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KID 80

MANUAL FOR USE AND MAINTENANCE

Rel.

Date

15/07/07

Cod.

*806015410*

S/N

COMPILER:

Bosi Andrea

APPROVAL:

Frattini Andrea

AUTOMATIC BAR FEEDER

ATTACHMENTS LIST

MANUAL FOR USE AND MAINTENANCE

KEYBOARD INSTRUCTION MANUAL

SPARE PARTS BOOK

SCHEMATICS

EC CONFORMITY DECLARATION FOR MACHINE

Summary of Contents for KID 80

Page 1: ...1 Date 15 07 07 Cod 806015410 S N COMPILER Bosi Andrea ON APPROVAL Frattini Andrea AUTOMATIC BAR FEEDER ATTACHMENTS LIST MANUAL FOR USE AND MAINTENANCE KEYBOARD INSTRUCTION MANUAL SPARE PARTS BOOK SCH...

Page 2: ...TLX 550879 MANUFACTURER IEMCA division of IGMI S p A ADDRESS Via Granarolo 167 48018 Faenza RA ITALY a capo2 Tel 0546 698000 Fax 0546 46338 0546 46224 a capo2 TLX 550879 TYPE OF DOCUMENT MANUAL FOR U...

Page 3: ...ORMATION KID 80 3 SAFETY GENERAL INFORMATION KID 80 4 MOVEMENT AND INSTALLATION KID 80 5 ADJUSTMENTS AND SETTING UP KID 80 6 USE AND OPERATION KID 80 7 BAR FEEDER MAINTENANCE KID 80 8 TROUBLES CAUSES...

Page 4: ......

Page 5: ...ION KID 80 EN 1 Pag 1 4 INDEX 1 1 WARRANTY CONDITIONS 2 1 2 PURPOSE OF THE MANUAL 2 1 3 MANUFACTURER AND BAR FEEDER IDENTIFICATION 3 1 4 ASSISTANCE REQUEST MODE 4 1 5 GLOSSARY AND TERMINOLOGY 4 1 6 AT...

Page 6: ...THE MANUAL This manual which is an integral part of the bar feeder has been carried out by the manufacturer in order to provide all necessary information for those who are authorised to interact with...

Page 7: ...s for the bar feeder operation and maintenance is supplied with the Keyboard instruction manual The Keyboard instruction manual contains all the instructions on how to use the installed software 1 3 M...

Page 8: ...rer and must be carried out by the maintenance technician Expert technician authorized person chosen among those who have the requirements competence and information needed for the installation operat...

Page 9: ...1 1 MAIN PARTS 3 2 2 OPERATING CYCLE 4 2 2 1 REGULAR CYCLE 4 2 2 2 FIXED PIECE FEEDING CYCLE 7 2 3 SAFETY DEVICES 9 2 4 SAFETY AND INFORMATION SIGNALS 10 2 4 1 BAR FEEDER DIMENSIONS 11 2 4 2 Noise le...

Page 10: ...spindle liner The operating cycle is directed by a PLC integrated in the electrical control panel which interacts with the lathe controls The bar feeder is provided with a remote push button panel all...

Page 11: ...device introduces the bar into the lathe G Bar pushing unit this device pushes the bar inside the lathe until it has been completely machined H Flag device this device is activated by the arrival of...

Page 12: ...u will find a concise description of the phases in this working cycle INFORMATION for further detailed information about working cycle selection and setting please see the keyboard instruction manual...

Page 13: ...t the same time the bar selector unit C returns to its initial position Subsequently the guide lifts and sets the bar in line with the loading axis The bar is inserted into the carriage lathe E that t...

Page 14: ...lathe operating cycle starts at the beginning of the bar facing phase At this point the bar is fed till it reaches the lathe bar stop then machining phase takes place until one piece has been fully ma...

Page 15: ...e bar drop control unit B are lifted At the same time also the bar selecting unit C that loads the first bar on the bar drop control unit is lifted The bar drop control unit B returns to its initial p...

Page 16: ...e remnant F as a residual of the previous machining and is positioned for the facing The lathe operating cycle starts at the beginning of the bar facing phase At this point the bar is precisely fed ac...

Page 17: ...closing it is possible to start the operating cycle again This one is endowed with a porthole allowing the visual inspection of the bar handling main components B Emergency stop button if activated e...

Page 18: ...er limbs do not put hands inside when there are components in motion B No guard removal it is forbidden to use the bar feeder without the guards installed and in operating conditions C Danger of elect...

