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1. 2 3 2 ES750 HSD ACE TEE 1 22 Pesaro PU Italy FNZ4100497 HMMM oo ASYNCHRONOUS 3 PHASE MOTOR RW pr Hz 85 667 2 3000 10000 kW 30 36 30 36 11 11 11 A 74 89 70 84 23 23 Ins C F IP 54 150kg Te 8 10 rpm x 1000 FNZ4100497 Rev 00 SP 150 110 62 Nominal voltage V 380 380 380 supplied by inverter Rated frequency Hz 85 200 667 Rated speed rpm 1275 3000 10000 Duty type S1 S6 S1 S6 S1 S6 cont 4096 cont 4096 cont 4096 Rated power kW 30 36 30 36 11 11 Rated torque Nm 224 269 95 5 114 6 10 5 10 5 Rated current A 74 89 70 84 23 23 Rated efficiency 0 8 Power factor cos o 0 8 Number of poles 8 Insulation class Class IP 54 Cooling type Liquid cooling Weight kg 150 e The maximum rated current S1 cont is used to set the maximum continuous I current parameter of the inverter 8 HSD S p A 0102h00a fm051112 2 Technical Specifications Parameters of the equivalent electrical network unit of Description measurement Value Nominal power S1 kW 30 Nominal current S1 A 74 Nominal line voltage V 380 Nominal speed at nominal load rpm 1211 Rated frequency Hz 85 No load line voltage V 373 No load current A 61 Stator resistance 20 C Q 0 218 Rotor resistance 20 C Q 0 19 Stator dispersion reactance
2. 1 Tool locking air inlet piston return 5 bar min 28 2 Cleaning of cone 4 bar tool coolant 10 3 Tool change air expulsion 6 5 bar min 28 4 Electrospindle pressurisation air inlet 4 bar 08 5 DPC Pressurisation air inlet 4 bar 28 Max pressure 4 bar HSD S p A 0104h00a fm051112 31 4 Installation and commissioning 4 7 ES750 connections for Oil cylinder Compressed air connection points 1 Cleaning of cone 4 bar tool coolant 26 2 Electrospindle pressurisation air inlet 4 bar 28 Max pressure 4 bar Hydraulic connection points 3 Oil inlet for tool release 60 barmin G1 4 4 Oil inlet for tool locking 10 barmin G1 4 4 8 Internal pressurisation The internal pneumatic pressurisation circuit prevents the entry of harmful particles inside the electrospindle This must be supplied with compressed air at 4 bar 58 PSI which outlets through the front labyrinth in the spindle nose area and the drainage holes of the DPC and the machine is on This will prevent the penetration of dust from other The pressurisation air must also be present when the electrospindle is stopped working areas With the spindle stopped check that there is a uniform flow of air from around the spindle shaft pressurisation and in the drainage holes of the DPC If this is not the case check the efficiency of the pneumatic circuit and check the connecti
3. 1 Front flange 6 2 holes M12 for extraction 12 Sensor connectors 2 8 fixing holes 912 5 7 Sensors 13 Cylinder 3 Nose 8 Pneumatic connectors 14 Spiral casing 4 ae 9 EC plate 15 Fixing surface 5 ISO coupling 10 Serial number 5 HSK connecting 11 Passage of power cables with device connector 1 4 HSD S p A 0102h00a fm051112 2 Technical Specifications 2 2 2 Oil piston version 1 Front flange 7 Sensors 12 Sensor connec tors 2 8fixing holes 212 5 7 Analog 13 Cylind 3 Nose 8 Hydraul t 14 Spiral g 4 dan saton 9 EC plate 15 Fixing surface 5 ISO coupling 10 Serial number 16 Fluids distributor 6 2 holes M12 f 11 Passage of power cables with traction connec tor 2 Technical Specifications 2 3 Characteristics and performance 2 3 1 ES748 HSD S p A www hsd it A he vem Via della Meccanica 16 Z Division ya etus NU FNZ4100487 Mf cons a V 380 380 oo 56 40 Hz 267 533 600 SES 4o00 8000 12000 2 7 al 17 20 12 14 88 E pai A 45 54 30 40 25 32 20 20 O8 Cos p0 8 n3 PASSERI Sea opa CE 12 rm x 1000 FNZ4100487 Rev 00 SP 150 110 62 Nominal voltage V 380 380 380 380 supplied by inverter Rated fre
4. 4 9 2 Cooling characteristics m Input cooling temperature t 20 C 30 C m Anticorrosive means Vmax 25 Vol m Solid materials filter lt 100 um Type of water additives BRAND TIPO TYPE ARAL SAROL 340 2 3 96 CINCINNATI CINCINNATI CIMCOOL MG 602 4 HENKEL P3 PREVOX 6710 2 3 CASTROL SYNTILO R PLUS 2 3 96 HSD S p A 0104h00a fm051112 33 4 Installation and commissioning 4 10 Tool cooling 4 10 1 Tool internal cooling and drainage of the rotating distributor The cooling water runs through the rotating distributor to the tool DPC patented The excess water runs through the DPC drainage holes The more the tool obstructs the flow the more the drained water The excess water gets eliminated To allow a complete drainage refer to the following instructions To make the distributor DPC correctly works and to avoid ruining the electrospindle follow the instructions below m The water to be used to internally cool the tool must comply with the below characteristics m Filter the cooling water by means of a 25 pm filter Perform regular maintenance on the filter in line with the manufacturer s instructions and replace it when it becomes saturated and less efficient m Supply the DPC with a lt 10 l min delivery 0 35 CFM m The distributor drainage holes must always be clear m The DPC drainage pipes must be orientated downwards The pipes must remain down
5. 6 9 4 Description of the sensors m Sensor S1 Tool holder present signal The signal from sensor S1 indicates the presence of the tool holder cone Ignore output S1 during the period from the release command to the couple tool command m Sensors S1 S4 Tool holder locked signal Both sensors S1 and S4 are connected in series sensor S1 checks the presence of the tool holder cone and in case it is present it enables the reading of sensor S4 which will check its position The output only changes to ON if both conditions are verified as positive Ignore the S1 S4 output during the period from the release command to the couple I tool command m Sensor S2 collet open signal Signal S2 is used during the tool change cycle it detects the opening of the collet and whether it is possible to continue with the next phases of the tool change cycle m Sensor S5 Piston upper end of stroke signal Sensor S5 is ON when the piston is at the upper end of stroke position The piston is double acting and should therefore be fed to be moved and maintained in this position The electrospindle can be seriously damaged if the rotation occurs when the piston is not at the upper end of stroke position locked state If outputs S1 or S5 change to OFF stop the rotation of the The electrospindle shaft can only rotate in the tool holder cone correctly A electrospindle shaft The ES750 electrospindle with oil cyl
6. 9 Disposal of the product 76 HSD S p A 0109h00a fm051112 10 Troubleshooting 10 Troubleshooting A Before carrying out any operations on the electrospindle read and implement all the warnings and recommendations regarding safety and maintenance Problems Cause Remedy m Check for the presence of mains voltage m Check the connectors No power supply m Check the integrity and continuity of the electrical connections The tool cdd m Insert a tool holder is not inserted The tool holder is not m See item The tool holder is not coupled inserted correctly in this chapter m Wait for the electrospindle to cool down the thermal switch will reset automatically The thermal switch to allow operation has tripped If the thermal switch trips frequently consult item The electrospindle The overheats later in this chapter electrospindle does not rotate The inverter protection has tripped Consult the manual or contact the manufacturer of the inverter The series of S1 S4 sensors is disconnected or faulty Check the connectors Check the integrity and continuity of the electrical connections Regulate the sensor as described in section 8 1 Replacement and adjustment of the sensor unit Replace the defective sensor as described in section 8 1 Replacement and adjustment of the sensor unit Rotation denied Consult the manuals or the suppliers of the machi
7. MECHATRONIC DIVISION Translation of the original instructions Electrospindle ES748 ES750 User Manual Edition Revision 1 1 H5801H0083 ENGLISH Serial number Information about the publication Information about the publication Code Issue Code of previous issue H5801H0083 1 Revision Description of updates 0 11 2011 new document 1 06 2012 General revision This manual has been prepared for use by customers only and contains information protected by copyright It must not be photocopied or reproduced in any form either fully or in part without the prior written consent of the manufacturer HSD S p A H5801H0083 fm051112 3 Information about the publication HSD S p A H5801H0083 fm051112 Index Index 1 Preliminary information 1 1 Documents supplied with the product 7 1 2 Scope of he Manual rss tee hte is ede eti ei bh meet m dala 7 1 3 Symbols used in the manual nasse ae 8 1 4 Risks associated with the use of the product senes 8 1 5 Product Informationi anali eo tidy ae e ete t teda 10 1 6 Cr Lalli 11 1 7 WA AT AFIS Seren Soe Saat rne 12 2 Technical Specifications 2 1 Description of main parts ES748 sss 13 2 2 Description of main parts ES750 sss 14 2 3 Characteristics and performance atena 16 3 Transport packing unpacking storage
8. Fax 39 0721 205 247 DICHIARA CHE LA QUASI MACCHINA 2006 42 CE ALLEGATO IIB DECLARE THAT THE PARTLY COMPLETED MACHINE 2006 42 EEC ANNEXE IIB Electrospindle ERKLART DASS DIE UNVOLLSTANDIGE MASCHINE 2006 42 EG ANLAGE IIB M rble E eri D CLARE QUE LA QUASI MACHINE 2006 42 CE ANNEXE IIB a G ass S es DECLARA QUE LA CASI MAQUINA 2006 42 CE ADJUNTO IIB Matricola Serial Number Seriennummer Num ro de s rie N mero de serie Codice HSD HSD Code Codice Cliente Customer Code HSD Code HSD Code Kunden Code Code C digo HSD client C digo del cliente RISPETTA I REQUISITI ESSENZIALI APPLICATI 2006 42 CE ALLEGATO I 1 1 5 1 3 2 1 3 4 1 3 6 1 5 01 1 5 08 1 5 09 1 5 10 1 5 11 1 7 1 1 7 3 1 7 4 1 7 4 1 1 74 2 1 7 4 3 IL FABBRICANTE SI IMPEGNA A TRASMETTERE IN RISPOSTA A D UNA RICHIESTA ADEGUATAMENTE MOTIVATA DALLE AUTORIT NAZIONALI INFORMAZIONI PERTINENTI LA QUASI MACCHINA PERSONA AUTORIZZATA A COSTITUIRE LA DOCUMENTAZIONE TECNICA PERTINENTE NOME E COGNOME GIUSEPPE GROSSO INDIRIZZO P LE ALFIO DE SIMONI SN 61122 PESARO ITALY IL FABBRICANTE VIETA LA MESSA IN SERVIZIO FINCH LA MACCHINA FINALE IN CUI DEVE ESSERE INCORPORATA NON E STATA DICHIARATA CONFORME SE DEL CASO ALLE DISPOSIZIONI DELLA PRESENTE DIRETTIVA COMPLIES WITH THE FOLLOWING APPLICABLE ESSENTIAL REQUIREMENTS 2006 42 EEC ANNEXE I 1 1 5 1 3 2 1 3 4 1 3 6 1 5 01 1 5 08 1 5 09 1 5 10 1 5 1
