HSD ES327 Assembly Instructions Manual Download Page 52

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4 Installation and commissioning

HSD S.p.A. © - 0104h03a.fm100713

4.6.2

Pneumatic connection points

Figure 1: Pneumatic connection points

ES327

Liquid ES330

Air ES330

ES331

ES332

ES370

Tool locking air inlet (piston return)

6 bar - 87 PSI

Air inlet for tool release and cone cleaning

6 bar - 87 PSI

Pressurisation air inlet

0.5 bar - 7.2 PSI

Air inlet for tool release (ES327 only)

6 bar - 87 PSI

Air inlet for pressurisation and cone cleaning (ES331 only)

1 bar - 14 PSI

Air inlet for cone cleaning (ES332 only)

4 bar - 58 PSI

Summary of Contents for ES327

Page 1: ...D M E C H A T R O N I C S O L U T I O N S Translation of the original instructions ENGLISH Serial number ES327 ES330 ES331 ES332 ES370 Electrospindle Assembly instructions Edition Revision 2 3 H5801H0084 ...

Page 2: ......

Page 3: ... It must not be photocopied or reproduced in any form either fully or in part without the prior written consent of the manufacturer Code Issue Code of previous issue H5801H0084 2 H5801H0044 Revision Description of updates 0 11 2011 new edition 1 07 2012 ES327 380V version 2 12 2012 revision of ES330 liquid version chapter 1 4 6 8 11 3 07 2013 revision chapter 1 9 12 paragraph 3 4 3 5 4 2 4 3 4 7 3...

Page 4: ...Information about the publication 4 HSD S p A H5801H0084 fm100713 ...

Page 5: ...n parts 23 2 6 ES370 Main parts 25 2 7 Characteristics and performance 27 3 Transport packing unpacking storage 3 1 Warnings 43 3 2 Dimensions and weights 43 3 3 Transport and packing conditions 43 3 4 Unpacking 44 3 5 Storage 45 4 Installation and commissioning 4 1 Preliminary installation checks 47 4 2 Preparing the factory services 47 4 3 Environmental requisites 47 4 4 Mechanical connections 4...

Page 6: ...6 6 Tool 73 6 7 Procedure to follow if the tool becomes jammed in the piece being machined 74 6 8 Sensors 75 6 9 Encoder optional 83 7 Programmed maintenance 7 1 Daily maintenance 92 7 2 Biweekly maintenance 94 7 3 Bearings 94 8 Replacing components 8 1 Replacing the electric fan 96 8 2 Shaft kit replacement 96 8 3 Encoder reader ES370 replacement 97 8 4 Replacement and adjustment of the sensor un...

Page 7: ...er who will integrate this HSD product onto his own machinery or partly completed machinery provides the necessary information for proper installation and maintenance of the unit in order to maintain it efficient and safe over time The manual forms an integral 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 requireme...

Page 8: ...tion The following is a list of the documents supplied with the product Assembly instructions this manual It contains warnings and instructions for the transport installation use maintenance and disposal of the product Supplied on digital support CD ROM Adobe Reader www adobe com is required for consultation Test report Contains the testing results performed on the unit Declaration of incorporatio...

Page 9: ...LY 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 GB 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 ...

Page 10: ...se 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 Never place hands arms or any other parts of the body near to moving parts The product must not be used in environments where there is an explosion risk The elimination of faults or anomalies in the operation of the product or modif...

Page 11: ...ose expected is not allowed Lifting the product in a manner other than how it is described in this manual or by using belts in points other than those indicated is not allowed 1 4 2 Risks involved in product maintenance 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 Isolate the product from the mains power supply...

Page 12: ...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 ...

Page 13: ...etter balancing G 0 4 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...

Page 14: ...er 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 Programmed maintenance A series of activities required ...

Page 15: ...2 Technical Specifications HSD S p A 0102h00a fm100713 15 2 Technical Specifications 2 1 Main parts ES327 11 10 8 2 1 4 7 6 5 3 9 ...

Page 16: ...er signal wiring outlet 2 Sensor compartment cover 3 Electrospindle casing joining area 4 Labyrinth with pressurisation 5 Collet HSK E25 6 Spindle shaft 7 Front flange 8 Casing sensors area 9 Serial number 10 Pneumatic cylinder area 11 Pneumatic and hydraulic joins ...

Page 17: ...2 Technical Specifications HSD S p A 0102h00a fm100713 17 2 2 Air cooled ES330 main parts 13 19 11 10 15 14 1 2 16 3 17 18 20 20 9 8 7 6 5 21 4 22 12 ...

