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

Automatic bar feeder with hydraulic suspension
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AUTOMATIC BAR FEEDER WITH
HYDRAULIC SUSPENSION
MANUAL FOR USE AND MAINTENANCE
KEYBOARD INSTRUCTION MANUAL
SPARE PARTS BOOK
SCHEMATICS
EC CONFORMITY DECLARATION FOR MACHINE
BOSS 332-545-551 E
BOSS 332r-545r-551r E
GB
MANUAL FOR USE AND MAINTENANCE
Rel. 1
Date
S/N
COMPILER:
ON APPROVAL:
ATTACHMENTS LIST
24/06/03
Cod.
Ragazzini Gian Luca
Bevini Claudio
346005400

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Summary of Contents for IEMCA BOSS 332-545-551 E

  • Page 1 AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION ATTACHMENTS LIST MANUAL FOR USE AND MAINTENANCE KEYBOARD INSTRUCTION MANUAL SPARE PARTS BOOK SCHEMATICS EC CONFORMITY DECLARATION FOR MACHINE BOSS 332-545-551 E BOSS 332r-545r-551r E MANUAL FOR USE AND MAINTENANCE Rel. 1 Date 24/06/03 Cod. 346005400...
  • Page 2 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 WITH HYDRAULIC SUSPENSION...
  • Page 3 GENERAL INFORMATION ..........BOSS 332/545/551 E-volution TECHNICAL INFORMATION........BOSS 332/545/551 E-volution SAFETY PROCEDURES - GENERAL INFORMATION..BOSS 332/545/551 E-volution HANDLING AND INSTALLATION ........BOSS332/545/551 E-volution ADJUSTMENTS AND SETTING-UP ......BOSS 332/545/551 E-volution USE AND OPERATION..........BOSS 332/545/551 E-volution BAR FEEDER MAINTENANCE ........BOSS 332/545/551 E-volution TROUBLES - CAUSES - CURES ........BOSS 332/545/551 E-volution PART REPLACEMENT ..........BOSS332/545/551 E-volution LIST OF AFTER-SALES CENTERS...

  • Page 5: Table Of Contents

    1 - GENERAL INFORMATION BOSS 332/545/551 E-volution INDEX TERMS OF WARRANTY.....................2 MANUAL PURPOSE....................3 MANUFACTURER AND BAR FEEDER IDENTIFICATION..........4 TECHNICAL ASSISTANCE ..................4 ANNEXES ENCLOSED ....................4 1 - Pag. 1 / 4...

  • Page 6: Terms Of Warranty

    The warranty shall begin from the date on the Installation Certificate duly filled in and signed. The document must be sent per mail to: CUSTOMER SERVICE IEMCA division of IGMI spa 48018 Faenza (Ra) ITALY - Via Granarolo,167 1 - Pag. 2 / 4...

  • Page 7: Manual Purpose

    1 - GENERAL INFORMATION BOSS 332/545/551 E-volution MANUAL PURPOSE This manual has been written and supplied by the manufacturer, the information herewith contained has been written in Italian (manufacturer's language) to be translated to other languages, in order to comply with legal and/or commercial requirements. This manual is integral part of the bar feeder and of its equipment.

  • Page 8: Manufacturer And Bar Feeder Identification

    1 - GENERAL INFORMATION BOSS 332/545/551 E-volution MANUFACTURER AND BAR FEEDER IDENTIFICATION A Manufacturer's identification B CE conformity marking C Year of manufacture D Bar feeder model E Serial number G Mains frequency H Absorption power M Feeding voltage N Direct driving voltage P Air pressure Q Bar feeder and pusher length R Breaking capacity...
  • Page 9 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution INDEX GENERAL BAR FEEDER DESCRIPTION...............2 OPERATING CYCLE ....................4 SAFETY DEVICES .....................7 SAFETY PLATES - LOCATION AND DESCRIPTION ............9 VERSION DESCRIPTION ..................10 TECHNICAL SPECIFICATIONS .................11 2.6.1 Noise levels ......................20 FITTINGS - FOREWORD ..................21 2.7.1 Bush-holder device - Description ................21 2.7.2 Axial displacement device - Description ..............22...

  • Page 10: General Bar Feeder Description

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution GENERAL BAR FEEDER DESCRIPTION The BOSS automatic bar feeder is used in the machine-tool industry and in particular, for automatic lathe feeding. It is particularly suitable for feeding fixed or sliding headstock lathes, numerical control or cam lathes.
  • Page 11 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution • MAIN PARTS A Magazine; where bars are stored. B Bar selection device; it allows the first bar to be lowered into the guides and holds back the remaining bars in the magazine. C Guides;...

  • Page 12: Operating Cycle

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution OPERATING CYCLE In the automatic operation mode, bar feeder movements are controlled in the sequence described below: 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.
  • Page 13 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution Clamps "D" close again to perform remnant "C" extraction check. If the remnant is still inserted in the bar-pusher collet, the feeder stops; otherwise, it continues its cycle. Upper guides "H" open together with bar pusher "A";...
  • Page 14 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution When the small pusher truck "M" completes its stroke, the required space has been created for bar- pusher insertion. The small pusher truck executes its return stroke. The upper guides H are closed; the bar-pusher A is positioned along the spindle axis.

