bsa 250/ 20 - cnczone.com-cnc machines, cadcam

12-96

M.I. 6457

BSA 250/Series 20

FAST INDEXING TURRETS

INSTRUCTIONS FOR USE AND MAINTENANCE

ISSUED

DUPLOMATIC

R

36 M.I.6457-1296

GENERAL RULES

• The tool turrets of Duplomatic design are provided for being incorporatedin numerically controlled turning machines, and they must be used only forthis purpose.The maximum performances of the turret are shown on the respectivetechnical data sheets.Any improper use or alteration of the turret relieves Duplomatic of any re-sponsibility for possible injury to persons and damage to property and willalso invalid any obligation for warranty.

• All necessary steps for the safety of the machine operator have to be ma-de by the machine builder who incorporates the turret in the tool machi-ne as prescribed by the European Machine Directive CE 89/392.

• Before installing and commisioning the turret, the technician and the ope-rator must have read carefully this Instructions Manual.

• For lifting the turret use only hoisting means which are suitable for theturret weight.

• Commissioning, adjustment and repair of the turret must be carriedout by skilled and authorized personnel who must follow the instruc-tions in this Manual for all necessary steps.

• Before any maintenance or repair job and before removing anysafeguard make sure that the machine's electric mains switch is on"OFF" position.It is absolutely forbidden to carry out any repair or maintenance job,when the turret is running.

• Duplomatic declines any responsibility for any accident or injuries to per-sons or damages to property due to non observance of the respective sa-fety rules and to the instructions shown in this Manual.

• The turret and its safety devices have been designed and built accordingto the following standards: "Machine Directives CE 89/392; 91/368; 93/44;93/68; 73/23; European standards EN 292/1-2; EN 60204-1.

1 M.I.6457-1296

INDEX sheet

1. TURRET IDENTIFICATION ............................................................................ 2

2. CHARACTERISTICS AND PERFORMANCES2.1 Technical data........................................................................................................... 32.2 Loading capacity ....................................................................................................... 32.3 Duty performances ................................................................................................. 4/5

3. INSTALLATION3.1 Box removing and lifting ............................................................................................ 73.2 Turret placing on the machine................................................................................... 83.3 Assembling of the tool holder disc ............................................................................ 83.4 Coolant operation ...................................................................................................... 93.5 Electrical connections ............................................................................................. 103.6 Wiring diagram ........................................................................................................ 113.7 Cycle ....................................................................................................................... 123.8 Cycle description ..................................................................................................... 133.9 Flow chart ............................................................................................................... 13

4. SERVICE OPERATIONS4.1 Replacement and adjustment of locking control switch .......................................... 144.2 Replacement and timing of the angular position transmitter ................................... 164.3 Indexing control adjustment and replacement ........................................................ 164.4 Excange of motor .................................................................................................... 174.5 Solenoid pre-indexer ............................................................................................... 174.6 Shock absorber ....................................................................................................... 174.7 The turret's restart-up after an accidental or emergency shut-down ....................... 184.8 Operation checks to be carried out in case of accidental collision .......................... 194.9 Instructions for the checking of the mechanical parts ............................................. 204.10 Lubrication .............................................................................................................. 23

5. ASSEMBLY DRAWINGS AND PART LISTS5.A Main section ....................................................................................................... 24/255.B Back view ................................................................................................................ 265.C Coolant circuit ......................................................................................................... 275.D Shock absorber ....................................................................................................... 285.E Motor and gear box ................................................................................................. 295.F Table to determine the motor code and the gears .................................................. 30

6. RECOMMENDED SPARE-PARTS FOR BSA 250/20 ........................................ 31

7. MAINTENANCE7.1 Periodic checks ....................................................................................................... 31

8. TROUBLE SHOOTING .......................................................................................... 32/33

2 M.I.6457-1296

1 - TURRET IDENTIFICATION

1.a - Turret name plateThe details for turret identification are printed on a name plate fixed on turret housing.

1.b - Model identification

(1) From 20 to 29 the performance and the overall dimensions do not change.

model serial Nr.

matr.

cod.R

code Nr.

VERSION CODE

STANDARD ---

AXIAL PASS PA

SERIE 20 ÷ 29 (1)

POSITIONS CODE

Nr. 8 Pos. 8

Nr. 12 Pos. 12

SIZE CODE

250 250CODE FREQUENCY AND INERTIA

50 50Hz Standard

60 60Hz Standard

50L 50Hz Slow

60L 60Hz Slow

50LL 50Hz Very slow

60LL 60Hz Very slow

OPTIONALS

BSA * - * - * /20 - * - * - *

MOTOR VOLT. AND FREQUENCY

220-380 220-380 V - 50/60 Hz

230-400 230-400 V - 50/60 Hz

400-440 400-440 V - 50/60 Hz

110 110 V - 50/60 Hz

3 M.I.6457-1296

2.2 - Loading capacity

2 - CHARACTERISTICS AND PERFORMANCES

2.1 - Technical data

F3

F2

F1

b

b

b

Max. tangential torque F1xb Nm 6000 6000 6000

Max. tilting torque to push F2xb Nm 10000 10000 10000

Max. tilting torque to lift F3xb Nm 4000 4000 4000

Unbalancing torque Nm 60

Transportable Masse Kg 180

Height h mm 120

Stations N° 8 ÷ 12

Version STD L LL

Inertia of transportable masses Kgm2 5 7,5 11

30° s 0,41 0,52 0,58Indexing time

45° s 0,53 0,68 0,76

30° s 0,240 0,320 0,360Rotating time only

45° s 0,360 0,480 0,540

Indexing time 180° s 1,61 2,12 2,38

Locking time s 0,170 0,210 0,230

Indexing frequency α = 90° cycle/min 9 7 6

Indexing accuracy deg.° ± 6"

Repeatability accuracy deg.° ± 2"

Mass (without tooldisc) Kg 120

Size BSA 250

4 M.I.6457-1296

The diagram refers to F1 values which cause elastic yelding within the rates shown in the schedule.

