IEMCA Elite Evo Series Manual For Use And Maintenance Download Page 115

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6 - USE AND OPERATION Elite112_220_Evo_SIII

6 - Pag. 1 / 1

INDEX

6.1

PRELIMINARY NOTE ON USE AND OPERATION ......................................................... 2

6.2 CONTROL

DESCRIPTION .......................................................................................... 2

6.3

KEYBOARD CONTROL DESCRIPTION ......................................................................... 5

6.4 LIGHT

INDICATOR DESCRIPTION ............................................................................. 9

6.5

BARS TO BE MACHINED - FEATURES AND PREPARATION ........................................ 10

6.5.1

BAR TO BE MACHINED - SOLID BARS ..................................................................... 10

6.5.2 BARSTOCK - PIPES ................................................................................................ 13

6.5.3 BAR

STRAIGHTNESS - Measurement ....................................................................... 14

6.6

BAR FEEDER SETUP AND AUTOMATIC CYCLE START ............................................... 16

6.6.1 Bar

magazine - Filling ............................................................................................. 17

6.6.2

Lubrication oil - Flow adjustment ............................................................................ 19

6.6.3 Automatic

cycle start .............................................................................................. 20

6.6.4

Guide channel opening/closing procedure ................................................................ 22

6.6.5

Cycle performing mode in the STEP BY STEP function .............................................. 23

6.7

BAR FEEDER STOP ................................................................................................. 24

6.8 AXIS

CALIBRATION PROCEDURE ............................................................................ 25

6.9

MACHINING CHANGE - QUICK GUIDE

.............................................................. 26

6.9.1

Machining type change with guide channel change .................................................. 26

6.9.2

Machining type change without guide channel change .............................................. 26

Summary of Contents for Elite Evo Series

Page 1: ...60005470 S N COMPILER Bosi Andrea ON APPROVAL Sbarzaglia Ivan This manual is a translation of the original document AUTOMATIC BAR FEEDER ATTACHMENTS LIST MANUAL FOR USE AND MAINTENANCE KEYBOARD INSTRUCTION MANUAL SPARE PARTS BOOK SCHEMATICS EC CONFORMITY DECLARATION FOR MACHINE ...

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Page 3: ...6224 TLX 550879 MANUFACTURER 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 MODEL Elite112 220Evo ...

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Page 5: ... 2 5 VERSION DESCRIPTION 21 2 6 TECHNICAL DATA 22 2 6 1 Noise levels 27 2 7 DEVICE FOR SLIDING HEADSTOCK LATHES FOREWORD 28 2 7 1 Axial displacement device Optional Description 28 2 7 2 Bar headstock synchronization device Description 29 2 7 3 Diaphragm bushing device OPTIONAL for Elite 220 only Description 30 2 7 3 1 Additional bush device Optional Description 30 2 7 4 Telescopic front nose Descr...

Page 6: ...tallation 6 4 4 2 Height Adjustment 6 4 4 3 Preliminary positioning 7 4 4 4 Front nose Installation 8 4 4 5 Levelling and alignment 9 4 4 7 Bar feeder fastening 16 4 5 DEVICE FOR SLIDING HEADSTOCK LATHES INSTALLATION 17 4 5 1 Bar headstock synchronization device 17 4 5 2 Telescopic front nose Installation 18 4 6 DEVICES FOR CAM LATHES INSTALLATION 19 4 6 1 Cam box 19 4 6 2 Camshaft release device ...

Page 7: ...3 4 Front nose Replacement 13 5 4 CAM BOX TIMING 14 5 5 BAR SUPPORT ASSEMBLY 17 5 6 Removal Feeding clamp device Adjustment 18 5 7 Sloped rack magazine enabling for Elite 220 only 19 5 7 1 Sloped rack magazine disabling for Elite 220 only 20 5 7 2 Bar guide plates and bar selectors Adjustment for Elite 220 only 21 6 USE AND OPERATION Elite112_220_Evo_SIII 1 6 1 PRELIMINARY NOTE ON USE AND OPERATIO...

Page 8: ... 25 7 BAR FEEDER MAINTENANCE Elite112_220_Evo_SIII 1 7 1 PRELIMINARY NOTE ON MAINTENANCE 2 7 2 SCHEDULED MAINTENANCE 2 7 3 MAINTENANCE GENERAL RULES 3 7 4 SCHEDULED MAINTENANCE 4 7 4 1 Revolving tip and collet Check 4 7 5 Lubricating oils Change 5 7 5 1 Lubricating oil Level check 6 7 5 2 Lubricating oil Change 7 7 5 3 Air filter unit Check 7 7 6 GREASING POINTS 8 7 7 DISPLACEMENT DEVICE USE 9 8 T...

Page 9: ...le 10 11 COLLETS Elite 1 11 1 HEXAGONAL BARS unit of measurement millimetres Table 2 11 2 SQUARE BARS unit of measurement millimetres Table 4 11 3 HEXAGONAL BARS unit of measurement inches Table 5 11 4 ROUND BARS unit of measurement inches Table 6 11 5 CONVERSION TABLE Inches Millimetres 7 11 6 COLLETS FOR BARS 001P Table 9 11 7 COLLETS FOR BARS 222 Table 11 11 8 COLLETS FOR BARS 602P Table 12 11 ...

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Page 11: ...te112_220_Evo_SIII EN 1 Pag 1 1 INDEX 1 1 WARRANTY CONDITIONS 2 1 2 PURPOSE OF THE MANUAL 3 1 3 MANUFACTURER AND BAR FEEDER IDENTIFICATION 4 1 4 ASSISTANCE REQUEST MODE 5 1 5 GLOSSARY AND TERMINOLOGY 5 1 6 ATTACHED DOCUMENTS 6 ...

Page 12: ...t assembly and coupling of the bar feeder to the lathe In particular prior to the first start up accurately make sure that the bar feeder is correctly aligned with the lathe and fixed with the expansion plugs as shown in chapter 4 The product warranty is valid only if the bar feeder is installed by an authorized technician with Original Installation Certificate Please ask the technician who will m...

Page 13: ...g symbols DANGER WARNING indicates impending danger which might cause serious injuries exert the maximum caution WARNING CAUTION indicates that it is necessary to adopt suitable behaviours so as to avoid accidents or damages to property INFORMATION these are technical instructions of particular importance For a quick search of the topics see the table of contents This manual which contains all the...

Page 14: ...eder model E Serial number G Mains frequency H Power consumption M Supply voltage N Bar feeder weight P Pneumatic system pressure Q Bar feeder and bar pusher length R Interrupting power S Basic Wiring Diagram Number T Interface Wiring Diagram Number INFORMATION always provide the manufacturer with the above mentioned specifications when requesting information or ordering spare parts etc ...

Page 15: ...bar feeder Expert operator authorized person chosen among those who have the requirements competence and information needed for the installation operation and scheduled maintenance of the bar feeder Loading axis axis of the bar coinciding with the spindle axis of the lathe Remnant final ejection portion of the machined bar Facing position position of the bar in the lathe during the facing phase So...

Page 16: ...rational parameter setting Interface wiring diagram Spare parts catalogue contains the coded drawings of the bar feeder components to use in case it is necessary to place an order of parts that need to be replaced CD Rom containing all the above mentioned documents inclusive of the Operation and Maintenance Manual the Brochure with all the technical requirements of the bar feeder the wiring diagra...

Page 17: ...CRIPTION 21 2 6 TECHNICAL DATA 22 2 6 1 Noise levels 27 2 7 DEVICE FOR SLIDING HEADSTOCK LATHES FOREWORD 28 2 7 1 Axial displacement device Optional Description 28 2 7 2 Bar headstock synchronization device Description 29 2 7 3 Diaphragm bushing device OPTIONAL for Elite 220 only Description 30 2 7 3 1 Additional bush device Optional Description 30 2 7 4 Telescopic front nose Description 31 2 8 DE...

Page 18: ...rials The guide channel is completely closed during machining a pump is provided to maintain a continuous oil flow inside the guide channel creating a hydrodynamic support effect these features allow the bar to rotate at high r p m with no vibrations and no surface damaging Thanks to the use of a BRUSHLESS and electronically controlled motor the bar speed torque value and bar feeding position may ...

