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IEMCA VIP 80 Manual For Use And Maintenance

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

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Summary of Contents for IEMCA VIP 80

  • Page 1 VIP 80 MANUAL FOR USE AND MAINTENANCE 03/11/99 805005440 REL. DATA COD.
  • Page 2 GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
  • Page 3 VIP 80 AUTOMATIC BAR FEEDER MANUAL FOR USE AND MAINTENANCE IEMCA IGMI division of S.p.A. 48018 - Faenza (RA) - ITALY Via Granarolo, 167 Tel. 0546/698000 - Fax. 0546/46338 ufficio commerciale 0546/46224 centralino TLX 550879...
  • Page 4 GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.

  • Page 5: Table Of Contents

    INDEX ..... 23 GENERAL INFORMATION 4.5.5 Bar passage guide - Installation ........4 ......23 1.1. MANUAL PURPOSE 4.6. PNEUMATIC CONNECTION ......24 1.2. MANUFACTURER AND MACHINE 4.7. ELECTRIC CONNECTION .......... 5 IDENTIFICATION 4.8. ADDITIONAL PUSH-BUTTON PANEL - ......5 ...........
  • Page 6 INDEX MACHINE MAINTENANCE .... 46 7.1. MAINTENANCE - GENERAL RULES ..... 47 7.2. PERIODIC MAINTENANCE - TABLE ........47 7.2.1 Air filter unit - Check ......48 7.2.2 Revolving tip - Inspection ......... 49 7.2.3 Lubricating points TROUBLES - CAUSES - REMEDIES ........

  • Page 7: General Information

    GENERAL INFORMATION Before carrying out any servicing whatsoever on the machine , it is of the utmost importance to read this manual carefully. 1.1. MANUAL PURPOSE This manual has been written and supplied by the manufacturer and is integral part of the machine and of its equipment.

  • Page 8: Manufacturer And Machine Identification

    GENERAL INFORMATION 1.2. MANUFACTURER AND MACHINE IDENTIFICATION (fig. 1) A - Manufacturer’s identification B - CE conformity marking C - Year of manufacture D - Machine model E - Serial number F - Feeding voltage G - Mains frequency H - Amperage L - Alternate driving voltage M - Direct driving voltage N - Weight.

  • Page 9: Technical Specifications

    TECHNICAL SPECIFICATIONS 2.1. DESCRIPTION OF MODELS VIP 80 bar feeders are available in two models, accor- ding to the max. length of the bar to feed. Model Type Max. bar length (mm) 1400 VIP 80 15 (*) 1560 (*) Model supplied upon request and for special installations only, to be agreed upon from time to time.

  • Page 10: Main Parts

    TECHNICAL SPECIFICATIONS • • • • • • • 28.002 Ec.2 2.2.1 Main parts (fig. 1) A - Magazine where bars are stored. B - Bar lifting device it lifts the first bar and moves it from the magazine on to the guide channel. C - Bar selector it lifts the first bar as this is lifted by the device B.

  • Page 11: Working Cycle - General Description

    TECHNICAL SPECIFICATIONS P - Switch cabinet it contains the electrical control panel. Q - Bar passage guide (OPTIONAL) this device, equipped with a guard, is necessary whenever there is a considerable gap between the feeder and the lathe. It is used to guide the bar while it covers the distance between the feeder and the lathe, thus improving bar feeding into the spindle.
  • Page 12 TECHNICAL SPECIFICATIONS – The guide C sinks (fig. 5). 28.006 Ec.0 – The bar pusher E sinks; the bar-pusher axis is positioned along the spindle axis (fig. 6). • 28.007 Ec.0 – The bar pusher E is engaged in the carriage D (fig.
  • Page 13 TECHNICAL SPECIFICATIONS – After each feeding, the bar pusher E moves back from the bar B (fig. 9). • • 28_010_1 – The bar remnant F is ejected either directly by the bar pusher E or by the next bar G which is fed on (fig.

  • Page 14: Safety Devices

    TECHNICAL SPECIFICATIONS 2.4. SAFETY DEVICES (fig. 12) A - Emergency button S85; in an emergency, press it to stop all feeder/lathe functions. B - Emergency button S86; in an emergency, press it to stop all feeder/lathe functions. C - Interlocked mobile guard: it is connected to the •...

  • Page 15: Technical Specifications

    TECHNICAL SPECIFICATIONS 2.6. TECHNICAL SPECIFICATIONS (fig. 14) 28_015_2 Model Min. bar diameter ø 5 mm Max. bar diameter ø 80 mm Min. bar length 250 mm Max. bar length 1400 mm 1560 mm Magazine capacity (working width) 750 mm Bar pusher diameter ø12 (10) - 15 (12) - 21 (18) mm Feeding speed (adjustable) MAX 750 mm/s...

  • Page 16: Axial Displacement Device

    TECHNICAL SPECIFICATIONS 2.7. AXIAL DISPLACEMENT DEVICE - DESCRIPTION (FIG.5) t allows the feeder to be moved away from the lathe to allow maintenance, cleaning or any other servicing of the lathe. Release and rotate lever A for conveying. DANGER - WARNING: Make sure that safety hook B has passed block C, in order to prevent the bar feeder from sliding freely over the guides.

  • Page 17: Safety Procedures - General Information

    ❑ Safety labour regulations issued by each country the manufacturer. authority shall be strictly complied with. ❑ Do not use hoses as grips. ❑ IEMCA declines any liability whatsoever for dama- ges to people or property due to the non-obser- vance of the above mentioned regulations. 3.4.