Page 18: ...es M8 mm H9 thread depth of 12 mm 8 Tool holder description 9 Cooling air outlet channels 10 Electrospindle nose 11 Labyrinth with pressurisation 12 Coupling system ISO30 collet 13 Cooling air inlet grid electric fan 14 Power wiring outlet cable clamp M25x1 5 15 Signal wiring outlet cable clamp M16x1 5 16 Electric flying female connector flying mounting plate 17 EC plate 18 Fixed male electronic c...

Page 19: ...2 Technical Specifications HSD S p A 0102h00a fm100713 19 2 3 Liquid cooled ES330 main parts 11 10 9 7 5 6 2 1 3 4 8 ...

Page 20: ...signal wiring outlet n 2 cable clamps 1xM12 1x 2 Sensor compartment cover 3 Electrospindle nose 4 Labyrinth with pressurisation 5 Coupling system ISO30 6 Spindle shaft 7 Front flange 8 Serial number 9 Casing 10 Pneumatic cylinder area 11 Pneumatic and hydraulic joins ...

Page 21: ...2 Technical Specifications HSD S p A 0102h00a fm100713 21 2 4 ES331 Main parts 3 5 2 6 4 12 7 9 10 8 11 1 ...

Page 22: ...t n 2 cable clamps 1xM12 1x 2 Sensor compartment cover 3 Electrospindle nose 4 Labyrinth with pressurisation 5 Coupling system ISO30 6 Spindle shaft 7 Front flange 8 Casing sensors area 9 Electrospindle casing 10 Pneumatic cylinder area 11 Pneumatic and hydraulic joins 12 Serial number ...

Page 23: ...2 Technical Specifications HSD S p A 0102h00a fm100713 23 2 5 ES332 Main parts 7 15 1 3 12 6 5 16 11 10 8 9 2 4 14 13 ...

Page 24: ...rtment cover 4 Pneumatic cylinder area 5 Electrospindle nose 6 Labyrinth with pressurisation 7 ISO coupling system 8 Power wiring outlet 9 Sensor wiring outlet 10 Pneumatic and hydraulic joins 11 Encoder wiring outlet 12 Front flange 13 EC plate 14 Serial number 15 Nozzles for external coolant Optional 16 Fixing holes ...

Page 25: ...2 Technical Specifications HSD S p A 0102h00a fm100713 25 2 6 ES370 Main parts 7 6 8 1 2 4 3 10 5 11 12 9 ...

Page 26: ...ic connector of the encoder 3 Sensors area 4 Helicoidal casing to optimise cooling 5 Electrospindle nose 6 Labyrinth with pressurisation 7 Stator cable outlet electrospindle power 8 No 2 of 3 Or seats for the hydraulic seal of the cooling cylinder liner 9 Serial number 10 Front flange 11 Spindle shaft 12 Tool coupling system ...

Page 27: ...000 40000 Duty type S1 cont S6 60 S1 cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 2 2 4 3 3 6 3 3 6 3 3 6 Rated torque Nm 1 1 1 3 1 1 1 3 0 95 1 14 0 71 0 86 Rated current A 15 18 14 16 8 13 15 6 Rated efficiency Power factor cos Number of poles 4 Insulation class F Cooling Liquid Weight Kg 15 IP level The maximum rated current S1 cont is used to set the maximum continuous current paramet...

Page 28: ...peed at nominal load Rpm 26100 P1400 Rated frequency Hz 900 P1134 No load line voltage V 196 P1135 No load current A 7 9 P1136 Stator resistance 20 C Ohm 0 18 P1137 Rotor resistance 20 C Ohm 0 236 P1138 Stator dispersion reactance Ohm 0 708 P1139 Rotor dispersion reactance Ohm 1 53 P1140 Main field reactance Ohm 13 P1141 Field weakening start speed Rpm 29200 P1142 Motor moment of inertia Kgm2 0 00...

Page 29: ... type S1 cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 3 3 6 3 3 6 3 3 6 Rated torque Nm 1 06 1 27 0 95 1 14 0 71 0 86 Rated current A 9 11 8 9 6 7 8 5 Rated efficiency 0 68 Power factor cos 0 68 Number of poles 4 Insulation class F Cooling Liquid Weight Kg 8 IP level The maximum rated current S1 cont is used to set the maximum continuous current parameter of the inverter ...

