106: ...the half bushing will open During the Automatic mode if pushed the half bushings will open and close according to the selected sequence If pressed again the half bushings will remain open during the entire operating cycle 4 BAR FEEDER STOP BUTTON red to stop the bar feeder and to reset Errors 5 EMERGENCY STOP BUTTON this button stops the bar feeder in an emergency situation To restart first you mu...

Page 107: ... mode 7 Selects the semi automatic mode Push to select press again to unselect 8 Multifunction Selects the previous parameter Moves the cursor towards the left 9 Starts step by step movement of an operation cycle every push of the key initiates a step in the cycle 10 Multifunction Sets the font Starts and turns off the oil pump Push to start the pump and push again to turn it off 11 Multifunction ...

Page 108: ...s the bar pusher to a low speed 20 Multifunction Number setting Resets the BAR FEEDER ZERO SETTING of the carriage Hold down the two start buttons and then the key release the two buttons and the key when the carriage starts moving towards the BAR FEEDER ZERO SETTING 21 Multifunction Number setting Closes the guide channels Push the two start buttons and then the key release the two buttons and th...

Page 109: ...ne cover is open BLINKING GREEN LIGHT it indicates that the bar feeder is in the automatic mode BLINKING RED LIGHT signals that the bar feeder is not operating or that it is in the manual mode OPTIONAL BLINKING BLUE LIGHT signals that the bar feeder is carrying out the bar change FIXED BLUE LIGHT signals that the PLC battery is exhausted OPTIONAL ...

Page 110: ... not feed bars having different sizes than the manufacturer s prescribed sizes clean the bar surface before loading bars Table 1 Maximum bar length Model Version Max length mm ft 21 2080 6 8 32 3200 10 5 37 3740 12 2 BOSS 332 BOSS 545 BOSS 551 44 4400 14 4 INFORMATION Bar must not present a straightness defect above 0 5 per 1000 ...

Page 111: ...re is not too much rag on bar rear end which might hinder insertion in the bar pusher collet In any case to improve operation during this phase we advise to chamfer the bar as shown in the figure If bars with front remnant ejection have to be machined we advise to chamfer the bar rear end as shown in the figure If bars have to be machined having a diameter equal to or only slightly smaller than th...

Page 112: ...s S max Quality 0 25 mm Good 0 25 S max 0 5 mm Mediocre 0 5 mm Problematic In order to obtain a reliable value it is necessary to repeat measurements on the whole bar length by positioning it on a series of supports at a distance of 500 mm from each other and comparing the different values between prisms INFORMATION Obviously bar straightness is proportional to the rigidity of the material and to ...

Page 113: ...ction bars For non round bars insert some bushings on the bar to be controlled Position 2 bushings on the 2 V supports In that case the measurement can be carried out as shown in the figure Rotate the bar on itself and carry out the measurement on a bushing external to the two V supports ...

Page 114: ...ons required if the feeder has to be started up for the first time Perform the software parametering refer to the Push button panel instruction manual Carry out feeder set up according to the bar to be machined paragraph 5 3 Prepare the bars to be machined paragraph 6 4 Feed bars to the magazine paragraph 6 5 1 Adjust lube oil flow paragraph 6 5 2 Start the automatic cycle paragraph 6 5 3 ...

Page 115: ...t loads with weights exceeding those prescribed by the applicable regulations in force ask for another worker s help if necessary CAUTION wear personal protections according to the regulations in force Follow these instructions to load bars open the upper guard place bars against the guard A and close the upper guard ...

Page 116: ...ally controlled during the feeder automatic cycle The pump is started after the feeder has completed bar change over it is stopped when the bar pusher approaches the bush holder device Oil flow should be adjusted according to bar diameter and profile through the valve located upstream from the installation Adjust oil flow in the bushing holder device as well ...

Page 117: ...s press the start buttons plus Enter the parameter values refer to the Push button panel instruction manual Press to move the bar fore end closer to the cutting tool To start machining press when the lathe collet is closed In this way you will obtain automatic bar feeding until bar running out or according to the selected program Empty the remnant collection box during machining Lift the remnant b...

Page 118: ...d in the area before the clamps area C the guide channels will only open after the carriage has automatically moved to the BAR FEEDER ZERO SETTING position CLOSING PROCEDURE If the carriage A is located in the area beyond the clamps area B close the guide channels by pressing the start buttons plus If the carriage is located in the area before the clamps area C move it to the BAR FEEDER ZERO SETTI...

