INDEX 302.087 GENERAL INFORMATION SAFETY PROCEDURES - GENERAL INFORMATION 1.1. WARRANTY CONDITIONS ....... 3 3.1. SAFETY GENERAL INSTRUCTIONS ..25 1.2. MANUAL PURPOSE ........... 3 3.2. HANDLING AND INSTALLATION - Safety 1.3. MANUFACTURER AND BAR FEEDER procedures IDENTIFICATION ............25 ..........
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INDEX 302.087 ADJUSTMENTS AND SETTING-UP BAR FEEDER MAINTENANCE 5.1. ADJUSTMENT AND SETTING-UP - 7.1. MAINTENANCE - GENERAL RULES ... 79 Foreword ............. 45 7.2. SCHEDULED MAINTENANCE ...... 80 5.2. GENERAL ADJUSTMENTS - Foreword 7.2.1 Revolving tip and collet - Check ..
GENERAL INFORMATION 302.087 Before carrying out any servicing whatsoever on the bar feeder, it is of the utmost impor- tance to read this manual carefully. 1.1. WARRANTY CONDITIONS The warranty validity is conditional on good alignment between the bar feeder and the lathe and the subse- quent bar feeder fixing to the ground with expansion plugs, as explained in the sections “Levelling and alignment”...
GENERAL INFORMATION 302.087 1.3. MANUFACTURER AND BAR FEEDER IDENTIFICATION IDM-3020870010.tif A - Manufacturer’s identification L - Alternate driving voltage B - CE conformity marking M - Direct driving voltage C - Year of manufacture N - Bar feeder weight. D - Bar feeder model INFORMATION: Always provide the Manufac- E - Serial number turer with the above mentioned specifications in...
TECHNICAL INFORMATION 302.087 2.1. GENERAL BAR FEEDER DESCRIPTION The GENIUS automatic bar feeder is used in the ma- The bar feeder can be used to feed bars, pipes and chine-tool industry and in particular, for automatic lathe various sections. feeding. It is particularly suitable for feeding fixed or The guide channel is fully closed during machining;...
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TECHNICAL INFORMATION 302.087 ❑ Main parts IEMCA228510011 A - Magazine; where bars are stored. H - Sensors unit; enable control and command of bar feeder movements. B - Bar selection device; it allows the first bar to be lowered into the guides and holds back the re- L - Clamps;...
TECHNICAL INFORMATION 302.087 2.2. OPERATING CYCLE - General description In the automatic operation mode, bar feeder movements are controlled in the sequence described below: Phase 1 The bar-pusher A feeds bar B in the lathe by following lathe impulses un- til bar end.
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TECHNICAL INFORMATION 302.087 Phase 4 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. IDM - 3020870060.tif Phase 5 The bar selector F is lowered, and all the bars in the magazine are held back except for the first bar G.
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TECHNICAL INFORMATION 302.087 Phase 7 The small pusher truck N starts its stroke. IDM - 3020870070.tif Phase 8 When the small pusher truck N com- pletes its stroke, the required space has been created for bar-pusher in- sertion. The small pusher truck executes its return stroke.
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TECHNICAL INFORMATION 302.087 Phase 10 The bar selector F rises. IEMCA228510231 Phase 11 The clamps D close, the bar-pusher A moves for- wards; the bar G is inserted into the bar-pusher collet. Phase 12 The bar-pusher A and bar G execute their facing stroke.
TECHNICAL INFORMATION 302.087 2.3. SAFETY DEVICES - Position and description IDM - 3020870130.tif A B-Emergency button; by working it, all feeder and visual inspection of the bar magazine area and the lathe functions are stopped in an emergency situ- terminals. ation.
TECHNICAL INFORMATION 302.087 2.4. SAFETY PLATES - Position and description IDM - 3020870140.tif A - Danger of arm crushing. D - Do not remove safety barriers. B - Beware of running parts. E - Wear working gloves and shoes. Do not lift manually loads exceeding 15 kg.
TECHNICAL INFORMATION 302.087 2.5. VERSION DESCRIPTION Table 1. Maximum bar length Version Max. length mm (ft) 3210 (10,5) 3730 (12,2) 4250 (13,9) Table 2. Max. bar-pusher extension Version A - Max extension (mm) 1218 1478 IEMCA228510021...
TECHNICAL INFORMATION 302.087 2.6. TECHNICAL SPECIFICATIONS IEMCA228510031 Table 3. Overall dimensions Version A (mm) B (mm ) 3755 1185 4275 1705 4795 2225...