9. Figure 4 HSK tool holder seat DO NOT use abrasive tools such as steel wool metal brushes emery cloth To clean the highlighted surfaces use a soft clean cloth acids or any other aggressive means At the end of the working day clean the surfaces highlighted in figures A from 1 to 4 with a soft and clean cloth imperfect cleaning can lead to serious consequences for the user s safety the wear of the electrospindle and the tool holder and the accuracy and efficiency of the machining operation 62 HSD S p A 0107h00a fm051112 7 Programmed maintenance 7 1 2 Never direct a jet of compressed air in the zone of the pressurised labyrinth seal in that any infiltration would damage the interior of the electrospindle Do not direct a jet of compressed air inside the electrospindle when the tool holder is not coupled as this could dirt the mating surface with the tool holder or cause machining residues to enter the electrospindle itself 1 Coupling surface 2 Labyrinth seal Protection of the tool holder seat The tool holder seat must always be protected from the intrusion of impurities which could soil oxidise or in any way degrade the contact surfaces never leave the electrospindle without a tool holder cone inserted AN AN ZN The cone used for protection must not have through holes To avoid sticking remove the tool holder in the electrospindle both after any h
10. Special Attorney Sonderbevollm chtiger Fond de pouvoir extraordinaire Ao Mandatario Especial M SQ006 Rev 09 25 03 2010 HSD S p A 0114h00a fm051112 85 13 Declaration of incorporation 86 HSD S p A 0114h00a fm051112 MECHATRONIC DIVISION HSD S p A Sede legale Via della Meccanica 16 61122 Pesaro PU Italy Tel 39 0721 439100 Fax 39 0721 439150 Sede centrale P le A De Simoni sn 61122 PESARO ITALIA Tel 39 0721 205 211 Fax 39 0721 205 247 E mail supporthsd hsd it web www hsd it
11. 3 1 Vire pe ee ot toniolo bb Aut dio hr nf 21 3 2 Dimensions and weights 2 2 2228 ae AR 21 3 3 Transport and packing conditions ssssssssessseennnnennnees 21 34 Unpacking sinti iii I 22 35 Mop ree Pc ee LR e 23 4 Installation and commissioning 4 1 Preliminary installation checken sn pectet Sa ee 25 42 Preparing the factory services nu ek 25 4 3 Mechanical connections ccccceccesssscseseseseseseseseseesesesceeescaceceucasacacanssasaeananeesesaceeeteaees 26 44 Specifications for the compressed air supplied to the manufacturer s products 27 4 5 Example diagrams for pneumatic circuits by the customer sss 29 4 6 ES748 and ES750 connections for air cylinder sse 31 47 ES750 connections for Oil cylinder rasen ee ite neue 32 4 8 Internal pressurisation sss 32 4 9 eric RR ERR 33 410 CTTOOLCOOIITIO ui oigo i ihe uen e a patat Lie tt NAS nn 34 4 11 Example diagram of the cone s cleaning circuit see 35 4 12 Electrical connections 2 oii eed eH Bla 36 HSD S p A H5801H0083TOC fm051112 5 Index 10 11 12 13 General post installation checks 5 1 Electrospindle pre startup checks ccccccseccseseseeseseecesescsesceceueacaesnsnsnsusatacsnseeesesataneetes 39 5 2 First start up checks sse netten nnne 41 Use and adjustment 6 1 Environmental condit
12. 4 A diff A A B diff B B Z diff Z Z Temporal flow of differential negated signals 3 25 3 2 75 2 5 A diff B diff Z diff 2 25 2 1 75 4 15 60 HSD S p A 0106h00a fm051112 7 Programmed maintenance 7 Programmed maintenance In order to be able to work in complete safety on an electrospindle installed on a machine refer to the machine s instruction manual Fully complying with programmed maintenance is essential for maintaining the usage and operating conditions envisaged by the manufacturer at the moment the product is placed on the market AN AN The frequency was assessed considering a 5 day working week 8 hours per day I under normal working conditions Thoroughly read this section before carrying out any maintenance operations on the electrospindle The safety requirements to take into account during the various phases of maintenance work on the electrospindle are m the maintenance and or lubrication operations must only be carried out by qualified skilled personnel appropriately authorised by the technical management of the works and in accordance with current directives and standards using equipment tools and products suitable for the purpose m Suitable clothing must be worn when carrying out maintenance operations such as close fitting overalls and safety shoes and avoiding at all costs loose clothing and that wi
13. Dry rotation possible Maximum capacity 60l min not allowed with pressurised air mantenere i collegamenti corti Drenaggio Ana compressa 10 bar n 0 min 5 bar n lt 10000 min ut Lubrorefrigerazione ee minimale Lubrorefrigerante max 80 bar 17 14 Sato Da ISO 4406 li If you want to use a rotating distributor other than the standard one offered by the manufacturer contact the manufacturer s technical service office 46 HSD S p A 0106h00a fm051112 6 Use and adjustment 6 8 Procedure to follow if the tool becomes jammed in the piece being machined into alarm status or stops with the tool locked onto the piece being machined do not move the spindle along the Z axis For models with ISOP type tool coupling in the case where the machine goes If possible free the piece by hand and then perform a tool change If this is not possible proceed as follows Supply air to the tool change circuit Slowly move the spindle away from the work piece by moving it along the Z axis until the collet opens sensor S2 output ON Make sure that the cone has been freed from the collet Move the spindle away from the work piece Then manually remove the jammed tool If this procedure is not followed the tool holder will drag
14. Q 0 572 Stator dispersion inductance mH 1 1 Rotor dispersion reactance Q 0 217 Rotor dispersion inductance mH 0 41 Main field reactance Q 3 063 Main field inductance mH 5 7 Field weakening start speed rpm 1275 Maximum motor speed rpm 10000 Power factor 0 8 Rotor moment of inertia Kg m 1 32E 01 Connection Y or D Y HSD S p A 0102h00a fm051112 19 2 Technical Specifications 20 HSD S p A 0102h00a fm051112 3 Transport packing unpacking storage 3 Transport packing unpacking storage 3 1 Warnings m Product lifting and handling operations can create hazardous situations for the personnel involved Therefore it is advisable to follow the instructions supplied by the manufacturer and to use the appropriate equipment m The installation and assembly operations must always be carried out by specialised technicians only m Allthe lifting and handling operations of the product and its parts must be performed with extreme care avoiding impacts that could compromise its operation or damage any coated parts The user is responsible for selecting the lifting equipment cables straps or A chains etc regarded as most suitable in terms of operation and capacity with respect to the weight of the load indicated on the packing and on the product label 3 2 Dimensions and weights m Weight of the packed product this is reported on the packing m Linear dimensions of the packed product these are re
15. chapter 7 HSD S p A 0104h00a fm051112 35 4 Installation and commissioning 4 12 AN i 4 12 1 Electrical connections The electricity supply to the electrospindle MUST be through an inverter The position of the electrical connectors or the outlet of the free cables is shown in paragraph 2 1 In addition to the supplied electrical plug connector pre wired plug connectors of various lengths are also available on request Power cables WHITE U Phase RED V Phase BLACK W Phase YELLOW GREEN Earth 36 HSD S p A 0104h00a fm051112 4 Installation and commissioning 4 12 2 Encoder wiring motor thermal probe ES748 Encoder L B 1Vpp and TTL with connector UB UB ROSA NERO BIANCO UB 5V UA ROSSO MARRONE UN GIALLO UN GRIGIO TTL manufacturer encoder without connector SONDA TERMICA MOTORE PONTE PIN 15 CON PIN 7 ES750 Encoder L B 1Vpp and TTL without connector WHITE UA BROWN UA PINK UB BLACK UB GREY UN Yellow UN RED UB 5V BLUE OV GND GREEN 5V Sense Yellow A GREEN A BROWN B BLUE B GREY N WHITE N RED 24V BLACK OV BROWN THERMAL BROWN THERMAL TTL manufacturer encoder without connector Yellow A GREEN A BROWN B B
16. conditions standard IEC 60034 1 2006 05 Contact the manufacturer for information regarding applications in special environments 6 2 Running in Prior to being packed the electrospindle is subjected to an automatic running in cycle to ensure the correct distribution of lubricant long life grease along the ball races of the bearings and to run in the balls and races of the bearings themselves The running in cycle also includes a detailed check of all the control and signalling devices through the simulation of various machining cycles on the test bench 63 Warm up The manufacturer uses high precision angular contact bearing pairs pre loaded and lubricated for life with special high speed grease When starting up the electrospindle for the first time each day allow it to run a short warm up cycle to allow the bearings to gradually reach a uniform operating temperature and obtain uniform expansion of the races and correct pre loading and rigidity The following cycle with a tool holder inserted and without performing AN machining operations is recommend m 50 maximum rated speed for 2 minutes m 75 maximum rated speed for 2 minutes m 100 maximum rated speed for 1 minute Pre heating cycle must also be performed each time the machine is not working for a period of time sufficient to cool the electrospindle to room temperature not be touched without taking the due precautions f During machining the spindle can reach hig
17. if the table is not verified repeat the procedure from the beginning if the table is verified make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders at the end of the cycle check that the table at point 11 is satisfied if so the adjustment procedure of S3 is finished if not repeat the procedure from the beginning HSD S p A 0108h00a fm051112 73 8 Replacing components 74 HSD S p A 0108h00a fm051112 9 Disposal of the product 9 Disposal of the product The electrospindle contains a spring that has been pre loaded with a force of A around one hundred kilograms This spring is applied to a screw dowel that can be violently ejected if the electrospindle is dismantled by inadequately trained personnel Only carry out the operations described in this manual Follow the instructions scrupulously and in the case of doubt contact the Manufacturer s Assistance Service At the end of the electrospindle s life cycle it is the user s responsibility to dispose of it in the correct manner First of all clean the various parts and then separate them into mechanical and electrical components The different materials such as electric motors copper windings metal components plastic materials etc must be sorted and separated then disposed of in accordance with the laws applicable in the country of installation HSD S p A 0109h00a fm051112 75