Page 19: ...SIONS A BAR LOADING AREA B WORK AREA 2 4 2 Noise levels During the machining the bar feeder is not noisy The only phase where there can be some short lasting peaks 85 dbA is the bar loading one This m...

Page 20: ...60 mm 2 1 4 Minimum bar length 500 mm Maximum bar length 1615 mm Magazine capacity Kg 250 Kg N 60 barre da 10 mm Bar change time with 1 000 mm bar 50 sec Feeding speed 0 500 mm sec Return speed 1000...

Page 21: ...ew position X Loading axis height Reinforcement Threaded holes on the base Slots on the supports 900 937 A 1 5 938 972 A 2 6 973 1007 A 3 7 1008 1042 A 4 8 1043 1077 A 5 9 1078 1112 A 6 10 1113 1147 A...

Page 22: ...RMATION KID 80 2 Pag 14 16 Bar and bar pusher diameter table A Bar Diameter mm B Bar pusher rod diameter mm C Bar pusher bearing diameter mm D Spindle liner mm 5 12 10 12 14 10 19 12 15 16 16 60 18 21...

Page 23: ...the equipment indicated below at the customer s disposal BAR FEEDER LATHE GUIDE directs the bar in the section between the bar feeder and the lathe It proves extremely necessary when this section exc...

Page 24: ...with axial displacement Screw position X Loading axis height Reinforcement Threaded holes on the base Slots on the supports 900 967 A 1 3 968 999 B 1000 1037 A 2 4 1038 1069 B 1070 1107 A 3 5 1108 11...

Page 25: ...AL INFORMATION KID 80 EN 3 Pag 1 4 INDEX 3 1 GENERAL 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 MAINTE...

Page 26: ...e with the instructions in this manual ensures the operator safety The user and expert operator must perform the specified duties only Do not tamper with the safety devices for any reason whatsoever C...

Page 27: ...hting and cleanliness of the working environment are of the utmost importance as far as personal safety is concerned The electric system connection must be carried out by skilled personnel only Make s...

Page 28: ...y 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...

Page 29: ...6 1 Loading axis height variation 5 4 6 2 Assembling the backing plates 5 4 6 3 Magazine positioning 6 4 6 4 Alignment and levelling 7 4 6 5 Bar feeder fastening 9 4 7 BAR FEEDER INSTALLATION with dis...

Page 30: ...4 2 PACKAGING AND UNPACKAGING A WITHOUT PACKAGING B PACKAGING ON PALLET C PACKAGING IN CRATE By reducing its dimensions the packaging is made according to the type of transport required In order to ma...

Page 31: ...used solutions In the transport phase in order to avoid untimely movements provide an adequate anchorage to the means of transport 4 4 MOTION AND LIFTING The bar feeder can be handled by a device prov...

Page 32: ...tive and law requirements carrying out all the installations and connections workmanlike Once the installation has been completed and before the operating phases he will check if the above mentioned r...

Page 33: ...need to change it proceed as follows Prepare the bar feeder for lifting Stretch the ropes Loosen on both sides the screws B and remove the screws A Bring the bar feeder to the loading axis height see...

Page 34: ...device Make sure that during lifting the pin B is correctly inserted in the cam housing C Connect the bar magazine to the bar feeder body making sure the bearings A fit in their slots D Fix the suppor...

Page 35: ...lling INFORMATION not only alignment and levelling are fundamental for the correct running of the bar feeder and for the WARRANTY VALIDITY but also they must be carried out only by a SKILLED STAFF WIT...

Page 36: ...e guide channel in order to use the beam plane to check the levelling Verify the alignment of both bar feeder axes and levelling Adjust the loading axis vertically through screws D Hit both sides of t...

Page 37: ...ections after making sure that alignment levelling and fastening are carried out correctly 4 7 BAR FEEDER INSTALLATION with displacement WARNING CAUTION the installation and connections must be carrie...

Page 38: ...tion The bar feeder is generally supplied with the loading axis height aligned to that of lathe spindle If you need to change it proceed as follows Prepare the bar feeder for lifting Stretch the ropes...

Page 39: ...device Make sure that during lifting the pin B is correctly inserted in the cam housing C Connect the bar magazine to the bar feeder body making sure the bearings A fit in their slots D Fix the suppo...

Page 40: ...MOVEMENT AND INSTALLATION KID 80 4 Pag 12 16 Fix the upper end of the rod to the block G by means of a self locking nut H Install the bar feeder lathe guide if provided Install the safety grid fixed g...

