IEMCA BOSS 542 CNC Manual For Use And Maintenance Download Page 69

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ADJUSTMENTS AND SETTING-UP

302.034

❑

Cam setting

Microswitches S90 and S91

•

Rotate manually shaft

up to a distance of 10

ap-

prox. from the collet opening, then

S90

microswitch

cam until wheel

is released.

•

Turn shaft

until the collet opens.

•

Turn

S91

microswitch cam to release the wheel.

•

Rotate shaft

until the collet closes.

•

Turn the cam to lift

S91

microswitch cam.

•

Rotate shaft

of 10

approx., then lift

S90

micros-

witch wheel.

INFORMATION: S90 and S91 microswitch
wheels must lower when the headstock is in a for-
ward position and lift when the headstock is back-
wards, in any case before the following feeding.

34.057 Ec. 0

LATHE CAM COMPLETE CYCLE

FORWARD

STOP

FEEDER CAM COMPLETE CYCLE

DISABLED

ENABLED

DISABLED

ENABLED

DISABLED

ENABLED

STROKE

CLOSED

OPEN

CLOSED

FEED

RETURN

BACKWARD

STOP

HEADSTOCK RETURN WITH CLOSED COLLET IF

REQUIRED FOR SPECIAL OPERATIONS

34.058 Ec. 0

Summary of Contents for BOSS 542 CNC

Page 1: ...REL DATA COD S N BOSS 542 CNC BOSS 542r CNC MINI BOSS 325 CNC MINI BOSS 325r CNC MANUAL FOR USE AND MAINTENANCE GB 4 01 06 98 336005410 ...

Page 2: ...ia Granarolo 167 Tel 0546 698000 Fax 0546 46338 ufficio commerciale 0546 46224 centralino TLX 550879 BOSS 542 CNC BOSS 542r CNC MINI BOSS 325 CNC MINI BOSS 325r CNC AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION MANUAL FOR USE AND MAINTENANCE GB ...

Page 3: ...EEDER MAINTENANCE SAFETY PROCEDURES 24 4 HANDLING AND INSTALLATION 4 1 PACKAGING 25 4 2 LIFTING 25 4 3 INSTALLATION AREA CHARACTERISTICS 27 4 4 FEEDER WITHOUT AXIAL DISPLACEMENT DEVICE INSTALLATION 28 4 4 1 Support plates and feet Installation 28 4 4 2 Height Adjustment 29 4 4 3 Preliminary positioning 30 4 4 4 Sleeve Installation 31 4 4 5 Levelling and alignment 32 4 4 6 Feeder fastening 35 4 4 7...

Page 4: ...ESUMING WORK AFTER POWER OFF 79 6 9 MACHINING CHANGE QUICK GUIDE 80 6 9 1 Machining type change with guide change over 80 6 9 2 Machining change without guide change over 80 7 BAR FEEDER MAINTENANCE 7 1 MAINTENANCE GENERAL RULES 81 7 2 SCHEDULED MAINTENANCE 82 7 2 1 Revolving tip and collet Check 82 7 2 2 Lubricating oil Level check 83 7 2 3 Lubricating oil Change 83 7 2 4 Clutch oil Check 84 7 2 ...

Page 5: ...e 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 harm hence it is necessary to pay the greatest attention CAUTION n order to avoid accidents or damages to proper ty suitable measures shall be adopted INFORMATION Information technical instructions h...

Page 6: ...tioned specifications in order to obtain information or whenever ordering spare parts etc 1 3 TECHNICAL ASSISTANCE Whenever necessary please apply to one of the Technical Assist ance Departments listed in the annex enclosed herein INFORMATION As far as technical servicing relevant to the bar feeder is concerned always specify the technical data printed nameplate 1 4 ANNEXES ENCLOSED Technical assi...

Page 7: ... vibrations and no surface damaging The use of a DC motor and of an electronically control led clutch make it possible to adjust the feeding speed and thrust to ideal values at any time during the machi ning cycle Bar remnant ejection can be caused by bar pusher fe eding or next bar feeding Bar feeder series BOSS are produced in the following models MINI BOSS 325 CNC standard version MINI BOSS 325...

Page 8: ...ction It also drives the bar feeder parts controlling guide opening closing and bar selection B Clamps they hold the bar during bar in troduction in and extraction from the bar pusher collet C Facing device it sends a signal at bar passage D Remnant collection box bar remnants are dropped into this box after extraction from the bar pusher collet F Lubricating pump it delivers oil to the guides G O...

Page 9: ...n 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 back wards 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 34 142 Ec 0 A B 34 012 Ec 0 A C 34 013 Ec 0 A C D D...

Page 10: ...et the feeder stops otherwise it continues its cycle The bar selection device F goes up all the bars in the magazine are held back except the first bar G The upper guides H and the bar pusher L are opened the bar G is dropped into the guide The small pusher truck M starts its stroke 34 006 Ec 0 G F 34 007 Ec 0 G L H 34 014 Ec 0 E D D 34 008 Ec 0 M ...

Page 11: ...stroke The upper guides H are closed the bar pusher L is po sitioned along the spindle axis The clamps D close the bar pusher L moves for wards the bar G is inserted into the bar pusher collet The bar selection device F is lowered The bar pusher A and bar G execute their facing stroke A new automatic work cycle is started 34 009 Ec 0 L F H 34 010 Ec 0 L G D D 34 141 Ec 0 M M 34 011 Ec 0 A G ...

Page 12: ... area even if the feeder and lathe functions are not stopped during the bar change over phase feeder and lathe functions are stopped when the guard is opened The operator can restart the cycle by closing the guard There are no risks for the operator in the involved area even if the feeder and lathe functions are not stopped D Fixed guard it is made from transparent material to allow visual inspect...

Page 13: ...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 Do not lift loads exceeding 15 kg manually E Caution Danger of electric contact 34 004 Ec 0 C B B C B A D C C B C E A B C D E ...

Page 14: ...SION DESCRIPTION Table 1 Maximum bar length Model Version Max length mm ft MINI BOSS BOSS 32 3200 10 5 37 3740 12 2 44 4400 14 4 Table 2 Max bar pusher extension Model Version A Max extension mm MINI BOSS BOSS N 937 L 1267 LL 1597 34 005 Ec 0 A ...

Page 15: ...AL SPECIFICATIONS Without axial displacement device the minimum dimension can be reduced to 850 mm Table 3 Overall dimensions Model Version A mm B mm MINI BOSS BOSS 32 3750 1327 37 4290 1867 44 4950 2527 34 015 Ec 1 MINI BOSS BOSS MINI BOSSr BOSSr ...

Page 16: ...00 mm sec max 800 mm sec Remnant length standard version 400 mm 400 mm Remnant length oversize version 700 mm 700 mm Bar change over time with 3000 mm bar 25 sec 23 sec Input voltage 380 Volt 380 Volt Mains frequency 50 Hz 50 Hz Control voltage 24 Volt D C 24 Volt D C Installed power 1 5 kW 2kW Oil quantity 40 l 40 l Air pressure 6 bar 6 bar Pneumatic energy average consumption 20 NL min 20 NL min...