  • Page 15: Safety Devices

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution SAFETY DEVICES A Emergency button; by working it, all feeder and lathe functions are stopped in an emergency situation. B Emergency button; by working it, all feeder and lathe functions are stopped in an emergency situation.
  • Page 16 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution D Fixed guard: it is made from transparent material to allow visual inspection of the bar magazine area. E Fixed guard: it prevents accidental access to the bar selection area. F Fixed guard: it prevents accidental access to the drive area. G Fixed guard: it prevents accidental access to the drive belt area.

  • Page 17: Safety Plates - Location And Description

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution SAFETY PLATES - LOCATION AND DESCRIPTION A Danger of upper limb crushing. B Caution! Moving parts. C Do not remove the safety barriers. D Wear safety gloves and shoes. E Caution! Danger of electric contact. F Warning: fix the bar feeder to the ground.

  • Page 18: Version Description

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution VERSION DESCRIPTION Table 1. Maximum bar length Model Version Max. length mm (ft) 2080 (6,8) BOSS 332 3200 (10,5) BOSS 545 3740 (12,2) BOSS 551 4400 (14,4) Table 2. Max. bar-pusher extension Model Version A –...

  • Page 19: Technical Specifications

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution TECHNICAL SPECIFICATIONS (*) Without axial displacement device, the minimum dimension can be reduced to 850 mm. Table 3. Overall dimensions Model Version A (mm) B (mm) 2603 BOSS 332 – BOSS 332r 3802 1220 BOSS 545 - BOSS 545r 4342...
  • Page 20 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution Table 4. General technical specifications BOSS 432 BOSS 545/551 Ø max 545 Ø min 4 mm Ø max 32 mm Ø min 5 mm 45 mm(1" (5/32") (1" 1/4) (3/16") 3/4) Round bar size Ø...
  • Page 21 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution Table 5. Working axis height Model Upper screws X (mm) Y (mm) position Working axis height Max. loading height Y 900÷940 1090 935÷975 1125 970÷1010 1160 BOSS 332 1005÷1045 1195 BOSS 545 1040÷1080 1230 BOSS 551 1075÷1115...
  • Page 22 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution Table 6. BOSS 332 guide, bar pusher, bar and tube diameters Model Guide Bar-pusher Bar diameter (mm) Largest tube diameter diameter diameter (mm) Min. Max. (mm) (mm) BOSS (*) valid also for prepared bars or normal bars machined with front remnant ejection. CAUTION: Barstock diameters for any guide channel are only given as an example.
  • Page 23 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution Table 7. BOSS 545 guide, bar pusher, bar and tube diameters Model Guide Bar-pusher Bar diameter (mm) Largest tube diameter (mm) diameter (mm) diameter (mm) Min. Max. BOSS (*) valid also for prepared bars or normal bars machined with front remnant ejection. 2 - Pag.
  • Page 24 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution CAUTION: Barstock diameters for any guide channel are only given as an example. A barstock diameter approximately 10 mm smaller than the guide channel diameter may cause vibration and failure to the bar feeder. Therefore, it may be necessary to slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application.
  • Page 25 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution Table 8. BOSS 551 guide, bar pusher, bar and tube diameters Model Guide Bar-pusher Bar diameter (mm) Largest tube diameter (mm) diameter (mm) diameter (mm) Min. Max. BOSS (*) valid also for prepared bars or normal bars machined with front remnant ejection. 2 - Pag.
  • Page 26 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution CAUTION: Barstock diameters for any guide channel are only given as an example. A barstock diameter approximately 10 mm smaller than the guide channel diameter may cause vibration and failure to the bar feeder. Therefore, it may be necessary to slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application.
  • Page 27 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution Table 9. BOSS 332 guides lubricating oils Tab.10. BOSS 545/551 guides lubricating oils ISO/UNI Make Name ISO/UNI Make Name rating rating Agip Acer 100 Agip Acer 150 Api Cis 100 Api Cis 150 Energol CS 100 Energol CS 150 Castrol...

  • Page 28: Noise Levels

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution 2.6.1 Noise levels Bar feeder does not cause acoustic noise. Noise occurs when lathe, connected to the bar feeder, is working and the bar is rotating into bar feeder guides. In such a case, noise level emitted depends on the following conditions: •...

  • Page 29: Fittings - Foreword

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution FITTINGS - FOREWORD To improve the feeder performance and increase its versatility, a few optional devices are available which are listed and then described below. 2.7.1 Bush-holder device - Description 2.7.2 Axial displacement device - Description 2.7.1 Bush-holder device - Description It is attached to the front part of the bar feeder.
  • Page 30 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution 2.7.2 Axial displacement device - Description It allows the feeder to be moved away from the lathe to allow maintenance, cleaning or any other servicing of the lathe. Table 12. Overall dimensions Model Version A (mm) B (mm)

  • Page 31: Device For Sliding Headstock Lathes - Foreword

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution DEVICE FOR SLIDING HEADSTOCK LATHES - FOREWORD This feeder has been designed and manufactured to be coupled to sliding headstock lathes too. To do this, special devices are available which are listed and then described below: 2.8.1 Bar/headstock synchronizing device - Description 2.8.2 Telescopic nose - Description 2.8.1...
  • Page 32 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution 2.8.2 Telescopic nose - Description It is used to optimize bar guiding between the bush-holder device and the lathe spindle. Table 13. Max stroke and overall dimensions Model Max stroke Overall dimensions A (mm) B (mm) BOSS 332 BOSS 545...

