Table of Contents
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AUTOMATIC BAR FEEDER
EN
MANUAL FOR USE AND MAINTENANCE
KEYBOARD INSTRUCTION MANUAL
SPARE PARTS BOOK
SCHEMATICS
EC CONFORMITY DECLARATION FOR MACHINE
BOSS 332-545 E - 552 HD
BOSS 332r-545r E - 552r HD
MANUAL FOR USE AND MAINTENANCE
Rel. 2
Date
S/N
COMPILER:
ON APPROVAL:
ATTACHMENTS LIST
30/01/2010
Cod.
Bosi Andrea
Ghinassi Andrea
346005410
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Table of Contents
Related Manuals for IEMCA BOSS 545 E
Summarization of Contents
1 - GENERAL INFORMATION
1.1 WARRANTY CONDITIONS
Details product warranty terms, emphasizing correct installation and authorized service.
1.2 PURPOSE OF THE MANUAL
Explains the manual's objective, structure, and the meaning of its warning and information symbols.
1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION
Provides essential identification details for the manufacturer and the bar feeder model.
1.4 ASSISTANCE REQUEST
Guides users on the process and required information for requesting technical assistance.
1.5 ATTACHMENT LIST
Lists all accompanying documents and manuals supplied with the bar feeder package.
2 - TECHNICAL INFORMATION
2.1 BAR FEEDER GENERAL DESCRIPTION
Offers a comprehensive overview of the bar feeder's capabilities, applications, and model variants.
2.2 OPERATING CYCLE
Describes the step-by-step process of the bar feeder's automatic operation cycle.
2.3 SAFETY DEVICES
Details the safety mechanisms and devices implemented to ensure operator and machine safety.
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION
Identifies and explains the purpose of all safety warning labels and plates on the equipment.
2.5 VERSION DESCRIPTION
Outlines the specifications and differences between various models and versions of the bar feeder.
2.6 TECHNICAL DATA
Presents detailed technical specifications, dimensions, weights, and performance data.
3 - SAFETY PROCEDURES - GENERAL INFORMATION
3.1 GENERAL SAFETY REGULATIONS
Establishes fundamental safety regulations and principles for all operations involving the bar feeder.
3.2 HANDLING AND INSTALLATION - Safety
Covers critical safety measures for the proper and secure handling and installation of the bar feeder.
3.3 ADJUSTMENTS AND SETUP - Safety
Details safety precautions that must be observed during all adjustment and setup procedures.
3.4 USE AND OPERATION - Safety
Provides essential safety guidelines for the everyday use and operation of the bar feeder.
3.5 BAR FEEDER MAINTENANCE - Safety
Outlines imperative safety practices to be followed during any maintenance activity on the bar feeder.
4 - HANDLING AND INSTALLATION
4.1 PACKAGING
Describes the various packaging methods used for shipping and protecting the bar feeder.
4.2 LIFTING
Provides detailed instructions and critical safety warnings for lifting and moving the bar feeder.
4.3 INSTALLATION AREA - FEATURES
Specifies the ideal environmental and spatial requirements for installing the bar feeder.
4.4 BAR FEEDER WITHOUT AXIAL DISPLACEMENT DEVICE - INSTALLATION
Step-by-step instructions for installing the bar feeder model without the axial displacement feature.
4.5 BAR FEEDER WITH AXIAL DISPLACEMENT DEVICE - INSTALLATION
Step-by-step instructions for installing the bar feeder model equipped with an axial displacement device.
4.6 DEVICE FOR SLIDING HEADSTOCK LATHES - INSTALLATION
Details the installation of specialized devices for integrating with sliding headstock lathes.
4.7 DEVICES FOR CAM LATHES - INSTALLATION
Details the installation of specialized devices for integrating with cam lathes.
4.8 LUBRICATION OIL - FILLING
Explains the procedure for filling the bar feeder's lubrication oil system and checking its level.
4.9 ELECTRICAL CONNECTION
Covers the essential steps and safety precautions for the electrical connection of the bar feeder.
4.10 PNEUMATIC CONNECTION
Guides the user through the process of connecting the pneumatic supply to the bar feeder.
4.11 SOFTWARE PARAMETERIZATION
Directs users to the appropriate manual for performing software parameterization.