Page 17: ... diameter mm MIN MAX MINI BOSS 13 10 3 8 10 12 3 10 12 17 15 5 13 15 16 5 14 16 21 16 5 14 16 18 5 16 18 19 5 17 19 20 5 18 20 26 23 5 21 23 25 5 23 25 28 25 5 23 25 27 5 25 27 BOSS 13 10 5 8 10 12 5 10 12 17 15 5 13 15 16 5 14 16 21 16 5 14 16 18 5 16 18 19 5 17 19 20 5 18 20 26 23 5 21 23 25 5 23 25 28 25 5 23 25 27 5 25 27 33 30 5 27 30 31 5 28 31 32 5 29 32 36 32 5 29 32 35 5 32 35 43 40 10 37...

Page 18: ...nis 100 Total Cortis 100 Azolla ZS 100 Q8 Verdi 100 Table 8 BOSS guides lubricating oils ISO and UNI symbols Make Name CB 150 Agip Acer 150 Api Api Cis 150 Aral Aral Degol Tu 150 BP Energol CS 150 Castrol Magna 150 Chevron Circulating Oil 150 Elf Movixa 150 Esso Nuto 150 Fina Solna 150 IP IP Hermea 150 Klüber Crucolan 150 Mobil Vactra Oil Extra Heavy Olio Fiat Daphne Hidrobak 150 HL Roloil Arm V 1...

Page 19: ...h of suitable diameter if supplied bar with a straightness within prescribed limits max arrows equal to 0 5 mm of the bar length spindle liner having the same diameter as the bar feeder guide 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 ...

Page 20: ...o 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 are open Closure is controlled by...

Page 21: ...cement 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 10 Overall dimensions Model Version A mm MINI BOSS BOSS 32 3170 37 3770 44 4370 34 018 Ec 0 34 017 Ec 0 ...

Page 22: ...2 Telescopic nose Description 2 8 1 Bar headstock synchronizing device Description It is used to connect the bar pusher and consequent ly the bar to the lathe headstock to obtain their syn chronized forwards backwards movement 2 8 2 Telescopic nose Description It is used to optimize bar guiding between the bush holder device and the lathe spindle Table 11 Max stroke and overall dimensions Model Ma...

Page 23: ...n 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 move ments The cams located in the box A are connect...

Page 24: ...TION 302 034 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 34 022 Ec 0 Axial version Radial version ...

Page 25: ... due to the non observance of the above mentioned regulations 3 2 HANDLING AND INSTALLATION Safety procedures Bar feeder shall be handled using suitable means and methods People shall not stand underneath a suspended load within the crane lift truck or other suitable means of lifting or transportation operating range The working and bar feeding area shall be delimited in order to prevent collision...

Page 26: ...g and tie Whenever necessary use strong working 5 finger gloves which do not reduce sensitivity and grip ping Use working shoes as well as personal protections as provided for by the accident prevention regula tions in force in every country Personnel in charge of maintenance shall be in formed should the machine fail to work properly Before starting the bar feeder make sure that there is no perso...

Page 27: ... in protective film C With crate the feeder is placed in a crate wrapped in protec tive film 4 2 LIFTING DANGER WARNING handling and lifting operations should be carried out with suitable equipment see weight ta ble 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 34 023 Ec 0 A B C ...

Page 28: ...bolts with threaded shanks A type 1 UNI ISO3266 M20 Use a hook type lifting device of suitable capacity Lifting with pallet Use a hook type lifting device of suitable capacity Lifting with crate Use a hook type lifting device of suitable capacity 34 024 Ec 1 A 34 025 Ec 0 34 137 Ec 0 ...

Page 29: ... 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 explosive atmosphere Table 1 Overall dimensions Model Version A mm B mm C mm MINI BOS...

Page 30: ...ut 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 34 027 Ec 0 A B ...

Page 31: ...nt proceed as follows tighten the lifting chains and remove the 16 screws A lift the feeder according to the required dimension X see table screw down the screws A and remove the eyebolts B Table 2 Working axis height Model Upper screws position X mm MINI BOSS BOSS 1 900 939 2 940 969 3 970 1009 4 1010 1039 5 1040 1079 6 1080 1109 7 1110 1149 8 1150 1179 9 1180 1200 34 128 Ec 0 A B 34 028 Ec 0 ...

Page 32: ...er all the way out In fixed head stock 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 Roughly adjust the working axis height to obtain alignment with the lathe by turning the feet screws Table 3 Max bar pusher extension Model Version A Max extension mm MINI BOSS BOSS N 937 L 1267 ...

Page 33: ...OSS Install the sleeve A in the bush holder device Install the oil recovery device B Connect the drain pipe to the tank BOSS Install the sleeve A in the bush holder device Install the oil recovery device B Connect the drain pipe to the tank 34 031 Ec 0 A B 34 032 Ec 0 A B ...

Page 34: ...t by ex perienced 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 Insert the supplied crank in the intermediate drive shaft and move the bar pusher to its backwards limit stop Move the crank to the guide opening screw shaft and open the upper guides 34 034 Ec 0 34 035 Ec 0 34 033 ...

Page 35: ...ly overturn the upper guides and according to feeder version remove either the first guide A for ver sion 32 or the second guide B for versions 37 or 44 Levelling Insert the templates in the specially provided holes in the beam Check levelling by positioning the level crosswise and lengthwise 34 036 Ec 0 34 037 Ec 0 B A 34 038 Ec 0 ...

Page 36: ...iper to check alignment near the sleeve C and the spindle D adopt a tolerance of 0 15 mm in all four directions It is also possible to carry out alignment by placing a bar in the guides Proceed as follows prepare a perfectly straight ground bar having an outside diameter equal to the max spindle bar pas sage and a length equal to twice the coupling dis tance see item B paragraph 4 4 3 place the ba...

Page 37: ...he result of a good ad justment compromise 4 4 6 Feeder fastening Ground fastening Drill the floor and fix the backing plates with expan sion plugs Fix the feeder to the plates through the tie rods 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 possi...

Page 38: ...g 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 meas ured dimension Move the headstock to its all the way forwards po sition Remove the cover E insta...

Page 39: ... it is firmly fastened to the ground and with a perfectly hor izontal 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 displace ment device 34 045 Ec 0 A B A A A ...

Page 40: ... 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 ad just if required through the screws A Roughly restore working axis height and alignment with the lathe if required 4 5 4 Sleeve Installa...

Page 41: ... 4 5 Positioning adjustment 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 of frame A During this phase any adjustment carried out during levelling should be preserved therefore in most cas es feeder ...

Page 42: ...lugs 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 34 050 Ec 0 34 051 Ec 0 A B A A A ...

Page 43: ...nstallation contact IEMCA service depart ment 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 to gether with shaft E Position the support F in such a way as not to hinder the headstock stroke and tighten the screw A Replace the side guard which had previously been removed 34 052 Ec 0 34 053 Ec 0 E F ...

