IEMCA MASTER865 VERSO MP SIII Instruction manual

MASTER865 VERSO MP SIII
EN MANUAL FOR USE AND MAINTENANCE
Rel. 0Date 31/12/2013 Cod.3810M05450
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 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: MASTER865 VERSO MP SIII

INDEX
1 GENERAL INFORMATION nome caricatore.....................................................................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......................................................................................................4
1.5 GLOSSARY AND TERMINOLOGY.......................................................................................4
1.6 ATTACHMENT LIST .............................................................................................................5
2 TECHNICAL INFORMATION nome caricatore .................................................................1
2.1 BAR FEEDER GENERAL DESCRIPTION............................................................................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 - LOCATION AND DESCRIPTION........................................................11
2.5 VERSION DESCRIPTION ...................................................................................................12
2.6 TECHNICAL DATA .............................................................................................................14
2.6.1 Noise levels ........................................................................................................................20
2.7 ACCESSORIES - FOREWORD...........................................................................................21
2.7.1 Bush holder device - Description .....................................................................................21
3 SAFETY PROCEDURES - GENERAL INFORMATION nome caricatore.........................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 CONFORMITY DECLARATION ......................................................................................6
3.7 General Description of Supply............................................................................................7
3.8 RESIDUAL RISKS.................................................................................................................8
3.9 FORESEEABLE MISUSES .................................................................................................13
4 HANDLING AND INSTALLATION nome caricatore .........................................................1

INDEX
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 ....................................................................6
4.4.1 Backing plates and support feet - Installation ..................................................................6
4.4.2 Height - Adjustment .............................................................................................................7
4.4.3 Preliminary positioning .......................................................................................................8
4.4.4 Sleeve - Installation..............................................................................................................9
4.4.5 Levelling and alignment ....................................................................................................10
4.4.6 Bar feeder fastening ..........................................................................................................15
4.5 LUBRICATION OIL - FILLING .....................................................................................16
4.6 ELECTRICAL CONNECTION
......................................................................................16
4.7 PNEUMATIC DEVICE LAYOUT..........................................................................................17
4.7.1 PNEUMATIC CONNECTION
.......................................................................................19
4.7.2 BAR FEEDER MOVEMENT WITHOUT POWER SUPPLY ................................................19
4.8 SOFTWARE PARAMETERIZATION
...........................................................................20
5 ADJUSTMENTS AND SETTING-UP nome caricatore ......................................................1
5.1 ADJUSTMENT AND SETUP - FOREWORD .................................................................2
5.2 GENERAL ADJUSTMENTS - FOREWORD ..................................................................2
5.2.1 Feeding chain - Adjustment ................................................................................................2
5.2.2 Pressure switch - Adjustment.............................................................................................3
5.3 BAR FEEDER SETUP ....................................................................................................4
5.3.1 Guide channels, half bushes, bar pusher and collet - Replacement ..............................4
5.3.2 BAR PUSHER REPLACEMENT PROCEDURE .................................................................13
5.3.3 Bar selectors - Adjustment ...............................................................................................14

INDEX
6 USE AND OPERATION MASTER 865 VERSO ..................................................................1
6.1 CONTROL DESCRIPTION....................................................................................................2
6.2 KEYBOARD CONTROL DESCRIPTION ..............................................................................4
6.3 LIGHT INDICATOR - SIGNAL DESCRIPTION .....................................................................7
6.4 BAR FEEDER TOOLING ......................................................................................................8
6.5 BARS TO BE MACHINED - FEATURES AND PREPARATION ..........................................8
6.5.1 BAR STRAIGHTNESS - Measurement..............................................................................10
6.6 BAR MAGAZINE - LOADING..............................................................................................11
6.7 AUTOMATIC CYCLE START..............................................................................................12
6.8 BAR LOADING - PROCEDURE..........................................................................................13
6.9 LUBRICATING OIL - FLOW ADJUSTMENT ......................................................................16
6.10 BAR FEEDER STOP ...........................................................................................................16
6.11 CYCLE PERFORMING MODE IN THE "STEP-BY-STEP" FUNCTION .............................17
7 BAR FEEDER MAINTENANCE MASTER 865 VERSO......................................................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 ......................................................................................................4
7.2.3 Air filter unit - Check............................................................................................................5
7.3 LUBRICATION POINT DIAGRAM .................................................................................6
8 TROUBLES - CAUSES - CURES MASTER 865 VERSO...................................................1
8.1 GENERAL FAILURES
...................................................................................................2
8.2 FEEDING INTO COLLET — Failures ............................................................................2
8.3 BAR FEEDING - Failures ..............................................................................................2
9 PART REPLACEMENT MASTER 865 VERSO ..................................................................1
9.1 FEEDING CHAIN — REPLACEMENT ...........................................................................2
9.2 REPLACEMENT OF THE GUIDE CHANNELS WITH INSERTS WITH
POLYURETHANE GUIDE CHANNELS ................................................................2