2.3 - Duty performances

F1 [N] Tangential force

F2 [N] Tilting force (to push)

F2

b

F1+

F1-

b

Turret size BSA 120 BSA 160 BSA 200 BSA 250

Max. elastic yelding mm 0,05 0,07 0,08 0,14

Distance from centre of measuring point mm 140 170 220 270

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 b [mm]

BSA 200-H

BSA 250

BSA 200

BSA 160

BSA 120

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 b [mm]

BSA 200-H

BSA 250

BSA 200

BSA 160

BSA 120

5 M.I.6457-1296

F3 [N] Tilting force (to lift)

F4 [N] Radial tilting force

F4a

F3

b

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 b [mm]

BSA 200-H

BSA 250

BSA 200

BSA 160

BSA 120

200000

10000080000

60000

40000

20000

100008000

6000

4000

2000

1000

0 100 200 300 400 500 a [mm]

BSA 200-H

BSA 250

BSA 200

BSA 160

BSA 120

6 M.I.6457-1296

7 M.I.6457-1296

3 - INSTALLATION

3.1 - Box removing and lifting

Fig. 1

Eyebolt M12

8 M.I.6457-1296

Fig. 3

3.3 - Assembling of the toolholder discBefore assembling the toolholder disc the coolant outlet shown on page 9 must be properly positioned.Before locking the disc fixing screws it's necessary to adjust its angular position by checking the height of the tool position.When the disc is correctly positioned, lock the screws (according to the torque rates shown in the table) and put the referencepins between the toolholder disc and the turret.The pins could be removed to allow the disc movement in case of crash and re-utilized for an eventual further re-alignment.

C

D

B

AE

0,01/100

Turret

Tool disc

3.2 - Turret placing on the machine

Make sure the fixing surface is clean and squared to ensure a proper tool alignment.Usually to bring the turret axis to the machine axis an adaptor plate (B) must be foreseen.Fix the turret to the machine's slide (A) by means of 8 appropriate screws (C) (high-resistant screws according to class 12.9 DIN912) and make sure that between the screw head and the turret the respective washer (D) of appropriate thickness (min. 5 mm)has been inserted.The reference pin (E) which is supplied together with the turret, is normally located at the opposite side of the working tool.Align the front surface of the disc in order to have it perpendicular to the spindle axis. Then lock the screws according to the torquerates shown in the table.In case of crash the turret may slip and turn around the reference pin. In this way any subsequent re-alignment will be facilitated.

Screws

Turret size

BSA 250

Type

M12 - 12.9

Tightening torque

[Nm]

115

Nr.

12

Reference pins

Nr.2 - ø12

Screws

Turret size

BSA 250

Type

M16 - 12.9

Tightening torque

[Nm]

185

Nr.

8

ø D

30

ø d

17

S

10

Code fixing set

0424133

øD

ød

s

9 M.I.6457-1296

Fig. 4

425

426

417328

325

420324

323

418

408

424

419

418

422

421 B

2

A

424

+ α

− α

417

419

423

422

421

1

3.4 - Coolant operation (Fig. 4)

The path for the coolant is designed in such a way that it exits always and only in line with the actual cutting tool it is necessaryto set the disc interconnecting valve in the position required.The coolant pipe coming from the pump must be connected to the A or the B inlet on the turret housing. Throught an internal paththe coolant passes from the housing to the (408) manifold ring that, by means of an anular groove brings it to the exit points 1,2.Normally, one of this outlet points is closed by a plug (418), while the other contains the small piston (417).The piston (417) slides on the rear surface of ring (323), which rotates as one piece with the turret ring and the tool-holder discby delivering the coolant to the working tool area.The piston can be positioned in any of the two positions provided by changing it with plug (418).The angular position of the coolant outlet can be modified by an amount of ± α as follows:— Loosen screws (325) and turn ring (323). When the desired position has been reached, tighten screws (325) again.— Loosen screws (425) and turn collector (408) for moving the small piston (417) into the position of the hole at the outlet on

ring (323).Then tighten screws (425) again.It is furthermore possible to replace quickly the piston for coolant without any need to disassemble the tool-holder disc, since piston(417) can be pulled out at the front of the turret side after having loosened screws (424) and removed plug (421).Coolant pressure:— continuous supply: max 7 bar;— by pressure cut-off during turret rotation: max 14 bar.

10 M.I.6457-1296

Fig. 6

3.5 - Electrical connections (Fig. 5)

The electric connection must be carried out according to diagram on page 11. The connection cable must be provided with fittingsand gaskets in order to avoid penetration of water into the turret.Figure 5 shows the exemple for correct electric connection.

Fig. 5

A - Turret housingB - Copper gasket according to DIN 7603/DC - Fitting PG 13,5D - Armoured cableE - Hose clamp

A B C D E

PG 13,5 (DIN 40430)

11 M.I.6457-1296

Fig. 7

3.6 - Wiring diagram

ELECTRIC MOTOR CHARACTERISTICS

Turret size Minimum required power Short circuit power

BSA 250BSA 250BSA 250BSA 250BSA 250 KVA 1,80 KVA 2,80

(1) Other voltages on request.(2) The termal detector gives a signal only motor overheating.

Tab. 1 Tab. 2ELECTRIC MOTOR'S WIRING (1)

3

Indexing control switch

Indexing solenoid

Thermal detector

Electric motor (three phase)

Locking control switch

Angular positions transmitter

(absolute)

10-30 V D. C. (ripple) 10%350 mA (supply)50 mA/exit (load)OUTPUT - PNP

10-30 V D. C. (ripple) 10%200 mA (load)

OUTPUT - PNP - NO

24 V D. C.44 W

135 C 1,5A 250V

(1)

220-380 V 50/60 Hz(For other characteristics

see tab. 1)

10-30 V D. C. (ripple) 10%200 mA (load)

OUTPUT - PNP - NO

CHARACTERISTICS WIRING NUMBER COLOUR SIGNALCOMPONENTREF.

