IEMCA BOSS 332 Instruction manual

BOSS 332-545 E - 552 HD
BOSS 332r-545r E - 552r HD
EN MANUAL FOR USE AND MAINTENANCE
Rel. 2Date 30/01/2010 Cod. 346005410
S/N
COMPILER: Bosi Andrea
ON APPROVAL: Ghinassi Andrea
AUTOMATIC BAR FEEDER
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
MODEL: BOSS 332-545 E - 552 HD
BOSS 332r-545r E - 552r HD

General Description of Supply
The bar feeder you bought is a machine designed to feed machine tools
properly prepared for bar machining. It consists of:
A basic unit made up of a metal structure, a control panel, safety devices and
protections in compliance with the EU regulations governing this sector.
A set of format parts related to the specific machining processes that the
machine will perform. According to the terminology used by Iemca these
parts are named: guide channels, bar pushers, revolving tips, collets, bushes
and sleeves. Because of the kind of use, these parts are subject to wear.
Any additional parts can be supplied upon request.
Applicable Safety Regulation
According to Directive 2006/42/EC article 2B, the bar feeder is an
interchangeable equipment and is supplied with the appropriate safety
devices.
Together with the supply you will find the EC declaration of conformity in
compliance with the above-mentioned Directive.
The list of the safety devices is shown in section 2, paragraph 2.3, of this
manual.
The bar feeder should be installed according to the manufacturer's
instructions which are highlighted in the supplied check list.
Should the bar feeder be used together with machine tools that do not have
the CE marking, Iemca reminds to their clients that they should assess if the
device is in compliance with Directive 2009/104/EC and subsequent
amendments even after installing the bar feeder.
Safety warning. Only qualified and properly trained personnel can work with
machine tools and the related interchangeable equipments.

EC CONFORMITY DECLARATION
(2006/42/ EC Regulation, Enclosure II, Part A)
Mr. TOMASO TAROZZI, acting as MANAGING DIRECTOR CEO and delegated by the
company I G M I S.p.A. DIVISIONE IEMCA with legal office and establishment in Via
Granarolo, 167 – 48018 FAENZA (RA) as manufacturer,
DECLARES
on his own responsibility that the machine:
AUTOMATIC BAR FEEDER
BOSS
(type/model) (registration number)
- is in compliance with the requirements of 2006/42/ EC regulation and with the national
implementing regulations,
- is in compliance with the following European regulations:
o2006/95/ EC regulation (low tension);
o2004/108/ EC regulation (electromagnetic compatibility).
Otherwise he declares that the person in charge for the technical issue editing is Mr. Giampaolo Morandi, General
director of the a.m. company.
TOMASO TAROZZI – Managing Director CEO
FAENZA, 01/01/2010
…………………………………………
(delegate signature)

1 GENERAL INFORMATION BOSS 332/545/552 HD
2 TECHNICAL INFORMATION BOSS 332/545/552 HD
3 SAFETY PROCEDURES - GENERAL INFORMATION BOSS 332/545/552 HD
4 HANDLING AND INSTALLATION BOSS 332/545/552 HD
5 ADJUSTMENTS AND SETTING-UP BOSS 332/545/552 HD
6 USE AND OPERATION BOSS 332/545/552 HD
7 BAR FEEDER MAINTENANCE BOSS 332/545/552 HD
8 TROUBLES - CAUSES - CURES BOSS 332/545/552 HD
9 PART REPLACEMENT BOSS 332/545/552 HD
10 GUIDE CHANNELS - BAR PUSHER - REVOLVING TIPS BOSS 332/545/552 HD
11 COLLETS BOSS 332/545/552 HD

1 - GENERAL INFORMATION BOSS 332/545/552 HD
EN
1 - Pag. 1 / 5
INDEX
1.1 WARRANTY CONDITIONS.........................................................................................2
1.2 PURPOSE OF THE MANUAL.......................................................................................3
1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION................................................4
1.4 ASSISTANCE REQUEST ............................................................................................4
1.5 ATTACHMENT LIST..................................................................................................4