INDEX
9.2.1 Disassembly of insert guide channels...............................................................................2
9.2.2 Polyurethane guide channel assembly..............................................................................4
9.2.3 Insert guide channels — Replacement for bar diameter variation..................................8
9.2.4 Insert guide channels — Replacement due to failure.....................................................17
9.3 PLC BATTERY — REPLACEMENT ............................................................................20
9.4 RECOMMENDED SPARE PARTS ..............................................................................21
9.5 DISPOSAL OF THE BAR FEEDER OR PARTS OF IT.......................................................21
10 GUIDE CHANNELS-BAR PUSHER-REVOLVING TIPS MASTER 865 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
10.4 Revolving tips øGR 20÷25 - Table ......................................................................................6
10.5 Revolving tips øGR 32÷45 - Table ......................................................................................7
10.6 Revolving tips øGR 51 70 - Table .......................................................................................9
11 COLLETS MASTER 865 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 COLLET FOR 011 BARS ....................................................................................................10
11.8 COLLET FOR BARS - Table ..............................................................................................10
11.9 PIPE COLLETS 012-077-377..............................................................................................12
11.10 PIPE COLLETS - Table.......................................................................................................12
11.11 EJECTOR 336 .....................................................................................................................15
11.12 EJECTOR — Guide channels ø<30 - Table ......................................................................15
11.13 EJECTOR — Guide channels ø>32 - Table ......................................................................17
11.14 COLLETS FOR BARS 602P ...............................................................................................19
11.15 COLLET FOR BARS - Table ..............................................................................................19
11.16 BORING COLLETS FOR BARS 601P ................................................................................21

INDEX
11.17 BORING COLLETS FOR SQUARE AND HEXAGONAL BARS - Table............................21
11.18 EJECTORS 602P..011 ........................................................................................................23
11.19 EJECTORS —Guide channels ø13÷28 - Table.................................................................23
11.20 PIPE COLLETS 603P..........................................................................................................25
11.21 PIPE COLLETS - Table.......................................................................................................25
11.22 COLLETS FOR BARS 076..................................................................................................27
11.23 COLLET FOR BARS - Table ..............................................................................................27
11.24 COLLETS FOR BARS 381P ...............................................................................................30
11.25 COLLET FOR BARS - Table ..............................................................................................30
11.26 EJECTORS 381P..011 - 381P..021.....................................................................................33
11.27 381P..021 EJECTORS - Guide channels ø33÷46 - Table.................................................33
11.28 381P..011 EJECTORS - Guide channels ø52÷71 - Table.................................................35
11.29 PIPE COLLETS 386P..........................................................................................................37
11.30 PIPE COLLETS - Table.......................................................................................................37
11.31 RINGS FOR COLLETS 078-225 .........................................................................................39
11.32 RINGS FOR COLLETS - Table...........................................................................................39

1 - GENERAL INFORMATION nome caricatore
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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 GLOSSARY AND TERMINOLOGY................................................................................4
1.6 ATTACHMENT LIST ..................................................................................................5

EN
1 - GENERAL INFORMATION nome caricatore
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The operations described in the paragraphs 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 nome caricatore
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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 can apply changes in the model described in this publication at any time
for any technical or business reason. Contact IEMCA service department for
further information.