  • Page 18: Machine Maintenance - Safety Procedures

    ❑ Preserve the exhausted oil in suitable containers and deliver it to stocking and disposal of polluting wastes companies. Do not pollute environment. ❑ Use original IEMCA spare parts only. - 15 -...

  • Page 19: Handling And Installation

    HANDLING AND INSTALLATION 4.1. PACKAGING (fig. 1) 28_016_2.bmp The machine can come in three different packagings: A - With no packaging. B - On a pallet: the feeder is placed on a pallet and wrapped in protective film. C - In a case: the feeder is placed in a case and wrapped in protective film.
  • Page 20 HANDLING AND INSTALLATION 28_017_2.bmp ❏ Lifting with no packaging (fig. 2) – Install the two round-eye eyebolts A with threaded stem (type 1 UNI - ISO 3266 M20). – Fit a wooden pad B. – Lift the bar pusher support C to prevent it from being damaged.

  • Page 21: Machine Setting - Characteristics

    HANDLING AND INSTALLATION ❏ Lifting with case (fig. 4) Use a hook-up lifting device of suitable capacity. 28.019 Ec.0 4.3. MACHINE SETTING - CHARACTERISTICS (fig. 5) – The floor should be stable and well-levelled so as to allow good anchoring to the ground. –...

  • Page 22: Preparing The Bar Feeder For Installation

    HANDLING AND INSTALLATION 4.4. PREPARING THE BAR FEEDER FOR INSTALLATION Before positioning and installing the bar feeder close to the lathe, do the following: – Lift the bar feeder and assemble plates A and feet B (fig. 6). 28.025 Ec.1 –...

  • Page 23: Installation - Foreword

    HANDLING AND INSTALLATION In case of axial displacement foot "D" is fixed directly to the base. – lift the magazine C and install the foot D as shown in figure 9; 28_082_1 DANGER - WARNING: The bar feeder should be fixed to the floor before loading bars in the magazine;...

  • Page 24: Height - Adjustment

    1118 - 1149 5 and 7 1150 - 1187 – tighten the screws A and remove the eyebolts B. 28_028_1.bmp For higher adjustments, shims are available that can be placed under the foot supports (ask IEMCA Service staff). 28_083_0.bmp - 21 -...

  • Page 25: Alignment - Levelling

    Should the floor be in such a condition so as not to guarantee a good anchorage of the feeder, fasten the feeder to the lathe. Fig. 17 shows a generic example. For more details, ask the "IEMCA Service staff". 28.033 Ec.0 - 22 -...

  • Page 26: Bar Passage Guide - Installation

    HANDLING AND INSTALLATION 4.5.5 Bar passage guide - Installation (fig. 18) – Saw the guide of the length L necessary to cover the distance between bar feeder and lathe spindle. – Position it in its seat. – Adjust the guide height. The bar axis (resting on the bar) should be aligned with the feeding axis.

  • Page 27: Electric Connection

    HANDLING AND INSTALLATION 4.7. ELECTRIC CONNECTION DANGER - WARNING: This type of intervention should only be entrusted to qualified personnel with specific skills in accordance with the applicable regulations and standards. As a rule, the feeder comes equipped with a multipolar electric plug to be plugged into the specially provided lathe socket (check the "Wiring diagram"...
  • Page 28 HANDLING AND INSTALLATION - 25 -...

  • Page 29: Adjustments And Setup

    ADJUSTMENTS AND SETUP 5.1. ADJUSTMENT AND SETUP - FOREWORD DANGER - WARNING: Unless otherwise stated in this manual, do not adjust the feeder when it is working. Besides normal adjustments which may become necessary over its service life, this machine should also be adjusted to suit its required type of work.

  • Page 30: Bar Pusher Working Position - Adjustment

    ADJUSTMENTS AND SETUP 5.2.2 Bar pusher working position - Adjustment (fig. 2) When the bar pusher A has been lowered, the groove on lever B must be aligned with the carriage pin C. To adjust the bar pusher working position: –...
  • Page 31 ADJUSTMENTS AND SETUP To be able to carry out the replacement, clear the front part of the feeder by proceeding as follows: – Press to start the feeder. – Press to select the manual cycle. – The feeder can be in two positions: guide lifted or bar pusher lowered.

  • Page 32: Magazine Inclination - Adjustment

    ADJUSTMENTS AND SETUP 5.3.2 Magazine inclination - Adjustment (fig. 4) Adjust the magazine inclination according to the bar diameter verifying its angle by means of index C. BAR DIAMETER INCLINATION (A) (mm) ø5÷15 22° ø16÷53 16° ø54÷70 10° ø71÷80 5° The data shown in the table refer to round bars.

  • Page 33: Guide Lifting Limit Switch - Adjustment

    ADJUSTMENTS AND SETUP 5.3.5 Guide lifting limit switch - Adjustment. (fig. 7) When the bar A, is on the lifted guide B, its axis must coincide with the loading axis. The lifting limit switch must be adjusted according to the stock diameter and shape.

  • Page 34: Bar Pusher - Selection And Installation

    ADJUSTMENTS AND SETUP 5.3.6 Bar pusher - Selection and installation (fig. 9) Install a bar pusher with a diameter which is suitable for the bar diameter (see table below). BAR DIAMETER ØA - ROD ØB - BEARING (mm) DIAMETER (MM) DIAMETER (MM) 5÷12 10÷19...

