USER’S MANUAL

Numerically controlled machining centre

Master

P5802P0010 English
Issue.Revision: 1.4
Serial number
 Document information

Document information

Code: Issue: Revision: Approval:

P5802P0010 1 4 UT-07/RM022

List of updates
Revision: Added: Cancelled: Modified:
0 new
1 Insertion of technological parameters
2 General update
3 Insertion of Master 30
4 Insertion of Master Twin

This manual, containing proprietary and reserved information, has been prepared by BIESSE for
the sole use of its customers. It is therefore forbidden to reproduce and/or divulge its contents,
whole or in part and in any form, without BIESSE written consent.

The manual is supplied with the machine and must therefore be appropriately stored in a known
place, to be easily accessible to operating and/or maintenance personnel. It must be carefully
referred to throughout the life of the machine, with which it must remain even in the event of its
sale to a third party.

This manual must be used by personnel adequately trained in the use of the machine.
BIESSE can neither be responsible nor be prosecuted as a result of damage deriving from the
incorrect use of this information. To avoid incorrect use of the equipment likely to endanger
personnel, it is important that all the documentation delivered with the machine be read and
understood.

The company reserves the right to modify the pictures and/or the contents of this manual without
notice. Not every picture and/or information contained in the chapters of this manual will
necessarily correspond to the machine purchased by the Customer.

BIESSE S.p.A. © - Copertina.fm270607 3

Document information

4 BIESSE S.p.A. © - Copertina.fm270607

 Table of contents

Table of contents

1. Introduction
Aim and limits of this Manual ...................................................................................... 13
Documents with the machine ..................................................................................... 13
Conventional notations .............................................................................................. 13
Warnings .................................................................................................................... 14
PC warranty limitations ............................................................................................... 14

2. General safety instructions

2.1 Lifting and handling the machine ..................................................................................... 15
2.2 Installation ........................................................................................................................ 15
2.3 Overcurrent protection ..................................................................................................... 16
2.4 Protection against indirect contacts ................................................................................. 16
2.5 Protection against fire ...................................................................................................... 16
2.6 Tooling up the machine .................................................................................................... 16
2.7 Setting up for operation and operating the machine ........................................................ 17
2.8 Maintenance .................................................................................................................... 18
2.9 Demolition ........................................................................................................................ 19
2.10 Danger signs .................................................................................................................... 20
2.11 General prohibition signs ................................................................................................. 21
2.12 Signs indicating obligatory actions ................................................................................... 21
2.13 Signs affixed to the machine ............................................................................................ 22

3. Warranty and After Sales Service

3.1 Warranty ........................................................................................................................... 23
3.2 After Sales Service ........................................................................................................... 23

4. Machine description
4.1 General description of the machine ................................................................................. 25
4.2 Configurations of machines of the Master line ................................................................ 25
4.3 General view and main component parts Master ............................................................. 31
4.4 Machine base ................................................................................................................... 35
4.5 X-Y axis beam .................................................................................................................. 36

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4.6 X axis carriage ................................................................................................................. 37

4.7 3 axes (X, Y, Z) head ....................................................................................................... 38
4.8 3 axes (X, Y, Z) operating head with tilting axis “T” ......................................................... 39
4.9 3 axes (X, Y, Z) operating head with “C” axis .................................................................. 40
4.10 4 axes operating head (X, Y, Z,C) ................................................................................... 41
4.11 3 axes (X, Y, Z) operating head with tilting axis “T” and “C” axis ..................................... 43
4.12 5 axes operating head ..................................................................................................... 44
4.13 Work table ........................................................................................................................ 45
4.14 Revolving type tool magazine .......................................................................................... 47
4.15 Linear type tool magazine ................................................................................................ 50
4.16 Revolving type head mounted tool-holder store (optional) ............................................. 52
4.17 Safety devices .................................................................................................................. 53
4.18 Identification of manufacturer and machine .................................................................... 55

5. Fundamental notions
5.1 Axes ................................................................................................................................ 57
5.2 Moving the axes in the manual mode ............................................................................. 60
5.3 Axes travel speed variation .............................................................................................. 60
5.4 Working areas ................................................................................................................. 60
5.5 Stops and suction cups .................................................................................................... 61
5.6 Origins .............................................................................................................................. 62
5.7 Direction of rotation of the spindles ................................................................................. 63
Definition of left-hand and right-hand rotation ............................................................ 63
5.8 Machine operation ........................................................................................................... 63

6. The Right and the Wrong ways to use the machine

6.1 The Right Way to use the machine .................................................................................. 65
6.2 Characteristics and dimensions of machinable materials ................................................ 65
6.3 Possible machining operations ........................................................................................ 66
6.4 Personnel qualifications ................................................................................................... 67
6.5 Operator work station ....................................................................................................... 67
Machine positioning ................................................................................................... 69
6.6 Danger area ..................................................................................................................... 69
6.7 Residual risks .................................................................................................................. 70

7. Technical characteristics
7.1 Layout .............................................................................................................................. 74
Master 23 ................................................................................................................... 74
Master 30 ................................................................................................................... 75
Master 33 - 35 ............................................................................................................ 77
Master 33 - 35 PLUS ................................................................................................. 79
Master 43 - 45 ............................................................................................................ 81
Master 43 - 45 Plus .................................................................................................... 83
Master 33 TWIN ........................................................................................................ 85

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Master 43 TWIN ......................................................................................................... 87

7.2 General data .................................................................................................................... 89
7.3 Admissible weight on worktop .......................................................................................... 89
7.4 Water consumption .......................................................................................................... 90
7.5 Electrical characteristics ................................................................................................... 90
7.6 Illumination ....................................................................................................................... 90
7.7 Technical data for 1400 W heat exchanger (in S1 operation) .......................................... 91
7.8 Main machine axes X, Y, Z ............................................................................................. 92
X axis displacements, Master 23 ................................................................................ 92
Y axis displacements, Master 23 ............................................................................... 93
X axis displacements, Master 3 - 4 and Plus versions .............................................. 94
Y axis displacements, Master 3 - 4 and Plus versions .............................................. 95
X - Y Axes displacement, Line Master 3 TWIN .......................................................... 96
7.9 Motor driven spindle ......................................................................................................... 96
7.9.1 Spindle characteristics .................................................................................................. 97
7.10 Vacuum system ................................................................................................................ 98
7.11 Working range along the Z axis ...................................................................................... 98
7.12 Noise level ...................................................................................................................... 104

8. Machine shipping and handling

8.1 Instructions about transport and installation of the machine .......................................... 105
8.2 Parts to be transported ................................................................................................... 106
8.3 Unloading of the machine .............................................................................................. 107
8.3.1 Responsibilities for machine loading and unloading ................................................... 107
Manufacturer’s responsibilities ................................................................................. 107
Buyer’s responsibilities ............................................................................................. 107
8.3.2 Lifting in safety ............................................................................................................ 107
Advice on the use of lifting equipment ...................................................................... 107
8.3.3 Lifting ........................................................................................................................... 109

9. Machine erection and installation

9.1 Machine arrangements, connection points, overall dimensions ............................. 111
9.2 Installation area requirements ........................................................................................ 111
Electrical system requirements ............................................................................... 111
Pneumatic system requirements .............................................................................. 112
Vacuum system requirements ................................................................................. 112
Floor requirements .................................................................................................. 113
Environmental requirements .................................................................................... 113
9.3 Machine supporting feet layout ...................................................................................... 114
9.4 Levelling the machine .................................................................................................... 117
Priming the external water pump .............................................................................. 119
9.5 Installing the guards ....................................................................................................... 120
9.6 Connecting the machine to the hydraulic plant .............................................................. 122
Connecting the mains water supply ......................................................................... 122
9.6.1 Using the machine with centralised machining water recovery system ...................... 123
9.6.2 Use of the machine with (optional) machining water collection tanks (optional) ......... 124

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9.7 Connection of the machine to the electrical system ....................................................... 125

9.7.1 Connecting cable ........................................................................................................ 126
9.7.2 Power ratings for Master machining centers ............................................................... 127
9.8 Connecting the machine to the air system ..................................................................... 129
9.9 Supplied equipment ....................................................................................................... 129

10. Machine controls and signalling devices

10.1 Location of machine controls and signalling devices Master 23 .................................. 132
10.2 Location of machine controls and signalling devices Master ........................................ 134
10.3 Main control panel .......................................................................................................... 138
10.4 Tool magazines pushbutton panels ............................................................................... 140
10.5 Lock/release tool pushbutton panel and connection for electric feeler .......................... 141
10.6 Remote control pushbutton panel .................................................................................. 142
Type RM850 ............................................................................................................. 142
10.6.1 Using the remote control ............................................................................................. 144

11. Tooling-up the machine

11.1 Information about tools .................................................................................................. 145
Diamond bonded wheel for edges (standard) ......................................................... 147
Polishing wheel for edges (standard) ...................................................................... 147
Bonded diamond wheel for chamfers ...................................................................... 148
Polishing wheel for chamfers ................................................................................... 148
Cylindrical miller for machining shapes (standard) ................................................... 149
Vertical drilling tool (standard) .................................................................................. 149
Vertical graphitising tool (standard) .......................................................................... 150
Hole flaring tool (Standard) ...................................................................................... 150
Horizontal milling aggregate, high body ................................................................... 151
Horizontal milling aggregate, low body .................................................................... 153
Cup shaped disc aggregate D=200 and horizontal miller ........................................ 155
Straight disc aggregate D=250 ................................................................................ 157
Straight disc aggregate D=350 ................................................................................. 159
Straight disc aggregate D=500 (with epicyclical gear reducer) ................................ 161
15° Cumbered disc for shaped edge cut .................................................................. 164
30° cumbered disc aggregate for shaped edge cut ................................................. 166
Cumbered disc aggregate D=250 ............................................................................ 168
Cup shaped wheel aggregate .................................................................................. 170
Flat edge aggregate wheel ....................................................................................... 172
Grinding aggregate for incisions .............................................................................. 176
Vertical drilling aggregate ......................................................................................... 178
11.1.1 Description of tool configuration parameters ............................................................... 180
Tools assembly ........................................................................................................ 181
Edge machining ....................................................................................................... 186
Edge chamfer machining ......................................................................................... 193
Inclination of the diamond rim profile ....................................................................... 208
Profile inclination values ........................................................................................... 210
11.1.2 Description of configuration parameters on marlbe and granite tools ......................... 220

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Routing (GRANITE) .................................................................................................. 221

Routing (MARBLE) ................................................................................................... 235
Special tools ............................................................................................................. 249
Aggregate straight disk D=200 ................................................................................. 250
Straight disk aggregate D=350 ................................................................................. 251
Aggregate straight disk D=500 (with epicyclic reduction unit) .................................. 252
Aggregate convex disk D=250 - 30° ........................................................................ 253
Aggregate convex disk D=180 - 30° ........................................................................ 254
Aggregate with horizontal cutter ............................................................................... 256
Aggregate bottom drilling ......................................................................................... 258
Aggregate for grooving - flute ................................................................................... 259
Aggregate for cup grinding ....................................................................................... 261
11.2 Tools assembly .............................................................................................................. 262
11.2.1 Tool assembly on ISO 40 taper spindle ...................................................................... 262
11.2.2 Grinding wheel assembly on ISO 40 tapered spindle ................................................ 264
11.2.3 Mounting the tools on the aggregates ......................................................................... 265
11.3 Use of the tracer ............................................................................................................. 267
11.4 Laser pre-setter group (optional) .................................................................................... 270
11.4.1 General rules and warnings ........................................................................................ 271
Precautions to be taken when using a laser device ................................................. 271
11.4.2 General description and technical data ....................................................................... 272
System’s functions and operating principles ............................................................ 272
Description of the system ......................................................................................... 272
11.4.3 Possible applications ................................................................................................... 274
Machining centres .................................................................................................... 274
11.4.4 Compressed air requirements ..................................................................................... 274
11.4.5 Technical characteristics ............................................................................................. 274
11.4.6 Operating ambient conditions ..................................................................................... 275
11.4.7 Shutter air filtering system ........................................................................................... 276
11.4.8 Curtain air filtering system ........................................................................................... 276
11.4.9 Maintenance ................................................................................................................ 276
11.5 Tool dresser for “vertical drill” (optional) ........................................................................ 277
11.6 Dresser for polishing wheels (optional) ......................................................................... 278
11.7 Workpiece rotated origin tracer (optional, 3 axes operating heads, with or without C/T axes)
279
11.8 Tracer of the origin of a randomly loaded workpiece (optional for 5 axes machine) ..... 280

12. Setting up the tool magazine

12.1 Setting up the revolving type tool magazine .................................................................. 281
Setting up the spindles ............................................................................................. 282
Setting up the tool magazine with aggregates ......................................................... 282
Usable tools .............................................................................................................. 283
Compatibility ............................................................................................................. 283
12.2 Setting up the linear type tool magazine ........................................................................ 285

13. Work table make-ready

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13.1 Positioning the mobile elements of the work table ......................................................... 287
13.1.1 Selection of the origin .................................................................................................. 287
13.1.2 Positioning stops and suction cups ............................................................................. 288
13.1.3 Positioning stops and suction cups with the Laser Projector ...................................... 289
General norms and warnings ................................................................................... 291

14. Basic machine operations

14.1 Starting the machine ...................................................................................................... 293
14.2 Resetting the machine axes ........................................................................................... 294
14.3 Warm-up cycles for the operating head ......................................................................... 294
14.4 Stopping the machine .................................................................................................... 294
14.5 Resetting the machine functions .................................................................................... 295
14.6 Turning off the machine ................................................................................................. 296

15. Machining operations

15.1 Warnings about machining ........................................................................................... 297
15.1.1 Warnings about working with Master Twin .................................................................. 297
15.2 Procedure for machining operations ............................................................................. 298
15.2.1 Procedure for machining with Master twin machine .................................................... 298
15.3 Meaning and selection of origins .................................................................................. 299
Meaning of origins .................................................................................................... 299
Description of parameters ........................................................................................ 299
15.4 Positioning and fixing of the workpiece .......................................................................... 300
15.5 Use of the machine in the manual mode (movement of the axes) ................................. 301
15.6 Machine operation in the automatic mode ..................................................................... 301
15.7 Starting machining operations ....................................................................................... 301
15.8 Machining cycle ............................................................................................................. 302
15.9 Machining of identical workpieces ................................................................................. 302
15.10 Tool change ................................................................................................................... 302
15.11 Unloading the workpiece ............................................................................................... 303
15.12 Interruption of machining operations .............................................................................. 303

16. Ordinary and extraordinary Maintenance

16.1 Ordinary maintenance .................................................................................................... 307
Cleaning ................................................................................................................... 308
Cleaning the Workable and the Lexan guards ......................................................... 308
Cleaning the tool store ............................................................................................. 309
Cleaning Stainless steel cones ............................................................................... 310
Cleaning the suction cups ........................................................................................ 311
................................................................................................................................. 311
................................................................................................................................. 311
................................................................................................................................. 311
Cleaning the process water pump ........................................................................... 312
Cleaning the filters of tool internal cooling water ...................................................... 313

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Cleaning the tanks (when applicable) ..................................................................... 314

Cleaning the process water pump filter (when applicable) ....................................... 315
Cleaning the vacuum filter ........................................................................................ 316
Cleaning the vacuum pump ..................................................................................... 317
Cleaning the guides ................................................................................................. 318
Centralised lubrication system maintenance ............................................................ 318
Lubrication system check ......................................................................................... 319
Filling-up the reservoir with lubricant ........................................................................ 319
Manual lubricating points .......................................................................................... 320
Manually lubricating Master 2 .................................................................................. 320
Manual lubrication 500mm saw aggregate disk store .............................................. 322
Maintenance of the tool aggregates ......................................................................... 323
Sliding doors maintenance ...................................................................................... 324
Maintenance of air treatment units ........................................................................... 325
Dynamic air drying filter ............................................................................................ 326
Cleaning and replacement of the dynamic air drying filter ....................................... 327
Oil remuval filter replacement ................................................................................... 328
Cleaning and replacement of the electro-mandrel pressurisation air filter ............... 330
Maintenance of the spindle cooling system .............................................................. 331
Maintenance of the Cerium Oxide tanks .................................................................. 333
Topping up the cerium oxide tank A ......................................................................... 333
Topping up the cerium oxide tank B ......................................................................... 333
Cerium duct washing cycle ....................................................................................... 334
Summary and frequency of maintenance operations ............................................... 335
16.1.1 Characteristics of lubricants ........................................................................................ 336
16.2 Extraordinary maintenance ........................................................................................... 337
16.2.1 Cleaning the worktop with aggregate brush (optional) ................................................ 337
Using the aggregate brush for cleaning the worktop (optional) ................................ 337
16.2.2 Rectifying the worktop ................................................................................................. 339

17. List of messages

18. De-installation - demolition

19. Annexes
19.1 Layout - Laser Projector Installation ............................................................................... 345

20. Drawings and diagrams

Analytical Index 351

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 1. Introduction

1. Introduction

Aim and limits of this Manual

This manual is for the user of the machine and contains all the basic information that he must know
before he can put it to work. The manual further contains the maintenance information essential to
keep the machine efficient and safe during its working life.

In order to make a correct use of the machine it is also necessary to consult the Software
Instructions and eventual Annexes.

The actual configuration of some machine members or associated devices described or pictured in
the manual may differ from the actual machine equipment. This however will not be an obstacle for
the full comprehension of the subject.

Documents with the machine

The main documents delivered with the machine are described in the following list.
! Operating Instructions ; contains the basic information related to the operation and the
maintenance of the machine.
! Software Instructions (CDrom); contains information about the procedures that must be
followed in order to write the programs that can be run on the software used on the machine.
! Electrical drawings; describing the electrical equipment of the machine for the use of the
trouble shooting engineer.
! Pneumatic system diagrams; describing the pneumatic system of the machine for the use of
the trouble shooting engineer.
! Declaration of uniformity to EC standards; certifying that the machine satisfies the
specified directives. Issued only for machines sold within the European Community market
and in other countries recognising Directive 98/37.

Conventional notations
Those parts of the text which must not overlooked are highlighted and preceded by the symbols
illustrated and defined here below.

Danger
Text highlighted by this symbol indicates imminent danger and must be carefully
considered in order to avoid bodily harm.

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1. Introduction

Attention
Text highlighted by this symbol indicates procedures and behaviour to be adopted in
order to avoid damage to the machine and associated objects.

Information
This symbol highlights particularly important indications that are not to be overlooked in any
case.

Warnings
Before the machine is put in operation, read the safety information at the end of this manual.

PC warranty limitations
The correct operation of the PC is guaranteed at the following conditions:
! The PC installed must carry the INTERMAC approval.

! The PC must be configured as per Operating Instructions issued by Intermac.

! NO Hardware, unless explicitly authorized by Intermac, must be mounted on the PC.

! NO Software, unless explicitly authorized by Intermac, must be installed on the PC. This
condition applies to the operating system (Windows) as well as to other application software.
As far as Windows in concerned, no eventual updates nor service packs must be installed
unless explicitly authorized by Intermac. In other words, the only version Windows and
included service pack is the one contained on the CD supplied with the PC.

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 2. General safety instructions

2. General safety instructions

If used by qualified personnel and in accordance with the recommendations and instructions
contained in this manual, the machine will operate in full safety. BIESSE will not be liable for
damages or bodily injuries deriving from the actions of inexperienced and unqualified operators, or
from failure to conform to the following recommendations.

Danger
Removing the machine or the switchboard cubicles protections to perform unscheduled
operations will expose the operator to dangerous situations. BIESSE will not be liable for
damages to the machine and injuries to the operators caused by the improper and
unscheduled or deliberately incorrect use of the machine.

Danger
In case of an electrical or mechanical breakdown, do not take any individual initiative to
operate or manoeuvre the machine, unless you are qualified to do so. You may
compromise your own safety and that of others.

The operator’s behaviour, as well as that of maintenance, cleaning, control etc. personnel, must be
thoroughly in conformity with the accident prevention regulations of the country of destination of
the machine.

2.1 Lifting and handling the machine

1. Lifting and moving the machine, or any part thereof, must be carried out by personnel with
specific experience, using equipment of adequate capacity.

2. Do not stand in the area of action of the crane during lifting operations.

3. The only correct way to lift the machine is the one described in this manual.

2.2 Installation
1. The installation of the machine must be carried out by personnel qualified for the job and
authorised by INTERMAC.

2. Before you start to install the machine check that its various parts and components do not
show signs of damage due to bumps, tearing or abrasions. Damaged electrical sheaths and
cables of the electrical system will compromise the electrical safety of the machine.

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2. General safety instructions

3. The machine room must be uniformly lit, without glare or stroboscopic effects due to the
lighting fixtures provided by the user.
The minimum values established by the regulation for industrial and craft activities for general
machining at the machine is 300 LUX (lx).

2.3 Overcurrent protection

1. The electrical equipment supplied with the machine is protected against overcurrents
(particularly short circuit currents) by devices appropriate for the internal need of the machine
itself.

2. The user has the responsibility to provide overcurrent protection for the supply line, and in
particular a protection against the presumed overcurrents deriving from short circuits on the
house system at the point of connection with the machine.

2.4 Protection against indirect contacts

1. The user’s upstream electrical system must be designed, installed and maintained in
conformity with the legally prescribed safety regulations concerning “low tension
applications”.

2. Within the mandatory conditions mentioned under point 1), the corresponding “earthing
protection system” must fully conform to all applicable prerequisites for coordination with the
associated active devices.

2.5 Protection against fire

1. Use only powder or gas fire extinguishers on electrical parts. Water jets directed against the
machine might cause short circuits. If the fire is not immediately extinguished, beware of
possible dispersions of air, water, oil and heating fluids. If the machine should burn for an
extended period of time, tanks and pipes under pressure might explode. Be therefore very
careful not to be hit by the fluids from bursting tanks and pipes.

2. It is good practice to place fire extinguishers by the machine. Fire prevention begins with a
clean machine, free from traces of oil, solvents, rags, etc.

2.6 Tooling up the machine

When selecting the tools that are to be mounted on the machine, please follow these instructions.

1. Never utilise revolving tools which are either deformed or cracked.

2. Make sure that revolving tools are perfectly balanced and sharpened and that they are the
right tools for the job in hand.

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 2. General safety instructions

3. Never use tools at speeds beyond the limits marked on them, or otherwise specified by their
manufacturer.

4. Before installing a tool in its working position, make sure that its guide and centring surfaces
are clean and not dented.

5. Tighten screws, bolts, nuts or rings of each tool with the prescribed torque.

6. Always check that the sense of rotation of the tool is the same as the spindle on which it will be
mounted.

7. Never exceed the limits given in this manual or otherwise supplied by BIESSE.

2.7 Setting up for operation and operating the

machine
1. Before starting to operate the machine, the operator must have full knowledge of the position
and function of all the controls and characteristics of the machine.

2. He must wear protective clothing, goggles, gloves, helmet and shoes of an approved type.

3. He must not try to modify the programs in safety control systems. BIESSE will not answer for
any damage or injury caused by such modifications, unless expressly authorised.

4. He must make sure nobody else comes anywhere near the machine during set-up operations.
Machine set-up must be carried out by only one person.

5. When entering the work area, he must take the key off the “Axes disconnection” selector, so
that nobody can start the machine inadvertently.

6. He must not leave tools on the machine when the setting-up job is finished.

7. Before starting the machine, he must check that no one is present in dangerous areas.

8. He must make sure that there are no obstructions to the free movement of the machine along
its axes, and that every guard, door and protection cover is in its place and securely fastened.

9. Before starting any machining operation, he must make sure that no one else has tampered
with the machine tooling.

10. He must not use the machine under the influence of drugs or drinks that might affect his
reflexes.

11. He must always keep the work area clean.

12. He must not climb on the machine whilst a program is running or when the axes are in motion.

13. In case of sudden power failure during machining operation, the electrically driven spindle
might continue to rotate by inertia. An operator must always wait a few minutes before going
anywhere near the tool, or always check, anyway , that the tool has come to rest.

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2. General safety instructions

2.8 Maintenance
1. Maintenance must be done at the indicated intervals.

2. In order to guarantee a faultless performance of the machine, always use original spare parts.

3. Before any maintenance or cleaning job, stop the machine and turn the power off, following
the procedures given in the manual.

4. Repair work on pneumatic components must be preceded by a pressure discharge of the

whole system.

5. Repair work on electric components must be done with power off and the emergency
pushbutton pressed.

6. Always wait 5 or 6 minutes before going near electronic equipment: condensers need some
time to disperse residual energy.

7. Only qualified personnel must be entrusted with maintenance.

8. Every time that a machine group has to be installed or taken down, be sure to use lifting
equipment of adequate load capacity.

9. Transfer the load immediately on adequate supports or trestles.

10. Do not attempt to climb on the machine or descend from it whilst it is in motion.

11. Never use petrol (gasoline), solvents or other flammable fluids to clean machine components.
Always use approved commercial detergents which are neither flammable nor toxic.

12. When doing repair work in areas which are not accessible from ground level, always use a
ladder or steps which conform to local or national standards.

13. Carry out all maintenance and repair work with the utmost care and attention, as described in
this manual.

14. Once the job is finished, check all safety devices for efficiency before putting the machine
back to work.

15. Always use protective equipment.

16. Use electrical tools which conform to current safety regulations.

17. Before starting the machine, make sure nobody is in the process of doing maintenance on it.

18. Do not work under or near any mechanism which is not adequately supported and fixed.

19. Before doing any cleaning, repair or other type of job on the machine, make sure to lock the
starter switch.

20. Wear goggles with side screens.

21. Before taking any guard off, bring the machine to a complete stop by turning off power at the
mains and make sure that none of its elements is still in motion.

22. The machine must be used for the work it was designed for.

23. The machine must always be used in accordance with the safety regulations in force in every
nation.

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 2. General safety instructions

24. Do not smoke, eat or drink while handling lubricants. Follow the existing regulations about
handling mineral oils and greases.

25. To avoid skin irritation and allergies, always wear goggles, or an anti splash screen, oil proof
gloves and clothing.

26. Keep lubricants in a naturally ventilated room and away from sources of heat (electrical
switchboard cubicles, free flames, etc.)

27. It is advisable to avoid direct contact between lubricants and pure oxygen or acids.

28. All used lubricants can be disposed of by committing them to authorised companies.

29. In the event of a lubricant spill, the product must be absorbed with sand, which can then be
collected and committed for incineration to a company authorised for the disposal of Special
Refuse. Wash the affected surfaces with a solvent (aliphatic or chlorine based), taking good
care that the vapours do not stagnate in the workshop.

30. Persons particularly sensitive to lubricants may develop an allergic reaction or a skin rash,
especially if the skin is already weakened by the action of abrasives (hand cleaners), by
wounds or by the chemical action of solvents and strongly alkaline detergents. Contact with
the eyes may cause irritation.

31. In cases of incorrect handling of lubricants there may be effects from over exposure, like for
instance a slight irritation of the eyes or of the skin. If this should happen, move away from the
polluted area and consult a physician.

32. If the lubricant comes into contact with the skin, wash with water and soap.

33. In the case of contact with the eyes, wash only with water.

34. If a lubricant which is classified as an “oil” is swallowed, contact a physician immediately.

35. If a lubricant which is classified as a “grease” is swallowed in small quantity, call a physician
immediately. If the quantity is not so small, say half a litre, drink one or two glasses of water
and call a physician immediately. Do not induce vomit if the person is unconscious and do not
give anything to be taken by the mouth.

2.9 Demolition
1. Demolition work must be entrusted to qualified personnel.

2. Turn the machine off, disconnect it from the electric supply line and discharge all the air from
the pneumatic system.

3. Dismount and put away all the tools still present on the machine.

4. Fasten all parts likely to move under inertial or gravity forces.

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2. General safety instructions

2.10 Danger signs

The following is a list with description of the danger signs present on the machine.

> DANGER ! Do not go near the gears or any other mechanism that might start to
move.

E DANGER ! Before doing any work on an electrical circuit, make sure that the
power is off.

= DANGER ! Risk of having hand crushed by moving mechanical elements.

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 2. General safety instructions

2.11 General prohibition signs

9 Do not remove safety guards. The temporary removal of guards and safety
devices is allowed only for purposes of necessary maintenance after all the
necessary safety measures have been taken.

7 Access to the machine operating area is prohibited.

8 Do not clean or lubricate moving machine parts.

? Do not smoke near the machine.

2.12 Signs indicating obligatory actions

6 Make sure all guards and safety devices are in full working order.

4 Turn off power before inserting or extracting an electric plug.

5 Appropriate clothing must be worn.

; Protective shoes must be worn.

0 A helmet must be worn.

3 Gloves must be worn.

1 Ear protection must be used.

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2. General safety instructions

2.13 Signs affixed to the machine

! Signs affixed to the machine must in no case be removed.

! Signs must be clearly legible and must not be covered by other objects.

! Signs that have deteriorated in time must be replaced. Ask the manufacturer for new ones.

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 3. Warranty and After Sales Service

3. Warranty and After Sales Service

3.1 Warranty
For information about the warranty please refer to the literature supplied with the sales contract.

3.2 After Sales Service

BIESSE S.p.A. has a worldwide organization for after sales service. The entire organization
constitutes an integrated network of service centers to which users can turn for information,
advice, or news.

In our service centers engineers with the knowledge and the operating experience of our
equipment are always available. These engineers are factory trained and can travel to wherever
they are needed.

The BIESSE authorized Service Centers are listed in the InDocs cd-rom.

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3. Warranty and After Sales Service

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 4. Machine description

4. Machine description

This chapter contains information about the machine, its main and optional component parts, and
about the configurations of its various available models.

4.1 General description of the machine

Master is a numerically controlled machining centre, which is capable of machining, with tools held
on the operating head, a workpiece (or more workpieces) held on a work table. In the following
paragraphs are described the various machine configurations of Master, and a general view of it in
which its main component parts are identified and described.

4.2 Configurations of machines of the Master line

The Master line of machines (*) includes the following models:
! Master 23;

! Master 30;

! Master 33 - 43 twin;

! Master 33 - 35;

! Master 43 - 45;

! Master 33 Plus - 35 Plus - 43 Plus - 45 Plus, with extended Z axis.

Information
The first number identifies the size of the machine; the second number identifies the number
of machining axes.

Information
This Manual covers the entire Master line of machines. Refer to the specific paragraph for
the characteristics of any particular Master model.

The model of every Master can be read on a plate whose position on the machine can be obtained
by referring to paragraph 4.18 “Identification of manufacturer and machine”.

* Refer to Appendix B1 for more information about the dimensions of the various models.

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4. Machine description

Master 23

Depending on the requested optional equipment, the machine can have the following
characteristics:
! 3 standard axes (X, Y, Z) machine

! 3 axes (X, Y, Z) machine with C axis aggregate

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 4. Machine description

Master 30

Depending on the optional equipment requested, the machine can have the following
characteristics:
! 3 standard axes (X, Y, Z) machine.

! 4 axes (X, Y, Z, T) machine, where “T” is the tilting axis for marble bas-relief surfaces.

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4. Machine description

Master 33 - 43 twin

The two machines are equipped as follows:

4-axis machine (X, Y, Z, C), where “C” is the interpoling axis which manages the movement of the
two electro-spindles.

Master 33 – 43

Depending on the optional equipment requested, the machine can have the following
characteristics:

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 4. Machine description

! 3 standard axes (X, Y, Z) machine .

! 3 axes (X, Y, Z) machine with C axis aggregate

! 4 axes (X, Y, Z, T) machine, where “T” is the tilting axis for marble bas-relief surfaces.

! 5 axes (X, Y, Z, T) machine with C axis aggregate.

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4. Machine description

Master 35 - 45

Depending on the optional equipment requested, the machine can have the following
characteristics:
! 5 axes (X, Y, Z, C, A) machine, anthropomorphic head.

Master 33 Plus - 35 Plus - 43 Plus - 45 Plus

Similar to Master 33 - 35 - 43 - 45, but with extended Z axis

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 4. Machine description

4.3 General view and main component parts Master

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4. Machine description

A - Base; of monolithic type: it includes the work table. For further information see page 35
B - Operating head; mounted on the moving beam, it includes an electric motor driven spindle.
The Master twin version has two electro-spindles.
C - Work table; supports the workpiece during machining. For further information see page 45
D - X axis moving beam; supports the operating head and moves along the machine side
frames. 36.
E - Revolving type and straight line type tool magazine; for further information see page 47
and page 50.
F - Switchboard cubicle; houses the main electronic equipment.
G - Numerical control and operator’s console; are used to operate the machine. For further
information see chapter 10. “Machine controls and signalling devices”.
H - Lubrication system; to lubricate the least accessible points of the machine (slide blocks,
slides, etc.)
I - Vacuum system; used for the suction cups. Vacuum pump of the liquid ring type.
L - Glycol spindle cooling system; to keep the electric motor driven spindle at constant
temperature.
M - Tool water cooling system; according to the version, it can work off the water mains or with
an appropriate water pump. It is equipped with filters to keep out impurities. It circulates water
through the body of the tool to cool it down and thus prevent swarf particles from sticking to
the cutting edge.
N - Process water recycling system; this is equipped with a pump to draw water either from the
central plant or from the settling tanks (optional) and send it under pressure to the nozzles
arranged around the tool.