U1 WhiteV1 GreenW1 BlackU2 WhiteV2 GreenW2 Black

See tab. 2

(2)1 Brown

2 Brown

5 Blue

6 Brown

7 Brown + V D. C.8 Black EXIT

9 Blue 0 V D. C.

7 Brown + V D. C.10 Black EXIT

9 Blue 0 V D. C.7 Brown + V D. C.

9 Blue 0 V D. C.11 White Bit 112 Yellow Bit 2

13 Green Bit 314 Violet Bit 415 Black Strobe

16 Pink Parity chech

Green/Yellow Ground

1

2

4

5

6

7

U1V1W1U2V2W2 WIRING

U1V1W1U2V2W2(380 V) WIRING (220 V)

4

3

5 1 2

7

6

12 M.I.6457-1296

3.7 - Cycle

cw—

—

——

c

cw

12

34

56

78

910

1112

10

10

10

10

10

10

01

10

01

10

01

10

00

01

11

10

00

01

00

00

00

01

11

11

11

01

00

11

00

10

11

11

11

11

11

11

1 B

IT

2 B

IT

3 B

IT

4 B

IT

PAR

ITY

CH

EC

K

ST

RO

BE

FU

NC

TIO

NP

OS

ITIO

NS

Tab.

1T

UR

RE

T S

IZE

250

Tab.

2

ALL

OW

ED

LA

G T

IME

MA

X

50 50 80 90 90

Slo

w

Ver

y S

low

R1

(ms)

R2

(ms)

R3

(ms)

Sta

ndar

d

1 4 5 6 7

CC

W

CW

01 1 0 1 0 1 0 1 0PO

S. 1

(S

TAR

T)

Ele

ct. M

otor

1 0 1 01

Inde

xing

sol

enoi

d

1 0 1 0 1 0

Inde

xing

con

trol

sw

itch

Lock

ing

cont

rol s

witc

h

Ang

ular

pos

ition

tran

smitt

er(a

bsol

ute)

1 B

IT

2 B

IT

3 B

IT

4 B

IT

PA

RIT

Y C

HE

CK

ST

RO

BE

CW

PO

S. 2

(S

TAR

T)

Wor

king

pos

ition

2 1 PO

S. 2

R1

R3

CC

W

12

1

R1

R3

PO

S. 1

R2

R2PO

S. 1

2Lo

cked

turr

et

Wor

king

pos

ition

Lock

ed tu

rret

NO

TE

:

For

the

R1-

R2-

R3

valu

e se

e T

ab. 2

Inde

xing

pin

mec

h. p

ositi

on

For

pos

ition

cod

ese

e T

ab. 1

13 M.I.6457-1296

3.9 - Flow chart

3.8.a - SignalsTo get a change of positions on the BSA turrets, the controlequipment (usually a N.C. equipment) must control thecomponents mentioned below according to a well definedsequence (see wiring diagram on page 11).• Motor (1)• Indexing solenoid (4)The following output signals from the turret are providedfor driving the positioning cycle:— Angolar position given by the angular position tran-

smitter (7)— Indexing control switch (5)— Locking control switch (6).

3.8.b - Description of the operating sequenceThis description refers to sequence cycle: the first part isthe sequence to pass from position 1 to position 2 withclockwise rotation, the second part gives the sequence topass from position 2 to position 12 with counterclockwiserotation.As indicated by the cycle the controls are to be performedaccording with the following sequence:

• Start motor rotation in the desired direction.• If, as in the case shown by the diagram, the next position(pos. 2) is the Stop position, when the strobe signalreached a zero level, the solenoid (4) is to be energized.In case of passage from position 2 to position 12, wait forthe reading signaling the passage on pos. 1 then, sincethe next one is the Stop position, wait until the next strobesignal reaches a zero level and (at that time only) energizethe solenoid (4).N.B.: The maximum lag time between the reading of thestrobe signal and the excitation of the solenoid (4) cannotexceed the R1 values indicated in the table.• The turret goes on rotating until the indexing pin, pushedby the solenoid (4), enters into the mechanical stop slot.This movement is detected by the sensor (5) which mustimmediately stop the motor that will re-start rotating in theopposite direction respecting the maximum lag time R2.With the sensor (5) signal and in combination with thereached signal position, give the START to the machine inorder to go on in working (see note).• Now the turret is locking. The completion of locking isdetected by the sensor (6) whose signal must be used forstopping the motor (1), with a maximum delay R3, and fordisabling the solenoid.

N.B.: The R1, R2, R3 times must be understood as realtimes execution of the controls and the signals checked onthe terminal board of the turret.For an accurate detection and measurement of the abovementioned values it is advisable to use adeguateinstrumentation such as an oscilloscope with memory andcurrent sensing devices.

IMPORTANT: For a good optimisation of the "chip tochip", times, the machine start at the excitation of theindexing control switch (5) (during "c" phase), incombination with the reached signal position. The followinglocking phase "d", very very short, is overlapped with therapid traverses of the machine.The locking control switch signal (6) must be used for thelocked turret codition control, continuously during theworking operations, and its absence must be an emergencycondition.

3.8 - Cycle description

(*) See tab. 2 sheet 12 ( Cycle ).

TURRETSTART CYCLE

SET ROTATION

1 BEFORE GOAL POSITION-STROBE

SET INDEXmax. allowed lag time

R1 = (*)

INDEX CONTROLSWITCH

START TO CNCFOR SLIDESGOIN TO THE

WORKING POSITION

LOCKINGCONTROL SWITCH

WORKINGSTART POINT

CONCIDENTPOSITION

START TOWORK

STOP ROTATIONSET REVERSE ROTATION

max. allowed lag timeR2 = (*)

YES

NO10

YES

NO

YES

NO YES

YES

NO

YES

FAULT

YES

STOP MOTORmax. allowed lag time

R3 = (*)

YES

14 M.I.6457-1296

4 - SERVICE OPERATIONS

4.1 - Replacement and adjustment of locking control switch (Fig. 8 - 9)This switch is operated by the part (141) in correspondance of the locking position.The turret is locked when the part (141) is moved to the top dead point or at least at a max. distance of 0.5 mm from it.The switch point of the proximity switch, to be used to stop the motor, must be adjusted with an advance to ensure that the motoris stopped in the zone of the locked turret.This advance is provided the counteract the R2 lag time or stated values (see table page 12).According to the type of turret the switch point, size "B", is shown in the mentioned table (page 15).