5 - ADJUSTMENTS AND SETTING-UP
5.1 ADJUSTMENT AND SETUP - FOREWORD
Introduces the fundamental principles and precautions for adjusting and setting up the bar feeder.
5.2 GENERAL ADJUSTMENTS - FOREWORD
Covers routine adjustments required for optimal operation, maintenance, and troubleshooting.
5.3 SETUP ACCORDING TO THE BAR TO BE MACHINED
Provides detailed procedures for configuring the bar feeder based on the specific bar dimensions and machining requirements.
5.4 CAM BOX - TIMING
Explains the critical process of timing the cam box components and microswitches for correct operation.
6 - USE AND OPERATION
6.1 CONTROL DESCRIPTION
Provides an overview of the bar feeder's control system, including operating modes and signals.
6.2 KEYBOARD CONTROL DESCRIPTION
Details the functionality and operation of all keys and controls on the handheld keyboard.
6.3 LIGHT INDICATOR - SIGNAL DESCRIPTION
Explains the meaning of the various indicator lights on the bar feeder for status monitoring.
6.4 BARS TO BE MACHINED - FEATURES AND PREPARATION
Covers essential features and preparation steps for bars to ensure successful machining.
6.5 BAR FEEDER SET-UP AND AUTOMATIC CYCLE START
Guides users through the initial setup and the process of starting the automatic machining cycle.
6.6 BAR FEEDER STOP
Explains the procedures for stopping the bar feeder, covering both emergency and normal shutdown.
6.7 AUTOMATIC CYCLE START AFTER MANUAL CYCLE OPERATIONS
Details how to resume the automatic cycle after performing manual operations or adjustments.
6.8 AUTOMATIC CYCLE START - RESUMING WORK AFTER POWER-OFF
Provides instructions for restarting the automatic cycle after the machine has been powered off.
6.9 MACHINING CHANGE - QUICK GUIDE
Offers a concise guide for changing machining parameters and setup for different operations.
7 - BAR FEEDER MAINTENANCE
7.1 MAINTENANCE – GENERAL RULES
Establishes essential safety and general rules to be followed during all maintenance activities.
7.2 SCHEDULED MAINTENANCE
Provides a detailed schedule for routine maintenance tasks based on hours or cycles.
7.3 AXIAL DISPLACEMENT DEVICE - USE
Explains the procedure for using the axial displacement device, including its detachment and reattachment.
8 - TROUBLES - CAUSES - CURES
8.1 GENERAL FAILURES
Lists common operational failures, their probable causes, and recommended solutions for general troubleshooting.
8.2 BAR MAGAZINE – Failures
Addresses specific issues related to the bar magazine, including causes and corrective actions.
8.3 FEEDING INTO COLLET – Failures
Details problems encountered during the bar feeding process into the collet and their solutions.
8.4 BAR FEEDING - Failures
Covers common failures during bar feeding, providing causes and steps for resolution.
9 - PART REPLACEMENT
9.1 FEEDING CHAIN – REPLACEMENT
Advises contacting the service department for complex feeding chain replacement procedures.
9.2 GUIDE CHANNEL OPENING BELT - REPLACEMENT
Provides a step-by-step guide for replacing the guide channel opening belt.
9.3 REPLACEMENT OF THE GUIDE CHANNELS WITH INSERTS WITH POLYURETHANE GUIDE CHANNELS
Explains the procedure for replacing guide channels, including those with inserts and polyurethane variants.
9.4 PLC BATTERY – REPLACEMENT
Details the process for replacing the PLC battery and the importance of timely replacement.
9.5 RECOMMENDED SPARE PARTS
Lists essential spare parts recommended for wear and tear over a two-year period of normal use.
9.6 Machine dismantling
States that machine dismantling must be performed by qualified personnel following safety regulations.
10 - GUIDE CHANNELS - BAR PUSHER - REVOLVING TIPS
10.1 TABLE
Presents a table for selecting appropriate guide channels and bar pushers based on bar diameter.
10.2 TABLE
Lists dimensions for guide channels and revolving tips correlated with bar and collet diameters.
10.3 Revolving tips ØGR 10÷27 - Table
Details revolving tips for specific collet types and ranges, including dimensions and codes.
10.4 Revolving tips ØGR 12÷27 - Table
Provides data on revolving tips for collets with quick coupling pins, covering dimensions and part numbers.
