IEMCA VIP 80 Instruction manual

REL. DATA COD.
S/N
VIP 80
MANUAL FOR USE AND MAINTENANCE
GB
1 03/11/99 805005440

REL. DATA COD.
S/N
302.088
GENIUS 112
GENIUS 226
GUÍA OPERATIVA DEL TECLADO
PARA EL TECNICO AUTORIZADO
E
1 29/05/00 227005505

302.028
IEMCA
division of
IGMI S.p.A.
48018 - Faenza (RA) - ITALY
Via Granarolo, 167
Tel. [phone] - Fax. [phone] ufficio commerciale
0546/46224 centralino
TLX 550879
VIP 80
AUTOMATIC
BAR FEEDER
MANUAL FOR USE AND MAINTENANCE
GB

REL. DATA COD.
S/N
302.088
GENIUS 112
GENIUS 226
GUÍA OPERATIVA DEL TECLADO
PARA EL TECNICO AUTORIZADO
E
1 29/05/00 227005505

- 2 -
302.028
1
GENERAL INFORMATION
1.1. MANUAL PURPOSE
...................................... 4
1.2. MANUFACTURER AND MACHINE
IDENTIFICATION
.......................................... 5
1.3. TECHNICAL ASSISTANCE
............................ 5
1.4. ANNEXES ENCLOSED
.................................. 5
2
TECHNICAL SPECIFICATIONS
2.1. DESCRIPTION OF MODELS
.......................... 6
2.2. GENERAL MACHINE DESCRIPTION
.............. 6
2.2.1 Main parts
..................................................... 7
2.3. WORKING CYCLE -
GENERAL DESCRIPTION
............................. 8
2.4. SAFETY DEVICES
...................................... 11
2.5. SAFETY LABELS - POSITION
AND DESCRIPTION
.................................... 11
2.6. TECHNICAL SPECIFICATIONS
.................... 12
2.6.1 Noise levels
................................................. 12
2.7 AXIAL DISPLACEMENT DEVICE
.................. 13
3
SAFETY PROCEDURES - GENERAL
INFORMATION
3.1. SAFETY GENERAL INSTRUCTIONS
............ 14
3.2. HANDLING AND INSTALLATION -
SAFETY PROCEDURES
.............................. 14
3.3. ADJUSTMENTS AND SETTING UP -
SAFETY PROCEDURES
.............................. 14
3.4. USE AND OPERATION -
SAFETY PROCEDURES
.............................. 14
3.5. MACHINE MAINTENANCE -
SAFETY PROCEDURES
.............................. 15
4
HANDLING AND INSTALLATION
4.1. PACKAGING
............................................... 16
4.2. LIFTING
...................................................... 16
4.3. MACHINE SETTING - CHARACTERISTICS
... 18
4.4. PREPARING THE BAR FEEDER FOR
INSTALLATION
........................................... 19
4.5. INSTALLATION - FOREWORD
..................... 20
4.5.1 Positioning
.................................................. 20
4.5.2 Height - Adjustment
...................................... 21
4.5.3 Alignment - Levelling
.................................... 22
4.5.4 Fixing the feeder to the lathe
......................... 22
4.5.5 Bar passage guide - Installation
..................... 23
4.6. PNEUMATIC CONNECTION
........................ 23
4.7. ELECTRIC CONNECTION
........................... 24
4.8. ADDITIONAL PUSH-BUTTON PANEL -
INSTALLATION
........................................... 24
4.9. SELF-LEARNING VALUES -
ENTRY INTO PROGRAM
............................. 24
5
ADJUSTMENTS AND SETUP
5.1. ADJUSTMENT AND SETUP - FOREWORD
... 26
5.2. GENERAL ADJUSTMENTS - FOREWORD
.... 26
5.2.1 Feed chain - Adjustment
............................... 26
5.2.2 Bar pusher working position - Adjustment
....... 27
5.3. ADJUSTMENTS ACCORDING TO
BAR TYPE - FOREWORD
............................ 27
5.3.1 Reduction sleeves - Diameter change-over
..... 27
5.3.2 Magazine inclination - Adjustment
.................. 29
5.3.3 Bar selection - Adjustment
............................ 29
5.3.4 Covering frame - Adjustment
......................... 29
5.3.5 Guide lifting limit switch - Adjustment.
............ 30
5.3.6 Bar pusher - Selection and installation
........... 31
5.3.7 (Optional) Bar passage guide - Adjustment
..... 31
6
USE AND OPERATION
6.1. PUSH-BUTTON PANEL - DESCRIPTION
OF CONTROLS
........................................... 32
6.2. ADDITIONAL PUSH-BUTTON PANEL -
DESCRIPTION OF CONTROLS
.................... 37
6.3. BAR STOCK - CHARACTERISTICS AND
PREPARATION
........................................... 38
6.4. TOOLING AND STARTING THE AUTOMATIC
CYCLE - OPERATION SEQUENCE
.............. 39
6.4.1 Bar magazine - Loading
................................ 39
6.4.2 Starting the automatic cycle
.......................... 40
6.5. FEEDER STOP
........................................... 42
6.6. STARTING THE AUTOMATIC CYCLE FOL-
LOWING MANUAL CYCLE OPERATIONS
..... 42
6.7. STARTING THE AUTOMATIC CYCLE -
RESUMING WORK FOLLOWING A
SWITCHING OFF
....................................... 43
6.8. NDICATOR LIGHTS - DESCRIPTION OF
INDICATION
..................... 44
INDEX
Any operations described in paragraphs preceded by this symbol should be carried out by a skilled operator. All the other ope-
rations may be carried out by either a skilled operator or a professional user.