Page 119: ...ms the first step Press the bar feeder performs the second step and so on 6 6 FEEDER STOP FEEDER EMERGENCY STOP CAUTION if the emergency stop is used during lathe machining before resuming work make sure that the sudden stop has not created any hazardous condition e g if the tool was cutting chips move the tool away from the workpiece before restarting the lathe To stop the feeder in an emergency ...

Page 120: ...ed position in the lathe collet and that the collet is closed Press to select the automatic mode the feeder will wait for an OPEN COLLET signal from the lathe 6 8 AUTOMATIC CYCLE START RESUMING WORK AFTER POWER OFF IF THE BAR PUSHER HAS BEEN MOVED WHILE ELECTRIC POWER WAS DISCONNECTED Power the lathe on Turn the main power switch to the position I ON Press to start the bar feeder Press to select t...

Page 121: ...s the half bushes the bar pusher and the collet paragraph 5 3 1 remove the bar pusher and the small pusher truck remove the lower guides first and then the upper guides remove the bar pusher support remove the front nose remove the half bushes remove the lathe spindle liner if necessary install a new set of parts by reversing the order of the above operations mount a collet suitable for the new ba...

Page 122: ...w half bushes mount a collet suitable for the new bar in the bar pusher insert the bar pusher in the guides Change the clamps if necessary paragraph 5 3 2 Adjust the bar guide plates and bar selectors paragraph 5 3 3 Place the bar in the guides and adjust the clamps paragraph 5 3 4 Check all the working parameters in the keyboard Prepare the lathe for the new type of machining Start the automatic ...

Page 123: ...EX 7 1 MAINTENANCE GENERAL RULES 2 7 2 SCHEDULED MAINTENANCE 3 7 2 1 Revolving tip and collet Check 3 7 2 2 Lubricating oil Level check 4 7 2 3 Lubricating oil Change 5 7 2 4 Guide opening screw Greasing 6 7 2 5 Air filter unit Check 6 7 3 AXIAL DISPLACEMENT DEVICE USE 7 ...

Page 124: ...h also increases operator s safety Do not use petrol or solvents which would damage the painted and transparent parts the cable sheaths etc INFORMATION oxidation can damage metal parts and electric equipment To protect the bar feeder when you expect not to use it for long periods of time disconnect it from mains voltage and from compressed air supply and cover it with a suitable protective sheet A...

Page 125: ...epair and cleanness check Guide opening screw Greasing Oil recovery device brushes Wear check Wear control Drive belt Tension check Guide opening belt Wear check Bar headstock synchronizing device Wear check 5000 Air filter Check PLC battery Replacement Safety devices Check operatio see safety devices Only if installed 7 2 1 Revolving tip and collet Check Remove the bar pusher as described under p...

Page 126: ...o the regulations in force Wait until the bar feeder has been off for at least 6 hours Check the level by means of the A indicator For any topping up pour the oil directly into the base Table 2 Guide lubricating oil characteristics Model Oil type BOSS 332 Classe C CKB 100 BOSS 545 551 Classe C CKB 150 See paragraph 2 6 for the comparative table ...

Page 127: ...anies specialized in pollutant disposal and storage Do not pollute the environment Drain the tank using an auxiliary pump Clean the tank bottom and pump suction system For loading pour the oil directly into the tank and check its level by means of the A indicator Table 3 Guide lubricating oil characteristics Model Oil type Quantity l BOSS 332 Classe C CKB 100 57 BOSS 545 551 Classe C CKB 150 57 Se...

Page 128: ... 7 7 2 4 Guide opening screw Greasing Open the upper guard and carry out greasing 7 2 5 Air filter unit Check FILTER A Make sure that cup B is not full of condensate If need be bleed the condensate by valve C Check the pressure switch adjustment see paragraph 5 2 2 ...

Page 129: ...etc Remove the eight screws A Insert the supplied rod B in its special hole turn the shaft C and insert the supplied pin D Cause the bar feeder to slide backwards Be careful not to damage any connection wires e g the lathe interface power lead the camshaft disengagement device lead the hand held keyboard lead the pneumatic connection cable etc Carry out all lathe maintenance operations Cause the b...