  • Page 35: Use And Operation

    USE AND OPERATION 028_051_2.bmp 6.1. PUSH-BUTTON PANEL - DESCRIPTION OF CONTROLS The push-button panel controls are divided as follows: A - Main controls. B - Controls for manual operation. C - Display controls and LEDS. - 32 -...
  • Page 36 USE AND OPERATION ❑ Main controls Green lighted push-button; it starts the feeder. Press the key and keep it pressed until the indicator light corre- sponding to the key itself turns on. Red push-button; it stops the feeder. Key-operated two-position selector Position : the push-button panel is enabled for the “message display”...
  • Page 37 USE AND OPERATION ❑ Programming and manual functions controls 28_053_2.bmp Key to select bar feeder manual operation. Key for bar pusher forward manual motion at low speed. Key to select bar feeder automatic opera- Key for bar pusher forward manual tion.
  • Page 38 USE AND OPERATION ❑ Display controls and LEDS 21 22 15 17 16 • F( ) IDM - 36.004 Ec. 0 Key for numerical value 1. 11 - Key for “minus” or “plus” sign. F( ) 12 - Key for “comma” sign. •...
  • Page 39 USE AND OPERATION 19 - Red LED: 22 - Green LED: OFF mode - It indicates that there is no OFF mode - signals that the display is not display warning ; active; ON mode - It indicates that there is ON mode - signals that the display is display warning .

  • Page 40: Additional Push-Button Panel - Description Of Controls

    USE AND OPERATION ADDITIONAL PUSH-BUTTON PANEL DESCRIPTION OF CONTROLS 28_055_2.bmp 26 - Selector for switching from the automatic cycle to the manual cycle and vice versa: position : manual cycle position : automatic cycle. 27 - Carriage progress/return selector: position <<< : carriage return position >>>...

  • Page 41: Bar Stock - Characteristics And Preparation

    USE AND OPERATION 6.2. 6.3. BAR STOCK - CHARACTERISTICS AND PREPARATION The bar stocks must comply with the features shown in the table. Model Min. bar diameter ø 5 mm Max. bar diameter ø 80 mm Min. bar length 250 mm Max.

  • Page 42: Tooling And Starting The Automatic Cycle - Operation Sequence

    USE AND OPERATION 6.4. TOOLING AND STARTING THE AUTOMATIC CYCLE - OPERATION SEQUENCE Bar feeder tooling and automatic cycle starting sequence for the first bar feeder start, are to be found below. – Adjust the feeder according to the type of bar to be machined (paragraph 5.3.).
  • Page 43 USE AND OPERATION 56_002_0.TIF 028_053_2 6.4.2 Starting the automatic cycle (fig. 9) – Switch on power supply from lathe. – To start bar feeder press (till indicator turns on) – Press to select the manual function. – Perform the "BAR FEEDER ZERO SETTING"...
  • Page 44 USE AND OPERATION – Press to lower the bar lifting device again. – Press to lift the guide. – Press to prefeed the bar. – Press to move the carriage back to its end- of-stroke position. – Press to lower the guide. –...

  • Page 45: Starting The Automatic Cycle

    USE AND OPERATION 6.5. FEEDER STOP CAUTION: After the feeder has stopped, do not move it manually. Use the push-buttons. ❑ Feeder emergency stop CAUTION: if the emergency stop is used during lathe machining, before resuming work make sure that the sudden stop has not created any hazardous condition (e.g., if the tool was cutting chips, move the tool away from the workpiece before restarting the lathe).

  • Page 46: Starting The Automatic Cycle - Resuming Work Following Aswitching Off

    USE AND OPERATION Otherwise, messages showing the operations to perform will be accordingly displayed. ❏ The bar feeder must shift to the AUTOMATIC mode, ready to receive the signal from lathe. Bring the bar feeder to the "BAR FEEDER WAI- TING"...
  • Page 47 USE AND OPERATION 6.8. PERFORMING A “STEP BY STEP” CYCLE Introduction This mode can be used for many reasons, as for instance; – to check a complete bar change cycle; – to check the bar feeder mechanics; – to load a single bar with the intent of checking the facing;...

  • Page 48: Ndicator Lights - Description Of

    USE AND OPERATION 6.9. INDICATOR LIGHTS - Description of indications Red light; signals that the bar feeder is not operating, or that it is in the manual mode. Green light; it indicates that the bar feeder is in the au- tomatic mode.

  • Page 49: Machine Maintenance

    MACHINE MAINTENANCE 7.1. MAINTENANCE - GENERAL RULES DANGER - WARNING: carry out machine maintenance and cleaning while the machine is off. Regular cleaning and maintenance are critical to ensure smooth operation and longer machine service life. It is recommended to regularly and effectively clean the machine, its accessories and work area, which also increases operator's safety.

  • Page 50: Periodic Maintenance - Table

    MACHINE MAINTENANCE 7.2. PERIODIC MAINTENANCE - TABLE FREQUENCY FEEDER OPERATIONS HOURS SECTION Periodically 200 1250 2000 Feed chain Tension check • and adjust- ment • Air filter Check • Revolving tip Check 7.2.1 Air filter unit - Check (fig. 1) ❑...

  • Page 51: Revolving Tip - Inspection

    MACHINE MAINTENANCE 7.2.2 Revolving tip - Inspection – Make the front end of the bar pusher come out of bushing A (fig.2). – Open the rear guard. 28.075 Ec.2 – Make sure that shaft B and bearing C turn properly with no excessive backlash.