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TECHNICAL INFORMATION 302.087 Table 4. General technical data Round bar diameter min 2 mm (5/64”) max 26 mm (1”) Square bar side min 2 mm (5/64”) max 18 mm (45/64”) Hexagonal bar height min 2 mm (5/64”) max 22 mm (7/8”) (key socket) Minimum bar length 1500 mm...
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TECHNICAL INFORMATION 302.087 Table 6. Diameters of guides, bar-pusher, bars and pipes Guide Bar-pusher Largest pipe Bar diameter (mm) diameter (mm) diameter (mm) diameter (mm) (*) 13,5 18,5 (*) 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.
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TECHNICAL INFORMATION 302.087 Table 7. Guides lubricating oils ISO/UNI rating Make Name Agip Acer 100 Api Cis 100 Energol CS 100 Castrol Magna 100 Chevron Circulating Oil 100 Movixa 100 Esso Nuto 100 Fina Solna 100 IP Hermea 100 Klüber Crucolan 100 CLASSE C CKB 100...
TECHNICAL INFORMATION 302.087 2.6.1 Noise levels • Bar feeder does not cause acoustic noise. spindle liner having the same diameter as the bar feeder guide channel diameter; Noise occurs when lathe, connected to the bar feeder, is • spindle rotation speed suitable for the material to be working and the bar is rotating into bar feeder guides.
TECHNICAL INFORMATION 302.087 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 IDM - 3020870180.tif...
TECHNICAL INFORMATION 302.087 2.7.3 Bush-holder device - Description It is attached to the front part of the bar feeder. Its func- tion its to reduce bar vibrations to a minimum, by keep- ing the bar centered during rotation through two half bushes A, which are coupled to form a round channel with a diameter just slightly larger than that of the bar being machined.
TECHNICAL INFORMATION 302.087 2.8.2 Telescopic nose - Description It is used to optimize bar guiding between the bush-holder device and the lathe spindle. Table 9. Max stroke and overall dimensions Overall dimensions Max stroke A (mm) B (mm) IDM - 3020870210.tif...
TECHNICAL INFORMATION 302.087 2.9. DEVICES FOR CAM LATHES - Description 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...
TECHNICAL INFORMATION 302.087 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. Radial version Axial version IDM - 3020870220.tif...
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TECHNICAL INFORMATION 302.087 PAGE LEFT BLANK INTENTIONALLY...
SAFETY PROCEDURES-GENERAL INFORMATION 302.087 3.1. SAFETY GENERAL INSTRUCTIONS It is of the utmost importance to read carefully Do not tamper with the safety devices for any reason this manual before carrying out any installa- whatsoever. tion, use, maintenance or other servicing on Safety labour regulations issued by each country au- the bar feeder.
SAFETY PROCEDURES-GENERAL INFORMATION 302.087 3.3. ADJUSTMENTS AND SETTING UP - Safety procedures Carry out the adjustments according to the use and Do not feed the machine with barstocks having dimen- maintenance manual. sions different from those recommended by the manu- facturer.
HANDLING AND INSTALLATION 302.087 4.1. PACKAGING There are three possible bar feeder packagings: C - With crate: the feeder is placed in a crate A - With no packaging. wrapped in protective film. B - With pallet: the feeder is placed on a pallet and wrapped in protective film.
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HANDLING AND INSTALLATION 302.087 ❑ 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. IDM - 3020870240.tif ❑ Lifting with pallet •...
HANDLING AND INSTALLATION 302.087 4.3. INSTALLATION AREA - Characteristics Without axial displacement With axial displacement The floor should be stable and levelled to guarantee The selected bar feeder setting should be suitably lit good fastening to the ground. and provided with an electric power and air outlets. Provide an area of suitable dimensions according to During operation, the feeder will release small amount the type of feeder use.
HANDLING AND INSTALLATION 302.087 4.4. INSTALLATION OF BAR FEEDER - Introduction Before carrying out feeder installation, check lathe sta- bility; make sure that it is firmly fastened to the ground and with a horizontal spindle axis. 4.4.1 Support plates and feet - Installation •...
HANDLING AND INSTALLATION 302.087 4.4.2 Height - Adjustment The feeder is normally factory-pre- set to have a working axis height ad- justed to lathe height. However, if feeder height needs ad- justment, proceed as follows: • tighten the lifting chains and remove the 16 screws A.