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 4. Machine description

V
S

Q
Z
T

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4. Machine description

O - Dynamic drying filter group; located before the pressure regualtor on the machine, it
discharges, automatically and at regular intervals, the condensate from its own collecting cup.
For further information see page 326.
P- Flow regulator; supplies air at nominal 7 bar pressure to the pneumatic system of the
machine. A pressure sensor on the machine is activated when the pressure drops below 6
bar.
Q- Pressure booster with air tank: is utilized to boost the air pressure in order to facilitate the
removal of the tool from the spindle.
R- Electro-mandrel pressurization group; is utilized to regulate the air pressure inside the
spindle motor, which is necessary to keep the water out. The machine is fitted with a sensor
which trips when the pressure falls below the factory set value. See paragraph 7.9.
S- Safety barrier; prevents access to dangerous areas of the machine.
T- Control pedals; used to operate the vacuum cups and the stops.
U- Cerium oxide plant; comprises tank, pump and stirrer.
V- Laser presetter air filter unit (optional); not present in figure, supplied on demand.
Z - Oil separator; is positioned upstream of the regulator filter, it acts to automatically, and at
regular intervals, discharging the oil that has accumulated in its collection vat. For further
details consult the maintenance chapter.

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 4. Machine description

4.4 Machine base

The machine base is made in one piece and consists of two beam-connected side frames. The
beams also act as supports for the girders on which the work table rests, surrounded by fixed and
mobile guards. All the on board machine equipment is housed in recesses on both sides of the
base. Adjustable feet A are provided for machine levelling.

Process water collecting trays B to go under the machine base can be supplied on request. The
tray for the vacuum pump C is supplied as standard with the machine.

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4. Machine description

4.5 X-Y axis beam

This is a mobile beam which supports the head carriage operating along the X axis. The beam ,
runs on re-circulating ball sliders along guides on the base side frames.

The beam is moved along the side frames by means of re-circulating-ball lead screws, each
driven by two brushless motors (one motor at each end) via timing belts.

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 4. Machine description

4.6 X axis carriage

The X axis carriage moves along the mobile beam on re-circulating ball type guides, driven by a
nut box and lead screw type mechanism, running on re-circulating ball bearings.
! On Master 23, screw (A) is driven by a brushless motor while the nut box remains stationary.

! on Master 3 - 4 (and Plus versions), lead screw (A) is stationary and nut-box on carriage (B)
rotates, driven by a brushless motor.

Master 23

Master 30-33-35-43-45 and Plus

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4. Machine description

4.7 3 axes (X, Y, Z) head

The operating head is mounted on the mobile beam and it includes:
A - Vertical axis Z, with its brushless motor and compensating pneumatic cylinder.
B - Electrically driven spindle.

Information
The electrically driven spindle is kept cool by a Glycol refrigerating system located on the
RH side of the machine, together with its heat exchanger.

Head 23 Head 33 - 43

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 4. Machine description

4.8 3 axes (X, Y, Z) operating head with tilting axis

“T”
The operating head is mounted on the mobile beam and it includes:
A - Vertical axis Z, with its brushless motor and compensating pneumatic cylinder.
B - Electrically driven spindle.

Information
The electrically driven spindle is kept cool by a Glycol refrigerating system located on the
RH side of the machine, together with its heat exchanger.

C- “T” axis , with brushless motor and precision gear reducer.

D- Pneumatic “T” axis, with pneumatic cylinder.

D
C

Head 33 T - 43 T Testa 30 T

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4. Machine description

4.9 3 axes (X, Y, Z) operating head with “C” axis

The operating head is mounted on the mobile beam and it includes:
A - Vertical axis Z, with its brushless motor and compensating pneumatic cylinder.
B - Electrically driven spindle.

Information
The electrically driven spindle is kept cool by a Glycol refrigerating system located on the
RH side of the machine, together with its heat exchanger.

C- “C” axis, mounted on the electrically driven spindle, it allows infinite rotation of the tool.

B
B

C
C

Head 23 C Head 33 C - 43 C

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 4. Machine description

4.10 4 axes operating head (X, Y, Z,C)

The Master twin version is characterised by an operating head with two independent spindles
which can be used as a couple or separated. The independent management guarantees the use
of different tools in the machining with double spring, and makes it possible to assign different
technological parameters to each spindle.

The operating head consists of:

A - Vertical axis Z, with brushless motor and compensation pneumatic cylinder.
B - 2 electro-spindles: called primary and secondary; the primary spindle is the one aligned
with the rotation of axis C.

Information
The electrically driven spindle is kept cool by a Glycol refrigerating system located on the
RH side of the machine, together with its heat exchanger.

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4. Machine description

C- Axis “C”, of infinite rotation type. Consents the interpolation and orientation of the two
electro-spindles, other than allowing the assembly of aggregates (on the primary
electro-spindle only).

A
C

Head 33 twin - 43 twin

In the upper part of the operating head are housed the following components:
! A rotating joint for fluids, carrying the cooling fluids.

! An rotating electrical connection, with brushes and sliding contacts.

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 4. Machine description

4.11 3 axes (X, Y, Z) operating head with tilting axis

“T” and “C” axis
The operating head is mounted on the mobile beam and it includes:
A - Vertical axis Z, with its brushless motor and compensating pneumatic cylinder.
B - Electrically driven spindle.

. Information
The electrically driven spindle is kept cool by a Glycol refrigerating system located on the
RH side of the machine, together with its heat exchanger.

C- “C” axis, mounted on the electrically driven spindle, it allows continuous rotation of the tool.
D - “T” axis , with brushless motor and precision gear reducer .

D
C

Head 33 CT - 43 CT

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4. Machine description

4.12 5 axes operating head

The operating head is mounted on the mobile beam and it includes:
A - Vertical axis Z, with its brushless motor and compensating pneumatic cylinder.
B - Electrically driven spindle.

Information
The electrically driven spindle is kept cool by a Glycol refrigerating system located on the
RH side of the machine, together with its heat exchanger.

A
B

Head 35 - 45

In the upper part of the operating head are housed the following components:
! A rotating joint for fluids, carrying the cooling fluids.

! An rotating electrical connection, with brushes and sliding contacts.

Information
Both devices are indispensable, since the C axis is in continuous rotation.

! A pressurised tank with incorporated stirrer and cerium oxide (used in glass polishing).

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 4. Machine description

4.13 Work table

The worktable is obtained with extruded aluminum sections fixed to the machine frame with
screws. The aluminum surface is ground directly on the machine after this has been installed.

Workpiece fixing devices

A - Suction cups:
• double: to hold onto the work table on one side and to hold the workpiece on the other side.
• for marble: available on request are also suction cups with screw clamps, necessary to
hold heavyweight workpieces 3-4 cm thick.
B - Stops: constitute a reference against which the workpieces are pushed.

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4. Machine description

Manifolds and stop cocks

Located in accessible positions under the work table on the front and on the back of the machining
area.

Every manifold includes:

- Black valves, to create vacuum between the worktable and the stops.
- Red and blue valves, to control the raising and the lowering of the stops.
- Yellow valves, to create vacuum between the worktable and the suction cup.
- White valves, to create vacuum between the suction cup and the workpiece.

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 4. Machine description

4.14 Revolving type tool magazine

On Master machines models 3-4 can be equipped with two tool magazines of the revolving type,
each holding up to 14 tools. The magazine located on the LH side is standard with the machine the
one on the RH side is on request.

In the Master twin version, the included magazine has been designed for the simultaneous change
of tool in the two electro-spindles. It contains 12 tools and makes it possible to change tools at the
same time on both spindles or only on the primary spindle. It is not possible to add aggregates.
On the right of the machine it is possible to assemble the same left magazine (optional) or, as an
alternative, a 14-position standard magazine used in the other versions, with the possibility to add
aggregates.
For further information please check paragraphs 11.2 and 12.1.

Information
If tool aggregates are placed in the magazine, the total number of available tools per
magazine diminishes on account of the extra size of the aggregates.

During a machining operation the tool magazines remain in their respective housing recesses,
which are closed by heavy doors. The magazines come out of their housings only when there is a
tool to be changed. They are pushed out by pneumatic cylinders and move on re-circulating ball
type sliders. The magazine is rotated by a geared motor located on the axis itself.

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4. Machine description

Revolving type tool magazine with 14 positions

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 4. Machine description

Master Twin revolving type tool magazine with 12 positions

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4. Machine description

4.15 Linear type tool magazine

The Master 30 machine is equipped with a linear tool holder store with 12-positions, positioned on
the left side of the work surface. It is possible on request (optional) to mount the same store on the
opposite side.

Master machine models 23 can be equipped with a linear type magazine which is located at the
rear (optional).

Information
If tool aggregates are placed in the magazine, the total number of available tools per
magazine diminishes on account of the extra size of the aggregates (on Master 23
machine).

On both machine versions the toll carrier store is fitted with a mobile section for the protection of
the tool cones.
Only in Master version 23 does the store advance in the direction of the operating head to permit
tool change.

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 4. Machine description

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4. Machine description

4.16 Revolving type head mounted tool-holder store

(optional)
On request, on Master machines size 3 and 4 and on the Master 23 machine, a revolving type
store able to contain up to 8 tools can be mounted, placed beside the operating head. This set,
conceived mainly to reduce tool change times during the machining phase, does not exclude the
possibility of also having the two revolver stores placed on the base installed on the machine.

Note
It is not possible to place aggregates on the head mounted store.

The store is an integral part of the operator head and follows all its movements. This means that
the need to rush to a store located on the top edge is eliminated; since it is only necessary for the
head to go to the established change position without leaving the workstation.
The rotation of the revolving unit takes place with a reduction gear motor placed on the axis.

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 4. Machine description

4.17 Safety devices

D
D

C
B

A - “Emergency” Pushbutton; used to bring the machine to an immediate stop, is located on the
main operator’s control panel. For further information, consult chapter 14.
On those models fitted with hand held button panel there is a second emergency button
located on the same. See paragraph 10.6
B - Isolating valve; used to achieve safe working conditions during machine maintenance or
repair operations. The valve can be padlocked to avoid the risk of being moved by someone
else. A knob is used to open and close the valve. When the knob is turned, the valve causes
the compressed air to be discharged from the machine system, or the air supply from the
house system to be shut off. To restore full working conditions, the knob of the valve must be
pressed and turned clockwise.
C - Fixed and mobile safety guards: completely enclose the machining area and protect the
operator against injury from moving parts.

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4. Machine description

D - Safety microswitches ; placed on the front and on the back guards (optional equipment),
they will stop the machine if the guards are opened whilst in operation.

Danger
Do not remove or tamper with the safety micro-switches placed on the mobile shelters.
Do not remove mobile and fixed shelters.
INTERMAC declines any responsibility in case of negligence.

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 4. Machine description

4.18 Identification of manufacturer and machine

Manufacturer and machine are identified through appropriate nameplates attached as shown on
the figure. The nameplates show various data. For machines sold within the European Common
Market, or in markets which recognise Directive 98/37, they also carry the CE mark.
A - logo
B - CE mark A
C B
C - address
D
D - model E
E - serial number F
F - year of construction G
G - weight H
H - air supply I
I - air consumption J

J - hydraulic supply K
L
K - water consumption
L - electricity supply
M - N electric diagram
N - Supply voltage
O - Maximum current load
P - nominal current load
Q - number of phases
R - power
S - frequency
electrical system data plate
T - power of interruption of short
circuit at supply voltage. A
C B
D
E
M
N
O
P
Q
R
S
T

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4. Machine description

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 5. Fundamental notions

5. Fundamental notions

5.1 Axes
A machine axis is, by definition, any displacement in space, positive or negative, by some specific
element of the machine itself.

The following is a description of the axes which can be present on different machine versions.
! 3 axes version:
3 axes operating head
• X axis: direction of travel along the mobile
beam and the side frames;
• Y axis: direction of travel along the stationary Z+
sides of the machine Y+ X+
• Z axis: direction of travel along the vertical
axis. Y-
X-
The 3 axes version is used for marble slabs or glass Z-
plates with polished edges.

! 3 axes version with “C” axis:

• X axis: direction of travel along the mobile 3 axes operating head with “C” axis
beam and the side frames;
• Y axis: direction of travel along the stationary
sides of the machine
Z+
• Z axis: direction of travel along the vertical Y+ X+
axis.
• “C” Axis (optional): consists of a particular
type of tool fixture which, when installed on X- Y-
the spindle of a 3 axes version machine, Z-
keeps an aggregate tool (disc type, etc.)
continuously rotating. The “C” axis is useful
for special machining operations.

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5. Fundamental notions

! 3 axes version with “T” axis: 3 axes operating head with T axis
• X axis: direction of travel along the mobile
beam and the side frames;
• Y axis: direction of travel along the stationary
sides of the machine Z+
Y+ X+
• Z axis: direction of travel along the vertical
axis.
• T axis (tilting): the head can be rotated from X- Y-
-5° to +5° . A tilting axle, controlled in Z-
conjunction with the Z and Y axes, is used to
machine bas-relief surfaces of kitchen tops.

A 4 axes version is standard for marble machining.

! 3 axes version with “C” and “T” axis: 3 axes operating head with C and T axes
• X axis: direction of travel along the mobile
beam and the side frames;
• Y axis: direction of travel along the stationary Z+
sides of the machine Y+ X+
• Z axis: direction of travel along the vertical
axis.
X- Y-
• T axis (tilting): the head can be rotated from
-5° to +5° . A tilting axle, controlled in Z-
conjunction with the Z and Y axes, is used to
machine bas-relief surfaces of kitchen tops.
• “C” Axis (optional): consists of a particular
type of tool fixture which, when installed on
the spindle of a 3 axes version machine,
keeps an aggregate tool (disc type, etc.) C
continuously rotating. The “C” axis is useful T
for special machining operations.

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 5. Fundamental notions

! 4 axes version:
4 axis operating head
• X axis: direction of travel along the mobile
beam and the side frames;
Z+
• Y axis: direction of travel along the stationary Y+
sides of the machine X+

• Z axis: direction of travel along the vertical

axis. X- Y-
• C axis: infinite rotation about the Z axis Z-

Information
The movements on the various axes can be
combined to machine special profiles. C

! 5 axes version: 5 axes operating head

• X axis: direction of travel along the mobile
beam and the side frames;
Z+
• Y axis: direction of travel along the stationary Y+
sides of the machine X+

• Z axis: direction of travel along the vertical

axis. X- Y-
• A axis: the head can rotate from -90° to +90°. Z-
• C axis: infinite rotation about the Z axis

Information
C
The movements on the various axes can be
combined to machine special profiles.
A

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5. Fundamental notions

5.2 Moving the axes in the manual mode

In some cases, during tooling-up operations, it may be more convenient to move the machine axes
manually. This is done through the control panel pushbuttons, having first selected the axis to be
moved. For further information consult the Software User’s Manual.

5.3 Axes travel speed variation

When moving the axes in the manual mode, their speed of travel can vary between 0 and 100% of
the maximum attainable manual speed. The variation is obtained through the control panel
pushbuttons.

For further information consult the Software User’s Manual.

When in the machining mode, the axis displacement speed variation is normally utilised when
testing a program to select the correct speed for the material to be machined, or as a means to
observe in more detail the movement of the axes at critical points in the program. In this case, too,
a speed variation between 0 and 100% of the programmed speed is obtained through the control
panel pushbuttons.

During machining, the rate of feed varies according to the nature of the workpiece (glass, marble,
granite) and on the type of aggregate with which the tool is made.

For further information consult the Software User’s Manual.

5.4 Working areas

The work table is divided into two areas, or “Stations” , to which correspond the subdivisions of the
vacuum and air systems. Station 1 is on the LH side of the machine and Station 2 on the RH side.

When workpieces of large dimensions are involved, the whole worktable is used.

1 2

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 5. Fundamental notions

5.5 Stops and suction cups

Stops and suction cups are positioned on the work table according to the geometrical shape to be
obtained from the workpiece, or according to the machining operations to be carried out to obtain
the desired finished product.

During this setting-up stage, the operator utilises a special purpose software with which, after the
cad drawing of the piece has been entered, the number of stops and suction cups can be
programmed.

For further information consult the Software User’s Manual.

If necessary, the tops of the suction cups may be lightly ground during machine installation in order
to obtain perfect alignment.

Grinding must be done by qualified personnel authorized by Intermac. Before they are ground, all
the suction cups of the same height will be arranged side by side and vacuum will be applied to
their bottom faces.

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5. Fundamental notions

5.6 Origins
The origin of the machine, or “absolute origin” (0), is a predetermined point of reference in relation
to which the position of a machine element can be established. The origin represents the main
point of reference for the X, Y and Z axes. There are on the machine also so called “working
origins” , which are used to establish the exact position of the workpiece.

Absolute origins (0)

The absolute (0) origin of the machine is an imaginary point represented by the zeroing cams set
by the manufacturer during the factory tests. The “0” origin is used as a basic starting point on
which the working origins will be subsequently set.

X0,Y0
X+

Y+

In particular:
! The Z axis zeroing cam is at the top (Z+);

! The X axis zeroing cam is on the LH side;

! The zeroing cam for the Y axis is at the rear.

Working origins

The working origins are determined by the workpiece positioning stops present on the work table.
Their relative data are entered in the user interface.

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 5. Fundamental notions

5.7 Direction of rotation of the spindles

The motor driven spindle connection is an ISO 40 type for spindles and aggregates and is capable
of rotation in both directions.

Definition of left-hand and right-hand rotation

Right hand (RH) rotation refers to a clockwise sense of rotation. Left hand (LH) rotation refers to
an anticlockwise sense of rotation.

The sense of rotation of a spindle is determined by observing it in the direction A, as indicated in

the following figure.
spindle

SX

DX

5.8 Machine operation

The following is a description of the operations which the machine will perform as a result of a
“start machining“ command.

Starting operations
! As a first step after the start command, the machine will zero all the axes and the head will
take position at the origin.
! If there is a tool present on the head, the machine will first unload the tool into the magazine
and then go through a spindle warm-up cycle.

Machining operations
! In the first instance, the head approaches the workpiece at a pre-established point and begins
to remove material from it. In order to cool the tool and to evacuate the grindings, water will be
sprayed on tool and workpiece alike by nozzles placed around the tool itself.
! If, on the other hand, a tool change is required, the machine will go through the tool changing
procedure without any intervention on the part of the operator. (see par. 15.10 “Tool change”)

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5. Fundamental notions

! The machine will then go through all the operations in the program until the workpiece is
finished, and it will stop in the initial origin position.

Caution
To not allow the stops to be ground as well.

! The operator can now open the guards, release the suction cups and unload the finished
workpiece in order to make room for a new one.

Information
The process water must be changed periodically and the accumulated sediments must be
accurately cleaned out of the tank.
If the production shop has a water purification plant, it might be possible to discharge the
water directly into the appropriate collecting ducts.

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 6. The Right and the Wrong ways to use the machine

6. The Right and the Wrong ways to

use the machine

6.1 The Right Way to use the machine

The machine has been designed to carry out programmed drilling, milling, chamfering, routing,
engraving, parting-off operations, through the use of a software for which par. 6.3 “Possible
machining operations” should be consulted).

Depending on the workpiece(s) dimensions, machine loading and unloading operations can be
carried out manually by the operator or with the aid of an overhead travelling crane or a hoist.

As regards the characteristics of the materials that can be machined, the specifications contained
in par. 6.2 “Characteristics and dimensions of machinable materials”.

6.2 Characteristics and dimensions of machinable

materials
With vertically mounted tools having a diameter not greater than 150 mm, the machine can
machine glass, marble and other stones in the following dimensions:

Y
X

The dimensions described hereunder refer to machining operations with 100 mm diameter tools.
X (mm) Y (mm) Z (mm)
Master 23 2500 1250 (*)
Master 3 3250 1625 (*)
Master 4 4065 2290 (*)
Master 3 Plus 3250 1625 (*)
Master 4 Plus 4065 2290 (*)
* Refer to axis Z displacement layout on page 98 of chapter 7.

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6. The Right and the Wrong ways to use the machine

Note
The machine cannot be configured for machining materials other than those listed. In
particular, it cannot carry out machining on metals, wood and plastic materials.

6.3 Possible machining operations

The machine can execute the following machining operations:
! drilling;

! profile milling;

! chamfering (grinding inclined planes of glass plates or mirrors);

! engraving on glass/crystal;

! excavating on marble blocks to obtain bowls for wash basins and bath tubs*;

! parting off marble and/or crystal by means of an appropriate sawing aggregate;

! making cavities or openings of various shapes on kitchen or bathroom furniture tops.

! Vertical and horizontal drilling;

! Vertical and horizontal milling, routing.

* (Materialis removed with special drilling tools which leave behind small columns to be removed at a later
stage. The walls of the cavity thus obtained are finished off with other milling tools).

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 6. The Right and the Wrong ways to use the machine

! Parting-off operations.

6.4 Personnel qualifications

The machine requires only one operator for the following activities:
! To make a drawing of the piece using a CAD program; to set the machining parameters using
a CAM program; to prepare the tool magazines.
! To load, position, fix and unload the workpieces.
In particular, the operator disposes the suction cups and the stops as established by the CAM
program.

Note
The presence of a second operator to perform the load and unload phases is not excluded.

6.5 Operator work station

In the course of his various duties, the operator occupies different positions around the machine:
! position A, to use machine controls or to enter program data;

There are two type A positions based on the type of configuration machine, with electricity cabinet
on the left (standard) or right (optional).
! position B, with guards open (machine in safe conditions) for positioning the piece to be
machined on the suction cap or unloading the piece already machined;
! position B, with guards closed, to check the implementation and the quality of the machining.

There are two type B positions: at the front or rear of the machine to equip the top. The rear
access is optional.
! position B1, with the guards open (machine in safe conditions), for all the operations needed
to ascend to the worktop;

Type B1 position: this position is not usually used, or is occupied for a very brief time with respect
to other areas. The operator has to assume a very uncomfortable posture.
! position C, with mobile access shelter to the open tool store (machine safety suspended) for
equipping the store.

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6. The Right and the Wrong ways to use the machine

There can be two C type positions, based on the type of configuration machine. Left (standard)
and in addition right (optional), Operations carried out in the C positions do not guarantee good
vision of the rest of the machine.

B1
C C

A A

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 6. The Right and the Wrong ways to use the machine

Machine positioning
The machine must be positioned in a covered factory premises, in accordance with health and
safety regulations. It is the employer’s responsibility to ensure that the operator works in
comfortable and stress-free conditions.

Respect the indications supplied on the lay out to position the machine so as to leave spaces and
escape routes according to the regulations, in the presence reopened open elements also.

It is necessary to have a minimum working space of 2 m^2 on each workstation indicated.

! The area where the machine is placed must guarantee a 10 m^3 volume of air.

2000
1000

800
800

6.6 Danger area

The whole machine area occupied by moving parts during operation is “danger area” , which is
however adequately protected by mobile and fixed guards, creating an enclosure around the work
table.

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6. The Right and the Wrong ways to use the machine

6.7 Residual risks

= DANGER ! Do not stand inside the machine when it is operatining and do

not get near the tool change area.

= DANGER ! Do not stand inside the machine when it is operatining.

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 6. The Right and the Wrong ways to use the machine

= DANGER ! Do not walk past the safety barriers of the machine, wether it
is operating or not. For access to the worktable use only the gates
provided and when the machine is off.

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6. The Right and the Wrong ways to use the machine

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 7. Technical characteristics

7. Technical characteristics

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7. Technical characteristics

7.1 Layout

Master 23
Connection point for main supply; (height from floor: 930 mm)

Connection point for pneumatic system; (height from floor 740mm)

Connection point for water system; (height from floor 450 mm)
PC cubicle

80 Variabile

Y
6460

830 4700 930 X

1315

2500

620

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 7. Technical characteristics

Master 30
706 piano di lavoro
3150 H max

67 Altezza variabile

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7. Technical characteristics

Connection point for main supply; (height from floor: 1800 mm)

Connection point for pneumatic system; (height from floor 460 mm)

Connection point for water system; (height from floor 900 mm)

PC cubicle

Y
1200
X
690 5970 690

820

3270
1660
3250
6880

H=1900
1420
1200

650
1800

Max absorbed power (15 Max absorbed power (22,5

kW)* 7,5 of which are taken kW)* 15 of which are taken by
by the spindle the spindle
*
(kW)= the declared absorbed power of the machine is the maximum
simultaneous power absorbed by it, duly increased by a safety margin to
allow adequate dimensioning of the whole system.

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 7. Technical characteristics

Master 33 - 35

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7. Technical characteristics

Connection point for main supply; (height from floor: 1170 mm)

Connection point for pneumatic system; (height from floor 460 mm)

Connection point for water system; (height from floor 750 mm)
PC cubicle

Max absorbed power (15 Max absorbed power (22,5

kW)* 7,5 of which are taken kW)* 15 of which are taken by
by the spindle the spindle
*
(kW)= the declared absorbed power of the machine is the maximum
simultaneous power absorbed by it, duly increased by a safety margin to
allow adequate dimensioning of the whole system.

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 7. Technical characteristics

Master 33 - 35 PLUS

706 Piano di lavoro

3520 Max

70 Quota variabile

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7. Technical characteristics

Connection point for main supply; (height from floor: 1170 mm)

Connection point for pneumatic system; (height from floor 460 mm)

Connection point for water system; (height from floor 750 mm)

PC cubicle

8170
1103 5962 670 Y
6560
X

2250
3219
1625

A
B
H=1900
H=1900

3250
6885 Open doors
650
MASTER 33-35
1420
1200

850
820
600

H=1900 H=1900

870 MASTER 33

1800 1800

Max absorbed power (15 Max absorbed power (22,5

kW)* 7,5 of which are taken kW)* 15 of which are taken by
by the spindle the spindle
*
(kW)= the declared absorbed power of the machine is the maximum
simultaneous power absorbed by it, duly increased by a safety margin to
allow adequate dimensioning of the whole system.

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 7. Technical characteristics

Master 43 - 45

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7. Technical characteristics

Connection point for main supply; (height from floor: 1170 mm)

Connection point for pneumatic system; (height from floor 460 mm)

Connection point for water system; (height from floor 750mm)

PC cubicle

Max absorbed power (15 Max absorbed power (22,5

kW)* 7,5 of which are taken kW)* 15 of which are taken by
by the spindle the spindle
*
(kW)= the declared absorbed power of the machine is the maximum
simultaneous power absorbed by it, duly increased by a safety margin to
allow adequate dimensioning of the whole system.

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 7. Technical characteristics

Master 43 - 45 Plus

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7. Technical characteristics

Connection point for main supply; (height from floor: 1170 mm)

Connection point for pneumatic system; (height from floor 460mm)

Connection point for water system; (height from floor 750mm)

PC cubicle

Max absorbed power (15 Max absorbed power (22,5

kW)* 7,5 of which are taken kW)* 15 of which are taken by
by the spindle the spindle
* (kW)= the declared absorbed power of the machine is the maximum

simultaneous power absorbed by it, duly increased by a safety margin to

allow adequate dimensioning of the whole system.

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 7. Technical characteristics

Master 33 TWIN
700 piano di lavoro
3150 H max

Quota variabile 70

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7. Technical characteristics

Connection point for main supply; (height from floor: 1170 mm)

Connection point for pneumatic system; (height from floor 460mm)

Connection point for water system; (height from floor 750mm)

PC cubicle

X
1200

820
670

4180
3219
1625

790 790

650 3250
5962
1420

6550
1200

H=1900 6885
1800

Max absorbed power (26 kW)* 9,2 kW on each Max abdorbed power (.... kW)* ... kW on
electro-spindle each electro-spindle
*
(kW)= the declared absorbed power of the machine is the maximum simultaneous power absorbed by it, duly
increased by a safety margin to allow adequate dimensioning of the whole system.

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 7. Technical characteristics

Master 43 TWIN
700 Piano lavoro
3150 H max

70 Quota variabile

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7. Technical characteristics

Connection point for main supply; (height from floor: 1170 mm)

Connection point for pneumatic system; (height from floor 460mm)

Connection point for water system; (height from floor 750mm)

PC cubicle

X 1200

820
660

4750
3930
2290

790 790

650
4069
294 6781 294
1420
1200

8913
H=1900

1800

Max absorbed power (26 kW)* for 9,2 kW on Max absorbed power (.... kW)* for .... kW on
each electro-spindle each electro-spindle
*
(kW)= the declared absorbed power of the machine is the maximum simultaneous power absorbed by it, duly
increased by a safety margin to allow adequate dimensioning of the whole system.

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 7. Technical characteristics

7.2 General data

23 30 33-35 43-45 33-35 Plus 43-45 Plus
Length* (mm): 5800 7350 8200 9000 8200 9000
Width (mm): 2440 3270 3220 3900 3220 3900
Maximum Height (mm): 2260 3150 3150 3150 3520 3520
Weight (machine) (kg): 3400 5650 5810 6800 6050 7030
Air consumption (N l/min): 160 200 200 200 200 200
Air pressure (bar) 7 7 7 7 7 7
*
With the tool magazines doors open.

33 TWIN 43 TWIN
Length* (mm): 8200 9000
Width (mm): 3220 3900
Maximum Height (mm): 3150 3150
Weight (machine) (kg): 5900 6900
Air consumption (N l/min): 250 250
Air pressure (bar) 7 7
* With the tool magazines doors open.

7.3 Admissible weight on worktop

On Machines of the Master 2 - 3 - 4 range it is possible to mount a work surface with a weight that
does not exceed 600 Kg/m2.

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7. Technical characteristics

7.4 Water consumption

External water Internal water Internal water
consumption consumption without consumption with
L/min pump L/min pump L/min
3 axes Master 110 10.5 18
4 axes Master (twin) 190 15
5 axes Master 83 9 12

7.5 Electrical characteristics

Refer to machine nameplates (see page 55).

7.6 Illumination
The Master range does not have its own illumination devices.The user must identify the two zones
are required by the standard:

Visual display area

the area in the immediate vicinity.

The minimum values prescribed by the standards for general craft and industrial operations of the
machine is of 300 LUX (lx).

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 7. Technical characteristics

7.7 Technical data for 1400 W heat exchanger (in S1

operation)
Fluid: water + glycol max. 15%
Max. ambient temperature: 35°
Minimum ambient temperature: -5° (with 15% glycol)
Hydraulic connections: 1/2” F BSP
Visual level indicator: ---
Supply: single phase 230V AC - frequency 50/60 Hz
Power consumption: max. 800 W (fans and pump running and
cooler ON)
Characteristic curve of pump: 15 l/1’ at 2,8 bar
(5 l/1’ at 3,8 bar and 40 l/1’ at 0,5 bar)
Internal flux controller under AC/DC supply: max 250V - 3A - 50W resistive load; 15 VA
inductive load
Alarm signal set at 3 l/min: (NO contact)
Delivery signal “ON”: for volumes over 3 l/min
Delivery signal “OFF”: for lower volumes
Approximate weight: 20 kg (empty)
Master 2 cooling circuit capacity: 7 liters
Master 3 cooling circuit capacity: 8 liters
Master 3 TWIN cooling circuit capacity: 9 liters
Master 4 cooling circuit capacity: 9 liters
Master 4 TWIN cooling circuit capacity: 10

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7. Technical characteristics

7.8 Main machine axes X, Y, Z

Machine axis X Y Z
Linear speeds (m/min) 60 30 15

X axis displacements, Master 23

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Y axis displacements, Master 23

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7. Technical characteristics

X axis displacements, Master 3 - 4 and Plus versions

Information
For Master 35/45/45 Plus:
The indicated useful travel distance applies to a vertical spindle.

Caution
When the axes are set in motion collisions are always a possibility: the utmost
ATTENTION on the part of the operator is always required.

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 7. Technical characteristics

Y axis displacements, Master 3 - 4 and Plus versions

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7. Technical characteristics

X - Y Axes displacement, Line Master 3 TWIN

3570

3175 MAX PEZZO "X" PER A

LVORAZIONE DOPPIA MOLA
MAX PIECE DIMENSION "X" WITH DOUBLE WHEEL WORKING

22
151
L WORKING
LVORAZIONE DOPPIA MOLA
MAX PIECE DIMENSION "Y" WITH DOUBLE WHEE

1740
1467 MAX PEZZO "Y" PER A

O 100

Information
When the twin machine uses only the primary spindle, the displacement of axis X-Y is
equal to Master series 3-4, 3-axes version.

