IEMCA MASTER 880 MP-E Manual For Use And Maintenance Download Page 34

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4 - HANDLING AND INSTALLATION

MASTER 880MP E-volution

4 - Pag. 1 / 17

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 case - Lifting ..................................................................................4

4.3

INSTALLATION AREA - CHARACTERISTICS

........................................................5

4.4

INSTALLATION OF THE BAR FEEDER - INTRODUCTION............................................6

4.4.1

Support plates and feet - Installation ......................................................................6

4.4.2

Height - Adjustment ...............................................................................................6

4.4.3

Preliminary positioning ...........................................................................................8

4.4.4

Sleeve - Installation................................................................................................9

4.4.5

Levelling and alignment ........................................................................................10

4.4.6

Feeder fastening ..................................................................................................15

4.5

LUBRICATING OIL - FILLING

..........................................................................16

4.6

ELECTRIC CONNECTION

................................................................................16

4.7

PNEUMATIC CONNECTION

.............................................................................17

4.8

SOFTWARE PARAMETRING

............................................................................17

Summary of Contents for MASTER 880 MP-E

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Page 4: ......

Page 5: ...ER 880MP E volution 4 HANDLING AND INSTALLATION MASTER 880MP E volution 5 ADJUSTMENTS AND SETTING UP MASTER 880MP E volution 6 USE AND OPERATION MASTER 880MP E volution 7 BAR FEEDER MAINTENANCE MASTER 880MP E volution 8 TROUBLES CAUSES CURES MASTER 880MP E volution 9 PART REPLACEMENT MASTER 880MP E volution 10 LIST OF AFTER SALES CENTERS ...

Page 6: ......

Page 7: ...ENERAL INFORMATION MASTER 880MP E volution GB 1 Pag 1 4 INDEX 1 1 TERMS OF WARRANTY 2 1 2 MANUAL PURPOSE 3 1 3 MANUFACTURER AND BAR FEEDER IDENTIFICATION 4 1 4 TECHNICAL ASSISTANCE 4 1 5 ANNEXES ENCLOSED 4 ...

Page 8: ...eder to lathe In particular before the first start up carry out an accurate check to make sure the bar feeder is correctly aligned with the lathe and fastened with the expansion plugs as shown in section 4 The product warranty is valid only if the bar loader is installed by an authorized technician with Original Installation Certificate Please ask the technician who will make the installation to s...

Page 9: ...rder to allow a quick search of contents consult the descriptive index Particularly important parts of this manual have been highlighted in bold type and preceded by the following symbols DANGER WARNING shows impending danger which might cause serious injuries exert the maximum caution CAUTION PRECAUTION indicates measures to be adopted to avoid accidents or damages to property INFORMATION technic...

Page 10: ...diagram T Number of interface wiring diagram INFORMATION Always provide the Manufacturer with the above mentioned specifications when requesting information or ordering spare parts etc 1 4 TECHNICAL ASSISTANCE Whenever necessary please apply to one of the Technical Assistance Centres shown in the attached list INFORMATION when requesting technical assistance for the bar feeder always specify the i...

Page 11: ...mponents 3 2 1 2 Hydraulic system Main components 4 2 1 3 Pneumatic system Main components 5 2 2 OPERATING CYCLE 6 2 3 Bar feeder Safety devices 10 2 4 SAFETY PLATES POSITION AND DESCRIPTION 11 2 5 DESCRIPTION OF THE VERSIONS 12 2 6 TECHNICAL DATA 13 2 6 1 Noise levels 18 2 7 FITTINGS FOREWORD 19 2 7 1 Bush holder device Description 19 ...

Page 12: ...er can be used to feed bars pipes and various sections The guide channel is fully closed during machining a pump is provided to maintain a continuous oil flow inside the channel creating a hydrodynamic support effect these characteristics allow the bar to rotate at a high r p m number with no vibrations and no surface damaging Thanks to the use of a BRUSHLESS and electronically controlled motor th...