HANDLING AND INSTALLATION 302.087 4.4.3 Preliminary positioning • Position the feeder behind the lathe, by taking into account the overall dimensions and side plays of both machines. The coupling distance B should not exceed the bar-pusher max. extension A. Table 3. Max. bar-pusher extension Version A - Max extension (mm) 1218...
HANDLING AND INSTALLATION 302.087 4.4.4 Nose - Installation • Install the sleeve A in the bush holder device. • Install the oil recovery device B. • Connect the drain pipe to the tank. IDM - 3020870280.tif...
HANDLING AND INSTALLATION 302.087 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 and resulting damage.
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HANDLING AND INSTALLATION 302.087 • Make the necessary corrections by adjusting the feet screws. IDM - 30208700690.tif ❑ Alignment • Position the bar pusher B at the in- let of spindle C of the lathe and check the alignment. • Position the bar pusher in the for- ward end-of-travel position, close to collet D of the lathe, and check...
HANDLING AND INSTALLATION 302.087 4.4.6 Feeder fastening ❑ Ground fastening CAUTION: failure to fix the bar feeder to the ground or bad bar feeder fixing to the ground can be the main cause of bar feeder bad operation and resulting damaging. •...
HANDLING AND INSTALLATION 302.087 4.5. ACCESSORIES - Installation 4.5.1 Precision facing device - Installation • Remove the screws and open the front cover. IEMCA228510061 INFORMATION: the figure shows a general example of in- stallation; contact IEMCA serv- department more information. •...
HANDLING AND INSTALLATION 302.087 4.6. DEVICES FOR SLIDING HEADSTOCK LATHES - Installation 4.6.1 Bar-headstock synchronisation device- Installation • Remove the screws and open the front cover. IEMCA228510061 INFORMATION: figure shows a general example of in- stallation; contact IEMCA serv- department more information.
HANDLING AND INSTALLATION 302.087 4.6.2 Telescopic front nose - Installation • Remove the fixed sleeve that had been installed to obtain alignment between the feeder and the lathe. • Fix the flange A (a general example is shown in the figure).
HANDLING AND INSTALLATION 302.087 4.7. DEVICES FOR CAM LATHES - Installation 4.7.1 Headstock return device - Installation • Remove the screws and open front cover A. Then re- move back cover B. IEMCA228510071 INFORMATION: the figure shows a general example of in- stallation;...
HANDLING AND INSTALLATION 302.087 • Install the (original lathe) spring L and adjust its tension through the ring nut M. • Refit the guard previously re- moved. IDM - 3020870740.tif 4.7.2 Cam box - Installation INFORMATION: the figure shows a general example of in- stallation;...
HANDLING AND INSTALLATION 302.087 4.7.3 Camshaft release device INFORMATION: the figures show a general example of instal- lation; contact IEMCA service department for more informa- tion. ❑ Radial version • Mount the articulation A in the flange B. • Mount the joint C in the articulation D and in the lathe control E.
HANDLING AND INSTALLATION 302.087 After completing the above-described operations, the actuator rotation stroke should be adjusted (this oper- ation is necessary for both the radial version and the axial version). • Loosen the screws, move the slides Q, retighten the screws P.
HANDLING AND INSTALLATION 302.087 4.10. PNEUMATIC CONNECTION INFORMATION: the opera- tions described below refer only to bar feeders fitted with pneu- matic devices. F B A • Fill the tank of lubricator A remov- ing plug B or cup C; the oil level must reach the MAX.
ADJUSTMENTS AND SETTING-UP 302.087 5.1. ADJUSTMENT AND SETTING-UP - Foreword DANGER - WARNING: do not perform any ad- These operations are listed and then described below: 5.2. General adjustments - Foreword justment while the feeder is in motion unless ex- 5.3.
ADJUSTMENTS AND SETTING-UP 302.087 5.2.1 Feed chain - Adjustment • Open the upper guard. IDM - 3020870290.tif • Remove guard A. • Loosen nut B. • Stretch the chain, moving the pinion in the direction of the arrow and lock nut B. •...
ADJUSTMENTS AND SETTING-UP 302.087 5.3. SETTING-UP THE BAR FEEDER ACCORDING TO THE BAR TO BE MACHINED Depending on the diameter of the bar previously ma- chined and that of the new cycle, various set-up oper- ations have to be performed. It is possible to establish the type of operation to be carried out with the aid of the following table.
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ADJUSTMENTS AND SETTING-UP 302.087 ❑ Example 1 • The previous machining cycle had been carried out un- replacing the bar pusher collet; • der these conditions: replacing the half-bushings; • setting up the guide channel closing mode; • Guide Bar-pusher Bar diameter replacing the nose;...