  • Page 52: Lubricating Points

    MACHINE MAINTENANCE 7.2.3 Lubricating points (fig.4) 28_063_3.bmp Lubricate Lubricate - 49 -...

  • Page 53: Troubles - Causes - Remedies

    TROUBLES - CAUSES - REMEDIES 8.1. GENERAL TROUBLES 8.2. BAR MAGAZINE - TROUBLES THE FEEDER WILL NOT START THE BAR WON'T ENTER MAGAZINE DURING LOADING Cause No power input. Cause The magazine covering frame is Remedy Cure too low. Check electric connection. Remedy Cure Cause...
  • Page 54 TROUBLES - CAUSES - REMEDIES Cause Bar passage guide adjustment too high. Remedy Cure Adjust bar passage guide to right height. Cause Feeder not aligned with lathe. Remedy Cure Check and correct alignment. THE CARRIAGE WON'T COMPLETE ITS PREFEED STROKE Cause The bar is too long.

  • Page 55: Part Replacement

    PART REPLACEMENT 9.1. FEED CHAIN - REPLACEMENT (fig. 1) – Remove the front guard. – Slacken the chain (see paragraph 5.2.1). – Remove the fork pin A and the link B. – Replace the chain. – Fit the link B and the fork pin A back in their posi- tion.

  • Page 56: Keyboard Battery - Replacement

    PART REPLACEMENT 9.3. KEYBOARD BATTERY REPLACEMENT (fig. 3) Replace the battery every year or when battery signal- ling lamp 23- sends a blinking red signal. INFORMATION: If no replacement takes place, date and hour disappear from the display. Replace the battery as follows: –...

  • Page 57: Feed Motor Drive - Replacement

    PART REPLACEMENT 9.5. FEED MOTOR DRIVE - Replacement – Disconnect power and remove the faulty drive A from its seat (fig. 5); settle the new drive and power the feeder back on. – Motor setting should now be checked (function T. offset);...

  • Page 58: Sensor Of The Short Feed Door - Replacement

    PART REPLACEMENT 9.6. SENSOR OF THE SHORT FEED DOOR - REPLACEMENT (Fig. 6) – Open the rear guard. – Replace sensor A keeping 1 mm distance from came B. 28_079_3.bmp - 55 -...
  • Page 59 ANALYTICAL INDEX 302.028 of the controls of the push-button panel, 32 Additional push-button panel, description of controls, of the main parts, 7 Diameter change-over of the reduction sleeves, 27 push-button panel, installation, 24 Adjustment according to bar type, foreword, 27 and set up, foreword, 26 Electric connection power supply, connection, 24 and setting up safety procedures, 14...
  • Page 60 ANALYTICAL INDEX 302.028 Noise levels, 12 Use and operation, safety procedures, 14 Operation sequence for tooling and starting the auto- Working cycle, general description, 8 matic cycle, 39 Packaging, 16 Periodic maintenance, table, 47 PLC battery replacement, 53 Pneumatic connection, 23 supply, connection, 23 Position and description of the safety labels, 11 Positioning, 20...
  • Page 61 VIP 80 AUTOMATIC BAR FEEDER 03/11/99 PUSH-BUTTON PANEL OPERATION GUIDE...
  • Page 62 GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.
  • Page 63 INDEX 302.061 GENERAL INFORMATION 1.1. PUSH BUTTON PANEL - CONTROL DESCRIPTION ............3 MAIN SCREENFUL - DESCRIPTION..................8 1.3. DATE AND CLOCK - PROGRAMMING ................10 INSTALLATION PROCEDURE 2.1. OPERATOR PARAMETERS - DESCRIPTION AND SETTING ........13 2.1.1 Operator parameters - Description..................17 2.2. ERRORS - CAUSES - SOLUTIONS ..................37 2.3.
  • Page 64 302.061...

  • Page 65: General Information

    GENERAL INFORMATION 302.061 1.1. PUSH BUTTON PANEL - Control description 028_051 Ec.2 A - Main controls. B - Controls for manual operation. C - Display controls and LEDs.
  • Page 66 GENERAL INFORMATION 302.061 ❑ Main controls Green lighted push-button; it star- ts the feeder. Press the key and S 73 keep it pressed until the indicator li- ght corresponding to the key itself turns on. Red push-button; it stops the fee- der.
  • Page 67 GENERAL INFORMATION 302.061 ❑ Programming and manual functions controls IDM - 61.003 Ec. 0 Key to select bar feeder manual opera- 12 - Key for manual forward movement of bar tion. pusher at low speed. Key to select bar feeder automatic opera- Key for manual backward movement of tion.
  • Page 68 GENERAL INFORMATION 302.061 ❑ Display controls and LEDs 21 22 15 17 16 • F( ) IDM - 36.004 Ec. 0 Key for numerical value 1. 12 - Key for “comma” sign. • Key for numerical value 2. 13 - Key for “CLEAR”...
  • Page 69 GENERAL INFORMATION 302.061 21 22 15 17 16 • F( ) IDM - 36.004 Ec. 0 19 - Red LED: 22 - Green LED: OFF mode - indicates that there is no si- OFF mode - signals that the display is not gnal on the display;...