Page 44: ...n contact IEMCA service depart ment 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 to gether with shaft E Position the support F in such a way as not to hinder the headstock stroke and tighten the screw A 34 054 Ec 0 34 053 Ec 0 E F E B C D A ...

Page 45: ...eplace the side guards which had previously been removed 4 7 2 Cam box INFORMATION the figure shows a general exam ple of installation contact IEMCA service depart ment for more information Install the sleeve A on the lathe camshaft B Connect the shaft C to the sleeve through the pin D 34 056 Ec 0 D C A B 34 055 Ec 0 G H E ...

Page 46: ...ut a hole and thread in the lathe casing to fix the transmission unit F and mount the disk G in the con trol 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 After completing the above described operations the actuator rotation stroke should be adjusted this opera tion is necessary for both the radial version and the ax ial vers...

Page 47: ...chnical staff to comply with the applicable standards and statu tory regulations in force DANGER WARNING the feeder must be electrically connected to the lathe which in turn must be connected to the plant wiring system in com pliance with the applicable regulations in force The feeder is normally provided with a multiple plug to plug into the special lathe outlet refer to the Wiring diagram if nec...

Page 48: ...ion 1 12 drops per 1000 l of air adjust by turning the screw F 4 11 ADDITIONAL PUSH BUTTON PANEL Installation According to working requirements the additional push button panel can be removed from its seat and installed near the lathe push button panel 4 12 SELF LEARNING DIMENSIONS Programming Self learning data depend on the type and size of the lathe to which the feeder is coupled This operation...

Page 49: ...ccording 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 type of bar to be machined 5 4 Cam box Timing 5 2 GENERAL ADJUSTMENTS Foreword Including all the necessary adjustments for good feeder operation They may become necessary after mainte...

Page 50: ...ce the guards that had previously been re moved 5 2 2 Drive chains Adjustment Remove the drive system guard Loosen the screws A stretch the primary chain B by pressing the support C in the direction of the arrow then tighten the screws A again Loosen the screws D stretch the secondary chain E by pressing the support F in the direction of the arrow then tighten the screws D Replace the guard that h...

Page 51: ...its lock screw The spring E must be released Release it if required by working the nut F and fork G Mount the pin C and loosen the ring nut H Move the solenoid shaft in the direction of the arrow and turn the screw L to adjust the solenoid shaft po sition to the indicated dimension Tighten the ring nut H Manually check that the clutch is free to turn Replace the guards that had previously been re ...

Page 52: ...or standard machined bars with front remnant ejection Table 1 Diameters of guides bar pusher bars and pipes Model Guide diameter mm Bar pusher diameter mm Bar diameter mm Pipe diameter mm MIN MAX MINI BOSS 13 10 3 8 10 12 3 10 12 17 15 5 13 15 16 5 14 16 21 16 5 14 16 18 5 16 18 19 5 17 19 20 5 18 20 26 23 5 21 23 25 5 23 25 28 25 5 23 25 27 5 25 27 BOSS 13 10 5 8 10 12 5 10 12 17 15 5 13 15 16 5 ...

Page 53: ...d been carried out under these condi tions 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 the magazine and clamps must be adjusted The information contained in this paragraph refers to Example 3 i e to the cases where it is necessary to carry out all adjustment operations and feeder set up These opera...

Page 54: ... feeder Press to select the manual cycle Open the upper guard Insert the supplied crank in the intermediate drive shaft and move the bar pusher forwards past the clamps area Move the crank to the guide opening screw shaft and open the upper guides Manually overturn them 34 033 Ec 0 34 067 Ec 0 34 068 Ec 0 34 069 Ec 0 ...

Page 55: ... opening then remove the truck from its seat Disassemble the lower guides in the sequence shown in the figure It is not necessary to remove the screws for disassembly just loosen them by approx 3 turns and cause the guide to slide from right to left to extract it It is only necessary to remove the screws for the last guide number 6 Now disassemble the upper guides by removing their screws Remove t...

Page 56: ...e C Remove the front half bushes in the following way MINI BOSS Remove the cover and manually extract the two half bushes BOSS Remove the cover fully 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 34 074 Ec 0 A B 34 149 Ec 0 C 34 075 Ec 0 34 076 Ec 0 A ...

Page 57: ...uitable liner for the new diameter Install suitable front half bushes for the new diameter in the following way MINI BOSS Insert the two half bushes and place the cover BOSS Insert the upper half bush turn the shaft A and insert the lower half bush Fully close the half bushes and place the cover 34 077 Ec 0 34 075 Ec 0 34 143 Ec 0 34 076 Ec 0 A ...

Page 58: ...pplied 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 bush M with another one suitable for the new diameter and place the ring L back Reinstall the sleeve H the spring G the bush F the spring E and the bush D The sleeve H and ...

Page 59: ...ble for the new diameter by reversing the or der of disassembly operations INFORMATION make sure that the lower guide screws have an oil inlet hole Choose a suitable collet for the bar diameter and profile check the attached summary tables 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...

Page 60: ...ir special recesses to pre vent accidental collet unscrewing from its connection Mount a bar pusher support suitable for the new diame ter Insert a small pusher truck suitable for the new diame ter in its special seat Move the small pusher truck to its rear limit stop and insert a bar pusher suitable for the new diameter Move the bar pusher for wards past the clamps area 34 080 Ec 0 34 073 Ec 0 34...

Page 61: ... pusher back to its rear limit stop The upper surface of the intermediate flag must be flush with the lower guides proceed as follows to ob tain adjustment Open the upper guides Loose the screw adjust the flag position and tighten the screw 34 082 Ec 0 34 083 Ec 0 34 034 Ec 0 34 035 Ec 0 34 084 Ec 0 ...

Page 62: ... machined have a different profile from the previously 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 Close the clamps and tighten hard the screw of knob A to lift the lower clamp as much as possible Open the upper guides Manually lift the lower lever and replace the cl...

Page 63: ...intermediate flag if necessary see par agraph 5 3 1 Manually overturn the upper guides Close the clamps Screw the screw B down to extract the clamps and replace them Restore the initial feeder conditions 34 138 Ec 0 34 069 Ec 0 34 087 Ec 0 34 139 Ec 0 B ...

Page 64: ...electors Adjustment Preliminary procedure Open the upper guard Close the upper guides sensor S2 must be ener gized Make sure that the bar selectors are lower than the magazine surface Prepare two bar remnants having a length of 1200 mm 34 033 Ec 0 34 089 Ec 0 34 140 Ec 0 S2 ...

Page 65: ...eration on all the plates Feed two bars to the magazine loosen the screws 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 34 090 Ec 0 A 34 091 Ec 0 A A A ...

Page 66: ...d between the two bars Turn the screw C to adjust the bar selector height the tips must touch the two bars only just without lift ing them Square bars Turn the screws B and C to adjust the bar selector transversal position and height the tips must lift the first bar and at the same time hold the second bar Open the upper guides the first bar must be dropped into the guides while the second bar sho...