  • Page 33: Devices For Cam Lathes - Foreword

    2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution DEVICES FOR CAM LATHES - FOREWORD This feeder has been designed and manufactured to be coupled to cam lathes too. To do this, special devices are available which are listed and then described below: 2.9.1 Headstock return device - Description 2.9.2 Cam box - Description 2.9.3 Camshaft release device - Description...
  • Page 34 2 - TECHNICAL INFORMATION BOSS 332/545/551 E-volution 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. Axial version Radial version 2 - Pag. 26 / 26...
  • Page 35 3 - SAFETY PROCEDURES - GENERAL INFORMATIONBOSS 332/545/551 E-volution INDEX GENERAL SAFETY PRESCRIPTIONS................2 HANDLING AND INSTALLATION - Safety ..............3 ADJUSTMENTS AND SETTING UP - Safety ..............3 USE AND OPERATION - Safety..................4 BAR FEEDER MAINTENANCE - Safety ................4 3 - Pag. 1 / 4...
  • Page 36 Comply strictly with the work health and safety regulations issued by the relevant authorities in the country of installation of the machine. • IEMCA declines any liability whatsoever for injury to persons or damage to property if the relevant safety prescriptions are disregarded. 3 - Pag. 2 / 4...
  • Page 37 3 - SAFETY PROCEDURES - GENERAL INFORMATIONBOSS 332/545/551 E-volution HANDLING AND INSTALLATION - Safety • The bar feeder must be handled using suitable means and methods. • Persons must not stand or transit underneath a suspended load, or within the range of action of the crane, lift truck or other suitable means of lifting and transportation.
  • Page 38 Keep spent oil in suitable containers and consign it to companies specialized in the storage and disposal of polluting waste products. • Do not pollute the environment. • Use original IEMCA spare parts only. 3 - Pag. 4 / 4...
  • Page 39 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution INDEX PACKAGING ......................3 LIFTING ......................3 INSTALLATION AREA - CHARACTERISTICS ............5 FEEDER WITHOUT AXIAL DISPLACEMENT DEVICE - INSTALLATION ....6 4.4.1 Support plates and feet - Installation................6 4.4.2 Height - Adjustment ....................7 4.4.3 Preliminary positioning .....................9 4.4.4 Sleeve - Installation ....................10 4.4.5...
  • Page 40 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.7.2 Cam box ........................25 4.7.3 Camshaft release device ..................26 LUBRICATING OIL - FILLING ................28 ELECTRIC CONNECTION ..................29 4.9.1 THREE-PHASE POWER SUPPLY ................29 4.9.2 SAFETY SIGNALS ....................29 4.9.2.1 EMERGENCY STOP ....................30 4.9.2.2 COVER SAFETY STOP (WHEN PROVIDED) ...............30 4.9.3 FUNCTION SIGNALS....................30 4.10...
  • Page 41 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution PACKAGING There are three possible bar feeder packagings: A WITH NO PACKAGING B WITH PALLET: the feeder is placed on a pallet and wrapped in protective film. C WITH CRATE: the feeder is placed in a crate wrapped in protective film. LIFTING DANGER - WARNING: handling and lifting operations should be carried out with suitable equipment...
  • Page 42 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution LIFTING WITH NO PACKAGING • Insert the two eyebolts with threaded shanks "A" (type 1 UNI - ISO3266 M20). • Use a hook type lifting device of suitable capacity. LIFTING WITH PALLET • Use a hook (or fork) type lifting device or of suitable capacity (see information on packaging).
  • Page 43 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution INSTALLATION AREA - CHARACTERISTICS The floor should be stable and levelled to guarantee good fastening to the ground. Provide an area of suitable dimensions according to the type of feeder use. The areas: "D" (work area), "E" (bar feeding area) and "F" (remnant discharge area) should be properly delimited to prevent collisions between the operator and any handling equipment or transport vehicles travelling near the bar feeder.
  • Page 44 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution FEEDER WITHOUT AXIAL DISPLACEMENT DEVICE - INSTALLATION Before carrying out feeder installation, check lathe stability; make sure that it is firmly fastened to the ground and with a horizontal spindle axis. 4.4.1 Support plates and feet - Installation •...
  • Page 45 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.4.2 Height - Adjustment The feeder is normally factory-preset to have a working axis height adjusted to lathe height. However, if feeder height needs adjustment, proceed as follows: • tighten the lifting chains and remove the 16 screws "A".
  • Page 46 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution Table 2. Working axis height Model Upper screws X (mm) Y (mm) position Working axis height Max. loading height Y 900÷940 1090 935÷975 1125 970÷1010 1160 BOSS 332 1005÷1045 1195 BOSS 545 1040÷1080 1230 BOSS 551 1075÷1115...
  • Page 47 In fixed headstock lathes, its stroke can be reduced to 100 mm to allow the feeder to be brought as close as possible to the lathe; contact IEMCA After-sales Service for more information. Table 3. Max. bar-pusher extension Model Version A –...
  • Page 48 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution • Roughly adjust the working axis height to obtain alignment with the lathe by turning the feet screws. 4.4.4 Sleeve - Installation BOSS 332 • Install the sleeve "A" in the bush holder device.