  • Page 70: Main Screenful - Description

    GENERAL INFORMATION 302.061 1.2. MAIN SCREENFUL - Description When loading is on, the following screenful appears on the display: it appears: B a r f e e d e r w a i t i n g MA N U A L MO D E P o s i t i o n f r o m ‘...
  • Page 71 GENERAL INFORMATION 302.061 Press: it appears: 1 5 . 0 P A S S WO R D : type password 0510 (not displayed): plus if code is P A S S WO R D : 1 5 . 0 * * * * wrong it appears: wait for some seconds and repeat.

  • Page 72: Date And Clock - Programming

    GENERAL INFORMATION 302.061 1.3. DATE AND CLOCK - Programming Access data entering mode turn the selector: onto position recall “MAIN MENU” press: MAIN it appears: 5 - 0 2 - 0 0 1 2 : 0 9 : 4 0 ME N U * * * * * *...
  • Page 73 GENERAL INFORMATION 302.061 Hour setting press: press: Minutes setting press: press: Seconds setting press: press: If only one value programming is needed For instance, if only the hour programming is needed press: more than once to move the selecting cursor onto the hour value. Hour setting press: Exiting from date and time programming mode...
  • Page 74 GENERAL INFORMATION 302.061...

  • Page 75: Installation Procedure

    INSTALLATION PROCEDURE 302.061 2.1. OPERATOR PARAMETERS - Description and setting Introduction These parameters concern programming of the bar feeder automatic cycle; the relative values must be entered on the basis of work requirements and type of machine to which the bar feeder is connected. CAUTION: each parameter has a specific default value (preset value).
  • Page 76 INSTALLATION PROCEDURE 302.061 ❑ Selecting the parameters in sequence press: parameter appears. Ex: n o . 1 B a r e n d a d j u s t m e n t ( mm ) – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – – ) M o v e ←→...
  • Page 77 INSTALLATION PROCEDURE 302.061 ❑ Entering or modifying the operator parameter value The required parameter should be displayed n o . 1 B a r e n d a d j u s t m e n t 1 1 5 ( mm ) –...
  • Page 78 INSTALLATION PROCEDURE 302.061 ❑ Entering or modifying the subparameter values The desired subparameter must be displayed. N e w s p e e d 1 0 0 0 ( mm / s e c ) C o n n e c t i o n a c c e l e r a t i o n 1 1 0 0 ( mm / s e c * s e c ) N e w...
  • Page 79 INSTALLATION PROCEDURE 302.061 ❑ Parameters with self-learned values A default value is assigned to the parameters. Actually, some parameters are self-learned variables of the PLC, which vary during normal bar feeder operation. On the screenful reproduced on this manual, the self-learned value is repre- sented by an asterisk (*).