18. kept under pressure when the piston needs to be kept at the upper end of stroke with the tool locked away from rotating parts HSD S p A 0104h00a fm051112 29 4 Installation and commissioning 4 5 2 Actuation of the tool change piston oil actuation optional Li The circuit indicated here is merely an example The electrospindle ES750 may be optionally fitted with an oil type cylinder to perform the tool change operations An example system layout is shown below 0 1 High pressure circuit 60 bar 4 Safety switch on the piston recovery circuit calibrated at 30 bar 2 Low pressure circuit 5 Oil inlet for tool release 3 Bistable solenoid valve 6 Oil inlet for tool locking li It is not necessary to supply 60 bar constantly for tool locking When the safety switch has confirmed piston recovery at the upper limit switch you can reduce the pressure to 10 bar 30 HSD S p A 0104h00a fm051112 4 Installation and commissioning 4 5 3 Pressurization supply 4 Bar i D lt H Q Q e 1 o OO 1 6 bar mains supply pressure 4 pressure regulator 4 bar 2 pre filter 5 um 5 pressure switch calibrated to 4 bar 3 oil separator filter 0 1 um 6 electrospindle pressurisation A The circuits proposed are indicative only 4 6 ES748 and ES750 connections for air cylinder Compressed air connection points
19. manufacturer s products f Introduce compressed air with purity according to ISO 8573 1 Class 2 4 3 i e e Class 2 for the solid particles size of the solid particles lt 1 um e Class 4 for humidity dew point lt 3 C 37 4 F Class 3 for total oil oil concentration lt 1 mg m Failure to comply with these specifications may cause the malfunction of the electrospindle The guarantee will be deemed as null and void if traces of pollutants are found during repairs HSD S p A 0104h00a fm051112 27 4 Installation and commissioning e Forexample compliance with the above specifications can be obtained following the l instructions written below m Ifthe machine has a lubricated air circuit this must be isolated from the dry air circuit feeding the electrospindle by means of non return valves m The filters shown in diagrams of the following figures must be installed as close as possible to the electrospindle m In view of the fact that the efficiency of the filters is lt 100 it is important that the machine tool is supplied with suitably treated air As an indication introduce compressed air with a purity according to ISO 8573 1 classes 7 6 4 into the circuits illustrated below i e Class 7 for solid particles dimensions of solid particles 40 um concentration of solid particles lt 10mg m Class 6 for humidity dew point 10 C F Class 4 for total oil oil concentra
20. the sensor unit as described in section 8 1 3 adjust it as follows 1 do not fully tighten the sensor as careful adjustment must be performed 2 attach the tool holder cone S1 short and check that the output of S1 is ON if the output is OFF rotate the sensor unit until it turns to ON 3 the sensor 4 is eccentric with respect to the nut 3 that holds it slowly rotate the nut in the direction that moves the sensor away from the tool holder stop as soon as the output of the sensor changes to OFF 4 delicately turn the nut back by about 15 20 so that the output of the sensor returns to ON 5 manually turn the shaft and check that the signal remains ON for the entire rotation 6 tighten the fixing screw 9 7 release the tool holder pressurising the piston at the value indicated in section 4 6 ES748 and ES750 connections for air cylinder and check that in this condition collet open the S1 output is OFF 8 remove the pressure from the piston and let the collet close without tool holder in this condition the S1 output must be OFF for the entire rotation of the shaft 9 if points 7 and 8 are not verified repeat the procedure from the beginning reducing the amplitude of the rotation performed at point 4 10 if points 7 and 8 are verified perform a cycle of 10 tool changes 11 at the end of the cycle make sure the following table is met CONDITION OUTPUT S1 to
21. 1 1 7 1 1 7 3 1 7 4 1 7 4 1 1 7 4 2 1 7 4 3 THE MANUFACTURER UNDERTAKES TO TRANSMIT IN RESPONSE TO A REASONED REQUEST BY THE NATIONAL AUTHORITIES RELEVANT INFORMATION ON THE PARTLY COMPLETED MACHINERY PERSON AUTHORISED TO COMPILE THE RELEVANT TECHNICAL DOCUMENTATION NAME AND SURNAME GIUSEPPE GROSSO ADDRESS P LE ALFIO DE SIMONI SN 61122 PESARO ITALY THE MANUFACTURER STATES THAT THE PARTLY COMPLETED MACHINERY MUST NOT BE PUT INTO SERVICE UNTIL THE FINAL MACHINERY INTO WHICH IT IS TO BE INCORPORATED HAS BEEN DECLARED IN CONFORMITY WITH THE PROVISIONS OF THIS DIRECTIVE WHERE APPROPRIATE DEN FOLGENDEN WESENTLICHEN ANFORDERUNGEN ENTSPRICHT 2006 42 EG ANLAGE I 1 1 5 1 3 2 1 3 4 1 3 6 1 5 01 1 5 08 1 5 09 1 5 10 1 5 11 1 7 1 1 7 3 1 7 4 1 7 4 1 1 7 4 2 1 7 4 3 DER HERSTELLER VERPFLICHTET SICH DIE SPEZIELLEN UNTERLAGEN ZUR UNVOLLST NDIGEN MASCHINE EINZELSTAATLICHEN STELLEN AUF VERLANGEN ZU BERMITTELN F R DIE AUSSTELLUNG DER TECHNISCHEN DOKUMENTATION BERECHTIGTE PERSON VOR UND NACHNAME GIUSEPPE GROSSO ANSCHRIFT P LE ALFIO DE SIMONI SN 61122 PESARO ITALY DIE UNVOLLST NDIGE MASCHINE DARF ERST DANN IN BETRIEB GENOMMEN WERDEN WENN FESTGESTELLT WURDE DASS DIE MASCHINE IN DIE DIE UNVOLLST NDIGE MASCHINE EINGEBAUT WERDEN SOLL DEN BESTIMMUNGEN DER VORLIEGENDEN RICHTLINIE ENTSPRICHT e EST CONFORME AUX CRIT RES ESSENTIELS APPLIQUES 2006 42 EG ANNEXE I 1 1 5 1 3 2 1 3 4 1 3 6
22. 1 5 01 1 5 08 1 5 09 1 5 10 1 5 11 1 7 1 1 7 3 1 7 4 1 7 4 1 1 7 4 2 1 7 4 3 LE FABRICANT S ENGAGE EN R PONSE UNE DEMANDE AD QUATEMENT MOTIV E DES AUTORIT S NATIONALES LEUR TRANSMETTRE DES INFORMATIONS CONCERNANT LA QUASI MACHINE PERSONNE AUTORIS E CONSTITUER LA DOCUMENTATION TECHNIQUE PERTINENTE PR NOM ET NOM GIUSEPPE GROSSO ADRESSE P LE ALFIO DE SIMONI SN 61122 PESARO ITALY LE FABRICANT INTERDIT LA MISE EN SERVICE TANT QUE LA MACHINE FINALE DANS LAQUELLE ELLE DOIT TRE INCORPOR E N AURA PAS T D CLAR E CONFORME LE CAS CH ANT AUX DISPOSITIONS DE LA PR SENTE DIRECTIVE RESPETA LOS SIGUIENTES REQUISITOS ESENCIALES APLICADOS 2006 42 EG ADJUNTO I 1 1 5 1 3 2 1 3 4 1 3 6 1 5 01 1 5 08 1 5 09 1 5 10 1 5 11 1 7 1 1 7 3 1 7 4 1 7 4 1 1 7 4 2 1 7 4 3 ELFABRICANTE SE COMPROMETE A TRANSMITIR COMO RESPUESTA A UNA SOLICITUD ADECUADAMENTE MOTIVADA DE LAS AUTORIDADES NACIONALES INFORMACIONES REFERENTES A LA CASI M QUINA PERSONA AUTORIZADA A CONSTITUIR LA DOCUMENTACION TECNICA PERTINENTE NOMBRE Y APELLIDO GIUSEPPE GROSSO DIRECCI N P LE ALFIO DE SIMONI SN 61122 PESARO ITALY EL FABRICANTE PROHIBE LA PUESTA EN SERVICIO HASTA QUE LA M QUINA FINAL EN LA CUAL DEBE SER INCORPORADA NO HAYA SIDO DECLARADA CONFORME SI ES EL CASO A LAS DISPOSICIONES DE LA PRESENTE DIRECTIVA Data Date Datum Date Fecha Pesaro 25 03 2010 Procuratore Speciale FABRIZIO PIERINI
23. A 0106h00a fm051112 53 6 Use and adjustment 6 10 3 Lenord Bauer Square Wave Encoder technical specifications CHARACTERISTICS VALUE Rated power supply 5V DC 5 Operating temperature 30 C 85 C 22 F 185 F Max operating altitude 2000m 6500ft Signal input 1024 pulses per rotation zero notch Signal output TTL electrical levels compatible OV 5V line driver Lenord Bauer Square Wave Encoder Signals D T T Period D Phase displacement D T 4 AN reader A voltage level higher than the one specified 5V 5 may damage the encoder 54 HSD S p A 0106h00a fm051112 6 Use and adjustment 6 10 4 Technical characteristics of the Lenord Bauer sine encoder CHARACTERISTICS VALUE Rated power supply U 5V DC 5 Operating temperature 30 C 85 C 22 F 185 F Max operating altitude 2000m 6500ft Signal input 256 pulses per rotation zero notch AB signal output 500 mV peak to peak with average value U ref U 2 1V peak to peak as difference of signals with average value U ref see figures below AIB signal phase displacement 90 a quarter period Z signal output 500 mV peak compared with idle value U ref x80mV 1V peak as difference of signals with idle value U ref 160mV 2 34V see fi
24. LUE B GREY N WHITE N RED 24V BLACK OV BROWN THERMAL BROWN THERMAL HSD S p A 0104h00a fm051112 37 4 Installation and commissioning 4 12 3 Sensor connections Sensor unit ES748 and ES750 with air cylinder RO gt o lt 100 Sensor unit ES750 with oil cylinder AiO gt o lt 4 12 4 Analogue sensor Available as an option only with electrospindles ES750 with oil cylinder COLOUR Signal BROWN 24V BLUE OV BLACK Output 38 HSD S p A 0104h00a fm051112 5 General post installation checks 5 General post installation checks 5 1 Electrospindle pre startup checks 5 1 1 Pneumatic circuit m Thetubes of the pneumatic circuit must be of the diameter specified in section 4 6 ES748 and ES750 connections for air cylinder Introduce dried and filtered compressed air according to the specifications in the said section m forthe connections see possible labels on the product and section 4 6 ES748 and ES750 connections for air cylinder m the pressurising air must always be present even when the electrospindle is stationary check with the electrospindle stationary and the tool holder inserted that a uniform and continuous flow of air exits from the labyrinth on the spindle nose m the cone cleaning air must be present during the tool change m The progress of the tool holder cone ejection must b
25. List of spare parts 82 HSD S p A 0112h00a fm051112 12 Assistance 12 Assistance HSD spa TECHNOLOGICAL EQUIPMENT FOR AUTOMATION registered office Via della Meccanica 16 61122 PESARO ITALY Loc Chiusa di Ginestreto factory headquarters P le Alfio De Simoni sn 61122 PESARO ITALY Tel 39 0721 205 211 Fax 39 0721 205 247 E mail supporthsd hsd it www hsd it HSD Deutschland GmbH Br ckenstrasse 32 D 73037 G ppingen Tel 49 0 7161 956660 Fax 49 0 7161 9566610 E mail supporthsddeut hsddeutschland de www hsddeutschland de HSD USA inc 3764 SW 30th Avenue 33312 Fort Lauderdale Florida USA Phone no 1 954 587 1991 Fax 1 954 587 8338 E mail supporthsdusa hsd it www hsdusa com HSD S p A 0113h00a fm051112 83 12 Assistance HSD Mechatronic Shangai co Lic D2 First floor 207 Taigu road Waigaogiao Free Trade Zone 200131 Shangai China Phone no 86 215866 1236 E mail sales hsd china cn www hsd china cn 84 HSD S p A 0113h00a fm051112 13 Declaration of incorporation 3 Declaration of incorporation HSD We CE MECHATRONIC D CLARATION D INCORPORATION DIVISION DECLARACI N DE INCORPORACI N IL FABBRICANTE THE MANUFACTURER HSD S p A registered office via Della Meccanica 16 61122 Pesaro PU Italy pb epu factory headquarters p le Alfio De Simoni s n 61122 Pesaro PU Italy ne Tel 39 0721 205 211