Page 13: ... it drives the bar pusher H Feed chain it transmits the motion from the drive to the bar pusher L Guide channel opening closing cylinder Y Upper guide channel unlock M Pneumatic bar drop control devices they control the bar during the drop into the guide channels N Clamps they hold the bar during its loading and removal from the bar pusher collet P Facing device it sends a signal during the bar pa...

Page 14: ...TROL VALVE 4 GUIDES 5 BUSHING 6 OIL RECOVERY TRAY Lubrication oil cycle forced by pump 2 installed in tank 1 the oil flows to guides 4 and bushing holder 5 to lubricate the bars in production From these two devices the oil enters recovery tray 6 from where it is returned to the tank via a filter for use in the next lubrication cycle ...

Page 15: ...PS E BAR SELECTORS F GUIDE CHANNEL PNEUMATIC LOCKING UNIT G GUIDE CHANNEL OPENING UNIT POS DENOMINATION POS DENOMINATION 1 FILTER 12 CYLINDER 2 PRESSURE GAUGE 13 ELETCTROVALVE 3 CYLINDER 14 CYLINDER 4 REGULATOR 15 REGULATOR 5 ELETCTROVALVE 16 ELETCTROVALVE 6 CYLINDER 17 CYLINDER 7 REGULATOR 18 ELETCTROVALVE 8 ELETCTROVALVE 19 CYLINDER 9 CYLINDER 20 REGULATOR 10 ELETCTROVALVE 21 ELETCTROVALVE 11 VA...

Page 16: ...ERATING CYCLE The automatic functioning controls the motions of the bar feeder according to the sequence described below The bar pusher A makes bar B move forward in the lathe until the bar runout The bar pusher A and remnant C are in their forwards limit stop position ...

Page 17: ...n dropping bar remnant C activates a control device If the bar remnant is still inside the collet of the bar pusher the bar feeder stops otherwise the cycle goes on The top guides G are lifted together with the bar pusher H and also the bar control devices are lifted ...

Page 18: ... L load bar M that falls into lower guides N with the help of levers H The 1st feeding carriage P stroke begins When the small pusher truck P completes its stroke the required space has been created for bar pusher insertion The small pusher truck executes its return stroke ...

Page 19: ...per guides G are closed the bar pusher H is positioned along the spindle axis The clamps D close the bar pusher A moves forwards the bar N is inserted into the bar pusher collet The bar pusher A and bar N execute their facing stroke A new automatic work cycle is started ...

Page 20: ...ntrols automatic cycle during the bar feeding phase the guard opens to allow magazine refilling Although the bar feeder and lathe functions are not stopped there are no residual risks for the operator within the area during the bar change phase on guard opening the bar feeder and lathe functions are stopped Guard closure allows the cycle to be restarted by the operator D Fixed guard it is made fro...

Page 21: ...ove the safety barriers D Wear safety gloves and shoes Do not lift loads exceeding 15 kg manually E Caution Danger of electric contact F Warning danger of falling material G Warning fix the bar feeder to the ground H Maximum overall weight of magazine loadable bars L Warning axial sliding N Warning respect the correct guide channel assembly direction ...

Page 22: ...NS Table 1 Bar length Modello Versione Lunghezza massima mm ft Lunghezza minima mm ft 33 3300 10 8 38 3800 12 4 MASTER 880 MP Evolution 43 4300 14 1 1000 3 2 Table 2 Bar pusher max extension Model Version Version A Max extension mm L 1350 33 38 43 LL 1600 MASTER 880 MP Evolution 38 43 XLL 1850 ...

Page 23: ...2 TECHNICAL INFORMATION MASTER 880MP E volution GB 2 Pag 13 19 2 6 TECHNICAL DATA Table 3 Overall dimensions Model Version A mm B mm 33 4000 1950 38 4500 2450 MASTER 880 MP Evolution 43 5000 2950 ...