ADJUSTMENTS AND SETTING-UP 302.087 5.3.1 Guide channels, bar pusher and collet - Replacement • Bring the bar pusher “completely backwards” to the “BAR FEEDER ZERO SETTING” position. • Open top guard. IDM - 3020870290.tif • Insert the crank (supplied) in shaft A and move flag B of the bar pusher to the opening.
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ADJUSTMENTS AND SETTING-UP 302.087 • Loosen the screws and turn all the supports over backwards. IEMCA228510081 • Lift the upper guide channels. IEMCA228510181 • Remove the upper guides. IDM - 3020870420.tif...
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ADJUSTMENTS AND SETTING-UP 302.087 • Remove the bottom guides. IEMCA228510091 • Remove the inner sleeve and re- place it with another sleeve suita- ble for the bar to machine. IDM - 3020870420.tif • Replace the parts E, F and G with other parts suitable for the bar.
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ADJUSTMENTS AND SETTING-UP 302.087 • Turn the guide channel H over backwards, after screwing out the screws. IDM - 3020820070.tif • Remove the tube L (with the bar pusher inside). IDM - 3020870430.tif • Choose a suitable collet for the bar; check the “GUIDE CHANNELS - BAR PUSHER - REVOLV- ING TIPS - COLLETS - Choice manual”.
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ADJUSTMENTS AND SETTING-UP 302.087 • Screw the collet into a bar pusher suitable for the bar. • Insert the bar pusher in a tube suit- able for the bar ( ø < 26 mm ). IDM - 3020870460.tif • For bars with ø > 26 mm, rest the bar pusher on the relevant sup- ports.
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ADJUSTMENTS AND SETTING-UP 302.087 • Install the tube L. IDM - 3020870470.tif • Turn the guide channel H over for- wards and screw down the screws. IDM - 3020820090.tif • Close the top guides and make sure that the flag B is inserted well into the carriage seat.
ADJUSTMENTS AND SETTING-UP 302.087 5.3.2 Half-bushings - Replacement • Remove the cover A, replace the two half-bushings B with other half-bushings suitable for the bar. • Put the cover back in place. IDM - 3020870480.tif 5.3.3 Guide channel closing - Set-up ❑...
ADJUSTMENTS AND SETTING-UP 302.087 5.3.3 Nose - Replacement INFORMATION: after removing the nose, repla- ce the spindle liner. ❑ Fixed nose • Remove the oil recovery A. • Replace the sleeve B with the sleeve suitable for the bar. • Fit the oil recovery and position the drain pipe inside the tank.
ADJUSTMENTS AND SETTING-UP 302.087 5.3.4 Bar magazine - Adjustment • Loosen screws A and lift the plates B. • Insert a few bars. • Adjust the height of the plates. The distance between the plates and shim C must be slightly great- er than the bar diameter.
ADJUSTMENTS AND SETTING-UP 302.087 5.3.4 Bar selection device - Adjustment • Lower the selectors to the lowest point of descent. IEMCA228510201 • Adjust the position of the selectors by using nuts A and B alternately. Nut A is used for adjusting the height, the nut B for transverse adjustments.
ADJUSTMENTS AND SETTING-UP 302.087 5.3.5 Clamps - Adjustment • The bar feeder guide channels must be closed and the bars con- tained in the magazine must be aligned with the plate A. IEMCA228510141 • Close the upper guard. • Press to start the bar feeder.
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ADJUSTMENTS AND SETTING-UP 302.087 • Lift the top clamp all the way up via the screw B. Lower the bottom clamp via the screw C. IDM - 3020870540.tif • Close the clamps. IDM - 3020870550.tif • Lift the bottom clamp using screw C, until the bar axis is lifted by about 2 mm above the bar pusher D axis.
ADJUSTMENTS AND SETTING-UP 302.087 5.3.6 Clutch thrust - Adjustment The feeding thrust received by the bar via the clutch must de adjusted according to the diameter of the bar itself. Adjustment can be carried out in three different ways: electronic adjustment, mechanical adjustment and ad- justment by changing the clutch pack configuration For the electronic adjustment, the values of a few pa- rameters must be changed;...
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ADJUSTMENTS AND SETTING-UP 302.087 Brake linings Disks First equipment configuration “Bottom” spacer “Top” spacer Supplied parts Brake linings Disks “Top” spacer Possible configurations Brake linings Disks “Top” spacer...