4.1.a - Replacement of the switch (Fig. 8)Remove the cover (146) to reach the proximity switch (105). To replace the switch disconnect the wires from the terminal board,unscrew the screw (321) of the block (306) and remove the switch.Once replaced and re-connected the new switch adjust the position as follows:

— With the screw (321) unscrewed, introduce a 1 ÷ 1,2 mm spacer (A) between the switch and the part (141).

— Push the switch against the spacer (A) (as shown on the figure) then lock in place with the screw (321).

— Remove the spacer (A).

Fig. 8

A

1 ÷ 1,2

141

142

304

118

116

139

140 307

306

105

321

166

305609

15 M.I.6457-1296

4.1.b- Adjusting procedure (Fig. 8 - 9)

a) With the turret correctly lock part ( (141) on the Nr. 3 position) energize the low voltage circuit only, do not apply mains voltageat this stage.

b) Loosen the two screws locking the support (306) and move it in the direction indicated by the arrow (4) until the switch is de-energized (verify this condition on the relevant Led of the electrical interface equipment).Move the support (306) forwards (direction indicated by the arrow (5) ) the exactly. find the point where the switch is re-energized. Starting from this point move the support (306) forward again (direction indicated by the arrow (5) ) of a distancecorresponding to the B value . To better check the displacement (B), it is advisable to use a dail as indicated on figure 9.

Fig. 9

Note: The "top position" can be slightly different changing the position (scattering "n" in figure 9)For the right adjustment please refer to the most external top position.

B = 1,1mm ± 0,2

Lower position (Unlocked turret)1

Switching point2

Top position (Locked turret)3

scattering "n"

141

5 4

105

306

16 M.I.6457-1296

Fig. 10

4.2 - Replacement and timing of the angular position transmitter (Fig. 8)

To replace this element remove the cover (146); the angular position transmitter is the component (116). Disconnect the wiresfrom the terminal board, unloose the two screws and remove the two fixing pieces (118). At this point it is possible to remove itfrom the turret. For the re-assembly proceed according to a reverse sequence, but before locking it, set the timing operations asfollows:

— Lock the turret at any position.

— Set an approximate positioning by rotating the unit to get corresponding position code (check by means of a voltmeter oron the machine PLC).

— Perform an accurate adjustment by rotating the unit until the strobe signal passes from 1 to 0; mark the position of the angularposition transmitter against its support then rotate in the opposite direction until the strobe signal passes again from 1 to0 and mark this new position.In such a way it is possible to determine the area where the strobe signal is 1; the width of this area will be 20°.Rotate 10° backwards the angular position transmitter so that the reference mark is halfway the angle found with thepreviously described procedure and tighten the screws of the fixing pieces (118).

4.3 - Indexing control adjustment and replacement (Fig. 10)

To reach the indexing control first remove the solenoid assy as shown on page 17.The switch (105) is locked by means of a block (106).To replace the switch disconnect the wires from the terminal board, loosen the cable clamp (145), unscrew the two screws (457)and remove the switch together with the block, simultaneously pushing the wire through the cable clamps (145).Once replaced the switch and before connecting the wires to the terminal board, provide for the adjustment of this position asfollows:

— Lock the screw (457).

— Once locked the screw (457/B) proceed as follows:- take a 0,9 ÷ 1,1 mm thick spacer.- introduce the spacer (A) between the pin (158) and the switch.- push the switch against the space (as shown by the figure) then lock it with the screw (457/B).- remove the spacer, connect the wires, tighten the cable clamp and re-assemble the solenoid.

A0,9 ÷ 1,1

158 106 457 105 145

457/B

17 M.I.6457-1296

Fig. 11

4.4 - Excange of motor (Fig. E)

The motor becomes accessible when the rear cover (146) of the turret has been removed.For pulling of the motor remove the respective wires from the terminal strip and loosen screws (147).

4.5 - Solenoid pre-indexer (Fig. 11)

4.5.a - Solenoid pre-indexer

The solenoid pre-indexer is the component shown by the number 4 on the sequential cycle and is the unit which, lifts or lowersthe pre-indexer pin, pre-sets the turret for its rotation (beginning of cycle) or for shut-down (end of rotation).To check this assy proceed as follows:• remove the rear cover of the turret (146), disconnect the solenoid wires from the terminal board, loosen the cable clamp and

push the cable inwards.• unscrew the screws (178) and remove the spacers (177).• remove the cap (193) after having unscrewed the screws (190) then remove the solenoid (157) (see fig. 11 and fig. 12).

4.5.b - Checks to be performed on the pin

Manually push the pin (158) and let it be pushed back by the springs to verify that it runs smoontly.In case of problems, completely remove the pin and check the springs (180) for correct condition and verify that the flats of thepin (158) is not damaged.

4.6 - Shock absorber (Fig. 11)

The purpose of the shock absorbing system is to dampen the impacts coming from the rotating part of the turret when this isstopped by means of pin (158).The system consists of two modular components (500), which are fitted in the turret body and which - by means of an elastichydraulic system - enable to dampen the shocks without any oscillation and a low noise-level.A reduction of efficiency of a shock absorbing device contributes to increase the noise-level during the indexing phase. In thiscase the modular components should be replaced.These components can be easily pulled out, as soon as screws (170) hase been loosened.

Important: If any cheking of the internal parts of the shock absorber module (500) becomes necessary, please ask our TecnicalDept. for more information.