7.9 Motor driven spindle

Speed of rotation (rpm): 12000 rpm
Motor power (kW): refer to electrical diagrams
Motor power depending on the output of the Inverter (kW) 7,5 o 15*
Motor power depending on the output of the Inverter TWIN (kW) 9,2 o .....*
Pressurization (bar) 4,5
*
according to the model of your machine.

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 7. Technical characteristics

7.9.1 Spindle characteristics

The power available at the tool is equal to the electric power supplied by the INVERTER which is
mounted inside the electrical cubicle.

This is made possible thanks to the dimensioning of the electrical package inside the spindle,
which will only admit the amount of current which the Inverter is able to supply.Pressurization

Electric power Electric power

spindle = B INVERTER = A

To maintain the spindle in efficient operating conditions both its lower (tool) side and upper side
must be protected with an air flow under positive pressure.
The air pressure thus created prevents the infiltration of water inside the spindle which would
damage the internal components.
Whether the machine is operating or not, there will always be air flowing out of the operating head.
The flow of air is controlled by a filter unit located on the operating head itself. An associated
pressure gauge will allow the operator to check the effective air pressure against the Intermac
recommended pressure, as indicated in paragraph 7.9 .

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7. Technical characteristics

NEVER SHUT OFF OR REDUCE THE AIR FLOW: THIS WOULD DEPRIVE THE SPINDLE OF
THE PROTECTION AGAINST THE INFILTRATION OF PROCESS WATER, CAUSING
BEARING SEIZURES AND DAMAGE TO OTHER COMPONENTS.

Upper pressurization

Lower pressurization

7.10 Vacuum system

Vacuum: - 68 cm Hg

7.11 Working range along the Z axis

Warning
On machines Master series 3 - 4 with magazine on the edge of the head, be careful
with the height of the piece on the working surface, considering a tool of L=65mm
assembled on the revolver:
- for Master 33-43, maximum passage on the piece: 280mm
- for Master 35-45, maximum passage on the piece: 160mm

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 7. Technical characteristics

Master 30-33-43

battuta metallica

Linea ingombro trave 595 mm

395 corsa Z
220

battuta metal
5

490

465
115
240

30

105

95

70

Master 33-43 Plus

Linea ingombro trave 905 mm

battuta metallica
240

650 corsa Z
725
300
35

105

100
75

battuta metallica

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7. Technical characteristics

Master 33-43 TWIN

Master 35-45

173,19

Linea ingombro trave 595 mm

O 350

67

430 Corsa asse Z

SOLO PER LAVORAZIONI DI SCRITTURA,

535

SCOLPITURA E FORATURA.
150

235
365

360
340
10
180

68,9
105

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 7. Technical characteristics

Master 35-45

173,19

Linea ingombro trave 595 mm

Accostatore H=213
127

535
50
365

213

213
MASSIMO SPESSORE LAVORABILE
SU VENTOSE H=213 battuta metallica

Master 35-45

Linea ingombro trave 595 mm

O 150

40 MAX SPESSORE LAVORABILE

365

187
32

105

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7. Technical characteristics

Master 35-45 Plus 530

Linea ingombro trave 905 mm

173,19

O 500

O 192
170

CORSA MAX. Z = 530

200

635
440

100
235

105

105
108
35

SOLO PER LAVORAZIONI DI SCRITTURA,

SCOLPITURA E FORATURA.

Master 35-45 Plus 530 - Curved glass fixtures

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3 axes - Master 23

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7. Technical characteristics

7.12 Noise level

The corrected level of sound pressure measured at the operator working position is:

Sound pressure level Glass Marble

db (A), when milling 77,21 78,48
db (A), when milling with circular blade tool 80,29 80,82

Measures have been taken in accordance with UNI EN ISO 3746 12/1997.

Types of machining:
Glass milling
To thickness 19 mm
Milling with disc blade
In depth 19 mm
Feed rate 1,5 m/min

Granite milling (pink porrino)

To thickness 30 mm
Milling with disc blade
In depth 20 mm
Feed rate 0,3 m/min

1 Hearing protection is recommended

Instruments: phonometer type : FON BK2230; make: BRUEL & KJAER.

Calibrator: ACOUSTIC CALIBRATOR 4231
K1= correction factor for background noise below 10 dB (A).
K3= correction factor for ambient background noise below 2.80 dB (A).

The indicated values of the noise pressure levels are emission levels and do not necessarily
represent actual operating levels. Although there is some correlation between emission levels and
exposition levels, this cannot be reliably utilised to establish if further precautions are necessary.
The factors which determine the level of exposition for factory personnel take into account the time
of exposition, the characteristics of the workroom, other sources of dust and noise; that is to say
other adjacent machines and processes. In any case, the present information will give the user of
the machine the possibility to evaluate dangers and risks in more detail.

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 8. Machine shipping and handling

8. Machine shipping and handling

The machine can be prepared for shipping depending on the various shipping methods available:
road, train, sea or air. The choice is normally discussed and agreed with the customer during the
sales negotiations. For transport purposes the machine is divided into several parts and this
Appendix gives a list of the items to be shipped (see page 106 and their respective weights).

8.1 Instructions about transport and installation of

the machine
Before starting any activity, please, read the following instructions carefully.
! Lifting and moving the machine are necessary operations to unload it from the transporting
vehicle and take it to its final location. These operations should be carried out by competent
personnel in accordance with the instructions contained in this Chapter on page 107.
! The area where the machine is to be installed must be well lit and ventilated, must afford
adequate space and must be equipped with connecting points to feed the various machine
systems (electrical, pneumatic, ….). Please consult par. “Machine arrangements, connection
points, overall dimensions” on page 111. The factory utilities to which the machine is to be
connected must have the characteristics described on page 111.
! The assembly, levelling and connecting the machine is to be carried out exclusively by
BIESSE Service personnel. The machine must therefore not be unpacked. The crates
containing machine equipment must not be opened. Above all else, do not start the machine
without the consent of expert and qualified technicians.

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8. Machine shipping and handling

8.2 Parts to be transported

The machine travels on truck or container without its front and back guards (doors and fixed side
covers), and without the control panels and other accessories. The switchboard cubicle is placed
beside the machine; the electrical cables have fast connectors that allow the cubicle to be
removed easily from the machine. During transport, the operating head of the machine is rested on
wooden blocks on the work table.

Information
Double length containers are used for the machine with the electrical cubicle and guards
packed separately.

The parts in shipment for the different machine models are as follows:
MASTER 23 Weight kg
Machine 3400
Console 70
MASTER 30 Weight Kg
Machine 5650
Switchboard cubicle 470
Guards: fixed panels and doors (front and rear) 620
MASTER 33-35-plus Weight kg
Machine (plus) 5810 (6000)
Switchboard cubicle – operators control panel 470
Guards: fixed panels and doors (front and rear) 620
MASTER 43-45-plus Weight kg
Machine (plus) 6800 (7000)
Switchboard cubicle – operators control panel 470
Guards: fixed panels and doors (front and rear) 665
MASTER 33 TWIN Weight kg
Machine 5900
Switchboard cubicle 470
Guards: fixed panels and doors (front and rear) 620
MASTER 43 TWIN Weight kg
Machine 6900
Switchboard cubicle 470
Guards: fixed panels and doors (front and rear) 665

Information
Master 43-45 models are packed in a wooden crate and transported by heavy haulage truck
without escort, their width being less than 3 m.

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 8. Machine shipping and handling

Information
Every machine model is supplied with a crate for transporting the equipment
envisaged. Handle exclusively with a forklift truck or trans-pallet.

Information
During transportation the Master 3 and 4 type machines require the movement of two
packs containing the front and rear protections. Handle exclusively with a forklift
truck or trans-pallet.

8.3 Unloading of the machine

8.3.1 Responsibilities for machine loading and unloading

Manufacturer’s responsibilities
It is manufacturer’s responsibility to unload the machine in the agreed place, where appropriate
unloading facilities are available and where the machine will not have to be moved near any other
personal property or employees of the buyer.

Buyer’s responsibilities
It is buyer’s the responsibility to move the machine within his own premises using means of
transportation and lifting of his own property, or rented for the occasion.
When the machine has reached its final location, the manufacturer’s engineer will proceed with its
installation and start up.

8.3.2 Lifting in safety

All slings used in lifting operations must conform to dpr 459/96 covering directives 98/37/CE.

Danger
Lifting slings and ropes must carry a visible label and must not show any signs of tear or
abrasion. Their maximum load capacity must never be exceeded.

Advice on the use of lifting equipment

! Never use slings for loads exceeding their rated capacity.

! When using multiple slings, take into account the change in load carrying capacity with the
increase of the angle at the vertex.

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8. Machine shipping and handling

! Do not use slings with a divergence above 120°. Over this limit, the load carrying capacity
decreases considerably for small increases of the angle.
! Always check the state of the slings before lifting a load.

! Never use damaged slings and check that their protective sleeves are in good conditions.

! Always protect the rope at the points of contact with sharp edges.

! Never bend the ropes near splices, sleeves or thimbles.

! Slings with slip knots must not diverge more than 120° at the vertex.

! Do not crush the slings under the load: always use some appropriate means to maintaining
the load off the floor.
! Do not pull a trapped sling from under the load.

! Always keep slings away from cutting or welding spots and from heat sources in general.

! Store slings in a dry place and lubricate them regularly to prevent rusting.

! Do not leave slings on the ground where they can be run over by wheels or tracks of passing
vehicles.

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 8. Machine shipping and handling

8.3.3 Lifting
The machine can be lifted by passing the slings through the appropriate holes in the base. The mid
section of the sling embraces the base and its ends are hooked on the hoisting equipment.
Lift the main machine structure with a wheel mounted or overhead travelling crane using the
following method:
! On Master 2: use 2 sling belts 7 meter long (max. load capacity: 3000 kg)

! On Master 3: use 2 sling belts 8 meter long (max. load capacity: 3000 kg)

! On Master 4: use 4 sling belts 8 meter long (max. load capacity: 3000 kg)

Danger
Master machines are not to be lifted with forklift trucks.

Caution
To avoid tilting or sudden movements of the machine and its component parts, the operating
head must be kept in a central position, or in line with the centre of gravity of the load. The
mobile beam, the machine axes and all other mobile components must be safely anchored
on their guides with appropriate clamps and brackets.
Machines of the Master line do not exceed 3 m in width and therefore do not have to travel
in an inclined position.

The switchboard cubicle is equipped with eye bolts and can be lifted with the use of ropes.
The unloading of the machine and its installation are carried out by BIESSE engineers.

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 9. Machine erection and installation

9. Machine erection and installation

9.1 Machine arrangements, connection points,

overall dimensions
For machine layouts indicating Master line arrangements, their overall dimensions and utilities
connecting points, please refer to chapter 7.1.

9.2 Installation area requirements

The following paragraphs describe the essential requirements regarding the various utilities to
which the machine is to be connected, as well as those of the room where it is to be installed.

Electrical system requirements

In the absence of different arrangements between manufacturer and customer, the quality of the
electrical system must guarantee conformity to the essential requirements of CEI 60204-1, IEC
204-1 standards.
! Main line tension: (see machine nameplate) tolerance: ± 10%

! Main line frequency: (see machine nameplate) tolerance: ± 2%

! Maximum power required: (see machine nameplate)

! Standards of conformity of the electrical system: CEI 64-8, IEC 364

The machine electrical system is not provided with differential type safety switch. The choice of
such a device must be made in accordance with the current legislation, with local regulations and
with the electrical systems of both the factory and the machine.
Choose the correct device after considering the following characteristics of the machine:

1. The measures to restrain electromagnetic interferences (line filter and screening) can produce
high frequency current dispersions above 30 mA.
30 mA differential type circuit breakers may not guarantee operational continuity under all
conditions

2. Also the DC circuits of a machine can have earthing problems (IEC 755).
Unless otherwise required by local regulations, or dictated by the characteristics of the specific
machine system, it would be advisable to install differential type circuit breakers which can be
set for current and time and which are not affected by high frequencies.

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9. Machine erection and installation

It is advisable to use differential switches with strong resistance to impulsive overtension of atmo-
spheric and maneuvering origin (class B):
Do not use differential switches of class AC.

Classes can be recognized by the following symbols:

For main line voltages up to 415 V, the machine switchboard includes a general main circuit
breaker which trips automatically in case of short circuit currents of up to 10 KA R.M.S. or 17 KA
peaks.

For main line voltages over 415 V, an automatic switch can withstand short circuit currents of up
to 5 KA.
If the presumed short circuit current at the point of connection with the machine is higher, steps
must be taken to limit it.

Installed electrical power

The machine is equipped with several electrical devices, the total installed power of which can be
obtained by consulting the data on its nameplate (see page 55).

Pneumatic system requirements

The pneumatic system must supply air at 7bar pressure with an admissible value tolerance of
between -05 bar to +3 bar.

For the exact compressed air consumption refer to the machine nameplate (See page 55).

Vacuum system requirements

The vacuum system is activated when the machine is turned on. The presence of a negative
pressure is monitored by a vacuum gauge mounted on the line.
The operator can check if there is vacuum pressure on the machine by referring to a gauge
present on the machine.

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 9. Machine erection and installation

Floor requirements
The machine must stand on an industrial floor having the following characteristics.

FOUNDATION
A Concrete Ground

B Steel mesh 1. Minimum load capacity = 1

kg/cm sq.

C Gravel 2. Must not be affected by changes

in temperature and humidity. Do
not install near external walls.
D Ground
Flooring
1. Loose gravel foundation 300 mm
minimum thickness.
2. Concrete with RBK resistance >
200, minimum thickness 200 mm,
reinforced with two layers of
welded steel mesh 8 mm diameter
and 200x200 mm pitch.
3. It is advisable to cast the floor 6
months before the machine is
installed.

VERTICAL LOADS

Maximum static anchor pre-load on each foot 14751 N

Maximum unit load on each foot 7 N/mmq

Levelling

MAXIMUM FLATNESS ERROR OF THE FLOOR ( non cumulative) 25 mm/m

MAXIMUM INCLINATION OF THE FLOOR IN ANY DIRECTION 0,4%

Environmental requirements
! Temperature: from +5° to +35 °C (from +5 to +50°C with air conditioning).

! Maximum relative humidity: 90% (without condensation).

! Maximum altitude: 1000 m (in the absence of different arrangements with customer).

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9.3 Machine supporting feet layout

Master 23
6 10 17 4 0 17 4 0
TP
12 0 0
VACUUM TANK
C a p a city = 6 0 0 l

O 8 0 N °6
SUP PORT FEET

O 70
N °2 W E E P H O L E S

TP
15 0 0

R E C Y C LE
C a p a c ity = 4 4 6 l T P = D IS C H A R G E P O I N T S F O R W A T E R O V E R L O A D -
A R R A N G E A G A T H E R IN G F O R T H E P R O C E S S
( O P T IO N A L) TP W A T E R IN E X C E S S . M E D I U M L O S S 1 0 l t/ m in
W IT H O U T I N T E R N A L W A T E R P U M P.

T U B E L E N G T H F O R T H E I N S T A L L A T IO N W IT H O U T R E C Y C L IN G T A N K S : 8 m

Master 30
680.5 2302 2302 680.5
TP TP

TP 600 130 3140 130

VACUUM
Capacity= 506 l
615

1195
835
1985

1400
700

625
130
620

O 90 N°4
O 80 N°6 WEEP HOLES
SUPPORT FEET
RECYCLE RECYCLE
Capacity= 625 l Capacity= 260 l
( OPTIONAL ) ( OPTIONAL )
TP= DISCHARGE POINTS FOR WATER OVERLOAD - According to the installation logistic requirements
ARRANGE A GATHERING FOR THE PROCESS is it possible to access to the tanks both from the
WATER IN EXCESS. MEDIUM LOSS 10 lt/min
WITHOUT INTERNAL WATER PUMP. front or rear side.
TUBE LENGTH FOR THE INSTALLATION WITHOUT RECYCLING TANKS: 12 m

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 9. Machine erection and installation

Master 33-35-PLUS
INTERNAL WATER TANK 680.5 2302 2302 680.5
TP TP TP
Capacity= 280 l
TP= DISCHARGE POINTS FORWATER OVERLOAD -
ARRANGEA GATHERING FORTHE PROCESS
600 130 3140 130 WATER IN EXCESS. MEDIUM LOSS 10 lt/min
WITHOUT INTERNALWATER PUMP.
1460
615

1195
O 90 N°4
WEEP HOLES
835
1985

1400
130 700

625
620

O 80 N°6 SUPPORT FEET

1940

RICYCLE RICYCLE
Capacity= 787 l Capacity= 260 l
( OPTIONAL ) ( OPTIONAL )
According to the installation logistic requirements
VACUUM TANK is it possible to access to the tanks both from the
Capacity= 506 l front or rear side.

TUBE LENGTH FORTHE INSTALLATION WITHOUT RECYCLINGTANKS: 12 m

Master 43-45-PLUS
68 0 .5 188 3 165 4 188 3 6 80 .5
TP TP
TP

130
600 396 0 130
O 90 N °6
W EEP H OLES

O 8 0 N°10 FEET SUPP ORT

RECY CLE
Ca pacity= 66 0 l
( OPTIONAL )
RECYC LE
Capa city= 660 l
( OPTION AL )
V ACUU M
Capa city= 650 l
T P = D IS C H A R G E P O IN T S F O R W A T E R O V E R L O A D -
A R R A N G E A G AT H E R IN G F O R T H E P R O C E S S
A c c o rd in g to th e in s ta lla tio n lo g is tic re q u ire m e n ts
W AT E R IN E X C E S S . M E D IU M L O S S 1 0 lt/m in is it p o s s ib le to a c c e s s to th e ta n k s b o th fro m th e
W IT H O U T IN T E R N A L W AT E R P U M P. fro n t o r re a r s id e .
T U B E L E N G T H F O R T H E IN S TA L L AT IO N W IT H O U T R E C Y C L IN G TA N K S : 2 4 m

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Master 33 TWIN
INTERNAL WATER TANK 680.5 2302 2302 680.5
TP TP TP
Capacity= 280 l
TP= DISCHARGE POINTS FORWATER OVERLOAD -
ARRANGE A GATHERING FORTHE PROCESS
600 130 3140 130 WATER IN EXCESS. MEDIUM LOSS 10 lt/min
WITHOUT INTERNAL WATER PUMP.
1460
615

1195
O 90 N°4
WEEP HOLES
835
1985

1400
700
130

625
620

O 80 N°6 SUPPORT FEET

1940

RICYCLE RICYCLE
Capacity= 787 l Capacity= 260 l
( OPTIONAL ) ( OPTIONAL )
According to the installation logistic requirements
VACUUM TANK is it possible to access to the tanks both from the
Capacity= 506 l front or rear side.

TUBE LENGTH FORTHE INSTALLATION WITHOUT RECYCLING TANKS: 12 m

Master 43 TWIN
680 1883 1654 1883 680
TP TP
TP

TP= DISCHARGE POINTS FORWATER OVERLOAD -

ARRANGE A GATHERING FORTHE PROCESS
WATER IN EXCESS. MEDIUM LOSS 10 lt/min
WITHOUT INTERNAL WATER PUMP.
130
2180

O 90 N°6
WEEP HOLES 600 3960 130
615

1195
1233

470
1030

2065
1417

700
130

625
620

O 80 N°10 SUPPORT FEET

According to the installation logistic requirements
is it possible to access to the tanks both from the
front or rear side.
2680

RICYCLE RICYCLE
Capacity= 920 l Capacity= 660 l
( OPTIONAL ) ( OPTIONAL)
VACUUM TANK
Capacity= 650 l
TUBE LENGTH FOR THE INS TALL ATION WITHOU T RECYCLING TANKS: 24 m

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 9. Machine erection and installation

9.4 Levelling the machine

Position the machine at the factory premises, always respecting the safety distances from the
infrastructure so as to guarantee escape routes even in the presence of open shelter elements.
Respect the spaces on every Master model installed.
Refer to paragraph 6.5 “Operator work station”

The machine is levelled according to the following procedures:

! Position the resting plates and fix them to the floor.

! Position the machine with its feet resting on the plates.

Information
Procure an engineer’s precision level (reading at least 0,05 mm/m) and a precision ground
plate of constant thickness (+ 0,01 mm).

To level the machine proceed as follows:

! Loosen the locknuts on the levelling feet screws.

! Rest the precision level on the machine side frames (x axis) and check the level.

! Rest the precision level on the work table in the X axis direction and check the level. Adjust the
level by rotating the levelling feet.
! Rest the precision level on the work table in the Y axis direction and check the level. Adjust the
level by rotating the levelling feet. Tighten the locknuts when the machine is correctly levelled.
! The above operations must now be repeated for another position on the work table.

Caution
Avoid undesirable stresses and strains on the machine structure by adjusting the height of
the levelling feet so that they are all equally loaded.
Incorrect positioning and levelling at this stage will cause in time abnormal wear in
mechanical components, and will eventually affect the performance of the machine.

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9. Machine erection and installation

Information
The stability of the machine will benefit from having the feet fixed to the floor plates after
correct positioning and levelling have been achieved.
This will preserve the accuracy of the machine by protecting it against the effects of external
vibrations.

! Remove the shipping fastners from the X and Y axes and the tool magazine.

! Having completed positioning and levelling, the work table must now be ground flat with an
adequate tool mounted on the motor driven spindle of the machine itself.

Information
If the machine is relocated, it must also be repositioned and relevelled, especially if it is
going to be used for machining glass (chamfering).

Caution
In the event of machine re-installation it will be necessary to contact the constructor.
INTERMAC declines all liability in the event of negligence.

Pumps installation
Caution
Once the machine levelling operatio is complete it is essential to lower the water pump and
the vacuum, bringing them to the ground. To do this loosen the fixed supports at the base. .

Danger
Do not switch the machine on with the pump raised from the ground.
This causes priming difficulties, which may result in faulty function and machine
shaking as the result of a dry start-up.
INTERMAC declines any responsibility, and will not provide any warranty cover in the
event of negligence.

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 9. Machine erection and installation

Priming the external water pump

1. Connect the air-cleaning valve of pump “A” to one of the empty white “B” taps with a tube.

2. Open shutter “C” of the suitably filled water tank.

3. Open air-cleaning valve “A” of the pump.

4. Start the machine vacuum.

5. Start the external water pump.

Once the pump is primed close air-cleaning valve ”A”, close the vacuum tap and remove the
vacuum tube..

Caution
Always ensure that the pumps are perfectly primed every time the machine is
switched on.

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9. Machine erection and installation

9.5 Installing the guards

Fixed protections

Mobile guard elements

A
A*
A A*

A A

A*

A=Mobile guard elements

A*=optional mobile guards

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 9. Machine erection and installation

Information
The guards are normally installed on the machine by INTERMAC authorized engineers. The
sequence represents the mounting logic.

Machine with fixed rear protections

Machine with removable rear protections

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9.6 Connecting the machine to the hydraulic plant

Connecting the mains water supply

Connect the mains water piping, internal diameter 14mm, above the internal water filter, fixing it to
the hose adapter connection.
The internal water filter has two inlets:
• the first used for supplying the internal cooling water and cleaning it during machining
• the second for filling the vacuum tank with water.

Note
Use the pipe supplied to connect the valve with the float of the vacuum tank to the
connection present at the entrance to the internal water filter.

Connection for vacuum tank filling

vacuum tank filling

water inlet

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 9. Machine erection and installation

9.6.1 Using the machine with centralised machining water

recovery system
When installation takes place without recirculation tanks (optional), the machine must be linked to
a centralised plant for machining water recovery and the supply of clean water to the pump
installed on the machine.
It is necessary to respect the following instructions for connecting the machining water pump in
order to avoid problems or damage to the components of the machine.

Connecting the machining water discharge points.

1. the machine is equipped with holes for discharging the machining water;

2. these holes must be connected using the supplied installation pipe without recirculating tanks.
It is necessary to cut the tube on the basis of the metres required for each discharge
operation.

3. arrange the pipes so as to convey the water into the discharge points of the centralised plant.

To identify the discharge points placed under the worktop refer to paragraph 9.3 “Machine
supporting feet layout”

Connecting the recirculation pump to the centralised plant

Note
The centralised plant for the supply of water cannot be connected directly to the machining
water pump because it might not guarantee a sufficient and continuous flow and create a
lack of liquid at the pump, damaging it.

Caution
Follow the instructions provided by the constructor carefully for the connection of
the water supplied by the centralised plant.

1. The water is to be stored inside a tank (not supplied by the constructor) so that the pump
always has sufficient water. Ensure a store of 250-300 litres of water if possible.

2. the machining pump must be connected to the tank.

3. the mains water supplied by the centralised plant must assure the continuous filling of the
tank, maintaining an optimal level.

4. install a valve with a float on the tank that restores the level necessary to the functioning of the
pump.

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9. Machine erection and installation

Note
The diagramshows the correct installation of the machining pump when a centralised plant
is present. The tank, which can be purchased from Intermac, guarantees the full efficiency
of the plant.

water inlet

working pump inlet

9.6.2 Use of the machine with (optional) machining water

collection tanks (optional)
When the machine is fitted with re-circulation tanks for the collection of the maching water it is
important to dispose of the excess water generated as the result of the liquid flows for tool cooling,
which is the internal water. The machine connected to the water mains, provides an average of 10
litresd of water a minute, which returns to the recovery tank and must be disposed of the prevent
overflowing.
The recirculation tanks together with the vacuum tank are fitted with overflow discharge elements
in order to discharge the water towards the disposal points.

Note
The machining water must be disposed of in a correct manner in accordance with current
local laws.

To paragraph 9.3 shows the water discharge points of the excess water indicated as “TP”.

Refer to paragraph 7.4 for details on internal water consumption rates in relation to the machine
type and optionals available.

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 9. Machine erection and installation

9.7 Connection of the machine to the electrical

system
Caution
Before connecting the machine make sure that its electrical system is compatible with the
available electricity supply.

Information
The earth line (protection circuit) must be connected before the phase lines.
The machine needs supply cables of adequate sectional area (refer to the attached
electrical drawings).
After all the cables have been connected, cover them with appropriate protection channels.

Connect the machine to the electrical supply system as follows:

1. Put the automatic switch that will connect to

the main line in position 0-OFF.

A
2. Make sure that the main switch of the
machine is in position 0-OFF, and open the
cubicle door.

3. Pass the 3 phase supply cable (ref.A)

through the opening on the side of the
L1 L2 L3 PE
switchboard cubicle.

4. Make the connections to their respective

terminals starting with the green/yellow
ground conductor (ref. PE), and proceed
with the phase conductors (ref. L1, L2, L3).

5. Check that the phase sequence is correct.

This can be done at the end of the
installation by turning ON the external water main switch
pump.

6. If the pump turns in the wrong direction, switch the machine OFF and invert the position of two
of the phase conductors (ref. L1, L2, L3).
Main switch:

The main switch located on the electrical cabinet, is used for connecting
and disconnecting the electricity supply. The switch can be padlocked to
prevent the risk of any tampering.
0 = power off.
1 = power on.

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9.7.1 Connecting cable

To consult the table for the machine model in your possession, compare the values indicated on
the main switch indicated on the wiring diagram..
Connecting current supply conductors in mm²
Two- way Minimum section Maximum section Type of Fastening clamp set
main switch cable-wire
30A 10 mm² 50 mm² Cu 7 Nm
40A 16 mm² 50 mm² Cu 7 Nm
63A 25 mm² 50 mm² Cu 7 Nm
80A 35 mm² 50 mm² Cu 7 Nm

Connecting current supply conductors in AWG

Two- way Minimum section Maximum section Type of Fastening clamp set
main switch cable-wire
30A AWG 8 AWG 2 Cu *45lb-in (5,4Nm)
40A AWG 6 AWG 1/0 Cu *120lb-in (5,4Nm)
63A AWG 4 AWG 1/0 Cu *120lb-in (5,4Nm)
80A AWG 2 AWG 1/0 Cu *120lb-in (5,4Nm)
*
Terminal lug not required

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 9. Machine erection and installation

9.7.2 Power ratings for Master machining centers

Nameplate data for Master serie 2 with 7,5 kW inveter spindle

*Installed power (kW) Nominal Voltage (V) Nominal Current (A)
13.4 480 20,51
13.4 440 22,38
13.4 400 24,62
13.4 200 49,24
13.4 220 44,24
*
For your specific machine you must always check the given power values with those appearing
in the electrical drawings. Check that the connections are correct by referring to the electrical
drawings.

Nameplate data for Master series 3 and 4 with 7,5 kW inverter spindle
*Installed Power (kW) Nominal Voltage (V) Nominal Current (A)
15 480 22,27
15 380 28,14
15 400 26,73
15 415 25,76
15 220 48,60
* For your specific machine you must always check the given power values with those appearing

in the electrical drawings. Check that the connections are correct by referring to the electrical
drawings.

Nameplate data for Master series 3 and 4 with 15 kW inverter spindle

*Installed Power (kW) Nominal Voltage (V) Nominal Current (A)
22,5 480 34,70
22,5 380 43,83
22,5 400 41,64
22,5 415 40,13
22,5 220 75,70
*
For your specific machine you must always check the given power values with those appearing
in the electrical drawings. Check that the connections are correct by referring to the electrical
drawings.

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9. Machine erection and installation

Nameplate data for Master series 3 and 4 TWIN with 9,2 kW inverter spindle
*Installed Power (kW Nominal Voltage (V) Nominal Current (A)
26 480 39
26 380 49
26 400 47
26 415 45
26 220 85
*
For your specific machine you must always check the given power values with those appearing in
the electrical drawings. Check that the connections are correct by referring to the electrical drawings.

Nameplate data for Master series 3 and4 TWIN with .... kW inverter spindle
*Installed Power (kW Nominal Voltage (V) Nominal Current (A)
480
380
400
415
220
*
For your specific machine you must always check the given power values with those appearing in
the electrical drawings. Check that the connections are correct by referring to the electrical drawings.

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 9. Machine erection and installation

9.8 Connecting the machine to the air system

Before making the connection to the factory air system, consult the installation area requirements
contained in par. 9.2.

The machine is connected to the factory air

system via a feed pipe connected to the intake
joint A (D = 14 mm), located on the same side
as the air drying unit.

The air pressure shown on the pressure gauge A B

must be 7 bar. If necessary, adjust the pressure
by proceeding as follows:

1. Get hold of knob B of the regulator and pull

it until it is free to rotate.

2. Turn it clockwise to increase the pressure

and anticlockwise to decrease it. Once the
pressure is adjusted, lock the knob by
pushing it back in.

9.9 Supplied equipment

The machine is supplied with an equipment kit where the components supplied do not need
particular requisites and/or procedures. The only special equipment supplied with the machine
consists of a device to facilitate the assembly and dismantling of tools on the cone. The procedure
is shown in chapter 11.

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 10. Machine controls and signalling devices

10. Machine controls and signalling

devices

This chapter contains descriptions of machine controls and signalling devices.

The first paragraph gives the locations of the various controls.

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10. Machine controls and signalling devices

10.1 Location of machine controls and signalling

devices Master 23

A - Main switch; for a detailed description see page 125

B - Control module for numerical control; consists of a personal computer (PC) complete with
monitor and keyboard, which allows the operator to control machine operations and
movements of the axes through an integrated software package. For further information see
the literature supplied with the PC and the instructions for the use of the software.
C - Main control panel; for a detailed description see on page 138
D - Workpiece fixing pedal; to control the suction cups and the stops.
E - Override; used to vary the travelling speed of the axes (where foreseen).
G - Pushbutton panels for tool magazines; for a detailed description see page 140.

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 10. Machine controls and signalling devices

H - Lock/unlock tool pushbutton and control of the electric tracer; the pushbutton makes it
possible to insert the tool manually, but it is mainly used for the control of the electric tracer on
the operating head. The push button is mainly used to activate/deactivate the electric tracer
and the stops and suction cups positioner. It can also be used for a tool change, although it is
more normal to do so in the semi-automatic mode, via the software.

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10. Machine controls and signalling devices

10.2 Location of machine controls and signalling

devices Master

A - Main switch; for a detailed description see page 125.

B - Control module for numerical control; consists of a personal computer (PC) complete with
monitor and keyboard, which allows the operator to control machine operations and
movements of the axes through an integrated software package. For further information see
the literature supplied with the PC and the instructions for the use of the software.
C - Main control panel; for a detailed description see on page 138

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 10. Machine controls and signalling devices

D - Workpiece fixing pedal; to control the suction cups and the stops.
E - Override; used to vary the travelling speed of the axes (where foreseen).
F - Tool magazines pushbutton panels; For more details see page 140.