ADJUSTMENTS AND SETTING-UP 302.087 5.4. PRECISION FACING DEVICE - ADJUSTMENT • Remove the screws and open front cover A. Then remove back cover IEMCA228510071 • Move the headstock forward to the maximum point of the working stroke. • Close latch C manually and posi- tion screw D at distance L, corre- sponding to the section of the bar to be faced.
ADJUSTMENTS AND SETTING-UP 302.087 5.5. 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 - Ar feeding control Controls the bar feeding motor start and stop and must be activated whenever the collet opens.
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ADJUSTMENTS AND SETTING-UP 302.087 Microswitches S90 and S91 • Rotate manually shaft A up to a distance of 10 ° approx. from the collet opening, then S90 micros- witch cam until wheel B is re- leased. • Turn shaft A until the collet opens. •...
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BASIC INFORMATION 302.087 6.1. DESCRIPTION OF THE CONTROLS The illustration shows the positions of both the electri- cal controls and hand-held keyboard. 302.087 Hand-held keyboard (for controls see section 6.2.) Bar feeder Stop button Bar feeder Start button Emergency Stop Main button switch...
BASIC INFORMATION 302.060 6.2. DESCRIPTION OF KEYBOARD CONTROLS –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. – Selects the automatic mode. –...
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BASIC INFORMATION 302.087 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. Multifunction – Number setting. – Moves the bar pusher to a high speed. Multifunction –...
BASIC INFORMATION 302.060 6.3. INDICATOR LIGHTS - Description of indications INFORMATION: The indicator light can also be placed on the rear part of the bar feeder where you find holes prepared for fixing and a slot to fit the ca- ble.
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BASIC INFORMATION 302.087 ❑ Solid bars Check that there is not too much rag on bar head, which might hinder insertion in the lathe collet. Check that there is not too much rag on bar rear end, which might hinder insertion in the bar-pusher collet. In any case, to improve operation during this phase, we advise to chamfer the bar as shown in the figure.
BASIC INFORMATION 302.060 ❑ Pipes If pipes have to be machined, their rear ends should be chamfered as shown in the figure. IDM - 34.145Ec.0 6.5. 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.
BASIC INFORMATION 302.087 6.5.1 Bar magazine - Filling CAUTION: do not manually lift loads with weights exceeding those prescribed by the appli- cable regulations in force; ask for another work- er’s help if necessary. Wear personal protections prescribed by the ap- plicable regulations in force.
BASIC INFORMATION 302.060 6.5.2 Lubrication oil - Flow adjustment The oil flow in the guide channels is automatically activated during the bar feeder automatic cycle. The pump starts up after the bar feeder has performed a bar change and stops when the bar pusher comes close to the nose.
BASIC INFORMATION 302.087 • Empty the remnant collection box during machining. CAUTION: do not manually lift weights exceed- ing those prescribed by the applicable regulations in force; ask for another worker’s help if neces- sary. Wear personal protections prescribed by the ap- plicable regulations in force.
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BASIC INFORMATION 302.060 ❑ Closing mode • If the carriage A is in its "BACK LIMIT STOP" position, close the guide channels by pressing the start buttons and A (“BACK LIMIT STOP” position) • If the carriage is at any point of its feeding stroke (area C), move it to its “BACK LIMIT STOP”...
BASIC INFORMATION 302.087 6.5.5 Cycle actuation mode in the “STEP-BY-STEP” function Introduction Procedure This mode can be used for many reasons, as for in- • Press to start the bar feeder; stance: • to check a complete bar change cycle; •...
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BAR FEEDER MAINTENANCE 302.087 7.1. MAINTENANCE - General rules DANGER - WARNING: carry out machine mainte- INFORMATION: oxidation can damage metal nance and cleaning while the machine is off. parts and electric equipment. Regular cleaning and maintenance are critical to en- To protect the bar feeder when you expect not to use sure smooth operation and longer machine service life.
BAR FEEDER MAINTENANCE 302.087 7.2. SCHEDULED MAINTENANCE Table 1. Scheduled maintenance Frequency Bar feeder part Operation to carry out Hours Periodi- Every year cally 1250 2500 Half bushes • Revolving tip and collet Wear check Half bushes • Half-bushing Wear check Half bushes •...
BAR FEEDER MAINTENANCE 302.087 7.2.2 Lubricating oil - Level check CAUTION: use the personal protection devices prescribed by regulations in force. • Wait until the bar feeder has been switched off for at least six hours. • Check the level on indicator A. •...