Page 67: ...bar pusher collet plus 1 mm then move the small pusher truck back to its rear limit stop Close the upper guides and continue to turn the crank until the clamps close or the sensor S5 becomes en ergized In the latter case loosen the clamps by turning the knob A and screw B and continue to turn the crank until the clamps are fully closed 34 093 Ec 0 A 34 094 Ec 0 34 095 Ec 0 S5 34 096 Ec 0 A B ...

Page 68: ...ING If the feeder is equipped with a cam box each cam should be timed to its own microswitch The timing procedure is as follows Microswitch function S90 Bar feed enabling It controls the bar feeding motor start stop It must be operated at each collet opening In addition it also controls operation of the bar headstock synchronizing device S91 Bar change over enabling It signals lathe collet opening...

Page 69: ...1 microswitch cam Rotate shaft A of 10 approx then lift S90 micros witch wheel INFORMATION S90 and S91 microswitch wheels must lower when the headstock is in a for ward position and lift when the headstock is back wards in any case before the following feeding 34 057 Ec 0 LATHE CAM COMPLETE CYCLE FORWARD STOP FEEDER CAM COMPLETE CYCLE DISABLED ENABLED DISABLED ENABLED DISABLED DISABLED DISABLED DI...

Page 70: ... 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 ad vanced through screw C Whenever servicing the camshaft disconnect the cam box according to the following procedure loosen clamp D and unscrew sleeve E service the lathe camshaft screw sleeve E and ti...

Page 71: ... as follows A Manual and programming function controls They control the bar feeder movements and program parameter functions B Programming controls They program both functions and parameters C Main functions controls They are used for starting stopping and for the selection of the working cycle 34 099 Ec 0 A B C A B C A ...

Page 72: ... Key to close the upper guides in the man ual mode it should be pressed simultane ously with the push button S82 or for number 9 10 Key for BAR FEEDER ZERO SETTING or for number 0 11 Key for bar pusher return or for the minus sign 12 Key for bar pusher small backwards move ments 13 Key for bar pusher small forwards move ments 14 Key for bar pusher feeding or for the point sign 15 Green push button...

Page 73: ... 20 Function key F3 21 Function key F4 22 Key for recalling the access code visualizing functions selecting the function following the one displayed 23 Key for deleting numbers in the parameters selecting the function preceding the one displayed 24 Key for parameter exit learning program exit function exit 34 101 Ec 0 ...

Page 74: ... Green lighted push button It starts the feeder 28 Red lighted push button It stops the feeder 29 Emergency push button It stops the feeder The feeder can be re started only after the push button has been manually released 30 Display INFORMATION for detailed information on pro gramming read the Push button panel operation guide 34 102 Ec 0 ...

Page 75: ... return position bar pusher feeding 34 Emergency push button to stop the bar feeder which can only be restarted after manual push but ton release 6 3 INDICATOR LIGHTS Description of indications Red light signals that the bar feeder is not operating or that it is in the manual mode Green light it indicates that the bar feeder is in the automatic mode Orange light signals that the bar feeder is carr...

Page 76: ...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 ma chined 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 the bar pusher diameter bar rear ends should be machine turned diameter D should be suitable for the ...

Page 77: ...aph 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 6 5 1 Bar magazine Filling CAUTION do not manually lift loads with weights exceeding those prescribed by the applicable regulations in force ask for another worker s help if necessary CAUTION wear personal protections prescribed by the applicable regulations in force Fol...

Page 78: ...ic 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 34 106 Ec 0 34 107 Ec 0 BOSS MINI BOSS 34 154 Ec 0 ...

Page 79: ...ush button panel instruction manual paragraph CN functions Description and use Turn the selector S95 to position 0 Turn the selector S94 to position to move the bar head closer to the cutting tool To start machining turn the selector S95 to position 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 If you wi...

Page 80: ...he bar pusher has been moved while electric pow er was disconnected a BAR FEEDER ZERO SET TING should be performed in the following way press if the upper guides are not closed the feeder will not perform BAR FEEDER ZERO SETTING messages are displayed concerning the operations to carry out in order to bring the guides to the required position After carrying out the required operations press Check ...

Page 81: ...n Press to start the bar feeder Press to select the manual mode Press to perform BAR FEEDER ZERO SETTING Move the bar in the lathe collet to the required posi tion and make sure that the collet is closed Press If the bar pusher has not been moved while electric power was dis connected Power the lathe on Press to start the feeder Make sure that the lathe collet is closed Press ...

Page 82: ...a collet suitable for the new bar in the bar pusher insert the bar pusher in the guides adjust the intermediate flag position Change the clamps if necessary paragraph 5 3 2 Adjust the bar guide plates and bar selectors para graph 5 3 3 Place the bar in the guides and adjust the clamps paragraph 5 3 4 Check all working parameters in the push button panel key Check the feed thrust in the push button...

Page 83: ...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 elec tric equipment To protect the bar feeder when you expect not to use it for long pe riods of time disconnect it from mains voltage and from com pressed air supply and cover it with a suitable protective sheet Any protection ...

Page 84: ... Frequency Hours Regularly Cycles 200 1250 2500 Revolving tip and collet Wear check Half bushes Half bushing Wear check Lubrication system Oil level check Oil change Guides Repair and cleanness check Clutch Oil level check Oil change Disk wear check Guide opening screw Greasing Oil recovery device brushes Wear check Feed chain Lubrication Tension check Driving motor brushes Wear inspection Drive c...

Page 85: ...dards in force INFORMATION store spent oil in special contain ers to be delivered to companies specialized in pol lutant disposal and storage Do not pollute the environment Drain the tank using an auxiliary pump Clean the tank bottom and pump suction system Fill up by pouring oil directly into the tank See paragraph 2 6 for the comparative table Table 2 Guide lubricating oil characteristics Model ...

Page 86: ...ove both guards A and B Position the clutch in such a way as to position the plug C as shown in the figure Remove the plug and make sure that the oil level is just up to the hole Top up if necessary by pouring oil BP Energol HLP D32 34 111 Ec 0 B A 34 112 Ec 0 C C ...

Page 87: ...pollutant disposal and storage Do not pollute the environment Remove both guards A and B Position one container under the clutch loosen the six cover screws and let oil flow out Retighten the six screws and position the clutch in such a way as to position the plug C as shown in the figure Remove the plug and pour oil type BP Energol HLP D32 Make sure that the oil level is just up to the plug hole ...

Page 88: ... the applicable standards in force Remove both guards A and B Remove the pin C Remove the two lower screws then the upper screws remove the support D with the electromag net lever Place a container under the clutch loosen the six cover screws and let oil flow out 34 111 Ec 0 B A 34 114 Ec 0 C 34 115 Ec 0 D 34 113 Ec 0 ...

Page 89: ... Clean the disks and check their wear place them back or re place them Reassemble in this order the pin L with its special spring the spacer H the pin G the circlip F the cover E Top oil up as is described in paragraph 7 2 5 Adjust the clutch as is described in paragraph 5 2 3 7 2 7 Guide opening screw Greasing Open the upper guard and carry out greasing 34 116 Ec 0 N E F G L H M 34 117 Ec 0 ...

