IEMCA BOSS 332-545-551 E Instruction manual

BOSS 332-545-551 E
BOSS 332r-545r-551r E
GB MANUAL FOR USE AND MAINTENANCE
Rel. 1Date 24/06/03 Cod. 346005400
S/N
COMPILER: Ragazzini Gian Luca
ON APPROVAL: Bevini Claudio
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

IEMCA S.p.A.
Via Granarolo, 167
Tel. [phone] - Fax. [phone]
TLX 550879
MANUFACTURER: IEMCA division of IGMI S.p.A.
ADDRESS: Via Granarolo, 167 - 48018 Faenza (RA) - ITALY
Tel. [phone] - Fax. [phone]
TLX 550879
TYPE OF DOCUMENT: MANUAL FOR USE AND MAINTENANCE
PRODUCT: AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION
MODEL: BOSS 332-545-551 E
BOSS 332r-545r-551r E

1 GENERAL INFORMATION ..........................................BOSS 332/545/551 E-volution
2 TECHNICAL INFORMATION.......................................BOSS 332/545/551 E-volution
3 SAFETY PROCEDURES - GENERAL INFORMATION....BOSS 332/545/551 E-volution
4 HANDLING AND INSTALLATION ................................BOSS332/545/551 E-volution
5 ADJUSTMENTS AND SETTING-UP .............................BOSS 332/545/551 E-volution
6 USE AND OPERATION................................................BOSS 332/545/551 E-volution
7 BAR FEEDER MAINTENANCE .....................................BOSS 332/545/551 E-volution
8 TROUBLES - CAUSES - CURES ...................................BOSS 332/545/551 E-volution
9 PART REPLACEMENT ..................................................BOSS332/545/551 E-volution
10 LIST OF AFTER-SALES CENTERS

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INDEX
1.1 TERMS OF WARRANTY.............................................................................................2
1.2 MANUAL PURPOSE...................................................................................................3
1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION................................................4
1.4 TECHNICAL ASSISTANCE .........................................................................................4
1.5 ANNEXES ENCLOSED ...............................................................................................4

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Operations described in paragraphs showing this symbol, must be performed by qualified
and skilled personnel only.
Any other operation can be performed either by qualified personnel or by professional
bar feeder operators.
Before carrying out any servicing whatsoever on the bar feeder, it is of the
utmost importance to read this manual carefully.
1.1 TERMS OF WARRANTY
The warranty validity is subordinated to a correct assembly and coupling of the bar feeder to
lathe. In particular, before the first start-up, carry out an accurate check to make sure the bar
feeder is correctly aligned with the lathe and fastened with the expansion plugs as shown in
section 4.
The product warranty is valid only if the bar loader is
installed by an authorized technician with Original
Installation Certificate. Please ask the technician, who will
make the installation, to show the certificate, in order to
ascertain the quality of the technical works being carried
out.
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

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1.2 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.
The compliance with the instructions contained herein ensures the operator and bar feeder
safety as well as a running economy and a longer life of the bar feeder itself.
In order to allow a quick search of contents, consult the descriptive index.
Particularly important parts of this manual have been highlighted in bold type and preceded by
the following symbols:
DANGER - WARNING:
shows impending danger which might cause serious injuries, exert the
maximum caution.
CAUTION - PRECAUTION
indicates measures to be adopted to avoid accidents or damages to property.
INFORMATION
technical instructions of particular importance.
For a quick search of topics see the table of contents.
In addition to this manual, which contains all the instructions for the bar feeder use and
maintenance, one more is supplied: the "Push-button panel instruction manual".
The "Push-button panel instruction manual" contains all the instructions on how to use the
installed software.

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1.3 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
S Number of base wiring diagram
T Number of interface wiring diagram
INFORMATION:
Always provide the Manufacturer with the above mentioned specifications when
requesting information or ordering spare parts, etc.
1.4 TECHNICAL ASSISTANCE
Whenever necessary, please apply to one of the Technical Assistance Centres shown in the
attached list.
INFORMATION
when requesting technical assistance for the bar feeder, always specify the
information shown on the machine dataplate.
1.5 ANNEXES ENCLOSED
• Push-button panel instruction manual.
• GUIDES - BAR PUSHER - REVOLVING TIPS - COLLETS. Manual for choice.
• Wiring diagram.
• Pneumatic diagram.

