IEMCA Master 80 UP HyperFlexible Page 133 Manual For Use And Maintenance Download

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8 - TROUBLES - CAUSES - SOLUTIONS

Master 80 UP HyperFlexible

8 - Pag. 1 / 1

INDEX

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

Summary of Contents for Master 80 UP HyperFlexible

Page 1: ...od 3840M05440 S N COMPILER Bosi Andrea ON APPROVAL Ragazzini Massimo 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 ...

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Page 3: ...46 698000 Fax 0546 46224 MANUFACTURER IEMCA division of IGMI S p A ADDRESS Via Granarolo 167 48018 Faenza RA ITALY Tel 0546 698000 Fax 0546 46338 0546 46224 TLX 550879 TYPE OF DOCUMENT MANUAL FOR USE AND MAINTENANCE PRODUCT AUTOMATIC BAR FEEDER MODEL Master 80 UP HyperFlexible ...

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Page 5: ...NERAL DESCRIPTION 10 2 2 1 OPERATING CYCLE 10 2 2 2 Magazine Operating cycle 15 2 3 SAFETY DEVICES POSITION AND DESCRIPTION 16 2 3 1 Bar feeder Safety devices 16 2 4 SAFETY PLATES LOCATION AND DESCRIPTION 17 2 5 VERSION DESCRIPTION 18 2 6 TECHNICAL DATA 20 2 6 1 Noise levels 26 2 7 ACCESSORIES FOREWORD 27 2 7 1 Bush holder device Description 27 3 SAFETY GENERAL INFORMATION Master 80 UP HyperFlexib...

Page 6: ...4 4 3 Preliminary positioning 9 4 4 4 Front nose Installation 10 4 4 5 Levelling and alignment 11 4 4 6 Bar feeder fastening 16 4 5 LUBRICATION OIL FILLING 17 4 6 ELECTRICAL CONNECTION 17 4 7 PNEUMATIC DEVICE LAYOUT 18 4 7 1 PNEUMATIC CONNECTION 21 4 7 2 BAR FEEDER HANDLING WITHOUT POWER SUPPLY 21 4 8 SOFTWARE PARAMETERIZATION 22 5 ADJUSTMENT AND SETUP Master 80 UP HyperFlexible 1 5 1 ADJUSTMENT A...

Page 7: ...UTTON PANEL CONTROL DESCRIPTION 9 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 17 6 9 BAR LOADING PROCEDURE 18 6 10 LUBRICATING OIL FLOW ADJUSTMENT 21 6 11 BAR FEEDER STOP 21 6 12 CYCLE PERFORMING MODE IN THE STEP BY STEP FUNCTION 22...

Page 8: ... PARTS 5 9 6 DISPOSAL OF THE BAR FEEDER OR PARTS OF IT 5 10 GUIDE CHANNELS BAR PUSHER REVOLVING TIPS Master 80 UP HyperFlexible 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 81 Table 7 11 COLLETS Master 80 UP HyperFlexible 1 11 1 CONVERSION TABLES 001 3 11 2 HEXAGONAL BARS uni...

Page 9: ... 601P 23 11 17 BORING COLLETS FOR SQUARE AND HEXAGONAL BARS Table 23 11 18 EJECTORS 602P 011 26 11 19 EJECTORS Guide channels ø13 28 Table 26 11 20 PIPE COLLETS 603P 28 11 21 PIPE COLLETS Table 28 11 22 COLLETS FOR BARS 381P 31 11 23 COLLET FOR BARS Table 31 11 24 EJECTORS 381P 011 381P 021 34 11 25 381P 021 EJECTORS Guide channels ø33 46 Table 34 11 26 381P 011 EJECTORS Guide channels ø52 86 Tabl...

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Page 11: ...L INFORMATION Master 80 UP HyperFlexible EN 1 Pag 1 1 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 ...

Page 12: ...ect 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...

Page 13: ...ymbols 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 in...

Page 14: ... 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 part...

Page 15: ...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 ...

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Page 17: ...s 7 2 1 4 Pneumatic system Main components 8 2 2 OPERATING CYCLE GENERAL DESCRIPTION 10 2 2 1 OPERATING CYCLE 10 2 2 2 Magazine Operating cycle 15 2 3 SAFETY DEVICES POSITION AND DESCRIPTION 16 2 3 1 Bar feeder Safety devices 16 2 4 SAFETY PLATES LOCATION AND DESCRIPTION 17 2 5 VERSION DESCRIPTION 18 2 6 TECHNICAL DATA 20 2 6 1 Noise levels 26 2 7 ACCESSORIES FOREWORD 27 2 7 1 Bush holder device D...

Page 18: ...hannel 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 bar feeding position may be determined at ...

Page 19: ...dels MASTER 80 HF UP standard version rack magazine MASTER 80r HF UP reversed version rack magazine When not otherwise specified the texts tables and pictures of this manual refer to the standard version As far as the reversed version is concerned consider that the magazine and the electric cabinet are placed on the opposite side ...

Page 20: ...g 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 fr...

Page 21: ...P REMNANT RECOVERY BOX collects the bar remnant Q LUBRICATION PUMP delivers the lubricating oil to the guide channels R OIL TANK contains the lubricating oil S 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 X PNEUMATIC SOLENOID VALVES Z PNE...

Page 22: ...components A BAR SUPPORT BRACKET supports the bars Thanks to its inclination the bars lean against the elevator uprights B ELEVATOR CARRIAGES move the bars from the magazine to the bar feeder guide channels C ELEVATOR CARRIAGE DRIVE drives the elevator carriages upstroke and downstroke ...

Page 23: ...rms 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 ...

Page 24: ... UNIT F GUIDE CHANNEL PNEUMATIC LOCKING UNIT G GUIDE CHANNEL OPENING UNIT H BAR PUSHER LOCKING TIPS POS Description POS Description 1 FILTER 12 CYLINDER 2 PRESSURE GAUGE 13 SOLENOID VALVE 3 CYLINDER 14 CYLINDER 4 REGULATOR 15 REGULATOR 5 SOLENOID VALVE 16 SOLENOID VALVE 6 CYLINDER 17 CYLINDER 7 REGULATOR 18 SOLENOID VALVE 8 SOLENOID VALVE 19 CYLINDER 9 CYLINDER 20 REGULATOR 10 SOLENOID VALVE 21 SO...

Page 25: ...2 TECHNICAL INFORMATION Master 80 UP HyperFlexible EN 2 Pag 9 9 ...

Page 26: ...der according to the sequence described below The bar pusher A makes bar B move forwards into the lathe until the bars are finished The bar pusher A during the machining phase in fixed points see operation manual Par 80 activates the locking devices to increase rigidity of the bar pusher and decrease vibrations The bar pusher A and remnant C are in their forwards limit stop position ...

Page 27: ...usher A moves forwards and place the remnant on the drop guide T then bar pusher moves backwards the clamps D close and open again for the remnant drop check and finally the remnant drop guide T is lowered and the remnant drops on the remnant conveyor belt E Remnant C is driven to the rear side and dropped in box F A sensor detects the remnant during the path if the remnant is still in the bar pus...

Page 28: ...rFlexible 2 Pag 12 12 The upper guide channels G are lifted together with the bar pusher H and also the bar drop control levers L are lifted The elevator carriages M lower the bar N drops on the lower guide channels P accompanied by the levers L ...

Page 29: ...erFlexible EN 2 Pag 13 13 The first feeding carriage Q stroke begins When the first feeding carriage Q completes its stroke the required space for bar pusher introduction has been created The first feeding carriage performs the return stroke ...

Page 30: ...per guide channels N close the bar pusher M 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 perform the facing stroke A new automatic working cycle is started ...

Page 31: ...sequence described below The elevator carriages A are in the highest position and support bar B which is ready to be unloaded in the guide channels C The elevator carriages A lower and let the bar B fall into the guide channels C The carriages continue lowering until they reach bar D and bring it in the highest position The cycle goes on until the bars are finished ...

