IEMCA Master 80 UP HyperFlexible Instruction manual

Master 80 UP HyperFlexible
EN MANUAL FOR USE AND MAINTENANCE
Rel. 0Date 30/09/2014 Cod.3840M05440
S/N
COMPILER: Bosi Andrea
ON APPROVAL: Ragazzini Massimo
This manual is a translation of the original document
AUTOMATIC BAR FEEDER
ATTACHMENTS LIST
MANUAL FOR USE AND MAINTENANCE
KEYBOARD INSTRUCTION MANUAL
SPARE PARTS BOOK
SCHEMATICS
EC CONFORMITY DECLARATION FOR MACHINE

IEMCA division of IGMI S.p.A.
Via Granarolo, 167
48018 - Faenza (RA) Italy
Tel. [phone] - Fax. [phone]
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: Master 80 UP HyperFlexible

INDEX
1 GENERAL INFORMATION Master 80 UP HyperFlexible.................................................1
1.1 WARRANTY CONDITIONS...................................................................................................2
1.2 PURPOSE OF THE MANUAL...............................................................................................3
1.3 MANUFACTURER AND BAR FEEDER IDENTIFICATION..................................................4
1.4 ASSISTANCE REQUEST......................................................................................................5
1.5 ATTACHMENT LIST .............................................................................................................5
2 TECHNICAL INFORMATION Master 80 UP HyperFlexible..............................................1
2.1 BAR FEEDER GENERAL DESCRIPTION............................................................................2
2.1.1 Bar feeder - Main components............................................................................................4
2.1.2 Magazine - Main components.............................................................................................6
2.1.3 Hydraulic system - Main components................................................................................7
2.1.4 Pneumatic system - Main components..............................................................................8
2.2 OPERATING CYCLE - GENERAL DESCRIPTION ............................................................10
2.2.1 OPERATING CYCLE...........................................................................................................10
2.2.2 Magazine - Operating cycle...............................................................................................15
2.3 SAFETY DEVICES - POSITION AND DESCRIPTION........................................................16
2.3.1 Bar feeder - Safety devices...............................................................................................16
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION........................................................17
2.5 VERSION DESCRIPTION ...................................................................................................18
2.6 TECHNICAL DATA .............................................................................................................20
2.6.1 Noise levels ........................................................................................................................26
2.7 ACCESSORIES - FOREWORD...........................................................................................27
2.7.1 Bush holder device - Description.....................................................................................27
3 SAFETY - GENERAL INFORMATION Master 80 UP HyperFlexible................................1
3.1 GENERAL SAFETY REGULATIONS ...................................................................................2
3.2 HANDLING AND INSTALLATION - Safety..........................................................................3
3.3 ADJUSTMENTS AND SETUP - Safety.................................................................................3
3.4 USE AND OPERATION - Safety...........................................................................................4
3.5 BAR FEEDER MAINTENANCE - Safety ..............................................................................5
3.6 EC DECLARATION OF CONFORMITY................................................................................6
3.7 General Description of Supply............................................................................................7
3.8 RESIDUAL RISKS.................................................................................................................8