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10. Machine controls and signalling devices

G - Lock/unlock tool pushbutton and control of the electric tracer. It is useful when inserting
a tool manually, but it is mostly utilised for the activation of the electric tracer on the operating
head.
The push button is mainly used to activate/deactivate the feeler and the stops and suction
cups positioner. It can also be used for a tool change, even though it is more normal to do so
in the semi-automatic mode, via the software.
H - Remote controls; is cable connected to the main control panel. Once it has been switched
on, it can remotely support certain manual or semi-automatic operations. It is mainly used
during worktable makeready operations.
I - Pressure gauges and regulators; located on the machine to indicate:

Vacuum suction cup on piece and workpiece (I1)

Vacuum stop on worktable (I2)

Air blow pressure gauge (I4)

0

0
Main pressure gauge (I3)

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10. Machine controls and signalling devices

10.3 Main control panel

G
F H
E
D
C
B
A

First row from left to right:

A - Machine ON (key selector): allows the operator to turn the machine ON

B - Machine ON (green light); when lit, it indicates that all auxiliary circuits of the
machine are ON.

C - Machine OFF (black pushbutton); is used to turn the machine OFF.

D - Axes disconnection (key selector); it allows the operator to deactivate the

machine axes so he can enter the work area in full safety. Can be activated with the
remote control.

Start station 1 E (pushbutton); activates machining operations on station 1.

1

Start station 2 F (pushbutton); activates machining operations on station 2.

2

G - not used

H - Emergency (red mushroom-head pushbutton); is used to bring the machine to

an immediate stop. Turn in the direction of the arrow to reset switch.

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Second row, left to right:

Filling-up Cerium oxide: pressing this key activates the pump for the transfer of
the Cerium oxide from the main tank to the reservoir located over the machine.

Manual operation of tool magazine 1: by pressing this key the operator can open
the guards ad extract tool magazine 1.

Manual operation of tool magazine: by pressing this key the operator can open
the guards ad extract tool magazine 2.

Vacuum pump ON/OFF: to turn the vacuum pump ON and OFF.

Decrease polishing pressure: pressing this key decreases the polishing pressure
on the workpiece.

Increase polishing pressure: pressing this key increases the polishing pressure
on the workpiece.

Secondary spindle decrease polishing pressure: pressing this key decreases the
polishing pressure on the workpiece.

Secondary spindle increase polishing pressure: pressing this key increases the
polishing pressure on the workpiece.

Start tracing cycle (mechanical and optical tracing).

Jog - : pressing this key causes the selected axis to move in the negative direction,
either continuously or in successive steps.

Jog +: pressing this key causes the selected axis to move in the positive direction,
either continuously or in successive steps.

Start : pressing this key will start the operating cycle

Stop : pressing this key will stop the operating cycle.

Reset : pressing this key will erase all the old programs present in the memory.

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Cerium oxide stirrer ON and OFF: by pressing this key the Cerium oxide tank
stirrer motors can be turned ON and OFF.

10.4 Tool magazines pushbutton panels

A - Pushbutton: allows the magazine to be rotated anticlockwise.

Magazine rotation is possible only if the guards are closed.

B - Pushbutton: allows the magazine to be rotated clockwise.

Magazine rotation is possible only if the guards are closed.

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10.5 Lock/release tool pushbutton panel and

connection for electric feeler

A - Pushbutton: will release the tool when pressed. Releasing the pushbutton will
cause the tool to be locked. It is used when inserting a tool manually, but it is mostly
utilised for the activation of the electric tracer.

Connection for tracer B: protected by a screw-on waterproof cap.

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10.6 Remote control pushbutton panel

Type RM850
A

C
H

D
E B
F I
G L
M
N

Emergency A pushbutton (red mushroom type); is used to bring the machine to an

immediate stop. Reset by rotation as indicated by the arrows.

“Present man” B button (3 positions)

Potentiometer C for manual-fast adjustment.

Start station 1 D pushbutton

Stop E pushbutton

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Menu scroll F pushbutton

Esc (disabled) G pushbutton

Potentiometer H for the adjustment of axes interpolation during machining.

Start station 2 I pushbutton

Reset L pushbutton

Confirm menu function M pushbutton (disabled).

Start N pushbutton.

This model of remote control can be used for the following:

1. Tooling.
With axes under power, (i.e.: doors closed or with the axes exclusion selector in position and
the “present man” pushbutton in the “power on” position), when the pushbutton of the station
in current use (D or I), the machine will go to next position. To bring on display the information
about the suction cup or the stop in need of positioning it will be necessary to use the
directional keys on the menu and bring the cursor on “Tooling” , followed by Enter “M”.
Press the Esc "G" key to return to main menu.

2. Start of machining program.

Keys "D" and "I" are a duplication of Start Station 1 and 2 pushbuttons on control console
P801.

3. Keys "L" and "E" are a duplication of "Reset" e "Stop" pushbuttons on control console P801.
Key "N" is the duplication of the Start pushbutton on control console P801, with certain
limitations: semi-automatic cycles cannot be launched with this key.

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10. Machine controls and signalling devices

4. Axes speed variation.

Before the potentiometers can be used they will have to be enabled. A potentiometer is
enabled when it is turned to 0, and the speed of the axes will depend on where it is set after
that, at least until keys + and – are clicked to vary it (fast-manual or interpolation). In this case
the potentiometer is disabled and it can be re-enabled only by bringing it back to 0.

10.6.1 Using the remote control

The remote control compatible with the Master machine has been introduced mainly for the
convenience of the operator, who is able to operate by the worktable during makeready without
having to go to the main control panel to enter the commands. Thanks to this portable type
pushbutton pad, it is possible to work with open doors by keeping just one pushbutton pressed,
and to position very quickly stops and suction cups.

Having chosen the program that suits the workpiece to be machined, the remote pad is then
activated with the same pushbutton which enables makeready operations on station 1 or on
station 2.

When either the station 1 or the station 2 pushbutton is selected, the machine will proceed with the
setting up of the selected worktable area, but only on condition that the set-square aggregate has
been loaded.

The pushbutton used to power the axes so that they can reach the predetermined points is located
on the side of the remote panel (present man’s button). This button has 3 positions. Two of these
(totally-pressed and released) prevent the machine from moving at all. In the intermediate position
(button pressed halfway) the axes will be allowed to move so that the operator can position stops
and suction cups. The suction cups diameters to be used will be indicated on the display.

During these operations the flashing light located on the electrical cubicle will warn that the guards
are open. With keys (F) it is possible to scroll through the different options on display (which are
temporarily disabled) and select “Makeready” . If working on station 1, the key which allows
positioning in sequence is F1 (enter/confirm). Key F1 must be pressed after each item has been
positioned, from the first to the very last. If working on station 2, the same procedure applies and
the enter/confirm key will now be F2.
Using keys (F) right and left arrow it is also possible to replicate the functions of the Jog- and Jog+
manual keys to either increase or reduce the shift speed.

Both remote control pads will allow the operator to control certain main machine functions, like
start-stop-reset, fast speed and axes interpolation during machining.

For instructions about the use of these functions, which are also available from the main console,
refer to the User’s Interface Manual.

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11. Tooling-up the machine

We say that a machine is tooled-up when it has been prepared for specific machining operations.
This chapter describes what must be done to tool a machine up, and how to do it.

For a description of the pushbuttons or the selectors mentioned in this chapter, consult chapter 10.
“Machine controls and signalling devices”.

11.1 Information about tools

This paragraph contains information about the characteristics, the type of connection and the
maximum dimensions that the tools must have to be utilised on the machine.

Bonded diamond tools contain diamond powder in varying quantities and of various grades. The
feed rate for the tool and the quality of the finish on the workpiece depend on the grade, or grain
size of the. A fine grain produces a good finish, but the machining speed will be low. With a coarse
grain the finish will be of coarser quality, but machining will be faster. During machining the tool is
subject to a process of wear which depends on the characteristics of the tool itself, on the
machining speed (translational or rotational) and on the type of surface being machined. As a
result the tool loses its profile progressively and after a while it must be “dressed” by removing a
small layer of its constituents.

Polishing tools are made with abrasive resins of various types and composition. The
characteristics of he constituents, together with the machining speeds and the type of surface
being machined, determine the final quality of the polished surface. Polishing tools are subject to a
higher rate of wear compared with diamond tools. In order to guarantee the quality of the polished
surface the computerised numerical control of the machine (CNC) keeps a constant check on the
wear of the tool, as a result of which its pressure on the workpiece is kept constant throughout its
travels.

Danger
The cup shaped aggregate is equipped with a protective hood which must be kept on
during machining to protect the operator and the machine from the spray and the solid
particles ejected by the rotating tool when tilted (5 axes machines). For this reason, working
with cup shaped tools without a hood is to be avoided under all circumstances.
INTERMAC declines all responsibilities and reserves the right to recede from its warranty
obligations in case of negligence on the part of the operator.

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Information
To obtain the best results with profiling tools, it is recommended that
you purchase them of the type with several internal water passages.

Equally important to guarantee a good surface finish is to have an

internal water flow not smaller than 7-8 liters.

Caution
The machine is fitted with spring fixture screws.These screws with lengths of 20 and 25mm
are used according to the spring thickness.
The threaded part should screw in by at least 10mm to guarantee the sealing potential.
The operator must therefore verify the length of the screw to be used and ensure that the
water passes through correctly through the side channels of the spring (if present).

Screw tightening torque for fixture of tool Tightening torque (Nm)

Screw M8 25.5
Screw M10 51
Screw M12 88

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Diamond bonded wheel for edges (standard)

Diamond bonded wheel for edges (standard)

Polishing wheel for edges (standard)

Polishing wheel for edges (standard)

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Bonded diamond wheel for chamfers

Bonded diamond wheel for chamfers

Polishing wheel for chamfers

Polishing wheel for chamfers

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Cylindrical miller for machining shapes (standard)

Cylindrical miller for machining shapes (standard)

Vertical drilling tool (standard)

Vertical drilling tool (standard)

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Vertical graphitising tool (standard)

Vertical graphitising tool (standard)

Hole flaring tool (Standard)

Hole flaring tool (Standard)

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Horizontal milling aggregate, high body

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Aggregate tools maximum dimensions:

Front: For D. = 0 to 35mm, admitted L. from 0 to 90mm
for D. = 35 to 80mm, admitted L. from 0 to 80mm
Tools with D.> 80 are not admitted

Posterior: For D. = 0 to 50mm, admitted L. from 0 to 70mm

Tools with D.> 50 are not admitted

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-4-5-6-7-8-11-12-15-16-17-18 (See
Setting up the Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 148 mm, admitted L. from 0 to 140 mm
Tools with D.> 148 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 184 mm, admitted L. from 0 to 160 mm
Tools with D.> 184 are not admitted

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Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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Horizontal milling aggregate, low body

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Aggregate tools maximum dimensions:

Front: For D. = 0 to 35mm, admitted L. from 0 to 90mm
for D. = 35 to 80mm, admitted L. from 0 to 80mm
Tools with D.> 80 are not admitted

Posterior: For D. = 0 to 80mm, admitted L. from 0 to 90mm

Tools with D.> 80 are not admitted

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-4-5-6-7-8-11-12-15-16-17-18 (See
Setting up the Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. (from 0 to 180 mm)
Tools with D.> 180 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. (from 0 to 180 mm)
Tools with D.> 180 are not admitted

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11. Tooling-up the machine

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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Cup shaped disc aggregate D=200 and horizontal miller

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Aggregate tools maximum dimensions:

Front: Disc D. Max 200 mm and thickness Max 6 mm - See Intermac drawing
Posterior: For D = 0 to 80mm, admitted L. from 0 to 90mm
Tools with D.> 80 are not admitted

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 130 mm, admitted L. from 0 to 270 mm
Tools with D.> 130 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 100 mm, admitted L. from 0 to 270 mm
Tools with D.> 100 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-4-5-6-7-8-11-12-15-16-17-18 (See
Setting up the Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 148 mm, admitted L. from 0 to 140mm
Tools with D.> 148 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 104 mm, admitted L. from 0 to 100 mm
Tools with D.> 104are not admitted

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11. Tooling-up the machine

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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Straight disc aggregate D=250

This type of tool can be used only on 5 axes machines and may not necessarily be standard
equipment.

Aggregate tools maximum dimensions:

Disc D. 250 mm and thickness 4 mm - see Intermac drawing.

Linear magazine:

An aggregate can be mounted only on positions, 1-18 (See Setting up the Linear Magazine).

It is possible to mount on the RH side of the aggregate a tool having the following
dimensions:
D. from 0 to 36 mm, admitted L. from 0 to 30 mm
Tools with D.> 36 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following
dimensions:
D. from 0 to 40 mm.

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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Straight disc aggregate D=350

This type of tool can be used only on 5 axes machines and may not necessarily be standard
equipment.

Max. tool dimensions for aggregate:

Disc D. 350 mm and thickness .4 mm (see drawing)

On revolving magazine

No tool can be mounted on the RH side of the aggregate.

No tool can be mounted on the LH side of the aggregate.

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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Straight disc aggregate D=500 (with epicyclical gear reducer)

This type of tool can be used only on 5 axes (Master 45 plus) machines and may not necessarily
be standard equipment.

Max. tool dimensions for the aggregate:

Use Ø 500 mm disc only with 4 mm thickness, see drawing.

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

Caution:
Do not use the aggregate with an advance direction parallel to disk axis.

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11. Tooling-up the machine

15° Cumbered disc for shaped edge cut

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Aggregate tools maximum dimensions:

Disc D. 200 mm - See Intermac drawing

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 50 mm, admitted L. from 0 to 270 mm
D. from 50 to 80 mm, admitted L. from 0 to 40 mm
Tools with D.> 80 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 60 mm, admitted L. from 0 to 270 mm
D. from 60 to 130 mm, admitted L. from 0 to 40 mm
Tools with D.> 130 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-4-5-6-7-8-11-12-15-16-17-18 (See
Setting up the Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 30 mm
Tools with D.> 30 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 30 mm
Tools with D.> 30 are not admitted

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Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.
Minimum machinable radius: 300 mm
Ideal machining radius: 325 mm
Maximum machinable radius: 600 mm

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11. Tooling-up the machine

30° cumbered disc aggregate for shaped edge cut

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Aggregate tools maximum dimensions:

Disc D. 185 mm - See Intermac drawing

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 50 mm, admitted L. from 0 to 270 mm
D. from 50 to 80 mm, admitted L. from 0 to 40 mm
Tools with D.> 80 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 60 mm, admitted L. from 0 to 270 mm
D. from 60 to 130 mm, admitted L. from 0 to 40 mm
Tools with D.> 130 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-4-5-6-7-8-11-12-15-16-17-18 (See
Setting up the Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 30 mm
Tools with D.> 30 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 30 mm
Tools with D.> 30 are not admitted

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 11. Tooling-up the machine

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.
Minimum machinable radius: 155 mm
Ideal machining radius: 160 mm
Maximum machinable radius: 320 mm

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Cumbered disc aggregate D=250

This type of tool can be used only on 5 axes operating head machines and may not necessarily be
standard equipment.

Maximum machinable height of slab :

With disc D.250 Angle 30° H.Max 75 mm

With disc D.250 Angle 15° H.Max 65 mm

With disc D.180 Angle 30° H.Max 35 mm

With disc D.180 Angle 15° H.Max 30 mm

On rotary magazine:

Aggregate tools maximum dimensions:

Spherical disc from D. 180 to D. 250, 15°/30° angle, and 4 mm thickness (see
Intermac drawing).

No tool can be mounted on the RH side of the aggregate.

It is possible to mount on the LH side of the aggregate a tool having the following
dimensions:
D. from 0 to 30 mm, admitted L. from 0 to 270 mm
Tools with D.> 30 are not admitted

Linear magazine:

An aggregate can be mounted only on positions, 1-18 (See Setting up the Linear
Magazine).

No tool can be mounted on the RH side of the aggregate.

It is possible to mount on the LH side of the aggregate a tool having the following
dimensions:
D. from 0 to 45.5 mm, admitted L. from 0 to 40 mm
Tools with D.> 45.5 are not admitted

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 11. Tooling-up the machine

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

DISC Min. machinable radius Ideal machining radius Max. machinable radius
D.250 - 30° 187 mm 220 mm 400 mm
D.250 - 15° 380 mm 405 mm 600 mm
D.180 - 30° 155 mm 160 mm 320 mm
D.180 - 15° 270 mm 290 mm 580 mm

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Cup shaped wheel aggregate

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Max tools dimensions for aggregate:

Only D.150 mm and L.40 mm (see drawing)
Tools having D.>150 are not admitted

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-4-5-6-7-8-11-12-15-16-17-18 (See
Setting up the Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 164 mm, admitted L. from 0 to 160 mm
Tools with D.> 164 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 164 mm, admitted L. from 0 to 160 mm
Tools with D.> 164 are not admitted

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 11. Tooling-up the machine

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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Flat edge aggregate wheel

This type of tool can be used only on 5 axes machines and may not necessarily be standard
equipment.

Max tools dimensions for aggregate:

Wheel D. Max. 150 mm and L. Max. 40 mm (see drawing)
Tools having D.>150 are not admitted

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 120 mm, admitted L. from 0 to 270 mm
Tools with D.> 120 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-7-12-16-17-18 (See Setting up the
Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 140 mm, admitted L. from 0 to 130 mm
Tools with D.> 140 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 148 mm, admitted L. from 0 to 140 mm
Tools with D.> 148 are not admitted

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 11. Tooling-up the machine

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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11. Tooling-up the machine

THE DIAGRAM BELOW IS VALID ONLY FOR AGGREGATES EQUIPPED WITH A

GRINDING WHEEL HAVING D=150 mm, WITH A MAXIMUM RAKE ANGLE OF 5°.
THE MINIMUM CHAMFER OBTAINABLE IS 15° .

LEGEND:

-- ALL CHAMFER WIDTH VALUES IN THE “RED ZONE” CANNOT BE OBTAINED WITH
THIS AGGREGATE.

-- ALL CHAMFER WIDTH VALUES IN THE “YELLOW ZONE” CAN ONLY BE OBTAINED
WITH A WHEEL HAVING H=40 mm (NEW WHEEL).

-- ALL CHAMFER WIDTH VALUES OBTAINED IN THE “GREEN ZONE” CAN BE

MACHINED ALSO WITH A WHEEL HAVING H=35 mm (WORN WHEEL).

GREEN ZONE
35
l H=
e
he
0
=4

w
H

E
ON
el

WZ
he

LO
w

YEL

RED ZONE

Danger
The cup shaped aggregate is equipped with a protective hood which must be kept on
during machining to protect the operator and the machine from the spray and the
solid particles ejected by the rotating tool when tilted (5 axes machines). For this
reason, working with cup shaped tools without a hood is to be avoided under all
circumstances.
INTERMAC declines all responsibilities and reserves the right to recede from its
warranty obligations in case of negligence on the part of the operator.

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11. Tooling-up the machine

Grinding aggregate for incisions

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Max tools dimensions for aggregate:

Only D.150 mm and L. from 5 to 30 mm (see drawing)
Tools having D.>150 are not admitted

On rotary magazine:
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 70 mm, admitted L. from 0 to 270 mm
Tools with D.> 70 are not admitted

On linear magazine:
An aggregate can be mounted only on positions 1-2-3-4-7-8-11-12-15-16-17-18 (See Setting
up the Linear Magazine).
It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 164 mm, admitted L. from 0 to 160 mm
Tools with D.> 164 are not admitted

It is possible to mount on the LH side of the aggregate a tool having the following dimensions:
D. from 0 to 164 mm, admitted L. from 0 to 160 mm
Tools with D.> 164 are not admitted

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Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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11. Tooling-up the machine

Vertical drilling aggregate

This type of tool can be used only on machines with a rotating axis, “C”, and may not necessarily
be standard equipment.

Max tools dimensions for the aggregate:

Special vertical drill D. from 14 to 60 mm, (see drawing)

On revolving magazine:

It is possible to mount on the RH side of the aggregate a tool having the following dimensions:
D. from 0 to 150 mm, admitted L. from 0 to 270 mm
Tools with D.> 150 are not admitted

No tool can be mounted on the LH side of the aggregate.

On linear magazine:

On the right hand side of the aggregate there are no tools with restricted dimensions.

No tool can be mounted on the LH side of the aggregate.

The second left hand side fork can take a tool having the following dimensions:
D from 0 to 100 mm

Caution:
Tools having dimensions greater than the above are considered unacceptable and Intermac
will not guarantee their performance.

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 11. Tooling-up the machine

Information
Intermac recommends an incision 3 mm deep for bottom drilling, followed by top drilling
using the appropriate tool.

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11.1.1 Description of tool configuration parameters

For a description of tool configuration parameters refer to User’s Interface Manual.

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Tools assembly
8 mm plate with flat profile tools

8 mm plate with round profile tools

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10 mm plate with flat profile tools

10 mm plate with round profile tools

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12 mm plate with flat profile tools

12 mm plate with round profile tools

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15 mm plate with flat profile tools

15 mm plate with round profile tools

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19 mm plate with flat profile tools

19 mm plate with round profile tools

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Edge machining
MACHINING FLAT EDGES WITH STANDARD WHEELS (D.100 mm)

Segmented rough diamond wheel Data

glass thickness 19 mm
rotational speed 5500 r.p.m.
feed 2000 mm/min.
tock removal 1.5 mm
number of cycles 1

Continuous rim fine diamond wheel Data

glass thickness 19 mm
rotational speed 5500 r.p.m.
feed 2000 mm/min.
tock removal 0.3 mm
number of cycles 1

Polishing wheel Data

glass thickness 19 mm
rotational speed 3500 r.p.m.
feed 2000 mm/min.
number of cycles 1
surface wear 60 micron/mt

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MACHINING FLAT EDGES WITH STANDARD WHEELS (D.35 mm)

Segmented rough diamond wheel Data

glass thickness 19 mm
rotational speed 7000 r.p.m.
feed 1000 mm/min.
tock removal 1 mm
number of cycles 1

Continuous rim fine diamond wheel Data

glass thickness 19 mm
rotational speed 7000 r.p.m.
feed 700 mm/min.
tock removal 0.3 mm
number of cycles 1

Polishing wheel Data

glass thickness 19 mm
rotational speed 4500 r.p.m.
feed 1000 mm/min.
number of cycles 1
surface wear 50 micron/mt

MACHINING A ROUNDED EDGE WITH STANDARD WHEELS (D.100 mm)

Continuous rim medium diamond wheel Data

glass thickness 3 - 4mm

rotational speed 5500 r.p.m.
feed 4000 mm/min.
tock removal 0.5 mm
number of cycles 1

Continuous rim medium diamond wheel Data

glass thickness 5 - 6mm

rotational speed 5500 r.p.m.
feed 3000 mm/min.
tock removal 0.5 mm
number of cycles 1

Soft polishing wheel Data

glass thickness 3 - 4 - 5 - 6 mm
rotational speed 3500 r.p.m.
feed 3000 mm/min.
number of cycles 1
surface wear 50 micron/mt

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MACHINING A ROUNDED EDGE WITH STANDARD WHEELS (D.100 mm)

Continuous rim rough diamond wheel Data

glass thickness 8 - 10 - 12 mm
rotational speed 5500 r.p.m.
feed 3000 mm/min.
tock removal 1 mm
number of cycles 1

Continuous rim fine diamond wheel Data

glass thickness 8 - 10 - 12 mm
rotational speed 5500 r.p.m.
feed 3000 mm/min.
tock removal 0.5 mm
number of cycles 1

Soft polishing wheel Data

glass thickness 8 - 10 - 12 mm
rotational speed 3500 r.p.m.
feed 1500 mm/min.
number of cycles 1
surface wear 80 micron/mt

MACHINING A ROUNDED EDGE WITH STANDARD WHEELS (D.100 mm)

Segmented rough diamond wheel Data

glass thickness 15 - 19 mm
rotational speed 5500 r.p.m.
feed 2000 mm/min.
tock removal 1 mm
number of cycles 1

Continuous rim rough diamond wheel Data

glass thickness 15 - 19 mm
rotational speed 5500 r.p.m.
feed 2000 mm/min.
tock removal 0.5 mm
number of cycles 1

Continuous rim fine diamond wheel Data

glass thickness 15 - 19 mm
rotational speed 5500 r.p.m.
feed 2000 mm/min.
tock removal 0.3 mm
number of cycles 1

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Soft polishing wheel Data

glass thickness 15 - 19 mm
rotational speed 3500 r.p.m.
feed 1500 mm/min..
number of cycles 1
surface wear 60 micron/mt

OG PROFILE WITH STANDARD WHEELS (D.100 mm)

Segmented rough diamond wheel 45° Data

glass thickness 19 mm
rotational speed 5500 giri/min.
feed 1200 mm/min..
number of cycles 1
tock removal 0 mm

Continuous rim rough diamond wheel Data

glass thickness 19 mm
rotational speed 5500 giri/min.
feed 1200 mm/min.
number of cycles 2
tock removal 0.5 mm

Continuous rim fine diamond wheel Data

glass thickness 19 mm
rotational speed 5500 giri/min.
feed 1200 mm/min.
number of cycles 1
tock removal 0.3 mm

Soft polishing wheel Data

glass thickness 19 mm
rotational speed 3500 giri/min.
feed 1200 mm/min.
number of cycles 1
surface wear 60 micron/mt

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TP PROFILE WITH STANDARD WHEELS (D.100 mm)

Segmented rough diamond wheel 45° Data

glass thickness 19 mm
rotational speed 5500 giri/min.
feed 1200 mm/min.
number of cycles 1
tock removal 0 mm

Continuous rim rough diamond wheel Data

glass thickness 19 mm
rotational speed 5500 giri/min.
feed 1200 mm/min.
number of cycles 1
tock removal 0.5 mm

Continuous rim fine diamond wheel Data

glass thickness 19 mm
rotational speed 5500 giri/min.
feed 1200 mm/min.
number of cycles 1
tock removal 0.3 mm

Soft polishing wheel Data

glass thickness 19 mm
rotational speed 3000 giri/min.
feed 1200 mm/min.
number of cycles 1
surface wear 60 micron/mt

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WF PROFILE WITH STANDARD WHEELS (D.100 mm)

Segmented rough diamond wheel 45° Data

glass thickness 19 mm
rotational speed 5500 r.p.m.
feed 1200 mm/min.
tock removal 0 mm
number of cycles 1

Continuous rim rough diamond wheel Data

glass thickness 19 mm
rotational speed 5500 r.p.m.
feed 1200 mm/min.
tock removal 0.5 mm
number of cycles 1 mm

Continuous rim fine diamond wheel Data

glass thickness 19 mm
rotational speed 5500 r.p.m.
feed 1200 mm/min.
tock removal 0.3 mm
number of cycles 1

Continuous rim extra fine resin wheel Data

glass thickness 19 mm
rotational speed 4500 r.p.m.
feed 1200 mm/min.
tock removal 0.2 mm
number of cycles 1

Soft polishing wheel Data

glass thickness 19 mm
rotational speed 3500 r.p.m.
feed 1200 mm/min.
number of cycles 1
surface wear 80 micron/mt

MILLING

Segmented rough wheel d.20 mm Data

glass thickness 19 mm
rotational speed 12000 r.p.m.
feed 700 mm/min.

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DRILLING

Drill 22 mm dia Data

rotational speed 1800 r.p.m.

feed (down travel speed) 15 mm/min.

SURFACE GRAPHITIZATION

Diamond bit (dia. 2 mm) Data

rotational speed 10000 r.p.m.

feed 500 mm/min.
depth of hole 0.1 mm

BORE FLARING

Flaring tool 45° (dia. 10 mm) Data

rotational speed 8000 r.p.m.

feed 300 mm/min.
stock removal 1 mm

CHAMFERING THE OUTER EDGE

Double wheel 45° (dia. 100 mm) Data

rotational speed 5500 r.p.m.

feed 2000 mm/min.
stock removal 0 mm
number of cycles 1

Flaring tool 45° (dia. 10 mm) Data

rotational speed 8000 r.p.m.

feed 500 mm/min.
stock removal 0 mm
number of cycles 1

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Edge chamfer machining

Manufacturer’s notes

The following machining parameters come as the result of tests carried out on standard machines
using tools supplied by DIAMUT.
Needless to say that when tools of a different nature are in use, the data given in the course of this
document may not correspond to actual working conditions.

The tables of the following pages have been subdivided by wheel diameter and chamfer angle,
and for each angle the minimum radii corresponding to three different values of angles of relief
have been found.

Information
THE DATA IN THE FOLLOWING TABLES APPLY TO ALL THICKNESSES OF GLASS
PLATE.
ALL THE TOOLS WHICH ARE PART OF THE SAME GROUP OF MACHINING
OPERATIONS MUST BE USED WITH THE SAME ANGLE OF RELIEF.
SHOULD IT BE NECESSARY TO CHANGE THE ANGLE OF RELIEF FOR A NEW
MACHINING OPERATION, IT WILL BE MORE CONVENIENT TO USE A GROUP OF
TOOLS DIFFERENT FROM THE ONE IN CURRENT USE. .
NEW TOOLS NEED A RUNNING-IN PERIOD FOR THE PROFILE TO ASSUME THE
REQUIRED INCLINATION.

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11. Tooling-up the machine

Definition of terms

Initials Meaning Description

AB Angle of chamfer Is the inclination of the chamfer relative to the surface of the
glass plate and is given in 1/10 of one degree.

AT Angle of relief Is the inclination of the tool while machining, and is given in
1/10 of one degree.

TU Tool type Type of tool used for machining operations

rpm Revolutions per Speed of rotation of the tool during machining operation
minute expressed in revolutions per minute.

FEED Feed Forward feed of the tool during machining operation

expressed in millimeters per minute.

LB CHAMFER WIDTH Width of the chamfer produced by the tool during machining
operation expressed in millimeters.

DIR Direction Sense of travel of the tool during machining operation.

RMINT Minimum Internal Minimum value of the internal radius of curvature obtainable
radius with machining operation expressed in millimeters.

RMEST Minimum external Minimum value of the external radius of curvature obtainable
radius with machining operation expressed in millimeters..

V1 Statistical wear Value of the wear experience by a polishing tool during the
machining operation expressed in microns per meter.

V2 Adaptive wear Value of the wear experienced by a polishing tool during a

machining operation expressed as a function of the nominal
power of the spindle motor.

DIS Display Value Shown on the monitor during machining with the
polishing tool, expressed in terms function of the spindle
motor nominal power.