Page 32: ...ned the bar feeder and lathe functions are suspended When the guard is closed the user can start the cycle again C FIXED GUARD made of transparent material to allow the visual detection of the bar drop area in the guide channels D FIXED GUARD hinders an accidental access to the moving components E FIXED GUARD prevents an accidental access to the bush holder device area F MAIN SWITCH disconnects th...

Page 33: ... Crushing danger of the upper limbs B Warning danger of electric contact C Pay attention to the moving parts D Warning it is forbidden to climb on the machine E Wear safety gloves and shoes Do not manually lift loads exceeding 15 kg F Warning danger of material falling G Warning fix the bar feeder to the ground ...

Page 34: ...80 UP HyperFlexible 2 Pag 18 18 2 5 VERSION DESCRIPTION Bar length Model Version Maximum length mm ft A Minimum length mm ft B Intermediate feelers MASTER 80 UP HyperFlex 33 3300 10 8 2000 6 5 38 3800 12 4 2500 8 2 43 4300 14 1 3000 9 8 ...

Page 35: ...yperFlexible EN 2 Pag 19 19 Max bar pusher extension Model Version Version A Max extension mm MASTER 80 UP HyperFlex 33 38 43 N 1045 L 1295 33 38 43 63 LL 1545 38 43 XLL 1795 38 43 XXL 2045 A01PF_MUM_02_05_04 C B A B Revolving tip C Nipple ...

Page 36: ...EN 2 TECHNICAL INFORMATION Master 80 UP HyperFlexible 2 Pag 20 20 2 6 TECHNICAL DATA ...

Page 37: ...ICAL INFORMATION Master 80 UP HyperFlexible EN 2 Pag 21 21 Overall dimensions Model Version A mm B mm C mm D mm E mm MASTER 80 UP HyperFlex 33 4330 3640 860 1250 800 38 4830 4140 1110 800 43 5330 4640 1360 800 ...

Page 38: ...4 1 ft Magazine capacity working width 600mm ex n 60 bars of ø 10mm ex n 7 bars of ø 80mm Maximum bar weight 120 kg Adjustable feeding speed 150 mm sec Adjustable return speed 950 mm sec Maximum remnant length ø 8 65 mm 400 mm ø 66 80 mm 250 mm Minimum remnant length 110 mm Bar change time with 3 000 mm bar 40 sec according to the bar ø Power supply voltage 230 400 Volt Mains frequency 50 60 Hz Co...

Page 39: ...is height Model Screw position XB mm High base XA mm Low base MASTER 80 UP HyperFlex 2 1221 1255 906 940 3 1256 1290 941 975 4 1391 1325 976 1010 5 1326 1360 1011 1045 6 1361 1395 1046 1080 7 1396 1430 1081 1115 8 1431 1465 1116 1150 9 1466 1500 1151 1185 10 1501 1535 1186 1220 ...

Page 40: ...25 33 32 10 29 31 36 35 10 32 35 38 37 11 35 37 43 42 12 39 42 46 45 15 42 45 52 51 15 20 47 51 57 56 15 20 52 55 61 60 15 20 56 59 66 65 15 20 61 64 69 68 15 20 63 67 71 70 15 20 65 69 73 72 15 20 67 71 76 75 15 20 70 74 81 80 15 20 75 79 86 85 15 20 80 80 Valid also for prepared bars or normal bars machined with front remnant ejection Ø 20mm brass WARNING CAUTION the collet external diameter sho...

Page 41: ...S 150 Agip Acer 150 Api Api Cis 150 Aral Aral Degol Tu 150 Castrol Magna 150 Chevron Circulating Oil 150 Elf Movixa 150 Esso Nuto 150 Fina Solina 150 IP IP Hermea 150 Klüber Crucolan 150 Olio FIAT Daphne Hidrobak 150 HL Roloil Arm V 150 Shell Vitrea 150 Tellus C 150 Tamoil Hydralic Oil 100 Texaco Rando oil HD 150 Total Cortis 150 Oil quantity 80 litres ...

Page 42: ...bar diameter use of a front guide bush of suitable diameter if supplied use of bars with a straightness within the set limits maximum deflection in mm equal to 0 5 of the bar length use of a spindle liner having the same diameter as the bar feeder guide channel diameter spindle rotation speed suitable for the material to be machined as to the bar feeder use of oil having features suitable for the ...

Page 43: ...ce may be used by only changing the diameter of the half bushings to greatly extend the range of diameters which can be machined without having to replace the guide channel OPERATION When the bar is dropped into the guide channel the two half bushes are open The closing phase is controlled by a pneumatic cylinder when the bar feeder has completed the bar loading cycle The oil flow for the machined...

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Page 45: ...RAL 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 DECLARATION OF CONFORMITY 6 3 7 General Description of Supply 7 3 8 RESIDUAL RISKS 8 3 9 FORESEEABLE MISUSES 13 ...

Page 46: ...e constant compliance with the instructions in this manual ensures the operator safety The user and expert operator must perform their specific tasks only Do not tamper with the safety devices for any reason whatsoever Strictly comply with the health and safety regulations at work issued by the relevant authorities in each country IEMCA declines any liability for injury to persons or damage to pro...

Page 47: ...r lighting and cleanliness of the working environment are of the utmost importance for personal safety The connection to the electrical installation must be carried out by skilled personnel only Make sure that the electrical installation is connected to an efficient earthing system by means of an appropriate cable 3 3 ADJUSTMENTS AND SETUP Safety Carry out the adjustments as described in the opera...

Page 48: ... cycle as recommended Do not put hands or anything else near or inside the moving parts or parts in tension Do not wear bracelets watches rings and ties If necessary use strong work gloves with five fingers which do not reduce the grip sensitivity or power Wear work shoes as well as personal protection equipment as provided for by the safety regulations in force in all countries Inform the mainten...

Page 49: ... in accordance with the foreseen procedures before carrying out lubrication or other operations Do not use matches lighters or torches as lightning means during operations with inflammable fluids Keep drain oil in suitable containers and deliver it to companies specialized in the storage and disposal of polluting waste products Avoid environmental pollution Use original IEMCA spare parts only Cons...

Page 50: ...that the machine AUTOMATIC BAR FEEDER is in compliance with the requirements of 2006 42 EC regulation and with the national implementing regulations is in compliance with the following European regulations o 2006 95 EC regulation low tension o 2004 108 EC regulation electromagnetic compatibility Otherwise he declares that the person in charge for the technical issue editing is Mr Giampaolo Morandi...

Page 51: ...request Applicable Safety Regulation According to Directive 2006 42 EC article 2B the bar feeder is an interchangeable equipment and is supplied with the appropriate safety devices Together with the supply you will find the EC declaration of conformity in compliance with the above mentioned Directive The list of the safety devices is shown in section 2 paragraph 2 3 of this manual The bar feeder s...

Page 52: ...ollow these indications wait 60 sec until the capacitor is discharged remove the three phase voltage by operating on the disconnecting device upstream from the supply line or disconnect the interface connector FLUID LEAKAGE RISK It is forbidden to top up the lubricating oil tank while the oil pump is running Do not let the oil or coolant leak from the lathe out to the bar feeder Here are some exam...

Page 53: ...lacement or maintenance work inside the bushing holding equipment should only be performed after switching the bar feeder off 2 With the bar feeder in automatic mode there is a potential crushing risk if you reach your hands and arms into the guide channel area bar pusher movement ...

Page 54: ...CNC sliding headstock lathes 3 The technician will perform installation without securing the bar feeder to the ground However in the report to the customer certifying that installation has been completed he will state that the customer requested that the machine be not secured to the ground BREAKING RISK DURING OPERATION 1 After performing scheduled or unscheduled maintenance work remove any forei...

Page 55: ... referenced above Stop the oil flow using the cock provided put the bar feeder in manual mode and switch off the oil pump by pressing the key on the keyboard ACCESS TO THE INTERVENTION POINTS USED FOR MAINTENANCE 1 Press the stop button before moving the bar pusher forward using the crank 2 During the work phase if protection guards have been removed it is strictly forbidden to insert the crank in...

Page 56: ...EQUENCE OF PHASES It is very important that the operator knows the sequence of the bar feeder work phases These can be found in the Instruction Manual supplied with the machine DIFFERENTIAL CURRENT DEVICE UPSTREAM FROM THE MACHINE USED TO PREVENT HAZARDOUS CONDITIONS IN CASE OF A FAILURE Make sure that the bar feeder is powered by a three phase power supply protected through a differential switch ...

