IEMCA MASTER 880-E P/F Instruction manual

MASTER 880-E P/F
MASTER 880r-E P/F
GB MANUAL FOR USE AND MAINTENANCE
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AUTOMATIC BAR FEEDER WITH
HYDRAULIC SUSPENSION
ATTACHMENTS LIST
MANUAL FOR USE AND MAINTENANCE
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j^krc^`qroboW IEMCA division of IGMI S.p.A.
^aaobppW Via Granarolo, 167 - 48018 Faenza (RA) - ITALY
Tel. [phone] - Fax. [phone]
TLX 550879
qvmb=lc=al`rjbkqW MANUAL FOR USE AND MAINTENANCE
molar`qW AUTOMATIC BAR FEEDER WITH HYDRAULIC SUSPENSION
jlabiW MASTER 880-E P/F
MASTER 880r-E P/F

1 GENERAL INFORMATION ................................... MASTER 880/880r P/F E-volution
2 TECHNICAL INFORMATION ................................ MASTER 880/880r P/F E-volution
3 SAFETY PROCEDURES - GENERAL INFORMATIONMASTER 880/880r P/F E-volution
4 HANDLING AND INSTALLATION......................... MASTER 880/880r P/F E-volution
5 ADJUSTMENTS AND SETTING-UP....................... MASTER 880/880r P/F E-volution
6 USE AND OPERATION......................................... MASTER 880/880r P/F E-volution
7 BAR FEEDER MAINTENANCE .............................. MASTER 880/880r P/F E-volution
8 TROUBLES - CAUSES - CURES............................. MASTER 880/880r P/F E-volution
9 PART REPLACEMENT .......................................... MASTER 880/880r P/F 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........................................................................................5
1.5 ANNEXES ENCLOSED..............................................................................................5

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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
U Cubicle weight
INFORMATION:
Always provide the Manufacturer with the above mentioned specifications when
requesting information or ordering spare parts, etc.

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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 DESCRIPTION OF THE BAR FEEDER .........................................................2
2.1.1 Bar feeder - Main components.................................................................................4
2.1.2 Rack magazine MASTER 880 P - Main components ...................................................6
2.1.3 Bar bundle magazine MASTER 880F - Main components............................................7
2.1.4 Hydraulic system - Main components .......................................................................8
2.1.5 Pneumatic system - Main components .....................................................................9
2.2 OPERATING CYCLE - GENERAL DESCRIPTION........................................................10
2.2.1 OPERATING CYCLE ..............................................................................................10
2.2.2 Rack magazine MASTER 880 P - Operating cycle ....................................................14
2.2.3 Bundle magazine MASTER 880 F - Operating cycle..................................................15
2.3 SAFETY DEVICES - POSITION AND DESCRIPTION ..................................................17
2.3.1 Bar feeder - Safety devices ...................................................................................17
2.3.2 Rack magazine MASTER 880 P - Safety devices ......................................................18
2.3.3 Bundle magazine MASTER 880 F - Safety devices ...................................................19
2.4 SAFETY PLATES - POSITION AND DESCRIPTION....................................................20
2.5 DESCRIPTION OF THE VERSIONS .........................................................................21
2.6 TECHNICAL DATA ................................................................................................23
2.6.1 Noise levels .........................................................................................................29
2.7 FITTINGS - FOREWORD .......................................................................................30
2.7.1 Bush-holder device - Description ...........................................................................30

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2.1 GENERAL DESCRIPTION OF THE BAR FEEDER
The MASTER 880 E-volution 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.
It is equipped with a hand-held control that enables
the operator to interact with all the controls
without forcing him to leave his work station.
It may load bars, tubes and various sections that
are kept in the rack magazine (MASTER 880P) or in
the bar bundle magazine (MASTER 880F).
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 motoreductor, the bar
speed, thrust value and feeding position may be
determined at any time during the working cycle.

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The MASTER 880 E-volution bar feeders are
available in the following models:
MASTER 880P (standard version) rack-type
magazine.
MASTER 880rP (reversed version) rack-type
magazine .
MASTER 880F (standard version) bundle-type
magazine.
MASTER 880rF (reversed version) bundle-type
magazine .
When not otherwise specified, the texts, tables and
pictures of this manual regard the standard version.
As far as the reverse version is concerned, it should
be borne in mind that the magazine and the electric
cabinet are mounted on the opposite side.