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STANDARD CHAMFER 25 mm WITH 100mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

3 3 Diamond 7500 500 23.5 clockwise 100 20 3

3 3 Resin nr.1 7500 500 24.5 anti 100 20 3

c.wise

3 3 Resin nr.2 7500 400 24.9 clockwise 100 20 3

3 3 Resin nr.3 7500 350 25 anti 100 20 2

c.wise

3 3 Polishing 1300 400 25 clockwise 100 20 5 6 6

3 7 Diamond 7500 400 23.5 clockwise 50 20 3

3 7 Resin nr.1 7500 400 24.5 anti 50 20 3

c.wise

3 7 Resin nr.2 7500 300 24.9 clockwise 50 20 3

3 7 Resin nr.3 7500 250 25 anti 50 20 2

c.wise

3 7 Polishing 1300 300 25 clockwise 50 20 5 6 6

3 10 Diamond 7500 350 23.5 clockwise 30 20 3

3 10 Resin nr.1 7500 350 24.5 anti 30 20 3

c.wise

3 10 Resin nr.2 7500 200 24.9 clockwise 30 20 3

3 10 Resin nr.3 7500 150 25 anti 30 20 2

c.wise

3 10 Polishing 1300 250 25 clockwise 30 20 5 6 6

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STANDARD CHAMFER 25 mm WITH 100mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

5.7 3 Diamond 7500 625 23.5 clockwise 250 20 3

5.7 3 Resin nr.1 7500 625 24.5 anti 250 20 3

c.wise

5.7 3 Resin nr.2 7500 375 24.9 clockwise 250 20 3

5.7 3 Resin nr.3 7500 300 25 anti 250 20 2

c.wise

5.7 3 Polishing 1300 500 25 clockwise 250 20 5 6 6

5.7 7 Diamond 7500 400 23.5 clockwise 75 20 3

5.7 7 Resin nr.1 7500 400 24.5 anti 75 20 3

c.wise

5.7 7 Resin nr.2 7500 350 24.9 clockwise 75 20 3

5.7 7 Resin nr.3 7500 300 25 anti 75 20 2

c.wise

5.7 7 Polishing 1300 400 25 clockwise 75 20 5 6 6

5.7 10 Diamond 7500 350 23.5 clockwise 40 20 3

5.7 10 Resin nr.1 7500 350 24.5 anti 40 20 3

c.wise

5.7 10 Resin nr.2 7500 200 24.9 clockwise 40 20 3

5.7 10 Resin nr.3 7500 150 25 anti 40 20 2

c.wise

5.7 10 Polishing 1300 250 25 clockwise 40 20 5 6 6

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STANDARD CHAMFER 25 mm WITH 100mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

7 3 Diamond 7500 625 23.5 clockwise 350 20 3

7 3 Resin nr.1 7500 625 24.5 anti 350 20 3

c.wise

7 3 Resin nr.2 7500 375 24.9 clockwise 350 20 3

7 3 Resin nr.3 7500 300 25 anti 350 20 2

c.wise

7 3 Polishing 1300 500 25 clockwise 350 20 5 6 6

7 7 Diamond 7500 500 23.5 clockwise 125 20 3

7 7 Resin nr.1 7500 500 24.5 anti 125 20 3

c.wise

7 7 Resin nr.2 7500 350 24.9 clockwise 125 20 3

7 7 Resin nr.3 7500 300 25 anti 125 20 2

c.wise

7 7 Polishing 1300 400 25 clockwise 125 20 5 6 6

7 10 Diamond 7500 400 23.5 clockwise 50 20 3

7 10 Resin nr.1 7500 400 24.5 anti 50 20 3

c.wise

7 10 Resin nr.2 7500 300 24.9 clockwise 50 20 3

7 10 Resin nr.3 7500 250 25 anti 50 20 2

c.wise

7 10 Polishing 1300 300 25 clockwise 50 20 5 6 6

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STANDARD CHAMFER 30 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

3 3 Diamond 5500 650 28.5 clockwise 150 30 3

3 3 Resin nr.1 5500 650 29.5 anti 150 30 3

c.wise

3 3 Resin nr.2 5500 375 29.9 clockwise 150 30 3

3 3 Resin nr.3 5500 300 30 anti 150 30 2

c.wise

3 3 Polishing 1000 500 30 clockwise 150 30 5 6 6

3 7 Diamond 5500 400 28.5 clockwise 75 30 3

3 7 Resin nr.1 5500 400 29.5 anti 75 30 3

c.wise

3 7 Resin nr.2 5500 250 29.9 clockwise 75 30 3

3 7 Resin nr.3 5500 200 30 anti 75 30 2

c.wise

3 7 Polishing 1000 400 30 clockwise 75 30 5 6 6

3 10 Diamond 5500 300 28.5 clockwise 50 30 3

3 10 Resin nr.1 5500 300 29.5 anti 50 30 3

c.wise

3 10 Resin nr.2 5500 200 29.9 clockwise 50 30 3

3 10 Resin nr.3 5500 150 30 anti 50 30 2

c.wise

3 10 Polishing 1000 300 30 clockwise 50 30 5 6 6

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STANDARD CHAMFER 30 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

5.7 3 Diamond 5500 650 28.5 clockwise 350 30 3

5.7 3 Resin nr.1 5500 650 29.5 anti 350 30 3

c.wise

5.7 3 Resin nr.2 5500 375 29.9 clockwise 350 30 3

5.7 3 Resin nr.3 5500 300 30 anti 350 30 2

c.wise

5.7 3 Polishing 1000 500 30 clockwise 350 30 5 6 6

5.7 7 Diamond 5500 500 28.5 clockwise 100 30 3

5.7 7 Resin nr.1 5500 500 29.5 anti 100 30 3

c.wise

5.7 7 Resin nr.2 5500 350 29.9 clockwise 100 30 3

5.7 7 Resin nr.3 5500 300 30 anti 100 30 2

c.wise

5.7 7 Polishing 1000 500 30 clockwise 100 30 5 6 6

5.7 10 Diamond 5500 350 28.5 clockwise 75 30 3

5.7 10 Resin nr.1 5500 350 29.5 anti 75 30 3

c.wise

5.7 10 Resin nr.2 5500 250 29.9 clockwise 75 30 3

5.7 10 Resin nr.3 5500 200 30 anti 75 30 2

c.wise

5.7 10 Polishing 1000 350 30 clockwise 75 30 5 6 6

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STANDARD CHAMFER 30 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

7 3 Diamond 5500 650 28.5 clockwise 500 30 3

7 3 Resin nr.1 5500 650 29.5 anti 500 30 3

c.wise

7 3 Resin nr.2 5500 400 29.9 clockwise 500 30 3

7 3 Resin nr.3 5500 350 30 anti 500 30 2

c.wise

7 3 Polishing 1000 500 30 clockwise 500 30 5 6 6

7 7 Diamond 5500 625 28.5 clockwise 250 30 3

7 7 Resin nr.1 5500 625 29.5 anti 250 30 3

c.wise

7 7 Resin nr.2 5500 375 29.9 clockwise 250 30 3

7 7 Resin nr.3 5500 300 30 anti 250 30 2

c.wise

7 7 Polishing 1000 500 30 clockwise 250 30 5 6 6

7 10 Diamond 5500 350 28.5 clockwise 100 30 3

7 10 Resin nr.1 5500 350 29.5 anti 100 30 3

c.wise

7 10 Resin nr.2 5500 300 29.9 clockwise 100 30 3

7 10 Resin nr.3 5500 250 30 anti 100 30 2

c.wise

7 10 Polishing 1000 350 30 clockwise 100 30 5 6 6

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STANDARD CHAMFER 35 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

3 3 Diamond 5500 650 33.5 clockwise 150 30 3

x2

3 3 Resin nr.1 5500 650 34.5 anti c.wise 150 30 3

3 3 Resin nr.2 5500 375 34.9 clockwise 150 30 3

3 3 Resin nr.3 5500 300 35 anti c.wise 150 30 2

3 3 Polishing 1000 500 35 clockwise 150 30 5 6 6

x2

3 7 Diamond 5500 400 33.5 clockwise 75 30 3

x2

3 7 Resin nr.1 5500 400 34.5 anti c.wise 75 30 3

3 7 Resin nr.2 5500 250 34.9 clockwise 75 30 3

3 7 Resin nr.3 5500 200 35 anti c.wise 75 30 2

3 7 Polishing 1000 400 35 clockwise 75 30 5 6 6

x2

3 10 Diamond 5500 300 33.5 clockwise 50 30 3

x2

3 10 Resin nr.1 5500 300 34.5 anti c.wise 50 30 3

3 10 Resin nr.2 5500 200 34.9 clockwise 50 30 3

3 10 Resin nr.3 5500 150 35 anti c.wise 50 30 2

3 10 Polishing 1000 300 35 clockwise 50 30 5 6 6

x2

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STANDARD CHAMFER 35 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMES V1 V2 DIS

T
(gra (gra (mm/ (mm) (mm)
di) di) min.) (mm)

5.7 3 Diamond 5500 650 33.5 clockwise 350 30 3

x2

5.7 3 Resin nr.1 5500 650 34.5 anti 350 30 3

c.wise

5.7 3 Resin nr.2 5500 375 34.9 clockwise 350 30 3

5.7 3 Resin nr.3 5500 300 35 anti 350 30 2

c.wise

5.7 3 Polishing 1000 500 35 clockwise 350 30 5 6 6

x2

5.7 7 Diamond 5500 500 33.5 clockwise 100 30 3

x2

5.7 7 Resin nr.1 5500 500 34.5 anti 100 30 3

c.wise

5.7 7 Resin nr.2 5500 350 34.9 clockwise 100 30 3

5.7 7 Resin nr.3 5500 300 35 anti 100 30 2

c.wise

5.7 7 Polishing 1000 500 35 clockwise 100 30 5 6 6

x2

5.7 10 Diamond 5500 350 33.5 clockwise 75 30 3

x2

5.7 10 Resin nr.1 5500 350 34.5 anti 75 30 3

c.wise

5.7 10 Resin nr.2 5500 250 34.9 clockwise 75 30 3

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 11. Tooling-up the machine

5.7 10 Resin nr.3 5500 200 35 anti 75 30 2

c.wise

5.7 10 Polishing 1000 350 35 clockwise 75 30 5 6 6

x2

STANDARD CHAMFER 35 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

7 3 Diamond 5500 650 33.5 clockwise 500 30 3

x2

7 3 Resin nr.1 5500 650 34.5 anti 500 30 3

c.wise

7 3 Resin nr.2 5500 400 34.9 clockwise 500 30 3

7 3 Resin nr.3 5500 350 35 anti 500 30 2

c.wise

7 3 Polishing 1000 500 35 clockwise 500 30 5 6 6

x2

7 7 Diamond 5500 625 33.5 clockwise 250 30 3

x2

7 7 Resin nr.1 5500 625 34.5 anti 250 30 3

c.wise

7 7 Resin nr.2 5500 375 34.9 clockwise 250 30 3

7 7 Resin nr.3 5500 300 35 anti 250 30 2

c.wise

7 7 Polishing 1000 500 35 clockwise 250 30 5 6 6

x2

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11. Tooling-up the machine

7 10 Diamond 5500 350 33.5 clockwise 100 30 3

x2

7 10 Resin nr.1 5500 350 34.5 anti 100 30 3

c.wise

7 10 Resin nr.2 5500 300 34.9 clockwise 100 30 3

7 10 Resin nr.3 5500 250 35 anti 100 30 2

c.wise

7 10 Polishing 1000 350 35 clockwise 100 30 5 6 6

x2

STANDARD CHAMFER 40 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

3 3 Diamond 5500 650 38.5 clockwise 150 30 3

x2

3 3 Resin nr.1 5500 650 39.5 anti 150 30 3

c.wise

3 3 Resin nr.2 5500 375 39.9 clockwise 150 30 3

3 3 Resin nr.3 5500 300 40 anti 150 30 2

c.wise

3 3 Polishing 1000 500 40 clockwise 150 30 5 6 6

x2

3 7 Diamond 5500 400 38.5 clockwise 75 30 3

x2

3 7 Resin nr.1 5500 400 39.5 anti 75 30 3

c.wise

3 7 Resin nr.2 5500 250 39.9 clockwise 75 30 3

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3 7 Resin nr.3 5500 200 40 anti 75 30 2

c.wise

3 7 Polishing 1000 400 40 clockwise 75 30 5 6 6

x2

3 10 Diamond 5500 300 38.5 clockwise 50 30 3

x2

3 10 Resin nr.1 5500 300 39.5 anti 50 30 3

c.wise

3 10 Resin nr.2 5500 200 39.9 clockwise 50 30 3

3 10 Resin nr.3 5500 150 40 anti 50 30 2

c.wise

3 10 Polishing 1000 300 40 clockwise 50 30 5 6 6

x2

STANDARD CHAMFER 40 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

5.7 3 Diamond 5500 650 38.5 clockwise 350 30 3

x2

5.7 3 Resin nr.1 5500 650 39.5 anti 350 30 3

c.wise

5.7 3 Resin nr.2 5500 375 39.9 clockwise 350 30 3

5.7 3 Resin nr.3 5500 300 40 anti 350 30 2

c.wise

5.7 3 Polishing 1000 500 40 clockwise 350 30 5 6 6

x2

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5.7 7 Diamond 5500 500 38.5 clockwise 100 30 3

x2

5.7 7 Resin nr.1 5500 500 39.5 anti 100 30 3

c.wise

5.7 7 Resin nr.2 5500 350 39.9 clockwise 100 30 3

5.7 7 Resin nr.3 5500 300 40 anti 100 30 2

c.wise

5.7 7 Polishing 1000 500 40 clockwise 100 30 5 6 6

x2

5.7 10 Diamond 5500 350 38.5 clockwise 75 30 3

x2

5.7 10 Resin nr.1 5500 350 39.5 anti 75 30 3

c.wise

5.7 10 Resin nr.2 5500 250 39.9 clockwise 75 30 3

5.7 10 Resin nr.3 5500 200 40 anti 75 30 2

c.wise

5.7 10 Polishing 1000 350 40 clockwise 75 30 5 6 6

x2

STANDARD CHAMFER 40 mm WITH 150mm DIAMETER WHEELS

AB AT TU r.p.m. FEED LB DIR RMINT RMEST V1 V2 DIS

(gra (gra (mm/ (mm) (mm) (mm)

di) di) min.)

7 3 Diamond 5500 650 38.5 clockwise 500 30 3

x2

7 3 Resin nr.1 5500 650 39.5 anti 500 30 3

c.wise

7 3 Resin nr.2 5500 400 39.9 clockwise 500 30 3

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7 3 Resin nr.3 5500 350 40 anti 500 30 2

c.wise

7 3 Polishing 1000 500 40 clockwise 500 30 5 6 6

x2

7 7 Diamond 5500 625 38.5 clockwise 250 30 3

x2

7 7 Resin nr.1 5500 625 39.5 anti 250 30 3

c.wise

7 7 Resin nr.2 5500 375 39.9 clockwise 250 30 3

7 7 Resin nr.3 5500 300 40 anti 250 30 2

c.wise

7 7 Polishing 1000 500 40 clockwise 250 30 5 6 6

x2

7 10 Diamond 5500 350 38.5 clockwise 100 30 3

x2

7 10 Resin nr.1 5500 350 39.5 anti 100 30 3

c.wise

7 10 Resin nr.2 5500 300 39.9 clockwise 100 30 3

7 10 Resin nr.3 5500 250 40 anti 100 30 2

c.wise

7 10 Polishing 1000 350 40 clockwise 100 30 5 6 6

x2

Notes on internal angle machining operations

The parameters used to produce a standard chamfer are also valid for an internal angle, provided
a few conditions are observed.
! THE INTERNAL ANGLE MUST BE DRAWN WITH TWO LINES HAVING A MINIMUM
LENGTH OF 40 mm.
! MACHINING MUST START FROM THE INSIDE OF THE ANGLE.

! THE ANGLE OF RELIEF OF THE TOOLS MUST BE 0,1 DEGREES, AND RIGOROUSLY
THE SAME FOR ALL THE TOOLS IN USE.

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Inclination of the diamond rim profile

The value of the inclination of the diamond rim profile of the wheel is utilized by the machine to
obtain an incision of the required width. On the basis of this datum the NC of the machine works
out the depth at which the tool is to work. Some of the wheel profiles used on the machine are
illustrated by the following figures.

SYMMETRICAL V PROFILE

P094 = Wheel profile angle

This is the most widely used wheel profile and is used to calculate the machining depth.

Tools having different profiles must always be represented like the one above. The wider the angle
of the wheel profile, the greater the is the depth of incision.

ROUND PROFILE

P094 =Wheel profile angle

Tools with a round profile are better suited to work with an inclination relative to the machining
trajectory. It is more difficult for the rim to become distorted as a result of the inclination of the
wheel. It is advisable to give the rim the same radius of curvature as the tool.

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ASYMMETRICAL V PROFILE

P094 = Wheel profile angle

The inclination of the asymmetrical V profile is referred to the inclination of its wider face.

SINUSOIDAL PROFILE

P094 = Wheel profile angle

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Profile inclination values

The following table gives the profile inclination values as a function of the width and the depth of
incision required.

The operator must take these values under consideration and relate them to the total thickness of
the plate and to the residual thickness of material remaining after the incision is made.

Important
AN EXCESSIVE DEPTH OF MACHINING MAY CAUSE THE PLATE TO BREAK. FOR THIS
REASON INTERMAC’S ADVICES IS TO USE TOOLS WHOSE WORKING DEPTH DOES NOT
EXCEED 33% OF THE THICKNESS OF THE PLATE.

EXAMPLE:
PLATE THICKNESS = 3 mm, DEPTH OF INCISION = 1 mm max.
PLATE THICKNESS = 4 mm, DEPTH OF INCISION 1,3 mm max.

The Pythagorean theorem can be used to calculate the depth and the width of the incision. The
wheel profile may be considered as made up of two right-angled triangles arranged end to end.

Vertical sides (P) represent the depth of the incision, while the sum (F) of the two horizontal sides
represents its width.

P094 = Wheel profile angle

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Incision width Incision depth Incision depth Incision depth

0.5 mm 1 mm 1.5 mm
6 9.46° 18.43° 26.56°
7 8.13° 15.94° 23.19°
8 7.12° 14.03° 20.55°
9 6.34° 12.5° 18.43°
10 5.71° 11.30° 16.69°
11 5.19° 10.30° 15.25°
12 4.76° 9.46° 14.03°
13 4.39° 8.74° 12.99°
14 4.08° 8.13° 12.09°
15 3.81° 7.59° 11.30°
16 3.57° 7.12° 10.61°
17 3.36° 6.70° 10.00°
18 3.17° 6.34° 9.46°
19 3.01° 6.00° 8.97°
20 2.86° 5.71° 8.53°
21 2.72° 5.44° 8.13°
22 2.60° 5.19° 7.76°
23 2.48° 4.96° 7.43°
24 2.38° 4.76° 7.12°
25 2.29° 4.57° 6.84°
26 2.20° 4.39° 6.58°
27 2.12° 4.23° 6.34°
28 2.04° 4.08° 6.11°
29 1.97° 3.94° 5.90°
30 1.90° 3.81° 5.71°

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6 mm INCISION (STANDARD V PROFILE)

P094

Medium grain continuous rim wheel (prof. V) Data

Incision width. (resulting depth = 1 mm) 6 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2500 mm/min.

Soft polishing wheel Data

Incision width. (resulting depth = 1 mm) 6 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2000 mm/min.

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10 mm INCISION (STANDARD V PROFILE)

P094

Medium grain continuous rim wheel (prof. V) Data

Incision width. (resulting depth = 1 mm) 10 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2500 mm/min.

Soft polishing wheel Data

Incision width. (resulting depth = 1 mm) 10 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2000 mm/min.

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20 mm INCISION (ROUND PROFILE)

P094

Rough grain segmented wheel (round profile R70) Data

Incision width. (resulting depth = 1 mm) 18 mm
Tool inclination 10°
Rotational speed 3000 rpm
Feed rate 1500 mm/min.

Fine grain continuous rim wheel (round profile R70) Data

Incision width. (resulting depth = 1 mm) 20 mm
Tool inclination 10°
Rotational speed 3000 rpm
Feed rate 2500 mm/min.

Soft polishing wheel (round profile R70) Data

Incision width. (resulting depth = 1 mm) 20 mm
Tool inclination 10°
Rotational speed 3000 rpm
Feed rate 1500 mm/min.

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20 mm INCISION (STANDARD V PROFILE)

P094

Rough grain segmented wheel (V profile) Data

Incision width. (resulting depth = 1 mm) 18 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1200 mm/min.

Fine grain continuous rim wheel (V profile) Data

Incision width. (resulting depth = 1 mm) 20 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2000 mm/min.

Soft polishing wheel (V profile) Data

Incision width. (resulting depth = 1 mm) 20 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1200 mm/min.

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30 mm INCISION (STANDARD V PROFILE)

P094

Rough grain segmented wheel (V profile) Data

Incision width. (resulting depth = 1 mm) 28 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1000 mm/min.

Fine grain continuous rim wheel (V profile) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2000 mm/min.

Soft polishing wheel (V profile) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1000 mm/min.

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30 mm INCISION (ROUND PROFILE)

P094

Rough grain segmented wheel (round profile R70) Data

Incision width. (resulting depth = 1 mm) 28 mm
Tool inclination 10°
Rotational speed 3000 rpm
Feed rate 1200 mm/min.

Fine grain continuous rim wheel (round profile R70) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 10°
Rotational speed 3000 rpm
Feed rate 2000 mm/min.

Soft polishing wheel (round profile R70) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 10°
Rotational speed 3000 rpm
Feed rate 1000 mm/min.

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30 mm INCISION (SINUSOIDAL PROFILE)

P094

Rough grain segmented wheel (SINUSOIDAL profile) Data

Incision width. (resulting depth = 1 mm) 28 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1200 mm/min.

Fine grain continuous rim wheel (SINUSOIDAL profile) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2000 mm/min.

Soft polishing wheel (SINUSOIDAL profile) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1000 mm/min.

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30 mm INCISION (ASYMMETRICAL V PROFILE)

P094

Rough grain segmented wheel (Asymmetrical V profile) Data

Incision width. (resulting depth = 1 mm) 28 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1200 mm/min.

Fine grain continuous rim wheel (Asymmetrical V profile) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 2000 mm/min.

Soft polishing wheel (Asymmetrical V profile) Data

Incision width. (resulting depth = 1 mm) 30 mm
Tool inclination 0°
Rotational speed 3000 rpm
Feed rate 1000 mm/min.

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11.1.2 Description of configuration parameters on marlbe and

granite tools
For the description of the tool configuration parameters please refer to the user interface manual.

Profile table

A Q

B T

C U

D V

E Z

G IC

H IS

I TP

O AR

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Routing (GRANITE)
FLAT PROFILE (type Z) WITH 120mm TOOL

R R

SLAB THICKNESS: 20 mm 6 TOOLS 5 TOOLS

1st Sector Diamond edge (large grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
removal 0.5 mm 0.6 mm
no. cycles 1 1
2nd CONTINUOUS Diamond edge (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge data data
(medium-fine grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 1000 mm/min.
removal 0.1 mm
no. cycles 1
1° polishing (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2° polishing (fine grain) data data

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Rotation speed 1400 r.p.m. 1400 r.p.m.

advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

SLAB THICKNESS: 30 mm 6 TOOLS 5 TOOLS

1ST Diamond edge in sections (thick grain) data data

Rotation speed 4500 r.p.m. 4500 r.p.m.

advance speed 800 mm/min. 800 mm/min.
removal 0.5 mm 0.6 mm
no. cycles 1 1
2nd CONTINUOUS Diamond edge (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS diamond edge data data
(medium-fine grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 800 mm/min.
removal 0.1 mm
no. cycles 1
1st polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2ND Polishing (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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BULL PROFILE (type V) WITH 120mm TOOL

Note:
The (optional) use of the tool with 45° profile permits the removal of excess material bifore
the routing stage with the same tools, from the contoured profile in order to prevent the early
and excessive wear of the same.

SLAB THICKNESS: 20 mm 6 TOOLS 5 TOOLS

without tool with 45° profile
1st Diamond edge in sections (coarse grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal -2 +0.5mm -2 +0.6mm
no. cycles 2 2
2nd CONTINUOUS Diamond edge (medium grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge (medium-fine data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 800 mm/min.
removal 0.1 mm
no. cycles 1
1st polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt

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2nd polisher (fine grain) data data

Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

SLAB THICKNES: 30 mm (1ST METHOD) 6 TOOLS 5 TOOLS

without 45° profile tool
1st Diamond edge (coarse grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal -2 +0.5mm -2 +0.6mm
no. cycles 2 2
2nd CONTINUOUS Diamond edge (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1

3rd CONTINUOUS Diamond edge° data data

CONTINOUS Diamond edge (medium-fine
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1

4th CONTINUOUS Diamond edge (fine grain) data data

Rotation speed 4500 r.p.m.

advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1st polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt

2nd polisher (fine grain) data data

Rotation speed 1400 r.p.m. 1400 r.p.m.

advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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SLAB THICKNESS: 30 mm (2nd Method) 7 TOOLS 6 TOOLS

with 45° profile tool
Double sector Diamond edge (large grain) 45° data data
profile
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0 mm 0 mm
no. cycles 1 1
1st Diamond edge in sections (large grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.5 mm 0.6 mm
no. cycles 1 1
2nd CONTINUOUS Diamond edge (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge data data
(medium-fine grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1st polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2nd polisher (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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OG PROFILE (type G) WITH 120 mm tool)

Note
The (optional) use of a tool with 45° profile permits the removal of excess material bifore the
routine operation using the same tools of the contoured profile, so as to prevent the early
wear of the same.

SLAB THICKNESS: 20 mm 6 TOOLS 5 TOOLS

without 45° profile tool
1st Diamond edge in sections (large grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal -2 +0.5mm -2 +0.6mm
no. cycles 2 2
2nd CONTINUOUS Diamond edge (medium grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge (medium-fine data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 800 mm/min.
removal 0.1 mm
no. cycles 1
1st polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt

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2nd polisher (fine grain) data data

Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

SLAB THICKNESS: 30 mm (1ST MEHTOD) 6 TOOLS 5 TOOLS

WITHOUT 45° tool
1st Diamond edge in sections (large grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal -3 +0.5mm -3 +0.6mm
no. cycles 2 2
2nd CONTINUOUS Diamond edge (medium grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge (medium-fine data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1st polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2ns polisher (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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SLAB THICKNESS: 30 mm (2nd ° METHOD) 7 TOOLS 6 TOOLS

with 45° profile tool
Double sector Diamond edge 45° profile data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0 mm 0 mm
no. cycles 1 1
1st Diamond edge in sections (large grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.5 mm 0.6 mm
no. cycles 1 1
2nd Diamond edge CONTINUOUS (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge data data
(medium-fine grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
(medium grain) CONTINUOUS (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1st Polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2nd Polisher (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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TRIPLE ROUND PROFILE (tYPE TP) WITH 120mm tool

NOTE:
The (optional) use of a tool with 45° profile permits the removal of excess material bifore the
routine operation using the same tools of the contoured profile, so as to prevent the early
wear of the same.

SLAB THICKNESS: 20 mm 6 TOOLS 5 TOOLS

without 45° profile tool
1st Diamond edge in sections (LARGE GRAIN) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal -2 +0.5mm -2 +0.6mm
no. cycles 2 2
2nd CONTINOUS Diamond edge (medium grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge (medium-fine grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 800 mm/min.
removal 0.1 mm
no. cycles 1
1st Polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2nd Polisher (fine grain) data data

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Rotation speed 1400 r.p.m. 1400 r.p.m.

advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

SLAB THICKNESS: 30 mm (1ST METHOD) 6 TOOLS 5 TOOLS

without 45° profile tool
1st Diamond edge in sections (LARGE GRAIN) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal -3 +0.5mm -3 +0.6mm
no. cycles 2 2
2nd CONTINUOUS Diamond edge (medium grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge (medium-fine data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1° Polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2nd Polisher (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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SLAB THICKNESS: 30 mm (2nd METHOD) 7 TOOLS 6 TOOLS

with 45° profile tool
Diamond edge with double sections 45° profile data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0 mm 0 mm
no. cycles 1 1
1st Diamond edge in sections (LARGE data data
GRAIN)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.5 mm 0.6 mm
no. cycles 1 1
2nd CONTINUOUS Diamond edge (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge data data
(medium-fine grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1° Polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2nd Polisher (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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WATER FALL (type A) WITH 120mm TOOL

NOTE:
The (optional) use of a tool with 45° profile permits the removal of excess material bifore the
routine operation using the same tools of the contoured profile, so as to prevent the early
wear of the same.

SLAB THICKNESS: 20 mm 6 TOOLS 5 TOOLS

without 45° profile tool
1stDiamond edge in sections (LARGE GRAIN) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal -2 +0.5mm -2 +0.6mm
no. cycles 2 2
2nd Diamond edge CONTINUOUS (medium grain) data data
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge (medium-fine data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 800 mm/min. 800 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 800 mm/min.
removal 0.1 mm
no. cycles 1
1st Polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt

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2nd Polisher (fine grain) data data

Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

SLAB THICKNESS: 30 mm (1° METODO) 6 TOOLS 5 TOOLS

without 45° profile tool
1stDiamond edge in sections (LARGE data data
GRAIN)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal -3 +0.5mm -3 +0.6mm
no. cycles 2 2
2nd CONTINUOUS Diamond edge (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS Diamond edge data data
(medium-fine grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
4th CONTINUOUS Diamond edge (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1st Polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2nd Polisher (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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SLAB THICKNESS: 30 mm (2nd METHOD) 7 TOOLS 6 TOOLS

with 45° profile tool
Double section Diamond edge (LARGE data data
GRAIN) profilo a 45°
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0 mm 0 mm
no. cycles 1 1

1st Diamond edge in sections (LARGE data data

GRAIN)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.5 mm 0.6 mm
no. cycles 1 1
2nd CONTINUOUS Diamond edge (medium data data
grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.3 mm
no. cycles 1 1
3rd CONTINUOUS diamond edge data data
(medium-fine grain)
Rotation speed 4500 r.p.m. 4500 r.p.m.
advance speed 700 mm/min. 700 mm/min.
removal 0.2 mm 0.1 mm
no. cycles 1 1
(medium grain) CONTINUOUS (fine grain) data data
Rotation speed 4500 r.p.m.
advance speed 700 mm/min.
removal 0.1 mm
no. cycles 1
1st Polisher (medium grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 15micron/mt 15 micron/mt
2nd Polisher (fine grain) data data
Rotation speed 1400 r.p.m. 1400 r.p.m.
advance speed 1000 mm/min. 1000 mm/min.
no. cycles 1 1
wear 10 micron/mt 10 micron/mt

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Routing (MARBLE)

Note
For the Master machine version with enlarged Z axis (PLUS) we recommend that durino the
polishing of slabs with V20 type profile, that a rotation speed of 1650 r.p.m.be set.

FLAT PROFILE (type Z) WITH 120 mm TOOL

R R

SLAB THICKNESS: 20 mm
1stDiamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 1000 mm/min.
removal 0.5 mm
no. cycles 1
2nd Diamond edge (fine grain) data
Rotation speed 4500 r.p.m.
advance speed 1000 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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11. Tooling-up the machine

SLAB THICKNESS: 30 mm

1st Diamond edge in sections (LARGE GRAIN) data

Rotation speed 4800 r.p.m.

advance speed 800 mm/min.
removal 0.5 mm
no. cycles 1

2nd Diamond edge (fine grain) data

Rotation speed 4800 r.p.m.

advance speed 800 mm/min.
removal 0.3 mm
no. cycles 1

1st Polisher (fine grain) data

Rotation speed 1400 r.p.m.

advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

BULL PROFILE (type V) WITH 120mm tool

NOTE:
The (optional) use of a tool with 45° profile permits the removal of excess material bifore the
routine operation using the same tools of the contoured profile, so as to prevent the early
wear of the same.

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SLAB THICKNESS: 20 mm
without 45° profile tool
1st Diamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal -2 +0.5mm
no. cycles 2
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 1000 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1650 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

SLAB THICKNESS: 30 mm
without 45° profile tool
1stDiamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal -3 +0.5mm
no. cycles 1
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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11. Tooling-up the machine

SLAB THICKNESS: 30 mm
with 45° profile tool
Double section Diamond edge (LARGE GRAIN) with 45° data
profile
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal 0 mm
no. cycles 1

1st Diamond edge in sections (LARGE GRAIN) data

Rotation speed 4800 r.p.m.

advance speed 800 mm/min.
removal 0.5 mm
no. cycles 1
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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OG PROFILE (type G) WITH 120mm TOOL

NOTE:
The (optional) use of a tool with 45° profile permits the removal of excess material bifore the
routine operation using the same tools of the contoured profile, so as to prevent the early
wear of the same.

SLAB THICKNESS: 20 mm
without 45° profile tool
1stDiamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal -2 +0.5mm
no. cycles 2
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 1000 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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11. Tooling-up the machine

SLAB THICKNESS: 30 mm
without 45° profile tool

1st Diamond edge in sections (LARGE GRAIN) data

Rotation speed 4800 r.p.m.

advance speed 800 mm/min.
removal -3 +0.5mm
no. cycles 1

2nd Diamond edge (fine grain) data

Rotation speed 4800 r.p.m.

advance speed 800 mm/min.
removal 0.3 mm
no. cycles 1

1st Polisher (fine grain) data

Rotation speed 1400 r.p.m.

advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

SLAB THICKNESS: 30 mm
with 45° profile tool
Double section Diamond edge (LARGE GRAIN) con profilo a data
45°
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0 mm
no. cycles 1

1st Diamond edge in sections (LARGE GRAIN) data

Rotation speed 4800 r.p.m.

advance speed 900 mm/min.
removal 0.5 mm
no. cycles 1
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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ROUND TYPE PROFILE (type TP) WITH 120mm TOOL

NOTE:
The (optional) use of a tool with 45° profile permits the removal of excess material bifore the
routing operation using the same tools of the contoured profile, so as to prevent the early
wear of the same.

SLAB THICKNESS: 20 mm
without 45° profile tool
1st Diamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal -2 +0.5mm
no. cycles 2
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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11. Tooling-up the machine

SLAB THICKNESS: 30 mm
without 45° profile tool

1st Diamond edge in sections (LARGE GRAIN) data

Rotation speed 4800 r.p.m.

advance speed 800 mm/min.
removal -3 +0.5mm
no. cycles 1

2nd Diamond edge (fine grain) data

Rotation speed 4800 r.p.m.

advance speed 800 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

SLAB THICKNESS: 30 mm
with 45° profile tool
Double section Diamond edge (LARGE GRAIN) with 45° data
profile
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0 mm
no. cycles 1

1st Diamond edge in sections (LARGE GRAIN) data

Rotation speed 4800 r.p.m.

advance speed 900 mm/min.
removal 0.5 mm
no. cycles 1
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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 11. Tooling-up the machine

WATER FALL (type A) WITH 120mm tool

NOTE:
The (optional) use of a tool with 45° profile permits the removal of excess material bifore the
routing operation using the same tools of the contoured profile, so as to prevent the early
wear of the same.