Page 24: ...Magazine capacity maximum allowable load 360 kg Magazine capacity Working width 270 320 mm es n 34 bars with a diameter Ø 8 mm n 4 bars with a diameter Ø 80 mm Remnant max length Ø 8 65 400 mm Ø 66 80 250 mm Bar change over time with 3000 mm bar 30 sec varying according to the bar diameter Adjustable feeding speed 150 mm sec Adjustable return speed 950 mm sec Imput voltage 230 400 Volt Control vol...

Page 25: ...height Model Screws position X mm High bedframe X mm Low bedframe 2 1215 1249 900 934 3 1250 1284 935 969 4 1285 1319 970 1004 5 1320 1354 1005 1039 6 1355 1389 1040 1074 7 1390 1424 1075 1109 8 1425 1459 1110 1144 9 1460 1494 1145 1179 MASTER 880 P MASTER 880 F 10 1495 1535 1180 1220 ...

Page 26: ... 37 11 35 37 43 42 12 39 42 46 45 15 42 45 52 51 18 47 51 57 56 22 52 56 61 60 30 56 60 66 65 38 61 65 69 68 48 63 68 71 70 48 65 70 73 72 50 67 72 76 75 50 70 75 81 80 52 75 80 MASTER 880 MP Evolution 86 85 55 80 80 Valid also for prepared bars or normal bars machined with front remnant ejection Recommended guide according to max lathe bar passage Example ø85 max bar passage GUIDES 86 61 33 Examp...

Page 27: ... BP Energol CS 150 Castrol Magna 150 Chevron Circulating Oil 150 Elf Movixa 150 Esso Nuto 150 Fina Solna 150 IP IP Hermea 150 Klüber Crucolan 150 Olio FIAT Daphne LPN 150 Roloil Arm V 150 Shell Vitrea 150 Tellus C 150 Tamoil Industrial Oil 150 Texaco Omnis 150 Total Cortis 150 Azolla ZS 150 CLASSE C CKB 150 Aral Aral Degol Tu 150 Oil quantity 80 litres ...

Page 28: ...front guide bush of suitable diameter if supplied bar with a straightness within prescribed limits max arrows equal to 0 5 mm of the bar length 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 diameter of the bar to be machined all bar feed...

Page 29: ...th a diameter just slightly larger than that of the bar being machined In many cases this device can be used by only changing the diameter of the half bushes 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 Closure is controlled by a pneumatic cylinder aft...

Page 30: ...ORMATION MASTER 880MP E volution GB 3 Pag 1 4 INDEX 3 1 GENERAL SAFETY PRESCRIPTIONS 2 3 2 HANDLING AND INSTALLATION Safety 3 3 3 ADJUSTMENTS AND SETTING UP Safety 3 3 4 USE AND OPERATION Safety 4 3 5 BAR FEEDER MAINTENANCE Safety 4 ...

Page 31: ...tructions in this manual is a guarantee of protection against injury The operator and skilled engineer must perform only their specified duties Do not tamper with the safety devices for any reason whatsoever Comply strictly with the work health and safety regulations issued by the relevant authorities in the country of installation of the machine IEMCA declines any liability whatsoever for injury ...

Page 32: ... feeder adequate lighting and a clean working environment are of the utmost importance as far as personal safety is concerned The electric system connection must be made exclusively by skilled electricians Make sure the electrical system is connected to an efficient earth circuit by means of a dedicated wire 3 3 ADJUSTMENTS AND SETTING UP Safety Carry out the adjustments as described in the user m...

Page 33: ... force in the country in which the machine is installed Inform maintenance personnel of all operating anomalies that come to your attention Before starting the bar feeder make sure that there are no personnel engaged in servicing or cleaning the machine 3 5 BAR FEEDER MAINTENANCE Safety Do not allow unauthorized persons to carry out maintenance Read this manual carefully before carrying out mainte...

Page 34: ... case Lifting 4 4 3 INSTALLATION AREA CHARACTERISTICS 5 4 4 INSTALLATION OF THE BAR FEEDER INTRODUCTION 6 4 4 1 Support plates and feet Installation 6 4 4 2 Height Adjustment 6 4 4 3 Preliminary positioning 8 4 4 4 Sleeve Installation 9 4 4 5 Levelling and alignment 10 4 4 6 Feeder fastening 15 4 5 LUBRICATING OIL FILLING 16 4 6 ELECTRIC CONNECTION 16 4 7 PNEUMATIC CONNECTION 17 4 8 SOFTWARE PARAM...