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2.1.1 Bar feeder - Main components
A Guide channels; they drive the bar during the machining.
B First feeding carriage; it pushes the bar forward until the necessary space for the bar pusher
connection has been created.
C Bar pusher; it pushes the bar during the machining. The collet is fixed on its front end.
D Bar pusher drive; it drives the bar pusher.
E Feed chain; it transmits the motion from the drive to the bar pusher.
F Opening and closing guide channels cylinder.
G Pneumatic bar drop control devices; they control the bar during the drop into the guide
channels.
H Pneumatic clamps; they hold the bar during its loading and removal from the bar pusher
collet.
L Facing device; it sends a signal during the bar passage.
M Remnant conveyor; it carries the bar remnant from the removal area to the collection box.
N Remnant conveyor drive; it drives the remnant conveyor.
P Remnant collection box; it collects the bar remnant.

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Q Lubrication pump; it delivers the lubricating oil to the guide channels.
R Oil tank; contains the lubricating oil.
S HAND-HELD KEYBOARD; it allows bar feeder programming and function actuation.
T Pneumatic bar drop controls cylinder
U Electric cabinet; houses the electric switchboard.
V Axial displacement; it helps to remove the bar feeder body from the lathe.
Z Pneumatic clamps cylinder

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2.1.2 Rack magazine MASTER 880 P - Main components
A BAR SUPPORTING ARMS; support bars. Thanks to their inclination, bars lean against the lift
truck uprights.
B LIFT TRUCKS; move bars from the magazine to the bar feeder guides.
C LIFT TRUCK MOTORISATION; actuates the upstroke and downstroke of the lifting trucks.

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2.1.3 Bar bundle magazine MASTER 880F - Main components
A Lifting belts; lift the bundle of bars so that some of them fall onto the selection table.
B Lifting belts driving; actuates the upstroke and downstroke of the lifting belts.
C Bar stopping levers; allow the bar controlled fall onto the selection table.
D Conveying belt; their forward-backward motion allows the bars to be selected and displaced.
E Conveying belt motorisation; actuates the conveying belts.
F Pressure foot; keeps the bars pressed against the.
G Feelers; detect the first bar coming from the conveying belts.
H Lower push-rods; hold the first bar coming from the conveying belts.
L Lift trucks; move bars from the magazine to the bar feeder guides.
M Lift truck motorisation; actuates the upstroke and the downstroke of the lifting trucks.

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2.1.4 Hydraulic system - Main components
Lubrication oil cycle: forced by pump (2) installed in tank (1), the oil flows to guides (4) and
bushing holder (5) to lubricate the bars in production.
From these two devices the oil enters recovery tray (6) from where it is returned to the tank
via a filter for use in the next lubrication cycle.

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2.1.5 Pneumatic system - Main components
A - PNEUMATIC BAR DROP CONTROLS UNIT
B - FACING CYLINDER
C - BUSHING DRIVE UNIT
D - PNEUMATIC CLAMPS UNIT
E - REMNANT DROP UNIT
F - PNEUMATIC GUIDES LOCKING UNIT
G - GUIDES OPENING UNIT
POS. DENOMINATION POS. DENOMINATION
1 FILTER 12 CYLINDER
2 PRESSURE GAUGE 13 ELETCTROVALVE
3 CYLINDER 14 CYLINDER
4REGULATOR 15REGULATOR
5 ELETCTROVALVE 16 ELETCTROVALVE
6 CYLINDER 17 CYLINDER
7 REGULATOR 18 ELETCTROVALVE
8 ELETCTROVALVE 19 CYLINDER
9CYLINDER 20REGULATOR
10 ELETCTROVALVE 21 ELETCTROVALVE
11 VALVE

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2.2 OPERATING CYCLE - GENERAL DESCRIPTION
The description of the operating cycle is the subject of the following paragraphs:
2.2.1 Bar feeder - Operating cycle
2.2.2 Rack magazine MASTER 880P - Operating cycle
2.2.3 Bar bundle magazine MASTER 880F - Operating cycle
2.2.1 OPERATING CYCLE
The automatic functioning controls the motions of the bar feeder according to the sequence
described below.
The bar pusher (A) makes bar (B) move forward in the lathe until the bar runout.
The bar-pusher (A) and remnant (C) are in their forwards limit stop position.

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Bar pusher (A) and remnant (C) reach their backwards limit stop position.
The clamps (D) close and the bar pusher moves backwards; the remnant is removed from the
collet. The clamps open, the bar pusher (A)is fed and the remnant is placed on to the remnant
drop guide(T), the bar pusher runs back, the clamps (D) close and open again for the remnant
drop control, then the remnant drop guide (T) is lowered and the remnant drops on to the
remnant conveyor belt (E).
Remnant (C) is driven to the rear side and dropped onto box (F). A sensor detects the presence
of the remnant during the path; if the remnant is still in the collet of the bar pusher the bar
feeder stops, otherwise the cycle goes on.
The top guides (G) are lifted together with the bar pusher (H), and also the bar control devices
are lifted.