SLAB THICKNESS: 20 mm
without 45° profile tool
1st Diamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal -2 +0.5mm
no. cycles 2
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 1000 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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11. Tooling-up the machine

SLAB THICKNESS: 30 mm
without 45° profile tool
1stDiamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 700 mm/min.
removal -3 +0.5mm
no. cycles 1
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

SLAB THICKNESS: 30 mm
with 45° profile tool
Double section Diamond edge (LARGE GRAIN) with 45° data
profile
Rotation speed 4800 r.p.m.
advance speed 700 mm/min.
removal 0 mm
no. cycles 1
1stDiamond edge in sections (LARGE GRAIN) data
Rotation speed 4800 r.p.m.
advance speed 800 mm/min.
removal 0.5 mm
no. cycles 1
2nd Diamond edge (fine grain) data
Rotation speed 4800 r.p.m.
advance speed 900 mm/min.
removal 0.3 mm
no. cycles 1
1st Polisher (fine grain) data
Rotation speed 1400 r.p.m.
advance speed 1000 mm/min.
no. cycles 1
wear 10micron/mt

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 11. Tooling-up the machine

HORIZONTAL SURFACE DRILLING

MATERIAL – GRANITE
Saw D.25mm data
rotation speed 1800 r.p.m.
advance speed (or descent) 25 mm/min.

MATERIAL – MARBLE
Hole D.25mm data
rotation speed 2500 r.p.m.
advance speed (or descent) 35 mm/min.

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STRAIGHT AND/OR CURVED CUTTING WITH CUTTER

MATERIAL – GRANITE
Sector roughing D. 20mm data
SLAB THICKNESS 20 mm
rotation speed 5000 r.p.m.
advance speed 250 mm/min.

MATERIAL – GRANITE
Sector roughing D. 20mm data
SLAB THICKNESS 30 mm
rotation speed 5000 r.p.m.
advance speed 230 mm/min.

MATERIAL – GRANITE
Electrolytic D.16mm data
SLAB THICKNESS 20 mm
rotation speed 10000 r.p.m.
advance speed 500 mm/min.

MATERIAL – GRANITE
Electrolytic D.16mm data
SLAB THICKNESS 30 mm
rotation speed 10000 r.p.m.
advance speed 400 mm/min.

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AREA HOLLOWING

MATERIAL - GRANITE
Crown shaped smash cutter D.85mm data
max machining depth 5 mm
rotation speed 4500 r.p.m.
maximum advance speed 400 mm/min.

CORING

MATERIAL - GRANITE
Core drill D.50mm data
rotation speed 1000 r.p.m.
advance speed (or descent) 15 mm/min.

Note
MAX permitted machining diameter: 50mm

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11. Tooling-up the machine

WRITING - ENGRAVING

MATERIAL - GRANIT
Diamond tip D.4mm data
rotation speed 6000 r.p.m.
advance speed (or descent) 400 mm/min.

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 11. Tooling-up the machine

Special tools
General

For special tools are intended those which are mounted on mechanical aggregates and which
make possible particular machining operations on a machine not particularly equipped to do so.

Each tool must be used in conjunction with mechanical devices called aggregates, which enable it
to be correctly utilized.

For its own machines INTERMAC has designed such aggregates, which make it possible to utilize
the following tools:

FLAT DIAMOND DISC To make a rectilinear cuts on glass, marble and granite.

CONCAVE DIAMOND DISC To make a curved cuts on glass, marble and granite

ENGRAVING DIAMOND WHEEL To engrave the surface of glass, marble and granite.

INCISION POLISHING WHEEL To polish engraved glass, marble and granite surfaces.

UPPER-LOWER-LATERAL For the drilling of the surfaces of glass sheets and marble
DRILLING and granite slabs and laterial drilling of marble and granite.

GRINDING For the grinding of glass sheet edges.

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11. Tooling-up the machine

Aggregate straight disk D=200

Master 23-33-43-53-63
Master TWIN
Master 35-45-55-65

Tool class 19 -
Saw disk with angular crossing

MAXIMUM MACHINING THICKNESS: 50mm

MAXIMUM SPINDLE ROTATION: 3500 r.p.m.

Technical parameters

Aggregate height (mm) 109 P 102

Aggregate C Offset (degrees) 90 P 99
Aggregate shift (mm) 110 P 109
Reduction ratio 1/1.6 (0.625)

Glass technological data

SLAB THICKNESS: 19mm

Tool constructor: DIAMUT

Disk diameter: 200mm

Disk thickness: 3mm

N° strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
1 22 1800 1000

Granite technological data (Limbara Sardo)

SLAB THICKNESS: 30mm

Tool constructor: DIAMUT

Disk diameter: 200mm

Disk thickness: 3mm

N° strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
2 17 1800 800

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Straight disk aggregate D=350

Master 35-45-55-65

Tool class 13 -
Cutting disk

MAXIMUM MACHINING THICKNESS: 50mm

MAXIMUM SPINDLE ROTATION: 3500 r.p.m.

Technical data

Aggregate height (mm) 45 P 102

Glass technological Data

SLAB THICKNESS: 19mm

Tool constructor: DIAMUT

Disk diameter: 350mm

Disk thickness: 3mm

N° strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
1 22 1300 1000

Granite technological data (Limbara Sardo)

SLAB THICKNESS: 30mm

Tool constructor: DIAMUT

Disk diameter: 350mm

Disk thickness: 3mm

N° strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
2 17 1800 500

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Aggregate straight disk D=500 (with epicyclic reduction unit)

Master 45 plus

Tool class 13 -
Cutting disk

MAXIMUM MACHINING THICKNESS: 110mm

MAXIMUM SPINDLE ROTATION: 4000 r.p.m.

Technical parameters

Aggregate height (mm) 99.25 P 102

Reduction ratio (*) 1/3.2

(*)=reduction ratio not NC controlled

Glass technological details

SLAB THICKNESS: 19mm

Tool constructor: DIAMUT

Disk diameter: 500mm

Disk thickness: 3.5mm

N° strokes Stroke depth Disk rotation Advance CAM rotation
(mm) (r.p.m.) (mm/min)
1 22 1200 1000 3840

Granite technological data (Limbara Sardo)

SLAB THICKNESS: 30mm

Tool constructor: DIAMUT

Disk diameter: 500mm

Disk thickness: 3.5mm

N° strokes Stroke depth Disk rotation Advance CAM rotation
(mm) (r.p.m.) (mm/min)
2 17 1200 500 3840

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Aggregate convex disk D=250 - 30°

Master 35-45-55-65

Tool class 15 -
Convex saw disk

MAXIMUM MACHINING THICKNESS: 50mm

MAXIMUM SPINDLE ROTATION: 3500 r.p.m.

Technical parameters

Aggregate height (mm) 40

Glass technological data

SLAB THICKNESS: 19mm

Tool constructor: DIAMUT

Disk diameter: 250mm

Disk thickness: 4mm

N° Strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
1 22 1800 800

Granite (Limbara Sardo)technological data

SLAB THICKNESS: 30mm

Tool constructor: DIAMUT

Disk diameter: 250mm

Disk thickness: 4mm

N° Strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
1 32 2000 400

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Aggregate convex disk D=180 - 30°

Master 23-33-43-53-63
Master TWIN

Tool class 20 -
Convex disk with angular crossing

MAXIMUM MACHINING THICKNESS: 30mm

MAXIMUM SPINDLE ROTATION: 3500 r.p.m.

Technical parameters

Aggregate height (mm) 126 P 102

Aggregate C Offset (degrees) 90 P 099
Aggregate shift 23.1 P 103
Reduction ratio 1 P 111

Data tecnologici vetro

SLAB THICKNESS: 19mm

Tool constructor: DIAMUT

Disk diameter: 180mm

Disk thickness: 3.5mm

N° Strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
1 22 2300 600

Granite (Limbara Sardo)technological data

SLAB THICKNESS: 30mm

Tool constructor: DIAMUT

Disk diameter: 180mm

Disk thickness: 3.5mm

N° Strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
1 32 2200 300
2 16 2200 450

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 11. Tooling-up the machine

Glass technological data - Master 23

SLAB THICKNESS: 19mm

Tool constructor: DIAMUT

Disk diameter: 180mm

Disk thickness: 3.5mm

N° Strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
1 22 2300 300

Granite (Limbara Sardo)technological data - Master 23

SLAB THICKNESS: 30mm

Tool constructor: DIAMUT

Disk diameter: 180mm

Disk thickness: 3.5mm

N° Strokes Stroke depth (mm) Rotation (r.p.m.) Advance (mm/min)
2 16 2200 200
3 11 2200 350

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Aggregate with horizontal cutter

Master 23-33-43-53-63
Master 35-45-55-65
Master TWIN

Tool class 10 -
Lateral writing aggregate
rear

SPINDLE MAXIMUM ROTATION: 3500 r.p.m.

front

Low body aggregate technical parameters

Front Rear
Aggregate height (mm) 109.6 109.6 P 102
Angle on the horizontal plane (degrees) 180 0 P 120
Aggregate C Offset (degrees) 90 270 P 099
Aggregate shift 109.27 109 P 109

High body aggregate technical parameters

Front Rear
Aggregate height (mm) 156.6 156.6 P 102
Angle on horizontal plane (degrees) 180 0 P 120
Aggregate C Offset (degrees) 90 270 P 099
Aggregate shift 109.27 109 P 109

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Anti-collision parameters
Parameter name (mm)
P 125 152
P 127 -155

Glass technological Data

Tool type Depth (mm) Rotation (r.p.m.) Advance (mm/min)

Bit for scrittura 2 3500 100
Core drill Ø10 2 2200 20
Dead hole tool Ø10 2 1600 20

Granite technological data (Limbara Sardo)

Tool type Depth (mm) Rotation (r.p.m.) Advance (mm/min)

Bit for scrittura 2 3500 100
Core drill Ø10 2 2000 20
Dead hole tool Ø10 2 1800 20

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Aggregate bottom drilling

Master 23-33-43-53-63
Master TWIN
Master 35-45-55-65

Tool Class 18 -
Lower core drill

MAXIMUM SPINDLE ROTATION: 3000 r.p.m.

MAXIMUM DISTANCE BETWEEN CENTRE OF

THE HOLE AND SLAB EDGE = 130mm

Technical parameters

Aggregate height (mm) 103.5 P 082

Lower hole aggregate height (mm) 60.9 P 086
Lower hole shift 192 P 084
Nearby position check =1 P 110

Glass technological data

Depth (mm) Rotation (r.p.m.) Advance (mm/min)
2 1750 30
4 1750 30

Anti-collision parameters
Parameter name (mm)
P 124 132
P 125 184
P 126 55

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Aggregate for grooving - flute

Master 23-33-43-53-63
Master TWIN
Master 35-45-55-65

Tool class 11 – Diamond edged grooving

Tool class 12 – Polishing grooving

MAXIMUM SPINDLE ROTATION: 3500 r.p.m.

Technical parameters

Aggregate height (mm) 109 P 102

Aggregate Offset C (degrees) 90 P 099
Aggregate shift 79.5 P 109

Glass incision technological Data

Tool type Depth (mm) Rotation (r.p.m.) Advance (mm/min)

Diamond edged V10 1 3000 1200
Ø140
Polisher V10 Ø140 0 3000 1000

Granite flute technological data - (Limbara Sardo)

Tool type Depth (mm) Rotation (r.p.m.) Advance (mm/min)

Rounded profile 2 2800 500
diamone edged R=5
Ø140
Rounded profile 0 2800 700
polisher R=5 Ø140

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Anti-collision parameters
Parameter name (mm)
P 127 -148
P 128 82
P 129 -120
P 130 85
P 131 -90

Tool measurements

Every tool destined for use on an INTERMAC machine must be accurately measured. The values
thus found must be inserted in the CNC memory (see paragraph 11.1 “Information about tools” in
this manual).

Tools which make a surface incision on the plate possess particular characteristics and must be
lined up by the machine operator responsible for the execution of the machining program before
this can be started. (See paragraph 11.1 “Information about tools” in this manual).

Important
THE AGGREGATE SUPPLIED BY INTERMAC CAN ACCEPT A WHEEL HAVING A MAXIMUM
RIM WIDTH OF 30 mm AND DIAMETER 150 mm.

TOOLS OF DIMENSIONS GREATER THAN THE ABOVE STATED ARE CONSIDERED

UNACCEPTABLE AND INTERMAC WILL NOT GUARANTEE THEIR PERFORMANCE.

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Aggregate for cup grinding

Master 23-33-43-53-63

Tool class 25 -
Aggregate for diamone edged cup grinding
Tool class 26 -
Polishing cup grinding aggregate

MAXIMUM SPINDLE ROTATION: 3500 r.p.m.

Technical parameters

Aggregate height (mm) 109.5 P 102

Aggregate Offset C (degrees) 90 P 099
Aggregate shift 72.7 P 109

Glass technological data

SLAB THICKNESS: 19mm

Tool constructor: DIAMUT

Tool diameter: 150mm

Tool type Removal (mm) Rotation (r.p.m.) Advance (mm/min)
Double layer resin for 0.3 3200 800
chamfer
3rd chamfer resin 0.1 3200 800
Cerium resinoid 0 1300 400
polisher

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11.2 Tools assembly

11.2.1 Tool assembly on ISO 40 taper spindle

There are two ways to fix a tool on a taper spindle, depending on the type of the cylindrical
aggregate:
• female thread in the cone for the aggregate male stud. The aggregate has a centring female
cone to fit on the spindle;
• flat mating surfaces held together by 4 M5 or M6 screws. The greater contact surface area
makes this type of aggregate mounting more suitable for heavy machining, when a greater
cutting force is required.

Caution:
Always use gloves.

In the case of a milling tool of the first type, of a vertical drill and of a flaring aggregate, assemble
the tool in the following manner:

1. Insert and lock the tapered spindle on the special support fixed to the work table.

2. Insert the tool in the threaded hole of the cone

3. Turn the tool down tight.

Drill Milling tool of the 1st type

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With a milling tool of the second type, assemble the tool in the following manner:

1. Insert and lock the tapered spindle on the special support fixed to the work table.

2. Insert the tool in the centring hole of the spindle.

3. Tighten the 4 fixing screws of the tool flange.

To install a vertical graphitising bit proceed in the following manner:

1. Insert and lock the tapered spindle on the special support fixed to the work table.

2. Loosen the locknut while holding the spindle so it does not rotate.

3. Insert the tool.

4. Tighten the locknut.

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11.2.2 Grinding wheel assembly on ISO 40 tapered spindle

To install the grinding wheel (bonded diamond, polishing or chamfering) on the tapered spindle,
proceed as follows:

Caution
Use gloves

1. Insert and lock the tapered spindle on the special support fixed to the work table.

2. Loosen the lock screw and extracts the spacer.

3. Insert the wheel.

4. Position the spacer and tighten the lock screw.

5. Tighten the screw to pack spacer and spring against the spindle.

Information
To set the height of the grindstones destined to machining with doube grindstone (twin
version), use the shims included to obtain the same height.

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11.2.3 Mounting the tools on the aggregates

To assemble a flat cup shaped diamond disc on the aggregate proceed in the following way:

Caution
Use gloves

1. Insert and lock the tapered end of the aggregate on the special support fixed to the work table.

2. Loosen the four disc locking screws.

3. Remove the flange.

4. Insert the tool.

5. Replace the flange.

6. Tighten the lock screws.

Caution
When inserting the disc, make sure to match the pin on the flange with the corresponding
hole on the disc.

To assemble the diamond bonded or polishing wheel on the aggregate proceed as follows:

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Caution
Use gloves.

1. Insert and lock the tapered end of the aggregate on the special support fixed to the work table.

2. Loosen the lock screw..

3. Remove the flange.

4. Insert the tool.

5. Replace the flange.

6. Tighten the lock screw.

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11.3 Use of the tracer

The tracer is a precision instrument which the machine uses to survey all the geometrical
characteristics of the workpiece: its thickness its position and its shape.

Caution
On the Master twin the tracer must be assembled on the primary spindle, or
measurements will be incorrect.

The machine considers the tracer as a tool. Its parameters are given under Technical data T05
Intermac, table S16, Tracing.

The instrument consists of two separate and independent elements, each one with its own
individual function during the surveying operation.

TYPE NOTES

Optical fibre sensor Used by the machine to determine the

position of the workpiece.

Mechanical button type limit switch Used by the machine to determine the
thickness of the workpiece and the height of
the suction cups.

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Caution
Avoid damage to the instrument by keeping it away from water; put it back in its case after
use and store in a safe place (see the maker’s instructions).

Optical fibres
The optical fibre element is a COAXIAL REFLECTION SENSOR, comprising a device to throw a
0,4 mm dia. light beam on the surface of the workpiece under survey.

Button type limit switch

This is a button type, fast acting single pole NC/NO contact switch, of 0,05 mm repeatability.

Swapping sensors
A few simple steps are required to change over from the optical sensor to the mechanical one.

Loosen the locking screw.

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Rotate by 90° the sensors

support.

Tighten the locking screw.

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11.4 Laser pre-setter group (optional)

General
The laser pre-setter group is a control device used by the machine to measure tool wear (height
and radius).
Its “U” shaped structure allows the tool to be read from two different points, so that a laser beam
can measure its dimensions.
The laser pre-setter can be installed on the machine, away from the work table.

The relevant parameters are given under I Technical data T05 Intermac, table S22 – tool
pre-setter.

The instrument can be mounted on a machine on its LH side, near the work table.

Use
The laser pre-setter will come into action automatically as a result of a command from the
operator, but it can also be used in the manual mode.

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11.4.1 General rules and warnings

Precautions to be taken when using a laser device

The laser system emitter utilises a Laser Diode as a visible light emitter (wavelength 670 Nm), with
a maximum optical power emission < 1 mW , which makes the device fall into class 2 of the
international standards IEC 825, ANSI Z136. All the safety precautions to be taken when using the
device can be had by consulting the above standard specifications.

It is recommended in particular:
! to avoid exposing the human eye directly to the laser beam, or even to its reflections from
mirrors, prisms, etc.;
! not to point intentionally the laser beam, absolutely under no circumstances whatsoever, in the
direction of other people working nearby;
! to work in such way that the laser beam is activated with its safety devices in working order
only for as long as it is needed for setting up or work purposes.;
! to affix in visible positions on the machine the labels supplied by the makers and here below
reproduced , which clearly indicate the presence of laser equipment.

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11.4.2 General description and technical data

System’s functions and operating principles

The no-contact Laser measuring device is used on the rotating tools of machining centres to
monitor the tool condition: wear control and measurement of length and diameter.

The system is based on a laser beam and on a high accuracy photo diode. The signals generated
by the system as a result of interruptions of the laser beam, are utilised by the machine CNC to
calculate the necessary dimensional values.

Description of the system

A laser diode generates a visible laser light beam and appropriate optical equipment provides for
its collimation and focusing. A photo diode receives the signal, and an appropriate circuitry
elaborates the information.

The electrical signals generated by the system as a result of the interruptions of the laser beam
are utilised by the CNC of the machine to calculate the dimensions.

The system is equipped with air actuated shutters to protect the optical openings of the emitter and
receiver from all the polluting agents present in the work areas of the machine: cooling liquids,
vapours, condensation, grindings, dust, etc….

A small air piston keeps all the openings shut when the system is not working, and opens the
shutter only for the fraction of second needed to take the reading.

Further protection of the device is provided by a filtered air barrier, which is always active in front of
the optical openings.

The level of protection of the Laser Measuring System conforms with standard IP67

The Laser Measuring System can measure tools as detailed in the table below.

The device can be supplied in the “Stand Alone” version, where emitter and receiver are mounted
on a specially designed support.

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PRE-SETTER OPERATING PARAMETERS

Tolerance on dia. Tolerance on height Ignore

After
Type of Preset Type of [mm] [mm] Wrong Spindle air
Type of tool dressing
Material interval preset measure- preset
preset
superiore inferiore superiore inferiore ment

Drill 5 2 0 0 0,1 0,2 1 1 1

Rim diamond Sectors 5 1 0,1 0,4 0 0 1 1 0

wheels
GLASS
&
Flaring tools Continuous 7 1 0,1 0,2 0 0 1 1 0

Diamond Diamond 5 2 0 0 0,05 0,2 1 1 0

beveling
wheels Resin 7 2 0 0 0,05 0,1 1 1 0

Sectors 8 2 0 0 0,1 0,3 1 1 1

Drill
Continuous 8 2 0 0 0,1 0,2 1 1 1

Diamond Sectors 5 1 0,1 0,6 0 0 1 1 0

wheels:
MARBLE Rim
& &
GRANITE Step Rim Continuous 7 1 0,1 0,3 0 0 1 1 0

Sectors 3 2 0 0 0,1 0,5 1 1 0

Diamond
wheels:
Step Rim Continuous 5 2 0 0 0,05 0,25 1 1 0

THE VALUES INDICATED IN THE TABLE MAY VARY DEPENDING ON TOOL BITE, FEED RATE AND
TYPE OF BONDING.

LEGENDA
Preset interval Represents the number of operations before the tool is measured

Indicates which measurements are made:

Type 0 Measures diameter and height with tool in rotation
Type 1 Measures only diameter with tool in rotation
Type of Preset Type 2 Measures only height with tool in rotation
Type 3 Measures diameter and height with spindle oriented
Type 4 Measures only diameter with spindle oriented
Type 5 Measured only height with spindle oriented

When the presetter finds a value which is outside the tolerance limits, the
measurement will be repeated up to 10 times, until the resulting value will return
Ignore wrong within tolerance. If the value remains out of tolerance after the 10th attempt and
measurement this field has value 1, the wrong value will be ignored and machining will continue
on the basis of the original dimensions; whereas if the field value is 0, the
measurement will be ignored and the program will be reset.

Field utilized only for tools of the DRILL type. If the value of the field is 1, a tool
Preset after dressing
preset will automatically take place after each dressing

NOTE
The preset function is non-active for all types of tools of the aggregate type, except when beveling diamond wheels are involved.
It is recommended not to preset polishing tools of all types: their diameter and height are automatically updated by the Numerical Control during
polishing operations.

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11.4.3 Possible applications

Machining centres
The great advantage of laser probes is that a moving tool can be checked without making any
contact with it, thus allowing a substantial reduction of machining time and eliminating the
risks of collision.

11.4.4 Compressed air requirements

The emitter and the receiver require for the air operated shutter and the air curtains an air supply
of the following characteristics:
! For the air operated shutter:

- Inlet air pressure: 5 bar; ISO 8573-1 Regulations, Class 5.7.5

- Degree of filtration; ISO 8573-1 Regulations, Class 5.7.5
- Connection fitting: H6
! For the air curtain :

- Inlet air pressure: 3 bar

- Degree of filtration; 0,5 µm ISO 8573-1 Regulations, Class 1.3.1
- Connection fitting: H4

Caution
The air must be dehumidified but not lubricated. If lubricated air is used there may be
problems of local pollution.

11.4.5 Technical characteristics

The unit of measure adopted by the makers of the instrument is in the SI system, after CNR-UNI
10003.
Type of instrument: Laser 75
Type of handling Pneumatic
Function of the instrument: No-contact control of tools in machining centres.
Electromagnetic emissions: Within the limits dictated by IEC 801.
Radiations: Visible laser radiation (l=670 nm ).
Maximum power emitted < 1 mW.
Class 2 device after IEC 825 ANSI Z136.
Level of protection: IP67

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11.4.6 Operating ambient conditions

Danger
The instrument must not be used in areas at risk of explosion or fire.

! Ambient temperature: 15÷ 40°C.

! Relative humidity: 90% max.

! Temperature variations: 2°C/h.

! Floor vibrations: absent.

280 mm support version with side connector

Dimensions for 280 mm version with side connector (Axial).

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11.4.7 Shutter air filtering system

For the maintenance of the shutter air filtering system refer to paragraph “Maintenance of air
treatment units”.

11.4.8 Curtain air filtering system

For the maintenance of the curtain air filtering system refer to paragraph “Maintenance of air
treatment units”.

The filter units are located in the service cubicle located on the right hand side of the machine, as
shown in paragraph 4.3.

11.4.9 Maintenance
! It is good practice to check periodically the conditions of cleanliness of the system, paying
particular attention to the optical openings of emitter and receiver.
! These parts can be cleaned with an appropriate cloth or with optical paper towels. Eventual
traces of dirt and/or grease can be removed with appropriate detergent fluid sprays or bottled
anhydrous compressed air.

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11.5 Tool dresser for “vertical drill” (optional)

General
The dresser for vertical drilling tools is used to renew the cutting edge of the tool when it has been
worn out by abrasion during machining. In practice, the dresser re-sharpens the cutting edge of
the tool. .
The dresser is mounted on the machine, outside the work area.

The relevant parameters can be found in technical data T05 Intermac, table S17 – tool dressers.

It is possible to install such an instrument on a machine, on one side or the other of the work table.
Its use will help cut machine cycle times.

How it is used
Tool dressing is performed automatically by the machine, but it can also be done manually, if this
is more convenient.

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11.6 Dresser for polishing wheels (optional)

General
The dresser for polishing wheels is used to renew the working surface of a wheel worn away
during machining. In practice it is used to eliminate the deformations appearing at the edges of the
wheel as machining proceeds.
This dresser is mounted on board the machine, away from the work table.

The relevant parameters are given in Technical Data T05 Intermac, table S23 – polishing wheels
dresser.

Such an instrument can be mounted on a machine on one side or the other of the work table, or on
both sides, to allow faster cycle times.

How it is used
Tool dressing is performed automatically by the machine during a machining cycle, but it can also
be done manually, if this is more convenient.

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11.7 Workpiece rotated origin tracer (optional, 3 axes

operating heads, with or without C/T axes)
General
The tracer of the origin is a precision instrument utilised by the machine to determine, relatively to
the X and Y axes, the position of a workpiece which has been casually placed on the work table. It
is an external device which can been utilised only on condition that the workpiece has at least two
straight edges at right angle to each other.

The relevant parameters are given in Technical data T05 Intermac, table S18, fixed tracer.
The instrument consists of two elements which can be described as follows:

1. the reading element, consisting of an optical fibre reading element and relative support;

2. the mobile part, which includes an air piston and a solenoid valve to control its up and down
displacements;

3. the protection guard for the reading element

when at rest in its parking position.

Optical fibre
The optical fibre detection element, a COAXIAL
REFLECTION SENSOR, is an emitter which throws
a ray of light 0,4 mm in diameter on the surface of
the piece to be measured.

How it is used
The instrument works automatically by lowering and
raising the reading element before a machining
operation, but it can also be used manually, if this is
more convenient.

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11.8 Tracer of the origin of a randomly loaded

workpiece (optional for 5 axes machine)
General
The tracer of origin is a precision instrument utilised by the machine to determine the position of a
workpiece which has been placed on the work table in a random manner with respect to the X and
Y axes. It is an external device which can been utilised only on condition that the workpiece has at
least two straight edges at right angle to each other.

The relevant parameters are given in Technical data T05 Intermac, table S18, fixed tracer.
The instrument consists of two elements which can be described as follows:

1. the reading element, consisting of an optical

fibre reading element and relative oscillating
support; stop area
2. the mobile part, which includes a rotary air
actuator and a solenoid valve to control its up
and down displacements;

The device is equipped with an air curtain to protect

it from sprays and grindings, activated every time
the instrument starts downwards to take a reading.

Optical fibre
The optical fibre detection element, a COAXIAL
REFLECTION SENSOR, is made up of an emitter
which throws a ray of light 0,4 mm in diameter on
the surface of the piece to be measured.

How it is used
The instrument works automatically by lowering and
raising the reading element before a machining
operation, but it can also be used manually, if this is
more convenient.
rod stop

Information
Clean periodically the contact areas between
the stop and the rod in order to avoid
accumulation of dirt, which would inevitably
affect the precision of the instrument.

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12. Setting up the tool magazine

This chapter explains how to prepare for work the various tool magazines. In particular, it gives
information about maximum tool dimensions, about the orientation and position of every aggregate
and the compatibility between spindles and aggregates when mounted in adjacent positions. In
case of more specific requirements, INTERMAC is available for further clarifications.

12.1 Setting up the revolving type tool magazine

The magazine accommodates the tools needed for the various machining operations. The types of
tools accepted by the revolving type magazine are specified on page 283.
Once the tools have been placed in the magazine, the numerical control software must be
supplied with all the necessary data (consult the user’s Software Manual).

In order to enable the magazine to receive the tools, this must be positioned all the way back in its
housing recess, well away from the work table.

Through a door placed on the side of the machine the operator can thus dispose the tools in the
magazine whilst the machine is operating*. Idle time due to tooling-up operations is thus reduced.

Master Twin version

The magazine installed on the twin version makes it possible to change tools on both spindles at
the same time, but the following conditions must be met:
• tools must be adjacent to each other and on coupled forks;
• both tools must have identical heights and identical working offsets.

* For reasons of safety, the machine cannot perform a tool change whilst the operator is in the process of
setting up the tool magazine. The magazine door is equipped with a safety microswitch that causes the
program to stop the machine when the automatic tool change cannot be executed. This safety feature is
contained in the machine program. Once the operator has finished preparing the magazine and the door has
been closed, the machine will resume operations from the point where it left off (no resetting needed).

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Setting up the spindles

When setting up the magazine with spindle
mounted tools, proceed as follows:

1. obtain the tools to be mounted;

2. rotate the magazine to the desired position;

3. open the magazine door;

4. position the tool on its holder as shown in the

picture;

5. turn the magazine to the next position until all

tools have been prearranged.

Setting up the tool magazine with aggregates

To position aggregates in the magazine proceed as
follows:

1. obtain the aggregates to be mounted;

2. rotate the magazine to the desired position

(check if applicable);

3. open the magazine door;

4. position the aggregate on its tool holder,

allowing for the aggregate dimensions: if
necessary leave adjacent positions empty;

Information
Owing to their weight, the aggregates must
be placed in the magazine mounted on appropriate fork-like holders equipped with
underside supports.

5. turn to the next position of the magazine until all aggregates have been arranged.

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Usable tools
The magazine can take tools and aggregates
having a taper connection to ISO 40 standards and
of the dimensions herebelow specified

(For the dimensions of the aggregates refer to L max = 240 mm

chapter 11.1 “Information about tools”) D max = 150 mm

L
Caution
For the revolver magazine on the edge of
the head, the maximum tool length is: D
L=65 mm for Master 3 - 4
L=70 mm for Master 23

Compatibility
When placing aggregates in the magazine the layouts shown here must be adhered to, so that the
weight of each aggregate will be equally distributed on the supporting structure. This will result in a
well balanced revolving magazine to make its rotation much smoother. For further information
about the dimensions of the aggregates, see par. 11.1 “Information about tools”.

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Maximum tool dimensions are given in par. “Usable tools” on page 283.

Arrangement for 2 aggregates Arrangement for 3 aggregates Arrangement for 4 aggregates

Arrangement for 5 aggregates Arrangement for 6 aggregates Arrangement for 7 aggregates

Caution
The white reinforced tool holding forks are for tools weighing not more than 3,5 kg.

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12.2 Setting up the linear type tool magazine

On those machines equipped with a linear magazine, tooling up during the operating stage is not
envisaged. The tooling operation can be undertaken only with the machine at a standstill and in
safe conditions..

On the Master 30 linear magazine, tool aggregate assembly is not envisaged,

On the Master 23 version, in the event of the use of aggregates the magazine will be fitted with
special slots to ensure the support of the special tool.

On both versions with linear magazine, it is possible to use tools with a type ISO 40 attachment
with a diameter of not over 150 mm.

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13. Work table make-ready

13.1 Positioning the mobile elements of the work

table

13.1.1 Selection of the origin

The are two ways to select the origin:
! stops and suction cups are positioned on the in relation to an origin decided by the operator.

! the origin is determined after the stops and the suction cups have been positioned on the work
table.

The first method is by far the most commonly used: suction cups and stops are positioned relative
to an origin decided by the operator. The coordinates of the various points on the profile to be
machined are then calculated relatively to that origin.

In the second case, the operator positions stops and suction cups on the basis of the shape of the
workpiece, and then determines the origin with the aid of a mechanical tracer.

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13.1.2 Positioning stops and suction cups

Caution
Should it be necessary to climb onto the work top for the fitting operations, use a ladder
positioned near the top, to making climbing up and down easier.

; Wear anti-slip shoes

Stops and suction cups are positioned on the basis of the final geometry of the workpiece and the
machining operations needed to obtain it.

During this stage the operator utilises a dedicated

software which, following the introduction of the drawing in
the system, allows the number of stops and suction cups
of various shapes and diameters to be properly
programmed.

The operator selects the “Position stops and suction cups”

function and launches the corresponding program. The
operating head positions itself near the edge of the work
table, where the operator will insert in the spindle a special
tool with shoulders at 90° to each other, against which the
stops and the suction cups will be positioned.

Caution
On the Master twin the aggregate bracket must
be assembled on the primary spindle, otherwise
the positioning will be incorrect.