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INDEX
2.1 GENERAL BAR FEEDER DESCRIPTION.......................................................................2
2.2 OPERATING CYCLE ..................................................................................................4
2.3 SAFETY DEVICES .....................................................................................................7
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION ......................................................9
2.5 VERSION DESCRIPTION .........................................................................................10
2.6 TECHNICAL SPECIFICATIONS.................................................................................11
2.6.1 Noise levels ...........................................................................................................20
2.7 FITTINGS - FOREWORD .........................................................................................21
2.7.1 Bush-holder device - Description .............................................................................21
2.7.2 Axial displacement device - Description ...................................................................22
2.8 DEVICE FOR SLIDING HEADSTOCK LATHES - FOREWORD .......................................23
2.8.1 Bar/headstock synchronizing device - Description.....................................................23
2.8.2 Telescopic nose - Description..................................................................................24
2.9 DEVICES FOR CAM LATHES - FOREWORD ...............................................................25
2.9.1 Headstock return device - Description .....................................................................25
2.9.2 Cam box - Description ............................................................................................25
2.9.3 Camshaft release device - Description .....................................................................26

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2.1 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.
The working cycle is controlled by a control panel with built-in PLC, which is able to dialogue
with the lathe control.
The digital hand-held keyboard makes programming easier and allows the bar-feeder functions
to be controlled without leaving the lathe.
The bar feeder can be used to feed bars, pipes and metallic as well as polymeric materials of
different sections. Avoid flammable materials.
The guide channel is fully closed during machining; a pump is provided to maintain a
continuous oil flow inside the channel, creating a hydrodynamic support effect; these
characteristics allow the bar to rotate at a high r.p.m. number, with no vibrations and no
surface damaging.
Thanks to the use of a "BRUSHLESS" and electronically controlled motor, the bar speed, thrust
value and feeding position may be determined at any time during the working cycle.
Bar remnant ejection can be caused by bar-pusher feeding or next bar feeding.
Bar feeder series BOSS are produced in the following models:
BOSS 332 (standard version)
BOSS 332r (reversed version)
BOSS 545 (standard version)
BOSS 545r (reversed version)
BOSS 551 (standard version)
BOSS 551r (reversed version)
The texts, tables and illustrations contained in this manual concern, unless otherwise stated,
the standard version (BOSS 332, BOSS 545 and BOSS 551) with the lathe on the operator's
right.
As for the reverse version (BOSS 332r, BOSS 545r and BOSS551r), with the lathe on the
operator's left, do not forget that the main parts are located on the opposite side, as mentioned
below.

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•MAINPARTS
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; they guide the bars during
machining.
D Bar-pusher; it pushes the bar during
machining.
E Feed chain; it transmits motion from
the drive system to the bar-pusher.
F Drive system; it drives the bar-
pusher.
G Insertion/extraction drive; it drives
the bar feeder parts controlling bar
insertion into the collet and
subsequent bar remnant extraction.
It also drives the bar feeder parts
controlling guide opening/closing and
bar selection.
H Clamps; they hold the bar during bar
introduction in and extraction from
the bar-pusher collet.
L Facing device; it sends a signal at
bar passage.
M Remnant collection box; bar
remnants are dropped into this box
after extraction from the bar-pusher
collet.
N Lubricating pump; it delivers oil to
the guides.
P Oil recovery device; it collects oil
flowing out of the guides.
Q Hand-held keyboard; it allows bar
feeder programming and function actuation.
R Electric cabinet; it contains the electric switchboard.
SLathe
T GUIDE CHANNELS OPENING SHAFT
VENCODER

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2.2 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.
The bar-pusher A and remnant C reach their
backwards limit stop position.
The clamps D close and the bar-pusher moves
back; the remnant is extracted from the collet.
The clamps open and the remnant is dropped into
the box E.

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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"; the bar selection device "F" moves upwards
thereby raising the first bar and withholding the
remaining bars. Bar "G" drips into the guide
channel.
Bar selection device "F" is lowered.
The small pusher truck "M" starts its stroke.