Page 30: ...peed at nominal load Rpm 26100 P1400 Rated frequency Hz 900 P1134 No load line voltage V 330 P1135 No load current A 4 6 P1136 Stator resistance 20 C Ohm 0 536 P1137 Rotor resistance 20 C Ohm 0 682 P1138 Stator dispersion reactance Ohm 2 05 P1139 Rotor dispersion reactance Ohm 4 48 P1140 Main field reactance Ohm 38 P1141 Field weakening start speed Rpm 28900 P1142 Motor moment of inertia Kgm2 0 00...

Page 31: ...S1 cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 4 4 5 4 4 5 3 7 4 1 2 5 2 6 Rated torque Nm 3 2 3 8 2 5 3 1 7 2 3 1 1 2 Rated current A 9 10 7 9 10 8 8 5 11 5 6 5 7 8 Rated efficiency 0 85 Power factor cos 0 7 Number of poles 4 Insulation class F Cooling Electric fan Weight Kg 15 IP level 50 The maximum rated current S1 cont is used to set the maximum continuous current parameter of the i...

Page 32: ... 380 Nominal speed at nominal load Rpm 11760 Rated frequency Hz 400 No load line voltage V 376 No load current A 3 Stator resistance 20 C Ohm 0 51 Rotor resistance 20 C Ohm 0 67 Stator dispersion reactance Ohm 2 4 Rotor dispersion reactance Ohm 5 7 Main field reactance Ohm 49 2 Field weakening start speed Rpm 12000 Maximum motor speed Rpm 24000 Power factor 0 8 Connection Y or D Y ...

Page 33: ...S1 cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 4 4 5 4 4 5 3 7 4 1 2 5 2 6 Rated torque Nm 3 2 3 8 2 5 3 1 7 2 3 1 1 2 Rated current A 16 19 16 19 2 15 20 3 11 5 14 Rated efficiency 0 85 Power factor cos 0 7 Number of poles 4 Insulation class F Cooling Electric fan Weight Kg 15 IP level 50 The maximum rated current S1 cont is used to set the maximum continuous current parameter of the in...

Page 34: ...220 Nominal speed at nominal load Rpm 11760 Rated frequency Hz 400 No load line voltage V 218 No load current A 7 Stator resistance 20 C Ohm 0 14 Rotor resistance 20 C Ohm 0 17 Stator dispersion reactance Ohm 0 8 Rotor dispersion reactance Ohm 1 8 Main field reactance Ohm 14 9 Field weakening start speed Rpm 12000 Maximum motor speed Rpm 24000 Power factor 0 8 Connection Y or D Y ...

Page 35: ...0 S1 cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 5 5 6 6 5 5 6 6 4 7 5 6 3 3 3 9 Rated torque Nm 4 4 5 3 3 5 4 2 2 5 3 1 3 1 6 Rated current A 12 5 15 12 5 15 10 8 13 8 9 6 Rated efficiency 0 85 Power factor cos 0 7 Number of poles 4 Insulation class F Cooling Liquid Weight Kg 28 IP level 54 The maximum rated current S1 cont is used to set the maximum continuous current parameter of the ...

Page 36: ...ge V 380 Nominal speed at nominal load Rpm 11760 Rated frequency Hz 400 No load line voltage V 376 No load current A 3 Stator resistance 20 C Ohm 0 51 Rotor resistance 20 C Ohm 0 67 Stator dispersion reactance Ohm 2 4 Rotor dispersion reactance Ohm 5 7 Main field reactance Ohm 49 2 Field weakening start speed Rpm 12000 Maximum motor speed Rpm 24000 Power factor 0 8 Connection Y or D Y ...

Page 37: ...1 cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 7 8 4 7 8 4 7 8 4 Rated torque Nm 5 6 6 7 3 7 4 5 2 8 3 3 Rated current A 23 27 5 16 5 20 1 16 18 9 Rated efficiency 0 86 Power factor cos 0 78 Number of poles 4 Insulation class F Cooling Liquid Weight Kg 26 The maximum rated current S1 cont is used to set the maximum continuous current parameter of the inverter ...

Page 38: ... No load line voltage V 257 No load current A 10 7 Stator resistance 20 C W 0 2 Rotor resistance 20 C W 0 16 Stator dispersion reactance W 0 6 Stator dispersion inductance mH 0 2 Rotor dispersion reactance W 1 1 Rotor dispersion inductance mH 0 45 Main field reactance W 13 5 Main field inductance mH 5 4 Field weakening start speed rpm 18000 Maximum motor speed rpm 24000 Power factor 0 78 Rotor mom...