Page 35: ...llet and wrapped in protective film C WITH CRATE the feeder is placed in a crate wrapped in protective film 4 2 LIFTING DANGER WARNING e lifting and handling are to be donwith proper means see weight table paragraph 2 6 and by skilled staff trained for this kind of manoeuvres 4 2 1 Bar feeder without packaging Lifting 4 2 2 Bar feeder with pallet Lifting 4 2 3 Bar feeder with case Lifting ...

Page 36: ...Pag 3 17 4 2 1 Bar feeder without packaging Lifting Assemble the two crosspieces A supplied Use a hooked lifting device of adequate capacity CAUTION PRECAUTION during the lifting and installation phases pay special attention to the section housing the motor B ...

Page 37: ...STALLATION MASTER 880MP E volution 4 Pag 4 17 4 2 2 Bar feeder with pallet Lifting Use a hook lifting device of adequate capacity load 4 2 3 Bar feeder with case Lifting Use a hook lifting device of adequate capacity load ...

Page 38: ...rly delimited to prevent collisions between the operator and any handling equipment or transport vehicles travelling near the bar feeder The selected bar feeder setting should be suitably lit and provided with an electric power and air outlets During operation the feeder will release small amount of oil vapors Make sure that the premises where the feeder is installed are suitably ventilated The fe...

Page 39: ...on the feeder next to the lathe Keep it lifted and install the plates A 4 4 2 Height Adjustment The feeder is normally factory preset to have a working axis height adjusted to lathe height However if feeder height needs adjustment proceed as follows stretch the lifting belts and remove screws C in the front and rear bases CAUTION PRECAUTION during the lifting and installation phases pay special at...

Page 40: ...frame X mm Low bedframe 2 1215 1249 900 934 3 1250 1284 935 969 4 1285 1319 970 1004 5 1320 1354 1005 1039 6 1355 1389 1040 1074 7 1390 1424 1075 1109 8 1425 1459 1110 1144 9 1460 1494 1145 1179 MASTER 880 P MASTER 880 F 10 1495 1535 1180 1220 tighten screws C remove the cross member and the eyebolts utilised for lifting purposes ...

Page 41: ...l dimensions and side plays of both machines The coupling distance B should not exceed the bar pusher max extension A Table 3 Max bar pusher extension Model Version Version A Max extension mm L 1350 33 38 43 LL 1600 MASTER 880 MP Evolution 38 43 XLL 1850 Roughly adjust the height of the working axis and the alignment with the lathe by turning the screws of plates A ...

Page 42: ... MASTER 880MP E volution GB 4 Pag 9 17 4 4 4 Sleeve Installation Install the sleeve A in the bush holder device Install the oil recovery device B Connect lubrication line C to the feeder nose Connect the drain pipe D to the tank ...

Page 43: ...on should be carried out by experienced personnel with the greatest accuracy CAUTION bad alignment can be the main cause of feeder malfunction and resulting damage CAUTION do not operate manually i e using the special crank when the electric power is connected PRELIMINARY PROCEDURE Open the upper guard To bring the bar pusher to its fully retracted position select manual mode and press key or on t...

Page 44: ...s both keys and to select semi automatic operating function Press repeatedly until the guide channels are open and the message GUIDE CHANNELS COMPLETELY OPEN is displayed Remove the first and the last lower guide channel by using the special wrench provided for the purpose ...

Page 45: ...D INSTALLATION MASTER 880MP E volution 4 Pag 12 17 LEVELLING Rest provided shelf on A supports Check the levelling by placing the level crosswise and lengthwise Carry out the required connections by turning the feet A ...