- 3 -
302.028
7
MACHINE MAINTENANCE
7.1. MAINTENANCE - GENERAL RULES
............ 46
7.2. PERIODIC MAINTENANCE - TABLE
............. 47
7.2.1 Air filter unit - Check
..................................... 47
7.2.2 Revolving tip - Inspection
.............................. 48
7.2.3 Lubricating points
......................................... 49
8
TROUBLES - CAUSES - REMEDIES
8.1. GENERAL TROUBLES
................................ 50
8.2. BAR MAGAZINE - TROUBLES
..................... 50
8.3. BAR FEEDING - TROUBLES
........................ 50
9
PART REPLACEMENT
9.1. FEED CHAIN - REPLACEMENT
................... 52
9.2. CARRIAGE BACK LIMIT SENSOR -
REPLACEMENT
.......................................... 52
9.3. KEYBOARD BATTERY - REPLACEMENT
...... 53
9.4. PLC BATTERY- REPLACEMENT
................. 53
9.5. FEED MOTOR DRIVE - REPLACEMENT
...... 54
9.6. SENSOR OF THE SHORT FEED DOOR -
REPLACEMENT
.......................................... 55
INDEX ANALYTICAL
.................................... 56
INDEX
Any operations described in paragraphs preceded by this symbol should be carried out by a skilled operator. All the other ope-
rations may be carried out by either a skilled operator or a professional user.

- 4 -
302.028
1
1
1
GENERAL INFORMATION
Before carrying out any servicing whatsoever on the
machine , it is of the utmost importance to read this
manual carefully.
1.1. MANUAL PURPOSE
This manual has been written and supplied by the
manufacturer and is integral part of the machine and of
its equipment.
The compliance with the instructions contained herein
ensures the operator and machine safety as well as a
running economy and a longer life of the machine itself.
Information contained herein is aimed both at the
trained operator(1) and skilled(2) engineer.
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 harm, hence it is necessary to pay
the greatest attention.
Caution - Precaution: in order to avoid accidents
or damages to property, suitable measures shall be
adopted.
Information: technical instructions having
particular importance.
(1) Operators in charge of the machine running, having a specific know-
ledge of the field in which the machine is to be used.
(2) Engineers having experience, technical skill and knowledge of the
legislative rules and regulations, who are able to carry out the neces-
sary servicing as well as to detect and avoid dangers when handling,
installing, using and servicing the machine.