EN
1 - GENERAL INFORMATION BOSS 332/545/552 HD
1 - Pag. 2 / 5
The operations described in the sections that are preceded by this symbol must be
performed by qualified and skilled personnel with specific abilities and precise technical
competence only.
Any other operation can be performed either by qualified personnel and/or by
professional bar feeder operators.
Before carrying out any operation on the bar feeder, it is of the utmost
importance to read this manual carefully.
1.1 WARRANTY CONDITIONS
The applicable warranty period is subordinated to a correct assembly and coupling of the bar
feeder to the lathe. In particular, prior to the first start-up, accurately make sure that the bar
feeder is correctly aligned with the lathe and fixed with the expansion plugs as shown in
chapter 4.
The product warranty is valid only if the bar feeder 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 operations being carried out.
The warranty shall begin from the date on the “Installation
Certificate” duly filled in and signed.
The document must be sent by mail to:
TECHNICAL SERVICE DEPARTMENT
IEMCA division of IGMI spa
48018 Faenza (Ra) ITALY - Via Granarolo, 167

1 - GENERAL INFORMATION BOSS 332/545/552 HD
EN
1 - Pag. 3 / 5
1.2 PURPOSE OF THE MANUAL
This manual has been written and supplied by the manufacturer, the information herein
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 equipment.
The compliance with the instructions herein ensures the operator and bar feeder safety as well
as economy of operation and longer life of the bar feeder itself.
The important parts of this manual have been highlighted in bold type and are preceded by the
following symbols:
DANGER - WARNING:
indicates impending danger which might cause serious injuries; exert the
maximum caution.
WARNING – CAUTION:
indicates that it is necessary to adopt suitable behaviours so as to avoid
accidents or damages to property.
INFORMATION:
these are technical instructions of particular importance.
For a quick search of the topics, see the table of contents.
This manual, which contains all the instructions for the bar feeder operation and maintenance,
is supplied with: the "Keyboard instruction manual".
The "Keyboard instruction manual" contains all the instructions on how to use the installed
software.
INFORMATION:
The data included in this publication are only given as an example.
IEMCA may apply changes to the model described in this publication at any time
for any technical or business reason. Contact IEMCA service department for
further information.

EN
1 - GENERAL INFORMATION BOSS 332/545/552 HD
1 - Pag. 4 / 5
1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION
A Manufacturer identification.
B EC mark of conformity.
C Year of manufacture.
D Bar feeder model.
E Serial number.
G Mains frequency.
H Power consumption.
M Supply voltage.
N Bar feeder weight.
P Pneumatic system pressure.
Q Bar feeder and bar pusher length.
R Interrupting power.
S Basic Wiring Diagram Number.
T Interface Wiring Diagram Number.
INFORMATION:
always provide the manufacturer with the above mentioned specifications when
requesting information or ordering spare parts, etc.
1.4 ASSISTANCE REQUEST
Whenever necessary, please apply to one of the centres shown in the "LIST OF THE CUSTOMER
SERVICE CENTRES".
INFORMATION:
when requesting technical assistance for the bar feeder, always specify the data
shown on the identification plate.
1.5 ATTACHMENT LIST
Together with this manual, the customer receives the following documents.
- Keyboard instruction manual; it contains all the operation instructions for the operational
parameter setting.
- Interface wiring diagram.
- Spare parts catalogue, contains the coded drawings of the bar feeder components to use in
case it is necessary to place an order of parts that need to be replaced.
- CD-Rom containing all the above-mentioned documents, inclusive of the Operation and
Maintenance Manual, the Brochure with all the technical requirements of the bar feeder, the
wiring diagram and a list of the service centres.

1 - GENERAL INFORMATION BOSS 332/545/552 HD
EN
1 - Pag. 5 / 5

2 - TECHNICAL INFORMATION BOSS 332/545/552 HD
EN
2 - Pag. 1 / 32
INDEX
2.1 BAR FEEDER GENERAL 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 DATA..................................................................................................11
2.6.1 Noise levels ...........................................................................................................25
2.7 ACCESSORIES - FOREWORD...................................................................................26
2.7.1 Bush holder device - Description.............................................................................26
2.7.2 Axial displacement device - Description ...................................................................27
2.8 DEVICE FOR SLIDING HEADSTOCK LATHES - FOREWORD .......................................28
2.8.1 Bar/headstock synchronizing device - Description.....................................................28
2.8.2 Telescopic front nose - Description..........................................................................29
2.9 DEVICES FOR CAM LATHES - FOREWORD...............................................................30
2.9.1 Headstock return device - Description .....................................................................30
2.9.2 Cam box - Description............................................................................................30
2.9.3 Camshaft release device - Description .....................................................................31