Page 46: ...e B use a sliding calliper to check alignment near the bushing C and the spindle D adopt a tolerance of 0 15 mm in all four directions It is also possible to carry out alignment by placing a bar in the guides Proceed as follows prepare a perfectly straight ground bar having an outside diameter equal to the max spindle bar passage and a length equal to twice the coupling distance see item B paragra...

Page 47: ...y required corrections should be carried out Adjust height by turning the A and B screws in the support feet carry out lateral adjustment with calibrated mallet blows on the sides of plates C During this phase any adjustment carried out during levelling should be preserved therefore in most cases feeder positioning will be the result of a good adjustment compromise ...

Page 48: ...sulting damaging Drill the floor and fix the backing plates with expansion plugs Drill the floor and fix the backing plates with the expansion plugs Use the highest possible number of plugs in order to guarantee good fixing Fix the feeder to the plates through the tie rods A and lock with nuts B Perform another levelling and alignment check Remove all the equipment used for levelling and alignment...

Page 49: ...2 6 for the comparative table 4 6 ELECTRIC CONNECTION DANGER WARNING this type of operation should only be entrusted to skilled technical staff to comply with the applicable standards and statutory regulations in force The feeder must be electrically connected to the lathe which in turn must be connected to the plant wiring system in compliance with the applicable regulations in force The feeder i...

Page 50: ...k system as shown in the figure CAUTION PRECAUTION to adjust pressure follow the directions in section 7 2 3 4 8 SOFTWARE PARAMETRING There should be an adequate parametring of the bar feeder software according to the working needs and to the type of lathe For information on this operation refer to the Keyboardf panel instruction manual ...

Page 51: ...UCTION TO ADJUSTEMENTS AND SET UP FOREWORD 2 5 2 GENERAL ADJUSTMENTS FOREWORD 2 5 2 1 Feeding chain Adjustment 3 5 2 2 Setting the pressure switch 3 5 3 BAR FEEDER SETTING UP 4 5 3 1 Guide channels half bushings bar pusher and collet Replacement 5 5 3 2 Adjusting the bar selectors 14 ...

Page 52: ...s necessary during its life setting ups depending on the bar dimensions and the type of bar magazine Such interventions are listed and explained as follows 5 2 General adjustments 5 3 Bar feeder setting up 5 2 GENERAL ADJUSTMENTS FOREWORD All adjustments necessary for the bar feeder good operation are meant They can be necessary for maintenance and as a cure to a trouble or they can be required af...

Page 53: ...y means of a dynamometric wrench then tighten the B screw by setting the torque to 4N meter and tighten both A fixing screws 5 2 2 Setting the pressure switch After unscrewing the glass protection the pressure switch can be properly adjusted by turning the relevant adjusting screw G Proper setting is 4 5 bars 0 45 MPa CAUTION Do not further turn anti clockwise when the green pointer is found on 0 ...

Page 54: ...Tube diameter mm 21 20 8 18 20 26 25 8 23 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 18 47 51 57 56 22 52 56 61 60 30 56 60 66 65 38 61 65 69 68 48 63 68 71 70 48 65 70 73 72 50 67 72 76 75 50 70 75 81 80 52 75 80 MASTER 880 MP Evolution 86 85 55 80 80 Valid also for prepared bars or normal bars machined with front remnant ejection Recommended guide accordi...

Page 55: ...bushings bar pusher and collet Replacement Push to start the bar feeder Push plus to select the semiautomatic function Press several times until top guide opening is obtained the displayed message must be GUIDE FULL OPENING Press to open the top cover Remove the bar pusher from the two supports ...

Page 56: ...TER 880MP E volution 5 Pag 6 14 Remove the block A and then the first feeding carriage B Remove the lower guide channels by using the special wrench provided for the purpose Replace the bar pusher supports with those of the new diameter ...

Page 57: ...he oil recovery device C and nose D Lower the G spring and remove the F cover open the two half bushings fully by turning the E shaft manually 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 Fully close the half bushes and install the cover ...

Page 58: ... and install a suitable liner for the new diameter Assemble sleeve D of the new diameter and the oil recovery C Turn the screw clockwise to move the feeder body forwards CAUTION PRECAUTION bring the body of the feeder up to the stop on the tank slowly thereby eliminating the risk of damaging the traverse unit ...