Page 39: ... cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 13 15 6 13 15 6 10 12 Rated torque Nm 10 3 12 4 6 9 8 3 4 4 8 Rated current A 27 5 33 27 5 33 21 5 26 Rated efficiency 0 88 Power factor cos 0 77 Number of poles 4 Insulation class F Cooling Liquid Weight Kg 35 The maximum rated current S1 cont is used to set the maximum continuous current parameter of the inverter ...

Page 40: ...00 No load line voltage V 374 No load current A 11 5 Stator resistance 20 C W 0 17 Rotor resistance 20 C W 0 13 Stator dispersion reactance W 1 4 Stator dispersion inductance mH 0 6 Rotor dispersion reactance W 0 5 Rotor dispersion inductance mH 0 18 Main field reactance W 19 Main field inductance mH 7 6 Field weakening start speed rpm 12000 Maximum motor speed rpm 24000 Power factor 0 77 Rotor mo...

Page 41: ...cont S6 60 S1 cont S6 60 S1 cont S6 60 Rated power kW 10 5 12 6 10 5 12 6 6 7 2 3 9 4 5 Rated torque Nm 9 5 11 5 5 6 6 7 1 9 2 3 1 1 2 Rated current A 22 1 26 7 22 26 7 13 15 7 7 4 8 9 Rated efficiency 0 85 Power factor cos 0 74 Number of poles 4 Insulation class F Cooling Liquid Weight Kg IP level 54 The maximum rated current S1 cont is used to set the maximum continuous current parameter of the ...

Page 42: ...380 Nominal speed at nominal load Rpm 10225 Rated frequency Hz 350 No load line voltage V 376 2 No load current A 5 9 Stator resistance 20 C Ohm 0 2 Rotor resistance 20 C Ohm 0 32 Stator dispersion reactance Ohm 1 5 Rotor dispersion reactance Ohm 3 1 Main field reactance Ohm 35 1 Field weakening start speed Rpm 10500 Maximum motor speed Rpm 30000 Power factor 0 85 Connection Y or D Y ...

Page 43: ... parts 3 2 Dimensions and weights Weight of the packed product this is reported on the packing Linear dimensions of the packed product these are reported 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...

Page 44: ...ivered 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 Transport temperature 25 C 60 C 13 F 140 F Non condensing relative humidity 5 55 Prior to opening the packing make sure that ...

Page 45: ...on of the product Manually rotate the shaft approximately once a month to make sure that the bearings remain perfectly greased Furthermore it is necessary that during storage the following environmental conditions are observed Storage temperature 5 C 55 C 23 F 131 F Non condensing relative humidity 5 55 The maximum storage time for an HSD product is 12 months For periods longer than 12 months the ...

Page 46: ...3 Transport packing unpacking storage 46 HSD S p A 0103h03a fm100713 ...

Page 47: ...ficient power rating The connection to the mains electricity supply must be carried out by a qualified electrician Installation must be performed in a sufficiently lit area 4 3 Environmental requisites Temperature from 5 to 40 C 41 104 F Maximum relative humidity 50 at 40 C 104 F Maximum altitude 1000 metres a s l unless agreed otherwise with the customer The customer is responsible for the entire...

Page 48: ...ES327 liquid ES330 The electrospindle must be assembled in clamped housing Make available a structure which has a hole equal to the diameter of the spindle and an opening of 0 02 mm it is advisable to use a thickness spacer appropriately machined When the motor has been inserted tighten the housing to obtain the correct pressure to lock the electrospindle 1 Housing 2 Fixing screws 1 Fixing structu...

Page 49: ...9 mm through bores for assembly on the machine ref 2 5 ES332 Main parts ES370 Use the 12 available Ø6 5 mm through bores for assembly on the machine ref 2 6 ES370 Main parts 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 1 Fixing structure of the electrospindle 2 Electrospindle r ...

Page 50: ... The expulsion system must also provide for a central hole for toolholder cone cleaning in the releasing phase Expulsion system specifications Force min 1000 Kg max 1250 Kg Screw dowel stroke between positions collet closed without tool and collet open 8 mm Diameter on stop 30 mm The expulsion system should not cause radial loads on the screw dowel 1 Pressurisation air outlet area 2 Exposed area o...

Page 51: ...shown in diagrams of the following figures must be installed as close as possible to the electrospindle In view of the fact that the efficiency of the filters is 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 partic...