Each time that the START “A” * pushbutton is pressed, the

operating head will go to position itself at the point where
the program decides that a stop, or a suction cup, is to be
placed.
Once the stop, or the suction cup, has been thus
positioned, START is again pressed and the operating
head will go to the next point, where the head will come to
rest, so that the operator can position the next stop, or
suction cup.
During this operations the machine can function with its
guards open, provided the operator maintains pressure on
a particular key throughout the movement of the head.

* “A” : this is the start machining pushbutton, or the START pushbutton on the handbox control panel.

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 13. Work table make-ready

Information
During this step by step displacements the head travels at a speed of 10 m/min, which is
slow enough not to constitute any danger for the operator.

When the stops have been positioned, the suction cups can be positioned in a similar way.

13.1.3 Positioning stops and suction cups with the Laser

Projector
Besides the possibility of positioning stops and suction cups with the aid of software, Intermac can
supply as an optional a Laser system which projects a beam on the worktable to pinpoint their
exact position in accordance with the characteristics of the workpiece. In
actual practice, the operator defines the geometry of the workpiece and decides the number and
the positions of stops and suction cups. At this point he will interface with he Laser system, which
will project on the worktable the shape of the workpiece and pinpoint the positions of stops and
suction cups by projecting circles whose diameter corresponds to the size of the requested object,
or other geometrical shapes depending on the chosen configuration.

The apparatus consists of a stand to keep the arm with the Laser source suspended over the
worktable. The stand is fixed by the side of the machine and its height remains adjusted even after
the installation has been completed.

The apparatus requires the application of 4 refracting elements positioned outside the working
area, which are needed for the automatic calibration of the system should this ever be necessary.
In addition, 4 holes must be drilled at the 4 corners of the table for use when the apparatus is first
installed, or when it needs reinstalling, or when the machine itself must be relocated.

See the instructions for the use of the Laser Projector by consulting the appropriate chapter in the
User’s Interface Manual.

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For detailed instructions about the installation of the laser projector, please see section 19.1
“Layout - Laser Projector Installation”.

Laser projector 4 Calibration holes on

table
Variable height
stand 4 Refracting elements

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General norms and warnings

Precautions when using a laser device

The supplied laser is 4002 G 05. The maximum optical power emitted is > 5 mW. The device is in
class 3A.
It is compliant with European norm DIN EN 60825 and norm 21 CFR 1040.10&1040.11 (USA).

In particular, it is advisable to:

! avoid exposure of the human ayes to laser beams, both directly and as a reflection on optical
devices (mirrors, prisms etc);
! it is absolutely forbidden to intentionally point the laser beam to people operating in the
adjoining areas;
! place, on visible positions on the machine, warnings indicating the use of laser devices (these
warnings are included and are illustrated below):

ATTENTION: symbol of general danger

ATTENTION: electric current

ATTENTION: laser beams

Do not:
! operate the laser emitter:
• after having your eyes checked
• under the influence of drugs or alcohol
• after ingesting medicine which might alter vision.
! use the laser emitter if it causes visible damage to the structure and to the electric
connections.
! use the laser emitter in case of malfunctioning. Disconnect the device from the mains in case
of detected problems.

Caution
Do not try to fix the device if it presents problems. Contact authorised personnel.

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 14. Basic machine operations

14. Basic machine operations

14.1 Starting the machine

To start the machine proceed as follows:

1. Check that on the machine there is no stop or emergency device engaged.

2. Turn on compressed air and process water.

3. Turn the general switch to the ON position. The general switch is located at the rear of the
switchboard cubicle.

4. Wait for the PC start.

5. Enter the password (if requested) in field “CENTRE 1”.

6. Wait for the interface to become activated.

7. Turn the machining centre ON by turning the key switch.

8. Do a global reset for the machine axes:

- Select icon “RESET”.
- Activate “GLOBAL RESET” flag .

- Press “START” to reset.

9. Wait for the spindle warm-up cycle to complete.

10. Wait for message “AXIS CALIBRATION IS OUT - AXIS MUST BE RESET” to disappear.

11. Turn vacuum pump ON by pressing the appropriate pushbutton.

12. Position the workpiece against the stop.

13. Fix the workpiece to the suction cups by pressing the pedal of the appropriate station.

14. Select the automatic mode of operation.

15. Open the work lists with icon “OPEN”.

16. Select the desired work list e press ENTER.

17. Select the program to be run and check that the values of fields origin, workpiece thickness,
quantity and stop at end of cycle, are correct.

18. Press START.

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14.2 Resetting the machine axes

The machine axes can be reset automatically all at once, or one at a time.
For the proper procedure to reset the axes, refer to the Software Manual.

Information
Before any motor is turned on the computer will go through a checking procedure. If even
only one of the motors fails the check-up, no motor will be started on the machine. For
further information refer to the Software User’s Manual.

14.3 Warm-up cycles for the operating head

When first starting the machine at the beginning of the day it is important to send the motor drive
spindle through a warm-up cycle. This will make it last longer.

When a spindle has remained idle for longer than 4 hours, the procedure should be repeated.
The warm-up cycle set by Intermac lets the spindle run at gradually increasing speeds for a
predetermine period of time.

Danger
During warm-up the spindle is run without the tool, because some tools cannot withstand
the speeds necessary to warm up the equipment.

14.4 Stopping the machine

Stopping the program; a program can be stopped in two different ways:
! At the end of a machining cycle the machine will stop in a “park” position, waiting for a new
program to be launched. At this point the operator will unload the finished workpiece and load
a new one.

! It is possible to press a stop pushbutton during the machining cycle to send the
machine in a “hold” mode. In such a case the axes will stop in the exact position they are in
when the stop is pressed.
The machine stops, motors are under tension and the program is hanged. The machine
stands waiting for the next command and there are two possibilities:

• press Start , so that the machine can resume work exactly from where it left off at
the time of the stop.

• press Reset , to leave the machine at a standstill and interrupt the current
machining program. In this case, if work is to be resumed with the same program, it must be
from the beginning.

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 14. Basic machine operations

Emergency stop; this type of stop is used in case it becomes necessary to bring the machine to
an immediate halt. This can be obtained by pressing the nearest Emergency pushbutton.

Information
Pressing an emergency pushbutton when the machine is in operation takes tension off all
the auxiliary circuits, as result of which all machining cycles, and the starting of other
devices that are not directly turned off, are disabled. The axes and all the other moving parts
of the machine are brought to a halt with the maximum braking current. The machine is
therefore brought very rapidly to a condition of complete safety.

A check on all the emergency stop devices present on the machine should be undertaken
at regular intervals to assure the efficiency of the same.

Caution
It is the operator’s responsibilty to ensure that no people or things are present in the
work area before starting any function of the machine.

14.5 Resetting the machine functions

After the machine has been stopped with an emergency pushbutton , its functions must
be reset. Proceed as follows:

! release the emergency pushbutton by turning it;

! zero all the error messages by pressing the appropriate software key (refer to the relative
manual);

! go once more through the machine starting sequence and turn the key switch .

As a result of an emergency stop which is not caused by the operator, all machine

movements are aborted: by turning the key switch the machine starts off again but
remains where it stood when the stop occurred. In this case it will be necessary to reload the
program that was being run, because in an emergency situation a total reset of all the non basic
machine settings takes place.

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14.6 Turning off the machine

The machine is turned off with the following procedure:

1. Always wait for the machine to terminate its work cycle.

2. Press the stop pushbutton.

3. Turn the vacuum pump off .

4. Turn the motors off.

5. Launch the KILL WRT command by clicking Start - Programs - WRT - KILL WRT. This will
close the NC software.

6. Proceed with the PC stop procedure by clicking Start – Close session – Stop system.

7. Wait for the PC stop procedure to complete.

8. Turn the general switch to the “0” position and eventually apply a padlock to it, then turn off the
factory mains switch.

9. Turn off the process water.

10. Turn off the air at the point of connection with the factory compressed air system.

11. Discharge all the air from the machine system through the isolating valve. Eventually, padlock
the isolating valve.

Information
If there is a solenoid valve that can also be padlocked, shutting off the air at the supply end
and discharging the pressure will not be necessary, as all this happens automatically the
moment the machine is stopped.

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 15. Machining operations

15. Machining operations

This chapter contains instructions on how to handle the machine during actual machining
operations, and the necessary procedures. Both the instructions and the procedures presuppose
that the operator has accurately prepared the machine beforehand and that he has experience in
the use of numerical control software. For a description of the machine controls mentioned here
(pushbuttons and selectors), refer to chapter 10. “Machine controls and signalling devices”.

15.1 Warnings about machining

Before starting machining:
! Run the spindle warm-up cycle immediately after the machine has been switched on and the
axes have been zeroed or, anyway, each time the NC meets with parameters requiring that
the cycle should be repeated.

During machining:
! Set adequate rotational and feed speeds.

! Clean the worktable and the process water tanks periodically.

! In cases of power failure, of an emergency stop or an otherwise sudden machine stop, wait 5
or 6 minutes before going near any electronic device, so that the condensers will have time to
lose the residual charge.

15.1.1 Warnings about working with Master Twin

Limits
Although it is possible to assemble two tools at the same time, some machinings require the use of
a single tool assembled on the primary spindle, while the secondary spindle is not programmed.
These machinings are:
- Milling
- Drilling
- Machining with aggregates

To know which aggregates are compatible with the Master twin consult chapter 11.

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The system will warn the operator in case of a shape that is impossible to machine with the double
grinding. It will also report possible polishing imperfections through AII (Automatic Imperfection
Indication).

15.2 Procedure for machining operations

The performance of a machining cycle presupposes:

1. That the machine has been tooled-up according to the instructions given in the appropriate
chapters.

2. That a program for the numerical control of the machine has been made using the CAD-CAM
software, or that an existing program has been loaded, and that one or the other have been
given the run command. See the Software User’s Manual about programs and programming.

Information
The CAD program is used to make a drawing and the CAM program is used to set the
machining parameters on the machine. When these are done, the operator must check if
the tooling-up is correct for the program in hand and, if necessary, places the correct tools in
the revolving magazine.

3. That a mode of operation of the machine is selected: automatic (see par. 15.6) or manual (see
par. 15.5)

15.2.1 Procedure for machining with Master twin machine

All the variables which manage the double-grindstone machining are present on the ICAM which
must be instaled on the machine PC.
It is possible to manage:
• the use of both spindles or of the primary spindle only;
• whether to machine with the primary or secondary spindle;
• whether to assemble two tools and machine with a single tool, while keeping the inactive
spindle at a distance.

These choices are subject to the type of tool being used. On the primary spindle it is advisable to
assemble a fine-grain tool, with a rougher tool on the secondary spindle.

Information
If the two tools require different advance movements, machining will be programmed with
the lowest advance movement.

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15.3 Meaning and selection of origins

Meaning of origins
The ORIGIN is a point of reference on the workpiece which identifies its position on the worktable
of the machine.
In general, the point of origin of a geometrical shape corresponds to one of the four corners of the
real or imaginary rectangle within which it is contained. The operator can chose from any one of
these points.
The choice of the point of origin is in relation to the use of the tracer, and it involves a different
approach to the drawing of the piece, depending on which one of the four corners has been
chosen:

! LOWER LH CORNER (origin 1): the drawing must be made in 1st quadrant of the Cartesian
coordinates (+ve side of both X and Y axes).

! LOWER RH CORNER (origin 2): the drawing must be made in 2nd quadrant of the Cartesian
coordinates (-ve side of X axis, +ve side of Y axis).

! UPPER RH CORNER (origin 3): the drawing must be made in 3rd quadrant of the Cartesian
coordinates (-ve side of X axis, -ve side of Y axis.

! UPPER RH CORNER (origin 4): the drawing must be made in 4th quadrant of the Cartesian
coordinates (+ve side of both X and Y axes).

Information
The origin can be entered manually by the operator or it can be determined with the
electronic tracer (see appropriate chapter).

Description of parameters
For a description of parameters see the user’s interface manual.

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15.4 Positioning and fixing of the workpiece

Positioning of the workpiece can only be done manually:

Caution
Raise the workpieces with suitable equipment in the case in which they exceed the
weight allowed by the current local regulations in force and should they have
dimensions exceeding a metre. Also use suitable lifting equipment for pieces that
have to be positioned at more than 800 mm from the external edge of the worktop.

1. If necessary, lift-up the stops by acting on the pedal.

2. Select the program.

3. Position stops and suction cups.

Information
The stops must be lifted now to allow positioning of the workpiece. The guards must be
closed before positioning of stops and suction cups can be started. During the positioning
itself, the guards may be left open.

4. Position the workpiece by pushing it against the stops.

5. Lower the stops and open the vacuum by pressing the appropriate pedal.

6. Close the safety guards.

7. Start the automatic machining program.

8. The selected program will run automatically.

9. End of program (the workpiece is still held by the suction cups.

10. Open the safety guards.

11. Unlock the workpiece free.

12. Lift up the stops by pressing the appropriate pedal.

13. Remove the workpiece.

Danger
When positioning the piece pay attention to the rise of the rabbets.

Risk of crushing your hands = between the rabbets and the piece.

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 15. Machining operations

Repeat steps 4 through 13 for the next workpiece.

15.5 Use of the machine in the manual mode

(movement of the axes)
Machining is carried out exclusively in an automatic mode on the instructions from a software
program. The operator must however be capable of moving the machine manually, either in a
continuous or in a step-by-step mode, on such occasions as when he has to move a tool away
from the workpiece in case of a machine stop, or when positioning suction cups and stops with the
special device attached to the spindle.

Manual operation is also required when calibrating a tool, which involves approaching very slowly
a point on the workpiece and checking the corresponding dimension. For manual mode
commands, see the software documentation.

NOTE: the machine can be operated manually through the appropriate continuous action keys

15.6 Machine operation in the automatic mode

For the operation of the machine in the automatic mode, refer to the user’s interface manual.

15.7 Starting machining operations

Machining operations are started by pressing the START pushbutton of the station (1 or 2) where
the workpiece is positioned.

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15.8 Machining cycle

Refer to the Software Manual for a description of machining cycles.

15.9 Machining of identical workpieces

Each station of the worktable has several origins and can therefore accept for machining several
exactly similar workpieces that will have been positioned on either station. In this case the
machine will proceed by optimizing the machining process.

Complete cycle
1. the machine loads the first tool;

2. all workpieces present will be worked by the first tool;

3. the machine executes the first tool change;

4. the next machining operation will be carried out on all workpieces present;

5. the machine executes the second tool change;

6. the machine will continue working in this manner until all machining operations are completed;

7. select the stop “flag” at the end of the operations; the axes will go to their parking positions
and the machine will stop. If no stop “flag” is selected, the machine will proceed with the next
job list.

Partial cycle
The partial cycle starts with the declared tool and ends with the last tool in the program.

Single tool cycle

Only machining by the declared tool will be involved.

15.10 Tool change

The tool change can be done in the automatic or in the semiautomatic mode. In either case the
operator must position the tool on the revolving magazine, from where the operating head will pick
it up.

In the semiautomatic mode the tool is picked up by moving the operating head via software, by
proceeding as follows:
! go to the appropriate software page and select the replacement tool;

! if there is a tool on the spindle, the software will deposit it in the magazine before picking up
the next selected tool;

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 15. Machining operations

! the operating head lowers;

! the protective cover of the machine work area opens;

! the tool magazine carriage comes out rotating at the same time, to align an empty tool housing
with the tool on the spindle;
! the carriage moves forward to receive the tool in the collet;

Information
Collisions are avoided by a sensor detecting the eventual presence of a tool in the collet, in
which case the machine is stopped and the tool change does not take place.

! the spindle collet releases the tool;

Information
The collet is pneumatically operated; an air blow is used to clean the spindle.

! the operating head rises and the tool is left in the magazine;

Information
At this point the cooling water still in the pipes is discharged.

! The magazine carriage turns to a new position where the next tool is to be picked-up, to
continue the machining operations;
! the operating head lowers and the collet will close on the tool;

! the tool magazine goes back;

! the operating head rises along the Z axis;

! the safety guard closes.

15.11 Unloading the workpiece

At the end of the machining cycle the operator releases the suction cups and takes the finished
piece off the work table.

15.12 Interruption of machining operations

To interrupt any kind of machining cycle the STOP pushbutton must be pressed.

The machine will temporarily suspend its activities without any change in the program, and will

remain in the “Hold” mode until START is pressed to resume work from where it was
interrupted.

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 16. Ordinary and extraordinary Maintenance

16. Ordinary and extraordinary

Maintenance

Introduction
This chapter contains information about the maintenance indispensable to keep the machine
efficient.

Caution
The machine must be switched off during maintenance operations. Remove the
power and pneumatic supply acting on the lockable devices and remove the keys to
prevent the machine being started by third parties. Consult the instructions relative
to paragraph 4.17 “Safety devices”

Caution
Clean the machine periodically because this will prevent breakdowns.
If the machine is not adequately cleaned and accumulated dirt is found
to be the cause impediments to the motion of the axes, the eventual
breakages and repairs will not be recognized under the terms of the
warranty.

Caution
Comply with the local regulations in force for the disposal of the products used
during maintenance.

Characteristics of external water

In order that the machine components in contact with water may be preserved in good conditions,
the water must respond to the following specification:
! Index of aggressiveness (I.A) = 11-12

! Electrical conductivity: not more than 1500 microS/cm

! Turbidity not above 300 mg/l

! Chlorides not above 300 mg/l

Information
Only an accurate analysis will tell if the water used for the machining process has the
required physical characteristics..

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If the water used does not have the required characteristics, Intermac may not accept warranty
claims for corrosion and for general malfunctions of the machine.

Beware of flocculating agents (poly-electrolytes)

Industrial waste water treatments for the dehydration of sediments may sometimes involve
products containing SODIUM CHLORIDE, which will inevitably corrode parts of a machining
centre.

Some products sold on the market contain Sodium Chloride in varying quantities, especially when
flocculating agents (poly-electrolytes) are in powder form.

It is advisable to utilise liquid poly-electrolytes, checking in any case that they do not contain
Sodium Chloride.

Customers are advised to request the formula of the flocculating agent from the supplier and to
make sure it does not contain SODIUM CHLORIDE.

Intermac will not accept claims under warranty if the flocculating agent used contains SODIUM
CHLORIDE, even if in small quantities.

Characteristics of internal water

Mains water must be used, or water having equal characteristics (in the case of using a centralised
plant for recovering machining water). To install the Master machine with a centralised plant
consult the paragraph 9.6.1 “Using the machine with centralised machining water recovery
system”.

Caution
Do not use water where solid particles are present in suspension that can, over time,
obstruct the “overflow” conduits.
Blocking these holes causes infiltrations in the lower areas of the electric-mandrel,
provoking damage to the electrical and mechanical components.

To maintain the best conditions of the components it is necessary that the water stays in the
following prameters:
! Index of aggressiveness (I.A) = 11-12

! Electrical conductivity: not more than 1500 microS/cm

! Turbidity not above 30 mg/l

! Chlorides not above 300 mg/l

The machine is equipped with a filter for purifying the internal water that serves to filter the water
before distributing it inside the machine.
For maintenance and information refer to page 313.

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 16. Ordinary and extraordinary Maintenance

General
Things to do before proceeding with any maintenance on the machine (unless otherwise directed):

1. switch off the vacuum and the tool cooling water pumps;

2. turn off the water at the point of intake from the factory network.

3. switch the machine off as per specific procedure and take the power off from the general
switch;

4. discharge the air from the machine system via the main intake;

5. apply padlocks on both the general switch and on the isolating air valve to make sure no one
else can interfere with them.

6. wear protective gloves before going near tools.

It is now possible to go near the operating head and the other devices in full safety, and to proceed
with replacement of parts or with maintenance operations.

16.1 Ordinary maintenance

The following table shows the general maintenance operations and the intervals between them.
The intervals are calculated on the basis of a 5 day-8 hours/day week, under normal ambient and
working conditions.

In the “Page“ column and for those operations that so require, is indicated the number of the page
with the description of the procedure to be followed.
Frequency Operation Page
Daily “Cleaning” 308
“Cleaning the Workable and the Lexan guards” 308
“Cleaning the suction cups” 311
Weekly “Cleaning the tanks (when applicable)” 314
Monthly “Cleaning the process water pump filter (when applicable)” 315
“Cleaning the vacuum filter” 316
“Cleaning the guides” 318
“Cleaning the process water pump” 312
“Cleaning the vacuum pump” 317

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16. Ordinary and extraordinary Maintenance

Cleaning
Correct cleaning of the machine and of the surrounding area will keep the working environment
safer and healthier: controls, signalling devices and warning lights will be more easily visible.

Caution
The machine must be OFF during all maintenance operations.

Remove all traces of dust and deposits of dirt wash with water and if necessary dry with
compressed air.
Clean and dry the floor around the machine so that water or other substances may not make it
slippery.

Besides cleaning the whole machine at the end of the work shift, do an accurate clean-up of the
driving members of the operating head, of the spindle and of the tools and their eventual
aggregates.

Clean the switchboard cubicle with a vacuum cleaner or a cloth, but not with compressed air,
which will only throw dust around, deposit it on contacts and cause problems.

Cleaning the Workable and the Lexan guards

Wash the worktable every day with clean water to prevent dust going hard, which would not only
make it difficult for the suction cups to adhere, but would also make the workpiece take up a false
position relative to the machining axes.
Clean very accurately the worktable and the Lexan guards once a week, using a de-scaling
product as described below.

De-scaling product for the worktable and the Lexan guards: “Nocal”

Warnings
! Individual protection

- Causes skin burns.

- Keep out of the reach of children .
- Avoid contact with the eyes by using protective goggles.
- Avoid contact with the skin by using protective clothing and rubber gloves.
! First aid measures

- Contact with skin: wash with water

- Contact with eyes : rinse with abundant water and consult the physician.
- If swallowed: consult a physician.

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Properties

Danger
The product is a pollutant. Do not use excessive amounts.
The product is highly acid and can attack marble, natural stone, painted or
galvanised surfaces.

Instructions for use

! Distribute the undiluted product on Lexan windows or on the worktable surface.

! Spread it immediately with a brush.

! Remove the overflow by collecting as much of it as possible with an appropriate container,

keeping it away from other machine parts or recirculation tanks.
! Rinse with abundant water.

Danger
Repeat the operation as often as necessary. Do not apply the product in other ways than
those described above.

Information
”Nocal” is available from INTERMAC in 1 and 2 Kg packages. Use code n° 3307A0033
when ordering.

Danger
The use of a product different from “Nocal” may damage machine parts.
Biesse S.p.a. may not accept warranty claims for corrosion and for general
malfunctions of the machine.

Cleaning the tool store

The machines in the Master range have three types of tool stores::
• rotare store
• rotare store on board head
• linear store (only for Master 23 and Master 30)

All the stores are equipped with tool store for the storage of either tools or aggregates.

The automatic tool change may cause the deposit of machining residues which risk jeopardizing
the correct tool position over time.
In order to avoid this, it is necessary to clean the tool holder forks during the normal machine
cleaning operations, using water and a brush.

Caution
It is necessari to absolutely avoid cleaning using the “Nocal” product supplied as it
may cause irreparabile damage to the tool carrier forks.
All the stores have a label applied which prohibits such an operation.

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16. Ordinary and extraordinary Maintenance

Biesse S.p.a. may assume the right not to recognize the guarantee conditions in
relation to the onset of corrosion or general malfunctions.

ATTENTION
DO NOT USE "NOCAL"
OR SIMILAR PRODUCT
TO CLEAN
TOOL HOLDING FORKS
See the instruction in the user's manual

Cleaning Stainless steel cones

The cone unit supplied by Intermac consists of two components of different material:
The tool in stainless steel to guarantee duration over time housed in Cone A, and the high
resistance steel fixing shank B for supporting stress.

It is possible that small areas of rusting form on the cone tool in stainless steel over time due to the
presence of carbides on the surface that in contact with the machining water triggers oxidisation.
This phenomenon should not cause alarm because it does not deform or compromise the
geometry of the piece in any way.

It is sufficient to remove these marks from the surface of the cone with a cloth, better if soaked in
alcohol.

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Cleaning the suction cups

Clean accurately the suction cups A..

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Cleaning the process water pump

The process water pump and the cooling water circuits must be cleaned a de-scaled once a
month. Proceed as follows:
! immerse pump A intake pipe in a separate container B containing a de-scaling product;

! place another container under the operating head to collect the liquid used for descaling and
return it to the main tank;
! run the pump for about 20 minutes to descale the system completely.

Caution
If the system is not cleaned as described the water flow will diminish as a result of
restrictions in the head and in the pump lines, causing difficulties during operations and
compromising the efficiency of the pump itself.

Caution
After doing maintenance on the water pump, before putting it back to work always check
sense of rotation with reference to the arrow on its body.

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 16. Ordinary and extraordinary Maintenance

Cleaning the filters of tool internal cooling water

On the tool cooling system there is a cup filter with internal cartridge (filtering capacity: 10 µm),
which will stop particles present in the cooling water from going into circulation and depositing in
the lines as scale.

When the impurities become an obstacle to the passage of the water and however once a quarter
the cartridges must be replaced.

To replace the cartridges (having first turned off the machine and the pump and relieved the water
pressure), proceed as follows:
! unscrew an remove cup A;

! extract the filter cartridge B;

! clean all deposits out and leave the filter cup clean;

! reassemble the filter by the reverse procedure.

Caution
After a filter cartridge replacement air bubbles may form in the system, causing the no-water
sensor to trip. It is advisable, after such operation, to purge the system before machining is
resumed.
The internal water in turned ON from the control panel. Wait for the water to flow out of the
spindle. The system has now been purged and machining can begin.

Danger
Do not run the machine without this filter: the rotary joint on the spindle may be
damaged.
INTERMAC does not take any responsibility nor will it accept claims under warranty
in case of negligence on the part of the operator.

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Cleaning the tanks (when applicable)

The formation of hard deposits inside the tanks A will reduce the available water volume.
When the deposit becomes excessive, the volume of water in the tank will no longer be sufficient
to cool the working elements during machining. Furthermore, when the cooling liquid is very dirty
the quality of finish will be poor and the performance of the diamond bonded tools will be
compromised.

It is therefore necessary to empty the tanks once a week and to remove the deposits with normal
digging implements.

Information
When changing the water close gate B placed in the suction vat, to keep the pump
triggered.
If it is necessary to remove the suction tube, do it by unscrewing elbow connection C to
facilitate the operation.

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Caution
When changing the water, the tanks must be filled up immediately to prevent the sludge
from going hard.
Working with insufficient water in the tanks must absolutely be avoided: this would not leave
sufficient time for the dust to settle on the bottom of the tank. Furthermore, the water would
warm up, causing the tools to lose their edge, thus producing a poor finish. Production
would be slowed down, too.

Note:
Always dispose of the machining water in a suitable manner in accordance with the local
regulations in force.

Cleaning the process water pump filter (when applicable)

The water pump is used to cool the external part of the tool during machining. Water is taken
directly from tanks located under the machine.
During machining the water picks up a considerable quantity of impurities, mainly those coming
from the removal of material from the workpieces.
It is therefore necessary to check once a month an eventually clean the filter located inside the
tank, using adequate descaling products.

Proceed as follows:
! Unscrew filter A from its holder B;

! immerse the filter in a container with a descaling product, and leave it for 20 minutes;

! rinse out the filter before replacing it.

Danger
Failure to maintain this filter clean may damage the pump.

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16. Ordinary and extraordinary Maintenance

Cleaning the vacuum filter

Vacuum pump A, which is used to fix the workpieces on the worktable, will work efficiently only if
the water is kept clean. The machine is therefore equipped with a water tank, where the pump
takes the water from and subsequently discharges it into.
The filter on the pump intake pipe should be checked once a month and eventually cleaned with a
descaling product.

Proceed as follows:
! immerse intake pipe B with the filter in container C with descaling product in it. Leave for about
20 minutes without turning the pump on.
! Rinse the filter in clean water before putting it back in the tank.

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 16. Ordinary and extraordinary Maintenance

Danger
Failure to maintain this filter clean may damage the pump.

Cleaning the vacuum pump

Information
If the water available is exceptionally hard, this pump also must be cleaned. (For the
water’s physical characteristics, refer to the relative paragraph in this chapter).

Clean the vacuum pump once a month with a descaling product. Proceed as follows:
! Disconnect the intake pipe A and the discharge pipe B;

! immerse both pipes in a container with a decaling product;

! keep the pump running for about 20 minutes, enough for the scales to dissolve.

Information
Turn the pump on with the specific key switch located on the pushbutton control panel.

! Rinse the pump with clean water at the end of the operation.

! reconnect all pipes;

Caution
Be sure not to alter the position of valve C positioned on the pump during cleaning.
Only Intermac authorised personnel are allowed to adjust the valve.

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16. Ordinary and extraordinary Maintenance

Cleaning the guides

Clean the X, Y, Z axes guides A, using a clean and dry cloth. Clean the re-circulating ball screws.
Brush out any form of hard deposits with a bronze brush. After cleaning, apply on the guides a thin
layer of MOBILUX EP1.

Centralised lubrication system maintenance

Maintenance details and intervals regarding the centralised lubrication system are shown in the
following table. The maintenance intervals have been determined on the assumption of a 5
day-8h/day week, with the machine operating under normal ambient and work conditions.
The Page column indicates, when applicable, the number of the page containing a description of
the maintenance procedure.
Frequency Operation Page
Weekly “Lubrication system check” 319
* “Filling-up the reservoir with lubricant” 319

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 16. Ordinary and extraordinary Maintenance

*
The system is equipped with a lubricant level control sensor. When the minimum level is reached, a message will
appear on the monitor to remind the operator that the tank must be replenished.
The system also has an additional sensor to generate a fault message in case of an interruption or a malfunction
in the automatic lubrication cycle.

Lubrication system check

The axes guides and their re-circulating ball sliders and lead screws with their nut-boxes are
automatically greased every 4 hours of running through grease distribution points.

The mechanical components of the machine will need about 0,007 kg of grease for every hour of
effective operation.

The operator must check that the lubrication system is working constantly.

Filling-up the reservoir with lubricant

The lubricant in the reservoir is fed through the system and distributed to the individual lubrication
points by a pneumatic pump. The reservoir for the centralised lubrication system can be filled-up
with new lubricant, having first turned off the air pressure in the pneumatic system. To
fill-up, proceed as follows:
! Fill up the hand pump with lubricant AGIP GR MU EP 1.

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16. Ordinary and extraordinary Maintenance

! Connect the feed-pump to point A and pump-in lubricant to the maximum level, or until it
comes out of the discharge hole B.

Manual lubricating points

Manually lubricating Master 2

The Master 2 series does not have a centralised lubricating plant, unless as an optional. It is
therefore necessary to lubricate the appropriate points each time the machine requires it.
The distributors for greasing the re-circulating ball sliders, the screws of axes X, Y, Z and tool
magazine are on the front of the machine to the right and left of girder A, in the rear of operator
head B and inside the service cabinet.

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 16. Ordinary and extraordinary Maintenance

The CN installed on the machine on the basis of the frequency set by the constructor, will advise
the operator to grease all the points signalled.
Only after having carried out greasing with the supplied manual pump is it necessary to remove
the message generated by the CN. Set the value of the D009 “Exec Lube” datum of the T05
INTERMAC \ S09 table LUBRICATION to 1 (with password level >=4).

In the case in which the edge head store is present, it is necessary to lubricate the store with the
distributor placed on rear D.

Danger
Failure to lubricate the components equipped with manual lubricator could cause
malfunctioning and breakage.
Biesse S.p.a. wil not be liable to respect the warranty conditions in the event of
operator negligence.

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Manual lubrication 500mm saw aggregate disk store

When, in the Master 3-4 machine, version plus (- enhanced Z axis series, the store for housing the
500mm saw aggregate disk store is present, it is necessary to lubricate the sliding door for
withdrawal of run D.

Danger
Failure to lubricate the components equipped with manual lubricator may cause
cause malfunctioning and breakage.
Biesse S.p.a. will not be liable to respect the warranty conditions in the event of
operator negligence.

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 16. Ordinary and extraordinary Maintenance

Maintenance of the tool aggregates

Certain of the tool aggregates make use of an oil beating lubrication system, and therefore, we
recommend that a regular check be made to check the level.

A cap A is located on the lower part of the aggregate which makes it possible to check the oil level.
The level should be maintained within the upper middle limit of the indicator.
Frequency Operation
Every 200 hours Oil level check
Every 1000 h Oil replacement

Intermac recommends the use of Mobil oil - Velocite E

A B

! For the topping up operation remove the upper cap B.

Check the level keeping the aggregate in horizontal position.
! To replace the oil, remove cap B and the level cap A
• Allow the used oil to flow out completely
• Replace level cap A
• Pour in the oil from slot B

At the end of the operation replace and tighten the caps previously removed.

Important
For disposal purpose follow the national regulations currently valid.

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Sliding doors maintenance

The mobile sections or guards slide by means of rollers on guides.
Proceed to remove the sediment accumulated on guides and rollers A. Then proceed to apply a
layer of protective grease on the wheels using a brush, the amount of lubricant to be used is up to
the operator.