  • Page 49 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution BOSS 545 - BOSS 551 • Install the sleeve "A" in the bush holder device. • Install the oil recovery device "B". • Connect the drain pipe to the tank. 4 - Pag. 11 / 32...
  • Page 50 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.4.5 Levelling and alignment FOREWORD Alignment between the feeder and lathe is the most critical installation phase; therefore, this operation should be carried out by experienced personnel with the greatest accuracy. CAUTION: bad alignment can be the main cause of feeder malfunction resulting...
  • Page 51 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution LEVELLING • Insert the templates in the specially provided holes in the beam. • Check levelling by positioning the level crosswise and lengthwise. • Carry out the required connections by turning the feet screws. 4 - Pag.
  • Page 52 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution ALIGNMENT • 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. To obtain alignment lead a (ø...
  • Page 53 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution • use a sliding calliper to check alignment near the sleeve "C" and the spindle "D"; adopt a tolerance of 0.15 mm in all four directions. • prepare a perfectly straight ground bar, having an outside diameter equal to the max.
  • Page 54 Wherever possible, the feeder should be fastened to the lathe through the suitable coupling unit according to lathe make and type. The figure shows a general example of fastening; contact IEMCA service department for more information. 4 - Pag. 16 / 32...
  • Page 55 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.4.7 Installation If the feeder If the feeder is equipped with a telescopic nose, proceed as described below: • Remove the fixed sleeve that had been installed to obtain alignment between the feeder and the lathe.
  • Page 56 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution FEEDER WITH AXIAL DISPLACEMENT DEVICE - INSTALLATION Before carrying out feeder installation, check lathe stability; make sure that it is firmly fastened to the ground and with a perfectly horizontal spindle axis. 4.5.1 Preliminary operations •...
  • Page 57 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.5.3 Preliminary positioning • Position the feeder behind the lathe, by taking into account the overall dimensions and side plays of both machines and the coupling distance (see item "B" paragraph 4.4.3) • Roughly adjust the working axis height to obtain alignment with the lathe by turning the feet screws.
  • Page 58 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.5.5 Levelling and alignment FOREWORD Alignment between the feeder and lathe is the most critical installation phase; therefore, this operation should be carried out by experienced personnel with the greatest accuracy. CAUTION: bad alignment can be the main cause of feeder malfunction and resulting damage.
  • Page 59 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution • Position the remaining eight plates under the axial sliding frame in the positions indicated in the figure, then tighten the cone end grub screws "B". 4 - Pag. 21 / 32...
  • Page 60 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.5.6 Feeder fastening Ground fastening • Drill the floor and fix the (axial sliding) frame with expansion plugs. • Perform a levelling and alignment check. • Tighten nuts "A" and screws "B". • Perform another levelling and alignment check.
  • Page 61 Bar/headstock synchronizing device • Open the upper guard. INFORMATION: the figure shows a general example of installation; contact IEMCA service department for more information. • Screw out the screw "A". • Install the bar "B" and tie-rod "C" and make sure that the headstock "D"...
  • Page 62 4.7.1 Headstock return device • Open the upper guard. INFORMATION: the figure shows a general example of installation; contact IEMCA service department for more information. • Remove the original headstock return unit from the lathe. • Loosen the screw "A".
  • Page 63 "H". 4.7.2 Cam box INFORMATION: the figure shows a general example of installation; contact IEMCA service department for more information. • Install the sleeve "A" on the lathe camshaft "B". • Connect the shaft "C" to the sleeve through the pin "D".
  • Page 64 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.7.3 Camshaft release device INFORMATION: the figures show a general example of installation; contact IEMCA service department for more information. Radial version • Mount the articulation "A" in the flange "B". • Mount the joint "C" in the articulation "D"...
  • Page 65 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution Axial version • Cut a hole and thread in the lathe casing to fix the transmission unit "F" and mount the disk "G" in the control "H". • Insert the shaft "L" in the joint "M" and lock with a pin;...
  • Page 66 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 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 the screws, move the slides "Q", retighten the screws "P".
  • Page 67 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution ELECTRIC CONNECTION DANGER - WARNING: this type of operation should only be entrusted to skilled technical staff to comply with the applicable standards and statutory 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 compliance with the applicable regulations in force.
  • Page 68 Any jumper on the safety signals, which had been set for bar feeder final test, should be removed in order to restore the safety signals. ATTENTION-DANGER Bar feeder safety depends on these connections, therefore IEMCA is not responsible for any enventual damage to persons or structures, caused by improper use of the above mentioned signals.