Page 19: ...P stores the bars E LUBRICATION PUMP delivers oil to the guide channels F REMNANT RECOVERY BOX bar remnants are dropped into this box after extraction from the bar pusher collet G KEYBOARD it allows bar feeder programming and function actuation H PRESSURE REGULATOR to adjust the pressure of the pneumatic devices L TELESCOPIC NOSE allows bar guidance between the bar feeder and the headstock M ENCOD...

Page 20: ... machining S MOTOR DRIVE moves the bar magazine to drop the bar onto the lower guide channel T CLAMPS hold the bar during the loading and removal from the bar pusher collet for Elite 220 only W OPENING CLOSING PNEUMATIC CYLINDER to provide motion to the pneumatic devices that allow upper and lower clamp opening closing U SYNCHRONIZATION DEVICE allows the synchronized movement of bar pusher and lat...

Page 21: ...LATOR FILTER GROUP B FACING CYLINDER C PNEUMATIC CLAMP CYLINDER D UPPER GUIDE CHANNEL OPENING CLOSING CYLINDER REMNANT DROP F REGULATOR G SOLENOID VALVE UNIT H BAR SELECTION UNIT for Elite 220 only I BUSHING DRIVE UNIT Optional for Elite 220 only L LOWER GUIDE CHANNEL OPENING CLOSING CYLINDER REMNANT DROP ...

Page 22: ...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 are in their backwards limit stop position The clamps D close and the bar pusher moves backwards the remnant is removed from the collet The clamps open and the remnant is dropped into the box E ...

Page 23: ...Rack Pilgrim Step Magazine Upper guide channels H open magazine bar feeding device F rises and lifts first bar G which falls onto the guide channel The bar selection device F is lowered Bar Drop from the Sloped Rack for Elite 220 only Upper guide channels H open together with bar pusher A bar selection device F moves upwards thereby lifting the first bar and withholding the remaining bars bar G dr...

Page 24: ...completes its stroke the required space has been created for bar pusher insertion The first feeding carriage performs the return stroke The upper guide channels H close 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 A H A12M_02_013_00 ...

Page 25: ...2 TECHNICAL INFORMATION Elite112_220_Evo_SIII EN 2 Pag 9 9 The bar pusher A and bar G carry out their facing stroke A new automatic working cycle is started ...

Page 26: ...al to or slightly shorter than the magazine length and after the facing phase The active rack sensors are sensors number 3 and number 4 From this position when the bar pusher reaches the preset encoder value the guide channel control cam moves until sensors number 5 4 switch on thus opening the first guide channel 3 5 6 7 8 9 4 2 1 A12M01_02_026a_00_3_4 3 5 6 7 8 9 4 2 1 A12M01_02_026a_00_5_4 ...

Page 27: ...rwards the guide channel control cam opens the third guide channel stopping on sensors 6 4 Following the same sequence when the bar pusher moves forwards the guide channel control cam opens the fourth guide channel stopping on sensors 7 4 3 5 6 7 8 9 4 2 1 A12M01_02_026a_00_6_4 3 5 6 7 8 9 4 2 1 A12M01_02_026a_00_7_4 ...

Page 28: ... cam opens the sixth guide channel stopping on sensors 9 When the guide channels 1 3 4 5 and 6 are lifted sensors 3 5 6 7 8 and 9 are all active Notice that even during the facing phase if the guide channel lifting values are reached the guide channel control cam must be positioned up to the opening of the corresponding sectors Guide channel number 2 is pneumatic and follows the logics like the ot...

Page 29: ...tches on to close the fifth guide channel sensor 8 should be OFF and sensor 4 ON to close the fourth guide channel sensor 7 should be OFF and sensor 4 ON to close the third guide channel sensor 6 should be OFF and sensor 4 should be ON and to close the first guide channel it must disengage sensor 5 and engage sensor 4 When all guide channels are closed again the only active sensors will be 3 and 4...

Page 30: ...ction sensor checks for the remnant presence If the cycle is set to removal or to bar change advance phases number 2 3 4 5 and 6 are skipped Via the feeding motor the remnant is removed at the preset value The clamps open and the remnant falls down The clamps close again to make sure that the remnant is no longer there and test the remnant bar detection sensor The clamps open again after checking ...

Page 31: ...OPENING BAR FEEDING 5 4 4 3 2 1 0 A12M_02_029_00 The guide channel control cam moves until it switches on sensor number 2 which is the only active sensor All four guide channels open The magazine performs a step and a new bar is fed into the guide channel 3 5 6 7 8 9 4 2 1 A12M01_02_029a_00 ...

Page 32: ...0_00 The guide channel control cam moves until it switches on sensor number 1 which is the only active sensor After the Feeding Removal clamp device the guide channels close The carriage moves up to the first feeding value set When the carriage reaches the first feeding value the first feeding carriage carries out the return stroke to zero 3 5 6 7 8 9 4 2 1 A12M01_02_030a_00 ...

Page 33: ... cam moves until it switches on sensors 3 and 4 which are the only active ones All guide channels close and also the clamps close to lock the bar during the clamp closure the new bar is detected via the remnant bar detection sensor Via the feeding motor the new bar is fed into the collet the clamps open and the facing stroke is carried out Restart from the 0 phase 3 5 6 7 8 9 4 2 1 A12M01_02_028a_...

Page 34: ...l be stopped if the guide channels are not closed during guard opening if the guide channels are closed the bar feeder functions are not disabled because no risks for the operator are present automatic cycle during the bar feeding phase the guard opening may be necessary for the purpose of filling the magazine Even if the bar feeder functions are not stopped there are no hazards for the operator i...

Page 35: ... of transparent material to allow visual inspection of the bar magazine area H REMNANT RECOVERY BOX it also acts as a fixed guard to prevent accidental access to moving parts M MAIN SWITCH disconnects the electric power supply during the operations in the electrical control panel and during the bar feeder inactivity periods ...

Page 36: ...nds inside when there are components in motion B Do not remove guards it is forbidden to use the bar feeder without the guards installed and in operating conditions C Electrocution hazard do not enter the powered elements D Risk of inopportune movements before carrying out the first start make sure that the bar feeder is adequately anchored to the ground E Obligaton of wearing appropriate clothes ...

Page 37: ...RIPTION Maximum minimum bar length Model Version Maximum length mm ft Minimum length mm Elite 32 3200 10 5 ft 1200 37 3700 12 ft 1200 Max bar pusher extension Model Version Version A Max extension mm Elite 32 37 L 915 LL 1200 XL 1485 A12M_02_25_00 B A C B Revolving tip C Nipple ...

Page 38: ...I 2 Pag 22 22 2 6 TECHNICAL DATA 141 641 650 B 910 C 76 5 A A12M_02_001_00_220 S 53 365 130 185 19 555 170 365 250 H 212 550 521 185 Overall dimensions 32 37 Model Version A mm B mm C mm H mm Elite 32 3788 1114 473 900 1200 37 4358 1635 522 900 1200 ...

Page 39: ...4 mm Adjustable feeding speed Max 1000 mm sec Adjustable return speed max 1600 mm sec Remnant length standard version min 80 mm max 400 mm Bar change time with 3 000 mm bar Version 32 26 sec Power supply voltage 230 400 Volt Mains frequency 50 Hz 60 Hz Control voltage 24 Volt D C Installed power 1 3 kW Oil quantity 40 l Maximum air supply pressure 8 bar Minimum air supply pressure 6 bar Pneumatic ...

Page 40: ... Adjustable feeding speed Max 1000 mm sec Adjustable return speed max 1600 mm sec Remnant length standard version min 80 mm max 400 mm Bar change time with 3 000 mm bar Version 32 26 sec Power supply voltage 230 400 Volt Mains frequency 50 Hz 60 Hz Control voltage 24 Volt D C Installed power 1 3 kW Oil quantity 40 l Maximum air supply pressure 8 bar Minimum air supply pressure 6 bar Pneumatic ener...

Page 41: ...mm Pilgrim step magazine max loading height Z mm Magazine with sloped rack max loading height Elite 1 905 945 960 1065 2 940 980 995 1100 3 975 1015 1030 1135 4 1010 1050 1065 1170 5 1045 1085 1100 1205 6 1080 1120 1135 1240 7 1115 1155 1170 1275 8 1150 1190 1205 1310 9 1185 1225 1240 1345 10 1220 1260 1275 1380 11 1255 1300 1315 1415 ...