Page 52: ...ES332 ES370 1 Tool locking air inlet piston return 6 bar 87 PSI 2 Air inlet for tool release and cone cleaning 6 bar 87 PSI 3 Pressurisation air inlet 0 5 bar 7 2 PSI 4 Air inlet for tool release ES327 only 6 bar 87 PSI 5 Air inlet for pressurisation and cone cleaning ES331 only 1 bar 14 PSI 6 Air inlet for cone cleaning ES332 only 4 bar 58 PSI 1 2 3 4 1 5 1 3 2 5 3 6 3 ...

Page 53: ...l flow regulator for regulating the ejection speed 5 Rapid discharge valve 6 Monostable 5 2 valve with electro pneumatic control and spring return 7 Pressure regulator with pressure switch calibrated to 6 bar 8 Oil separator filter 0 1 µm 9 Pre filter 5 µm 10 Mains power supply 11 Continuous flow of pressurisation air 12 Air inlet for pressurisation and cone cleaning 1 bar 14 PSI 13 Pressure regul...

Page 54: ...ating the ejection speed 5 Rapid discharge valve 6 Monostable 5 2 valve with electro pneumatic control and spring return 7 Pressure regulator with pressure switch calibrated to 6 bar 8 Oil separator filter 0 1 µm 9 Pre filter 5 µm 10 Mains power supply 11 Continuous flow of pressurisation air 12 Pressurisation air inlet 0 5 bar 7 3 PSI 13 Pressure regulator with pressure switch calibrated to 0 5 b...

Page 55: ...or regulating the ejection speed 5 Rapid discharge valve 6 Monostable 5 2 valve with electro pneumatic control and spring return 7 Pressure regulator with pressure switch calibrated to 6 bar 8 Oil separator filter 0 1 µm 9 Pre filter 5 µm 10 Mains power supply 11 Continuous flow of pressurisation air 12 Pressurisation air inlet 0 5 bar 7 3 PSI 13 Pressure regulator with pressure switch calibrated ...

Page 56: ...nd their degree of cleanliness should be checked periodically as described in section 7 Programmed maintenance 1 Mains power supply 2 Pre filter 5 µm 3 Oil separator filter 0 1 µm 4 Pressurisation air inlet 4 bar 58 PSI 5 Continuous flow of pressurisation air 6 Exposed area of the screw dowel with Ø hole for cone cleaning 6 bar 87 PSI THE PROPOSED CIRCUIT IS PURELY EXEMPLARY The jet of compressed ...

Page 57: ...events 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 7 1 Cooler specifications Cooling characteristics Input cooling temperature t 20 C 30 C Anticorrosive means Vmax 25 Vol Solid materials filter 100 µm Type of water additives The gaskets isolating ...

Page 58: ...The following figures illustrate the hydraulic connection points according to the correspondence shown in this table Figure 6 Hydraulic connection points 1 Motor cooling liquid inlet 2 Motor cooling liquid outlet 3 Oil inlet for front piston 4 Oil inlet for rear piston ES370 ES330L ES327 2 1 2 1 2 1 ...

Page 59: ...4 Installation and commissioning HSD S p A 0104h03a fm100713 59 ES331 ES332 1 2 4 3 1 2 4 3 ...

Page 60: ...ample Reference Description 1 High pressure circuit 50 bar Max 2 Low pressure circuit 3 Bistable solenoid valve 4 Safety switch on the piston return circuit calibrated at 30 bar Max 5 Oil inlet for tool release 6 Oil inlet for tool locking It is not necessary to supply 50 bar constantly for tool locking When the safety switch has confirmed piston recovery at the upper limit switch you can reduce t...

Page 61: ... PIN DESCRIPTION 1 Thermal alarm 2 Earth PE W common with PIN 7 3 0 V Electric fan 4 Motor phase U 5 Thermal alarm 6 Motor phase V 7 Earth PE W common with PIN 2 8 Motor phase W 9 24 V DC Electric fan PIN DESCRIPTION 1 OUTPUT Sensor S2 2 OUTPUT Sensor S1 3 Not used 4 24V DC Sensors 5 24 V DC Button light 6 0 V Sensors 7 24 V DC Button 8 Button OUTPUT 9 Not used 10 Not used 11 0 V Button and button...

Page 62: ... fm100713 4 8 3 ES331 encoder connector 4 8 4 ES332 encoder connector PIN DESCRIPTION 1 A 2 A 3 Z 7 0V 10 5V 11 B 12 B 13 Z 16 5V Sense 17 Encoder cable screening PIN DESCRIPTION A A B A C B D GND E Z F 5V G Encoder cable screening J B H A B F E D G K J C ...