26. S4 for HSK version only S5 if the cylinder unit is present and with a thermal alarm NAME SIGNAL INFORMATION S1 Tool holder present 2 Collet open Tool uncoupled S3 Tool is lacking or is too long S1 S4 Correct tool holder coupling S5 Piston at the upper end of stroke j Only for ES750 version with oil cylinder For HSK version only If the cylinder unit is present 1 Electrospindle version ES750 fitted with oil cylinder may also be fitted with an analogic sensor 48 HSD S p A 0106h00a fm051112 6 Use and adjustment 6 9 1 Electrospindle statuses and corresponding analogue sensor outputs Reading range 2 5 mm Power supply 14 30 VDC Output voltage 0 10 V Collet closed without tool 3 5 5 V 23 Collet closed tool coupled 2 3 5 V 23 Output voltage Tool badly coupled 1 2 2 V 23 Tool ejected 0 8 1 2 V 23 6 9 2 Technical characteristics of inductive sensors Proximity PNP type Normally Open N O Power supply voltage 10 30V DC Maximum load 100 mA No load absorption lt 17 mA Nominal reading distance 1mm S4 HSK version Proximity PNP type Normally Closed N C Power supply voltage 10 30V DC Maximum load 100 mA No load absorption lt 17 mA Nominal reading distance 1 mm 6 9 3 Status of the electrospindle and output of the inductive se
27. actice or similar action that could damage or completely destroy the product if not respected or carried out correctly i Information Highlights particularly important information of a general nature that must not be ignored 1 4 Risks associated with the use of the product The manufacturer is not aware and cannot be aware of how the product will be installed Consequently the installer or final user must perform a risk analysis relating specifically to the type of installation and the methods adopted It is nevertheless the responsibility of the installer to ensure that there is adequate protection against risks of accidental contact with moving parts The installer and user must also take into account the possible presence of other types of risk in particular that deriving from the entry of foreign bodies and the use of explosive flammable toxic or hot gases Consideration should also be given to risks inherent to maintenance operations which must be carried out under conditions of maximum safety by ensuring that the product is isolated and at a complete standstill An overall risk analysis must be carried out on the completed machine on which the manufacturer s product will be installed A conformity declaration must then be issued in line with Appendix IIA of directive 2006 42 EC and its subsequent amendments The product must not be put into service until the machine in which it has been incorporated has been made to comply w
28. adjustment operation are only authorised with the original spare parts of the manufacturer described in this section of the manual Any other type of intervention is not allowed and will invalidate the warranty HSD S p A 0108h00a fm051112 65 8 Replacing components 8 1 Replacement and adjustment of the sensor unit 8 1 1 Identification of the sensors ES748 and ES750 ES750 with air cylinder with oil cylinder 8 1 2 Description of the sensor unit The sensors are pre assembled in calibrated nuts to be easily inserted into the electrospindle at the correct depth It is therefore important to correctly identify the sensor to be replaced for this purpose both the sensors installed on the electrospindle and those supplied as spares are supplied with a numbered label figure below A The exchange of sensors damages moving parts Figure 5 Sensor unit ES748 and ES750 with air cylinder 66 HSD S p A 0108h00a fm051112 8 Replacing components Er 9 8 C D Figure 6 locking the sensor with brackets Figure 7 locking the sensor with a block ES748 and ES750 with air cylinder ES748 and ES750 with air cylinder Figure 8 Sensor unit ES750 with oil cylinder Figure 9 locking the s
29. cess from the beginning if not necessary move the sensor then make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders at the end of the cycle check that point 8 is satisfied without moving the sensor if necessary move the sensor then repeat the whole process from the beginning if itis not necessary to move the sensor then the S2 adjustment process is complete 70 HSD S p A 0108h00a fm051112 8 Replacing components 8 1 7 Adjustment of the S4 sensor only present in HSK models After having replaced the sensor as described in paragraph 8 1 3 calibrate it as follows 1 put thickness spacers of 0 15 mm and 0 18 mm between the stop surfaces of the tool holder cone and the shaft spindle as shown in the figure below Insert and lock the tool holder cone in the spindle then check that the signal from sensor S4 corresponds to that indicated in the following table SPACER OUTPUT CIIM UH INTRODUCED S4 tool holder blocked 0 15 mm ON tool holder blocked 0 18 mm OFF collet open tool holder ejected WEE Rotate the shaft manually and check that the table is verified for the entire 360 rotation if not rotate the sensor until the position necessary to obtain the output described in the table is found Fully tighten screw 9 perform a cycle of 10 tool changes at the end of the cycle check that the table shown i
30. cycles 10000 Cycles Contact interruption time lt ims Contact resistance according to MIL R 5757 lt 50 mQ Isolation voltage 2kV 6 10 Encoder 6 10 1 General description The encoder incrementally encodes the position data detected by signals A and B A negated and B negated The signals are in phase quadrature i e the signals A B A and B are offset from each other by 90 degrees The encoder also provides Zero and Zero denied signals There are two encoder models available with a different number of rotation pulses depending on the electrospindle m Square Wave from the manufacturer m Lenord Bauer Square Wave m Sine Lenord Bauer 52 HSD S p A 0106h00a fm051112 6 Use and adjustment 6 10 2 Technical characteristics of the manufacturer s rectangular encoder CHARACTERISTICS VALUE Rated power supply 12 V DC 24 V DC 10 Absorption 99 mA to 12 V DC 51 mA to 24 V DC Operating temperature 0 C 70 C 32 F 158 F Max operating altitude 2000m 6500ft Signal input 750 pulses per rotation zero notch Signal output TTL electrical levels compatible OV 5V line driver Manufacturer s Square Wa ve encoder signal T D a 5V ad dr LI w 5V BI ll LI LI 5V A rene 5V ris 5V Z NEN ov e 5V Z I ov T Period D Phase displacement D T 4 HSD S p
31. e that specified in section 6 4 1 Tool holder locking and ejection device 5 1 2 Hydraulic circuit m The liquids used must meet the specifications and instructions in section 4 9 Refrigerator 5 1 3 Electrical circuit m The earth of the product indicated in the section from 4 12 must be IN connected to the earth of the machine m The thermal cut out must activate a safety procedure to protect the electrospindle windings against overheating see section 6 9 5 Use and technical characteristics of the thermal alarm HSD S p A 0105h00a fm051112 39 5 General post installation checks 5 1 4 Inverter programming The maximum voltage set on the inverter must correspond to the rated value indicated on the motor rating plate The set frequency value at which the voltage becomes maximum rated frequency must correspond to the rated value indicated on the motor rating plate The maximum speed set on the inverter must correspond to the value indicated on the motor rating plate The maximum continuous current set on the inverter must correspond to the rated current value indicated on the motor rating plate Contact the manufacturer if it is considered necessary to check the other parameters of the inverter 40 HSD S p A 0105h00a fm051112 5 General post installation checks A First start up checks Start the electrospindle only if the sensors where present verify the following conditions s
32. eavy work as well as at the end ofthe working day and replace it with a clean tool holder at room temperature to protect the interior of the electrospindle from the external environment The tool holder to be removed may be hot Use gloves HSD S p A 0107h00a fm051112 63 7 Programmed maintenance 7 2 Biweekly maintenance 7 2 1 Tool holder cone cleaning with alcohol m For all versions Carefully clean the contact surfaces of the tool holders shown in the figure 1 and 3 with a clean and soft cloth moistened with ethyl alcohol 7 3 Bearings Do not touch the bearings as they are permanently lubricated with special high speed grease and DO NOT NEED THE PERIODIC ADDITION OF GREASE 64 HSD S p A 0107h00a fm051112 8 Replacing components p o gt gt Replacing components In order to be able to work in complete safety on an electrospindle installed on a machine refer to the machine s instruction manual The electrospindle contains a spring that has been pre loaded with a force of around one hundred kilograms This spring is applied to a screw dowel that can be violently ejected if the electrospindle is dismantled by inadequately trained personnel Only carry out the operations described in this manual Follow the instructions scrupulously and in the case of doubt contact the Manufacturer s Assistance Service Observe the maintenance safety instructions given on page 61 Replacement and
33. ed the sensor as described in paragraph 8 1 3 calibrate it as follows 1 No n a 10 11 12 13 14 15 16 act on the cylinder to bring the spindle to a collet open tool holder ejected condition supplying it with the pressure indicated in paragraph 4 6 ES748 and ES750 connections for air cylinder in these conditions position B takes on the maximum value figure 11 as shown in both figures 10 and 11 check with a depth gauge that position B of the ejector relating to the nose spindle assumes the B1 value indicated in table 1 if not do not proceed further and contact the Assistance Service of the manufacturer discharge completely the cylinder s pressure in these conditions position B takes on the minimum value feed the cylinder by means of a unidirectional pressure regulator set initially at 0 bar 0 PSI increase the pressure with 0 1 bar steps 1 5 PSI in order to make the ejector move slowly stop when position B reaches value B2 if necessary loosen the screw 9 Figure 6 locking the sensor with brackets ES748 and ES750 with air cylinder relating to sensor S2 turn the sensor S2 until the position in which the signal ON with B gt B2 and OFF with B B2 is found Fully tighten screw 9 perform a cycle of 10 tool changes at the end of the cycle check that point 8 is satisfied without moving the sensor if necessary move the sensor then repeat the whole pro