Page 42: ...p Acer 32 Api Api Cis 32 BP Energol CS 32 Castrol Magna 32 Chevron Circulating Oil 32 Elf Movixa 32 Esso Nuto 32 Fina Solna 32 IP IP Hermea 32 Klüber Crucolan 32 Mobil Vectra Oil Heavy Olio FIAT Daphne LPN 32 Roloil Arm V 32 Shell Vitrea 32 Tellus C 32 Tamoil Industrial Oil 32 Texaco Omnis 32 Total Cortis 32 Q8 Verdi 32 Oil quantity 40 litres ...

Page 43: ...eder 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 machined bar all bar feeder guards must be closed Should the above mentioned conditions be met the noise level emitted during the bar rotation into the guide channel measured in compliance with the international standards will ...

Page 44: ...een designed and manufactured to be coupled to sliding headstock lathes too To this purpose the following special device is available 2 7 1 Axial displacement device Optional Description It allows the bar feeder to be moved away from the lathe to allow maintenance cleaning or any other servicing of the lathe A12M_02_014_00_1 600 mm ...

Page 45: ...e112_220_Evo_SIII EN 2 Pag 29 29 2 7 2 Bar headstock synchronization 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 46: ...der has completed the bar loading cycle The oil flow for the machined bar lubrication and support starts together with the closing phase When the bar pusher approaches the device the diaphragm baffle plates open to allow it to transit and the oil flow is simultaneously discontinued 2 7 3 1 Additional bush device Optional Description The additional bush B is installed in the rear part of the slidin...

Page 47: ...sed to optimize bar guiding between the front portion of the bar feeder and the lathe spindle example with diaphragm bush for Elite 220 only Example Elite 112 Evo Maximum stroke and overall dimension Model Max stroke A mm Overall dimensions B mm Elite 120 230 160 320 170 200 220 260 320 310 A12M_05_03_02_02s ...

Page 48: ...e available which are listed and then described below 2 8 1 Cam box Description Used to synchronize the bar feeder and cam lathe movements The cams located in the box A are connected to the lathe camshaft B 2 8 2 Camshaft release device Description Releases and engages the camshaft during the bar change phase A radial version and an axial version of this device are available A Radial version B Axi...

Page 49: ...L SAFETY REGULATIONS 2 3 2 HANDLING AND INSTALLATION Safety 3 3 3 ADJUSTMENTS AND SETUP Safety 3 3 4 USE AND OPERATION Safety 4 3 5 BAR FEEDER MAINTENANCE Safety 4 3 6 EC DECLARATION OF CONFORMITY 5 3 7 GENERAL DESCRIPTION OF SUPPLY 6 3 8 RESIDUAL RISKS 7 3 9 FORESEEABLE MISUSES 12 ...

Page 50: ...ulations at work issued by the relevant authorities in each country IEMCA declines any liability for injury to persons or damage to property if the relevant safety regulations are disregarded The bar feeder must only be used for the procedures indicated by IEMCA no other improper use is allowed During operation the bar feeder will release small amounts of oil mist Install the bar feeder in a suita...

Page 51: ...ighting and cleanliness of the working environment are of the utmost importance for personal safety The connection to the electrical installation must be carried out by skilled personnel only Make sure that the electrical installation is connected to an efficient earthing system by means of an appropriate cable 3 3 ADJUSTMENTS AND SETUP Safety Carry out the adjustments as described in the operatio...

Page 52: ...r by the safety regulations in force in all countries Inform the maintenance personnel of any operating anomalies Before starting the bar feeder make sure that there is no personnel engaged in servicing or cleaning the machine 3 5 BAR FEEDER MAINTENANCE Safety Do not allow unauthorized personnel to carry out maintenance operations Read this manual carefully before carrying out maintenance operatio...

Page 53: ...on his own responsibility that the machine AUTOMATIC BAR FEEDER ELITE type model registration number is in compliance with the requirements of 2006 42 EC regulation and with the national implementing regulations is in compliance with the following European regulations o 2006 95 EC regulation low tension o 2004 108 EC regulation electromagnetic compatibility Otherwise he declares that the person in...

Page 54: ...uest Applicable Safety Regulation According to Directive 2006 42 EC article 2B the bar feeder is an interchangeable equipment and is supplied with the appropriate safety devices Together with the supply you will find the EC declaration of conformity in compliance with the above mentioned Directive The list of the safety devices is shown in section 2 paragraph 2 3 of this manual The bar feeder shou...

Page 55: ...low these indications wait 60 sec until the capacitor is discharged remove the three phase voltage by operating on the disconnecting device upstream from the supply line or disconnect the interface connector FLUID LEAKAGE RISK It is forbidden to top up the lubricating oil tank while the oil pump is running Do not let the oil or coolant leak from the lathe out to the bar feeder Here are some exampl...

Page 56: ...ement or maintenance work inside the bushing holding equipment should only be performed after switching the bar feeder off 2 With the bar feeder in automatic mode there is a potential crushing risk if you reach your hands and arms into the guide channel area bar pusher movement ...

Page 57: ...sliding headstock lathes 3 The technician will perform installation without securing the bar feeder to the ground However in the report to the customer certifying that installation has been completed he will state that the customer requested that the machine be not secured to the ground BREAKING RISK DURING OPERATION 1 After performing scheduled or unscheduled maintenance work remove any foreign o...

Page 58: ...ferenced above Stop the oil flow using the cock provided put the bar feeder in manual mode and switch off the oil pump by pressing the key on the keyboard ACCESS TO THE INTERVENTION POINTS USED FOR MAINTENANCE 1 Press the stop button before moving the bar pusher forward using the crank 2 During the work phase if protection guards have been removed it is strictly forbidden to insert the crank into ...

Page 59: ...ENCE OF PHASES It is very important that the operator knows the sequence of the bar feeder work phases These can be found in the Instruction Manual supplied with the machine DIFFERENTIAL CURRENT DEVICE UPSTREAM FROM THE MACHINE USED TO PREVENT HAZARDOUS CONDITIONS IN CASE OF A FAILURE Make sure that the bar feeder is powered by a three phase power supply protected through a differential switch wit...

Page 60: ...the manufacturer Do not load bars made of flammable materials Do not load bars with a greater straightness than the one recommended by the manufacturer Do not load bars with sizes or shapes different than those recommended by the manufacturer Do not interfere with any body part on the bar feed axis Do not approach the bar feeder with open flames or very hot objects for examples cigarettes Danger o...

Page 61: ...itioning 7 4 4 4 Front nose Installation 8 4 4 5 Levelling and alignment 9 4 4 7 Bar feeder fastening 16 4 5 DEVICE FOR SLIDING HEADSTOCK LATHES INSTALLATION 17 4 5 1 Bar headstock synchronization device 17 4 5 2 Telescopic front nose Installation 18 4 6 DEVICES FOR CAM LATHES INSTALLATION 19 4 6 1 Cam box 19 4 6 2 Camshaft release device 20 4 7 LUBRICATION OIL FILLING 22 4 8 ELECTRICAL CONNECTION...

Page 62: ...ANDLING AND INSTALLATION Elite112_220_Evo_SIII 4 Pag 2 2 4 8 3 FUNCTION SIGNALS 26 4 9 PNEUMATIC DEVICE LAYOUT 27 4 9 1 PNEUMATIC CONNECTION 30 4 10 MACHINING PARAMETERS SETTING 32 4 11 BAR FEEDER TESTING 32 ...

Page 63: ...TE the bar feeder is contained in a crate and wrapped with protective film 4 1 1 BAR SUPPORT DISASSEMBLING WARNING CAUTION Bar support B should be disassembled during the transport and handling phase Loosen screws A Remove bar support Tighten screws A 4 2 LIFTING DANGER WARNING handling and lifting operations should be carried out with suitable equipment see weight table in section 2 6 and by spec...

Page 64: ...plates inside the bar feeder foot as shown in the picture Use a hook lifting device of adequate capacity LIFTING WITH PALLET Use a hook or fork type lifting device 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 DANGER WARNING never use any lifting systems or devices different from the one...

Page 65: ... handling equipment or transport vehicles travelling near the bar feeder The selected area should be illuminated and provided with an electric and pneumatic power supply socket During operation the bar feeder will release small amounts of oil mist Install the bar feeder in a suitably ventilated area but not exposed to weather conditions The bar feeder has not been designed for use in an explosive ...