Page 90: ...liminate the inner dust due to the brush wear Replace brushes D if they are less than 9 mm in length Reassemble bell E plugs C and the guards previously re moved BOSS Remove plugs C brushes D bell E and cover F Blow air into brush housigngs D bell hole E and ter minal board housing G in order to completely elimi nate the inner dust due to the brush wear Replace brushes D if they are less than 11 m...

Page 91: ...d use 7 2 9 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 Lubricator D Check that the oil level is not under the suction level If need be top up as follows disconnect the compressed air supply fill the tank removing plug E or cup F the oil level must reach the MAX reference 9 11 Cst at 40 C ISO VG 10 See paragraph 2 6 for t...

Page 92: ...he supplied rod B in its special hole turn the shaft C and insert the supplied pin D Cause the bar feeder to slide backwards by taking care not to damage the connection cables if any e g the lathe interface wire the camshaft release device cable the additional push button panel cable the pneumatic connection hose etc Carry out all lathe maintenance operations Cause the bar feeder to slide forwards...

Page 93: ...No 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 TROUBLES CAUSES CURES The bar will not enter the maga zine during feeding The bar plates are too low Adjust the plates position The first ...

Page 94: ...mps Collet diameter not suitable for bar diameter Change the collet Too much rag on bar rear end Trim bar rag before feeding TROUBLES CAUSES CURES Difficult bar introduction in the lathe spindle The bar feeder is not aligned with the lathe Check and correct alignment Difficult bar introduction in the lathe collet Excessive rag on bar rear ends Trim bar rag before feeding ...

Page 95: ...n is a highly complex operation call IEMCA after sales service 9 2 PRIMARY CHAIN AND PINION Replacement Remove the drive system guard Loosen the screws A and slacken both chains Remove the fork B extract the connection link C and re move the primary chain 34 120 Ec 0 34 121 Ec 0 C B A A ...

Page 96: ...the arrow then tighten the screws A Place back the guard which had previously been re moved 9 3 GUIDE OPENING BELT Replacement Remove the guard Manually turn the pulley A and simultaneously pull the belt all the way out Place a new belt in the pulley B lead it into the pulley A and turn the belt until it is fully inserted Place back the guard which had previously been re moved 34 122 Ec 0 D E F 34...

Page 97: ...al Disconnect the electric control board through the au tomatic three phase switch F1 Remove the EEPROM through the relevant grippers and fit the new EEPROM giving the greatest atten tion to location marks A Keep push button pressed and switch on the bar feeder through the automatic three phase switch F1 Release push button displayed enter the code not displayed displayed press to confirm default ...

Page 98: ...eter values before replacing the board see the Push button panel instruction manual Check and note down the total and partial operation hours of the driving motor see Control Panel In struction Manual The hour amount will be reset af ter the card replacement and cannot be set again Disconnect the electric control board through the au tomatic three phase switch F1 Disconnect all connectors six Remo...

Page 99: ...press displayed press Assign values to parameters and to parameters protected by the access code previously noted see the Push button panel instruction manual 0546 p r e s s E N T E R t o c o n f i r m a s s i g n d e f a u l t v a l u e t o a l l p a r a m e t e r s CN C B O S S I EMCA P r e s s r u n n i n g p u s h b u t t o n 0 AU T MAN ...

Page 100: ...tected by access codes Description and use the display must show press the bar pusher should not move not even by deci mal displacements see the display If the bar pusher moves motor set up must be per formed DANGER WARNING live control panel dan ger of electric contact Turn the screw BIL clockwise or counterclockwise with small sharp movements until the bar pusher is stopped Check the setting tha...

Page 101: ...oil BP ENERGOL HLP D32 500 gr 24220019 Primary chain 8x3 1 24290602 Connection link 8x3 1 24220030 Feed chain 3 8 x5 32 1 24290603 Connection link 3 8 x5 32 1 34320040 Motor brushes SIBONI 5x10 L54R 4 32210401 Limit switch BERO 3RG4611 0AB04 SIEMENS 1 32210004 Limit switch BERO 3RG4012 0AG07 SIEMENS 3 34320042 Motor brushes 6x9x22 L59 MPC BOSS 4 34320043 Motor brushes 12x7x18 L59 MPC MINI BOSS 2 B...

Page 102: ...100 9 302 034 ...

Page 103: ... OHNWUR 0HFKDQLVFKHU HWULHE 5HEJDUWHQZHJ HLO DP 5KHLQ 7HO D PDLO 7 0 6 S 9LD UDQDUROR DHQ D 5 7HO D PDLO 6 7 5 1 6 7 5 1 DQWRQ 7LFLQR 0 6 S 9LD UDQDUROR DHQ D 5 7HO 7HOHID PDLO 6 1 HQVRQ RPSRQHQW RUJHQV DWD OLQJVDHV 3KRQH D PDLO ZZZ NHQVRQ VH 6 7 5 1 6 7 5 1 6XLVVH UDQoDLVH 563 RQH LQGXVWULHOOH RUWpEHUW 7HO 7HOHID 7 1 52 0 2 1R WK 5RDG 7DLFKXQJ QGXVWULDO 3DUN 7DLFKXQJ 7DLZDQ 5 2 7HO 7HOHID PDLO 3 ...

Page 104: ...GB 67 2 7 5 6 6 17 56 3DJ 1 35 0RI KLQD 5RRP 6KDQJKDL 6KL H SDUWPHQW 1R 1RUWK DR L 5RDG X XL LVWULFW 6KDQJKDL KLQD 7HO D PDLO ...

Page 105: ...AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION PUSH BUTTON PANEL OPERATION GUIDE GB 01 06 98 BOSS 542 CNC BOSS 542r CNC MINI BOSS 325 CNC MINI BOSS 325r CNC ...

Page 106: ...scription and entry 21 3 1 1 DESCRIPTION OF PARAMETERS 24 3 2 PARAMETERS PROTECTED BY THE ACCESS CODE Description 35 3 2 1 DESCRIPTION OF PROTECTED PARAMETERS 37 3 3 NC FUNCTIONS Description and operation 38 3 4 NC FUNCTIONS PROTECTED BY THE ACCESS CODE Description and operation 40 3 4 1 PROTECTED FUNCTIONS Description and operation 42 3 5 ERRORS CAUSES CURES 48 4 INFORMATION AIMED AT THE AUTHORIS...

Page 107: ...2 302 035 ...

Page 108: ... as follows A Manual and programming function controls they control the bar feeder movements and program parameter functions B Programming controls they program both functions and parameters C Main functions controls they are used for starting stopping and for the selection of the working cycle 34 099 Ec 0 A B C A B C A ...

Page 109: ... Key to close the upper guides in the man ual mode it should be pressed simultane ously with the push button S82 or for number 9 10 Key for BAR FEEDER ZERO SETTING or for number 0 11 Key for bar pusher return or for the minus sign 12 Key for bar pusher small backwards movements 13 Key for bar pusher small forwards move ments 14 Key for bar pusher feeding or for the point sign 15 Green push button ...