34. ensor with bracket ES750 with oil cylinder 1 Electric connector 6 Calibrated position 2 Eccentricity marking 7 Bracket and block 3 Pre inserted nut 8 Sensor unit 4 Sensor 9 Screw 5 Eccentricity between the nut and sensor for adjustment 8 1 3 Replacing and regulating the sensor group For the replacement and adjustment of the sensors illustrated in this and subsequent paragraphs refer to figures 5 and 6 or 8 and 9 of the previous paragraph 5 remove the screw 9 that blocks the bracket or block 7 of the sensor unit 8 to replace 6 remove the defective sensor unit from its seat and disconnect its electrical connector 1 7 connectthe electrical connector of the new sensor unit with the corresponding numbered connector on the spindle 8 verify the functionality of the new sensor by placing the end in contact with a metal object 9 insert the new sensor unit in the empty seat HSD S p A 0108h00a fm051112 67 Replacing components 10 11 12 8 reposition the bracket 7 and tighten the screw 9 but not fully so that the sensor unit can rotate rotate the sensor unit by a few degrees or few mm at a time until the outputs required in the following paragraphs are obtained tighten the screw 9 holding the sensor unit with a fixed wrench in order to keep the calibration performed 1 4 Adjusting sensor S1 After having replaced
35. essure or pneumatic circuit inefficient m Check the required pressure values in section 4 4 Specifications for the compressed air supplied to the manufacturer s products m Check the integrity and efficiency of the pneumatic circuit m Contact the manufacturer s assistance service One of the sensors does not supply the required output Sensor disconnected or faulty m Check the connectors m Checkthe integrity and continuity of the electrical connections m Regulate the sensor as described in section 8 1 Replacement and adjustment of the sensor unit m Replace the defective sensor as described in section 8 1 Replacement and adjustment of the sensor unit 78 HSD S p A 0110h00a fm051112 10 Troubleshooting Problems Cause Remedy Insufficient cooling m Check the specifications of the system at paragraph 4 9 Refrigerator m Check the integrity and efficiency of the cooling circuit The electrospindle Machinin l u overheats edm m Lighten the machining Me vari m Check the parameters on the plate of the arameters are electrospindle and in chapter 2 Technical as Specifications in the paragraphs related i to the actual model The inverter m Check the parameters on the plate of the Performance lower arameters Are electrospindle and in chapter 2 Technical than specifications sr Specifications in the paragraphs related to the ac
36. etter balancing G 0 4 balance quality ss grade indicates maximum balancing precision G assumes discrete values in multiples of 2 5 G 0 4 G 1 G 2 5 Rated voltage Maximum power supply voltage Rated frequency Minimum frequency at which the maximum power supply voltage is provided Rated characteristics The set of nominal values reached at rated frequency Service type S1 Operation at constant load with a duration sufficient to ensure that the motor reaches thermal equilibrium Abbreviated to S1 Standard CEI EN 60034 1 Service type S6 sequence of identical operating cycles each consisting of a period of operation at constant load and a period of operation with no load with constant rpm and without any intermediate rest times Abbreviated to S6 followed by the percentage ratio between the period of operation under load and the duration of one cycle For example S6 40 40 operating time under load 60 operating time without load standard CEI EN 60034 1 HSD S p A 0101h00a fm051112 11 1 Preliminary information Torque and power C torque C Nm 60xW W power 2xnxrpm rpm revolutions per minute The precise definition of torque and power is beyond the scope of this manual Nevertheless it can be said that torque is the force with which the tool bites into the work piece and for the same torque the force increases as the dia
37. gures below HSD S p A 0106h00a fm051112 95 6 Use and adjustment Temporal flow of signal A 2 75 2 5 2 25 VV 2 75 2 5 2 25 JUN NEN 3 25 2 75 4 2 5 a 2 25 4 1 75 J A diff A A AVV 56 HSD S p A 0106h00a fm051112 6 Use and adjustment Temporal flow of signal B 2 75 4 2 5 4 2 25 2 75 4 2 5 4 2 25 B diff B B 3 25 4 2 75 2 5 4 2 25 4 1 75 J HSD S p A 0106h00a fm051112 57 6 Use and adjustment Temporal flow of signal Z 2 75 2 5 4 2 25 2 75 4 2 5 4 2 25 Z diff Z Z 3 5 4 2 5 1 75 58 HSD S p A 0106h00a fm051112 6 Use and adjustment Displacement of signals A and B 2 75 2 5 B 2 25 Displacement of signals A and B negated 2 75 4 2 5 4 2 25 4 HSD S p A 0106h00a fm051112 59 6 Use and adjustment Temporal flow of differential signals 3 5 4 ft B diff A diff 2 diff 1 75 T Period D Phase displacement D T
38. h temperatures and as such must N To perform the preheat it is necessary to insert a tool holder WITHOUT a tool HSD S p A 0106h00a fm051112 43 6 Use and adjustment 6 4 Collet 6 4 1 Tool holder locking and ejection device The tool holder is locked mechanically by means of elastic springs that develop an axial force equal to ELECTROSPINDLE MODEL AXIAL FORCE OF THE SPRING AXIAL FORCE ON THE TOOL HOLDER ISO 50 9900 N 10 9900 N 10 HSK B100 9800 N 10 28000 N 10 The tool holder locking and ejection are activated by the movement of a double acting compressed air piston with a pressure of 10 6 5 Tool holder cone m The geometry of the taper of the cones must comply with norm DIN69893 m The geometry of the taper of the cones has to reflect the standard DIN69871 m Avoid the presence of inserts slots or other forms that could disturb the dynamic balance of the tool holder m The dynamic balance quality grade must be G 2 5 or better standard 1501940 m The balancing is carried out with the tool holder assembled cone spring collet ring nut tool IN It is forbidden to use tool holders that do not comply with the above conditions Non compliance with these instructions can lead to a risk of breakage or an imperfect coupling of the tool holder cone with the resulting risks for the user A NOTE In the ISO tool ho
39. imultaneously gt gt E Sensor 1 ON Tool holder cone present Sensor 2 OFF Collet closed Sensor S1 S4 ON Tool holder cone inserted and in contact with the HSK versions only HSK surface Sensor 5 ON Piston in safety The sensor ON condition corresponds to an output of 24 V I The sensor OFF condition corresponds to an output of 0 V With ES750 fitted with oil cylinder only start up the electrospindle if the sensors indicate that the tool is connected see the table in paragraph 6 9 Sensors The electrospindle must not be started without the tool holder inserted The cylinder of the spindle is double acting the cylinder must be kept under pressure to hold the piston on the upper limit switch away from fast rotating parts The safety condition is indicated by the output ON of sensor S5 The control sensors must intervene according to the logic described in paragraph 6 9 Sensors The tool change cycle must only take place with the shaft stopped m with the tool holder inserted and without performing machining operations perform the preheating cycle described in paragraph 6 3 HSD S p A 0105h00a fm051112 41 5 General post installation checks 42 HSD S p A 0105h00a fm051112 6 Use and adjustment 6 Use and adjustment 6 1 Environmental conditions The manufacturer has tested and verified its electrospindles according to environmental
40. inder is fitted with sensor S3 instead of sensor S5 If sensor S3 is ON then the tool is lacking or is too long m Sensor S3 Lacking tool or too long tool signal The signal from sensor S3 indicates the lacking of the tool in the closed collet or indicates a too long tool in the cone out of tolerance If the shaft starts running this will ruin the collet and could break and release some parts of the electrospindle HSD S p A 0106h00a fm051112 51 6 Use and adjustment 6 9 5 Use and technical characteristics of the thermal alarm The electrospindle is fitted with a normally closed bimetallic strip switch inserted in the electric windings of the stator which opens when a temperature that may damage the windings is reached The contacts re close when the temperature reduces and returns to the safe values The thermal alarm must be connected to the Numerical Control which should interrupt the machining operation and stop the rotation of the spindle shaft if the switch opens If the shaft stops while the tool is still being pushed against the piece being machined the spindle bearings may break If the tool is not immediately moved away from the piece and the rotation stopped there is a risk of burning out the stator For the bimetallic strip switch connection see section 4 12 Electrical connections Technical characteristics of the bimetallic strip Power supply 48 V DC MAX Current 1 6 A MAX Switching
41. ions sse nennen 43 6 2 a In IL INRA cies setackes fetch rar ti st Arr E 43 6 3 LUE LUE s cesse tierce tee EN LT en e Tee dodo 43 6 4 CORRE pa en UA RU METRE 44 6 5 Tool holder Cone aic e RP ete ei etit e ien drei eins 44 6 6 d 45 6 7 Fluids diStriDUtOF ss 0 irr ar Enns n IER RED te 46 6 8 Procedure to follow if the tool becomes jammed in the piece being machined 4T 6 9 NISI ARRIERE ILLO IL 48 0 10 Encode dun dade iste tiri ee GR o nen aa 52 Programmed maintenance 7 1 Daily maintenance eil 62 7 2 Biweekly maintenance TE 64 7 3 A are ne ee A A ce 64 Replacing components 8 1 Replacement and adjustment of the sensor unit 66 Disposal of the product Troubleshooting List of spare parts Assistance Declaration of incorporation HSD S p A H5801H0083TOC fm051112 1 Preliminary information 1 Preliminary information 1 1 Documents supplied with the product The following documents are supplied together with the product m Declaration of incorporation as provided for by Appendix IIB of Directive 2006 42 EC m Product test certificate m This manual containing warnings and instructions for the transport installation use maintenance and disposal of the product li Check that all the documents listed above are present on delivery of the product If necessary further copies can be obtained on request from the manufacturer 1 2 Scope of the manual The manual forms an in