Page 66: ...he bar feeder next to the lathe Keep it lifted and install the plates A and feet B in the positions shown in the figure 4 4 2 Height Adjustment The bar feeder is normally supplied with the working axis height adjusted to the lathe height However if an adjustment is needed proceed as follows remove the 8 screws A from the plates B on the outer side of bar feeder feet fix the plates with the screws ...

Page 67: ...should not exceed the bar pusher maximum extension A 1 Fixed headstock or sliding rest lathe 2 Sliding headstock CNC lathe 3 Sliding headstock cam lathe INFORMATION it is not always necessary to drive the bar pusher all the way out In fixed headstock lathes its stroke can be reduced to 100 mm to allow the bar feeder to be brought as close as possible to the lathe contact IEMCA After sales Service ...

Page 68: ...just the height of the working axis and the alignment with the lathe by turning the screws of the support feed 4 4 4 Front nose Installation ELITE Install the front nose A on the front plate Install the oil recovery tank B Connect the drain pipe C to the tank A12M_04_016a_00 ...

Page 69: ...eder and lathe is the most critical installation phase therefore this operation should be carried out by experienced personnel with the greatest accuracy WARNING CAUTION an error during the alignment may be the major cause of a bad operation of the bar feeder and of its consequent damage PRELIMINARY PROCEDURE Open the upper guard ...

Page 70: ...ite112_220_Evo_SIII 4 Pag 10 10 LEVELLING Check oil levelling by positioning the level crosswise and lengthwise on the supports of the lower guide channel Carry out the required modifications by turning the screws A on the support feet ...

Page 71: ...MENT Insert the supplied CH8 wrench in the intermediate drive shaft and move the bar pusher to its backwards limit stop To access the shaft you need to remove the protection guard A To access the guide channel opening and closing shaft you need to remove the protection guard B ...

Page 72: ...ND INSTALLATION Elite112_220_Evo_SIII 4 Pag 12 12 Loosen screw C Leave screw E to support the guard the microswitch D is now free and the display shows the message 18 Error Bar Feeder Emergency see instruction manual ...

Page 73: ... channel opening shaft and open the upper guide channels To obtain alignment lead a ø 1 mm nylon thread between the lathe collet and the bar feeder rear plate then proceed as follows place a drilled bush A in the lathe collet stretch out the thread to the hole in the rear plate B B A A12M_04_027_00 ...

Page 74: ...the four directions prepare a perfectly straight ground bar with an external diameter equal to the maximum spindle bar passage and with a length equal to the double coupling distance see B in the Preliminary Positioning section Chap 4 place the bar in the guide channel and cause it to slide forwards and backwards in the spindle until the lathe collet area is reached ...

Page 75: ...e carried out Adjust height by turning the screws in the support feet carry out lateral adjustments with calibrated mallet blows on the sides of plates E During this phase any adjustment carried out during the levelling phase should be preserved therefore in most cases it is necessary to find the correct adjustment of the bar feeder position To access the shaft you need to remove the protection gu...

Page 76: ...ng and alignment once more Remove all the equipment used for the levelling and alignment phases and restore the initial bar feeder conditions FASTENING TO THE LATHE Wherever possible the bar feeder should be fixed to the lathe with a suitable coupling unit according to lathe brand and type The figure shows a general example of fixing contact IEMCA service department for more information ...

Page 77: ...e upper guard INFORMATION the figure shows a general example of installation contact IEMCA service department for more information Loosen 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 78: ...ATION the lathe spindle front nose B should not turn If it does a support or another similar device should be fitted to prevent telescopic front nose turning after it has been installed Move the headstock to its completely backwards position and measure the value L Push the telescopic front nose to its stroke end less 5 mm and cut tube D by the value measured Move the headstock to its completely f...

Page 79: ...4 6 DEVICES FOR CAM LATHES INSTALLATION 4 6 1 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 80: ... 6 2 Camshaft release device INFORMATION the figure shows 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 81: ...rt shaft L into joint M and fix it using a pin O Insert the other end of shaft L into joint N and fix it using pin R After completing the above described operations the actuator rotation stroke should be adjusted this operation is necessary for both the radial version and the axial version Loosen screws P position cursors Q to the mechanical limit stop and tighten screws P ...

Page 82: ...2 22 4 7 LUBRICATION OIL FILLING WARNING CAUTION wear personal protections according to the regulations in force Open the rear base door and pour oil into the tank Check the level by means of the indicator A See Technical Data in Chap 2 for the comparative table ...

Page 83: ...eder is normally provided with 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 8 1 THREE PHASE POWER SUPPLY The robot must be provided with a three phase voltage and with a suitable earthing connection The three phase supply line shou...

Page 84: ...der Guard safety signal from the lathe to the robot 2 channels contacts off open guards Whenever the above mentioned channels are closed the bar feeder informs the lathe that the guards are closed and the lathe can so carry out all the movements displacement as well as Whenever one of the bar feeder guards is open these signals are stopped in this case the lathe immediately stops safety class 3 al...

Page 85: ...4 HANDLING AND INSTALLATION Elite112_220_Evo_SIII EN 4 Pag 25 25 DANGER WARNING ...

Page 86: ...sary to its correct operation These signals are managed by a PLC and can be grouped into inputs signals from lathe to bar feeder and outputs signals from bar feeder to lathe The signals that have been implemented are the result of our long experience and allow the connection with every type of lathe it is therefore possible that only some of them are used IMPORTANT for further information please r...

Page 87: ...BREVIATION DESCRIPTION FUNCTION 112 Evo 220 Evo C1 Cylinder Controls the clamp opening and closing C2 Cylinder Controls the upstroke of the remnant drop lower guide channel C3 Cylinder Controls the upstroke of the remnant drop upper guide channel C4 Cylinder Controls the short feed gate upstroke ...

Page 88: ...Evo C5 Cylinder Controls the bar lifting plate upstroke and downstroke C6 Cylinder Controls the fore bush opening and closing D Distributor pressure switch Dispenses and adjusts the supply flow inside the pneumatic system VB Solenoid valve unit Cylinder or piston control device see description Solenoid valve box ...

Page 89: ...r lifting upstroke control solenoid valve Bar selection plate upstroke downstroke C Fore bush control solenoid valve Fore bush opening closing D Clamp device control solenoid valve Clamp device closing E Remnant drop solenoid valve Remnant drop lower guide channel opening closing F Facing control device solenoid valve Facing control device resetting Optional For Elite 220 Evo only ...

Page 90: ... CONNECTION Connect the pipe with Ø 8 of the pneumatic network to the quick coupling connection A Install an upstream 3 way cock to perform the sectioning and the pressure release With knob B adjust the pressure at 6 bar IMPORTANT the supply air must be filtered A12M_04_025_00 B A ...

Page 91: ...in case of an emergency it is possible to move the pneumatic units using the solenoid valves manually keep button A pressed using a small screwdriver press the buttons B present on the individual solenoid valves to move the unit INFORMATION For the movement description of each solenoid valve refer to section 4 10 Pneumatic device layout ...

Page 92: ...eeder coupling and to the working needs See the Keyboard instruction manual to assign adequate values 4 11 BAR FEEDER TESTING INFORMATION the bar feeder testing must be carried out following a preset procedure which is possibly indicated and authorised by the manufacturer During the bar feeder testing phase check if the safety conditions are adequate and start it only if this requirement is in con...

Page 93: ...5 3 1 Guide channels half bushes bar pusher and collet Replacement 7 5 3 2 Diaphragm bushing device Description for Elite 220 only 11 5 3 4 Front nose Replacement 13 5 4 CAM BOX TIMING 14 5 5 BAR SUPPORT ASSEMBLY 17 5 6 Removal Feeding clamp device Adjustment 18 5 7 Sloped rack magazine enabling for Elite 220 only 19 5 7 1 Sloped rack magazine disabling for Elite 220 only 20 5 7 2 Bar guide plates...

Page 94: ...s 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 setup may also include replacement of a few components These operations are listed and then described below 5 2 GENERAL ADJUSTMENTS FOREWORD All the necessary adjustments for correct bar feeder operation are included They may become necessary for maintenanc...

Page 95: ... After operating the bar feeder for some hours you should always check the tensioning of the bar pusher feeding chains The chains must be adjusted as follows loosen two nuts B and two screws C adjust the chains tension through screws A restore the bar feeder initial operating conditions ...