Note: Any incorrect opening of the shock absorber module (500) during the first year of the unit's lifetime will invalidate ourguarantee on this product.

159

176

175

502

500

190

194 193

180

157

158

180

179

178

177

170

171

500

170

171

501128 181

501502

18 M.I.6457-1296

4.7 - The turret's restart-up after an accidental or emergency shut-down

This operation is required in case the turret stops during rotation due to lack of electricity or sequential cycle mismanegement.This turret-up after an accidental or emergency shut-down must be performed in the same rotation direction which it hadat the moment of shut-down.

4.7.a)Operate one of the turret's positioning cycles. In the case that the controller doesn't accept the positioning command, becausethe point of departure is wrong and the turret is not locked, see point (4.7.b)

4.7.b)In order to return to the normal turret positioning, it is necessary to have at one's disposal a set of manual commands (push-buttontype) to manually start up the individual cycle phase for each component in order to operate the solenoid and motor in anindipendent manner, accordimg to the opportune sequences. To reset the turret's normal condition, follow these steps:

— Energize the indexing electromagnet (4).

— Operate the motor's rotation in order to turn the turret in the same direction that it turned at the moment of interruption.Cut off the motor's feed as soon as the indexing pin stops the rotation.

— Reverse the motor's rotation in order to lock the turret, cutting of the feed as soon as you have the locking microswitch signal.

— De-energize the electromagnet (4).

— The turret, at this point, is normally indexed and locked in position and ready to go in an automatic cycle.

4.7.c)If the re-timing — as described in point (4.7.a) and (4.7.b) — doesn't work because the necessary manual commands are notavailable or because the rotation direction at the time of shut-down wasn't known, the following manual re-timing procedure becarried out:

— Desconnect the turret's electrical connections. This operation serves to electrically isolate the turret with a resultantde-energizing of the indexing solenoid.

— Remove the solenoid cover (193).

— Remove the rear cover (146).

— Push by hand down wards the part (192) and contemporally, by means of a key as stated in Fig. 12 rotate the motor.

— Rotate the motor shaft up to the part (192) will push the pin (158) indide the slot relevant to an indexing position andkeep always pushed the part (192).

— For locking the turret, make turning around of the motor continue (during this step keep part (192) depressed).It is suitable to turn it into the direction where less resistance is felt (the opposite direction is locked against rotation).

— If the rotation direction is the right one you can see the ring (141) page 14 is moving towards the outside signallingthat the turret is going to be locked. Right locking is got when the ring (141) is in the top position (before starting torecover); in this situation the proximity switch must be energized.

— Now the turret is ready to start again in the automatic cycle.

19 M.I.6457-1296

Fig. 12

4.8 - Operation checks to be carried out in case of accidental collision

This inconvenience presents two different conditions:• The collision between the disc and the machine occurs while the disc is locked.• While the disc is unlocked. The most frequent condition is the collision while the disc is locked and, normally, the following

operations are to be performed for re-starting the machine:

— Loosen the screws locking the disc.

— Introduce the suitable setting pin supplied with the machine.

— Tighten the screws and remove the setting pin. Repeat the above sequence also for the screws locking the turret to thesaddle.

Having completed the above operations, the turret usually is aligned again and ready to be operated.Should the collision occur while the disc is unlocked, or in case of malfunction after the re-alignment operations previouslydescribed, the mechanical parts are to be checked in conformity with the procedure illustred in the next chapter.

190

193

192

146

20 M.I.6457-1296

4.9 - Instructions for the checking of the mechanical parts

This check is to be performed in the following cases:

— Accidental collision with the lathe, when after retiming the turret does not work correctly.

— Misfunctions which cannot be eliminated after checking the motor, the brake, the encoder, the turret timing and the max.lag times of the electrical equipment of the machine.

4.9.a-Disassembly instructions (see Fig. A-B)

— Remove the toolholder disc from the turret.

— Remove the ring and seal complete (408) from the turret and check the condition of the seal (123).

— Remove the rear cover of the turret (146).

— Remove the encoder (116).

— Remove the proximity switch (105) and its support (306).

— Remove the motor support (350).

— Remove the snap ring (138).

— Remove the screws (101) and the relevant pins.

— At this point, even with the turret locked, the wholemechanical group can be removed through the front of the turret.

— The various components of the mechanical assy can be dismantled further after removing the locking nut (310).

4.9.b-Checks to be performed on the mechanical elements.

— Check the conditions of the bearing (317).

— Check that the three roller and pins (130) are not damaged.

— Check that the surface of the cam (128) is not damaged.

— Check that all sliding surfaces are in good condition and that all gaskets are undamaged.

4.9.c-Assembly instructions

— Carefully clean and wash the various components before reassembly. The assembly must be carried out in thereverse sequence of the above disassembly instructions and the turret on the mechanical assy must be unlocked.

— Before locking the collar (310) check the preload of the springs, proceeding as follows (Fig. 13):Assembly the spacer (309)Screw the collar (310) until it touches the springs (133).Then tighten the collar and makesure that the springs are compressed in according with the X-Y values indicatedin the table of Fig. 13, if necessary modify the spacer (309).

— After assembly check, with the turret unlocked, the 0,1 mm backlash on the main shaft; in the opposite case modifythe ring (136) thichness to get the ring clearance.

21 M.I.6457-1296

Fig. 13

LENGHT AFTER PREOLADING

UNLOADED LENGHT

BSA 250 9 2,2 ± 0,05

Turret size Normall value

X [mm] X-Y [mm]

X

308

133

309

310

311

Y

22 M.I.6457-1296

Fig. 14

4.9.d - Check of the right mechanic locking of turretAfter re-assembling of the turret or in case you suspect the toolholder disc is not mechanically locked(also if the electrical indexingcycle is properly operating).A rod (313) allows to inspect the right shifting of the locking inside parts and the consequent application of the power given bythe cup-springs (Fig. 13).Shifting remark must be executed in the following way:

— Position a dial gauge as per Fig. 14.