10.5 Revolving tips ØGR 30÷51 - Table
Lists revolving tips for collets in the ØGR 30-51 range, including dimensions and special fitting notes.
10.6 Revolving tips ØGR 30÷51 - Table
Details revolving tips for collets with quick coupling screws in the ØGR 30-51 range.
11 - COLLETS
11.1 CONVERSION TABLES 001
Contains conversion tables, possibly for units or measurements related to collets.
11.2 HEXAGONAL BARS (unit of measurement "millimetres") - Table
Table correlating hexagonal bar diameters (mm) with internal collet diameters for selection.
11.3 SQUARE BARS (unit of measurement "millimetres") - Table
Table correlating square bar diameters (mm) with internal collet diameters for selection.
11.4 HEXAGONAL BARS (unit of measurement "inches") - Table
Table correlating hexagonal bar diameters (inches) with internal collet diameters for selection.
11.5 ROUND BARS - (unit of measurement "inches") - Table
Table correlating round bar diameters (inches) with internal collet diameters for selection.
11.6 CONVERSION TABLE Inches/Millimetres
Provides a comprehensive table for converting measurements between inches and millimeters.
11.7 EJECTOR 336
Introduces Ejector 336 and its application, referencing a table for guide channels Ø<30.
11.8 EJECTORS - Guide channels Ø<30 - Table
Lists ejectors suitable for guide channels with diameters below 30 mm, including dimensions and part numbers.
11.9 EJECTORS - Guide channels Ø>32 - Table
Lists ejectors suitable for guide channels with diameters above 32 mm, including dimensions and part numbers.
11.10 PIPE COLLETS 012-077-377
Introduces a specific series of pipe collets and refers to a table for selection.
11.11 PIPE COLLETS - Table
Provides a table for pipe collets, detailing dimensions and code structures for selection.
11.12 COLLET FOR 011 BARS
Introduces collets for 011 bars, referencing a table for specific selection criteria.
11.13 COLLET FOR BARS - Table
Offers a table for selecting collets for various bars, including dimensions and code structures.
11.14 BORING COLLETS FOR BARS 601P
Introduces boring collets for 601P bars, directing users to a table for selection.
11.15 BORING COLLETS FOR SQUARE AND HEXAGONAL BARS - Table
Provides a table for selecting boring collets suitable for square and hexagonal bars.
11.16 COLLETS FOR BARS 602P
Introduces collets for bars 602P, referencing a table for specific selection.
11.17 COLLET FOR BARS - Table
Offers a table for selecting collets for bars, detailing dimensions and code structures.
11.18 EJECTOR 602P..011
Introduces Ejector 602P..011 and refers to a table for guide channels ø13÷28.
11.19 EJECTORS - Guide channels ø13÷28 - Table
Lists ejectors compatible with guide channels from ø13 to ø28 mm, including dimensions and codes.
11.20 PIPE COLLETS 603P
Introduces pipe collets 603P and refers to a table for selection criteria.
11.21 PIPE COLLETS - Table
Provides a table for pipe collets 603P, including dimensions and code structures.
11.22 COLLETS FOR BARS 076
Introduces collets for bars 076 and refers to a table for selection.
11.23 COLLET FOR BARS - Table
Offers a table for selecting collets for bars 076, detailing dimensions and code structures.
11.24 COLLETS FOR BARS 381P
Introduces collets for bars 381P, referencing a table for selection.
11.25 COLLET FOR BARS - Table
Provides a table for selecting collets for bars 381P, including dimensions and code structures.
11.26 EJECTORS 381P..011 - 381P..021
Introduces ejectors 381P..011 and 381P..021, referring to tables for guide channels.
11.27 381P..021 EJECTORS - Guide channels Ø33÷46 - Table
Lists ejectors for guide channels Ø33-46 mm, including dimensions and part numbers.
11.28 381P..011 EJECTORS - Guide channels Ø52÷86 - Table
Lists ejectors for guide channels Ø52-86 mm, including dimensions and part numbers.
11.29 RINGS FOR COLLETS 078-225
Introduces rings for collets 078-225 and refers to a table for selection.
11.30 RINGS FOR COLLETS - Table
Provides a table for rings used with collets, detailing dimensions and part numbers.
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