Page 96: ... unscrewing the glass protection the pressure switch can be properly adjusted by turning the relevant adjusting screw A Proper setting is 4 5 bar 0 45 MPa WARNING CAUTION Do not further turn anticlockwise when the green pointer is on 0 This may cause damage to the pressure switch A12M_05_002_00 A ...

Page 97: ...r pusher bar and pipe diameters GUIDE DIAMETER mm REVOLVING TIP DIAMETER mm BAR DIAMETER mm LARGEST TUBE DIAMETER mm MIN MAX ELITE 6 5 5 2 1 6 4 7 5 5 8 7 5 2 6 4 7 11 8 5 3 7 4 8 11 10 5 3 8 10 14 12 5 3 10 12 14 13 5 3 11 13 16 15 5 4 13 15 18 16 5 4 14 16 18 17 5 4 15 17 20 18 5 4 16 18 20 19 5 4 17 19 22 20 5 5 18 20 22 21 5 5 19 20 24 22 5 6 19 20 24 23 5 6 20 20 ELITE 112 guide channel bar p...

Page 98: ...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 WARNING CAUTION the collet external diameter should be at least 0 5 mm smaller than the bar pusher external diameter INFORMATION the bar feeder is usually supplied with a bar pusher whose diameter is equal to the lathe spindle drawbar hole Sometim...

Page 99: ... to manual mode Press on the keyboard or use the socket screw key to bring the bar pusher backwards to its limit stop Open the upper guard Open the upper guide channels using the supplied allen wrench for further information refer to the BAR FEEDER HANDLING WITHOUT POWER SUPPLY section Chap 4 DANGER WARNING Before using the crank press the STOP button A12M_05_003_00_112EVO ...

Page 100: ...eeder the bar feeder supports F and the first feeding device G must not be replaced even when changing the bar feeder diameter Now remove and replace the upper and lower guide channels Remove the front nose as follows Fixed front nose Remove the oil recovery device A and front nose B A12M_05_004_01 G F A12M_05_005_01 A12M_05_006_00 B A ...

Page 101: ...12_220_Evo_SIII EN 5 Pag 9 9 Telescopic front nose Remove front nose C Remove the internal front nose If necessary remove the lathe spindle liner and install another one suitable for the diameter of the guide channel A12M_05_008_00 ...

Page 102: ...ct IEMCA service department for further information Legend 4 Quick coupling collet for bars To facilitate the bar entry into the lathe collet if the diameter of the bars to be machined is 3mm it is necessary to insert a bush with a central hole equal to the diameter of the bar feeder guide channels with a 45 kirving the material with which to make the bush can be brass or teflon A12M_05_009_02 ...

Page 103: ...e bar to be machined Further adjust the regulation during bar rotation if necessary If you are using guide channels D 6mm and D 8mm we recommend to disable the device by inserting also the appropriate front noses into the device Remove the front nose E and the flanges F and G Assemble the front nose H supplied with the bar feeder that has the same diameter of the guide channel following the diagra...

Page 104: ...C The front nose and bushings must be suitable for the bar Reassemble ring A TELESCOPIC FRONT NOSE STROKE 170 220 320 Remove the front nose from its housing Remove ring A Remove bush E front nose D springs C and bushes B Put back in place the bushings B the springs C and the front nose D the bushings and the front nose must be suitable for the bar Put back in place bush E its substitution depends ...

Page 105: ...Elite 220 only Remove the oil recovery device C Loosen grub screws D Replace the front nose A with another front nose suitable for the bar Length B must cover the distance between the bar feeder and the lathe Fit the oil recovery device and position the drain pipe inside the tank Tighten grub screws D to lock the front nose ...

Page 106: ...ning In addition it also controls operation of the bar headstock synchronization device S91 Bar change enabling It signals lathe collet opening closing to the bar feeder It determines the camshaft stop position at bar end S92 Feeding stop enabling Only used in sliding headstock lathes It disables the bar feeder feed thrust during any operations requiring headstock return with closed collet S99 Cam...

Page 107: ...E HEADSTOCK PHASE COLLET LATHE BAR FEEDER CAM COMPLETE CYCLE PHASE MICROSWITCH S90 PHASE MICROSWITCH S91 PHASE MICROSWITCH S92 A STROKE G CLOSED B FEEDING H OPEN C FORWARD STOP L CLOSED D RETURN M DISABLED E BACKWARD STOP N DISABLED F Possible headstock return with closed collet for special operations ...

Page 108: ...sed 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 wheel Rotate shaft A by 10 approx then also 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 follo...

Page 109: ...he timing is to be performed on lathe cam GENERAL REMARKS Microswitch activation can be either delayed or advanced through screw C Whenever servicing the camshaft of the lathe disconnect the cam box according to the following procedure loosen clamp D and unscrew sleeve E service the lathe camshaft screw sleeve E and tighten clamp D should shaft F be out of phase loosen sleeve G screws rotate it an...

Page 110: ...It is necessary if bar pushers with reduced diameter are used e g guide channel D 24mm and bar pusher D 22 5mm Place a bar in the clamp area as shown in the image Close the clamps pneumatically Move the bar pusher collet near to the bar Loosen nut C and screw D Loosen the screw A until the bar is aligned with the bar pusher collet Tighten the screw D and the nut C DANGER WARNING Pneumatic power A ...

Page 111: ...Release the safety pin B Move the magazine upwards until the pin B enters again in the appropriate reference hole Magazine high Lock the handles A making sure that the magazine is at its limit stop upwards i e at the end of the guide slots C During automatic operation with the guard closed it is possible to check the magazine currently used by selecting the parameter 16 Magazine mode on the handhe...

Page 112: ...Pilgrim Step magazine follow the procedure described below Loosen the handle A at the end of the bar magazine Release the safety pin B Bend the magazine until the pin B enters again into the appropriate reference hole Magazine low Lock the handles A making sure that the magazine is at its limit stop downwards i e at the end of the guide slots C A12M_05_007_03 C A B C A ...

Page 113: ...or inserting the bar if necessary Load at least two bars C on the racks D Place the backing place B on the bars and pull it back by 2 3mm Tighten the handle A Bar selector adjustment Bar selection stop adjustment only if the sloped rack magazine is available With the magazine high and locked turn the knob A until the index B reaches the diameter of the bar on the graduated scale C A12M_05_007_00s ...

Page 114: ......

Page 115: ... 13 6 5 3 BAR STRAIGHTNESS Measurement 14 6 6 BAR FEEDER SETUP AND AUTOMATIC CYCLE START 16 6 6 1 Bar magazine Filling 17 6 6 2 Lubrication oil Flow adjustment 19 6 6 3 Automatic cycle start 20 6 6 4 Guide channel opening closing procedure 22 6 6 5 Cycle performing mode in the STEP BY STEP function 23 6 7 BAR FEEDER STOP 24 6 8 AXIS CALIBRATION PROCEDURE 25 6 9 MACHINING CHANGE QUICK GUIDE 26 6 9 ...

Page 116: ...vided by the manufacturer and do not tamper with any devices to obtain different performances Before use make sure that the safety devices are perfectly installed and efficient Besides satisfying the above mentioned requirements users must enforce and follow all safety regulations and carefully read the control description and the commissioning 6 2 CONTROL DESCRIPTION INFORMATION From the keyboard...

Page 117: ...he keyboard controls 6 1 5 A12G220_01_001_00 1 MAIN SWITCH turns the power supply on and off Position 0 OFF the machine is not powered Position I ON the machine is powered 5 EMERGENCY STOP PUSH BUTTON stops the bar feeder in case of emergency For restart release the push button manually 6 KEYBOARD display and main controls ...

Page 118: ...EN 6 USE AND OPERATION Elite112_220_Evo_SIII 6 Pag 4 4 ...

Page 119: ... leftwards 7 It resets the BAR FEEDER ZERO SETTING of the carriage Hold down both start buttons and then the key release both buttons and the key when the carriage starts moving towards the BAR FEEDER ZERO SETTING position 8 Lifts and lowers the bar selectors LED on when selector switches are at their down position 9 Magazine step by step backward button every time the button is pressed the bar in...

Page 120: ...y one step A Bar feeder start button green light press the button to start the bar feeder and hold it down until the button lights up B Bar feeder stop button red press this button to stop the bar feeder and reset the Errors C Remnant detection disabling button white light Press the button to feed a new bar without the detection of bar remnant in the bar pusher collet D Half bushes opening and clo...