Page 57: ...ness than the one recommended by the manufacturer Do not load bars with sizes or shapes different than those recommended by the manufacturer Do not interfere with any body part on the bar feed axis Do not approach the bar feeder with open flames or very hot objects for examples cigarettes Danger of oil flammability Do not draw electricity or pneumatic energy from the bar feeder to power other mach...

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Page 59: ...RES 5 4 4 BAR FEEDER INSTALLATION FOREWORD 5 4 4 1 Backing plates and support feet Installation 6 4 4 2 Height Adjustment 7 4 4 3 Preliminary positioning 9 4 4 4 Front nose Installation 10 4 4 5 Levelling and alignment 11 4 4 6 Bar feeder fastening 16 4 5 LUBRICATION OIL FILLING 17 4 6 ELECTRICAL CONNECTION 17 4 7 PNEUMATIC DEVICE LAYOUT 18 4 7 1 PNEUMATIC CONNECTION 21 4 7 2 BAR FEEDER HANDLING W...

Page 60: ...aging A WITHOUT PACKAGING B WITH PALLET the bar feeder is placed on a pallet and wrapped with protective film C WITH CRATE the bar feeder is contained in a crate and wrapped with protective film 4 2 LIFTING DANGER WARNING lifting and handling shall be carried out using suitable means and performed by skilled personnel only ...

Page 61: ...out packaging Lifting Fit the two lifting brackets A at a distance of 2 710 mm from each other with magazine L 33 Use a hook lifting device of adequate capacity ELECTRIC CABINET Install two round eyebolts A with threaded stem 1 UNI ISO3266 M10 Use a hook lifting device of adequate capacity ...

Page 62: ...TION Master 80 UP HyperFlexible 4 Pag 4 4 4 2 2 Bar feeder with pallet Lifting Use a hook type lifting device of suitable load capacity 4 2 3 Bar feeder with crate Lifting Use a hook type lifting device of suitable load capacity ...

Page 63: ... transport travelling near the bar feeder The selected area should be illuminated and provided with an electric and pneumatic power supply socket During operation the bar feeder will release small amounts of oil mist Install the bar feeder in a suitably ventilated area The bar feeder has not been designed for use in an explosive atmosphere Model Version A mm E mm MASTER 80 UP HyperFlex 33 4330 800...

Page 64: ... AND INSTALLATION Master 80 UP HyperFlexible 4 Pag 6 6 4 4 1 Backing plates and support feet Installation Position the bar feeder next to the lathe Lift it and install the plates in the positions shown in the figure ...

Page 65: ... height However if an adjustment is needed proceed as follows stretch the lifting chains and remove screws A in the front and rear bases remove all the brackets B of the magazine feet lift or lower the bar feeder according to the necessary X value see table The height of the working axis may be adjusted according to the data indicated in the table of the Technical data section ...

Page 66: ...EN 4 HANDLING AND INSTALLATION Master 80 UP HyperFlexible 4 Pag 8 8 tighten screws A and fit brackets B again ...

Page 67: ...ed and moving dimensions of both machines The coupling distance B should not exceed the bar pusher maximum extension A 1 Fixed headstock or sliding rest lathe 2 Sliding headstock CNC lathe 3 Sliding headstock cam lathe Max bar pusher extension Model Version Version A Max extension mm MASTER 80 UP HyperFlex 33 38 43 N 1100 L 1350 LL 1600 XLL 1850 XXL 2100 ...

Page 68: ...t of the working axis and the alignment with the lathe by turning the screws of the support feet 4 4 4 Front nose Installation Install the front nose A in the bush holder device Install the oil recovery tank B Connect the lubrication pipe C to the front nose Connect the drain pipe D to the tank ...

Page 69: ...herefore this operation should be carried out with the greatest accuracy by experienced personnel WARNING CAUTION an error during the alignment may be the major cause of a bad operation of the bar feeder and of its consequent damage PRELIMINARY PROCEDURE Open the upper guard To bring the bar pusher to its backward limit stop press the or button in manual mode on the handheld keyboard ...

Page 70: ...e 4 Pag 12 12 Press and to select the semiautomatic function Press several times until the upper guide channels open GUIDE CHANNEL FULL OPENING should appear on the display Remove the first and last lower guide channels by pressing on the pressure couplings ...

Page 71: ...Master 80 UP HyperFlexible EN 4 Pag 13 13 LEVELLING Rest the special shelf on the supports Check the levelling by positioning the level crosswise and lengthwise Carry out the required corrections by turning the support feet screws ...

Page 72: ...k with a sliding caliper the alignment near the bush C and the spindle D use a tolerance of 0 15 mm in the four directions It is also possible to carry out the alignment by placing a bar in the guide channels Proceed as follows prepare a perfectly straight ground bar with an external diameter equal to the maximum spindle bar passage and with a length equal to the double coupling distance see B in ...

Page 73: ...ar feeder with either the thread or the bar any required corrections should be carried out Adjust the height by turning the support feet screws During this phase any adjustment carried out during the levelling phase should be preserved therefore in most cases it is necessary to find the correct adjustment of the bar feeder position ...

Page 74: ...ay be the major cause of a bad operation of the bar feeder and of its consequent damage Drill the floor and fix the backing plates with expansion plugs Use the higher number of expansion plugs to ensure a correct fastening Check the levelling and alignment once more Remove all the equipment used for the levelling and alignment phases and restore the initial bar feeder conditions ...

Page 75: ...ICAL CONNECTION DANGER WARNING this type of operation should only be entrusted to skilled personnel with precise technical competence and specific abilities to comply with the applicable standards and regulations in force The feeder must be electrically connected to the lathe which in turn must be connected to the electrical installation in compliance with the applicable regulations in force The b...

Page 76: ...ide channel locking C4 Cylinder Enables the guide channel upstroke and downstroke C5 Cylinder Controls the bar drop control devices upstroke and downstroke C6 Cylinder Resets the short feed gate C7 Cylinder Enables the bush opening and closing C8 Cylinder Enables the bar pusher locking A142 Solenoid valve unit Cylinder or piston control device see description Solenoid valve box S1241 Distributor p...

Page 77: ...Clamp control solenoid valve Clamp closing Pos 6 Guide channel unlocking control device solenoid valve Guide channel unlock Pos 7 Remnant drop feeding control solenoid valve Remnant drop downstroke Pos 8 Flag control solenoid valve Facing flag upstroke Pos 9 Bar pusher locking control device solenoid valve Bar pusher locking Pos 10 Bar pusher locking control device solenoid valve Bar pusher lockin...

Page 78: ...EN 4 HANDLING AND INSTALLATION Master 80 UP HyperFlexible 4 Pag 20 20 INFORMATION the solenoid valves from position n 9 to position n 14 are used according to the bar feeder configuration ...

Page 79: ...ual 4 7 2 BAR FEEDER HANDLING WITHOUT POWER SUPPLY Without power supply or in case of an emergency it is possible to move the pneumatic units using the solenoid valves manually By means of a small screwdriver turn switch A to position 1 With the same tool turn switches B placed on each solenoid valve to move the unit INFORMATION For the movement description of each solenoid valve refer to the Pneu...

Page 80: ...exible 4 Pag 22 22 4 8 SOFTWARE PARAMETERIZATION The bar feeder software should be correctly parameterized according to the working needs and the lathe type For further information on how to carry out this operation check the Keyboard instruction manual ...

Page 81: ...tment 4 5 2 3 Elevator carriage chains Adjustment 4 5 3 BAR FEEDER SETUP 5 5 3 1 Guide channels half bushes bar pusher and collet Replacement 5 5 3 2 BAR PUSHER REPLACEMENT PROCEDURE 14 5 3 3 Remnant passage door spring Adjustment 16 5 3 4 REMNANT DROP CHUTE ENABLING 17 5 4 MAGAZINE SETUP 18 5 4 1 Bar supporting bracket Setup 18 5 4 2 Elevator carriage drive Adjustment 21 5 4 3 Elevator carriages ...