  • Page 80: Operator Parameters - Description

    INSTALLATION PROCEDURE 302.061 2.1.1 Operator parameters - Description n o . 1 B a r e n d a d j u s t m e n t : > 1 0 0 ( mm ) ( i n c h e s ) Phase machining Defines the position of the point at which the bar feeder must...
  • Page 81 INSTALLATION PROCEDURE 302.061 n o . 4 S h o r t f e e d s a f e t y : > 0 ( mm ) 0 ( i n c h e s ) Phase machining With each feed, it checks that the bar feeding corresponds to the value set at parameter 6 while remaining within the tole- parameter 4 rance set at parameter 4 .
  • Page 82 INSTALLATION PROCEDURE 302.061 n o . 6 Wo r k p i e c e l e n g t h > 0 ( mm ) ( i n c h e s ) Phase machining It defines the feeding control at every open collet.
  • Page 83 INSTALLATION PROCEDURE 302.061 n o . 7 O p e n c o l l e t s p e e d : > 2 0 0 ( mm / s e c ) ( 1 0 0 ) Phase machining It defines the speed value in “FEEDING”.
  • Page 84 INSTALLATION PROCEDURE 302.061 n o . 1 2 C o l l e t e n t r y s p e e d : > 2 0 0 ( mm / s e c ) Phase ( 1 0 0 ) bar change Defines the slow speed value in the slow speed section ( parameter 11 ).
  • Page 85 INSTALLATION PROCEDURE 302.061 n o . 1 8 S p i n d l e i m p u l s e s : > 0 , 5 ( s e c ) Phase bar change Defines the duration of the ON impulse received by the lathe to turn the spindle. It is required to facilitate the feed of shaped bars into the collet.
  • Page 86 INSTALLATION PROCEDURE 302.061 Mode 1 - “Ejection” or 2 - “Bar change advance” Introduction These modes can be implemented PROGRAM only if the lathe allows subprograms. The subprogram must move away the stop after the “bar end” signal. When the stop is moved away, the bar remnant can be ejected from the lathe side.
  • Page 87 INSTALLATION PROCEDURE 302.061 2 - “Bar change advance” Allows the bar feeder to perform the bar change while the lathe is beginning the machining of the last workpiece. The bar change starts in advance, without waiting for the end of the machining of the last workpiece and that the bar pusher has reached point F.
  • Page 88 INSTALLATION PROCEDURE 302.061 Sliding headstock lathes: enter the headstock stroke value, ad- ding some millimetres to avoid any contact between the bar-pu- sher and the bar during machining. Headstock stroke +2÷3 mm Headstock stroke 31.060 Ec.1 n o . 2 6 Wo r k p i e c e s p r i o r l a t h e...
  • Page 89 INSTALLATION PROCEDURE 302.061 n o . 2 9 M a x . f e e d i n g p o s i t i o n m o d i f i c a t i o n ( i n c h e s ) : >...
  • Page 90 INSTALLATION PROCEDURE 302.061 n o . 3 0 L a n g u a g e 1 I - 2 G B - 3 D - 4 F - 5 E : > 1 Phase Defines the language of the messages on screen. •...
  • Page 91 INSTALLATION PROCEDURE 302.061 1 - (RETURN) As soon as the bar feeder reaches the “BAR END” position, it activates relay K1 lathe “COLLET CLOSING”. With the next “COLLET OPENING”, the bar feeder receives the “FEEDING” and “BAR CHANGE” signals. With “BAR CHANGE-OVER” signal activated, relays K13 and K19B are also activated.
  • Page 92 INSTALLATION PROCEDURE 302.061 2 - (K13 IMMEDIATE) When the bar feeder reaches the “BAR END” position, it activates relay K1, lathe “COLLET CLOSING”. With the next “COLLET OPENING”, the bar feeder receives the “FEEDING” and “BAR CHANGE” signals”. Relay K13 activates through the “FEEDING” signal following the “BAR END” signal.
  • Page 93 INSTALLATION PROCEDURE 302.061 3 - (IMMEDIATE RETURN) During lathe “OPEN COLLET” feeding, when the bar feeder detects the “BAR END” signal, relays K1-K13-K19B activates at the same time, thus allowing the bar feeder to perform the “BAR CHANGE-OVER”. Interface signal cycle diagram BAR CHANGE-OVER CYCLE MACHINING MACHINING...
  • Page 94 INSTALLATION PROCEDURE 302.061 4 - (FEEDING) As far as “BAR CHANGE-OVER” signal control is concerned, this option dif- fers from option 1 - (RETURN). Said signal controls more bar-pusher feeding movements, whenever they are required by lathe during workpiece machining. In this condition, the “BAR CHANGE”...
  • Page 95 INSTALLATION PROCEDURE 302.061 5 - (K1 ENABLED) This option allows the lathe to check, at any cycle, if the bar feeder has rea- ched the “BAR END” position, thus activating relay K1. Relays K13-K19B are activated at the following collet opening, through the “FEEDING”...
  • Page 96 INSTALLATION PROCEDURE 302.061 n o . 3 2 i mm e d i a t e e x i t : > 0 Fase machining The bar end signal K1 is sent to the lathe as soon as the bar feeder detects the end of the bar.
  • Page 97 INSTALLATION PROCEDURE 302.061 n o . 3 5 F i x e d w o r k p i e c e f e e d i n g : > 0 Phase machining Subparameters Wo r k p i e c e l e n g h t C u t t i n g t o o l...
  • Page 98 INSTALLATION PROCEDURE 302.061 n o . 3 6 K 1 5 D i s a b l i n g : > 1 Phase machining Turns off the signalling of parameter 35 in position 1 at every use. n o . 3 7 K 1 5 t i m e : >...
  • Page 99 INSTALLATION PROCEDURE 302.061 n o . 4 0 S u b s pi n d l e m o d e : > 0 Phase machining Subparameters Wo r k p i e c e l e n g h t C u t t i n g t o o l l e n g h t...

  • Page 100: Errors - Causes - Solutions

    INSTALLATION PROCEDURE 302.061 2.2. ERRORS - CAUSES - SOLUTIONS The display may signal the occurrence of errors during the calibration of the bar feeder or the machining of pieces. These errors may be the result of incorrect programming, operational errors, or mechanical or electrical faults. When errors are detected, the bar feeder stops.
  • Page 101 INSTALLATION PROCEDURE 302.061 E r r o r : f e e d s t o p ERROR CAUSE SOLUTION Check the “INTERFACE FROM The bar pusher stop interface signal LATHE” signal. The carriage has stopped moving. from the lathe is present. Check the wiring.
  • Page 102 INSTALLATION PROCEDURE 302.061 E r r o r : t h e b a r f a i l s e n t e r i n t o t h e c o l l e t ERROR CAUSE SOLUTION Check the diameter of the bushing.
  • Page 103 INSTALLATION PROCEDURE 302.061 E r r o r : g a t e o p e n ERROR CAUSE SOLUTION Check that the area is free from The gate could not close because of obstruction (swarf, bar remnants, At the beginning of the first feeding an obstacle.
  • Page 104 INSTALLATION PROCEDURE 302.061 E r r o r : l o n g f e e d ERROR CAUSE SOLUTION Check the value of parameter 5 During feed, the bar is at a position The value of parameter 5 is too past that given by based on the length of the piece to high.
  • Page 105 INSTALLATION PROCEDURE 302.061 ( E r r o r : . . . ) P r e s e t q . t y r e a c h e d , r e s e t ! ! ! CAUSE SOLUTION Reset the number of workpieces at parameter 26 , then...
  • Page 106 INSTALLATION PROCEDURE 302.061 E r r o r : s a f e t y f r o m l a t h e ERROR CAUSE SOLUTION The interface from lathe signal, Check the “SAFETY FROM LATHE” The safety devices of the lathe are which stops the bar feeder, is interface signal.
  • Page 107 INSTALLATION PROCEDURE 302.061 E r r o r : f l a g n o t k n o c k e d ERROR CAUSE SOLUTION Load new bars into the bar feeder The short feed flag was not knocked No bar.
  • Page 108 INSTALLATION PROCEDURE 302.061 E r r o r : t h r e a d s a f e t y ERROR CAUSE SOLUTION Check the correct operation of the Threading device fault. device on the lathe. Check the correct operation of the The lathe failed to the thread on the Threading device fault.
  • Page 109 Check on the display the position of Encoder fault. the bar pusher carriage, and verify that the position change indicated corresponds to the actual movement. facing flag IDM - 61.021 Ec.0 Contact IEMCA technical assi- Card fault. stance.
  • Page 110 INSTALLATION PROCEDURE 302.061 R e s e t w i t h S T O P ! ! ! ERROR CAUSE SOLUTION Examples: Wrong bar-pusher move- The bar feeder has stopped due to Correct fault and reset with STOP ment, bar not loaded in collet, bar a fault.
  • Page 111 INSTALLATION PROCEDURE 302.061 E r r o r : M a n u a l f r o m k e y b o a r d ERROR CAUSE CURE After the selector switch on the To actuate the “AUTOMATIC” mode The “MANUAL”...
  • Page 112 INSTALLATION PROCEDURE 302.061 E r r o r : f a c i n g t i m e o u t ERROR CAUSE SOLUTION Check the K15 interface signal: The bar reached the facing position, "Cycle Start". The bar feeder does not actuate the but the lathe did not restart.
  • Page 113 Bar change was not completed in restart the work cycle. system stops the machine if the bar the expected time. In case of serious faults, contact change cycle is not completed IEMCA technical assistance. within a set time.
  • Page 114 INSTALLATION PROCEDURE 302.061 P L C b a t t e r y e x h a u s t e d ERROR CAUSE SOLUTION Replace the battery within one day Signals that the charge of the PLC Battery charge low. (See Chapter 9 of the Use and batter is low.