INDEX
3.9 FORESEEABLE MISUSES.................................................................................................13
4 HANDLING AND INSTALLATION Master 80 UP HyperFlexible......................................1
4.1 PACKAGING .........................................................................................................................2
4.2 LIFTING
..........................................................................................................................2
4.2.1 Bar feeder without packaging - Lifting...............................................................................3
4.2.2 Bar feeder with pallet - Lifting.............................................................................................4
4.2.3 Bar feeder with crate - Lifting .............................................................................................4
4.3 INSTALLATION AREA - FEATURES ............................................................................5
4.4 BAR FEEDER INSTALLATION - FOREWORD....................................................................5
4.4.1 Backing plates and support feet - Installation ..................................................................6
4.4.2 Height - Adjustment.............................................................................................................7
4.4.3 Preliminary positioning .......................................................................................................9
4.4.4 Front nose - Installation ....................................................................................................10
4.4.5 Levelling and alignment....................................................................................................11
4.4.6 Bar feeder fastening ..........................................................................................................16
4.5 LUBRICATION OIL - FILLING .....................................................................................17
4.6 ELECTRICAL CONNECTION
......................................................................................17
4.7 PNEUMATIC DEVICE LAYOUT..........................................................................................18
4.7.1 PNEUMATIC CONNECTION
.......................................................................................21
4.7.2 BAR FEEDER HANDLING WITHOUT POWER SUPPLY ..................................................21
4.8 SOFTWARE PARAMETERIZATION
...........................................................................22
5 ADJUSTMENT AND SETUP Master 80 UP HyperFlexible...............................................1
5.1 ADJUSTMENT AND SETUP - FOREWORD .................................................................2
5.2 GENERAL ADJUSTMENTS - FOREWORD ..................................................................2
5.2.1 Feeding chain - Adjustment................................................................................................2
5.2.2 Remnant conveyor belt - Adjustment ................................................................................4
5.2.3 Elevator carriage chains - Adjustment...............................................................................4
5.3 BAR FEEDER SETUP ....................................................................................................5

INDEX
5.3.1 Guide channels, half bushes, bar pusher and collet - Replacement ..............................5
5.3.2 BAR PUSHER REPLACEMENT PROCEDURE .................................................................14
5.3.3 Remnant passage door spring - Adjustment ..................................................................15
5.3.4 REMNANT DROP CHUTE – ENABLING ....................................................................16
5.4 MAGAZINE SETUP
......................................................................................................17
5.4.1 Bar supporting bracket - Setup ........................................................................................17
5.4.2 Elevator carriage drive - Adjustment ...............................................................................20
5.4.3 Elevator carriages - Setup.................................................................................................20
6 USE AND OPERATION Master 80 UP HyperFlexible.......................................................1
6.1 CONTROL DESCRIPTION....................................................................................................2
6.2 KEYBOARD CONTROL DESCRIPTION ..............................................................................5
6.3 MAGAZINE PUSH-BUTTON PANEL - CONTROL DESCRIPTION .....................................9
6.4 LIGHT INDICATOR - SIGNAL DESCRIPTION...................................................................10
6.5 BAR FEEDER TOOLING ....................................................................................................11
6.6 BARS TO BE MACHINED - FEATURES AND PREPARATION ........................................11
6.6.1 BAR STRAIGHTNESS - Measurement..............................................................................13
6.7 BAR MAGAZINE - LOADING..............................................................................................15
6.8 AUTOMATIC CYCLE START..............................................................................................17
6.9 BAR LOADING - PROCEDURE..........................................................................................18
6.10 LUBRICATING OIL - FLOW ADJUSTMENT......................................................................21
6.11 BAR FEEDER STOP...........................................................................................................21
6.12 CYCLE PERFORMING MODE IN THE "STEP-BY-STEP" FUNCTION.............................22
7 BAR FEEDER MAINTENANCE Master 80 UP HyperFlexible..........................................1
7.1 MAINTENANCE – GENERAL RULES ...........................................................................2
7.2 SCHEDULED MAINTENANCE
......................................................................................3
7.2.1 Lubricating oil - Level check...............................................................................................4
7.2.2 Lubricating oil - Change......................................................................................................5
7.2.3 Oil filter - Cleaning...............................................................................................................6
7.2.4 Air filter unit - Check............................................................................................................7
7.3 LUBRICATION POINT DIAGRAM .................................................................................8