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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 Base 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 GLOSSARY AND TERMINOLOGY
Some recurrent words in the manual are here described in order to provide a more complete
understanding of their meaning.
Routine maintenance: set of operations necessary to ensure the appropriate operation and
efficiency of the bar feeder. Usually these operations are programmed by the manufacturer who
defines the necessary competence and the assistance procedures.
Extraordinary maintenance: set of operations necessary to ensure the appropriate operation and
efficiency of the bar feeder. These operations are not programmed by the manufacturer and
must be carried out by the maintenance technician.
Expert technician: authorized person chosen among those who have the requirements,
competence and information needed for the installation, operation and unscheduled
maintenance of the bar feeder.

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Expert operator: authorized person chosen among those who have the requirements,
competence and information needed for the installation, operation and scheduled maintenance
of the bar feeder.
Loading axis: axis of the bar coinciding with the spindle axis of the lathe.
Remnant: final ejection portion of the machined bar.
Facing position: position of the bar in the lathe, during the facing phase.
Solenoid valve: is essentially a valve that allows a fluid (liquid or gaseous) to pass through an
opening detected by the same valve; the actuator of the mechanical drive of the valve is
electrically controlled.
Magneto-thermal switch: also called automatic relay, is an electrotechnic device able to stop a
circuit in case of overvoltage.
Threading tool: the tap is a threading device, which can be used manually with the tap wrench
or mechanically fitted to the tap wrench. It kirves the female threads inside the holes for the
internal screw threads and nuts. The thread carried out with the tap wrench is called tapping.
An actuator is a mechanism through which an agent (examples of actuators are the electrical
motors, the hydraulic cylinders, the relays, the electroactive polymers, the pneumatic devices)
acts on the environment. The agent can either be an artificial intelligent agent or any other
self-governing being (human, animal).
1.6 ATTACHMENT LIST
• Spare parts catalogue
• Keyboard instruction manual
• Interface wiring diagram
• CD:
Depliant
Spare parts catalogue
Instruction manual
Operation and maintenance manual
Base wiring diagram
List of customer service centres.

2 - TECHNICAL INFORMATION nome caricatore
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INDEX
2.1 BAR FEEDER GENERAL DESCRIPTION.......................................................................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 - LOCATION AND DESCRIPTION ....................................................11
2.5 VERSION DESCRIPTION .........................................................................................12
2.6 TECHNICAL DATA ..................................................................................................14
2.6.1 Noise levels ...........................................................................................................20
2.7 ACCESSORIES - FOREWORD...................................................................................21
2.7.1 Bush holder device - Description .............................................................................21

EN
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2.1 BAR FEEDER GENERAL DESCRIPTION
The MASTER 880 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.

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2.1.1 Bar feeder - Main components
A Magazine; stores the bars.
B Bar selectors; select the first bar contained in the magazine, so that it can be afterwards
loaded by the lifting devices.
C Bar lifting devices; lift the first bar available in the magazine.
D Guide channels; drive the bar during the machining.
E First feeding carriage; moves the bar forwards until the necessary space for the bar pusher
introduction has been created.
F Bar pusher; pushes the bar during the machining. The collet is fixed on its front end.
G Bar pusher motor drive; moves the bar pusher.
H Feeding chain; transmits the motion from the motor drive to the bar pusher.
L Guide channel opening/closing cylinder.
Y Upper guide channel unlocking.
M Pneumatic bar drop control levers; control the bar during the drop into the guide channels.
N Clamps; hold the bar during the loading and removal from the collet of the bar pusher.
P Facing device; sends a signal during the bar passage.
Q Remnant recovery box; collects the bar remnant.
R Lubrication pump; delivers oil to the guide channels.
S Oil tank; contains the lubricating oil.
T Hand-held keyboard; allows the bar feeder programming and function activation.
U Electric cabinet; houses the electrical control panel.
V Axial displacement; allows moving the bar feeder body away from the lathe.
Z Pneumatic bar drop control cylinder
X Pneumatic clamp cylinder

EN
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2.1.2 Hydraulic system - Main components
The oil performs the following cycle: it is forced by pump (2) of tank (1), it flows into the guide
channels (4) and bush holder device (5) in order to lubricate the bars during the machining.
From these two devices, the oil is gathered in the recovery tank (6) and filtered in the oil tank,
from where it flows again for a new lubrication cycle.