Page 59: ...tion GB 5 Pag 9 14 Assemble the lower guide channels of the new diameter Choose collet fit to bar diameter and profile see BAR PUSHER GUIDES COLLET ROTARY GROUPS Manual for the choice INFORMATION contact IEMCA After Sales service for more information ...

Page 60: ...rew H and the counter screw L CAUTION the collet outside diameter should be at least 0 5 mm smaller than the bar pusher outside diameter Install the collet in the bar pusher and make sure that the rings are riveted in their special recesses to prevent accidental collet unscrewing from its connection Install a suitable 1st feeding carriage B for the new diameter followed by the block A ...

Page 61: ...e matches G support Properly position bar pusher radially so that in next phase of upper guides locking matching between bar pusher and B 1st feeding carriage occurs correctly CAUTION The above mentioned positioning has to be assured Therefore during set ups or maintenance operations if bar pusher is struck involuntarily it has to be correctly repositioned ...

Page 62: ...GB 5 ADJUSTMENTS AND SETTING UP MASTER 880MP E volution 5 Pag 12 14 Press at the same time both bar feeder operation keys and the key to partially open the upper guide channels ...

Page 63: ... 13 14 Loosen all the elastic clamps H Socket screw key CH6 supplied Close the upper guide channels until the sensor D activates By executing this operation you will cause the upper guide channels to rest against the lower guide channels Tighten all the clamps H ...

Page 64: ...NG UP MASTER 880MP E volution 5 Pag 14 14 5 3 2 Adjusting the bar selectors Properly position selectors A so that only the first bar B is found along the path followed by lifts C during their travel Work on knob D for adjustment ...

Page 65: ...DICATOR SIGNAL DESCRIPTION 6 6 4 BAR FEEDER SETUP 7 6 5 BARS TO BE MACHINED CHARACTERISTICS AND PREPARATION 8 6 5 1 BAR STRAIGTHNESS Measuration 10 6 6 BAR MAGAZINE LOADING 11 6 7 AUTOMATIC CYCLE START 12 6 8 BAR LOADING PROCEDURE 13 6 9 LUBRICATION OIL FLOW ADJUSTMENT 16 6 10 BAR FEEDER STOP 16 6 11 CYCLE EXECUTION MODE IN THE STEP BY STEP FUNCTION 17 ...

Page 66: ... it is possible to start automatically the bar feeder even when lathe MAN AUT signal is in Manual mode INFORMATION When Automatic mode is on the bar feeding is possible only when lathe MAN AUT signal is in Automatic mode INFORMATION Pressing Manual mode button it is possible to prevent the bar feeder automatic start by the lathe ...

Page 67: ...shings open the selector is not lit In Automatic mode if turned to 1 the half bushings close the selector is lit and open according to a preset sequence If turned to 0 the half bushings remain open during the whole working cycle the selector is not lit 4 BAR FEEDER STOP BUTTON red to stop the bar feeder and to reset Errors 5 EMERGENCY STOP BUTTON this button stops the bar feeder in an emergency si...

Page 68: ...he manual mode 7 Selects the semi automatic mode Push to select press again to unselect 8 Multifunction Selects the previous parameter Moves the cursor towards the left 9 Starts step by step movement of an operation cycle every push of the key initiates a step in the cycle 10 Lifts and lowers the bar selectors LED illuminated when selectors are at their down position 11 Opens Closes the clamps LED...

Page 69: ...ion mode Resets the values held before the modifications which were not confirmed 24 Confirms the data entered 26 Multifunction Number setting Starts and turns off the oil pump push to start and push again to turn off 27 Multifunction Number setting Loads the programme from the PLC entering default settings in the parameters 28 Multifunction key Sets the numerical value Shifts the bar pusher at a ...