42. it as follows 1 donot fully tighten the sensor as careful adjustment must be performed 2 attach the tool holder cone S1 long and check that the output of S3 is ON if the output is OFF move the sensor unit towards the spindle s nose until it turns to ON 3 move the socket in the tool holder opposite direction and stop when the output is OFF 4 delicately move forwards the socket by a few mm at a time so that the output of the sensor returns to ON 5 manually turn the shaft and check that the signal remains ON for the entire rotation 6 tighten the fixing screw 9 7 release the tool holder pressurising the piston at the value indicated in section 4 9 Refrigerator and check that in this condition collet open the S1 output is OFF 8 remove the pressure from the piston and let the collet close without tool holder in this condition the S3 output must be ON for the entire rotation of the shaft 9 if points 7 and 8 are not verified repeat the procedure from the beginning reducing the amplitude of the movement performed at point 4 10 if points 7 and 8 are verified perform a cycle of 10 tool changes 11 at the end of the cycle make sure the following table is met CONDITION OUTPUT S1 tool holder blocked oo holder DIOCKe ON x no tool holder i with collet closed ON collet open tool holder ejected OFF for the entire rotation of the shaft 12 13 14
43. ith the requirements of Directive 2006 42 EC and its subsequent amendments 1 4 1 Risks associated with improper handling and or use It is absolutely forbidden to bypass remove modify or render inoperative any safety devices controls or guards protecting individual parts or the product as a whole m Never place hands arms or any other parts of the body near to moving parts m The product must not be used in environments where there is an explosion risk m The elimination of faults or anomalies in the operation of the product or modifications to the type of operation or installation must not be carried out by unauthorised personnel 8 HSD S p A 0101h00a fm051112 1 Preliminary information m On completion of any extraordinary maintenance involving the removal of guards barriers or other safety devices these must be replaced before starting the product making sure that they are positioned correctly and in full working order m All guards and safety devices must be maintained efficient and in perfect condition Warning and danger signs and symbols must be clearly legible and must never be removed m When performing troubleshooting operation on the product take all the necessary precautions described in the Instruction Manual to prevent damage or injury m Remember to tighten all screws nuts and locking rings of each mechanical component that has been adjusted or set up m Before starting the product make sure that al
44. ition the output of S5 is ON free the piston at the upper end of stroke return air inlet of the cylinder feed the tool holder expulsion air inlet of the cylinder by means of a unidirectional pressure regulator set initially at O bar 0 PSI increase the supply pressure in increments of 0 1 bar 1 5 psi and simultaneously turn the shaft by hand to check that it rotates freely and is not being held back by friction with the piston when the S5 output is OFF the manual rotation of the shaft must still be completely free if the cylinder rubs against the shaft when the sensor S5 is ON this means that the sensor has been advanced too much at the point 6 of this procedure repeat the entire procedure performing a finer advance at the point 6 if point 14 of the procedure is satisfied perform 50 tool eject return to upper end of stroke cycles check the calibration by repeating steps from 9 to 16 of this procedure four times 8 1 9 Adjustment of the sensors for ES750 with oil cylinder Unlike the standard electrospindles the sensors for version ES750 with oil cylinder are fitted with a socket that allows them to be adjusted by moving along the spindle axis The adjustment of both sensors S1 and S2 are performed the same way 72 HSD S p A 0108h00a fm051112 8 Replacing components 8 1 10 Adjusting sensor S3 After having replaced the sensor unit as described in section 8 1 3 adjust
45. l the safety devices are installed and in perfect working order If this is not the case under no circumstances must the product be started instead inform the works safety manager or the department head m The operator must be provided with Personal Protection Equipment PPE as provided for by current legislation Loose bulky clothing and accessories ties wide sleeves etc must not be worn 1 4 2 Risks specific to product maintenance N In order to be able to work in complete safety on a product already installed on a machine refer to the machine s instruction manual m Isolate the product from the mains power supply before proceeding with any maintenance operations m Even though the product has been disconnected from the mains power supply the rotating and mobile parts may still be in motion due to inertia Therefore prior to carrying out any maintenance operations make sure that the rotating and mobile parts of the product are stationary 1 4 3 Residual risks The product has been analysed in compliance with Directive 2006 42 EC in order to identify possible risk sources The risks that remain residual risks and the relative countermeasures are highlighted in the relative sections of this manual HSD S p A 0101h00a fm051112 9 1 Preliminary information 1 5 Product Information 1 5 1 Purpose of the product The product cannot function on its own itis a machine component designed to be assembled with other
46. lders the tenons positions does not comply with norm DIN69871 For further information refer to the spindle drawing 44 HSD S p A 0106h00a fm051112 6 Use and adjustment 6 5 1 General recommendations regarding tool holder cones A IMPORTANT The choice of tool holder is a determining factor as regards safety The tapered surfaces of the tool holder and its housing on the spindle shaft must be kept extremely clean to allow safe coupling see section 7 Programmed maintenance During machining operations avoid all contact whatsoever between the non cutting rotating parts and the piece being machined The tool holder cone seating must always be protected against the entry of impurities use a Suitable plug or a tool holder cone At the end of the working day always remove the tool holder cone from the electrospindle to avoid sticking Close the tool holder housing using a clean tool holder cone at ambient temperature Do not rotate the electrospindle without a tool holder inserted Rotating the electrospindle without a tool holder will upset the balance and operation of the HSK collet The tool holder must be introduced until in contact with the nucleus of the collet 6 6 Tool The tools must have a dynamic balance grade of G 2 5 or greater standard 1501940 THE TOOL MANUFACTURER 1 RESPECT THE MAXIMUM REVOLUTIONS PER MINUTE rpm INDICATED BY Depending on the type and quality of the machining
47. machine parts or incorporated in machinery in order to constitute a machine as provided for by Directive 2006 42 EC The product must not be put into service until the machine in which it has been incorporated has been made to comply with the requirements of Directive 2006 42 EC and its subsequent amendments 1 5 2 Identification of the product and manufacturer The serial number represents the only means recognised by the manufacturer of identifying the product The product user is responsible for ensuring that the serial number remains intact The position of the product serial number is shown in chapter 2 Technical Specifications li An adhesive is applied to the product bearing the address of the registered offices of the manufacturer 1 0 HSD S p A 0101h00a fm051112 1 Preliminary information 1 6 Glossary Tool holder cone locking system as described in standard DIN 69871 Bec ISO A plate similar to that shown alongside is fixed to the CONE ISO DIN 69871 SCREW electrospindle to indicate the DOWEL type of locking system FNAG051082 T Tool holder cone connection system described in standard DIN 69893 PISIS The electrospindle carries a plate similar to the one shown alongside indicating the type of HSK DIN 69893 CONE connection Dynamic The balance quality of a rotating object according to standard ISO 1940 1 indicated by the letter G Low G values indicate b
48. meter of the tool decreases Power instead is proportional to the torque and speed of rotation and as such determines the maximum machining speed in line with tool performance characteristics of the material being machined and the type of machining Coolant Fluid liquid or gas including air used to transfer heat from the spindle to the environment Scheduled maintenance A series of activities required to maintain the condition and operation of the product the same as that provided for by the manufacturer at the moment of its introduction onto the market The maintenance is carried out by means of programmed adjustments repairs part replacements etc 1 7 Warranty For information about the warranty please refer to the documentation issued on purchase of the machine 12 HSD S p A 0101h00a fm051112 2 Technical Specifications 2 Technical Specifications 2 1 1 Front flange 7 Sensors 13 Cylinder 2 8fixing holes 212 5 8 Pneumatic connectors 14 Spiral casing 3 Nose 9 EC plate 15 Fixing surface 4 PESSSUNSANON 10 Serial number labyrinth 5 ISO coupling 11 Passage of power cables with connector 6 ANAS M TENO 12 Sensor connectors extraction HSD S p A 0102h00a fm051112 1 3 2 Technical Specifications 2 2 Description of main parts ES750 2 2 1 Air piston version
49. n point 2 has been satisfied for the entire 360 rotation of the shaft Otherwise repeat the procedure from the start if the table is verified make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders at the end of the cycle check that the table shown in point 2 has been satisfied for the entire 360 rotation of the shaft Otherwise repeat the procedure from the start if the table in point 2 is satisfied the calibration of S4 is complete HSD S p A 0108h00a fm051112 71 8 Replacing components 8 1 8 Adjusting sensor S5 After having replaced the sensor as described in paragraph 8 1 3 calibrate it as follows 1 2 3 e o o N 9 10 11 12 13 14 15 16 17 attach a tool holder properly before proceeding with the calibration of the sensor supply 6 bar 87 PSI to the cylinder to keep the piston at the upper limit switch position the sensor in the highest position allowed by the movement 5 high opposite direction to the tool holder verify that in this condition the output of S5 is OFF slowly move the sensor downwards until the position needed for S5 output to be ON is found move the sensor a little further downwards lock the position of the sensor by tightening the screw 9 perform 10 tool eject back to upper limit switch cycles move the piston to the upper limit switch verify that in this cond