Page 63: ... 13 Z 16 5V Sense 17 Encoder cable screening The electricity supply to the electrospindle MUST be through an inverter CABLE ES327 CABLE ES330 ES370 CABLE ES331 ES332 AWG14 ES331 AWG10 ES332 DESCRIPTION Blue couple Orange couple Yellow green Yellow green Yellow green Earth PE W Brown White White Motor phase U Blue Red Red Motor phase V Black Black Black Motor phase W 1 2 3 4 5 6 7 8 9 10 11 12 13 1...

Page 64: ... ES330 LIQUID COLOUR DESCRIPTION COLOUR DESCRIPTION Sensor S1 Sensor S2 Green 24 V Green 24 V White 0 V White 0 V Brown Output Brown Output Sensor S2 Sensor S3 Pink 24 V Pink 24 V Yellow 0 V Yellow 0 V Grey Output Grey Output Sensor S3 Sensor S4 Black 24 V Black 24 V Blue 0 V Blue 0 V Red Output Red Output Pulse counter Sensor Purple 24 V Orange 0 V Beige Output ...

Page 65: ... Thermal alarm PIN DESCRIPTION A OUTPUT S2 Tool released B OUTPUT S1 S4 Tool locked C OUTPUT S5 no tool D 24V CC sensor feed S1 S2 S5 E 0V sensor feed S1 S2 S4 S5 F Motor thermal alarm BIMETALLIC N C 130 C G Motor thermal alarm BIMETALLIC N C 130 C J OUTPUT S2 Tool released H A B F E D G K J C ...

Page 66: ...4 Installation and commissioning 66 HSD S p A 0104h03a fm100713 ...

Page 67: ...supply dry filtered compressed air in accordance with that indicated for connections see possible labels on the product and section 4 6 Pneumatic connections the cone cleaning air must be present during the tool change the progress of the tool holder cone ejection must be that specified in section 6 5 Tool holder locking and ejection device Check that there are no jets of compressed air water or o...

Page 68: ...ol sensors must intervene according to the logic described in section 6 8 The tool change cycle must only take place with the shaft stopped with the tool holder inserted and without performing machining operations perform the preheating cycle described in section 6 3 The earth of the product indicated in section 4 9 Electronic connections for models with free cables must be connected to the earth ...

Page 69: ...ices through the simulation of various machining cycles on the test bench 6 3 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 ob...

Page 70: ...ction of the tool holder cone HSK E25 must be about 0 5 mm 0 6 mm The ejection of the tool holder cone HSK E40 A40 must be about 0 5 mm 0 6 mm The ejection of the tool holder cone BT30 must be about 0 5 mm 0 6 mm During machining the spindle can reach high temperatures and as such must not be touched without taking the due precautions Only for HSK models To perform the preheat it is necessary to i...

Page 71: ...l Change Cycle Tool Locked Tool Released Tool Locked All electrospindles of the manufacturer are equipped with a mechanical reaction system that neutralises the axial force of the piston on the shaft during the tool change phase thus guaranteeing the integrity of the precision bearings CONE ISO30 DIN69871 HSD SCREW DOWEL 0804H0009 HSK CONE DIN69893 CONE ISO30 DIN69871 SCREW DOWEL MAS 403 PT1 CONE ...

Page 72: ... thread locking compound LOCTITE 2701 or other equivalent product on the thread of the screw dowel Tighten the screw dowel to the cone with a torque of 62 Nm Leave the cone to rest to allow the thread locking compound to set 12 hours in the case of LOCTITE 270 or according to the manufacturer s instructions if an alternative equivalent product is used 6 5 3 General recommendations regarding tool h...

Page 73: ...grade G 2 5 or better standard ISO1940 Depending on the type and quality of the machining 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 a...

Page 74: ...ut ON Make sure that the cone has been freed from the collet Move the spindle away from the workpiece Then manually remove the jammed tool If this procedure is not followed the tool holder will drag 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...

Page 75: ...scription 1 ISO cone 2 Spindle shaft 3 ISO collet or nut 4 Screw dowel The arrows indicate the direction in which the locking system returns after having freed the cone 5 Point at which the collet will hit the shaft 6 Screw dowel breakage NAME SIGNAL INFORMATION S1 Tool holder cone coupled S2 Collet open Tool uncoupled S3 Shaft stopped Thermal Alarm Motor overheated stop the electrospindle UTENSIL...