  • Page 69 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution These signals are driven 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 application of the bar feeder on every lathe type: it is therefore possible that some of them are not used.
  • Page 70 4 - HANDLING AND INSTALLATION BOSS332/545/551 E-volution 4.10 PNEUMATIC CONNECTION • Fill the tank of lubricator "A" removing plug "B" or cup "C"; the oil level must reach the MAX. reference. For the oil comparison table, see section 2.6. • Connect pipe "D"...
  • Page 71 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution INDEX ADJUSTMENT AND SETTING-UP - FOREWORD ...........2 GENERAL ADJUSTMENTS - FOREWORD ..............3 5.2.1 Feeding chain - Adjustment ..................3 5.2.2 Setting the pressure switch..................3 SET-UP ACCORDING TO THE BAR TO BE MACHINED ..........4 5.3.1 Guides, half bushes, bar-pusher and collet - Replacement ........11 5.3.2...
  • Page 72 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution ADJUSTMENT AND SETTING-UP - FOREWORD DANGER - WARNING: do not perform any adjustment while the feeder is in motion unless explicitly requested in the manual. In addition to normal adjustments throughout its service life, this bar feeder also needs set-up according to the type of operation.
  • Page 73 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution GENERAL ADJUSTMENTS - FOREWORD Including all the necessary adjustments for good feeder operation. They may become necessary after maintenance, trouble fixing or component replacement. 5.2.1 Feeding chain - Adjustment 5.2.2 Drive belt - Adjustment 5.2.3 Pressure switch - Adjustment 5.2.1 Feeding chain - Adjustment...
  • Page 74 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution SET-UP ACCORDING TO THE BAR TO BE MACHINED According to the "new" bar diameter, a few or several operations must be carried out based on the diameter of the previously machined bar. The table shows the available guide diameters with the corresponding range of bar-pushers to be mounted and the range of diameters of the bars to be machined.
  • Page 75 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Table 1. BOSS 332 guide, bar pusher, bar and tube diameters Model Guide Bar-pusher Bar diameter (mm) Largest tube diameter diameter diameter (mm) Min. Max. (mm) (mm) BOSS (*) valid also for prepared bars or normal bars machined with front remnant ejection. CAUTION: Barstock diameters for any guide channel are only given as an example.
  • Page 76 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Table 2. BOSS 545 guide, bar pusher, bar and tube diameters Model Guide Bar-pusher Bar diameter (mm) Largest tube diameter (mm) diameter (mm) diameter (mm) Min. Max. BOSS (*) valid also for prepared bars or normal bars machined with front remnant ejection. 5 - Pag.
  • Page 77 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution CAUTION: Barstock diameters for any guide channel are only given as an example. A barstock diameter approximately 10 mm smaller than the guide channel diameter may cause vibration and failure to the bar feeder. Therefore, it may be necessary to slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application.
  • Page 78 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Table 3. BOSS 551 guide, bar pusher, bar and tube diameters Model Guide Bar-pusher Bar diameter (mm) Largest tube diameter (mm) diameter (mm) diameter (mm) Min. Max. BOSS (*) valid also for prepared bars or normal bars machined with front remnant ejection. 5 - Pag.
  • Page 79 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution CAUTION: Barstock diameters for any guide channel are only given as an example. A barstock diameter approximately 10 mm smaller than the guide channel diameter may cause vibration and failure to the bar feeder. Therefore, it may be necessary to slow down the bar rotation speed or to change the guide channel diameter in order to obtain the best performance for a specific application.
  • Page 80 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Example 1 The previous machining cycle had been carried out under these conditions: Guide Bar-pusher diameter (mm) diameter diameter (mm) (mm) The new machining cycle requires feeding of 10 mm bars. In this case, the half bushes and bar-pusher collet must be replaced and the magazine must be adjusted.
  • Page 81 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution 5.3.1 Guides, half bushes, bar-pusher and collet - Replacement • When the magazine is empty (no bars) set the feeder to manual mode. • Open the upper guard. • Use the keyboard to move the bar pusher forwards beyond the area of the bar extraction/introduction clamps unit.
  • Page 82 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution • Move the small pusher truck forwards until the flag reaches the opening, then remove the truck from its seat. • Disassemble the lower guides • Proceed disassembling the upper guides. 1 - Fastening screw version 2 - Quick fastening version 5 - Pag.
  • Page 83 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution • Remove the bar pusher support. A Guides with Ø=13÷46 B Guide with Ø=52 1 Support 2 Spacer 5 - Pag. 13 / 33...
  • Page 84 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Remove the nose in the following way: Fixed nose • Remove the oil recovery device "A" and nose "B". Telescopic nose • Remove the nose "C". Remove the front half bushes in the following way: BOSS 332 •...