Page 82: ... life also adjustments depending on the bar dimensions and the magazine type 5 2 GENERAL ADJUSTMENTS FOREWORD All the necessary adjustments for correct bar feeder operation are included They may become necessary for maintenance troubleshooting or component replacement 5 2 1 Feeding chain Adjustment Remove the screw E lower the rear lever and move the bar feeder body backwards WARNING CAUTION befor...

Page 83: ... both screws A and adjust the chain tension by turning screw B Restore the bar feeder initial operating conditions WARNING CAUTION Perform the chain adjustment by means of a torque wrench tighten screw B by setting the torque to 4N meter then tighten both fixing screws A ...

Page 84: ...ust the conveyor belt tension through screws B INFORMATION screw or unscrew the right and left screws by making the same number of turns Tighten the screws A If during operation the conveyor belt does not turn in a centred way it will be necessary to adjust the centring by using one of the two screws B 5 2 3 Elevator carriage chains Adjustment Loosen screw A Act on screw B to adjust the chain tens...

Page 85: ...on the machine Refer to the Guide channel bar pusher bar and pipe diameter table in section 2 5 3 1 Guide channels half bushes bar pusher and collet Replacement Press to start the bar feeder press and to select the semiautomatic function Press several times until the upper guide channels open GUIDE CHANNEL FULL OPENING should appear on the display Press and open the upper guard ...

Page 86: ...ADJUSTMENT AND SETUP Master 80 UP HyperFlexible 5 Pag 6 6 Remove the bar pusher from both supports For the bar pusher replacement refer to the next section Disassemble the first feeding pin B from the flag A ...

Page 87: ...5 ADJUSTMENT AND SETUP Master 80 UP HyperFlexible EN 5 Pag 7 7 Remove the lower and upper guide channels Replace the bar pusher supports with those of new diameter ...

Page 88: ...power the lathe off Remove the oil recovery device C and sleeve D Lower spring G and remove cover F completely open the two half bushings by manually turning shaft E and remove the lower half bushing Close the upper half bushing by turning the shaft again then replace it Turn the shaft and fit the lower half bushing Close the half bushes completely and install the cover E A01PF_MUM_05_03_00 ...

Page 89: ...meter if necessary Assemble sleeve D of the new diameter and the oil recovery C Move the bar feeder body forwards and lift the rear lever turn screw E clockwise to block the lever WARNING CAUTION gradually bring the bar feeder body up to the stop placed on the tank thereby eliminating the risk of damaging the displacement device A01PF_MUM_05_03_01 E ...

Page 90: ...ameter INFORMATION Warning follow the correct assembly direction of the guide channels WARNING CAUTION Use the specific screws allowing to lock the guide channels The screws have a printed code and can be classified into two types Upper guide channel fastening screws 380010951 Lower guide channel fastening screws 380010941 ...

Page 91: ... bar diameter and profile see GUIDE CHANNELS BAR PUSHER REVOLVING TIPS and COLLETS section INFORMATION contact IEMCA service department for further information WARNING CAUTION At every collet change model 381p 381p 011 381p 021 e 386p it is necessary to install the grub screw H and the counter screw L ...

Page 92: ...iameter Install the collet in the bar pusher and make sure that the rings are riveted in their special recess to prevent accidental loosening of the collet and or its connection Assemble the first feeding pin B of the new diameter on the flag A Insert the bar pusher into both supports Properly position the bar pusher in the axial direction so that F groove matches support G ...

Page 93: ... occurs correctly WARNING CAUTION the above mentioned positioning has to be always assured Therefore during the setup or maintenance operations if the bar pusher is struck involuntarily it has to be correctly repositioned Press the start buttons together with to close the guide channels The machine is now ready to load the bar Perform a cycle in the STEP by STEP function INFORMATION Warning follow...

Page 94: ...r pusher replacement In particular by pressing the bar pusher is positioned past the clamp device the guide channels open the bar pusher moves to the completely backwards position and the bar drop control devices are lifted allowing for the bar pusher removal INFORMATION If during the above mentioned operations is released the procedure will stop By pressing the button again the procedure will sta...

Page 95: ...5 Close the bar feeder guard reset the start button pupa_boss _avvio 1 enter manual mode and by pressing move the bar pusher forwards until the clamp position is exceeded of at least 200 mm Close the guide channels and Restore the machining cycle of the bar feeder ...

Page 96: ...esistance so that the door may intercept the detection sensor The bar feeder is normally supplied with the spring adjusted for large diameter bars with small diameter bars it could be necessary to reduce the spring preload proceeding as follows Remove the lower guide channel in correspondence to the door Adjust the preload of spring A by turning nuts B Restore the bar feeder initial operating cond...

Page 97: ... 5 Pag 17 17 5 3 4 REMNANT DROP CHUTE ENABLING If a remnant does not drop onto the remnant conveyor belt after the guide drop T parameter 45 can be enabled see description in the instruction manual so that the guide starts vibrating and the remnant drops ...

Page 98: ...5 ADJUSTMENT AND SETUP Master 80 UP HyperFlexible 5 Pag 18 18 5 4 MAGAZINE SETUP 5 4 1 Bar supporting bracket Setup Adjust the inclination of the bar supporting bracket Move the supporting bracket upwards ...

Page 99: ...TMENT AND SETUP Master 80 UP HyperFlexible EN 5 Pag 19 19 Remove the bracket crosswise from left to right Move the supporting bracket downwards and reposition the pin by moving it crosswise from left to right ...

Page 100: ...special profiles in position Adjust as follows install the containment bracket inserting pin D in the special hole loosen screw E and lift the bracket position two spacers slightly thicker approx 0 5 mm than the diameters of the bars to be machined under the bracket keep the bracket pressed against the spacers and tighten screw E adjust the position of push rod F so as to leave the necessary space...

Page 101: ...d for whatever reason Adjust as follows Loosen screw A tighten or loosen ring nut B tighten screw A WARNING CAUTION do not screw the ring nut too much the joint could be locked 5 4 3 Elevator carriages Setup Adjust the position of the bar gripping lever A according to the bar diameter and section Adjust as follows bring the elevator carriages at about half stroke by means of selector switch B to m...

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Page 103: ...PTION 9 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 17 6 9 BAR LOADING PROCEDURE 18 6 10 LUBRICATING OIL FLOW ADJUSTMENT 21 6 11 BAR FEEDER STOP 21 6 12 CYCLE PERFORMING MODE IN THE STEP BY STEP FUNCTION 22 ...

Page 104: ...ly start the bar feeder even when the Lathe MAN AUT signal is in Manual mode INFORMATION When the bar feeder is in Automatic mode the bar feeding is possible only when the Lathe MAN AUT signal is in Automatic mode INFORMATION By pressing the Manual mode button on the handheld keyboard it is possible to prevent the bar feeder Automatic start by the lathe ...

Page 105: ...f both the electrical and handheld keyboard 1 controls 2 MAIN SWITCH turns the power supply on and off Position 0 OFF the machine is not powered Position I ON the machine is powered 3 EMERGENCY STOP PUSH BUTTON stops the bar feeder in case of emergency For restart release the push button manually ...

Page 106: ...EN 6 USE AND OPERATION Master 80 UP HyperFlexible 6 Pag 4 4 ...

Page 107: ...rriage starts moving towards the BAR FEEDER ZERO SETTING position WARNING CAUTION List of causes that require to carry out the 0 Axis in manual mode Carrying out the manual 0 Axis periodically is recommended If the bar pusher axis is moved by means of the crank with the bar feeder powered off no power supply If the feeding chain is tightened by means of the mechanical chain tightener see Operation...

Page 108: ...pen 17 Lifts and lowers the pneumatic bar drop control devices the LED is on when the devices are in the bottom position 18 Errors reset button 19 Bar feeder stop button red press this button to stop the bar feeder 20 Remnant detection disabling button white light Press the button to feed a new bar without the detection of bar remnant in the bar pusher collet 21 Half bush opening and closing butto...