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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.
The clamps "D" close, the bar-pusher "A" moves
forwards; the bar "G" is inserted into the bar-
pusher collet.
The bar-pusher "A" and bar "G" execute their facing
stroke. A new automatic work cycle is started.

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2.3 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.
C Interlocked mobile guard: associated with microswitch C1.
According to the cycle setting, its functions are:
manual cycle;
- when the guard is opened the feeder will be stopped if the guides are not closed.
- when the guard is opened, if the guide channels are closed the feeder functions are not
disabled because no operator risks are present.
automatic cycle;
- during the bar feeding phase guard opening may be necessary for the purpose of
restocking the magazine. Even if the feeder functions are not disabled there are no
operator hazards present inside the area.
- during the bar change procedure the feeder will stop when the guard is opened. Closing
the guard allows the user to restart the feeder.

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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.
H Remnant collection tank: it also acts as a fixed guard to prevent accidental access to moving
parts.
L Fixed guard: it prevents accidental access to the bush-holder device.
M Main switch: cuts out the electric energy source during interventions in the electric
switchboard and during the bar feeder periods of inactivity.

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2.4 SAFETY PLATES - LOCATION AND DESCRIPTION
A Danger of upper limb crushing.
BCaution!Movingparts.
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.

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2.5 VERSION DESCRIPTION
Table 1. Maximum bar length
Model Version Max. length mm (ft)
21 2080 (6,8)
32 3200 (10,5)
37 3740 (12,2)
BOSS 332
BOSS 545
BOSS 551
44 4400 (14,4)
Table 2. Max. bar-pusher extension
Model Version A – Max extension (mm)
N 937
L 1267
BOSS 332
BOSS 545
BOSS 551 LL 1597

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2.6 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)
21 2603 /
32 3802 1220
37 4342 1760
BOSS 332 – BOSS 332r
BOSS 545 - BOSS 545r
BOSS 551 - BOSS 551r
44 5002 2420

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Table 4. General technical specifications
BOSS 432 BOSS 545/551
Round bar size
Ø min 4 mm
(5/32")
Ø max 32 mm
(1" 1/4)
Ø min 5 mm
(3/16")
Ø max 545
45 mm(1"
3/4)
Ø max 551
51mm(2")(***)
Hex bar size (key socket) min 4 mm
(3/16")
max 27 mm
(1" 1/16)
min 5 mm
(3/16")
max 36 mm(*)
(1" 7/16)
Max bar length
Mod. 32 – 3200 mm (10,5 ft)
Mod. 37 – 3740 mm (12,2 ft)
Mod. 44 – 4400 mm (14,4 ft)
Mod. 21 – 2080 mm (6,9 ft)
Mod. 32 – 3200 mm (10,5 ft)
Mod. 37 – 3740 mm (12,2 ft)
Mod. 44 – 4400 mm (14,4 ft)
Magazine capacity (working width) n. 28 barre ø 10 mm (3/8") n. 28 barre ø 10 mm (3/8")
(Adjustable) feeding speed Max 1000 mm/sec Max 750 mm/sec
(Adjustable) return speed Max 1800 mm/sec Max 1200 mm/sec
Remnant length (standard version) 400 mm Mod. 21 – 295 mm
400 mm
Remnant length (oversize version *) 700 mm 700 mm
Bar change-over time (with 3000 mm bar)
Version 32
30 sec 30 sec
Input voltage 230/400 Volt 230/400 Volt
Mains frequency 50 Hz / 60 Hz 50 Hz / 60 Hz
Control voltage 24 Volt D.C. 24 Volt D.C.
Installed power 2 kW 2 kW
Oil quantity 57 l 57 l
Air max. pressure. 8 bar 8 bar
Pneumatic energy average consumption (**) 20 NL/min 20 NL/min
Dry weight
Mod. 32 – 835 kg.
Mod. 37 – 900 kg.
Mod. 44 – 980 kg.
Mod. 21 – 620 kg.
Mod. 32 – 835 kg.
Mod. 37 – 900 kg.
Mod. 44 – 980 kg.
(*) excluded version 32 LL and 21
(**) Approximate value depending on the number of activation cycles.
(***) valid also for prepared bars or normal bars machined with front remnant ejection.