  • Page 85 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution BOSS 545/551 • 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"...
  • Page 86 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Install front half-bushings suitable for the bar in the following way: BOSS 332 • Insert the two half bushes and place the cover. BOSS 545/551 • Insert the upper half bush, turn the shaft "A" and insert the lower half bush.
  • Page 87 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Place the nose back as follows: Fixed nose • Install the nose "B" suitable for diameter of the guides and the oil recovery device "A". Telescopic nose It is not necessary to change the whole telescopic nose assembly: only a few components supplied as a spare part kit need to be changed.
  • Page 88 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution • Place the sleeve back into its seat. For BOSS 332 only If the "new" guide diameter is 13 mm, the intermediate flag should be changed as follows. • Remove the two rings "A", the spring "B" and the flag •...
  • Page 89 IEMCA After-Sales service for more information. Legend: 1 "IEMCA" collet for pipes 2 "IEMCA" collet for bars 3 "IEMCA" collet for machined bars with remnant front ejection 4 "SCHLENKER" collet for bars 5 Ring 6 Collet connection 5 - Pag. 19 / 33...
  • Page 90 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution CAUTION-PRECAUTION : At every collet change (modell 381p, 381p..011, 381p..021 e 386p) it is necessary to install the grub screw H and the counter screw L. 5 - Pag. 20 / 33...
  • Page 91 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution CAUTION: the collet outside diameter should be at least 0.5 mm smaller than the bar-pusher outside diameter. • Install the collet in the bar-pusher and make sure that the rings are riveted in their special recesses to prevent accidental collet unscrewing from its connection.
  • Page 92 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution • Install the 1st feeding carriage into its seat. • Bring the 1st feeding carriage to its backward stroke limit and fit the bar pusher. • Move the bar-pusher forwards past the clamps area.
  • Page 93 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution • Close the guard. • On the keyboard press the two blue buttons and the guides closing button simultaneously: now close the guides. • Bring the bar pusher to its backward limit stop by means of the keyboard.
  • Page 94 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Open the guard and proceed as follows: • Loose the screw, adjust the flag position and tighten the screw. • Close the upper guides. • Move the bar-pusher forwards and backwards in the flag area to make sure that its stroke is not hindered.
  • Page 95 (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: •...
  • Page 96 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution • Unscrew screws "A" and change the clamp. • Restore the initial conditions of the bar feeder. 5 - Pag. 26 / 33...
  • Page 97 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution 5.3.3 Bar guide plates and bar selectors - Adjustment Preliminary procedure • Open the upper guard. • Close the upper guides (sensor "A" must be energized) • Make sure that the bar selectors are lower than the magazine surface.
  • Page 98 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Adjustment of the bar guide plates • Loosen the handle "A", lift the plate and tighten the handle "A"; repeat this operation on all the plates. • Feed two bars to the magazine, loosen the handle "A"...
  • Page 99 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Adjusting the bar selectors Make the adjustment as follows. • Use screw "B" to adjust the transverse position of bar stop "A" so that selectors "C" lift just one bar. • Open the upper guides; the first bar must be dropped into the guides, while the second bar should be retained in the magazine until the next bar closure.
  • Page 100 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution CAM BOX - TIMING 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.
  • Page 101 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution CAM SETTING LATHE CAM COMPLETE CYCLE PHASE HEADSTOCK PHASE COLLET LATHE FEEDER CAM COMPLETE CYCLE PHASE MICROSWITCH PHASE MICROSWITCH PHASE MICROSWITCH A STROKE CLOSED B FEED OPEN C FORWARD STOP CLOSED D RETURN DISABLED E BACKWARD STOP ENABLED...
  • Page 102 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Microswitches S90 and S91 • Rotate manually shaft "A" up to a distance of 10° approx. from the collet opening, then "S90" microswitch cam until wheel "B" is released. • Turn shaft "A" until the collet opens. •...
  • Page 103 5 - ADJUSTMENTS AND SETTING-UP BOSS 332/545/551 E-volution Microswitch S92 • Rotate manually shaft "A" until the headstock starts its return stroke with closed collet. • Release "S92" microswitch wheel. • Continue rotation until the headstock has completed its return stroke. •...
  • Page 104 6 - USE AND OPERATION BOSS 332/545/551 E-volution INDEX DESCRIPTION OF THE CONTROLS ................2 DESCRIPTION OF KEYBOARD CONTROLS..............4 LUMINOUS INDICATOR - SIGNAL DESCRIPTION ............6 BARS TO BE MACHINED - CHARACTERISTICS AND PREPARATION ......7 6.4.1 BAR STRAIGTHNESS - Measuration ................9 FEEDER SET-UP AND AUTOMATIC CYCLE START.............11 6.5.1 Bar magazine - Filling.....................12 6.5.2...