Page 70: ...ver is open BLINKING GREEN LIGHT it indicates that the bar feeder is in the automatic mode BLINKING RED LIGHT signals that the bar feeder is not operating or that it is in the manual mode OPTIONAL BLINKING BLUE LIGHT signals that the bar feeder is carrying out the bar change FIXED BLUE LIGHT signals that the PLC battery is exhausted OPTIONAL ...

Page 71: ...r feeder setup assuming that one wants to start it for the first time Carry out feeder set up according to the bar to be machined paragraph 5 3 Preparing the bars to be processed section 6 5 Load the bar magazine paragraph 6 6 Starting the automatic cycle sections 6 7 and 6 8 Adjust the lubricating oil flow paragraph 6 9 ...

Page 72: ...l Version MAX Length mm ft MIN Length mm ft 33 3300 10 8 38 3800 12 4 MASTER 880 MP Evolution 43 4300 14 1 1000 3 2 INFORMATION Bar must not present a straightness defect above 0 5 per 1000 Please find herewith some advice to optimise the bar feeder performances Usually barstocks do not need any preliminary operations to be carried out on ends nevertheless to obtain the best results when loading t...

Page 73: ... during this phase we advise to chamfer the bar as shown in the figure If bars with front remnant ejection have to be machined we advise to chamfer the bar rear end as shown in the figure If bars have to be machined having a diameter equal to or only slightly smaller than the bar pusher diameter bar rear ends should be machine turned diameter D should be suitable for the collet size installed in t...

Page 74: ...S max Quality 0 25 mm Good 0 25 S max 0 5 mm Mediocre 0 5 mm Problematic In order to obtain a reliable value it is necessary to repeat 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 different values between prisms INFORMATION Obviously bar straightness is proportional to the rigidity of the material and to th...

Page 75: ...e the bar on itself and carry out the measurement on a bushing external to the two V supports 6 6 BAR MAGAZINE LOADING CAUTION do not manually lift loads heavier than those mentioned by the regulations in force ask for an assistant s help if needed CAUTION make use of the personal protections recommended by the regulations in force Open the top cover Position the bars against plate A and close the...

Page 76: ...switch to the position I ON Press to start the bar feeder Press to select the manual mode Carry out a BAR FEEDER ZERO SETTING in the following way press the start buttons plus INFORMATION Axes zero setting can be performed with the guides open or closed Load one bar in the guides and start the automatic cycle See section 6 8 ...

Page 77: ...SHER RETURN AFTER REMNANT DROP Press and to select the SEMIAUTOMATIC function Press phase BAR PUSHER RETURN Press phase CLAMP CLOSING Press phase DROP REMNANT REMOVAL Press phase CLAMP OPENING AFTER REMOVAL Press phase REMNANT DROP FEEDING Press phase CLAMP CLOSING DROP CONTROL Press phase CLAMP OPENING AFTER DROP CONTROL Press phase ZERO AXIS Press phase GUIDE FULL OPENING SEMIAUTOMATIC Procedure...

Page 78: ...re was a bar in the guide channels that has prevented the short feed door from resetting Push to drop the bar into place 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 79: ...STER 880MP E volution GB 6 Pag 15 17 Push to raise the bar drop control device Push to raise the bar from magazine and rest it on bar drop control device Push for about 2 secs to activate AUTOMATIC mode MANUAL Procedure Push ...

Page 80: ... EMERGENCY STOP CAUTION if the emergency stop is enabled during the lathe machining before starting the working cycle again make sure that no dangerous condition due to the sudden stop has occurred Example if the tool was removing chip take the piece far from the lathe before starting the lathe again To stop the bar feeder in the emergency status press one of the emergency push buttons of the bar ...

Page 81: ...ON This mode can be used for many reasons as for instance to check a complete bar change cycle to check the bar feeder mechanics eccetera Procedure Press to start the bar feeder Press and to select the semiautomatic function Press the bar feeder performs the first step Press the bar feeder performs the second step and so on ...

Page 82: ... 880MP E volution GB 7 Pag 1 7 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 Air filter unit Check 6 7 3 SCHEME OF THE LUBRICATION POINTS 7 ...