Page 110: ...2 20 Function key F3 21 Function key F4 22 Key for recalling the access code visualizing functions selecting the function following the one displayed 23 Key for deleting numbers in the parameters selecting the function preceding the one displayed 24 Key for parameter exit learning program exit function exit 34 101 Ec 0 ...

Page 111: ...ecting key 26 Feeder manual function selecting key 27 Green lighted push button it starts the feeder 28 Red push button it stops the feeder 29 Emergency push button it stops the feeder The feeder can be re started only after the push button has been manually released 30 Display 34 102 Ec 0 ...

Page 112: ...ayed Perform the BAR FEEDER ZERO SETTING according to the following pro cedure press If the upper guides are not closed the feeder will not execute the BAR FEED ER ZERO SETTING messages are displayed concerning the operations to carry out to bring the upper guides to the required position As soon as the above mentioned procedure has been performed press CN C B O S S I EMCA P r e s s r u n n i n g ...

Page 113: ...bars opening the upper guides are opening or are open or are closing closing the upper guides are closed facing the bar feeder is performing the facing stroke 5 It shows the small pusher truck and bar pusher position with respect to BAR FEEDER ZERO SETTING 6 Shows functions not requiring an access code see paragraph NC functions Description and operation 5 3 1 2 6 4 F1C l u t c h F2 P a r a m e t ...

Page 114: ...umatically to lathe Preliminary procedure The functions protected by access codes must be entered starting from the main menu press the following message will be displayed enter the access code not displayed Should the code be false the following message will be displayed press any key Ex and repeat the procedure If the code is correct the following message will be displayed F1 C l u t c h F2 P a ...

Page 115: ...ll functions up press five times or scroll them down bypressing once the display will read by pressing the display will read Ex F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r B 1 3 9 0 C B 4 0 C 1 3 5 0 A 3 6 0 F 3 2 0 0 L 2 3 8 0 B o 2 0 6 0 C XX X X ...

Page 116: ... values should be checked and modified if required according to the values listed in the following table 1 5 2 3 6 7 8 4 7 8 10 6 35 002 Ec 0 9 Fixed headstock lathe CNC type sliding headstock lathe Cam sliding headstock lathe Moving sleeve lathe 11 4 4 4 Legend 1 All the way back bar pusher position 2 Bar pusher position at bush holder device inlet opening of half bushes 3 Bar pusher position at ...

Page 117: ...d dimensions DIMENSION C B it is a dimension the value of which is automatically learnt by the pro gram No operator s action is needed DIMENSION C XXXX it is a variable value dimension referred to point C No operator s action is needed DIMENSION A 36 0 fixed value dimension It is the all the way back bar pusher posi tion after the extraction movement No operator s action is needed To return to the...

Page 118: ...n bypressing once the display will read by pressing the display will read press key in the value E g see table Version 32N 37N 44N B 1060 1060 1060 Version 32L 37L 44L B 1390 1390 1390 Version 32LL 37LL 44LL B 1720 1720 1720 F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r 1 B p r e f 2 C B 3 C 4 B u s h 5 L u b 6 E n d 1390 ...

Page 119: ...bypressing once the display will read by pressing the display will read press key in the value E g see table Version 32N 37N 44N Bo 2390 2930 3590 Version 32L 37L 44L Bo 2060 2600 3260 Version 32LL 37LL 44LL Bo 1730 2270 2930 F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r 1 B p r e f 2 C B 3 C 4 B u s h 5 L u b 6 E n d 2600 ...

Page 120: ... bypressing once the display will read by pressing the display will read press key in the value E g see table Version 32N 37N 44N L 2710 3250 3910 Version 32L 37L 44L L 2380 2920 3580 Version 32LL 37LL 44LL L 2050 2590 3250 F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r 1 B p r e f 2 C B 3 C 4 B u s h 5 L u b 6 E n d 2920 ...

Page 121: ...er device inlet opening of half bushes 3 Bar pusher position at nose outlet lubrication stop 4 All the way forwards bar pusher position 5 Facing flag 6 Spindle 7 All the way back headstock position 8 All the way forwards headstock position 9 All the way back sleeve position 10 All the way forwards sleeve position 11 All the way back bar pusher position after the ex traction movement 1 5 2 3 6 7 8 ...

Page 122: ...302 035 the display will read by pressing the display will read press enter the value detected E g F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r 1 B p r e f 2 C B 3 C 4 B u s h 5 L u b 6 E n d 1200 ...

Page 123: ...gend 1 All the way back bar pusher position 2 Bar pusher position at bush holder device inlet opening of half bushes 3 Bar pusher position at nose outlet lubrication stop 4 All the way forwards bar pusher position 5 Facing flag 6 Spindle 7 All the way back headstock position 8 All the way forwards headstock position 9 All the way back sleeve position 10 All the way forwards sleeve position 11 All ...

Page 124: ...e times or scroll them down bypressing once the display will read press the following screenful will be displayed press enter the value detected E g F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r 1 B p r e f 2 C B 3 C 4 B u s h 5 L u b 6 E n d 3740 ...

Page 125: ... read Ex To exit from functions protected by the access code Scroll functions up press or scroll them down by pressing the following message will be displayed press F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r B 1 3 9 0 C B 1 9 0 C 1 2 0 0 A 3 6 0 F 3 7 4 0 L 2 9 2 0 B o 2 6 0 0 C X X XX F1U s e r m o d e F2 0 p i e c e s F3Mo t T h o u r F4Mo t P h o u r ...

Page 126: ...the and ma chining Some parameters have a default value pre set value Should said values not be changed the bar feeder will perform the automatic cycle Parameters are relevant either to the working or bar change over phase In the working phase lathe performs machining whereas during the bar change over the lathe stops to allow the bar feeder to change the bar General instructions Start from the ma...

Page 127: ...x To enter or change the parameter value The required value must be displayed Ex enter the value to assign Ex the following message will be displayed In case of typing error press to clear the figure To return to the main menu press m o v e t o p a r a m e t e r n o 1 mm n o 1 b a r e n d a d j u s t m e n t 125 1 2 5 mm n o 1 b a r e n d a d j u s t m e n t ...

Page 128: ...ll parameter values return to the previous values press to clear the change relevant to the displayed parameter the parameter returns to the previous value by pressing the following message will be displayed enter the number of the required parameter Ex by pressing the parameter defaults To return to the main menu press twice F1C a n c e l a l l F2 C a n c e l F3G o t o p a r F4D e f a u l t Funct...

Page 129: ...int C facing point Accepts both positive and negative values Controls facing position 1 In position the bar moves to the point defined in parameter 2 2 To the stop the bar exceeds the point defined in parameter 2 and moves to the bar catch or to the tool 1 Phase Default machining 100 mm mm n o 1 b a r e n d a d j u s t m e n t parameter 1 35 003 Ec 0 mm n o 2 f a c i n g l e n g t h 2 Phase Defaul...