BAR FEEDER MAINTENANCE 302.087 7.2.4 Clutch oil - Checking CAUTION: use the personal protection devices prescribed by regulations in force. • Remove guard A. • Position the clutch so that cap B is at the highest point. • Remove the cap. The oil level must reach the hole.
BAR FEEDER MAINTENANCE 302.087 • Position the clutch so that the hole in the cap is at the highest point. Pour in BP Energol HLP-D32 type oil; the oil level must reach the hole. • Screw the cap on and refit the guard previously re- moved.
BAR FEEDER MAINTENANCE 302.087 • Remove cover C. • Loosen the ring nuts M and N to lower the clutch shaft and be able to remove the screws P and the pin Q. • Remove the plate R and the disks S with their brake linings.
BAR FEEDER MAINTENANCE 302.087 • Remove covers B and the brushes C. • Blow air inside to remove dust produced by wearing of the brushes. CAUTION: remove both plugs so that air blown into a hole can come out of the second hole. If only one cap is removed, dust will expand inside the motor and damage the motor.
BAR FEEDER MAINTENANCE 302.087 7.3. AXIAL DISPLACEMENT DEVICE - Use • If the feeder is fixed to the bar, re- lease it. Disconnect any installed devices (e.g. the bar/headstock synchronizing device, the cam box, the camshaft release device etc.). • Loosen the screw completely.
TROUBLES - CAUSES - CURES 302.087 8.1. GENERAL FAULTS TROUBLE CAUSES CURES No power. Check the electric connections. Open guard. Close the guard. Disconnect emergency The bar feeder will not start. Actuated emergency devices. devices. Reset the motor overload cut-out Motor thermal switch tripped with the special push-buttons.
TROUBLES - CAUSES - CURES 302.087 8.3. INSERTION IN THE COLLET - Faults TROUBLES CAUSES CURES Bad clamps adjustment. Adjust the clamps. The bar will not be inserted in Collet diameter not suitable for Change the collet. the collet. bar diameter. Too much rag on bar rear end.
PART REPLACEMENT 302.087 9.1. FEED CHAIN - Replacement Replacement of the feed chain is a highly complex op- eration; call IEMCA after-sales service. 9.2. CLUTCH DISKS - Replacement To replace, follow the procedure described in para- graph 7.2.6. 9.3. FEED MOTOR BRUSHES - Replacement To replace, follow the procedure described in para- graph 7.2.7.
PART REPLACEMENT 302.087 9.4. PLC BATTERY - Replacement Replace the battery at least every year, and when the following message is displayed: INFORMATION: when this message is displayed, PLC battery exhausted the battery should be replaced within one day, oth- erwise, the “PLC/NC Software”...
PART REPLACEMENT 302.087 9.5. KEYBOARD BATTERY - Replacement The keyboard battery should be replaced every year. INFORMATION: failure to replace the battery can cause the calendar – clock memory to be delet- • Disconnect power. • Screw out the six screws and remove the two half- shells.
PART REPLACEMENT 302.087 9.6. FEED MOTOR DRIVE - Replacement • Disconnect electric power, open the electrical switchboard doors. • Remove the drive A from its seat by lifting the lever B, and insert the new drive. IDM-3020870990.tif • Close the doors and connect electric power again. •...
PART REPLACEMENT 302.087 9.7. RECOMMENDED SPARE PARTS - List 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 Code Name Characteristics Notes...
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CONSULTING THE MANUAL • COMMENT CONSULTER CE MANUEL 302.062 Read this introductory section carefully; it will help you easily trace the data you require. This manual is divided into a number of parts which are in turn divided into a number of sections (see contents page). These contain de- tailed information relative to the equipping of the bar feeders depending on the cross-section of the barstock, its diameter, the type of collet to be used, etc.
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CONSULTING THE MANUAL • COMMENT CONSULTER CE MANUEL 302.062 Consult the "REVOLVING TIP - Table" section to select the revolving tip according to the diameter of the guide chan- BOSS 542 - MINIBOSS 325 nel and that of the bar pusher, and the collet model to be REVOLVING TIP - Table EMBOUT TOURNANT - Tableau used...
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CONSULTING THE MANUAL • COMMENT CONSULTER CE MANUEL 302.062 Consult the "001 - Conversion Tables" section which con- tains the conversion tables for defining the internal diameter of the collet depending on the: Conversion tables Tableaux de conversion - profile and cross-section of the barstock - the unit of measurement of the section dimensions (in millime- tres for square and hexagonal sections, and in inches for round and hexagonal sections).