Page 109: ... 25 Multifunction Sets the numerical value Opens the guide channels Push both start buttons and then the key release both buttons and the key only when the movement is finished 26 Multifunction Sets the numerical value Closes the guide channels Push both start buttons and then the key release both buttons and the key only when the movement is finished 27 Multifunction Sets the numerical value Reca...

Page 110: ...erical value Moves the bar pusher at a low speed 31 It moves the bar pusher at high speed 32 Multifunction Stops the selection function Restores the value prior to the non confirmed modification 33 Multifunction Sets the font Turns on off the oil pump Press to turn on the pump and press again to turn it off 34 Sets the numerical value 35 Confirms the entered data 36 Sets the numerical value ...

Page 111: ...ain only after the button has been manually released 2 Selector switch for setting the magazine in the manual or automatic mode position 0 the magazine is preset for the manual function position 1 the magazine is preset for the automatic function 3 Selector switch for controlling the elevator carriages upstroke and downstroke position Ï elevator carriages upstroke position Ð elevator carriages dow...

Page 112: ...n manual mode BLINKING ORANGE LIGHT indicates that the magazine is open OPTIONAL FIXED GREEN LIGHT indicates that the bar feeder is in the automatic mode FIXED RED LIGHT indicates that the bar feeder is not operating or that it is in the manual mode OPTIONAL BLINKING BLUE LIGHT the bar feeder is carrying out the bar change FIXED BLUE LIGHT indicates that the PLC battery is exhausted OPTIONAL ...

Page 113: ...he lubricating oil flow 6 6 BARS TO BE MACHINED FEATURES AND PREPARATION WARNING CAUTION do not insert bars having different sizes than the ones set by the manufacturer For maximum length of the bar see section VERSION DESCRIPTION in Chapter 2 INFORMATION the bar must not have a straightness defect above 0 5 per 1 000 Please find hereafter some advices to optimise the bar feeder performances Usual...

Page 114: ...igure If bars with front remnant ejection have to be machined we advise to chamfer the bar rear end as shown in the figure When machining bars having a diameter equal to or only slightly smaller than the bar pusher diameter it is necessary to turn the bar rear ends diameter D should be suitable for the collet installed in the bar pusher PIPES If pipes are to be machined the rear end of the pipe mu...

Page 115: ...x Quality 0 25 mm Good 0 25 S max 0 5 mm Average 0 5 mm Problematic In order to obtain a reliable value it is necessary to repeat the measurements on the whole bar length by positioning it on a series of supports at a distance of 500 mm from each other and comparing the values between the different prisms INFORMATION The bar straightness is obviously proportional to the rigidity of the material an...

Page 116: ... Rotate the bar on itself and carry out the measurement on a bush external to both V supports INFORMATION The use of the bar feeder for polygonal bar machining hexagonal square bars etc is allowed accepting that this will lead to higher wear of the guide channel in comparison to round bars bar rotation speed decrease in comparison to round bars The higher wear of the guide channel is due to the sh...

Page 117: ...lift weights exceeding those foreseen by the applicable regulations in force ask for help if necessary WARNING CAUTION wear personal protections according to the regulations in force MAGAZINE If the bar containment brackets are installed remove them from their housing and make them turn of 90 Place the bars on the rack ...

Page 118: ...ble 6 Pag 16 16 Rotate the selector switch A from 0 to 1 magazine in automatic mode 6 7 1 Empty magazine OPTIONAL Sensor B detects the presence of the bar in the magazine the orange light blinks to signal that the magazine is empty see section 6 4 ...

Page 119: ...bar feeder Press to select the manual mode Carry out a bar feeder zero setting in the following way press the start buttons and INFORMATION The zero axis can be performed with open or closed guide channels Before performing the zero axis make sure the bar pusher is not in the back limit stop position Load one bar in the guide channels and start the automatic cycle ...

Page 120: ...PENING AFTER REMOVAL Press phase REMNANT DROP FEEDING Press phase BAR PUSHER RETURN AFTER REMNANT DROP Press phase CLAMP CLOSING DROP CONTROL Press phase CLAMP OPENING AFTER DROP CONTROL Press and to select the SEMIAUTOMATIC function Press phase ZERO AXIS Press phase GUIDE FULL OPENING Press phase REMNANT DROP Press phase BAR DROP CONTROL DEVICES UPWARDS SEMIAUTOMATIC Procedure MANUAL Procedure ...

Page 121: ...he guide channels that has prevented the short feed gate resetting Press to cause the bar to drop from the magazine and appoggiare agli accompagnatori Press Phase BAR LOADING Press Phase BAR FIRST FEEDING Press Phase CARRIAGE RETURN SEMIAUTOMATIC procedure Press Phase GUIDE AND CLAMP FULL CLOSING Press Phase BAR INTRO INTO COLLET Press Phase CLAMP WORKING POSITION Press Phase FACING ...

Page 122: ...r 80 UP HyperFlexible 6 Pag 20 20 Push to raise the bar drop control device Press to cause the bar to drop from the magazine and appoggiare agli accompagnatori Push for about 2 secs to activate AUTOMATIC mode MANUAL Procedure Push ...

Page 123: ...TOP BAR FEEDER EMERGENCY STOP WARNING CAUTION if the emergency stop is activated whilst the lathe is working before restarting the machining cycle check that no dangerous conditions arose due to the sudden stop Example if the tool was removing chips before restarting the lathe distance the tool from the piece To stop the bar feeder in emergency press one of the emergency buttons of the bar feeder ...

Page 124: ...as for instance to check a complete bar change cycle to check the bar feeder mechanics etc Procedure press to start the bar feeder make sure that the remnant drop device is closed otherwise press and to close it press and to select the semiautomatic function press and the bar feeder performs the first step press and the bar feeder performs the second step and so on ...

Page 125: ...Flexible EN 7 Pag 1 1 INDEX 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 5 7 2 3 Oil filter Cleaning 6 7 2 4 Air filter unit Check 7 7 3 LUBRICATION POINT DIAGRAM 8 ...

Page 126: ...s recommended as it increases the operator safety as well Do not use petrol or solvents which would damage the painted and transparent parts the cable sheaths etc INFORMATION oxidation can damage metal parts and electric equipment To protect the bar feeder during long inactivity periods disconnect it from the mains voltage remove the compressed air and cover it with a cloth of suitable material An...

Page 127: ...7 BAR FEEDER MAINTENANCE Master 80 UP HyperFlexible EN 7 Pag 3 3 7 2 SCHEDULED MAINTENANCE Scheduled maintenance ...

Page 128: ...check WARNING CAUTION wear personal protections according to the regulations in force Wait until the bar feeder has been off for at least 6 hours Check the level by means of the indicator A Remove cover B and pour the oil directly in the tank to fill up if necessary Oil features Class C CKB 150 ...

Page 129: ...ON store drain oil in special containers to be delivered to companies specialised in pollutant disposal and storage Avoid environment pollution Remove cover A Drain the tank using an auxiliary pump Clean the tank bottom and the pump suction system For the loading pour the oil directly in the tank and check the level through the indicator B Oil features Class C CKB 150 quantity 80 l ...

Page 130: ... filter Cleaning WARNING CAUTION wear personal protections according to the regulations in force Wait until the bar feeder has been off for at least 6 hours Remove cover A Remove filter B and clean the filtering mesh Replace the filter and cover in their respective locations ...

Page 131: ...e switch set to a pressure of 4 5 bar To adjust the pressure switch proceed as follows remove the pressure gauge glass protection turn the adjusting screw D counter clockwise to increase pressure or clockwise to decrease it once finished replace the pressure gauge glass protection WARNING CAUTION should the pressure switch pointer show a Pressure 0 do not absolutely turn the adjusting screw D cloc...

Page 132: ...EN 7 BAR FEEDER MAINTENANCE Master 80 UP HyperFlexible 7 Pag 8 8 7 3 LUBRICATION POINT DIAGRAM Oil ...

Page 133: ...CAUSES SOLUTIONS Master 80 UP HyperFlexible EN 8 Pag 1 1 INDEX 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 ...

Page 134: ...EN 8 TROUBLES CAUSES SOLUTIONS Master 80 UP HyperFlexible 8 Pag 2 2 ...