INDEX
8 TROUBLES - CAUSES - SOLUTIONS Master 80 UP HyperFlexible...............................1
8.1 GENERAL FAILURES
...................................................................................................3
8.2 ELEVATOR CARRIAGES - FAILURES................................................................................3
8.3 FEEDING INTO COLLET – Failures .............................................................................4
8.4 BAR FEEDING - Failures ..............................................................................................4
8.5 REMNANT MOVEMENT - FAILURES ..................................................................................4
9 PART REPLACEMENT Master 80 UP HyperFlexible.......................................................1
9.1 FEEDING CHAIN – REPLACEMENT ............................................................................2
9.2 ELEVATOR CARRIAGE DRIVE SAFETY JOINT - REPLACEMENT ...........................2
9.3 REMNANT CONVEYOR BELT - REPLACEMENT ........................................................3
9.4 PLC BATTERY – REPLACEMENT ...............................................................................4
9.5 RECOMMENDED SPARE PARTS ................................................................................5
9.6 DISPOSAL OF THE BAR FEEDER OR PARTS OF IT.........................................................5
10 GUIDE CHANNELS-BAR PUSHER-REVOLVING TIPS Master 80 UP
HyperFlexible .......................................................................................................1
10.1 GUIDE CHANNELS AND BAR PUSHER .............................................................................2
10.2 REVOLVING TIP - TABLE ....................................................................................................3
10.3 Revolving tips øGR 20 25 - Table.....................................................................................5
10.4 Revolving tips øGR 20 25 - Table.....................................................................................6
10.5 Revolving tips øGR 32 81 - Table.....................................................................................7
11 COLLETS Master 80 UP HyperFlexible ............................................................................1
11.1 CONVERSION TABLES 001.................................................................................................3
11.2 HEXAGONAL BARS (unit of measurement "millimetres") - Table ..................................3
11.3 SQUARE BARS (unit of measurement "millimetres") - Table..........................................5
11.4 HEXAGONAL BARS (unit of measurement "inches") - Table..........................................6
11.5 ROUND BARS - (unit of measurement "inches") - Table..................................................7
11.6 CONVERSION TABLE Inches/Millimetres..........................................................................8

INDEX
11.7 COLLETS FOR 001P BARS ...............................................................................................10
11.8 COLLET FOR BARS - Table ..............................................................................................10
11.9 PIPE COLLETS 012-077-377..............................................................................................13
11.10 PIPE COLLETS - Table.......................................................................................................13
11.11 EJECTOR 336.....................................................................................................................17
11.12 EJECTOR – Guide channels ø<30 - Table........................................................................17
11.13 EJECTOR – Guide channels ø>32 - Table........................................................................19
11.14 COLLETS FOR BARS 602P ...............................................................................................21
11.15 COLLET FOR BARS - Table ..............................................................................................21
11.16 BORING COLLETS FOR BARS 601P................................................................................23
11.17 BORING COLLETS FOR SQUARE AND HEXAGONAL BARS - Table............................23
11.18 EJECTORS 602P..011 ........................................................................................................26
11.19 EJECTORS - Guide channels ø13 28 - Table.................................................................26
11.20 PIPE COLLETS 603P..........................................................................................................28
11.21 PIPE COLLETS - Table.......................................................................................................28
11.22 COLLETS FOR BARS 381P ...............................................................................................31
11.23 COLLET FOR BARS - Table ..............................................................................................31
11.24 EJECTORS 381P..011 - 381P..021.....................................................................................34
11.25 381P..021 EJECTORS - Guide channels ø33 46 - Table...............................................34
11.26 381P..011 EJECTORS - Guide channels ø52 86 - Table...............................................36
11.27 PIPE COLLETS 386P..........................................................................................................38
11.28 PIPE COLLETS - Table.......................................................................................................38
11.29 RINGS FOR COLLETS 078-225 .........................................................................................40
11.30 RINGS FOR COLLETS - Table...........................................................................................40

1 - GENERAL INFORMATION Master 80 UP HyperFlexible
EN
1 - Pag. 1 / 1
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 ............................................................................................5
1.5 ATTACHMENT LIST..................................................................................................5

EN
1 - GENERAL INFORMATION Master 80 UP HyperFlexible
1 - Pag. 2 / 2
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 Master 80 UP HyperFlexible
EN
1 - Pag. 3 / 3
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 Master 80 UP HyperFlexible
1 - Pag. 4 / 4
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.
U Electric cabinet weight
INFORMATION:
always provide the manufacturer with the above mentioned specifications when
requesting information or ordering spare parts, etc.