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SYMBOLS AND ABBREVIATIONS • SYMBOLES ET ABRÉVIATIONS 302.062 ❑ Symbols Parts of the text which are of considerable importance are highlighted in bold and are preceded by the following symbols: CAUTION: indicates that it is necessary to adopt suitable measures for preventing accidents and damage to ob- jects.
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GENIUS 226 302.062 GUIDE-BARRES ET POUSSETTE - GUIDE CHANNELS AND BAR Tableau PUSHER - Table Le choix des guide-barres et de la poussette doit être The choice of guide channels and bar pusher must be fait en fonction du diamètre de la barre à usiner. Le made according to the diameter of the barstock.
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GENIUS 226 GENIUS 112-GENIUS 118-GENIUS 226 302.062 ❑ GENIUS 226 ❑ GENIUS 226 PRECAUTION: le champ d'application des pin- CAUTION: the field of application of collets for ces pour les diamètres des barres usinables dans machining specific bar diameters in the different chaque guide-barre est celui qui est indiqué...
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GENIUS 226 302.062 EMBOUT TOURNANT - Tableau REVOLVING TIP - Table Le choix de l’embout tournant doit être fait en fonction The choice of the revolving tip depends on the diame- du diamètre des guide-barres, de celui de la poussette ter of the guide channel, that of the bar pusher and the et de la version de l’enclenchement de la pince.
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GENIUS 112-GENIUS 118-GENIUS 226 302.062 ❑ GENIUS 226 ❑ GENIUS 226 øB øC (mm) (mm) øGR (mm) See section Collet version - Guide channel Bar pusher Revolving tip Revolving tip code Voir section (type of coupling) diameter Code embout diameter diameter Version pince - D GENIUS 112 -...
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GENIUS 226 GENIUS 11GENIUS 226 302.062 EMBOUTS TOURNANTS øGR 15÷29 - REVOLVING TIPS øGR 15÷29 - Tableau Table ❑ ❑ ❑ ❑ Pour pinces à accouplement fileté (IEMCA) ❑ ❑ ❑ ❑ For collet with threaded coupling (IEMCA) Collet • Pince See section •...
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GENIUS 226 302.062 EMBOUTS TOURNANTS øGR 15÷29 - REVOLVING TIPS øGR 15÷29 - Tableau Table ❑ Pour pinces à accouplement avec goupille ❑ For collet with pin coupling (SCHL) (SCHL) 602P Collet • Pince 602P See section • Voir fascicule See section •...
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GENIUS 226 302.062 EMBOUTS TOURNANTS øGR REVOLVING TIPS øGR 7,5÷8,5 - 7,5÷8,5 - Tableau Table ❑ ❑ ❑ ❑ Pour pinces à accouplement fileté (IEMCA) ❑ ❑ ❑ ❑ For collet with threaded coupling (IEMCA) See section • Voir fascicule Collet •...
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GENIUS 226 302.062 EMBOUTS TOURNANTS øGR 10÷12 - REVOLVING TIPS øGR 10÷12 - Tableau Table ❑ ❑ ❑ ❑ Pour pinces à accouplement fileté (IEMCA) ❑ ❑ ❑ ❑ For collet with threaded coupling (IEMCA) Collet • Pince See section • Voir fascicule See section •...
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GENIUS 226 302.062 EMBOUTS TOURNANTS øGR 10÷12 - REVOLVING TIPS øGR 10÷12 - Tableau Table ❑ Pour pinces à accouplement avec goupille ❑ For collet with pin coupling (SCHL) (SCHL) 602P Collet • Pince 602P See section • Voir fascicule See section •...
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CONVERSION TABLES TABLEAUX DE CONVERSION 01/06/01 REL. DATA...
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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302.062 BARRES HEXAGONALES (unité de HEXAGONAL BARS (unit of mesure “millimètres”) - Tableau measurement “millimetres”) - Table Avant de procéder au choix de la pince en acier, il est Before selecting the steel collet, define the internal dia- nécessaire d’ établir son diamètre interne øA, après meter øA by consulting the table below.
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302.062 BARRES CARRÉES (unité de SQUARE BARS (unit of mesure “millimètres”) - Tableau measurement “millimetres”) - Table Avant de procéder au choix de la pince en acier, il est Before selecting the steel collet, define the internal dia- nécessaire d’ établir son diamètre interne øA, après meter øA by consulting the table below.