  • Page 115: Programme Identification Data - Displaying Procedures

    INSTALLATION PROCEDURE 302.061 2.3. PROGRAMME IDENTIFICATION DATA - Displaying procedures The four programs installed in the bar feeder are as follows: - Push-button panel Firmware; - Push-button panel Software; - PLC/CN Software. - PLC/CN Firmware. For various reasons (e.g., request for assistance) it may be useful to display the identification data of the first three programs listed, according to the fol- lowing procedure.
  • Page 116 GENIUS 112 GENIUS 226 GUÍA OPERATIVA DEL TECLADO PARA EL TECNICO AUTORIZADO 29/05/00 227005505 REL. DATA COD.

  • Page 117: Setup Information

    SETUP INFORMATION 302.061 3.1. PROTECTED PARAMETERS FOR SETTING-UP - Description Foreword These parameters affect the bar feeder configuration and the bar feeder-lathe inter- face. Entering or modifying the value of such parameters is mainly required during the installation of the bar feeder, performed by an authorised technician. CAUTION: Each parameter has a specific default value (preset value).
  • Page 118 SETUP INFORMATION 302.061 ❑ Accessing the setup protected parameters Access the data entering mode turn the selector: onto position recall “MAIN MENU” press: MAIN date time it appears: 5 - 0 2 - 0 0 1 2 : 0 9 : 4 0 * * * ME N U * * *...
  • Page 119 SETUP INFORMATION 302.061 ❑ General procedures Selecting the parameters in sequence press: it appears. Ex: n . 4 7 P h a s e Z E R O A X I S Selecting the parameter required Recall “MAIN MENU” press: MAIN it appears: 5 - 0 2 - 0 0...
  • Page 120 SETUP INFORMATION 302.061 ❑ Subparameters Some parameters have subparameters. To access the subparameters, scroll down the parameter screen image press many times: to return to the parameter screen image press many times: ❑ Parameters with self-learned values A default value is assigned to the parameters. Actually, some parameters are self-learned variables of the PLC, which vary during normal bar feeder operation.

  • Page 121: Description Of Bar Feeder Phase Parameters

    SETUP INFORMATION 302.061 3.1.1 Description of bar feeder phase parameters n . 4 6 P h a s e R E T U R N Subparameters P o s i t i o n 0 ( mm ) S p e e d 1 5 0 0 ( 2 0 0 0 )( mm / s e c ) A c c e l e r a t i o n 3 0 0 0 ( mm / s e c * s e c )
  • Page 122 SETUP INFORMATION 302.061 n o . 4 9 P h a s e B A R L O A D I N G The phase during which the bar from the magazine is loaded on the guide. n o . 5 0 P H A S E G U I D E C H A N N E L...
  • Page 123 SETUP INFORMATION 302.061 n o . 5 2 P h a s e F E E D I N G R E T U R N A F T E R 1 s t Subparameters P o s i t i o n * ( mm ) 1 5 0 0 ( 2 0 0 0) ( mm / s e c ) S p e e d...

  • Page 124: Description Of Reference Value Parameters

    SETUP INFORMATION 302.061 3.1.2 Description of reference value parameters n o . 5 7 M a x . b a r l e n g h t ( i n c h e s ) 1 2 0 0 ( mm ) It defines the maximum length of the loadable bar.
  • Page 125 SETUP INFORMATION 302.061 n o . 6 1 I N T R O D U C T I O N V A L U E ( X ) * ( mm ) ( i n c h e s ) n o .
  • Page 126 SETUP INFORMATION 302.061 n o . 6 5 C O L L E T + F A C I N G V A L U E ( C I ) * ( mm ) ( i n c h e s ) The value of this parameter is self-learnt by the program.