Page 76: ...nitoring its state and a thermal alarm for protecting the electric windings 6 8 4 ES331 electrospindle sensors The ES331 electrospindle is equipped with inductive sensors to monitor its condition NAME SIGNAL INFORMATION S1 Tool holder cone coupled S2 Collet open Tool uncoupled Thermal Alarm Motor overheated stop the electrospindle NAME SIGNAL INFORMATION S2 Tool ejected S3 No tool S4 Tool coupled ...

Page 77: ...RMATION S1 Tool holder cone coupled S2 Collet open Tool uncoupled S1 S4 HSK cone locked in the correct position S5 Cylinder in place Thermal Alarm Motor overheated stop the electrospindle NAME SIGNAL INFORMATION S1 Tool holder cone coupled S4 HSK cone coupled and in the correct position Thermal Alarm Motor overheated stop the electrospindle In the case of electrospindle models without sensors it i...

Page 78: ...ut with no tool holder cone OFF OFF The electrospindle shaft can only rotate in the tool holder cone coupled state if S1 output changes to OFF stop the rotation of the electrospindle shaft STATE S2 S3 S4 Pulse counter Sensor Collet open tool holder cone ejected ON OFF OFF STILL Tool holder cone coupled OFF OFF ON IDLE or STARTED UP Depending on the operating status of the electrospindle Collet clo...

Page 79: ...fm100713 79 ES331 DIAGRAM SETTING SENSORS TOOL OUT TOOL IN TOOL IN WITHOUT TOOL 0 3 0 0 10 0 5 0 0 10 0 7 0 0 10 S2 S4 S3 CONDITIONS WITHOUT TOOL TOOL IN TOOL OUT S2 OFF ON ON OFF OFF ON ON OFF OFF S3 S4 S2 S3 S4 BROWN BLU BLACK 0V UB10 30V PNP NO ...

Page 80: ...ith no tool holder cone OFF OFF OFF ON STATE S1 S1 S4 Tool holder cone coupled but not in contact with the HSK surface ON OFF Tool holder cone coupled ON OFF Tool holder cone missing OFF OFF Tool holder cone locked correctly ON ON The electrospindle shaft can only rotate in the tool holder cone locked correctly state if S1 or S1 S4 output changes to OFF stop the rotation of the electrospindle shaf...

Page 81: ...gnal 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 Sensor S3 shaft stopped signal Sensor S3 supplies two ON pulses and two OFF pulses at each rotation of the shaft as shown in the figure below Ignore output S1 during the period from the tool release command to the tool couple ...

Page 82: ...PTC Thermistor In some versions a PTC thermistor may be inserted into the stator windings to check the temperature When the operation temperature has almost been reached 130 C resistance increases briskly This signal must be used by a device which stops the machine to protect the electrospindle The operation temperature threshold varies according to the type of electrospindle for further informati...

Page 83: ...facturer Lenord Bauer Square Wave Sine Lenord Bauer Diagram Temperature Resistance according to DIN44081 44082 Principal Characteristic values Nominal operation temperature TNF from 50 C to 200 C in steps of 10K or 5K Characteristic values for every thermistor PTC Resistance Measurement voltage Resistance in the area of a temperature from 20 C to TNF 20K 20 to 250 2 5 V Resistance at TNF 5K 550 2 ...

Page 84: ...ion 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 400 pulses per rotation zero notch Signal output TTL electrical levels compatible 0V 5V line driver A voltage level higher than the one specified 24V 10 may damage the encoder reader T Period D Phase displacement D T 4 D T 5 V Z Z 0 V 5 V 0 V 5 V 0 V 5 V 0 V B B A A 5 V ...

Page 85: ... 5 Operating temperature 30 C 85 C 22 F 185 F Max operating altitude 2000m 6500ft Signal input 1024 impulses per rev zero mark 256 impulses multiplied x4 internally Signal output TTL electrical levels compatible 0V 5V line driver T Period D Phase displacement D T 4 A voltage level higher than the one specified 5V 5 may damage the encoder reader D T Z Z B B A A 5 V 0 V 5 V 0 V 5 V 0 V 5 V 0 V 5 V 0...

Page 86: ...tion zero notch 100 pulses per rotation zero notch A B 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 A B signal phase displacement 90 a quarter period Z signal output 500 mV peak compared with idle value U ref 80mV 1V peak as difference of signals with idle value U ref 160mV 2 34V see figures below...

Page 87: ...6 Operation and regulation HSD S p A 0106h03a fm100713 87 Trend of signal B over time B B B DIFF B B 360 electrical de ...