Page 41: ...Y VALIDITY but also they must be carried out only by a SKILLED STAFF WITH PRECISE TECHNICAL COMPETENCE For these operations proceed as follows Position the bar feeder near the lathe see figure Put the...

Page 42: ...ns of the screws F after loosening the screws G Hit both sides of the frame H with a mallet for the adjustment of the loading axis horizontally 4 8 4 Bar feeder fastening INFORMATION considering that...

Page 43: ...D 80 EN 4 Pag 15 16 Drill the floor in the direction of the frame holes Fasten the frame with the expansion plugs Reinstall the two guide sections after making sure that alignment levelling and fasten...

Page 44: ...eted before starting the bar feeder inspect if the above mentioned requirements have been fulfilled Connect the multipolar connector provided with the bar feeder to the lathe socket 4 10 WORKING PARAM...

Page 45: ...SETTING UP KID 80 EN 5 Pag 1 6 INDEX 5 1 PRELIMINARY NOTE ON ADJUSTMENT 2 5 2 MAGAZINE ADJUSTMENT AND BAR SELECTION 2 5 3 LOADING AXIS ADJUSTMENT 4 5 4 BAR FEEDER LATHE GUIDE ADJUSTMENT 5 5 5 FEEDING...

Page 46: ...o prevent anyone from approaching all the devices that if started could cause unexpected damage and harm to people 5 2 MAGAZINE ADJUSTMENT AND BAR SELECTION Bar magazine adjustment must be carried out...

Page 47: ...er of the bar to be loaded For the adjustment proceed as follows Turn lever A to adjust bar magazine inclination according to the type of the bars to be machined Turn knob C to adjust the bar stop dev...

Page 48: ...al bars set the measurement of the wrench on the millimetre counter Square bars set the measurement X obtained from the following table on the millimetre counter L mm X 5 5 8 8 10 10 12 12 15 15 18 18...

Page 49: ...ADJUSTMENT The adjustment must be carried out according to the diameter of the bar pusher bearings and bar to be machined Adjust the guide height displayed on the graduated rod A in order to respect...

Page 50: ...lows Open the upper guard To check the belt tension adopt the method indicated in the figure The resulting value C must be 10 to 15 mm Loosen nut A Adjust the belt tension through the screw B and lock...

Page 51: ...3 KEYBOARD CONTROLS DESCRIPTION 4 6 4 LIGHT INDICATOR DESCRIPTION 5 6 5 BAR PREPARATION sections and tubes 6 6 6 MAGAZINE LOADING 6 6 7 BAR FEEDER TOOLING 6 6 8 BAR PUSHER CHANGE 7 6 9 LATHE SPINDLE L...

Page 52: ...apart from being authorised and appropriately informed at the first use will have to carry out some manoeuvres to test the controls and the main functions Exclusively use the machine according to the...

Page 53: ...ng 3 Bar feeder Stop button red light press this button to stop the bar feeder 4 Emergency stop button to stop the bar feeder under emergency conditions you will have to manually release this button b...

Page 54: ...selected value during modification phase 14 ARROW BUTTON to go to the next page The cursor is moved downward to reduce the selected value during modification phase 15 SHIFT BUTTON ENTER while modifyi...

Page 55: ...he magazine This signal will continue until the bars in the magazine have run out Flashing blue light OPT Signals that the bar feeder is carrying out the bar change Red light OPT Signals that the bar...

Page 56: ...ions shall prepare all the necessary conditions to guarantee his her own safety and that of the people directly involved In particular respect the regulations in force on the subject of health and saf...

Page 57: ...Reset if necessary the work parameters see Keyboard instruction manual 6 8 BAR PUSHER CHANGE For this operation proceed as follows Open the upper guard Adjust screw A and lock nut in order to uncouple...

Page 58: ...in the area between the lathe and the bar feeder move the bar feeder away if it is equipped with a displacing device otherwise proceed as indicated Press the button to select manual mode Turn and hol...

Page 59: ...e If necessary let the bar feeder devices reach the cycle start position Press the button rapidly twice to carry out the Bar Feeder Zero Setting Turn the selector switch to the left and leave it turne...

Page 60: ...selecting unit bar drop control device and bar pusher are lifted Turn the selector switch to the right and leave it turned the bar is loaded and the guide is lifted for pre feeding Turn the selector...

Page 61: ...er operations after machining stop INFORMATION press no emergency buttons for normal stop Wait until piece machining has been completed and the automatic cycle has stopped Press the button on board th...