— Unlock the turret manually driving the motor as shown at page 18 - 19.

— Push the rod (313) towards the inside up to the touching.

— Reset the dial gauge.

— Manually get the locking and check the rod has got the shifting stated in Fig. 14.If the checked vaule "Z" is not corrisponding to the stated one the reasons could be the following ones:• Wrong assembly of inside parts.• Excessive wearing of the rollers (130) or of the cam (128) or of the toothing (111-112).• Presence of dirt between the contact surfaces.

N.B.: After prolungated working time it is possible to inspect a lower value; min. acceptable value is 0,05 mm.

313 165 314

400 Z = 0,15 ÷ 0,20 mm

23 M.I.6457-1296

4.10.b - Recommended lubricant

FLUID GREASECENTOPLEX GLP 500 - KLüBER LUBRICATION

4.10 - LubricationThe mechanical part of the turret is supplied with permanent lubrication and therefore it does not require periodical refillings orlubricant changes.The lubricant is to be changed only in case of complete disassembly of the turret.The lubricant is to be filled before assembling the solenoid (157) and the pin (158) pouring it through the hole of the pin (158).

4.10.a - Recommended capacity of lubricant used

Turret size Lubricant quantity

cm3 Kg

BSA 250 600 0,56

AustraliaKlüber LubricationA Division of Freudenberg (Australia) Pty. Ltd.14 Daniel StreetP. O. Box 164, Botany N S W 2019, SydneyTel. (02) 666-5744, Telex 26121 lesco

Bundesrepublik DeutschlandKlüber Lubrication Munchen KGGeisenhausenerstrasse 7, Postfach 70 10 47D-8000 Munchen 70Tel. (089) 78 76-0, Telex 523 131Telefax 3a (089) 78 76 333

Schweiz / SuisseKlüber Lubrication AG (SCHWEIZ)Thurgauer Strasse 39, CH-8050 ZurichTel. (01) 302 79 79, Telex 823 194 klub ch

BrasilKlüber Lubrication Industria e Comércio Ltda.Rua Sao Paulo, 345Distrito Industrial de Alphaville06400 Barueri - Sao PauloTel. 421 5511/421 5155/421 5150Telex (011) 39209

BelgiqueKlüber Lubrication Belge S. A.95 Rue Cardinal Mercier, B-7760 DottigniesTel. (056) 48 98 71, Telex 0046-57059,Telefax 0032-56 48 98 49

NipponNOK Klüber Co. Ltd.Seiwa Building, 1 - 12 - 15 Shiba-DaimonMinato-ku, Tokyo 105Tel. (03) 432-4211, Telex 242-2152 nok tokTelefax 0081/34 36 59 68

ArgentinaKlüber Lubrication Argentina S. A.Bdo. de Irigoyen 566 - 2° D1072 Buenos AiresTel. (01) 37-6371, Telex 22832 laqui ar

Republic of KoreaKlüber Lubrication (KOREA) Ltd.Head Office/Factory:1132, jung ri-dong suh-gu,P. O. Box 146, Daegu 630Tel. (053) 529160/1/2, Telex klkco k 54384

Republic of the PhilippinesKlüber Lubrication International Ltd.6th Floor Rediffusion House822 Lai Chi Kok RoadKowloon, Hong KongTel. (02) 3-741 42 29, 3-741 42 30Telex (02) 38337 fvi hxTelefax 3-7453667

United States of AmericaKlüber Lubrication Corp.Grenier Industrial Airpark, Manchester,New Hampshire 03103Tel. (0603) 669-7789, Telex 94-3494Telefax (603) 627-3718

Republic of South AfricaKlüber Lubrication (Pty) Ltd.Harpur House, 1 Dover StreetP. O. Box 3924, Randburg 2125Tel. (011) 789-3242, Telex 4-22 455 sa

EspañaKlüber Lubrication Iberica S. A.Carretera Nacional 152 km 22Parets del Valles (Barcelona)Tel. (03) 562 17 11, 562 17 90, 562 18 00Telex 93659 Klub e

FranceKlüber Lubrication France S. A.10-16 Allee E. Ducretet Z IBP1437, F-26014 Valence CedexTel. (75) 44-02-34, Telex 345 637

Great BritainKlüber Lubrication Great BritainLtd.Hough Mills, Halifax, West Yorkshire, HX3 7BNTel. (0422) 205115, Telex 517197

Hong KongKlüber Lubrication International Ltd.6th Floor Rediffusion House822 Lai Chi Kok RoadKowloon, Hong KongTel. (02) 3-741 42 29, 3-741 42 30Telex (02) 38337 fvi hxTelefax 3-7453667

ItaliaKlüber Lubrication Italia S.R.L.Via Monferrato Sesto Ulteriano,20098 S. GiulianoCasella postale 13.104, I-20130 MilanoTel. (02) 98.81.121 Telex 316090Telefax 0039/29 88 11 24

JOsterreichKlüber Lubrication Austria Ges. m. b. H.Franz-Wolfram-Scherer-Strasse 32, SalzburgPostfach 49, A-5101 Bergheim.Tel. (0662) 52 705-0, Telex 0047-633326

A DanmarkKlüber Lubrication A/SSoenderlandsgade 11, DK-7500 HolstebroTel. (07) 42 46 20, (07) 42 42 77, Telex 0055-66424

DK

AUS E RA

B

BR

CH

D

F ROK

GB RP

HK USA

I ZA

24 M.I.6457-1296

5. ASSEMBLY DRAWINGS AND PART LISTS

5.A - Main section

N.B. When ordering any spare part, please state both the reference number of the part and the complete name andcode number of the BSA.