50. ne the numerical control and the inverter that is connected to the electrospindle HSD S p A 0110h00a fm051112 TT 10 Troubleshooting Problems Cause Remedy The tool holder does not couple Foreign bodies between the tool holder and shaft spindle m Remove the macroscopic impurities and clean as described in section 7 Programmed maintenance The tool holder cone is not the correct type m Choose a tool holder according to the indications described in section 6 5 Tool holder cone The collet does not open due to insufficient pressure m Check the required pressure values in section 4 4 Specifications for the compressed air supplied to the manufacturer s products m Check the integrity and efficiency of the pneumatic circuit Sensor S2 is disconnected or faulty m Check the connectors m Checkthe integrity and continuity of the electrical connections m Regulate the sensor as described in section 8 1 Replacement and adjustment of the sensor unit m Replace the defective sensor as described in section 8 1 Replacement and adjustment of the sensor unit The tool holder does not eject Insufficient pressure m Check the required pressure values in section 4 4 Specifications for the compressed air supplied to the manufacturer s products m Check the integrity and efficiency of the pneumatic circuit No pressurisation Insufficient pr
51. nsors S1 S2 S5 Collet open tool holder cone ejected SER SH OFF Tool holder cone locked correctly ON OFF ON Collet closed but with no tool holder cone OFF OFF ON according to the operational status of the machine HSD S p A 0106h00a fm051112 49 6 Use and adjustment HSK B100 1 S2 S1 S4 S5 Collet open tool holder cone ejected OFF an OFF OFF Tool holder cone locked correctly ON OFF ON ON Collet closed but with no tool holder cone OFF OFF OFF ON s according to the operational status of the machine ES750 with oil cylinder Status S1 S2 S3 Tool released OFF ON OFF No tool holder ON OFF ON Tool holder connected ON OFF OFF Tool holder badly connected case 1 tool too ON OFF ON long Tool holder badly connected case 2 tool too OFF OFF OFF short Tool holder present but not correctly locked This situation is indicated by the output N 1 S1 S4 ON OFF This condition is dangerous ifit is detected stop the rotation or the tool change procedure inspect the machine and remove the cause preventing the tool holder from coupling correctly The electrospindle shaft can only rotate in the too holder cone correctly A locked state If outputs S1 S4 and S5 change to OFF stop the rotation of the electrospindle shaft 50 HSD S p A 0106h00a fm051112 6 Use and adjustment
52. ol holder blocked ON no tool holder with collet closed OFF collet open tool holder ejected OFF for the entire rotation of the shaft 12 if the table is not verified repeat the procedure from the beginning 68 HSD S p A 0108h00a fm051112 8 Replacing components 13 14 if the table is verified make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders at the end of the cycle check that the table at point 11 is satisfied if so the adjustment procedure of S1 is finished if not repeat the procedure from the beginning 8 1 5 Adjustment of sensor S2 for ISO models After having replaced the sensor as described in paragraph 8 1 3 calibrate it as follows 1 2 10 11 12 13 14 15 attach a tool holder properly before proceeding with the calibration of the sensor check that the output of S2 is OFF if the output is ON rotate the sensor unit until it turns to OFF feed the cylinder by means of a unidirectional pressure regulator set initially at O bar 0 PSI increase the feed pressure in increments of 0 1 bar 1 5 PSI to slowly advance the piston and at the same time check that the output of S2 is OFF as long as the tool holder is firmly blocked the S2 output must be OFF if the output changes during the advance of the piston rotate the sensor unit slightly until the output returns
53. ons 2 eae 4800 litres hourO 1 Pressurisation air 80 I min 10 consumption 2 8 cfm volume with P 4 bar 58 PSI and T 20 C 68 F 32 HSD S p A 0104h00a fm051112 4 Installation and commissioning 49 Refrigerator The manufacturer recommends the use of demineralized water for the cooling system with the addition of 1096 ethylene glycol and anti corrosion additives to ensure the smooth operation of the circuit and the motor The gaskets isolating the cooling circuits inside the electrospindle are made of NBR use additives that do not degrade this material On request the manufacturer supplies ARTIC FLU 5 code H2161H0022 which is a pre mixed ready to use liquid coolant tried and tested by himself The product contains monoethylene glycol and eco friendly corrosion inhibitors without amines nitrates and phosphates and can guarantee protection against corrosion for approximately 1 year ARTIC FLU 5 prevents the formation of rust scale and foam deposits as well as hardening cracking and swelling of seals and couplings The coolant complies with various international standards including CUNA NC 956 16 4 9 1 Cooler specifications m 3400 W ES748 m 5200 W ES750 Minimum flow 5 litres minute Cooling capacity Demineralized water 10 Ethylene Glycol corrosion inhibitor Cooler set temperature 25 3 C 77 5 F Coolant type
54. operation to be performed and the material used it is the users responsibility to operate at lower speeds NEVER HIGHER than those specified by the tool manufacturer When selecting the tool to use the following recommendations must be taken into consideration Always use tools with optimum sharpness qualities and correctly tightened in the relative tool holder Never use deformed or damaged tools or those with missing parts or not perfectly balanced Always make sure that all the surfaces are unmarked and perfectly clean before inserting the tool in the relative collet The essential requisites for using high speed tools are compact short and light tools precise with any inserts correctly fitted with a high degree of safety balanced and symmetrically coupled with the tool holder With cutting edges near to the rotation axis HSD S p A 0106h00a fm051112 45 6 Use and adjustment 6 7 Fluids distributor As an option the electrospindle can be fitted with a rotating distributor for internal tool cooling purposes The cooling is performed with the aid of cooling liquids This option is only available for the ES750 electrospindle fitted with oil cylinder The hydraulic connection points are illustrated in section 4 9 The standard distributor must have the following characteristics Characteristics Minimum pressure 5 bar Maximum pressure 80 bar Cooling liquid filtering degree 50 um
55. ported in the documents accompanying the product 3 3 Transport and packing conditions The product is shipped protected by a VCI plastic wrapping and expanded foam and packed in a wooden case or in a special cardboard box The following figure illustrates methods that can be used to lift the case using cables and a forklift In the case of a forklift make sure that the centre of gravity of the case is between the forks when lifting HSD S p A 0103h00a fm051112 21 3 Transport packing unpacking storage The examples shown are for information purposes only in that it is not possible for the manufacturer to determine all the possible configurations for lifting its products beforehand 3 4 Unpacking AN Prior to opening the packing make sure that the seals are still intact If the product is delivered in a wooden case insert a screwdriver under the fastener Use the screwdriver as a lever taking care not to damage the case or its contents If the product is packed in a cardboard box remove the strips of adhesive tape taking care not to damage the box or its contents I The expanded foam and plastic wrapping must be disposed of as plastic material 22 HSD S p A 0103h00a fm051112 3 Transport packing unpacking storage 3 5 Storage If the product is to be placed in storage it must be protected against weather humidity dust and aggressive atmospheric and environmental agents It is the
56. quency Hz 133 267 533 800 Rated speed rpm 2000 4000 8000 12000 Duty type 1 S6 S1 S6 S1 S6 S1 S6 cont 40 cont 40 cont 40 cont 40 Rated power kW 20 24 17 20 12 14 8 8 Rated torque Nm 95 4 114 5 40 5 47 7 14 8 16 7 64 64 Rated current A 45 54 30 40 25 32 20 20 Rated efficiency n 0 8 Power factor cos o 0 8 Number of poles 8 Insulation class Class IP 54 Cooling type Liquid cooling Weight kg 105 e The maximum rated current S1 cont is used to set the maximum continuous I current parameter of the inverter 1 6 HSD S p A 0102h00a fm051112 2 Technical Specifications Parameters of the equivalent electrical network Description NL Um Value Nominal power S1 kW 20 Nominal current S1 A 45 Nominal line voltage V 380 Nominal speed at nominal load rpm 1995 Rated frequency Hz 133 No load line voltage V 366 No load current A 26 3 Stator resistance 20 C Q 0 206 Rotor resistance 20 C Q 0 138 Stator dispersion reactance Q 0 682 Stator dispersion inductance mH 0 82 Rotor dispersion reactance Q 0 32 Rotor dispersion inductance mH 0 38 Main field reactance Q 0 901 Main field inductance mH 1 08 Field weakening start speed rpm 2000 Maximum motor speed rpm 12000 Power factor 0 80 Rotor moment of inertia Kg m 6 57E 02 Connection YorD Y HSD S p A 0102h00a fm051112 17 2 Technical Specifications