EN
2 - TECHNICAL INFORMATION BOSS 332/545/552 HD
2 - Pag. 2 / 32
2.1 BAR FEEDER GENERAL 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 operating cycle is controlled by a PLC, integrated in the electrical control panel, which is
able to communicate with the lathe control system.
The digital handheld 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, various sections and metallic as well as
polymeric materials. Do not use flammable materials.
The guide channel is completely closed during machining; a pump is provided to maintain a
continuous oil flow inside the guide channel, creating a hydrodynamic support effect; these
features allow the bar to rotate at high r.p.m., with no vibrations and no surface damaging.
Thanks to the use of a "BRUSHLESS" and electronically controlled motor, the bar speed, torque
value and bar feeding position may be determined at any time during the working cycle.
The bar pusher returns with the remnant, which is removed and then falls into the remnant
recovery box through a slot of the following size: L=400 mm, for Standard Remnant Drop (CSS)
or L=700 mm for Oversize Remnant Drop (CSM). Please refer to the "VERSION DESCRIPTION"
section in ch. 2 for technical specifications.
The bar remnant ejection can be performed by the bar pusher feeding or next bar feeding.
The BOSS bar feeders are available in the following models:
BOSS 332 (standard version, magazine length: 21, 32, 37, 44, 64)
BOSS 332r (reversed version, magazine length: 32, 37, 44)
BOSS 545 (standard version, magazine length: 21, 32, 37, 44)
BOSS 545r (reversed version, magazine length: 32, 37, 44)
BOSS 552 HD (standard version, magazine length: 21, 32, 37, 44)
BOSS 552r HD (reversed version, magazine length: 32, 37, 44)
Unless otherwise stated, the texts, tables and illustrations contained in this manual refer to the
standard version (BOSS 332, BOSS 545 and BOSS 552 HD) with the lathe on the operator's
right.
As for the reversed versions (BOSS 332r, BOSS 545r and BOSS 552r HD), with the lathe on the
operator's left, please note that the main parts are located on the opposite side, as mentioned
below.

2 - TECHNICAL INFORMATION BOSS 332/545/552 HD
EN
2 - Pag. 3 / 32
• MAIN PARTS
A MAGAZINE; it stores the bars.
B BAR SELECTION DEVICE; it enables
the first bar to be lowered into the
guide channels and holds the
remaining bars in the magazine.
C GUIDE CHANNELS; they guide the
bars during machining.
D BAR PUSHER; it pushes the bar
during machining.
E FEED CHAIN; transmits the motion
from the motor drive to the bar
pusher.
F DRIVE SYSTEM; it moves the bar
pusher.
G FEEDING- REMOVAL DRIVE; it drives
the bar feeder parts that control bar
feeding into the collet and
subsequent bar remnant removal. It
also drives the bar feeder parts that
control guide channel
opening/closing and bar selection.
H CLAMPS; they hold the bar during
loading and removal from the collet
of the bar pusher.
L FACING DEVICE; it sends a signal
when the bar passes.
M REMNANT RECOVERY BOX; bar
remnants are dropped into this box
after removal from the bar pusher
collet.
N LUBRICATION PUMP; it delivers oil to
the guide channels.
P OIL RECOVERY DEVICE; it collects oil
flowing out of the guide channels.
Q HANDHELD KEYBOARD; it allows bar feeder programming and function activation.
R ELECTRIC CABINET; it houses the electrical control panel.
S LATHE
T GUIDE CHANNEL OPENING SHAFT
V ENCODER

EN
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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 pulses, 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 removed from the collet. The
clamps open and the remnant is dropped into the
box E.

2 - TECHNICAL INFORMATION BOSS 332/545/552 HD
EN
2 - Pag. 5 / 32
Clamps "D" close again to check remnant "C"
removal.
If the remnant is still inserted in the bar pusher
collet, the bar feeder stops; otherwise, it
continues its cycle.
Upper guide channels "H" open together with bar
pusher "A"; bar selector "F" moves upwards
thereby lifting the first bar and withholding the
remaining bars; bar "G" drops into the guide
channel.
Bar selector "F" is lowered.
The first feeding carriage "M" starts its stroke.