Page 135: ... has been reset but the automatic cycle will not start No lathe signal Check the electrical connection with the lathe The pneumatic devices do not respond to controls No air Check the air system The first feeding and feeding are stopped unexpectedly Motor thermal circuit breaker burnt Reset the motor circuit breaker with the special buttons 8 2 ELEVATOR CARRIAGES FAILURES TROUBLES CAUSES SOLUTIONS...

Page 136: ...icult bar introduction into lathe spindle Bar feeder not aligned with lathe Check and correct the alignment Difficult bar introduction into lathe collet Excessive rag on bar fore end Trim rag before feeding 8 5 REMNANT MOVEMENT FAILURES TROUBLES CAUSES SOLUTIONS Remnant cannot be ejected Remnant conveyor belt is not adjusted at optimal tension and therefore drive the shaft slides not being able to...

Page 137: ...9 Pag 1 1 INDEX 9 1 FEEDING CHAIN REPLACEMENT 2 9 2 ELEVATOR CARRIAGE DRIVE SAFETY JOINT REPLACEMENT 2 9 3 REMNANT CONVEYOR BELT REPLACEMENT 3 9 4 PLC BATTERY REPLACEMENT 4 9 5 RECOMMENDED SPARE PARTS 5 9 6 DISPOSAL OF THE BAR FEEDER OR PARTS OF IT 5 ...

Page 138: ...ct IEMCA service department 9 2 ELEVATOR CARRIAGE DRIVE SAFETY JOINT REPLACEMENT Slacken the drive chain Remove ring nut A and extract in order spring B washer C bearing D pinion E Remove ring nut F and extract in order shaft G flange H Reassemble all components in the inverted order replacing the worn flange H and pinion E with the new ones Tension the chain ...

Page 139: ... belt so that it can be removed from its seat Splice one end of the worn belt with one end of the new belt Slide out the worn belt so that the new one can be simultaneously inserted along the entire path Separate the worn belt from the new one Splice the ends of the new belt using lacing A Tension the belt according to the instructions given in Remnant conveyor belt section 5 Restore the bar feede...

Page 140: ...s displayed PLC battery exhausted INFORMATION when this message is displayed the battery should be replaced within one day otherwise the PLC NC Software data will be deleted unscrew plug A and remove battery B insert a new battery 3 6 volts lithium AA battery and make sure that it is introduced correctly then tighten the plug A PLC battery exhausted ...

Page 141: ...r 3RG4012 0AG07 1 32210013 Sensor 3RG4012 0AG33 1 32210017 Sensor 3RG4012 0AG00 1 32210019 Sensor 3RG4012 0AG33 Z 1 Bar pusher Specify diameter and length 1 Revolving tip Specify diameter 1 Collet Specify internal and external diameter 1 To order the parts refer to the Spare Parts Catalogue 9 6 DISPOSAL OF THE BAR FEEDER OR PARTS OF IT INFORMATION this operation must be carried out by specialized ...

Page 142: ......

Page 143: ...LVING TIPSMaster 80 UP HyperFlexible EN 10 Pag 1 1 INDEX 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 81 Table 7 ...

Page 144: ...with a bar pusher whose diameter is equal to the maximum bar passage of the lathe Sometimes in order to ensure the best working conditions it may be necessary to use a bar pusher with a smaller diameter A Guide channels B Bar pusher C Revolving tip D Collet E Bar INFORMATION upon customer s request and according to the internal diameter of lathe spindle hole the bar pusher and the revolving tips m...

Page 145: ...0 UP HyperFlexible EN 10 Pag 3 3 10 2 REVOLVING TIP TABLE The choice of the revolving tip depends on the diameter of the guide channel and bar pusher and on the version of the collet coupling A Guide channels B Bar pusher C Revolving tip D Collet E Bar ...

Page 146: ...ck coupling pin 36 35 Threaded IEMCA 35 D02153550 With quick coupling pin 38 37 Threaded IEMCA 37 D02153750 With quick coupling pin 43 42 Threaded IEMCA 42 D02154250 With quick coupling pin 46 45 Threaded IEMCA 45 D02154550 52 51 With quick coupling pin IEMCA With quick coupling screw IEMCA Threaded OPTIONAL 51 D02155150 57 56 56 D02155650 61 60 60 D02156050 66 65 65 D02156550 69 68 68 D02156850 7...

Page 147: ... Table For collets with threaded coupling IEMCA CH double ended fork wrench DIN3110 B See conversion table therefore collet table F Revolving tip øGR mm Revolving tip code øF øB mm GP mm G1 mm øC mm P mm CH1 mm CH mm 20 D02152050 M10x1 20 5 172 2 29 M12 38 5 19 15 25 D02152550 M10x1 25 5 172 2 29 8 M16 38 5 24 21 ...

Page 148: ...GR 20 25 Table For collets with quick coupling pin OPTIONAL CH double ended fork wrench DIN3110 B See conversion table therefore collet table F Revolving tip øGR mm Revolving tip code A2 øF øB mm GP mm G1 mm øC mm CH mm 20 D02152051 37 5 Ø14 20 5 172 7 29 M12 19 25 D02152551 37 5 Ø20 25 5 172 5 29 8 M16 21 ...

Page 149: ...OLVING TIPSMaster 80 UP HyperFlexible EN 10 Pag 7 7 10 5 Revolving tips øGR 32 81 Table For collets with threaded coupling IEMCA CH double ended fork wrench DIN3110 B See conversion table therefore collet table F Ring L Revolving tip ...

Page 150: ...0 32 65 46 70 5 72 D02157250 32 68 50 72 5 75 D02157550 32 72 54 75 5 80 D02158050 32 75 58 80 5 85 D02158550 32 82 58 85 5 øGR mm Revolving tip code øC mm G1 mm GP mm A2 mm 32 D02153250 M24X2 50 75 165 46 35 D02153550 M24X2 50 75 165 46 37 D02153750 M24X2 50 75 165 46 42 D02154250 M30X2 60 165 46 45 D02154550 M30X2 60 165 46 51 D02155150 M42X2 60 181 50 56 D02155650 M42X2 60 181 43 60 D02156050 M...

Page 151: ...7 377 13 11 10 PIPE COLLETS Table 13 11 11 EJECTOR 336 17 11 12 EJECTOR Guide channels ø 30 Table 17 11 13 EJECTOR Guide channels ø 32 Table 19 11 14 COLLETS FOR BARS 602P 21 11 15 COLLET FOR BARS Table 21 11 16 BORING COLLETS FOR BARS 601P 23 11 17 BORING COLLETS FOR SQUARE AND HEXAGONAL BARS Table 23 11 18 EJECTORS 602P 011 26 11 19 EJECTORS Guide channels ø13 28 Table 26 11 20 PIPE COLLETS 603P...

Page 152: ...EN 11 COLLETS Master 80 UP HyperFlexible 11 Pag 2 2 11 27 PIPE COLLETS 386P 38 11 28 PIPE COLLETS Table 38 11 29 RINGS FOR COLLETS 078 225 40 11 30 RINGS FOR COLLETS Table 40 ...

Page 153: ...6 8 4 4 61 4 5 33 38 10 37 8 4 5 5 19 5 34 39 25 39 5 5 77 5 5 35 40 41 40 2 5 5 6 35 6 2 36 41 56 41 3 6 6 92 6 8 38 43 87 43 5 6 5 7 50 7 3 39 45 03 44 8 7 8 08 7 8 40 46 18 46 7 5 8 66 8 5 41 47 34 47 8 9 23 9 42 48 49 48 2 9 10 39 10 2 43 49 65 49 5 10 11 54 11 3 44 50 80 50 5 11 12 70 12 5 45 51 96 51 8 12 13 85 13 5 46 53 11 52 8 13 15 02 14 8 48 55 42 55 14 16 16 16 50 57 73 57 5 15 17 32 1...

Page 154: ...LLETS Master 80 UP HyperFlexible 11 Pag 4 4 Y Zx1 154 ØA Y Zx1 154 ØA mm mm mm mm mm mm 23 26 55 26 2 72 83 08 82 5 24 27 71 27 5 75 86 55 86 25 28 86 28 5 80 92 32 91 75 26 30 02 29 8 85 98 1 97 5 27 31 17 31 ...