57. refore necessary to m carry out periodic checks to ascertain the general storage condition of the product m Manually rotate the shaft approximately once a month to make sure that the bearings remain perfectly greased STORAGE TEMPERATURE from 5 C 41 F to 55 C 131 F RELATIVE HUMIDITY WITHOUT CONDENSATION from 5 to 55 HSD S p A 0103h00a fm051112 23 3 Transport packing unpacking storage 24 HSD S p A 0103h00a fm051112 4 installation and commissioning 4 Installation and commissioning 41 Preliminary installation checks Before carrying out any operations MAKE SURE m that no part of the electrospindle has been damaged by impact or any other cause during transport and or handling m that the connectors are undamaged 4 2 Preparing the factory services It is the responsibility of the customer to ensure the availability of the factory services e g electricity supply compressed air supply etc The electricity supply line of the electrospindle must have a sufficient power rating The connection to the mains electricity supply must be carried out by a qualified electrician as far as the connectors The user must guarantee all the safety conditions necessary for earthing the electrospindle The earthing system must comply with current standards in the country of installation and must be checked regularly by qualified personnel The customer is responsible for the entire power
58. supply system to the product HSD S p A 0104h00a fm051112 25 4 Installation and commissioning 4 3 Mechanical connections The load bearing structure on which the product is to be mounted must be sufficiently rigid to support the weight and type of machining to be carried out 4 3 1 Fixing structure for spindles with round casing AN The fixing structure to which the spindle is fixed must have a flatness of less than 0 015 mm and a perpendicularity to the axis of the spindle of less than 0 015 mm 70 015 A 0015 yo _ Fixing structure of the electrospindle N Electrospindle 26 HSD S p A 0104h00a fm051112 4 Installation and commissioning 4 3 2 Tool change system The tool holder magazine has to position the cones with the following accuracy both ISO and HSK concentricity between the spindle shaft and tool holder cone 1 0 2 mm HSK only perpendicolarity between the spindle shaft and the tool holder contact surface 0 1 mm 1 Spindle shaft ISO Tool holder cone ISO HSK spindle shaft AJOJN 01 HSK tool holder cone 44 Specifications for the compressed air supplied to the
59. tegral part of the product and as such must accompany it at all times otherwise the product will be lacking in one of its primary safety requirements The manual must be well taken care of distributed and made available to all personnel involved The purpose of the warnings contained in the manual is to safeguard the health and safety of personnel exposed to residual risks The manual provides information on the most appropriate behaviour to adopt for the correct use of the product as provided for by the manufacturer In the case where the information contained in the manual conflicts with health and safety standards contact the manufacturer to request the necessary corrections and or adaptations In order to prevent incorrect operation that could constitute a hazard for personnel and or cause damage to the product all the documents supplied with the product must be read and fully understood The manual must be stored in an appropriate location and must always be readily available for consultation i The information contained in the manual is indispensable for using the product in a safe and correct manner for the purposes for which it has been designed HSD S p A 0101h00a fm051112 7 1 Preliminary information 1 3 Symbols used in the manual Danger Indicates a procedure practice or similar action that could cause injury if not respected or carried out correctly A Caution Indicates an operating procedure pr
60. th protruding parts m During the various maintenance phases it is advisable to delimit the machine and identify it with a sign indicating MACHINE UNDER MAINTENANCE During all maintenance operations make sure that the electrospindle m is disconnected from the electricity supply m and that the tool is absolutely stationary not rotating The maintenance manager must make use of a well co ordinated team of personnel capable of guaranteeing the absolute safety of anyone exposed to possible hazardous situations All personnel taking part in the maintenance operations must be in full visual contact with each other in order to be able to signal any dangers that may arise HSD S p A 0107h00a fm051112 61 7 Programmed maintenance 7 1 Daily maintenance 7 1 1 Control and cleaning of the tool holder seat and tool holder cone The surfaces of contact between tool holder and tool holder seat must be kept clean to ensure a secure coupling At the beginning of the working day make sure that the surfaces highlighted in the figures from 1 to 4 are clean and free of dust grease coolant oil metal particles or machining waste as well as free of traces of oxide or scale if necessary clean with a clean and soft cloth Figure 1 ISO tool holder Figure 3 HSK tool holder Figure 2 4 nical ISO tool holder housing 1 Conica surfaces in black 2 Contact surfaces in grey HSK only
61. the locking system collet screw dowel with it until the cone is released After which the collet will move back violently due to the force exerted by the spring and could cause damage to the screw dowel HSD S p A 0106h00a fm051112 47 6 Use and adjustment 1 2 3 G N Description 1 ISO cone 2 Spindle shaft UTENSILE BLOCCATO P 3 ISO Collet or nut gt 4 Screw dowel The arrows indicate the direction in which the locking system SS NI UTENSILE RILASCIATO returns after having NNNSSSSNNSNSSNNSNNSNSNNSNNNN freed the cone Point at which the TULILILTCILILTCTLI T 5 collet will hit the shaft IMPATTO 6 Screw dowel breakage SS 3 S N N N Z Z Z 7 NIIT E SJ N TI DANS SSAA MEARNS 6 9 Sensors The electrospindles are fitted with inductive sensors for monitoring S1 S2 S3 version ES750 with oil cylinder only
62. tion 5 mg m m Atthe end of the working day discharge the compressed air system to allow the filters to drain automatically m Perform regular maintenance on the filters in line with the manufacturer s instructions and replace them when they become saturated and less efficient approximately every 6 12 months 4 1 Main compressed air supply Y o Pre filter 5 um Oil separator filter 0 1 pm Bon To the manufacturer s product 28 HSD S p A 0104h00a fm051112 4 Installation and commissioning 45 Example diagrams for pneumatic circuits by the customer 4 5 1 Actuation of the tool change piston air actuation l Optional 2 J 5 x _ 4 u 0 SW amp 9 e OR amp Q af Tus B G FA 4 G L 11 9 Z E 8 1 6 bar mains supply pressure 7 monostable 5 2 valve with electro pneumatic control and spring return 2 airmultiplier 2 1 8 unidirectional flow regulator to adjust the locking impulse 3 pre filter 5 um 9 oylinder for the tool change 4 oil separator filter 0 1 um 10 Tool release air inlet 5 pressure regulator min 6 bar 11 Piston at the upper end of stroke return air max 10 bar inlet 6 pneumatic tank Tank volume 0 4 useful volume 0 28 AN The cylinder of this electrospindle is double acting the cylinder must be
63. to OFF when the tool holder begins to loosen but is not yet free to fall the S2 output must still remain OFF if necessary rotate the sensor unit when the supply pressure at which the tool holder is finally free to fall is reached increase the pressure further by 0 2 bar 3 psi and block the pressure regulator rotate the sensor unit so that in this condition the S2 output is ON perform a cycle of 10 tool changes atthe end of the cycle check that steps 1 to 8 have been verified without having to rotate the sensor if the requested output have not been verified repeat the entire procedure from the beginning if the requested output are verified make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders atthe end of the cycle check that steps 1 to 8 have been verified without having to rotate the sensor if the requested output have not been verified repeat the entire procedure from the beginning if the requested output have verified the adjustment procedure of S2 is finished HSD S p A 0108h00a fm051112 69 8 Replacing components 8 1 6 Adjustment of sensor S2 for HSK models Table 1 B values B1 B2 HSK E25 6 5 6 35 HSK E40 F50 8 5 8 35 HSK F63 10 5 10 3 HSK A63 B80 10 5 10 3 Figure 10 Figure 11 A ejector ejector position B reference position 0 1 mm After having replac
64. tual model Electrospindle vibrates The tool holder is not balanced m Choose a tool holder according to the indications described in section 6 5 Tool holder cone The tool is not balanced m Choose and use the tool as shown in section 6 6 Tool Dirt between the tool holder cone and shaft spindle m Remove the macroscopic impurities and clean as described in section 7 Programmed maintenance m Check the parameters on the plate of the Ubi electrospindle and in chapter 2 Technical so Specifications in the paragraphs related to the actual model di m Lighten the machining Electrospindle vibrates Fixing screws loose m Tighten the fixing screws Bearings damaged m Contact the manufacturer s assistance service Bearings noisy Bearings damaged m Contact the manufacturer s assistance service HSD S p A 0110h00a fm051112 79 10 Troubleshooting 80 HSD S p A 0110h00a fm051112 11 List of spare parts 11 List of spare parts Manufacturer code Description H3811H1242 Calibration sensor gauges H5664H0062 Inductive sensor S1 H5664H0063 Inductive sensor ES750 with oil cylinder H5664H0040 Inductive sensor 2138A0547 Sensor plug connectors 2138A0548 Sensor plug connectors 90 2138A0326 17 pin female connectors Encoder HSD S p A 0112h00a fm051112 81 11
65. wards orientated even when the machine moves the electrospindle figures below m Tilt the electrospindle towards the drainage holes side figure below DPC 34 HSD S p A 0104h00a fm051112 4 Installation and commissioning 4 10 2 Tool external cooling The water to be used to externally cool the tool must comply with the below characteristics m aggressive index A l 11 12 m Electric conductibility no greater than 600 microS cm m Turbidity not higher than 20 mg l m Chlorides no greater than 300mg l Only with an accurate analysis is it possible to establish whether the water used for the machining operation falls within the required parameters Do not use additives with sodium chloride NaCl as they provoke corrosion N rust 4 11 Example diagram of the cone s cleaning circuit Air inlet 4 bar Water inlet for the tool To be connected to the tool coolant cone cleaning inlet The diagram in the figure represents a possible example of the pneumatic circuit for the automatic cleaning of the cone During the tool change the water supply is interrupted and replaced by pressurised air which removes any particles The jet of compressed air must be on until the collet remains open The control and regular cleaning of the cone is imperative as described in

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