GENERAL INFORMATION 1
- 5 -
302.028
1.2. MANUFACTURER AND MACHINE
IDENTIFICATION (fig. 1)
A-Manufacturer’s identification
B-CE conformity marking
C-Year of manufacture
D-Machine model
E-Serial number
F-Feeding voltage
G- Mains frequency
H-Amperage
L-Alternate driving voltage
M- Direct driving voltage
N-Weight.
Always provide the Manufacturer with the above
mentioned specifications in order to obtain information
or whenever ordering spare parts, etc.
1.3. TECHNICAL ASSISTANCE
Whenever necessary, please apply to one of the
Technical Assistance Departments listed in the annex
enclosed herein.
As far as technical servicing relevant to the bar feeder is
concerned, always specify the technical data printed on
the machine nameplate.
1.4. ANNEXES ENCLOSED
– Technical assistance departments list.
– Electric diagram.
– Pneumatic diagram.
– Push-button panel operation guide.
– Instructions for lathe connection.
1
M
G
E
A
LC
28.001 Ec.0
D
F
B
H N

- 6 -
302.028
2
TECHNICAL SPECIFICATIONS
2.1. DESCRIPTION OF MODELS
VIP 80 bar feeders are available in two models, accor-
ding to the max. length of the bar to feed.
(*)
Model supplied upon request and for special
installations only, to be agreed upon from time to
time.
2.2. GENERAL MACHINE DESCRIPTION
The automatic bar feeder VIP 80 is used in the
machine-tooling sector and specifically to
automatically feed a lathe.
It can feed either round, hexagonal or square bars
having a max length contained within the lathe spindle
length.
Its working cycle is handled by an integrated PLC in the
control board, which is able to dialogue with the lathe
control system.
The main digital push-button panel makes programming
easier.
The removable additional push-button panel makes it
possible to control the main functions without any need
to move away from the lathe.
Ejection of bar remnants is obtained through either the
bar pusher feed or the next bar feed.
Changing over from one diameter to another is very
easy and fast. It takes only a few minutes.
The bar feeder has been designed so as to allow quick
change of the spindle reduction sleeves.
Model Type Max. bar length (mm)
VIP 80 14 1400
15 (*) 1560
2
2

TECHNICAL SPECIFICATIONS 2
- 7 -
302.028
2.2.1 Main parts (fig. 1)
A - Magazine
where bars are stored.
B - Bar lifting device
it lifts the first bar and moves it from the magazine
on to the guide channel.
C - Bar selector
it lifts the first bar as this is lifted by the device B.
All the other bars remain in the magazine.
D - Guide
it guides the bar as it is inserted into the lathe
spindle.
E - Stock guide tube lifting/lowering device
it lifts/lowers the stock guide tube.
F - Bar pusher
as a result of the feeding stroke, it pushes bars
into the lathe.
G - Bar pusher lifting/lowering device
it lifts/lowers the bar pusher.
H - Prefeed and feed carriage
it prefeeds and feeds bars.
L - Motor
it powers the carriage H.
M - Main push-button panel
it controls and programs all feeder functions.
N - Additional push-button panel
it makes it possible to control the main functions
without any need to move away from the lathe.
1
28.002 Ec.2
•
P•
•
E
L
H
F
N
M
•
•
•
C
•
A
B
D
G
Q

TECHNICAL SPECIFICATIONS
2
302.028
- 8 -
P - Switch cabinet
it contains the electrical control panel.
Q - Bar passage guide (OPTIONAL)
this device, equipped with a guard, is necessary
whenever there is a considerable gap between the
feeder and the lathe.
It is used to guide the bar while it covers the
distance between the feeder and the lathe, thus
improving bar feeding into the spindle.
2.3. WORKING CYCLE - GENERAL
DESCRIPTION
The automatic control system controls machine
movements according to the following sequence:
–The bar lifting device Alifts the first bar Bin the
magazine. The bar falls into guide C(fig. 2).
–The guide Crises. The axis of the bar Bis
positioned along the spindle axis (fig. 3).
–The prefeed carriage Dinserts the bar Binto the
lathe.
The prefeed carriage strokes back (fig. 4).
2
28.003 Ec.0
A
B
•
C
3
28.004 Ec.0
B
C•
4
28_005_1
•
•
BD

