IEMCA MASTER 880-VERSO P Instruction manual

MASTER 880-VERSO P/F
MASTER 880r-VERSO P/F
EN MANUAL FOR USE AND MAINTENANCE
Rel. 1Date 15/07/2011 Cod.3800M05410
S/N
COMPILER Bosi Andrea
ON APPROVAL Sbarzaglia Ivan
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 A BUCCI AUTOMATIONS DIVISION
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 880-VERSO P/F
MASTER 880r-VERSO P/F

INDEX
1 GENERAL INFORMATION MASTER 880/880r VERSO ....................................................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 880/880r VERSO.................................................1
2.1 BAR FEEDER GENERAL DESCRIPTION............................................................................2
2.1.1 Bar feeder - Main components............................................................................................4
2.1.2 MASTER 880 P Rack magazine - Main components.........................................................6
2.1.3 MASTER 880F Bar bundle magazine - 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 ............................................................11
2.2.1 OPERATING CYCLE...........................................................................................................11
2.2.2 MASTER 880 P Rack magazine - Operating cycle...........................................................16
2.2.3 MASTER 880 F bar bundle magazine - Operating cycle.................................................17
2.3 SAFETY DEVICES - POSITION AND DESCRIPTION........................................................19
2.3.1 Bar feeder - Safety devices...............................................................................................19
2.3.2 MASTER 880 P rack magazine - Safety devices..............................................................20
2.3.3 MASTER 880 F bundle magazine - Safety devices .........................................................21
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION........................................................22
2.5 VERSION DESCRIPTION ...................................................................................................23
2.6 TECHNICAL DATA .............................................................................................................25
2.6.1 Noise levels ........................................................................................................................33
2.7 ACCESSORIES - FOREWORD...........................................................................................34
2.7.1 Bush holder device - Description.....................................................................................34
3 SAFETY PROCEDURES - GENERAL INFORMATION MASTER 880/880r VERSO.........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

INDEX
3.5 BAR FEEDER MAINTENANCE - Safety ..............................................................................5
3.6 EC CONFORMITY DECLARATION......................................................................................6
3.7 General Description of Supply............................................................................................7
3.8 RESIDUAL RISKS.................................................................................................................8
3.9 FORESEEABLE MISUSES.................................................................................................13
4 HANDLING AND INSTALLATION MASTER 880/880r VERSO.........................................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.............................................................................................5
4.2.3 Bar feeder with crate - Lifting .............................................................................................5
4.3 INSTALLATION AREA - FEATURES ...............................................................................6
4.4 BAR FEEDER INSTALLATION - FOREWORD....................................................................7
4.4.1 Backing plates and support feet - Installation ..................................................................7
4.4.2 Height - Adjustment.............................................................................................................8
4.4.3 Preliminary positioning .....................................................................................................10
4.4.4 Sleeve - Installation............................................................................................................11
4.4.5 Levelling and alignment....................................................................................................12
4.4.6 Bar feeder fastening ..........................................................................................................17
4.5 LUBRICATION OIL - FILLING .........................................................................................18
4.6 ELECTRICAL CONNECTION ..........................................................................................18
4.7 PNEUMATIC DEVICE LAYOUT..........................................................................................19
4.7.1 PNEUMATIC CONNECTION ...........................................................................................21
4.7.2 BAR FEEDER MOVEMENT WITHOUT POWER SUPPLY ................................................21
4.8 S OFTWARE PARAMETERIZATION ...............................................................................22
5 ADJUSTMENTS AND SETTING-UP MASTER 880/880r VERSO......................................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
5.2.4 MASTER 880 F displacement belts - Adjustment .............................................................5