Page 121: ...4 Multifunction Sets the numerical value Opens the guide channels Push both start buttons and then the key release both buttons and the key only when the movement is finished 25 Multifunction Sets the numerical value Closes the guide channels Push both start buttons and then the key release both buttons and the key only when the movement is finished 26 Multifunction Sets the numerical value Recall...

Page 122: ...he bar pusher at high speed 30 Multifunction Stops the selection function Restores the value prior to the non confirmed modification 31 Multifunction Sets the font Turns on off the oil pump Press to turn on the pump and press again to turn it off 32 Multifunction Sets the numerical value Loads the program from the PLC entering the default values in the parameters 33 Confirms the entered data 34 Se...

Page 123: ...automatic mode Red light OPT signals that the bar feeder is in stopping conditions or that it is working in manual mode Blinking blue light OPT indicates that the bar feeder is carrying out the bar change Orange light OPT signals that there is only one bar in the magazine This signal will continue until the bars in the magazine have run out ...

Page 124: ...erformances Usually it is not necessary to perform preliminary operations on the bar ends but to obtain optimum results during loading it is advisable to chamfer them 6 5 1 BAR TO BE MACHINED SOLID BARS Make sure that there is not too much rag on the front end which might hinder from entering the lathe collet Check that there is not too much rag on bar rear end which might hinder insertion in the ...

Page 125: ...o_SIII EN 6 Pag 11 11 When machining bars having a diameter equal to or only slightly smaller than the bar pusher diameter it is necessary to turn the bar rear ends diameter D should be suitable for the collet installed in the bar pusher ...

Page 126: ...annels and bar pusher are installed there is no need to turn the rear end of the bars Guide channel revolving tip turning bar diameters and turning length Elite112 220Evo Model Guide channel diameterø A mm Revolving tip diameter ø B mm Turning maximum diameterø C mm Turning length L mm Bar diameter ø D mm Elite 112 220 5 4 5 3 16 3 6 4 0 6 5 5 4 16 4 8 5 0 8 7 5 5 5 16 6 1 7 0 11 8 5 6 5 16 6 6 8 ...

Page 127: ...6 USE AND OPERATION Elite112_220_Evo_SIII EN 6 Pag 13 13 6 5 2 BARSTOCK PIPES If pipes have to be machined their rear ends should be chamfered as shown in the figure ...

Page 128: ...uality 0 25 mm Good 0 25 S max 0 5 mm Average 0 5 mm Problematic In order to obtain a reliable value it is necessary to repeat the 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 values between the different prisms INFORMATION The bar straightness is obviously proportional to the rigidity of the material and t...

Page 129: ...section bars With shaped bars insert some bushes on the bar to be controlled Position 2 bushings on both 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 bush external to both V supports ...

Page 130: ...he software parameterization refer to the Keyboard Instruction Manual Set up according to the bar to be machined section Setup according to the bar to be machined Chap 5 Prepare the bars to be machined section Bars to be machined features and preparation Chap 6 Loading the bar magazine section Bar magazine Loading Chap 6 Adjust the lubricating oil flow section Lubricating oil flow regulation Chap ...

Page 131: ... lifting device WARNING CAUTION wear personal protections according to the regulations in force Follow these instructions to load bars make sure the guide channels are closed open the upper guard Pilgrim Step Magazine Configuration position the bars against the reference level A and close the upper guard Sloped Rack Magazine Configuration for Elite 220 only position the bars against the reference ...

Page 132: ...EN 6 USE AND OPERATION Elite112_220_Evo_SIII 6 Pag 18 18 Prepare the bars according to the diameter and set parameter 16 as shown in the figure ...

Page 133: ...in the guides is automatically controlled during the feeder automatic cycle The pump is started when the bar feeder has completed the bar change and stops when the bar pusher approaches the bar end position Oil flow should be adjusted according to bar diameter and profile through the valve placed upstream ...

Page 134: ...R PUSHER HAS NOT BEEN MOVED WHILE POWER SUPPLY WAS DISCONNECTED ZERO AXIS CONTROL MAY NOT BE PERFORMED WHEN TURNING THE MACHINE ON AGAIN After carrying out the above mentioned operations perform next step Enter the parameter values refer to the Keyboard Instruction Manual Press the manual feed button to bring the bar fore end near the cutting tool To start machining press when the lathe collet is ...

Page 135: ...ads with weights exceeding those foreseen by the applicable regulations in force WARNING CAUTION keep hands out of remnant drop area after the remnant box has been pulled off WARNING CAUTION wear personal protections according to the regulations in force Place the box back under the remnant outlet ...

Page 136: ...ions If the guide channels are in an intermediate position upper guide channels not closed nor open press the key to open completely CLOSING PROCEDURE If the upper guide channels are open and the first feeding carriage is moved from its ZERO AXIS position by pressing the following will appear move the carriage to ZERO AXIS position by pressing the manual return key As soon as the carriage reaches ...

Page 137: ...eeder check that the guide channels of the bar feeder are closed If not close the guide channels in manual mode 2 press and then to select the semiautomatic function 3 press the bar feeder performs the first step bar pusher return 4 press the bar feeder performs the second step and so on 5 once the maximum opening condition of the upper guide channels is reached press to start the bar feeder devic...

Page 138: ...e tool was removing chips before restarting the lathe distance the tool from the piece To stop the bar feeder in emergency press one of the emergency buttons of the bar feeder or lathe BAR FEEDER STOP AT THE WORKING CYCLE END WARNING CAUTION when stopping the machine normally do not use the emergency buttons 1 Complete the operations of your working schedule 2 Stop the bar feeder 3 Stop the lathe ...

Page 139: ...l feeding units that could alter the AXIS control operations Procedure Move the feeding carriage from its completely backwards position in manual mode then simultaneously press Zero_Macchina_sx dito and for at least 2 seconds until Offset appears on the display Now the operator may release the buttons INFORMATION Before performing the above mentioned procedure make sure that the mechanics have no ...

Page 140: ...t section Guide channels bar pusher and collet Replacement Chap 5 remove the bar pusher remove the lower and upper guide channels remove the front nose if necessary remove the lathe spindle liner install a new set of parts by reversing the order of the above operations mount a collet suitable for the new bar in the bar pusher insert the bar pusher in the guide channels Check all the machining para...

Page 141: ...7 2 SCHEDULED MAINTENANCE 2 7 3 MAINTENANCE GENERAL RULES 3 7 4 SCHEDULED MAINTENANCE 4 7 4 1 Revolving tip and collet Check 4 7 5 Lubricating oils Change 5 7 5 1 Lubricating oil Level check 6 7 5 2 Lubricating oil Change 7 7 5 3 Air filter unit Check 7 7 6 GREASING POINTS 8 7 7 DISPLACEMENT DEVICE USE 9 ...

Page 142: ...t is recommended to adequately signal the adjacent areas and to prevent anyone from approaching any of the devices that if activated could cause unexpected dangerous situations and injure people 7 2 SCHEDULED MAINTENANCE IMPORTANT keep the bar feeder in conditions of maximum efficiency carrying out the programmed maintenance operations provided by the manufacturer Good maintenance will allow the b...

Page 143: ...recommended as it increases the operator safety as well 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 during long inactivity periods disconnect it from the mains voltage remove the compressed air and cover it with a cloth of suitable material Any ...

Page 144: ...tem Oil level check Oil change Guide channels Integrity and cleanness check Feed chains Lubrication Tensioning check Air filter Check PLC battery Replacement Safety devices Check the efficiency see Safety devices 7 4 1 Revolving tip and collet Check Remove the bar pusher as described in Guide channels bar pusher and collet Replacement Chap5 Check that the revolving tip A can turn freely without to...

Page 145: ...loosening the clamp A Place the free end of the pipe in a container having a minimum capacity of 50 litres Operate the bar feeder pump and drain the tank until you hear the pump is sucking air Reconnect pipe B to coupling C and tighten the clamp A In order to remove the rest of the oil place a container minimum capacity 10 l under the tank and remove plug D Unscrew the drain plug and let the oil b...

Page 146: ... CAUTION wear personal protections according to the regulations in force Wait until the bar feeder has been off for at least 6 hours Check the level by means of the indicator A Open the rear base door and pour oil into the machine to top up See section Technical Data in Chap 2 for the comparative table ...