Page 155: ...4 5 65 5 5 26 36 76 36 4 5 6 36 6 2 27 38 17 37 5 5 7 07 6 8 28 39 59 38 5 5 5 7 77 7 5 30 42 42 41 5 6 8 48 8 3 32 45 24 44 5 6 5 9 19 9 34 48 07 47 7 9 89 9 7 35 49 49 48 5 8 11 31 11 36 50 90 50 8 5 12 01 11 8 37 52 31 51 5 9 12 72 12 5 38 53 73 52 5 10 14 14 13 8 39 55 15 54 5 10 5 14 84 14 5 40 56 56 55 5 11 15 55 15 41 57 97 57 12 16 97 16 5 42 59 38 58 5 12 5 17 67 17 43 60 08 59 13 18 38 1...

Page 156: ...9 16 46 5 1 53 64 3 8 10 75 27 64 1 5 8 47 25 1 55 64 7 16 12 5 31 64 1 11 16 49 1 15 16 1 2 14 25 9 16 1 3 4 50 75 2 9 16 16 25 41 64 1 13 16 52 75 2 5 64 5 8 18 45 64 1 7 8 54 5 2 9 64 11 16 19 75 25 32 1 15 16 56 25 2 7 32 3 4 21 75 55 64 2 58 2 9 32 13 16 23 5 59 64 2 1 16 59 75 2 11 32 7 8 25 25 63 64 2 1 8 61 5 2 27 64 15 16 27 25 1 5 64 2 3 16 63 5 2 1 2 1 29 1 9 64 2 1 4 65 25 2 37 64 1 1 ...

Page 157: ...25 11 64 4 4 43 64 17 1 11 16 43 3 16 4 8 11 16 17 5 1 3 4 44 5 13 64 5 2 45 64 18 1 13 16 46 7 32 5 6 23 32 18 25 1 7 8 47 75 15 64 6 47 64 18 75 1 15 16 49 25 1 4 6 4 3 4 19 2 50 75 17 64 6 8 49 64 19 5 2 1 16 52 5 9 32 7 2 25 32 19 75 2 1 8 54 19 64 7 6 51 64 20 25 2 3 16 55 5 5 16 8 13 16 20 75 2 1 4 57 25 21 64 8 4 53 64 21 2 5 16 58 75 11 32 8 8 27 32 21 5 2 3 8 60 5 23 64 9 1 55 64 21 75 2 ...

Page 158: ...943 8 58 340 6 82 550 0 82 946 9 83 343 8 83 740 6 5 16 21 64 11 32 23 64 0 312 5 0 328 125 0 343 75 0 359 375 7 937 5 8 334 4 8 731 2 9 128 1 33 337 5 33 734 4 34 131 2 34 528 1 58 737 5 59 134 4 59 531 2 59 928 1 84 137 5 84 534 4 84 931 2 85 328 1 3 8 25 64 13 32 27 64 c 0 375 0 390 625 0 406 25 0 421 875 9 525 0 9 921 9 10 318 8 10 715 6 34 925 0 35 321 9 35 718 8 36 115 6 60 325 0 60 721 9 61...

Page 159: ...71 040 6 95 250 0 95 646 9 96 043 8 96 440 6 13 16 53 64 27 32 55 64 0 812 5 0 828 125 0 843 75 0 859 375 20 637 5 21 034 4 21 431 2 21 828 1 46 037 5 46 434 4 46 831 2 47 228 1 71 437 5 71 834 4 72 231 2 72 628 1 96 837 5 97 234 4 97 631 2 98 028 1 7 8 57 64 29 32 59 64 0 875 0 890 625 0 906 25 0 921 875 22 225 0 22 621 9 23 018 8 23 415 6 47 625 0 48 021 9 48 418 8 48 815 6 73 025 0 73 421 9 73 ...

Page 160: ...ction 2 6 WARNING CAUTION the collet external diameter should be at least 0 5 mm smaller than the bar pusher external diameter INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure CH double ended fork wrench DIN3110 A Collet B Ba...

Page 161: ... M7x0 75 2 10 15 M8x1 3 13 16 M8x1 10 14 17 M8x1 11 15 18 M8x1 12 16 2 19 M8x1 13 17 20 M10x1 3 18 23 M10x1 14 21 25 M10x1 18 23 27 M10x1 20 25 5 30 M10x1 21 27 32 M25x1 5 23 30 34 M25x1 5 27 32 35 M25x1 5 29 32 37 M25x1 5 32 34 38 M25x1 5 31 33 40 M25x1 5 33 37 42 M25x1 5 37 40 45 M25x1 5 39 42 48 M25x1 5 40 44 50 M25x1 5 44 46 51 M25x1 5 46 47 52 M25x1 5 47 48 55 M25x1 5 48 51 56 M25x1 5 51 52 ...

Page 162: ...g 12 12 External diameter mm øD Diameter mm øF Internal diameter mm øA MIN MAX 58 M25x1 5 52 54 60 M25x1 5 54 56 64 M25x1 5 56 59 65 M25x1 5 59 61 68 M25x1 5 61 64 70 M25x1 5 64 66 72 M25x1 5 66 67 74 M25x1 5 67 70 76 M25x1 5 70 72 80 M25x1 5 72 75 ...

Page 163: ...mm smaller than the bar pusher external diameter INFORMATION the collets 377 bar feeder BOSS with øF M10x1 have been designed to be assembled on lower revolving tips with ø28 if mounted on the revolving tips with greater diameter as ø30 and with nipples 078800030 it is necessary to lengthen the bar pusher carriage first feeding value of 7 5 mm INFORMATION upon specific request non standard collets...

Page 164: ...e CH double ended fork wrench DIN3110 A Collets for pipe type AS øF M7x0 75 M8x1 B Collets for pipe type BOSS øF M10x1 C Collets for pipe type T560 øF M17x1 M25x1 D Collets for pipe type T560 øF M25x1 5 E Bar diameter F Example 5 mm 060 10 mm 100 12 5 mm 125 G Category ...

Page 165: ...eter mm øA MIN MAX 10 M6x0 75 5 9 6 12 M7x0 75 5 9 5 15 M8x1 5 13 16 M8x1 13 5 14 20 M10x1 6 18 23 M10x1 8 21 75 24 M17x1 6 23 5 25 M10x1 14 23 5 27 M17x1 23 25 5 29 M17x1 22 27 29 M25x1 5 8 27 30 M25x1 5 25 26 75 32 M25x1 5 27 30 25 35 M25x1 5 29 33 37 M25x1 5 33 5 33 5 38 M25x1 5 32 33 40 M25x1 5 33 25 37 ...

Page 166: ...Flexible 11 Pag 16 16 External diameter mm øD Diameter mm øF External diameter mm øA MIN MAX 42 M25x1 5 37 5 40 44 45 M25x1 5 40 42 5 49 M25x1 5 43 46 5 54 55 M25x1 5 46 5 52 5 59 M25x1 5 52 5 56 64 M25x1 5 56 5 61 68 M25x1 5 61 5 66 ...

Page 167: ...ter of the ejector must be at least 0 5 mm less than the external diameter of the bar pusher INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets CH double ended fork wrench DIN3110 A Ejector ...

Page 168: ...6 5 10 6 336803120 M8x1 8 12 18 15 30 75 6 5 26 5 13 10 336803150 M8x1 8 12 18 18 32 6 5 26 5 15 10 336803180 M10x1 10 15 5 26 20 44 4 8 2 38 5 17 10 336803200 M10x1 10 15 5 26 23 46 8 2 38 5 19 10 336803230 M10x1 10 15 5 26 25 47 8 2 38 5 22 12 336803250 M10x1 10 15 5 26 27 48 8 2 38 5 24 12 336803270 M10x1 10 15 5 26 29 49 8 2 38 5 27 12 336803290 ...

Page 169: ...e ejector must be at least 0 5 mm less than the external diameter of the bar pusher INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets CH double ended fork wrench DIN3110 A Ejector ...