101 Screw M12x20 A12.9 0531225 12

105 Proximity 0661254 1

106 Switch holder 0327459 1

108 Key 0323612 2

109 Screw M12x35 A12.9 0531219 8

110 Spring 0115271 4

111Toothings 8-12 pos. 0425803 1

112

114 Pin 12x40 0550201 4

Encoder 8 pos. 0661256116 1

Encoder 12 pos. 0661246

117 Screw M5x10 0530030 2

122 O-Ring OR 172 0591423 1

123 Gasket 0591397 1

124 O-Ring OR 172 0591423 1

125 O-Ring OR 4412 0590582 1

126 O-Ring OR 4850 0591412 1

127 Key 0323835 1

Cam 8 pos. 0328611128 1

Cam 12 pos. 0328612

129 Screw M5x10 0530486 3

130 Roller 0421849 3

133 Spring 0321217 1

136 Spacer 0550756 1

138 Snap ring 0550761 1

139 O-Ring OR 3118 0590313 1

140 O-Ring OR 3168 0590322 1

141 Ring 0323796 1

142 Spring 0321661 1

145 Inlet connect. 0671722 2

146 Rear cover 0324896 1

(1) See Fig. 10

147 Screw M6x20 0530047 3

150 O-Ring OR 4975 0590400 1

151 Rod 0323837 1

152 Cam 0323844 1

157 Solenoid 0425883 1

158 Pin 0323829 1

159 O-Ring OR 3268 0590525 1

166 Screw M4x8 0530385 1

304 Encoder holder 0325595 1

305 Coupling 0325596 1

308 Plate 0325591 1

309 Spacer 0325592 1

310 Ring nut 0323838 1

311 Main shaft 0325590 1

315 Rollholder 0328068 1

316 Plate 0631742 1

317 Bearing 0631741 1

319 See sheet 30 M.I. 6457 - -

Coolant ring 8 pos. 0326293323 1

Coolant ring 12 pos. 0326292

324 Holder 0323910 3

325 Screw M5x10 0530030 3

328 O-Ring OR 2050 0590298 8/12

350 Gear box 0325561 1

400 Housing 0326298 1

408 Coolant flange 0326364 1

409 O-Ring OR 2.152 0591212 1

Screw M6x30 0530050 3439

Screw M6x45 0530053 2

457 Screw M4x16 0530022 2

Ref. Description Code Q.ty Ref. Description Code Q.ty

(1)

25M

.I.64

57-1

296

108

159

157

400

158

106

105

152

151

150

145

350

147

310

146

319

166

116

305

139

141

140

138

439

142

136

133

308

317

316

315

130

129

128

126

112

408

124

323

409

101

117

325

324

109

110

311

111

127

114

125

122

123

328

309

304 Fig

. A

26 M.I.6457-1296

Fig. B

5.B - Back view


105 Proximity 0661254 1

115 Elect. block 0490146 1

118 Encoder holder 0113203 2

120 Elect. block 0490147 1

Plug 0671182 4121

O-Ring OR 2068 0590301 4

162 Name plate 0328080 1

163 Rivet 0530521 4

165 O-Ring OR 2018 0590161 1

(1) See Fig. 8

(2) See Fig. 14


307 Screw M5x20 0530034 1

313 Rod 0325594 1

314 Screw M6x10 0531156 1

321 Screw M4x12 0530021 1

410 Board holder 0325598 1

411 Reference pin 0326338 1

609 Washer 0329652 1


(1)

(2)

(1)

(1)

105

120

313

411

118

314

115

306

410

163

121

162

27 M.I.6457-1296

Fig. C

5.C - Coolant circuit

425

426

417328

325

420324

323

418

408

424

419

418

422

421 B

2

A

424

+ α

− α

417

419

423

422

421

1


Coolant ring 8 pos. 0326293323 1

Coolant ring 12 pos. 0326292

324 Holder 0323910 3

325 Screw M5x10 0530030 3

328 O-Ring OR 2050 0590298 8/12

408 Coolant flange 0326364 1

417 Coolant valve 0326360 1

418 Plug 0326359 1

419 O-Ring OR 2050 0590298 2

420 Spring 0319956 1

421 Plug 0326362 2

422 O-Ring OR 2056 0590299 2

423 Plug 0326361 1

424 Screw 0323851 2

425 Screw M6x25 0530319 4

426 Holder 0326389 4


28 M.I.6457-1296

5.D - Shock absorber

Fig. D


Cam 8 pos. 0328611128 1

Cam 12 pos. 0328612

157 Solenoid 0425883 1

158 Pin 0323829 1

159 O-Ring OR 3268 0590525 1

170 Screw M6x16 0530045 12

171 O-Ring OR 033 0591453 2

175 Bushing 0837062 1

176 Screw M5x25 0530035 1

177 Holder 0323833 2

178 Screw M6x10 0530043 2

179 Pin 6x28 0550196 1

180 Spring 0324080 2

181 Shaft 0328487 1

190 Screw M3x8 0530267 4

193 Plate 0328079 1

194 O-Ring OR 2.34 0591411 1

500 Shock absorber 0426219 2

501 Spacer 0328613 2

502 Screw M4x25 0530025 4


159

176

175

502

500

190

194 193

180

157

158

180

179

178

177

170

171

500

170

171

501

128 181

501

502

29 M.I.6457-1296

5.E - Motor and gear box

Fig. E(1) See sheet 30


220 Gasket 0590754 1

223 Bearing 0630661 1

251 Bearing 0630156 2

252 Spacer 0630277 1

253 Bearing 0631643 1

254 Bearing 0630687 1

255 Bushing 0324125 4

256 Screw M8x30 0530327 4

257 Washer 0550011 4


260 Pin 8x20 0550489 2

261 Gear 0323773 1

350 Gear box 0325561 1

351 Gasket 0325593 1

440 Snap ring 0550402 1

Z3See sheet 30 M.I. 6457 - -

Z4


223

239

256

260

350

351

220

352Z3 (1)

253

255

Z4 (1) 251

260

261

254

222

353

225

231 238

257

258

252

440

30 M.I.6457-1296

5.F - Table to determine the motor code and the gears (Fig. F)

MOTORZ3

Z4

Fig. F

400/440 V

0426229

MOTOR

50 Hz 0328137 0328138

60 Hz 0328139 0328140

50 Hz L 0328139 0328140

60 Hz L 0323765 0323772

50 Hz LL 0323765 0323772

60 Hz LL 0328642 0328643

BSA 250/20

SIZE

Z3 Z4 220/380 V 230/400 V 110 V

0426227 0426673 0426228

VERSION GEARS

31 M.I.6457-1296

6 - RECOMMENDED SPARE-PARTS FOR BSA 250/20


7 - MAINTENANCE

7.1 - Periodic checksThe turret is life-lubrificated so no replacement or filling lubrificant is required.