INDEX
5.2.5 MASTER 880 F Displacement belt drive chain - Adjustment...........................................6
5.2.6 MASTER 880 F elevator carriage drive chain - Adjustment.............................................7
5.2.7 MASTER 880 F lifting belt control cams - Adjustment .....................................................8
5.3 BAR FEEDER SETUP .......................................................................................................9
5.3.1 Guide channels, half-bushings, bar pusher and collet - Replacement...........................9
5.3.2 BAR PUSHER REPLACEMENT PROCEDURE .................................................................17
5.3.3 Remnant passage door spring - Adjustment ..................................................................19
5.3.4 REMNANT DROP CHUTE — ENABLING .......................................................................20
5.4 RACK MAGAZINE SETUP - MASTER 880 P .................................................................21
5.4.1 Bar supporting brackets - Setup ......................................................................................21
5.4.2 Elevator drive - Adjustment ..............................................................................................22
5.4.3 Elevator carriages - Setup.................................................................................................23
5.5 BAR BUNDLE MAGAZINE SETUP - MASTER 880 F ....................................................25
5.5.1 Bar stop levers - Adjustment............................................................................................25
5.5.2 Pressure foot - Adjustment...............................................................................................26
5.5.3 Separation push-rods - Adjustment.................................................................................28
5.5.4 Bar selection — Setup.......................................................................................................29
5.5.5 Elevator drive - Adjustment ..............................................................................................33
6 USE AND OPERATION MASTER 880/880r VERSO..........................................................1
6.1 CONTROL DESCRIPTION....................................................................................................2
6.2 KEYBOARD CONTROL DESCRIPTION ..............................................................................4
6.3 MAGAZINE PUSH-BUTTON PANEL - CONTROL DESCRIPTION .....................................8
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..............................................................................................18
6.9 BAR LOADING - PROCEDURE..........................................................................................19
6.10 LUBRICATING OIL - FLOW ADJUSTMENT......................................................................22
6.11 BAR FEEDER STOP...........................................................................................................22
6.12 CYCLE PERFORMING MODE IN THE "STEP-BY-STEP" FUNCTION.............................23

INDEX
7 棒材送料机保养 MASTER 880/880r VERSO.......................................................................1
7.1 保养 — 通则.......................................................................................................................2
7.2 计划保养 .............................................................................................................................3
7.2.1 润滑油 - 油位检查...................................................................................................................4
7.2.2 润滑油 - 换油..........................................................................................................................5
7.2.3 滤油器 - 清洗..........................................................................................................................6
7.2.4 空气过滤器装置 - 检查 ...........................................................................................................7
7.3 润滑点示意图 ......................................................................................................................8
8 TROUBLES - CAUSES - CURES MASTER 880/880r VERSO ..........................................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 880/880r VERSO..........................................................1
9.1 FEEDING CHAIN – REPLACEMENT ................................................................................2
9.2 ELEVATOR CARRIAGE DRIVE SAFETY JOINT - REPLACEMENT ...............................2
9.3 REPLACEMENT OF THE GUIDE CHANNELS WITH INSERTS WITH
POLYURETHANE GUIDE CHANNELS................................................................3
9.3.1 Disassembly of insert guide channels...............................................................................3
9.3.2 Polyurethane guide channel assembly..............................................................................5
9.3.3 Insert guide channels – Replacement for bar diameter variation ...................................9
9.3.4 Insert guide channels – Replacement due to failure ......................................................17
9.4 REMNANT CONVEYOR BELT - REPLACEMENT .........................................................20
9.5 PLC BATTERY – REPLACEMENT .................................................................................21
9.6 RECOMMENDED SPARE PARTS ..................................................................................22
9.7 DISPOSAL OF THE BAR FEEDER OR PARTS OF IT.......................................................22
10 GUIDE CHANNELS-BAR PUSHER-REVOLVING TIPS MASTER 880/880r VERSO........1
10.1 GUIDE CHANNELS AND BAR PUSHER .............................................................................2
10.2 REVOLVING TIP - TABLE ....................................................................................................3
10.3 Revolving tips øGR 20÷25 - Table ......................................................................................5

INDEX
10.4 Revolving tips øGR 20÷25 - Table ......................................................................................6
10.5 Revolving tips øGR 32÷45 - Table ......................................................................................7
10.6 Revolving tips øGR 51÷85 - Table ......................................................................................9
11 COLLETS MASTER 880/880r VERSO ...............................................................................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
11.7 COLLETS FOR 011P 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.....................................................................................................................16
11.12 EJECTOR — Guide channels ø<30 - Table......................................................................16
11.13 EJECTOR — Guide channels ø>32 - Table......................................................................18
11.14 COLLETS FOR BARS 602P ...............................................................................................20
11.15 COLLET FOR BARS - Table ..............................................................................................20
11.16 BORING COLLETS FOR BARS 601P................................................................................22
11.17 BORING COLLETS FOR SQUARE AND HEXAGONAL BARS - Table............................22
11.18 EJECTORS 602P..011 ........................................................................................................24
11.19 EJECTORS —Guide channels ø13÷28 - Table.................................................................24
11.20 PIPE COLLETS 603P..........................................................................................................26
11.21 PIPE COLLETS - Table.......................................................................................................26
11.22 COLLETS FOR BARS 076..................................................................................................28
11.23 COLLET FOR BARS - Table ..............................................................................................28
11.24 COLLETS FOR BARS 381P ...............................................................................................31
11.25 COLLET FOR BARS - Table ..............................................................................................31
11.26 EJECTORS 381P..011 - 381P..021.....................................................................................34
11.27 381P..021 EJECTORS - Guide channels ø33÷46 - Table.................................................34
11.28 381P..011 EJECTORS - Guide channels ø52÷86 - Table.................................................36
11.29 PIPE COLLETS 386P..........................................................................................................38

