IEMCA MASTER 880 MP E-volution Instruction manual

MASTER 880 MP E-volution
GB MANUAL FOR USE AND MAINTENANCE
Rel. 1Date 01/10/02 Cod. 381005410
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: MASTER 880 MP E-volution

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

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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
Please note that the validity of the warranty is subject to a correct alignment of the bar feeder
and to the consequent floor fastening by expansion plugs (as indicated at chapter 4.4.6).

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1.2 MANUAL PURPOSE
This manual has been written and supplied by the manufacturer and 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 and/or the index.
In addition to this manual, which contains all the instructions for the bar feeder use and
maintenance, two more are supplied: the "Push-button panel instruction manual" and the
"Quick reference guide".
The "Push-button panel instruction manual" contains all the instructions on how to use the
installed software.
The "Quick reference guide" contains the minimum required instructions to use the bar feeder
and the 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 DESCRIPTION OF THE BAR FEEDER .........................................................2
2.1.1 Bar feeder - Main components.................................................................................3
2.1.2 Hydraulic system - Main components .......................................................................4
2.1.3 Pneumatic system - Main components .....................................................................5
2.2 OPERATING CYCLE ................................................................................................6
2.3 Bar feeder - Safety devices ...................................................................................10
2.4 SAFETY PLATES - POSITION AND DESCRIPTION....................................................11
2.5 DESCRIPTION OF THE VERSIONS .........................................................................12
2.6 TECHNICAL DATA ................................................................................................13
2.6.1 Noise levels .........................................................................................................18
2.7 FITTINGS - FOREWORD .......................................................................................19
2.7.1 Bush-holder device - Description ...........................................................................19

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2.1 GENERAL DESCRIPTION OF THE BAR FEEDER
The MASTER 880 automatic bar feeder is used in the machine-tool industry and in particular,
for automatic lathe feeding.
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 various sections.
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.
The lathe tooling and maintenance can be easily carried out due to the axial displacement of
the bar feeder body.

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2.1.1 Bar feeder - Main components
A Magazine; where bars are stored.
B Bar selectors; this selects the first bar contained in the magazine, so that it can be
afterwards loaded by the lifting device.
C Bar lifting device; this lifts the first bar contained in the magazine.
D Guide channels; they drive the bar during the machining.
E First feeding carriage; it pushes the bar forward until the necessary space for the bar pusher
connection has been created.
F Bar pusher; it pushes the bar during the machining. The collet is fixed on its front end.
G Bar pusher drive; it drives the bar pusher.
H Feed chain; it transmits the motion from the drive to the bar pusher.
L Cam drive; it drives the opening and closing of the clamps, the opening and closing of the
guide channels, the lifting and lowering of the bar drop device.
M Pneumatic bar drop control devices; they control the bar during the drop into the guide
channels.
N Clamps; they hold the bar during its loading and removal from the bar pusher collet.
P Facing device; it sends a signal during the bar passage.
Q Remnant collection box; it collects the bar remnant.
R Lubricating pump; it delivers oil to the guides.
S Oil tank; contains the lubricating oil.
T Hand-held keyboard; it allows bar feeder programming and function actuation.
U Electric cabinet; houses the electric switchboard.
V Axial displacement; it helps to remove the bar feeder body from the lathe.
Z Pneumatic bar drop controls cylinder
X Pneumatic clamps cylinder

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2.1.2 Hydraulic system - Main components
1TANK
2PUMP
3 DIRECTIONAL CONTROL VALVE
4GUIDES
5BUSHING
6 OIL RECOVERY TRAY
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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2.1.3 Pneumatic system - Main components
A - PNEUMATIC BAR DROP CONTROL DEVICE UNIT
B - FACING UNIT
C - BUSHING DRIVE UNIT
D - BAR SELECTORS UNIT
E - PNEUMATIC CLAMPS CYLINDER
POS. DENOMINATION
1FILTER
2 PRESSURE GAUGE
3VALVE
4 ELETCTROVALVE
5 CONNECTION
6CYLINDER
7CYLINDER
8VALVE
9CYLINDER
10 CYLINDER
11 CYLINDER
12 VALVE

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2.2 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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The 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 and the bar remnant drops into collection box (E).
When dropping, bar remnant (C) activates a control device. If the bar remnant is still inside 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.

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Bar lifts (L) load bar (M) that falls into lower guides (N) with the help of levers (H).
The 1st feeding carriage (P) stroke begins.
When the small pusher truck (P) completes its stroke, the required space has been created for
bar-pusher insertion.
The small pusher truck executes its return stroke.

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The upper guides (G) are closed; the bar-pusher (H) is positioned along the spindle axis.
The clamps (D) close, the bar-pusher (A) moves forwards; the bar (N) is inserted into the bar-
pusher collet.
The bar-pusher (A) and bar (N) execute their facing stroke. A new automatic work cycle is
started.

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2.3 Bar feeder - Safety devices
A-B Emergency push-button; when pressed, all the bar feeder and lathe functions stop in
emergency condition.
C Interlocked mobile guard: associated with microswitch C1.
According to the cycle setting, its functions are.
manual cycle;
-on guard opening, the bar feeder controls are locked with the exception of bar pusher
movement controls.
automatic cycle;
-during the bar feeding phase, the guard opens to allow magazine refilling. Although the bar
feeder and lathe functions are not stopped, there are no residual risks for the operator
within the area.
-during the bar change phase, on guard opening, the bar feeder and lathe functions are
stopped. Guard closure allows the cycle to be restarted by the operator.
D Fixed guard: it is made from transparent material to allow visual inspection of the bar feeder
devices.
E Fixed guard: hinders an accidental access to the operating components.
F Fixed guard: it prevents accidental access to the bar selection area.

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2.4 SAFETY PLATES - POSITION AND DESCRIPTION
A Danger of upper limb crushing.
C Do not remove the safety barriers.
D Wear safety gloves and shoes.
Do not lift loads exceeding 15 kg manually.
E Caution! Danger of electric contact.
F Warning; danger of falling material.
G Warning: fix the bar feeder to the ground.
H Maximum overall weight of magazine loadable bars.
L Warning; axial sliding
M Warning; oil leakage.
N Warning; respect the correct guide channel assembly direction.

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2.5 DESCRIPTION OF THE VERSIONS
Table 1. Bar length
Modello Versione Lunghezza massima
mm (ft)
Lunghezza minima
mm (ft)
33 3300 (10,8)
38 3800 (12,4)
MASTER
880 MP
Evolution 43 4300 (14,1)
1000 (3,2)
Table 2. Bar pusher max. extension
Model Version Version A - Max. extension
(mm)
L 1350
33-38-43 LL 1600
MASTER 880 MP
Evolution 38-43 XLL 1850