  • Page 105 6 - USE AND OPERATION BOSS 332/545/551 E-volution DESCRIPTION OF THE CONTROLS INFORMATION: from the hand-held keyboard it is possible to start automatically the bar feeder, even when lathe 'MAN/AUT' signal is in Manual mode. INFORMATION: When Automatic mode is on, the bar feeding is possible only when lathe 'MAN/AUT' signal is in Automatic mode.
  • Page 106 6 - USE AND OPERATION BOSS 332/545/551 E-volution The illustration shows the positions of both the electrical controls and hand-held keyboard "1". 2 MAIN SWITCH: turns the power supply on and off. Position 0 (OFF) the machine has no power supply. Position I (ON) the machine has power supply.
  • Page 107 6 - USE AND OPERATION BOSS 332/545/551 E-volution DESCRIPTION OF KEYBOARD CONTROLS 1 Start buttons: opposite buttons that when pushed together will start some procedures. Press the two buttons, and at the same time, the key corresponding to the required function. 2 Selects the automatic mode.
  • Page 108 6 - USE AND OPERATION BOSS 332/545/551 E-volution 16 Multifunction Number setting. Opens the guide channels. Hold down the two start buttons and then the key; release the two buttons and the key only when the movement has terminated. 17 Multifunction Number setting.
  • Page 109 6 - USE AND OPERATION BOSS 332/545/551 E-volution LUMINOUS INDICATOR - SIGNAL DESCRIPTION BLINKIGN ORANGE LIGHT; the bar feeder magazine cover is open. BLINKING GREEN LIGHT; it indicates that the bar feeder is in the automatic mode. BLINKING RED LIGHT; signals that the bar feeder is not operating, or that it is in the manual mode.
  • Page 110 6 - USE AND OPERATION BOSS 332/545/551 E-volution BARS TO BE MACHINED - CHARACTERISTICS AND PREPARATION CAUTION: do not feed bars having different sizes than the manufacturer's prescribed sizes. clean the bar surface before loading bars. Table 1. Maximum bar length Model Version Max.
  • Page 111 6 - USE AND OPERATION BOSS 332/545/551 E-volution Please find herewith some advice to optimise the bar feeder performances. Usually barstocks do not need any preliminary operations to be carried out on ends, nevertheless to obtain the best results when loading them, it is advisable to chamfer them. SOLID BARS Check that there is not too much rag on bar head, which might hinder insertion in the lathe collet.
  • Page 112 6 - USE AND OPERATION BOSS 332/545/551 E-volution 6.4.1 BAR STRAIGTHNESS - Measuration The bar vibrations are partially caused by the condition of the bar itself: in case the bar is not perfectly straight, this can cause vibrations. Round bars As stated also in the UNI-10233/2 regulation, the bar straightness can be measured by positioning the bar on two V-supports and control its...
  • Page 113 6 - USE AND OPERATION BOSS 332/545/551 E-volution Hexagonal, square and section bars For non-round bars, insert some bushings on the bar to be controlled. Position 2 bushings on the 2 V-supports. In that case, the measurement can be carried out as shown in the figure.
  • Page 114 6 - USE AND OPERATION BOSS 332/545/551 E-volution FEEDER SET-UP AND AUTOMATIC CYCLE START The following list is a sequence of feeder set-up and automatic cycle start operations required if the feeder has to be started up for the first time. •...
  • Page 115 6 - USE AND OPERATION BOSS 332/545/551 E-volution 6.5.1 Bar magazine - Filling CAUTION: do not manually lift loads with weights exceeding those prescribed applicable regulations in force; ask for another worker's help if necessary. CAUTION: wear personal protections according to the regulations in force.
  • Page 116 6 - USE AND OPERATION BOSS 332/545/551 E-volution 6.5.2 Lubrication oil - Flow adjustment Oil flow in the guides and bush-holder device is automatically controlled during the feeder automatic cycle. The pump is started after the feeder has completed bar change-over; it is stopped when the bar-pusher approaches the bush-holder device.
  • Page 117 6 - USE AND OPERATION BOSS 332/545/551 E-volution 6.5.3 Automatic cycle start • Power the lathe on. • Turn the main power switch to the position I (ON). • Press to start the bar feeder. • Press to select the manual mode. •...
  • Page 118 6 - USE AND OPERATION BOSS 332/545/551 E-volution 6.5.4 Guide channel opening/closing procedure The following instructions concern guide channel opening and closing in the manual function. OPENING PROCEDURE Open the guide channels by pressing the start buttons plus ; if the carriage "A"...
  • Page 119 6 - USE AND OPERATION BOSS 332/545/551 E-volution 6.5.5 Cycle actuation mode in the STEP BY STEP function Introduction This mode can be used for many reasons, as for instance: • to check a complete bar change cycle; • to check the bar feeder mechanics; •...
  • Page 120 6 - USE AND OPERATION BOSS 332/545/551 E-volution AUTOMATIC CYCLE START AFTER MANUAL CYCLE OPERATIONS • If the bar-pusher has been moved while electric power was disconnected, a "BAR FEEDER ZERO SETTING" should be performed in the following way: press the start buttons plus if the upper guides are not closed, the feeder will not perform "BAR FEEDER ZERO SETTING";...
  • Page 121 6 - USE AND OPERATION BOSS 332/545/551 E-volution MACHINING CHANGE - QUICK GUIDE The purpose of this paragraph is to provide the operator with a quick guide to the operations required for machining type change (either with or without guide change-over). The relevant information is contained in the paragraphs listed below and then described.
  • Page 122 6 - USE AND OPERATION BOSS 332/545/551 E-volution 6.9.2 Machining type change without guide change-over • Replace the half bushes and collet (paragraph 5.3.1) remove the bar-pusher; remove the half bushes; mount the new half bushes; mount a collet suitable for the "new" bar in the bar-pusher; insert the bar-pusher in the guides;...