Page 62: ...low the unit restart Follow the instructions given hereunder to perform this operation Press the button on the machine to start the bar feeder and hold it down until the indicator light on the button...

Page 63: ...the bar selecting and bar drop control devices and the bar pusher are lifted Turn selector switch and hold it to the right the bar drop control device is lowered and the guide channel lifts for pre fe...

Page 64: ...s limit position Turn the selector switch to the right and leave it turned the bar pusher and guide are raised without loading the bar Remove bar from guide channel of the bar feeder Turn selector swi...

Page 65: ...7 BAR FEEDER MAINTENANCE KID 80 EN 7 Pag 1 6 INDEX 7 1 PRELIMINARY NOTE ON MAINTENANCE 2 7 2 SCHEDULED MAINTENANCE 3 7 3 GREASING POINTS 4 7 4 DISPLACEMENT DEVICE USE 5...

Page 66: ...nce start all safety devices provided and check if it is necessary to inform the staff operating around and people close to the area In particular it is recommended to adequately signal the adjacent a...

Page 67: ...ice life as well as constant keeping of safety requirements Frequency Hours Component Kind of intervention 200 500 1250 2500 Yearl y Test wear and if necessary adjust the tension Feeding belt Test wea...

Page 68: ...EN 7 BAR FEEDER MAINTENANCE KID 80 7 Pag 4 6 7 3 GREASING POINTS Grease Grease...

Page 69: ...connection cables Perform this operation following the instructions given hereunder Disconnect the bar feeder lathe fastening unit if installed Lower the lever A until it releases then rotate it forw...

Page 70: ...EN 7 BAR FEEDER MAINTENANCE KID 80 7 Pag 6 6...

Page 71: ...7 BAR FEEDER MAINTENANCE KID 80 EN 7 Pag 1 6 INDEX 7 1 PRELIMINARY NOTE ON MAINTENANCE 2 7 2 SCHEDULED MAINTENANCE 3 7 3 GREASING POINTS 4 7 4 DISPLACEMENT DEVICE USE 5...

Page 72: ...nce start all safety devices provided and check if it is necessary to inform the staff operating around and people close to the area In particular it is recommended to adequately signal the adjacent a...

Page 73: ...ice life as well as constant keeping of safety requirements Frequency Hours Component Kind of intervention 200 500 1250 2500 Yearl y Test wear and if necessary adjust the tension Feeding belt Test wea...

Page 74: ...EN 7 BAR FEEDER MAINTENANCE KID 80 7 Pag 4 6 7 3 GREASING POINTS Grease Grease...

Page 75: ...connection cables Perform this operation following the instructions given hereunder Disconnect the bar feeder lathe fastening unit if installed Lower the lever A until it releases then rotate it forw...

Page 76: ...EN 7 BAR FEEDER MAINTENANCE KID 80 7 Pag 6 6...

Page 77: ...8 TROUBLES CAUSES SOLUTIONS KID 80 EN 8 Pag 1 2 INDEX 8 1 GENERIC TROUBLESHOOTING 2 8 2 BAR MAGAZINE TROUBLESHOOTING 2 8 3 TROUBLESHOOTING DURING BAR FEEDING 2...

Page 78: ...position see par 5 2 The first bar in magazine is not lifted The limit stops are not well adjusted Adjust the stops see par 5 2 The second bar in the magazine lifts together with the first one The li...

Page 79: ...D 80 EN 9 Pag 1 4 INDEX 9 1 PRELIMINARY NOTE ON PARTS REPLACEMENT 2 9 2 REPLACEMENT OF THE FIXED TIP 2 9 3 FEEDING BELT REPLACEMENT 2 9 4 PLC BATTERY REPLACEMENT 3 9 5 RECOMMENDED SPARE PARTS 4 9 6 BA...

Page 80: ...ople derived from the use of non original spare parts and from any repair carried out without the manufacturer s authorisation For spare parts ordering follow the indications reported on the spare par...

Page 81: ...ed PLC troubles may turn up Switch bar feeder power supply off Open the doors of the electrical control panel take out the battery and put in the new one battery type SIEMENS 6ES7 291 88A20 0XA0 WARNI...

Page 82: ...ode Name Features Notes Qty 32210013 Sensor BERO 3RG4012 0AG33 BERO 2 806002431 Roller conveyor guide unit 1 24373000 Feeding belt HTD 8 M20 479 PA 1 Bar pusher Specify diameter 1 Fixed tip Specify di...

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