TECHNICAL SPECIFICATIONS 2
- 9 -
302.028
–The guide Csinks (fig. 5).
–The bar pusher Esinks; the bar-pusher axis is
positioned along the spindle axis (fig. 6).
–The bar pusher Eis engaged in the carriage
D(fig. 7).
–The bar pusher E causes the bar Bto move on
according to the lathe impulses until it comes to an
end (fig. 8).
5
28.006 Ec.0
C
6
28.007 Ec.0
E•
7
28_008_1
••
D
E
8
28_009_1
E
B
•
•

TECHNICAL SPECIFICATIONS
2
302.028
- 10 -
–After each feeding, the bar pusher E moves back
from the bar B(fig. 9).
–The bar remnant Fis ejected either directly by the
bar pusher Eor by the next bar Gwhich is fed
on (fig. 10).
–The bar pusher E strokes back and rises (fig. 11).
–The feeder begins a new automatic working cycle.
9
28_010_1
•
•
E
B
10
28_011_1
•
•
E F
GF
•
•
11
28_012_1
•
EE

TECHNICAL SPECIFICATIONS 2
- 11 -
302.028
2.4. SAFETY DEVICES (fig. 12)
A - Emergency button S85;
in an emergency, press it to stop all feeder/lathe
functions.
B - Emergency button S86;
in an emergency, press it to stop all feeder/lathe
functions.
C - Interlocked mobile guard: it is connected to the
microswitch S61.
When the guard is opened, the feeder/lathe func-
tions are disabled.
By closing the guard back, the user can restart the
cycle.
2.5. SAFETY LABELS - POSITION AND
DESCRIPTION (fig. 13)
A-Caution: working parts.
B-Do not remove the safety barriers.
C-Caution: danger of electric contact.
D-Danger of upper limbs crushing.
12
28_013_2
S85 S86 S61
•
C
S61
A-S85
B-S86
13
28_014_2
A B
C D
B
B
C
B
B
B
A
D

TECHNICAL SPECIFICATIONS
2
302.028
- 12 -
2.6. TECHNICAL SPECIFICATIONS (fig. 14)
2.6.1 Noise levels
Usually, the bar feeder does not cause any acoustic
noise during machining, since the bar rotates inside
the lathe spindle.
During the bar feeding, with the bar feeder under normal
conditions, the max. noise peaks average 85 dbA (mea-
surement performed in compliance with the internatio-
nal standards).
Model
14 15
Min. bar diameter ø5 mm
Max. bar diameter ø80 mm
Min. bar length 250 mm
Max. bar length 1400 mm 1560 mm
Magazine capacity (working width) 750 mm
Bar pusher diameter ø12 (10) - 15 (12) - 21 (18) mm
Feeding speed (adjustable) MAX 750 mm/s
Return speed (adjustable) MAX 750 mm/s
Bar change-over time 16s
Input voltage 230/400 Volt
Control voltage 24 Volt D.C.
Installed power 1,5 KW
Air pressure 6 bar
Weight 450 kg
14
28_015_2

TECHNICAL SPECIFICATIONS
2
302.028
- 13 -
2.7. AXIAL DISPLACEMENT DEVICE -
DESCRIPTION (FIG.5)
t allows the feeder to be moved away from the lathe to
allow maintenance, cleaning or any other servicing of
the lathe.
Release and rotate lever Afor conveying.
DANGER - WARNING: Make sure that safety hook B
has passed block C, in order to prevent the bar feeder
from sliding freely over the guides.
To move the bar feeder back to working position, rele-
ase safety hook Band move lever Ato its initial posi-
tion after conveying.
CAUTION: In order to guarantee a good working, keep
axial displacement bars cleaned and lubricated.
5
28_089_0
A
C
B