Page 130: ...8 TROUBLES CAUSES CURES BOSS 332 545 551 E volution GB 8 Pag 1 3 INDEX 8 1 GENERAL FAULTS 2 8 2 BAR MAGAZINE Faults 2 8 3 INSERTION IN THE COLLET Faults 3 8 4 BAR FEEDING Faults 3 ...

Page 131: ...o lathe signal Check electric connection to the lathe The pneumatic devices will not respond to controls No air Check the air system The pre feed and feed suddenly stop Motor thermal switch tripped Reset the motor overload cut out with the special push buttons 8 2 BAR MAGAZINE Faults PROBLEMS CAUSES REMEDIES During the loading operation the bar cannot be inserted into the magazine The bar contrast...

Page 132: ...iameter not suitable for bar diameter Change collet Excessive rag on bar rear end Trim rag before feeding 8 4 BAR FEEDING Faults PROBLEMS CAUSES CORRECTIVE ACTION Difficult bar introduction into lathe spindle Bar feeder not aligned with lathe Check and correct alignment Difficult bar introduction into lathe collet Excessive rag on bar rear end Trim rag before feeding ...

Page 133: ...51 E volution GB 9 Pag 1 5 INDEX 9 1 FEED CHAIN REPLACEMENT 2 9 2 GUIDE OPENING BELT REPLACEMENT 2 9 3 KEYBOARD BATTERY REPLACEMENT 3 9 4 PLC BATTERY REPLACEMENT 4 9 5 RECOMMENDED SPARE PARTS 5 9 6 Machine Dismantling qualification 5 ...

Page 134: ...eration call IEMCA after sales service 9 2 GUIDE OPENING BELT REPLACEMENT Open the guard by unscrewing the fastening screws Manually turn the pulley B and simultaneously pull the belt all the way out Place a new belt in the pulley C lead it into the pulley B and turn the belt until it is fully inserted Re close the previously opened guard ...

Page 135: ...e calendar clock memory to be deleted Disconnect power Screw out the six screws and remove the two half shells Remove battery A from its housing Insert the new battery type DURACELL DL2430 DANGER WARNING danger of battery explosion if the battery is mounted with inverted polarity Reassemble the two half shells and screw down the six screws Reconnect mains supply INFORMATION Discard used batteries ...

Page 136: ...ing message is displayed PLC battery exhausted INFORMATION when this message is displayed the battery should be replaced within one day otherwise the PLC NC Software data will be deleted Unscrew cap A and pull out battery B Insert a new battery AA 3 6 volts lithium type battery and make sure that it is introduced correctly then tighten the cap A ...

Page 137: ...O 3RG4012 0AG07 SIEMENS 3 Tav 101 201 Spare Parts Book Bar pusher Specify diameter and length 1 Tav 100 200 Spare Parts Book Revolving tip Specify diameter 1 Collet Specify inside and outside diameter 1 38130001 Battery Battery 3 Volt VARTA CR2032 Hand held and fixed kieyboards 1 BOSS 332 BOSS 545 BOSS 551 38130009 Battery Battery 3 6 Volt Plc Arteco 1 9 6 Machine Dismantling qualification This op...

Page 138: ...10 LIST OF AFTER SALES CENTERS GB 10 Pag 1 3 INDEX 10 1 LIST OF AFTER SALES CENTERS 2 ...

Page 139: ...491 Email ITALY IEMCA S p A Via Granarolo 167 I 48018 Faenza RA Tel 0546 698208 Fax 0546 698290 Email SWITZERLAND Canton Ticino IEMCA S p A Via Granarolo 167 I 48018 Faenza RA Tel 0546 698208 Telefax 0546 698290 Email SWEDEN Kenson Component AB Box 114 44139 Alingsaes Phone 46 322 637890 Fax 46 322 633367 E mail www kenson se SWITZERLAND Suisse Française BARSPEED Zone industrielle CH 2607 Cortéber...

Page 140: ...ST OF AFTER SALES CENTERS GB 10 Pag 3 3 CHINA PRC IGM of China Room 28F Shanghai Shiye Apartment No 38 North Cao Xi Road Xu Hui District Shanghai 200030 China Tel 0086 21 64686020 Fax 0086 21 64877987 E mail ...

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IEMCA BOSS 332-545-551 E, Manual For Use And Maintenance

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