Page 147: ...llution Drain the tank using an auxiliary pump Clean the tank bottom and the pump suction system For the loading pour the oil directly in the tank and check the level through the indicator A See section Technical Data in Chap 2 for the comparative table and the required quantities 7 5 3 Air filter unit Check FILTER A Make sure that cup B is not full of condensate Drain the condensate by means of v...

Page 148: ...EN 7 BAR FEEDER MAINTENANCE Elite112_220_Evo_SIII 7 Pag 8 8 7 6 GREASING POINTS A12M_06_003_00 Grease ...

Page 149: ...urn the screw counter clockwise to move the bar feeder body backwards Perform this operation following the instructions given hereunder Disconnect the bar feeder lathe fastening unit if installed Remove the safety screw E Move the bar feeder until the completely backwards position is reached Lmax 600mm Carry out all lathe tooling and or maintenance operations required Put the bar feeder again in i...

Page 150: ......

Page 151: ...8 TROUBLES CAUSES SOLUTIONS Elite112_220_Evo_SIII EN 8 Pag 1 1 INDEX 8 1 GENERAL FAILURES 2 8 2 FEEDING INTO COLLET Failures 2 8 3 BAR FEEDING Failures 2 8 4 GUIDE CHANNEL IRREGULAR MOVEMENT Failures 2 ...

Page 152: ...ectedly Motor thermal circuit breaker burnt Reset the thermal circuit breaker with the special buttons 8 2 FEEDING INTO COLLET Failures TROUBLES CAUSES SOLUTIONS Bar fails to enter collet Collet diameter not suitable for bar diameter Change collet Excessive rag on bar rear end Trim rag before feeding 8 3 BAR FEEDING Failures TROUBLES CAUSES SOLUTIONS Difficult bar introduction into lathe spindle B...

Page 153: ...9 PART REPLACEMENT Elite112_220_Evo_SIII EN 9 Pag 1 1 INDEX 9 1 FEEDING BELT REPLACEMENT 2 9 2 PLC BATTERY REPLACEMENT 3 9 3 RECOMMENDED SPARE PARTS 4 9 4 Machine dismantling 4 ...

Page 154: ...EN 9 PART REPLACEMENT Elite112_220_Evo_SIII 9 Pag 2 2 9 1 FEEDING BELT REPLACEMENT The replacement of the feeding belt is a very complex operation contact IEMCA service department ...

Page 155: ... 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 plug A and remove battery B insert a new battery AA 3 6 volts lithium type battery and make sure it is properly fitted then tighten plug A PLC battery exhausted ...

Page 156: ...o order the parts refer to the Spare Parts Catalogue 9 4 Machine dismantling This operation is to be carried out by expert operators according to the safety at work regulations in force Do not throw non biodegradable products lubricating oils and non ferrous components rubber PVC resins etc in the environment Dispose of the same according to the regulations in force ...

Page 157: ...TIPS Elite EN 10 Pag 1 1 INDEX 10 1 GUIDE CHANNELS AND BAR PUSHER 2 10 2 REVOLVING TIP TABLE 3 10 3 Revolving tips øGR 5 Table 6 10 4 Revolving tips øGR 7 5 Table 7 10 5 Revolving tips ØGR 10 23 Table 8 10 6 Revolving tips ØGR 10 23 Table 10 ...

Page 158: ... pusher whose diameter is equal to the maximum bar passage of the lathe Sometimes in order to ensure the best working conditions it may be necessary to use a bar pusher with a smaller diameter A Bar B Collet C Revolving tip D Bar pusher E Guide channels INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their ...

Page 159: ...HANNELS BAR PUSHER REVOLVING TIPS Elite EN 10 Pag 3 3 10 2 REVOLVING TIP TABLE The choice of the revolving tip depends on the diameter of the guide channel and bar pusher and on the version of the collet coupling ...

Page 160: ...EMCA 8 5 D73150805 10 With quick coupling pin 10 5 D71151010 D71151011 14 13 Threaded IEMCA 13 5 D71151310 12 12 5 D71151210 13 With quick coupling pin 13 5 D71151311 12 12 5 D71151211 16 14 Threaded IEMCA 14 5 D71141510 15 5 D71151510 15 With quick coupling pin 14 5 D71141510 15 5 D71151510 18 15 Threaded IEMCA 15 5 D71151510 With quick coupling pin D71151511 Threaded IEMCA 16 5 D71151610 17 With...

Page 161: ...terøGR mm Revolving tip code 20 18 Threaded IEMCA 18 5 D71151810 19 5 D71151910 With quick coupling pin 18 5 D71151811 19 5 D71151911 22 20 Threaded IEMCA 20 5 D71152010 21 5 D71152110 With quick coupling pin 20 5 D71152011 21 5 D71152111 24 20 Threaded IEMCA 21 5 D71152110 22 5 D71152210 21 5 D71152111 With quick coupling pin 22 5 D71152211 23 23 5 D71152310 D71152311 ...

Page 162: ...le For collets with threaded coupling IEMCA SCHL A Collet B See file C See file 001 then 222 D Revolving tip CH double ended fork wrench DIN3110 øGR mm Revolving tip code øF mm øB mm GP mm G1 mm C mm P mm CH mm 5 D00150500 M4 5 5 80 10 M4 7 5 SCHLENKER 5 D00150501 M4 5 5 81 10 M4 7 5 ANDRE FREY ...

Page 163: ...g tips øGR 7 5 Table For collets with threaded coupling IEMCA A Collet B See file C See file 001 then 011 D Revolving tip CH double ended fork wrench DIN3110 øGR mm Revolving tip code øF mm øB mm GP mm G1 mm C mm A1 mm P mm CH mm 7 5 D73150705 M5x0 5 7 5 151 25 M6x0 75 17 24 5 7 ...

Page 164: ...ER REVOLVING TIPS Elite 10 Pag 8 8 10 5 Revolving tips ØGR 10 23 Table For collets with threaded coupling IEMCA A Collet D Pipe collet B See file E Ejector C See file 001 F Revolving tip then 011 CH double ended fork wrench DIN3110 ...

Page 165: ...6 5 10 14 D71151410 M8x1 14 5 160 35 12 6 3 26 5 13 15 D71151510 M8x1 15 5 160 35 12 6 3 26 5 13 16 D71151610 M8x1 16 5 160 35 12 6 3 26 5 13 17 D71151710 M8x1 17 5 160 35 12 6 3 26 5 13 18 D71151810 M8x1 18 5 160 35 12 6 4 26 5 13 19 D71151910 M8x1 19 5 160 35 12 6 4 26 5 13 20 D71152010 M10x1 20 5 172 5 35 14 6 4 38 5 15 1 21 D71152110 M10x1 21 5 172 5 35 14 6 4 38 5 15 1 22 D71152210 M10x1 22 5...

Page 166: ...E CHANNELS BAR PUSHER REVOLVING TIPS Elite 10 Pag 10 10 10 6 Revolving tips ØGR 10 23 Table For collets with quick coupling pin A Collet B See file C See file 001 then 602P D Ejector E Pipe collet F Revolving tip ...

Page 167: ...0 8 6 3 18 4 14 D71151411 11 14 5 160 35 12 6 3 18 5 6 15 D71151511 11 15 5 160 35 12 6 3 18 5 6 16 D71151611 11 16 5 160 35 12 6 3 18 5 6 17 D71151611 11 17 5 160 35 12 6 3 18 5 6 18 D71151811 11 18 5 160 35 12 6 4 18 5 6 19 D71151911 11 19 5 160 35 12 6 4 18 5 6 20 D71152011 14 20 5 172 5 35 14 6 4 37 5 8 1 1 21 D71152111 14 21 5 172 5 35 14 6 4 37 5 8 1 1 22 D71152211 14 22 5 172 5 35 14 6 4 37...

Page 168: ......

Page 169: ...ches Table 5 11 4 ROUND BARS unit of measurement inches Table 6 11 5 CONVERSION TABLE Inches Millimetres 7 11 6 COLLETS FOR BARS 001P Table 9 11 7 COLLETS FOR BARS 222 Table 11 11 8 COLLETS FOR BARS 602P Table 12 11 9 BORING COLLETS FOR SQUARE AND HEXAGONAL BARS 601P Table 14 11 10 EJECTORS 602P Guide channels ø14 24 Table 16 11 11 PIPE COLLETS 603P Table 17 11 12 COLLETS FOR BARS 22164 Table 19 ...