INDEX
11.30 PIPE COLLETS - Table.......................................................................................................38
11.31 RINGS FOR COLLETS 078-225 .........................................................................................40
11.32 RINGS FOR COLLETS - Table...........................................................................................40

1 - GENERAL INFORMATION MASTER 880/880r VERSO
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 ............................................................................................5
1.5 ATTACHMENT LIST..................................................................................................5

EN
1 - GENERAL INFORMATION MASTER 880/880r VERSO
1 - Pag. 2 / 5
Operations described in sections showing this symbol, must be performed by qualified
and skilled personnel only, 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:
SERVIZIO TECNICO CLIENTI
IEMCA A BUCCI AUTOMATIONS DIVISION
48018 Faenza (Ra) ITALY - Via Granarolo, 167

1 - GENERAL INFORMATION MASTER 880/880r VERSO
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.
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 880/880r VERSO
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.
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 880/880r VERSO
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 880/880r VERSO
EN
2 - Pag. 1 / 34
INDEX
2.1 BAR FEEDER GENERAL DESCRIPTION.......................................................................2
2.1.1 Bar feeder - Main components..................................................................................4
2.1.2 MASTER 880 P Rack magazine - Main components.....................................................6
2.1.3 MASTER 880F Bar bundle magazine - 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.........................................................11
2.2.1 OPERATING CYCLE ................................................................................................11
2.2.2 MASTER 880 P Rack magazine - Operating cycle......................................................16
2.2.3 MASTER 880 F bar bundle magazine - Operating cycle.............................................17
2.3 SAFETY DEVICES - POSITION AND DESCRIPTION ...................................................19
2.3.1 Bar feeder - Safety devices.....................................................................................19
2.3.2 MASTER 880 P rack magazine - Safety devices ........................................................20
2.3.3 MASTER 880 F bundle magazine - Safety devices.....................................................21
2.4 SAFETY PLATES - LOCATION AND DESCRIPTION ....................................................22
2.5 VERSION DESCRIPTION.........................................................................................23
2.6 TECHNICAL DATA..................................................................................................25
2.6.1 Noise levels ...........................................................................................................33
2.7 ACCESSORIES - FOREWORD...................................................................................34
2.7.1 Bush holder device - Description.............................................................................34

EN
2 - TECHNICAL INFORMATION MASTER 880/880r VERSO
2 - Pag. 2 / 34
2.1 BAR FEEDER GENERAL DESCRIPTION
The MASTER 880 E-volution 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 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 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 feeding position may be
determined at any time during the working cycle.
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 880/880r VERSO
EN
2 - Pag. 3 / 34
The MASTER 880 E-volution bar feeders are
available in the following models:
MASTER 880P (standard version) rack magazine
MASTER 880rP (reversed version) rack magazine
MASTER 880F (standard version) bundle magazine
MASTER 880rF (reversed version) bundle magazine.
When not otherwise specified, the texts, tables and
pictures of this manual refer to the standard
version. As far as the reverse version is concerned,
consider that the magazine and the electric cabinet
are placed on the opposite side.

EN
2 - TECHNICAL INFORMATION MASTER 880/880r VERSO
2 - Pag. 4 / 34
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.
L FACING DEVICE; sends a signal during the bar passage.
M REMNANT CONVEYOR BELT; carries the bar remnant from the ejection area to the recovery
box.
N REMNANT CONVEYOR BELT DRIVE; it moves the remnant conveyor belt.
P REMNANT RECOVERY BOX; collects the bar remnant.