7.1.a - Front gasket

Check the conditions of gasket ref. 123 proceeding as stated on sheet 20 point 4.9.a, every 4.000 working hours of the machine,at least.If en excessive wear is noted, it's advisable to replace the gasket.

105 Proximity 0661254 2


Encoder 8 pos. 0661256116 1

Encoder 12 pos. 0661246

122 O-Ring OR 172 0591423 1

123 Gasket 0591397 1

124 O-Ring OR 172 0591423 1

125 O-Ring OR 4412 0590582 1

126 O-Ring OR 4850 0591412 1

139 O-Ring OR 3118 0590313 1

140 O-Ring OR 3168 0590322 1

150 O-Ring OR 4975 0590400 1

159 O-Ring OR 3268 0590525 1

171 O-Ring OR 033 0591453 2

194 O-Ring OR 2.34 0591411 1

220 Gasket 0590754 1


328 O-Ring OR2050 0590298 8/12

409 O-Ring OR 2.152 0591212 1

417 Coolant valve 0326360 1

418 Plug 0326359 1

419 O-Ring OR 2050 0590298 2

420 Spring 0319956 1

422 O-Ring OR 2056 0590299 2



***

**

*****

*

* Spare parts which might be required on the occasion of periodical checking (see point 7.1.a)

32 M.I.6457-1296

8 - TROUBLE SHOOTING

FAILURE

1) Unlocked turret(after indexing cycle lockingswitch signal = 0)

1.1 Faulty locking switch1.2 Faulty motor supply1.3 Faulty motor1.4 Faulty mechanism1.5 Wrong adjustment of locking

switch1.6 R3 lag time too long

1.1 Check and if necessary replacethe proximity switch

1.2 Check the 3 phase of motor andfeeding voltage

1.3 Check the motor winding and ifnecessary replace

1.4 It's necessary an internal check(see sheet 20). Please contact theService Center

1.5 Adjust the locking switch as shownon sheets 14-15

1.6 The lag time must be reduced tothe limit indicated on sheet 12

PROBABLE CAUSES HOW TO DO

2) Unlocked turret(after indexing cycle, the turret ismechanically unlocked but lockingswitch signal = 1)

2.1 Faulty locking switch2.2 Sticking bush (see sheet 14

ref. 141)2.3 Wrong adjustment of locking

switch

2.1 Check and if necessary replacethe proximity switch

2.2 Please contact the Service Center2.3 Adjust the locking switch as shown

on sheets 14-15

3) The tool disc doesn't rotate 3.1 Faulty indexing switch(signal always = 1)

3.2 Indexing solenoid always ener-gized

3.3 Indexing device sticking3.4 Faulty motor supply3.5 Faulty motor3.6 Turret rotating in wrong direction

after an unlocking for accidentalreasons

3.7 Faulty mechanism

3.1 Check and if necessary replacethe indexing switch

3.2 Check the relevant electric circuit3.3 Check both pin, springs (ref. 180)

and solenoid (see sheet 17)3.4 Check the 3 phase of motor and

feeding voltage3.5 Check the motor winding and if

necessary replace3.6 Reverse the rotation or re-timing

as per sheet 183.7 It's necessary an internal check

(see sheet 20). Please contact theService Center

4) The tool disc goes on rota-ting without indexing

4.1 Faulty angular position transmitter4.2 Missed supply of indexing cycle4.3 Faulty index solenoid4.4 Indexing device sticking

4.1 Check the angular position signals4.2 Check the solenoid feeding voltage4.3 Check the solenoid winding and if

necessary replace4.4 Check both pin, springs (ref. 180)

and solenoid (see sheet 17)

5.1 Indexing device sticking5.2 Lag time R1 too long

5.1 Check both pin, springs (ref. 180)and solenoid (see sheet 17)

5.2 The lag time must be reduced tothe limit indicated on sheet 12

5) Turret indexed in wrongposition

33 M.I.6457-1296

FAILURE

6) Excessive bounce at theindexing

6.1 Excessive inertia6.2 Faulty shock absorbers

6.1 Verify the inertia (it cannot exceedthe values indicated on sheet 3)

6.2 Check the shock absorbers(see sheet 17)

PROBABLE CAUSES HOW TO DO

7) Disc rotation is not smooth,action is jerky

7.1 Excessive unbalance torque 7.1 Verify unbalance torque (it cannotexceed the values indicated onsheet 3) if necessary add or remo-move tool holders to counterbalan-ce the disc

8) Thermal detector signalsmotor overheating

8.1 Excessive frequency of turret cycle8.2 Faulty motor supply8.3 Faulty motor8.4 Turret restarting in wrong direction

after an unlocking for accidentalreasons

8.5 Faulty mechanism

8.1 Verify the admitted value of toolchange frequency (see sheet 3)and if necessary reduce the fre-quency

8.2 Check the 3 phase of motor andfeeding voltage

8.3 Check the motor winding and ifnecessary replace

8.4 Reverse the rotation or re-timingas per sheet 18

8.5 Manually rotate the motor shaft tocheck for free mechanism

e-mail: [email protected]

come visit Duplomatic homepage:www.duplomatic.com

DUPLOMATIC S.p.A.AUTOMATION DIVISION

20025 LEGNANO (MI) - ITALYP.LE BOZZI, 1

TEL. 0331/472111 - 472252FAX 0331/455161 DUPLOMATIC

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