  • Page 127: Axis Function Parameter Description

    INFORMATION: Once the parameter values are set, the power supply must be disabled and then enabled again, if the set values are to be self-learned. It is recommended to avoid changing these parameters; if a change is necessary, call the IEMCA service depart- ment.
  • Page 128 SETUP INFORMATION 302.061 E p s S t 0 , 5 0 ( mm ) T i m S t 1 0 0 ( s e c / 1 0 0 0 ) F c M i n - 1 2 ( mm ) 1 6 3 0 ( mm ) F c M a x Version...
  • Page 129 SETUP INFORMATION 302.061 n o . 7 3 F a s t f o r w a r d m o t i o n Subparameters S p e e d 5 0 0 ( mm / s e c ) 2 0 0 0 ( mm / s e c * s e c ) A c c e l e r a t i o n It defines the speed of the bar pusher carriage related to key n.
  • Page 130 SETUP INFORMATION 302.061 n o . 7 7 T h r u s t v a l u e p a i r c h e c k s e l e c t i o n Subparameters T h r u s t v a l u e f o r b a r...

  • Page 131: Interface Parameters - Description

    SETUP INFORMATION 302.061 3.1.4 Interface parameters - Description n o . 8 5 I n t e r f a c e s i g n a l s Subparameters F e e d ( 0 = N O / 1 = N C ) ( 0 = N O / 1 = N C ) B a r c h a n g e...

  • Page 132: Description Of Generic Parameters

    SETUP INFORMATION 302.061 3.1.5 Description of generic parameters n o . 8 7 F i r s t f e e d i n g s p e e d c h a n g e Subparameters N e w s p e e d 9 0 0 ( 8 0 0 )( mm / s e c ) a c c e l e r a t .
  • Page 133 SETUP INFORMATION 302.061 n o . 8 8 F a c i n g s p e e d c h a n g e Subparameters N e w s p e e d ( s e e p a r a m . N o . 1 2 ) * ( mm / s e c ) a c c e l e r a t .
  • Page 134 SETUP INFORMATION 302.061 n o . 9 0 Wr o n g b a r f e e d e r p h a s e : > 0 0 - K37 enabled with guide channels closed in manual mode. 1 - Bar feeder in manual mode and lathe in automatic mode.
  • Page 135 SETUP INFORMATION 302.061 n o . 9 6 R e t u r n s a f e t y < – > P . 4 6 D : > 4 ( mm ) Tolerance referred to parameter 46 . n o .
  • Page 137 It is also necessary to transmit the identification data of ters compiled, together with the values assigned (atta- the HARDWARE installed in the bar feeder (attach- chments A, B, C, D, E, F), to the IEMCA service. ment G). ❑ Example of filling in...
  • Page 139 302.061 Customer Date Bar feeder model Machine tool model LIST OF GENERIC PARAMETERS Default Assigned Description of parameters Page par. value value Bar end adjustment mm-inch Facing length mm-inch Facing mode Short feed safety mm-inch Long feed safety mm-inch Workpiece lenght mm-inch Open collet speed mm/sec...
  • Page 140 302.061 Default Assigned Description of parameters Page par. value value k1 immediate exit k2 inversion Feeding torque Fixed workpiece feeding Workpiece lenght Cutting tool lenght k15 Disabling sec 36 K15 time sec 36 K13 time Spindle stop Sub spindle mode mm-inch Workpiece lenght Cutting tool lenght...
  • Page 141 302.061 Customer Date Bar feeder model Machine tool model LIST OF BAR FEEDER PHASE PARAMETERS Default Assigned Description of parameters Page par. value value Phase 1 - RETURN Position Speed 1500 mm/sec Acceleration 3000 mm/sec Phase 2 - ZERO AXIS Research speed Release speed mm/sec...
  • Page 142 302.061...
  • Page 143 302.061 Customer Date Bar feeder model Machine tool model LIST OF REFERENCE VALUE PARAMETERS Default Assigned Description of parameters Page par. value value Max . bar lenght 1200 mm-inch First feeding value (B) 1622 mm-inch Bar loading value (X) mm-inch Collet-flag distance (B1C) 1375 mm-inch...
  • Page 145 302.061 Customer Date Bar feeder model Machine tool model LIST OF AXIS FUNCTION PARAMETERS Default Assigned Description of parameters Page par. value value Axis parametring MmImp 2857,5 mm/imp. InvEn InvVo TipAb TodAb TyAzz PDfh VelMx 1666 mm/sec DecEm 6000 mm/sec AlgCo PrcFd ErrEc...
  • Page 146 302.061 Default Assigned Description of parameters Page par. value value Fast forward motion Speed mm/sec Acceleration 2000 mm/sec Fast backward motion Speed -500 mm/sec Acceleration 2000 mm/sec Zero point research motion Thrust value pair check selection Thrust value for bar change Manual thrust value pair Collet inlet torque Feeding torque...
  • Page 147 302.061 Customer Date Bar feeder model Machine tool model LIST OF INTERFACE PARAMETERS Default Assigned Description of parameters Page par. value value Interface signals Feed Bar change Manual/automatic from lathe Loading cycle Feed stop Threading safety Start from lathe Safety from lathe Door safety Startup safety Startup start...
  • Page 149 302.061 Customer Date Bar feeder model Machine tool model LIST OF GENERIC PARAMETERS Default Assigned Description of parameters Page par. value value First feeding speed change New speed Connection acceleration. New speed point Facing speed change New speed Connection acceleration 2000 New speed point Exhibition demo...
  • Page 151 302.061 Customer Date Bar feeder model Machine tool model HARDWARE IDENTIFICATION DATA PLC card serial number: Enabling card serial number: EEPROM model:...

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