Page 170: ...33 38 10 37 8 4 5 5 19 5 34 39 25 39 5 5 77 5 5 35 40 41 40 2 5 5 6 35 6 2 36 41 56 41 3 6 6 92 6 8 38 43 87 43 5 6 5 7 50 7 3 39 45 03 44 8 7 8 08 7 8 40 46 18 46 7 5 8 66 8 5 41 47 34 47 8 9 23 9 42 48 49 48 2 9 10 39 10 2 43 49 65 49 5 10 11 54 11 3 44 50 80 50 5 11 12 70 12 5 45 51 96 51 8 12 13 85 13 5 46 53 11 52 8 13 15 02 14 8 48 55 42 55 14 16 16 16 50 57 73 57 5 15 17 32 17 2 52 60 04 59...

Page 171: ...11 COLLETS Elite EN 11 Pag 3 3 Y Zx1 154 Y Zx1 154 mm mm mm mm mm mm 23 26 55 26 2 72 83 08 82 5 24 27 71 27 5 75 86 55 86 25 28 86 28 5 80 92 32 91 75 26 30 02 29 8 85 98 1 97 5 27 31 17 31 ...

Page 172: ...26 36 76 36 4 5 6 36 6 2 27 38 17 37 5 5 7 07 6 8 28 39 59 38 5 5 5 7 77 7 5 30 42 42 41 5 6 8 48 8 3 32 45 24 44 5 6 5 9 19 9 34 48 07 47 7 9 89 9 7 35 49 49 48 5 8 11 31 11 36 50 90 50 8 5 12 01 11 8 37 52 31 51 5 9 12 72 12 5 38 53 73 52 5 10 14 14 13 8 39 55 15 54 5 10 5 14 84 14 5 40 56 56 55 5 11 15 55 15 41 57 97 57 12 16 97 16 5 42 59 38 58 5 12 5 17 67 17 43 60 08 59 13 18 38 18 44 62 21 ...

Page 173: ... 53 64 3 8 10 75 27 64 1 5 8 47 25 1 55 64 7 16 12 5 31 64 1 11 16 49 1 15 16 1 2 14 25 9 16 1 3 4 50 75 2 9 16 16 25 41 64 1 13 16 52 75 2 5 64 5 8 18 45 64 1 7 8 54 5 2 9 64 11 16 19 75 25 32 1 15 16 56 25 2 7 32 3 4 21 75 55 64 2 58 2 9 32 13 16 23 5 59 64 2 1 16 59 75 2 11 32 7 8 25 25 63 64 2 1 8 61 5 2 27 64 15 16 27 25 1 5 64 2 3 16 63 5 2 1 2 1 29 1 9 64 2 1 4 65 25 2 37 64 1 1 16 30 75 1 ...

Page 174: ... 4 43 64 17 1 11 16 43 3 16 4 8 11 16 17 5 1 3 4 44 5 13 64 5 2 45 64 18 1 13 16 46 7 32 5 6 23 32 18 25 1 7 8 47 75 15 64 6 47 64 18 75 1 15 16 49 25 1 4 6 4 3 4 19 2 50 75 17 64 6 8 49 64 19 5 2 1 16 52 5 9 32 7 2 25 32 19 75 2 1 8 54 19 64 7 6 51 64 20 25 2 3 16 55 5 5 16 8 13 16 20 75 2 1 4 57 25 21 64 8 4 53 64 21 2 5 16 58 75 11 32 8 8 27 32 21 5 2 3 8 60 5 23 64 9 1 55 64 21 75 2 7 16 62 3 ...

Page 175: ...40 6 82 550 0 82 946 9 83 343 8 83 740 6 5 16 21 64 11 32 23 64 0 312 5 0 328 125 0 343 75 0 359 375 7 937 5 8 334 4 8 731 2 9 128 1 33 337 5 33 734 4 34 131 2 34 528 1 58 737 5 59 134 4 59 531 2 59 928 1 84 137 5 84 534 4 84 931 2 85 328 1 3 8 25 64 13 32 27 64 c 0 375 0 390 625 0 406 25 0 421 875 9 525 0 9 921 9 10 318 8 10 715 6 34 925 0 35 321 9 35 718 8 36 115 6 60 325 0 60 721 9 61 118 8 61 ...

Page 176: ...5 250 0 95 646 9 96 043 8 96 440 6 13 16 53 64 27 32 55 64 0 812 5 0 828 125 0 843 75 0 859 375 20 637 5 21 034 4 21 431 2 21 828 1 46 037 5 46 434 4 46 831 2 47 228 1 71 437 5 71 834 4 72 231 2 72 628 1 96 837 5 97 234 4 97 631 2 98 028 1 7 8 57 64 29 32 59 64 0 875 0 890 625 0 906 25 0 921 875 22 225 0 22 621 9 23 018 8 23 415 6 47 625 0 48 021 9 48 418 8 48 815 6 73 025 0 73 421 9 73 818 8 74 2...

Page 177: ...external diameter INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure CH double ended fork wrench DIN3110 A Collet B Bar diameter Example 0 8 mm 008 3 mm 030 12 25 mm 122 12 5 mm 125 D Category ...

Page 178: ... 10 10 External diameter mm øD Diameter mm øF Internal diameter mm øA MIN MAX 7 5 M5x0 5 2 6 4 10 M6x0 75 3 8 12 M7x0 75 3 10 15 M8x1 4 13 16 M8x1 13 14 17 M8x1 14 15 18 M8x1 15 16 2 19 M8x1 16 2 17 20 M10x1 5 18 23 M10x1 14 21 ...

Page 179: ...Pag 11 11 11 7 COLLETS FOR BARS 222 Table Code structure A Collet B Bar diameter Example 0 8 mm 08 3 mm 30 D Category External diameter mm øD Diameter mm øF Internal diameter mm øA MIN MAX 5 M4x0 5 0 7 3 5 5 4 M4x0 5 3 6 4 7 ...

Page 180: ...an the bar pusher external diameter INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure A Collet B Bar diameter C Example 3 mm 030 3 5 mm 035 12 5 mm 125 12 75 mm 127 D Category ...

Page 181: ...lite EN 11 Pag 13 13 External diameter mm øD Diameter mm øF Internal diameter mm øA MIN MAX 10 Ø7 G6 3 8 12 Ø8 G6 3 10 15 Ø11 G6 4 13 16 Ø11 G6 11 14 18 Ø11 G6 8 16 20 Ø14 G6 6 18 21 Ø14 G6 16 5 19 23 Ø14 G6 14 21 ...

Page 182: ... Conversion Tables but refer directly to the table below INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure A Collet B Bar diameter C Example 3 mm 030 3 5 mm 035 12 5 mm 125 12 75 mm 127 D Category ...

Page 183: ...TS Elite EN 11 Pag 15 15 S square bars S E 1 414 S hexagonal bars S E 1 154 External diameter mm øD Diameter mm øF MIN MAX MIN MAX 3 3 3 4 7 5 M5x0 5 4 6 5 7 12 Ø8 G6 6 10 6 13 18 Ø11 G6 7 12 5 16 15 21 Ø14 G6 ...

Page 184: ...r INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets A Ejector øE mm øF mm øD mm L mm Code no 12 8 8 24 602P12011 15 11 11 26 602P15011 16 11 12 26 602P16011 18 11 12 27 5 602P18011 19 11 12 28 602P19011 20 14 12 47 5 602P20011 23 14 12 49 60...

Page 185: ...e revolving tips are designed with an oversized length Therefore the first feeding value of the bar pusher carriage shall be increased of 7 5 mm with respect to the standard value INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code struct...

Page 186: ...EN 11 COLLETS Elite 11 Pag 18 18 External diameter mm øD Diameter mm øF External diameter mm øA MIN MAX 12 Ø8 G6 5 9 5 15 Ø11 G6 5 11 15 16 Ø11 G6 11 5 14 20 Ø14 G6 6 18 ...

Page 187: ... Pag 19 19 11 12 COLLETS FOR BARS 22164 Table Code structure A Collet B Code structure C Bar diameter D Example 0 8 mm 08 3 mm 30 E Category External diameter mm øD Diameter mm øF Internal diameter mm øA MIN MAX 5 M4 0 7 4 7 ...

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