Information
Do not put grease on the sliding door guides.

A
A

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Maintenance of air treatment units

The following table describes the maintenance needed on the air treatment units, and the
frequency with which it must be done.
Frequency Operation
Every 900 h Dynamic air drying filter cleaning
Electrospindle pressurisation air filter cleaning
Every 1800 h Dynamic air drying filter replacement
Electrospindle pressurisation air filter replacement
Every 3000 h Oil remuval filter replacement

The main air treatment unit is used to regulate the air pressure to the machine during operation.

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Dynamic air drying filter

The dynamic air drying filter is mounted on the machine, upstream of the pressure regulator and it
is used to discharge automatically and at regular intervals the condensate which collects in its cup.

Caution
Absolutely no lubricating oil, nor any other liquid substance, must be introduced into the
dryer or the regulator filter cups. This will inevitably cause to malfunctions.

Description
The dynamic air dryer consists of the following
parts:
! Upper part (A), with threaded inlet and outlet A
connection holes. .
! Cup (B), with condensate discharge device.

! Filtering cartridge (50 micron (C).

Principle of operation
The dynamic air drying filter is different from the
usual types of such devices in so far as it works
B
in three distinct steps, in each one of which the
air is “treated” to separate it from liquid and solid
particles. C
! Step 1: expansion

The air is expanded. Its temperature drops

and the air vapour contents will condense.
! Step 2: centrifuging

The air flow accelerates whilst going

through the cup in a circular stream. The resulting centrifugal force throws the heavier water
droplets towards the wall of the cup, where they collect to flow eventually to the bottom.
! Step 3: filtration

A 50 micron filter cartridge traps all the solid particles above this size.

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Cleaning and replacement of the dynamic air drying filter

Clean and replace the filter by proceeding as follow:
! Make sure the system is not under pressure; the pressure gauge at its inlet must show “0”.

! Remove filter cup A. Push down lever B to remove the cup.

! Rotate the cup clockwise through 45° and take off downward.

! Rotate ring nut C clockwise to remove filtering element D.

! Clean the cartridge with soap, water and compressed air or, if necessary, change it.

! Clean out the cup to remove eventual dirt deposits.

! Reassemble the filter by the reverse procedure.

Information
Consult the spare parts manual for the spare parts code or contact the assistance service.

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16. Ordinary and extraordinary Maintenance

Oil remuval filter replacement

Thel oil removal filter mounted upstream of the pressare regulator, is used to eliminate the quantità
of oil present in the compressed air bifore entering the machine system.

To change the filtering element of the air oil extractor every 3000 hours, proceed as described:

1. hold cup A and give it a light push upwards, then rotate clockwise and take the cup off
downward.

2. rotate clockwise to remove filtering element B.

3. proceed in reverse order to assemble.

Information
Consult the spare parts manual for the spare parts code or contact the assistance service.

Information
the filter is equipped with an automatic discharge element.

Caution
Comply with the local regulations in force for the disposal of the filter.

A
B

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 16. Ordinary and extraordinary Maintenance

Oil extractor filter maintenance alert messages

A meter is active through the CN, calculating the hours of work on the machine. After 2800 hours
of operation a message appears on the monitor after the last intervention, which signals the need
to change the filtering element within the indicated hour time limit.

PLC9788>Change oil extracting air filter (see use manual) by hour: …This message continues to
appear up to the end of the hours available. Should the element fail to be changed, within 3000
hours envisaged, a new message is generated:

PLC9787> Change oil extracting air filter (see use manual)

This message will remain visible until changing the filtering element takes place.

Zero setting procedure

It is possible to eliminate the alert message and set the counters to zero only after having changed
the filtering element.

Proceed as follows:
• open out the technical data
• enter the password for the administrator user level (level 7)
• see table T05 INTERMAC/S53 PROGRAMMED MAINTENANCE

At this point 3 columns are shown that indicate:

D001 Element D002 Maintenance carried out D003 Hours since last
maintenance
1 Oil extraction filter .....
2
3
4

! name of the element for which maintenance is required, in our case the OIL EXTRACTION
FILTER (D001)
! field for notifying the maintenance (D002)

! hours since last maintenance carried out (D003)

• in column D002 select “1.Mainteance carried out”
• save the operations carried out with the “save” key
• press the “Reset” key present on the console or on the palm keyboard.

Datum D003 will be set to zero and the alert message disappear.

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16. Ordinary and extraordinary Maintenance

Cleaning and replacement of the electro-mandrel pressurisation air filter

The electro-mandrel pressurisation group is on the operator head.

Clean and replace the filter by proceeding as follow:

! Make sure the system is not under pressure; the pressure gauge at its inlet must show “0”.

! Rotate the cup A clockwise and take off downward.

! Rotate ring nut C clockwise to remove filtering element B.

! Clean the cartridge with soap, water and compressed air or, if necessary, change it.

! Clean out the cup to remove eventual dirt deposits.

! Reassemble the filter by the reverse proceedure.

Note:
Consult the spare parts manual for the spare parts code or contact the assistance service.

Information
the filter is equipped with an automatic discharge element..

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 16. Ordinary and extraordinary Maintenance

Maintenance of the spindle cooling system

The following table describes the maintenance needed for the spindle cooling system, and the
frequency with which it must be done.The maintenance intervals have been determined on the
assumption of a 5 day-8h/day week, with the machine operating under normal ambient and work
conditions.
Frequency Operation
Monthly “Glycol level check”
“Cleaning the radiator”
Yearly “Complete change of Glycol”
When needed “Top-up Glycol (through upper filler)”

The unit includes a flow metering device for the liquid circulating in the cooling circuit. Should the
flow fall below a certain volume, a fault message will appear on the monitor and the machine will
not be allowed to operate until the fault is eliminated. Check the heat exchanger as a possible
cause of the problem. Check the level of the coolant and make sure the pump is working. Add
coolant through the filler cap if necessary, or contact the manufacturer if the fault requires
something more than normal maintenance.
Use an anti-freeze which does not contain nitrites, amines or phosphates, and which will keep its
characteristics at high and low temperatures, winter and summer.

The fluid used must neither be aggressive nor corrosive for the metallic components, especially
those which are easily attacked by an acid, but should on the contrary protect the surfaces that
come into contact with it including plastic, which is easily subject to swelling.

The anti-freeze should in addition limit as much as possible the formation of scale during its
passage through the cooling circuits and should have anti-foaming properties, in order to favor the
heat exchange as much as possible.

Caution
The level of the coolant should be checked periodically and should be kept within the
prescribed limits to guarantee a perfect heat exchange and therefore the efficiency of the
spindle.

! It is advisable to clean the internal components of the exchanger every month as the cooling
suction cup eases the accumulation of dust, causing obstruction of the radiator. This could
reduce the thermal exchange and cause the probable overheating of the electro-mandrel.

Proceed as follows:
• disconnect the machine power supply
• remove the lateral access casing to the exchanger
• blow a jet of compressed air on the radiator and all the components, removing every trace of
dirt (dust, etc.).
• proceed inversely to remount.

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Information
The cooling fluid level is indicated by a graduated scale on the heat exchanger, which is
located on the right hand side of the machine beam.

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 16. Ordinary and extraordinary Maintenance

Maintenance of the Cerium Oxide tanks

The following table describes the maintenance needed for the Cerium Oxide tank, and the
frequency with which it must be done. The maintenance intervals have been determined on the
assumption of a 5 day-8h/day week, with the machine operating under normal ambient and work
conditions. The Page column indicates, when applicable, the number of the page containing a
description of the maintenance procedure.
Frequency Operation Page
Monthly “Clean tanks A and B”
When needed “Topping up the cerium oxide tank A” 333
If the level falls “Topping up the cerium oxide tank B” 333
below the notch

Topping up the cerium oxide tank A

Cerium oxide diluted in water is used to polish glass after grinding (chamfering), so that all
machining marks will be removed and the surface will return mirror like. The polishing agent is
applied with a spray nozzle and a felt wheel incorporating a cerium reservoir. Main tank A and
pump must be cleaned periodically, as well as the agitator tank B, feed pipes and applicators. For
a more effective cleaning of the connecting pipe, detach this from tank A and from the agitator tank
B and connect it to a water mains to remove the sediments.

Topping up the cerium oxide tank B

Tank B is replenished by pressing the appropriate key on the main console. This can be done at
any moment, also during machining.

For the correct batching of the cerium oxide during machine operation, it is advisable to keep the
level of the liquid in the agitator tank constantly above the notch located on the side of tank B.

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16. Ordinary and extraordinary Maintenance

Cerium duct washing cycle

The cerium duct must always be washed out within a short time after it has been used, and always
before the machine is stopped. When cerium is being used, should the machine be stopped for
an emergency or any other cause, the duct must be cleaned within 10 seconds.

In all the other cases cleaning becomes necessary after 120 minutes from the last time it was
used. The request for the washing cycle does not stop the machining program. The operator must
start the duct cleaning cycle with the appropriate pushbutton. The cycle lasts 10 seconds, after
which the duct may be considered clean.

Danger
During maintenance and tank filling activities the operator must take the following
precautions:
- wear a protective mask with dust filter;
- wear rubber gloves;
- wear safety goggles;
- wear safety clothing.

“Cerox” cleaning glass product

Warning
! Individual protection

- Do not inhale.
- Keep out of the reach of children. - Avoid contact with the eyes using protective goggles.
- Avoid contact with the skin using suitable protective clothing and rubber gloves.
! First aid measures

- Contact with the skin: wash with water.

- Contact with the eyes: immediately rinse with abundant water.
- Indigestion: consult a doctor. Do not provoke vomit.

Properties
• Name: Cerox
• Composition: mixture with a cerium oxide - lanthanum oxide base.

Dangerous components: Fluorides of rare-earth elements (CAS: 68188-85-2): <10% N°EINECS

269-166-1.

Note:
This product has no harmful effects to the environment, It is however advisdalbe to
dispose the product in authorized disposal centres. Always following the local waste
disposal laws in force.

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 16. Ordinary and extraordinary Maintenance

Summary and frequency of maintenance operations

The following table contains a summary of all maintenance operations and the intervals at which
they must occur. The maintenance intervals have been determined on the assumption of a 5
day-8h/day week, with the machine operating under normal ambient and work conditions. The
Page column indicates, when applicable, the number of the page containing a description of the
maintenance procedure.
Frequency Part Operation Page
daily Machine “Cleaning” 308
“Cleaning the Workable and the Lexan 308
guards”
“Cleaning the suction cups” 311
weekly Machine “Cleaning the filters of tool internal 313
cooling water”
“Cleaning the tanks (when applicable)” 314
Lubrication system “Lubrication system check” 319
every two 500mm saw aggregate disk “Manual lubrication 500mm saw 322
week store aggregate disk store”
monthly Machine “Cleaning the process water pump filter 315
(when applicable)”
“Cleaning the process water pump” 312
“Cleaning the vacuum pump” 317
“Cleaning the vacuum filter” 316
“Cleaning the guides” 318
Sliding doors “Sliding doors maintenance” 324
every dynamic air drying filter “Cleaning and replacement of the 327
900-1800 h dynamic air drying filter”
pressurisation air filter “Cleaning and replacement of the 330
electro-mandrel pressurisation air filter”
yearly Centralised lubrication “Complete change of Glycol”
system
every 3000 Oil remuval filter “Oil remuval filter replacement” 328
h
when Spindle cooling system “Top-up Glycol (through upper filler)”
needed Cerium oxide tank “Topping up the cerium oxide tank A” 333
Stainless steel cones “Cleaning Stainless steel cones” 310
If the level Cerium oxide tank “Topping up the cerium oxide tank B” 333
falls below
the notch
* Centralised lubrication “Filling-up the reservoir with lubricant” 319
system
*
The unit is equipped with a lubricant level sensor. When the minimum level is reached, a message appears on
the monitor to tell the operator that it is time to replenish the tank.

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16. Ordinary and extraordinary Maintenance

16.1.1 Characteristics of lubricants

Use the same lubricants used by the manufacturer and resort to equivalent types only when it is
absolutely impossible to obtain the required product. If an equivalent product must be used, clean
out the system of all possible residue of the original product. This is to avoid eventual chemical
reactions between products of different types, which could prove damaging for the machine.
Recommended lubricant Equivalent product Use
MOBIL OIL - Velocite E See table of equivalents ! Gears aggregate
MOBILUX EP 1 ESSO BEACON EP 1 ! Guides
KLÜBER TRIBOSTAR 1 EP*
! Re-circulating ball sliders
KLÜBER CENTOPLEX 1
EP**

***
AGIP ANTIFREEZ EXTRA Read the product ! Spindle cooling system
characteristics given in the
paragraph dealing with the
spindle cooling system.
*
Only for the Italian market
**
International market
***
Other lubricants of NGLI 0 grade

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 16. Ordinary and extraordinary Maintenance

16.2 Extraordinary maintenance

16.2.1 Cleaning the worktop with aggregate brush (optional)

Every so often it is thought necessary, other than the daily cleaning of the top carried out manually
with the auxiliary of suitable equipment and “Nocal” descaling (or equivalent product), to remove
sediment and incrustations from the surface of the top with the special aggregate brush. Installed
on the mandrel and set in rotation it removes every impurity, regenerating the surface and
guaranteeing the enhanced holding potential of the equipment such as suction cups and rabbets,
in the shortest possible time and with minimum operator intervention.

Using the aggregate brush for cleaning the worktop (optional)

The aggregate brush is simply a brush with diamond bristles with a 200mm diameter mounted on
a cone with an ISO-40.connection. It is usable exclusively for cleaning the worktop on the entire
range of Master CNC centres having a worktop in aluminium.

Installation and use of the aggregate

The aggregate is mounted on the operator head like a normal tool.

Caution
On theMaster twin the brush aggregate must be assembled on the primary spindle.

Caution
It is not possible to place the aggregate brush on any of the utensil stores present on the
Master line. It requires manual assembly.

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16. Ordinary and extraordinary Maintenance

The software that controls it, once activated, moves the head whilst loading, showing in the
messages field, below right of the interface, the message “1234 LOADING TOP CLEANING
AGGREGATE”. The operator must rotate the disconnection axes key, open the gripper using the
special c key on the head and manually insert the cone inside the mandrel. Then, after having
turned the key to the original position and pressed the “OK” key with the left-hand key of the
mouse in the message “I157 PRESS OK TO CONTINUE” present in interface, the cycle will start.
At the end of the operation, the head will enter the unloading position (equivalent to the load
position) to allow the manual unloading of the aggregate with the usual unloading the tool present
on the mandrel procedure.

It is necessary to press the key inside the “Fixed Cycles” folder in the Master interface to

access the parameters inherent to the cleaning cycle.

The table below is presented to the user who can personalise it prior to starting the cycle using the
“OK” key and successively “Start” on the keyboard.
Field name Range Default value Meaning
Forward speed >0 15000 mm/min Speed of the grindstone for
cleaning the top
Rotation speed [0, 5000] 2000 r.p.m. Rotation speed for cleaning
the top
Internal water (0=OFF / 1=ON) [0,1] 1 Use of the internal water
Worktop choice (1/2) [1,2] 1 Worktop choice
(Meaningful only for the
Masters equipped with
central bulkheads)

Setting the aggregate

It is possible to act partially on the parameters of the “S44 CLEANING WORKTOP” table present
under “T05 INTERMAC”.
The constructor sets the parameters and it is advisable to modify them only for special needs.

Note
The parameter that should be updated during the use of the brush is D019 that acts on the
height of the Z axis. Brush wear will require the operator to modify this height. Descend in Z
until touching the bristles of the brush on the top, generating a slight resistance to the
manual rotation of the tool. Read the ABSOLUTE height of Z and show it in parameter
D019.

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16.2.2 Rectifying the worktop

The worktop mounted on the Master line consists of aluminium extrusion elements that are fixed to
the base and ground at the moment of installing the machine.
It is possible to grind the surface after installation, when considered necessary, using a specific
insertion tool for aluminium purchasable from INTERMAC. .
This grinding operation is limited in two aspects:
• it must be carried out using a programme specially developed for managing the grinding tool
• the material may be ground and removed to a maximum of 4 mm , otherwise the reliability of
the worktop might be compromised.

Caution
Before beginning any operation make sure that the worktop is completely free of objects.

Caution
If the machine is equipped with fixed equipment near the worktop take the greatest care
during the height change stage. Check the passage of the tool to be ground.

Apply to an authorised INTERMAC technician to undertake worktop grinding.

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 17. List of messages

17. List of messages

Possible machine faults appear on display in the form of error messages, which are brief
descriptions identified by an alphanumeric code. For more information refer to User’s Interface
Manual.

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17. List of messages

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 18. De-installation - demolition

18. De-installation - demolition

During its lifetime the machine may happen to be transferred to another location. In this case
proceed as follows:

1. Turn the machine off and disconnect it from all supply lines.

2. Remove and put away all the tools still present on the machine.

3. Clean the machine and protect with appropriate products all those parts that may rust.

4. For transport and shipping, use all the implements and the methods described in this manual.

The machine utilises lubricating oils and greases. What remains of them in some sections of the
machine cannot be recovered. To get rid of the remains, use approved, naturally degrading
products. Part of the lubricants, on the other hand, can be recovered from the tanks and consigned
to a service company specialising in the disposal of used lubricants.

Lubricants that can be recovered for further use can be taken out of the tanks and consigned to
the same service company. Residual Cerium oxide, small batteries, accumulators, buffer batteries
from electronic cards and conditioners, must be disposed of in the appropriate manner.

When the machine has reached the end of its useful life, it must be demolished in such a way as to
make it impossible to reutilise it for the same type of work for which it was designed and
constructed, while still leaving its component parts and materials in a condition to be recycled.
Such recycling must however not imply the use of the parts for processes similar to those for which
they were originally designed.

BIESSE does not take any responsibility for damages to people or property deriving from the use
of parts of the machine utilised for functions and in circumstances different from the original ones.
BIESSE will not recognise, implicitly or explicitly, the suitability of parts reutilised after the definitive
deactivation of the machine for demolition purposes.

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18. De-installation - demolition

344 BIESSE S.p.A. © - Capitolo18.fm270607

 19. Annexes

19. Annexes

19.1 Layout - Laser Projector Installation

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19. Annexes

346 BIESSE S.p.A. © - Capitolo19.fm270607

 19. Annexes

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19. Annexes

348 BIESSE S.p.A. © - Capitolo19.fm270607

 20. Drawings and diagrams

20. Drawings and diagrams

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20. Drawings and diagrams

350 BIESSE S.p.A. © - Capitolo20.fm270607

 Analytical Index

Analytical Index C
CE mark, 55
cerium duct
washing cycle, 334
cerium oxide
topping up in the tank A, 333
topping up in the tank B, 333
cerium oxide plant, 34
cerium oxide tank
1400 W heat exchanger cerium duct washing cycle, 334
data, 91 topping up the cerium oxide tank A, 333
3 axes head, 38 topping up the cerium oxide tank B, 333
3 axes operating head with “C” axis, 40 cerium oxide tanks
3 axes operating head with “T” tilting axis and “C” axis, 43 maintenance, 333
3 axes operating head with tilting axis “T”, 39 change
4 axes operating head, 41 tool, 302
5 axes operating head, 44 characteristics
of lubricants, 336
A of the spindle, 97
after sales service, 23 cleaning
aggregate brush, 337 dynamic air drying filter, 327
use and installation, 337 electro-mandrel pressurisation group air filter, 330
aggregates filters of tool internal cooling water, 313
mounting on revolving type tool magazine, 281 guides, 318
air consumption, 55 of the vacuum pump, 317
air pressure process water pump, 312
supply pressure, 112 process water pump filter (when applicable), 315
air system suction cups, 311
connection, 129 tanks (if applicable), 314
air treatment units the machine, 308
maintenance, 325 tool store, 309
ambient temperature in the installation area, 113 vacuum filter, 316
arrangements worktable and lexan guards, 308
of machine, 111 compressed air (see pneumatic system), 112
assembly configurations
instructions, 105 of the machine, 25
of grinding wheel on ISO 40 tapered spindle, 264 connection
of the guards, 120 air system, 129
of tool on ISO 40 taper spindle, 262 electrical system, 125
of tools, 262 of hydraulic system, 122
of tools with aggregates, 265 connection points on machine, 111
axes connections
machine, 57, 92 instructions, 105
manual mode displacement, 60 control module for numerical control, 132, 134
reset, 294 control of electric feeler, 136
travel speed variation, 60 control of electric tracer, 133
axes disconnection control pedals, 34
key selector, 138 controls, 132, 142
axes disconnections, 138
control module for numerical control, 132, 134
B location, 132, 134
base, 32 lock/unlock tool push button, 133, 136
machine OFF, 138

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Analytical Index

machine ON warning light, 138 pushbutton, 138, 142

main control panel, 132, 134, 138 emergency pushbutton, 53
main switch, 125, 132, 134 equipment
Override, 132, 135 of the machine, 129
pressure gauges and regulators, 136 executable machining operations, 66
remote controls, 136 execution of double-grindstone machining
start station 1, 138 procedure, 298
start station 2, 138
tool lock/unlock pushbutton panels, 141 F
tool magazines pushbutton panels, 135, 140
Filling
workpiece fixing pedal, 132, 135
vacuum tank, 122
fill-up
D reservoir with lubricant, 319
danger area filters
on machine, 69 of tool internal cooling water
data cleaning, 313
1400 W heat exchanger, 91 floor of machine room, 113
demolition frequency, 55
safety information, 19 of maintenance operations, 335
description
marble/granite tool configuration parameters, 220
of tool configuration parameters, 180
G
dimensions general data
machine overall dimensions, 111 admissible weight on worktop, 89
directive 98/37, 55 of machine, 89
dresser for polishing wheels (optional), 278 general description
drilling of the machine, 25
vertical,horizontal, 66 general view
dynamic air drying filter, 326 machine, 31
of the machine, 31
grinding wheel
E assembly on ISO 40 tapered spindle, 264
electric plant guards
power ratings for Master machining centers, 127 assembly, 120
electric tracer connection point, 141 guides
electrical characteristics cleaning, 318
of machine, 90
electrical system H
connection, 125
handling
frequency, 55
the tracer, 267
installed power, 112
head mounted revolving type tool store, 52
maximum current load, 55
humidity in the installation area, 113
nominal current load, 55
hydraulic system
number of phases, 55
connection, 122
power, 55
hydraulic system supply, 55
power of interruption of short circuit at supply voltage,
55
requirements, 111 I
section of connecting cable, 126 illumination, 90
supply voltage, 55 ilumination, 90
electricity supply, 55 information
electro-mandrel pressurisation group air filter, 330 about tools, 145
electro-mandrel pressurization group, 34 installation
emergency of the machine,instructions, 105

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 Analytical Index

using the machine with recirculating tanks, 124 general cleaning, 308
installation area general data, 89
requirements, 111 general description, 25
interruption how to use, 65
of machining, 303 layout, 74
isolating valve, 53 levelling the machine, 117
main components, 31
K manual lubricating points, 320
manual operation, 301
key selector
operation, 63
axes disconnection, 138
operation in automatic mode, 301
ordinary maintenance, 307
L pumps installation, 118
labels resetting of functions, 295
affixed to the machine, 22 starting, 293
danger signals, 20 stop, 294
general prohibition signals, 21 turn off, 296
signs indicating obligatory actions, 21 unloading, 107
laser presetter air filter unit, 34 water consumption, 90
laser pre-setter group (optional), 270 machine base, 35
layout machine models
machine supporting feet, 114 identification of own model, 55
levelling machine OFF
instructions, 105 pushbutton, 138
lifting machine ON
instructions, 105 pushbutton, 138
safety instructions, 15 machine ON warning light
linear type tool magazine, 50 warning light, 138
setting up, 285 machine parts
location due for transportation, 106
of machine controls, 132 machine serial number, 55
of signalling devices, 132 machine supporting feet layout, 114
of the controls, 134 machining
of the signalling devices, 134 interruption, 303
lock/unlock tool push button, 133, 136 of identical workpieces, 302
lubricants, 336 parting off, 67
lubrication starting, 301
check-up, 319 vertical and horizontal milling, 66
lubrication system, 32 vertical drilling,horizontal drilling, 66
lubricant reservoir fill-up, 319 warnings, 297
maintenance, 318 machining cycle, 302
lubrication system check-up, 319 machining operations
procedure, 298
M machining water
machinable materials disposal, 124
characteristics, 65 main components, 32, 34, 44
dimensions of machinable materials, 65 3 axes head, 38
machine, 90 3 axes operating head with “C” axis, 40
axes, 57 3 axes operating head with “T” tilting axis and “C”
configurations, 25 axis, 43
danger area, 69 3 axes operating head with tilting axis “T”, 39
electrical characteristics, 90 base, 32
extraordinary maintenance, 337 cerium oxide plant, 34

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Analytical Index

control pedals, 34 maximum current load, 55

dynamic drying filter group, 34 meaning and selection
electro-mandrel pressurization group, 34 of origins, 299
laser presetter air filter unit, 34 milling
linear type tool magazine, 50 vertical and horizontal, 66
machine base, 35 motor driven spindle
numerical control, 32 technical characteristics, 96
of the machine, 31 moving
oil separator, 34 instructions, 105
operating head, 32
operator console, 32 N
pressure booster with air tank, 34
N electric diagram, 55
pressure regulator, 34
noise level, 104
process water recycling system, 32
noise produced by the machine, 104
revolving type tool magazine, 32, 47
nominal current load, 55
spindle glycol cooling system, 32
number of phases of electrical supply, 55
straight line tool magazine, 32
numerical control, 32
switchboard cubicle, 32
work table, 32, 45
X - Y axis beam, 36
O
X axis carriage, 37 of the machine, 337
X axis moving beam, 32 oil remuval filter
main control panel, 132, 134, 138 maintenance, 328
main parts oil separator, 34
4 axes operating head, 41 operating head, 32
head mounted revolving type tool store, 52 warm-up cycles, 294
main switch, 125, 132, 134 operation, 17
Maintenance of machine in automatic mode, 301
rectifying the worktop, 339 of machine in manual mode, 301
maintenance, 337 of the machine, 63
air treatment units, 325 operator console, 32
cerium oxide tanks, 333 origins, 62
dynamic air drying filter, 326 meaning and selection, 299
frequency of operations, 335 Override, 132, 135
lubrication system, 318
manual lubricating, 320 P
of machine, 307 parting-off
of sliding doors, 324 machining, 67
of the electro-mandrel pressurisation group, 330 pedal
oil remuval filter, 328 workpiece fixing, 132, 135
safety information, 18 personnel
spindle cooling system, 331 qualifications, 67
table of operations, 335 place of installation
maintenance operations, 335 instructions, 105
manufacturer pneumatic system, 112
address, 55 air consumption, 112
logo, 55 air supply pressure, 55
manufacturer identification, 55 maintenance air treatment units, 325
manufacturer’s address, 55 supply pressure, 112
manufacturer’s logo, 55 positioning
Marble/granite tool configuration mobile elements of work table, 287
parameters description, 220 of machine, 107
maximum altitude of the installation area, 113 positioning and fixing

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 Analytical Index

of the workpiece, 300 Q

potentiometer
qualifications
for manual-fast adjustment, 142
personnel, 67
for the adjustment of axes interpolation during
machining, 143
power, 55 R
power ratings for Master machining centers, 127 rectifying, 339
pressure booster with air tank, 34 reference points, 62
pressure gauges, 136 remote control panel, 142
pressure regulator, 34 type P402, 142
pressure regulators, 136 type RM850, 142
pressurization use, 144
of the spindle, 97 remote control panel type RM850
procedure confirm menu function, 143
execution of double-grindstone machining, 298 emergency pushbutton, 142
for machining operations, 298 Esc, 143
process water pump menu scroll, 143
cleaning, 312 potentiometer for manual-fast adjustment, 142
process water pump filter potentiometer for the adjustment of axes interpolation
cleaning, 315 during machining, 143
process water recycling system, 32 pushbutton “present man’s”, 142
pumps pushbutton Start, 143
installation, 118 Reset, 143
pushbotton start station 1, 142
secondary spindle decrease polishing pressure, 139 start station 2, 143
pushbutton, 139 Stop, 142
Cerium oxide stirrer ON and OFF, 140 remote controls, 136
confirm menu function, 143 replacement
decrease polishing pressure, 139 dynamic air drying filter, 327
emergency, 53, 138 oil remuval filter, 328
Esc, 143 reset
filling-up cerium oxide, 139 the machine axes, 294
increase polishing pressure, 139 resetting
Jog -, 139 the machine functions, 295
Jog +, 139 residual risks, 70
machine OFF, 138 revolving type tool magazine, 47
machine ON, 138 compatibility, 283
manual operation of tool magazine 1, 139 positioning aggregates, 282
manual operation of tool magazine 2, 139 setting up the spindles, 282
menu scroll, 143 setting-up, 281
“present man’s”, 142 usable tools, 283
Reset, 139, 143
secondary spindle increase polishing pressure, 139 S
Start, 139, 143
safety, 15
start station 1, 138, 142
danger signals, 20
start station 2, 138, 143
devices, 53
start tracing cycle, 139
during demolition of the machine, 19
Stop, 139, 142
during lifting and handling, 15
vacuum pump ON/OFF, 139
during machine installation, 15
pushbutton panels
during maintenance operations, 18
tool lock/unlock, 141
general prohibition signs, 21
pushbutton panels for tool magazines, 132
installation of tools, 16
overcurrent protection, 16

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Analytical Index

protection against fire, 16 of main machine, 92

protection against indirect contacts, 16 of motor driven spindle, 96
signs affixed to the machine, 22 of vacuum system, 98
signs indicating obligatory actions, 21 Technical features, 90
safety barrier, 34 tool
safety devices, 53 assembly on ISO 40 taper spindle, 262
emergency pushbutton, 53 change, 302
isolating valve, 53 tool configuration
safety guards, 53 parameters description, 180
safety microswitches, 54 tool dresser for "vertical drill" (optional), 277
safety guards, 53 tool magazines pushbutton panels, 135, 140
safety microswitches, 54 tool store
setting up for operation, 17 cleaning, 309
short circuit tool water cooling system, 32
power of interruption of short circuit at supply voltage, tools
55 assembly, 262
signalling devices assembly with aggregates, 265
location, 132, 134 information, 145
signals mounting on linear type magazine, 285
general prohibitions, 21 mounting on revolving type tool magazine, 281
signs safety information, 16
affixed to the machine, 22 tracer
sliding doors handling, 267
maintenance, 324 tracer of the origin of a randomly loaded workpiece
spindle (optional for 5 axes machine), 280
characteristics, 97 transport
pressurization, 97 of machine parts, 106
spindle cooling system of the machine,instructions, 105
maintenance, 331 turning off
spindle glycol cooling system, 32 the machine, 296
spindles
information about the sense of rotation, 63 U
start station 1
unloading
pushbutton, 138, 142
lifting, 109
start station 2
lifting in safety, 107
pushbutton, 138, 143
of the machine, 107
starting
responsibility for the unloading, 107
machining operations, 301
the workpiece, 303
starting the machine, 293
use, 337
stop
of remote control panel, 144
emergency, 295
of the machine, 65
the machine, 294
stops and suction cups, 61
straight cutting tool magazine, 32 V
supplied equipment, 129 vacuum
supply voltage, 55 filling the tank, 122
switchboard cubicle, 32 vacuum filter
system requirements, 112 cleaning, 316
vacuum pump
T cleaning, 317
vacuum system, 32
tanks
minimum flow speed, 112
cleaning, 314
system requirements, 112
technical characteristics
technical characteristics, 98

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 Analytical Index

W
warm-up cycles
for the operating head, 294
warning light
machine ON, 138
warnings
about machining, 297
about working with Master twin, 297
warranty, 23
water
characteristics, 306
water characteristics
internal water, 306
water consumption, 55
of machine, 90
weight of machine, 55
work station, 67
work table, 32, 45
positioning mobile elements, 287
positioning stops and suction cups, 288
positioning stops and suction cups with the Laser
Projector, 289
selection of origin, 287
working areas, 60
working range
along Z axis, 98
working with Master Twin
warnings, 297
workpiece
positioning and fixing, 300
unloading, 303
workpiece rotated origin tracer (optional, 3 axes operating
heads, with or without C/T axes), 279
worktop, 339
admissible weight, 89

X
X axis moving beam, 32

Y
year of construction of the machine, 55

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Analytical Index

358 BIESSE S.p.A. © - P5802P0010IX.fm270607

BIESSE S.p.A.
Sede legale Unità produttiva Intermac
Via della Meccanica, 16 Via dell’Economia
61100 Pesaro (PU) Italy 61100 Pesaro (PU) Italy
Tel. +39 0721 439100 Tel. +39 0721 483100
Fax +39 0721 439150 Fax +39 0721 482148
sales@biesse.it
www.biesse.com