Page 83: ... work area which also increases operator s safety 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 periods of inactivity disconnect it from the mains let the compressed air out and cover with a piece of adequate cloth Any protection used ...

Page 84: ...out 200 500 1250 2500 Every year Periodi cally Revolving tip and collet Wear check Half bushing Wear check Oil level check Lubrication system Oil change Guides Repair and cleanness check Guide opening screw Greasing Lubrication Feed chain Tension check Guide opening belt Wear check Air filter Check Keyboard battery Replacement MASTER 880 MP Evolution PLC Battery Replacement ...

Page 85: ...r the personal protections prescribed by the applicable standards in force Wait until the bar feeder has been off for at least 6 hours Check the level through the indicator A Pour the oil directly in the tank to fill up if needed Oil characteristics C CLASS CKB 150 See paragraph 2 6 for the comparative table ...

Page 86: ...ontainers to be delivered to companies specialized in pollutant disposal and storage Remove the cover A and grid B Empty the tank with the use of an auxiliary pump or through the draining plug C Clean the tank bottom and pump suction system To load pour the oil directly in the tank and check the level through the indicator D Oil characteristics C CLASS CKB 150 amount 80 l See paragraph 2 6 for the...

Page 87: ...ondensate by valve C The filter is equipped with a control pressure switch set to a pressure of 4 5 bar remove the pressure gauge protecting glass turn the adjusting screw G anticlockwise to increase pressure or clockwise to lower it after this operation replace the pressure gauge protecting glass CAUTION should the pressure switch needle point a Pressure 0 do not absolutely turn the adjusting scr...

Page 88: ...7 BAR FEEDER MAINTENANCE MASTER 880MP E volution GB 7 Pag 7 7 7 3 SCHEME OF THE LUBRICATION POINTS Engrasar Aceitar ...

Page 89: ...8 TROUBLES CAUSES CURES MASTER 880MP E volution GB 8 Pag 1 2 INDEX 8 1 GENERAL FAULTS 2 8 2 INSERTION IN THE COLLET Faults 2 8 3 BAR FEEDING Faults 2 ...

Page 90: ...neumatic devices will not respond to controls No air Check the air system The pre feed and feed suddenly stop Motor thermal switch tripped Reset the motor overload cut out with the special push buttons 8 2 INSERTION IN THE COLLET Faults PROBLEMS CAUSES CORRECTIVE ACTION Bar fails to enter collet Collet diameter not suitable for bar diameter Change collet Excessive rag on bar rear end Trim rag befo...

Page 91: ...9 PART REPLACEMENT MASTER 880MP E volution GB 9 Pag 1 4 INDEX 9 1 FEED CHAIN REPLACEMENT 2 9 2 PLC BATTERY REPLACEMENT 2 9 3 KEYBOARD BATTERY REPLACEMENT 3 9 4 RECOMMENDED SPARE PARTS 4 ...

Page 92: ...eplace the battery at least every year and when the following message is 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 cap A and pull out battery B insert a new battery AA 3 6volts lithium type battery and make sure that it is introduced correctly then tighten the c...

Page 93: ...emory to be deleted Disconnect power Screw out the six screws and remove the two half shells Remove the battery A from its housing Insert a new battery type DURACELL DL2430 DANGER WARNING danger of battery explosion if the battery is mounted with inverted poles Put the two half shells back in place and screw down the six screws Connect electric power again INFORMATION Discard spent batteries by de...

Page 94: ...08 Feed chain 1 2 x5 16 For model 33 1 24220109 Feed chain 1 2 x5 16 For model 38 1 24220121 Feed chain 1 2 x5 16 For model 43 1 24290606 Connecting link 1 2 x5 16 1 32210004 Sensor 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 Rotary unit Specify diameter 1 MASTER 880 MP_E Collet Specify i...

Page 95: ...10 LIST OF AFTER SALES CENTERS GB 10 Pag 1 3 INDEX 10 1 LIST OF AFTER SALES CENTERS 2 ...

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IEMCA MASTER 880 MP-E, Manual For Use And Maintenance

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