- 14 -
302.028
3
SAFETY PROCEDURES - GENERAL INFORMATION
3.1. SAFETY GENERAL INSTRUCTIONS
It is of the utmost importance to read carefully this
manual before carrying out any installation, use,
maintenance or other servicing on the machine. The
compliance with the instructions contained herein
ensures safety both of man and machine.
❑Both the operator and skilled engineer in charge
shall keep to their task.
❑Do not tamper with the safety devices for any rea-
son whatsoever.
❑Safety labour regulations issued by each country
authority shall be strictly complied with.
❑IEMCA declines any liability whatsoever for dama-
ges to people or property due to the non-obser-
vance of the above mentioned regulations.
3.2. HANDLING AND INSTALLATION - SAFETY
PROCEDURES
❑Machine shall be handled using suitable means
and methods.
❑People shall not stand underneath a suspended
load, within the crane, lift truck or other suitable
means of lifting or transportation operating range.
❑The working and bar feeding area shall be delimi-
ted in order to prevent collisions between the ope-
rator and transportation or handling means, if any,
either of the materials to be machined or other
material.
❑A proper machine installation, as well as lighting
and cleaning of the area, are of the utmost impor-
tance as far as personal safety is concerned.
❑The electric system connection shall be carried out
by skilled personnel only.
❑Make sure the electric system is earth connected
through a suitable cable.
3.3. ADJUSTMENTS AND SETTING UP -
SAFETY PROCEDURES
❑Carry out the adjustments according to the use
and maintenance manual.
❑Do not change the working parameters to obtain
performances different from those designed and
tested.
❑Do not adjust the machine when it is running
unless otherwise specified in the use and mainte-
nance manual.
❑Do not feed the machine with barstocks having
dimensions different from those recommended by
the manufacturer.
❑Do not use hoses as grips.
3.4. USE AND OPERATION - SAFETY
PROCEDURES
❑The working area around the machine shall always
be kept clean and empty in order to allow an imme-
diate access to the emergency devices, thus
allowing the bar feeding operations without cau-
sing danger and hindrance.
❑Carry out the starting cycle sequence as recom-
mended.
❑Do not introduce hands or other parts near or
inside running parts or energised parts of the
machine.
❑Take off bracelet, watch, ring and tie.
❑Whenever necessary, use strong working 5 finger
gloves, which do not reduce sensitivity and grip-
ping.
❑Use working shoes as well as personal protections
as provided for by the accident prevention regula-
tions in force in every country.
❑Personnel in charge of maintenance shall be infor-
med should the machine fail to work properly.
❑Before starting the machine, make sure that there
is no personnel carrying out maintenance or clea-
ning operations.

SAFETY PROCEDURES - GENERAL INFORMATION 3
- 15 -
302.028
3.5. MACHINE MAINTENANCE - SAFETY
PROCEDURES
❑Non-authorised people are not allowed to carry out
maintenance.
❑Read carefully this manual before carrying out any
maintenance whatsoever.
❑Do not lubricate, repair or adjust the machine
during its working cycle, unless otherwise specified
by this manual.
❑Stop the machine in accordance with the safety
procedures before carrying out lubrication.
❑Do not light the working area with matches, lighters
or torches when servicing the machine using
inflammable fluids.
❑Preserve the exhausted oil in suitable containers
and deliver it to stocking and disposal of polluting
wastes companies.
Do not pollute environment.
❑Use original IEMCA spare parts only.

- 16 -
302.028
4
HANDLING AND INSTALLATION
4.1. PACKAGING (fig. 1)
The machine can come in three different packagings:
A - With no packaging.
B - On a pallet: the feeder is placed on a pallet and
wrapped in protective film.
C - In a case: the feeder is placed in a case and
wrapped in protective film.
4.2. LIFTING
DANGER - WARNING: Lifting and handling operations
should be carried out with suitable equipment by skilled
staff specially trained for this kind of manoeuvres.
According to the type of packaging used, lifting should
be carried out as follows.
A B C
1
28_016_2.bmp
3

HANDLING AND INSTALLATION
4
302.028
- 17 -
❏Lifting with no packaging (fig. 2)
– Install the two round-eye eyebolts Awith threaded
stem (type 1 UNI - ISO 3266 M20).
– Fit a wooden pad B.
– Lift the bar pusher support C to prevent it from being
damaged.
– Use a hook-up lifting device having a suitable
capacity.
❏Lifting with pallet (fig. 3)
Use a hook-up lifting device of suitable capacity.
2
28_017_2.bmp
B
A
C
A
3
28_018_2.bmp