Page 130: ...Increase the workpiece length of at least two millimetres INFORMATION in sliding headstock lathes this parameter can be used to check a possible tool break enter a value of a few millimetres max 5 mm Controls the section length for each feeding increasing speed before the open collet speed section parameter 7 Should value entered be zero the bar feeds at open collet speed all along the feeding str...

Page 131: ...l from lathe the bar pusher con tinues to push according to the time previously entered Application example to be used when the mechanical collet closing is slow double cone collet Controls the slowing down section length before the entry into collet This value concerns point C facing point Along said section the bar moves according to the entry into collet speed parameter 11 n o 7 o p e n c o l l...

Page 132: ...et easier Controls any slowing down point parameter 10 Description of phases the bar is fed along the slowing down section the bar meets with the obstacle collet thus activating impulses the bar enters into collet INFORMATION should the bar find another obstacle before getting out of the slowing down section the bar feeder stops in an EMERGENCY Controls the impulse forward backward stroke paramete...

Page 133: ...ry into collet easier Description of phases the bar is fed along the slowing down section parameter 10 the bar meets with the obstacle collet and the lathe receives the impulse to turn the spindle according to the time previously entered the spindle slows down and stops according to the time entered into parameter 18 the bar receives the feeding impulse if the bar enters into collet the cycle cont...

Page 134: ...le the CYCLE START signal must be delayed when the spindle needs a certain time before reaching the correct working rotation speed Controls the bar remnant 1 Extraction 2 Ejection 3 Bar change over advance 1 Extraction Description of the phases at bar end the bar pusher and remnant are in the lathe spindle 18 Phase Default bar change over 0 sec s e c n o 1 8 s p i n d l e i m p u l s e s o f f 19 ...

Page 135: ... from the lathe side 2 Ejection There are two selections possible a Ejection through the new bar b Ejection through the bar pusher a Ejection through the new bar Description of phases the lathe receives the BAR END signal from the bar feeder machines the last workpiece shifts into the subprogram the catch moves away and sends the OPEN COLLET and BAR CHANGE OVER signals the bar pusher reaches point...

Page 136: ...fit a switch S59 controlling the bar change over cycle into the electric control panel see the electric diagram use the lathe BAR CHANGE OVER ADVANCE signal if supplied Description of phases the lathe receives the BAR END signal from the bar feeder thus activating input 449 the bar feeder pusher strokes back inserts the new bar into the guide and waits for the OPEN COLLET and BAR CHANGE OVER signa...

Page 137: ...he collet is closed the feed motor is stopped and disabled when the collet is open feed motor stopped 4 locked The bar headstock synchronizing function is enabled when the collet is closed the feed motor is stopped and disabled when the collet is open feed motor stopped 5 sync with open collet This mode is only active when parameter 33 is in mode 3 SLIDING BUSH The bar headstock synchronizing func...

Page 138: ...tops the lathe with OPEN COLLET 0 Parameter function desactivated 0 When minutes entered have elapsed the bar feeder stops lathe with OPEN COLLET It sets the voltage received by the feed motor during bar thrust with a closed collet It will accept values from 0 to 7 This parameter is only active when parameter 33 is in mode 2 SLIDING 24 Phase Default 0 machining n o 2 4 b a r p u s h e r s t o p w ...

Page 139: ...enever the lathe collet is replaced with a collet having different dimensions When adjusting point F parameter 1 changes as shown in the figure Controls the language of the information displayed 1 Italiano 2 Francais 3 English 4 Deutsch 5 Español 6 Svenska or Suomi 28 Phase Default bar change over 0 mm mm n o 2 8 m a x f e e d i n g p o s i t i o n m o d i f i c a t i o n F 31 047 Ec 0 No adjustme...

Page 140: ...ess the following message will be displayed enter the access code not displayed Should the code be false the following message will be displayed press any key Ex and repeat the procedure If the code is correct the following message will be displayed General procedure Start from the main menu by pressing the last parameter will be displayed F1C l u t c h F2 P a r a m e t F3Ma c h i n i n g F4C N e ...

Page 141: ...parameter press the following message will be displayed enter the required parameter number Ex To return to the main menu press To exit from parameters protected by the access code Scroll functions up press or scroll them down by pressing the following message will be displayed press m o v e t o p a r a m e t e r n o 31 F1U s e r m o d e F2 0 p i e c e s F3Mo t T h o u r F4Mo t P h o u r ...

Page 142: ...e contact 5 active closed continuous contact 0 when contact is off 1 when contact is on 2 man from lathe aut from bar feeder 31 Phase Default 1 n o 3 1 b a r f e e d e r i n t e r f a c e c o n t r o l 32 Phase Default 0 n o 3 2 K 1 i mm e d i a t e e x i t 33 Phase Default 1 n o 3 3 t y p e o f h e a d s t o c k 34 Phase Default 1 n o 3 4 f e e d i n g s t o p m o d e 65 Phase Default 1 n o 6 5 t...

Page 143: ... thrust value according to the bar dimensions and features min 0 max 125 INFORMATION should thrust be too weak the bar fails to feed or has some dif ficulty during feeding should thrust be too strong the bar feeding might damage both the lathe and the bar Allows access to parameters see paragraph Parameters Description and entry Positions bar feeder in the WORKING phase press F1C l u t c h F2 P a ...

Page 144: ... bar or bar remnant it must be in the OPEN COLLET and BAR CHANGE OVER condition Bar feeder must be in the WORKING phase bar must be in the magazine only press The bar pusher accomplishes a forward stroke The bar pusher accomplishes a backward stroke and as it is with no remnant the function remnant safety has to be overridden press The bar pusher concludes the bar change cycle Function F4 ...

Page 145: ...ressing The following sequence will be displayed F1C l u t c h F2 P a r a m e t F3Ma c h i n i n g F4C N e w b a r Ma n u a l p i e c e s n o 0 m a c h i n i n g 0 0 t y p e t h e c o d e 0546 w r o n g c o d e p r e s s a n y k e y r i g h t c o d e F1C l u t c h F2 P a r a m e t F3Ma c h i n i n g F4C N e w b a r Ma n u a l p i e c e s n o 0 m a c h i n i n g 0 0 F1 P o i n t s F2G o t o F3 F4 F...

Page 146: ...in menu press one or more times To exit from functions protected by the access code Scroll functions up press or scroll them down by pressing the following message will be displayed press F1U s e r m o d e F2 0 p i e c e s F3Mo t T h o u r F4Mo t P h o u r ...

Page 147: ... 8 10 6 35 002 Ec 0 9 11 4 4 4 Fixed headstock lathe CNC type sliding headstock lathe Cam sliding headstock lathe Moving sleeve lathe Legend 1 All the way back bar pusher position 2 Bar pusher position at bush holder device inlet opening of half bushes 3 Bar pusher position at nose outlet lubrication stop 4 All the way forwards bar pusher position 5 Facing flag 6 Spindle 7 All the way back headsto...