  • Page 123 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution INDEX MAINTENANCE - GENERAL RULES ..............2 SCHEDULED MAINTENANCE ................3 7.2.1 Revolving tip and collet - Check ................3 7.2.2 Lubricating oil - Level check..................4 7.2.3 Lubricating oil - Change....................5 7.2.4 Guide opening screw - Greasing................6 7.2.5 Air filter unit - Check ....................6 AXIAL DISPLACEMENT DEVICE - USE...
  • Page 124 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution MAINTENANCE - GENERAL RULES DANGER - WARNING: carry out machine maintenance and cleaning while the machine is off. Regular cleaning and maintenance are critical to ensure smooth operation and longer machine service life. It is recommended to regularly and effectively clean the machine, its accessories and work area, which also increases operator's safety.
  • Page 125 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution SCHEDULED MAINTENANCE Table 1. Scheduled maintenance Frequency Hours Operation to carry Bar feeder part Every Regularly Cycles year 1250 2500 Revolving tip and collet Wear check • Half-bushing Wear check • Oil level check •...
  • Page 126 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution 7.2.2 Lubricating oil - Level check 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 "A" indicator. For any topping up, pour the oil directly into the base Table 2.
  • Page 127 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution 7.2.3 Lubricating oil - Change CAUTION: wear personal protections according to the regulations in force. INFORMATION: store spent oil in special containers to be delivered to companies specialized in pollutant disposal and storage. Do not pollute the environment. •...
  • Page 128 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution 7.2.4 Guide opening screw - Greasing • Open the upper guard and carry out greasing. 7.2.5 Air filter unit - Check FILTER A • Make sure that cup "B" is not full of condensate. If need be, bleed the condensate by valve "C".
  • Page 129 7 - BAR FEEDER MAINTENANCE BOSS 332/545/551 E-volution AXIAL DISPLACEMENT DEVICE - USE • If the feeder is fixed to the bar, release it. Disconnect any installed devices (e.g. the bar/headstock synchronizing device, the cam box, the camshaft release device etc.). •...
  • Page 130 8 - TROUBLES - CAUSES - CURES BOSS 332/545/551 E-volution INDEX GENERAL FAULTS .....................2 BAR MAGAZINE - Faults ..................2 INSERTION IN THE COLLET - Faults ..............3 BAR FEEDING - Faults ..................3 8 - Pag. 1 / 3...
  • Page 131 8 - TROUBLES - CAUSES - CURES BOSS 332/545/551 E-volution GENERAL FAULTS TROUBLE CAUSES CURES No power Check the electric connections Open guard Close the guard The bar feeder will not start Emergency systems on Disconnect the emergency devices Motor thermal switch tripped Reset the motor overload cut-out with the special push-buttons.
  • Page 132 8 - TROUBLES - CAUSES - CURES BOSS 332/545/551 E-volution INSERTION IN THE COLLET - Faults PROBLEMS CAUSES CORRECTIVE ACTION Collet diameter not suitable Change collet. Bar fails to enter collet. for bar diameter. Excessive rag on bar rear Trim rag before feeding. end.
  • Page 133 9 - PART REPLACEMENT BOSS332/545/551 E-volution INDEX FEED CHAIN - REPLACEMENT ................2 GUIDE OPENING BELT - REPLACEMENT .............2 KEYBOARD BATTERY - REPLACEMENT ...............3 PLC BATTERY - REPLACEMENT ................4 RECOMMENDED SPARE PARTS ................5 Machine Dismantling [qualification] ................5 9 - Pag. 1 / 5...
  • Page 134 9 - PART REPLACEMENT BOSS332/545/551 E-volution FEED CHAIN - REPLACEMENT Replacement of the feed chain is a highly complex operation; call IEMCA after-sales service. GUIDE OPENING BELT - REPLACEMENT • Open the guard by unscrewing the fastening screws. • Manually turn the pulley "B" and simultaneously pull the belt all the way out.
  • Page 135 9 - PART REPLACEMENT BOSS332/545/551 E-volution KEYBOARD BATTERY - REPLACEMENT Replace the battery at least every year, and when the following message is displayed "KEYBOARD BATTERY EXHAUSTED": INFORMATION: failure to replace the battery can cause the calendar - clock memory to be deleted. •...
  • Page 136 9 - PART REPLACEMENT BOSS332/545/551 E-volution PLC BATTERY - REPLACEMENT Replace the battery at least every year, and when the following message is displayed: "PLC battery exhausted" INFORMATION: when this message is displayed, the battery should be replaced within one day, otherwise, the "PLC/NC Software"...
  • Page 137 9 - PART REPLACEMENT BOSS332/545/551 E-volution RECOMMENDED SPARE PARTS The heavy-wear parts or easily broken parts are listed below (this list refers to bar feeder requirements for a two year's period of normal use). Table 1. Original spares table Model Code Name Characteristics...
  • Page 138 10 - LIST OF AFTER-SALES CENTERS INDEX 10.1 LIST OF AFTER-SALES CENTERS................2 10 - Pag. 1 / 3...
  • Page 139 7 Dolphin Industrial Fax ++44 1722 421071 Ltd. Estate, Southampton www.kitagawaeurope.com Road SP12NB Salisbury Tel +33 450 896960 FRANCE: IEMCA France Z.I. Des Grands Pres Telefax +33 450 896135 145, Email : rue Louis Armand 74300 Cluses GERMANY: Hoßfeld GmbH Königsberger Straße 10...
  • Page 140 10 - LIST OF AFTER-SALES CENTERS IGM of China Room 28F, Shanghai Tel 0086 21 64686020 CHINA (PRC): Fax 0086 21 64877987 Shiye Apartment No.38, E-mail: North Cao Xi Road,Xu Hui District, Shanghai 200030 China 10 - Pag. 3 / 3...

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