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302.062 BARRES HEXAGONALES (unité de HEXAGONAL BARS (unit of mesure “pouces”) - Tableau measurement “inches”) - Table Avant de procéder au choix de la pince en acier, il est Before selecting the steel collet, define the internal dia- nécessaire d’établir son diamètre interne øA, après meter øA by consulting the table below.
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302.062 BARRES RONDES (unité de mesure ROUND BARS (unit of “pouces”) - Tableau measurement “inches”) - Table Avant de procéder au choix de la pince en acier, il est Before selecting the steel collet, define the internal dia- nécessaire d’ établir son diamètre interne øA, après meter øA by consulting the table below.
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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COLLETS FOR BARS PINCES POUR BARRES 30/10/02 REL. DATA...
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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302.062 PINCES POUR BARRES - COLLETS FOR BARS - Table Tableau CAUTION: the external diameter of the collet PRECAUTION: le diamètre externe de la pince must be at least 0.5 mm less than the external di- doit être inférieur d’au moins 0,5 mm au diamètre ameter of the bar pusher.
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012 - 077 - 377 COLLETS FOR TUBES PINCES POUR TUBES 30/10/02 REL. DATA...
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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012-077-377 302.062 012-077-377 012-077-377 PINCES POUR COLLETS FOR TUBES - Tableau TUBES - Table PRECAUTION: le diamètre externe de la pince CAUTION: the external diameter of the collet doit être inférieur d’au moins 0,5 mm au diamètre must be at least 0.5 mm less than the external di- externe de la poussette.
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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COLLETS FOR TUBES PINCES POUR TUBES 30/10/02 REL. DATA...
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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302.062 PINCES POUR TUBES - COLLETS FOR TUBES - Table Tableau CAUTION: the external diameter of the collet must be at least 0.5 mm less than the external di- PRECAUTION: le diamètre externe de la pince ameter of the bar pusher. doit être inférieur d’au moins 0,5 mm au diamètre Note for ordering externe de la poussette.
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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302.062 ÉJECTEURS - GUIDES Ø<30 - EJECTORS - GUIDES Ø<30 - TABLEAU TABLE PRECAUTION: le diamètre externe de l’éjecteur CAUTION: the external diameter of the collet doit être inférieur d’au moins 0,5 mm au diamètre must be at least 0.5 mm less than the external di- externe de la poussette.
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302.062 ÉJECTEURS - GUIDES Ø>32 - EJECTORS - GUIDES Ø>32 - TABLEAU TABLE PRECAUTION: le diamètre externe de l’éjecteur CAUTION: the external diameter of the collet doit être inférieur d’au moins 0,5 mm au diamètre must be at least 0.5 mm less than the external di- externe de la poussette.
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601P “UNILOCK” COLLETS FOR BARS PINCES “UNILOCK” POUR CARRÉES 01/06/01 REL. DATA...
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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601P 302.062 601P 601P PINCES “UNILOCK” POUR “UNILOCK” COLLETS FOR BARRES CARRÉES - Tableau SQUARE BARS - Table AVERTISSEMENT: pour définir le diamètre in- INFORMATION: for defining the internal diame- terne øA ne pas consulter le fascicule “001 - Ta- ter øA do not consult “001 - Conversion Tables”...
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601P 302.062 601P 601P “UNILOCK” COLLETS FOR PINCES “UNILOCK” POUR HEXAGONAL BARS - Table BARRES HEXAGONALES - Tableau INFORMATION: for defining the internal diame- AVERTISSEMENT: pour définir le diamètre in- terne øA ne pas consulter le fascicule “001 - Ta- ter øA do not consult “001 - Conversion Tables”...
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602P COLLETS FOR BARS PINCES POUR BARRES 01/12/01 REL. DATA...
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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602P 302.062 602P 602P COLLETS FOR BARS - Table PINCES POUR BARRES - Tableau PRECAUTION: le diamètre externe de la pince CAUTION: the external diameter of the collet doit être inférieur d’au moins 0,5 mm au diamètre must be at least 0.5 mm less than the external di- externe de la poussette.
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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602P..011 302.062 602P..011 602P..011 ÉJECTEURS - GUIDES EJECTORS - GUIDES Ø13÷28 - TABLEAU Ø13÷28 - TABLE PRECAUTION: le diamètre externe de l’éjecteur CAUTION: the external diameter of the collet doit être inférieur d’au moins 0,5 mm au diamètre must be at least 0.5 mm less than the external di- externe de la poussette.
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GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
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