Page 148: ...ition value mm Ex Function used to move back the bar pusher small pusher truck For a short shift press and release it quickly To obtain a continuous shift press and keep it pressed Function for feeding the small pusher truck or the bar pusher For a short shift press and release it quickly To obtain a continuous shift press and keep it pressed Function F2 200 Function F3 Function F4 ...

Page 149: ...ncy Function used to open the facing flag press Function used to close the facing flag press Function used to open the bush holder device press Function used to close the bush holder device press F1 F l a g o p e n F2 F l a g c l F3 B u s h o p e n F4 B u s h c l Function F1 Function F2 Function F3 Function F4 ...

Page 150: ...g motor operation hours press to reset press When power supply is connected from the lathe it appears it means that 1250 partial operation hours are over and that the motor brush inspection is needed see Use and maintenance manual After servicing the hour counter has to be reset following the above mentio ned instructions Such hour amount has to be reset also if the motor replacement takes place I...

Page 151: ...ards downwards facing press to scroll phases up press to scroll them down press the bar feeder performs the pre set phase press Displays values assigned to the electronic board inputs press Displays values assigned to the electronic board outputs press F1 T o f f s e t F2 P h a s e s F3 S h o w i n F4 S h o w o u t Function F1 Function F2 Function F3 Function F4 ...

Page 152: ...o the piece counter Example assign value 1000 start machining value 1001 will be displayed after the first workpiece press enter the value Ex Enters or changes the self learning values see Self learning values entry into program F1 L e a r n i n g s F2V e r s i o n F3 S p i e c e s F4 I n s S e l f l e a r Function F1 Function F2 Function F3 1000 Function F4 ...

Page 153: ...EEDER ZERO SETTING The max limit is defined by parameter 81 Parameter 81 value is too low Apply to IEMCA service depart ment ERROR CAUSE CURE Bar pusher or small pusher truck feeding not smooth The bar pusher or small pusher truck cannot run freely Remove the cause preventing the regular sliding Electromagnetic clutch operation fault Y10 Check and or replace the electro magnet Electromagnetic clut...

Page 154: ...ible length Contact IEMCA after sales service to modify the bar feeder accordingly special parts for oversize remnant dropping Extraction from the bar pusher col let has not occurred due to wrong clamp adjustment or clamps not suitable for bar profile Adjust or change the clamps ERROR CAUSE CURE During its pre feed or facing stroke the bar has gone too far beyond the point C Value of parameter 2 i...

Page 155: ...ght Adjust the sleeve Rag left by the cutting tool Sharpen the cutting tool Clamp sensor S5 malfunction Check and or replace the sensor ERROR CAUSE CURE During bar change over the clamps have not detected bar presence Bars have run out in the magazine Load bars Bad adjustment of bar selectors Adjust bar selectors Clamp sensor S5 malfunction Check and or replace the sensor 207 E r r o r n o r e m n...

Page 156: ...ck and or replace the electro magnet Electromagnetic clutch bad adjust ment Adjust the electromagnetic clutch Clutch operation fault Check the clutch oil level and disk wear Encoder failure Check the electric connection Check the encoder splining into the pinion shaft Replace the encoder Faulty board Check and or replace the board ERROR CAUSE CURE At pre feed stroke start the facing flag is not cl...

Page 157: ...der failure Check the electric connection Check the encoder splining into the pinion shaft Replace the encoder Faulty board Check and or replace the board ERROR CAUSE CURE The bar exceeds value entered into parameter 5 during feeding Parameter value 5 is too low less than the bar feed Check the bar feed and enter a value at least 2 mm higher into parameter 5 The lathe bar catch is not correctly po...

Page 158: ...heck the encoder splining into the pinion shaft Replace the encoder Faulty board Check and or replace the board ERROR CAUSE CURE The bar pusher has reached the BAR FEEDER ZERO SETTING position but the encoder has detected a different ZERO SET TING position If the difference between the two BAR FEEDER ZERO SETTING positions exceeds 100 mm error 214 is displayed BAR FEEDER ZERO SETTING position fail...

Page 159: ...8 malfunction Check and or replace the sensors ERROR CAUSE CURE The open collet signal exceeded the max time previously entered into parameter 21 During the working phase Parameter 21 value is less than the real lathe collet opening Check the real COLLET OPE NING time and enter one more second into parameter 21 INFORMATION should parameter 21 value be zero its function is overridden During the bar...

Page 160: ...are powered The thermal switch Q2 of motor M3 controlling guide opening and insertion extraction has tripped Motor overheating Check motor rated current Check current range at phase wires The thermal switch Q1 of motor M2 controlling the lubricating sys tem has tripped Check thermal switch setting If motor absorption is higher than the rated value see the data plate check the motor controlled mech...

Page 161: ...into parameter 8 is higher than the real COLLET OPE NING time Reduce parameter 8 value must be less than the real COLLET OPENING time or increase the lathe COLLET OPENING time Bar change over phase The bar machining is over The lathe sends the OPEN COLLET and BAR CHANGE OVER signals The bar pusher delays for some programmable time before moving backwards the OPEN COLLET signal has been interrup te...

Page 162: ...CURE Bar feeders with parameter 65 into 3 active continuos open contact or 5 active closed continuous con tact mode only The START signal from lathe fails to be continuous Failure of lathe interfacing Check lathe interfacing and condi tion Faulty board Check and or replace the board ERROR CAUSE CURE During the machining phase the guides are not fully closed the sen sor S2 is not energized Faulty s...

Page 163: ...unzionamento dell innesto elettromagnetico Y10 d innesto frizione Verificare e o sostituire l elettromag nete L innesto elettromagnetico della frizione é mal regolato Regolare l innesto elettromagnetico Difetto di funzionamento della frizione Verificare il livello dell olio della frizione e lo stato di usura dei dischi Encoder failure Check the electric connection Check the encoder splining into t...

Page 164: ... stroke value mm 13 DIMENSION Bo Half bush opening point value 1350 mm 14 DIMENSION L Lubrication stop point value 1350 mm 15 DIMENSION C Bar facing stroke value 1350 mm 16 DIMENSION F Bar pusher furthest feeding point value 1300 mm 18 PLC card serial number Enabling card serial number EEPROM model LIST OF THE SELF LEARNING VALUES HARDWARE IDENTIFICATION DATA ...

Page 165: ...60 3 OPERATION INFORMATION 302 035 ...

Page 166: ...10 mm mm 27 15 Bush opening machining 80 mm mm 28 16 Bushing closing bar change over 150 mm mm 28 17 Spindle impulses on bar change over 0 sec sec 28 18 Spindle impulses off bar change over 0 sec sec 29 19 Cycle start lag bar change over 0 sec sec 29 20 Remnant handling bar change over 1 29 21 Open collet timeout machining 0 sec sec 31 22 Workpiece timeout machining 0 sec sec 31 23 Use of synchron...

Page 167: ...62 302 035 3 ...

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IEMCA BOSS 542 CNC, Manual For Use And Maintenance

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