Page 170: ...10 82 5 56 5 336803310 32 14 81 55 336803320 35 18 80 5 54 5 336803350 40 18 83 57 336803400 42 18 84 58 336803420 44 20 84 58 336803440 45 21 84 58 336803450 50 23 84 58 336803500 52 25 84 58 336803520 55 28 84 58 336803550 60 33 84 58 336803600 65 38 84 58 336803650 70 43 84 58 336803700 ...

Page 171: ...ipe diameters in section 2 6 WARNING CAUTION the collet external diameter should be at least 0 5 mm smaller than the bar pusher external diameter INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure A Collet B Bar diameter C Exam...

Page 172: ...AX 10 Ø7 G6 3 8 12 Ø8 G6 3 10 15 Ø11 G6 4 13 16 Ø11 G6 11 14 18 Ø11 G6 8 16 20 Ø14 G6 6 18 21 Ø14 G6 16 5 19 23 Ø14 G6 14 21 25 Ø20 G6 4 3 23 27 Ø20 G6 21 25 5 29 Ø20 G6 22 75 27 32 Ø20 G6 6 30 35 Ø20 G6 27 32 36 Ø20 G6 26 34 39 Ø20 G6 32 37 42 Ø20 G6 31 40 45 Ø20 G6 33 42 51 Ø20 G6 39 75 47 52 Ø20 G6 44 49 56 Ø20 G6 47 52 ...

Page 173: ...r bar and pipe diameters in section 2 6 INFORMATION to determine the internal diameter øA do not refer to file 001 Conversion Tables but refer directly to the table below INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure A Col...

Page 174: ...EN 11 COLLETS Master 80 UP HyperFlexible 11 Pag 24 24 ...

Page 175: ...øD Diameter mm øF MIN MAX MIN MAX 3 3 3 4 7 5 M5x0 5 4 6 5 7 12 Ø8 G6 6 10 6 13 18 Ø11 G6 7 12 5 16 15 21 Ø14 G6 10 12 8 5 19 25 Ø20 G6 13 15 25 M5x0 5 16 17 29 Ø8 G6 17 7 8 29 Ø20 G6 18 20 32 Ø11 G6 20 25 32 Ø20 G6 21 1 1 8 36 Ø20 G6 21 23 36 Ø14 G6 1 1 16 1 1 16 40 Ø20 G6 WARNING Values indicated with are expressed in inches ...

Page 176: ...TION the external diameter of the ejector must be at least 0 5 mm less than the external diameter of the bar pusher INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets A Ejector ...

Page 177: ...1 26 602P15011 16 11 12 26 602P16011 18 11 12 27 5 602P18011 19 11 12 28 602P19011 20 14 12 47 5 602P20011 23 14 12 49 602P23011 25 20 12 50 5 602P25011 27 20 12 51 5 602P27011 29 20 14 51 5 602P29011 30 20 15 51 5 602P30011 35 20 18 51 5 602P35011 40 20 18 55 602P40011 45 20 19 56 602P45011 51 20 25 56 602P51011 ...

Page 178: ... least 0 5 mm smaller than the bar pusher external diameter INFORMATION For the 603P collets fitted with a quick coupling allowing the assembly on the revolving tips are designed with an oversized length Therefore the first feeding value of the bar pusher carriage shall be increased of 7 5 mm with respect to the standard value INFORMATION upon specific request non standard collets with reduced thi...

Page 179: ...11 COLLETS Master 80 UP HyperFlexible EN 11 Pag 29 29 Code structure A Bar diameter B Example 5 mm 060 10 mm 100 12 5 mm 125 C Category ...

Page 180: ...mm øD Diameter mm øF External diameter mm øA MIN MAX 12 Ø8 G6 5 9 5 15 Ø11 G6 5 11 15 16 Ø11 G6 11 5 14 20 Ø14 G6 6 18 25 Ø20 G6 10 23 27 Ø20 G6 21 5 25 29 Ø20 G6 25 5 27 32 Ø20 G6 15 30 35 Ø20 G6 23 33 40 Ø20 G6 34 37 42 Ø20 G6 23 40 44 45 Ø20 G6 39 5 42 5 49 Ø20 G6 30 45 ...

Page 181: ...e diameters in section 2 6 WARNING CAUTION the collet external diameter should be at least 0 5 mm smaller than the bar pusher external diameter INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure A Collet B Bar diameter C Exampl...

Page 182: ...iameter mm øA MIN MAX 32 Ø20 G6 10 29 35 Ø20 G6 27 32 37 Ø20 G6 29 34 40 Ø20 G6 30 33 42 Ø20 G6 33 25 39 44 Ø20 G6 38 38 75 45 Ø20 G6 39 42 48 Ø20 G6 40 42 75 49 Ø20 G6 43 43 75 50 Ø20 G6 44 47 51 Ø20 G6 45 47 52 Ø20 G6 45 47 75 54 Ø20 G6 48 49 75 56 Ø20 G6 49 75 52 58 Ø20 G6 51 52 75 59 Ø20 G6 53 53 75 ...

Page 183: ...ameter mm øF Internal diameter mm øA MIN MAX 60 Ø20 G6 54 56 62 Ø20 G6 56 56 75 64 Ø20 G6 57 60 65 Ø20 G6 59 61 66 Ø20 G6 60 62 68 Ø20 G6 61 25 63 75 70 Ø20 G6 64 65 75 72 Ø20 G6 65 25 67 74 75 Ø20 G6 67 25 70 76 Ø20 G6 69 70 78 Ø20 G6 70 25 72 80 Ø20 G6 69 75 76 75 85 Ø20 G6 74 80 ...

Page 184: ...the external diameter of the ejector must be at least 0 5 mm less than the external diameter of the bar pusher INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets CH4 T Allen wrench DIN 911 A Ejector ...

Page 185: ... 80 UP HyperFlexible EN 11 Pag 35 35 øE mm øD mm L mm Code no 30 12 69 381P30021 31 13 70 381P31021 32 14 71 381P32021 35 18 69 381P35021 37 18 70 381P37021 40 18 71 5 381P40021 42 18 72 5 381P42021 45 21 72 5 381P45021 ...

Page 186: ...meter of the ejector must be at least 0 5 mm less than the external diameter of the bar pusher INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets CH4 T Allen wrench DIN 911 A Ejector ...

Page 187: ... mm øS mm øD mm Code no 51 52 5 50 25 381P51011 56 52 5 55 30 381P56011 60 52 5 59 34 381P60011 65 52 5 64 39 381P65011 68 52 5 67 42 381P68011 70 52 5 69 44 381P70011 72 52 5 71 46 381P72011 75 52 5 74 50 381P75011 80 52 5 79 55 381P80011 85 52 5 84 60 381P85011 ...

Page 188: ...ameters in section 2 6 WARNING CAUTION the collet external diameter should be at least 0 5 mm smaller than the bar pusher external diameter INFORMATION upon specific request non standard collets with reduced thickness which are not mentioned in this table may be supplied as well Their durability is however below the durability of standard collets Code structure A Collet B Bar diameter C Example 40...

Page 189: ...40 Ø20 G6 23 34 75 41 Ø20 G6 35 37 44 Ø20 G6 36 40 45 Ø20 G6 40 25 42 49 Ø20 G6 42 45 5 50 Ø20 G6 43 47 54 Ø20 G6 46 50 56 Ø20 G6 49 52 25 59 Ø20 G6 52 5 54 75 60 Ø20 G6 54 56 75 64 Ø20 G6 57 58 75 65 Ø20 G6 59 60 75 68 Ø20 G6 61 63 75 70 Ø20 G6 64 65 75 71 Ø20 G6 66 66 75 75 Ø20 G6 67 70 80 Ø20 G6 70 77 5 85 Ø20 G6 74 25 76 ...

Page 190: ... 225 11 30 RINGS FOR COLLETS Table A Revolving tip B Collet C Ring øA mm øB mm øD mm øF Ring p n 8 14 16 22540008 12 18 20 22540004 12 25 25 078800220 17 24 30 M17x1 22540026 17 30 35 078800200 25 30 30 M25x1 5 078800220 25 35 40 22540009 25 45 51 078800230 Only for collets 316 TAL ...

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