1 - GENERAL INFORMATION Master 80 UP HyperFlexible
EN
1 - Pag. 5 / 5
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
• Spare parts catalogue
• Keyboard instruction manual
• Interface wiring diagram
• CD:
Depliant
Spare parts catalogue
Instruction manual
Operation and maintenance manual
Guide channel assembly diagram
Base wiring diagram
List of customer service centres.

2 - TECHNICAL INFORMATION Master 80 UP HyperFlexible
EN
2 - Pag. 1 / 1
INDEX
2.1 BAR FEEDER GENERAL DESCRIPTION.......................................................................2
2.1.1 Bar feeder - Main components..................................................................................4
2.1.2 Magazine - Main components....................................................................................6
2.1.3 Hydraulic system - Main components ........................................................................7
2.1.4 Pneumatic system - Main components.......................................................................8
2.2 OPERATING CYCLE - GENERAL DESCRIPTION.........................................................10
2.2.1 OPERATING CYCLE ................................................................................................10
2.2.2 Magazine - Operating cycle.....................................................................................15
2.3 SAFETY DEVICES - POSITION AND DESCRIPTION ...................................................16
2.3.1 Bar feeder - Safety devices.....................................................................................16
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION ....................................................17
2.5 VERSION DESCRIPTION.........................................................................................18
2.6 TECHNICAL DATA..................................................................................................20
2.6.1 Noise levels ...........................................................................................................26
2.7 ACCESSORIES - FOREWORD...................................................................................27
2.7.1 Bush holder device - Description.............................................................................27

EN
2 - TECHNICAL INFORMATION Master 80 UP HyperFlexible
2 - Pag. 2 / 2
2.1 BAR FEEDER GENERAL DESCRIPTION
The MASTER 80 HF UP automatic bar feeder is used
in the machine-tool industry and in particular for
automatic lathe feeding.
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 and
various sections.
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 machined bar remnant: the remnant is removed and dropped
onto the conveyor, which drops it onto the collection box.
The bar remnant ejection can be performed by the bar pusher feeding or next bar feeding.
The lathe tooling and maintenance can be easily carried out thanks to the axial displacement of
the bar feeder body.

2 - TECHNICAL INFORMATION Master 80 UP HyperFlexible
EN
2 - Pag. 3 / 3
The MASTER 80 HF UP bar feeders are available in
the following models:
MASTER 80 HF UP (standard version) rack magazine
MASTER 80r HF UP (reversed version) rack
magazine
When not otherwise specified, the texts, tables and
pictures of this manual refer to the standard
version. As far as the reversed version is
concerned, consider that the magazine and the
electric cabinet are placed on the opposite side.

EN
2 - TECHNICAL INFORMATION Master 80 UP HyperFlexible
2 - Pag. 4 / 4
2.1.1 Bar feeder - Main components
A GUIDE CHANNELS; drive the bar during the machining.
B FIRST FEEDING CARRIAGE; moves the bar forwards until the necessary space for the bar
pusher introduction has been created.
C BAR PUSHER; pushes the bar during the machining. The collet is fixed on its front end.
D BAR PUSHER MOTOR DRIVE; moves the bar pusher.
E FEED CHAIN; transmits the motion from the motor drive to the bar pusher.
F GUIDE CHANNEL OPENING/CLOSING CYLINDER
Y UPPER GUIDE CHANNEL UNLOCKING.
G PNEUMATIC BAR DROP CONTROL LEVERS; guide the bar during the drop into the guide
channels.
H PNEUMATIC CLAMPS; hold the bar during the loading and removal from the collet of the bar
pusher.
K LUBRICATION SYSTEM
L FACING DEVICE; it sends a signal when the bar passes.