Page 88: ...6 Operation and regulation 88 HSD S p A 0106h03a fm100713 Trend of signal Z over time Z 2 2 25 2 5 2 75 3 Z 2 2 25 2 5 2 75 3 Z diff Z Z 1 75 2 2 25 2 5 2 75 3 3 25 3 5 1 0 75 0 5 0 25 0 0 25 0 5 0 75 ...

Page 89: ...6 Operation and regulation HSD S p A 0106h03a fm100713 89 Phase displacement of signals A and B Phase displacement of inverted signals A and B 2 2 25 2 5 2 75 3 A B 2 2 25 2 5 2 75 3 A B ...

Page 90: ...6 Operation and regulation 90 HSD S p A 0106h03a fm100713 Trend of differential signals over time T Period D Phase displacement D T 4 A diff A A B diff B B Z diff Z Z 1 0 75 0 5 0 25 0 0 75 0 5 0 25 ...

Page 91: ...able to delimit the machine and identify it with a sign indicating MACHINE UNDER MAINTENANCE During all maintenance operations make sure that the electrospindle is disconnected from the electricity supply 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 expose...

Page 92: ... necessary clean with a clean and soft cloth Figure 7 ISO tool holder Figure 8 ISO tool holder seat 1 Conical surfaces in black 2 Contact surfaces in grey HSK only Figure 9 HSK tool holder Figure 10 HSK tool holder seat To clean the highlighted surfaces use a soft clean cloth DO NOT use abrasive tools such as steel wool metal brushes emery cloth acids or any other aggressive means At the end of th...

Page 93: ... 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 The cone used for protection must not have through holes To avoid sticking remove the tool holder in the electrospindle both a...

Page 94: ... clean and soft cloth moistened with ethyl alcohol For HSK versions only after cleaning with ethyl alcohol spray the tapered surface with the product KLÜBER LUSIN PROTECT G 31 and uniformly distribute using a dry clean cloth Rinse and dry the product before re using the tool holder 7 3 Bearings Do not touch the bearings as they are permanently lubricated with special high speed grease and DO NOT N...

Page 95: ...owel 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 91 Replacement and adjustment operation are only authorised with the origi...

Page 96: ...rotate by blowing some compressed air 8 2 Shaft kit replacement Spare shaft kits are available for installation in the event of worn bearings The shaft kits include a shaft already run in bearings rotor screw dowel and coupling system To obtain the correct shaft kit for the model in question inform the Manufacturer s sales office of the spindle serial number The serial number is usually stamped on...

Page 97: ...hickness spacer which had previously been inserted Op Description 1 Remove the no 3 screws TCEI 4x20 from the rear balancing block 2 Remove the balancing block 3 Remove the 6 screws TCEI 6x20 from the front flange of the electrospindle 4 Gently remove the worn shaft kit by pulling it from the front flange 5 Insert the new kit in the same way checking the presence of the ORM0040 10 gasket and repla...

Page 98: ...having unscrewed the 4 screws that lock it The adjustment of the sensors in model ES327 occurs by moving the sensor axially in relation to the electrospindle while with models ES330 and ES370 the adjustment occurs by rotating the sensor unit and taking advantage of the eccentricity of the nut that contains it 8 4 2 Identification and description of the sensor unit ES327 Figure 12 S1 sensor S1 S2 s...

Page 99: ...r for adjustment L calibrated position 3 Sensor 4 nut 5 electric connector Figure 14 S2 sensor S2 S3 sensor S3 S4 sensor S4 SC pulse counter sensor SC 1 screws 2 washer e eccentricity between the nut and sensor for adjustment L calibrated position 3 Sensor 4 nut 5 free cable outlet TIRANTE cod 08 04 H0009 CONO ISO 30 DIN 69871 S1 S2 2 1 e L 5 3 3 4 SC S2 S4 S3 1 2 e L 3 4 1 SEZIONE A A 5 ...

Page 100: ...ock e eccentricity between the nut and sensor for adjustment L calibrated position 3 Sensor 4 nut 5 free cable outlet Figure 16 S1 sensor S1 S2 sensor S2 S3 sensor S3 1 screws 2 washer L calibrated position 3 Sensor 4 nut 5 electric connector 6 Slot with clearance 7 Calibration movement 3 4 5 e L S3 S2 2 1 S4 S5 S2 S1 S4 3 4 5 1 2 7 L 6 ...

Page 101: ...D S p A 0108h02a fm100713 101 ES370 Figure 17 S1 sensor S1 S4 sensor S4 1 screws 2 washer e eccentricity between the nut and sensor for adjustment L calibrated position 3 Sensor 4 nut 5 electric connector S4 S1 2 1 e L 5 3 3 4 ...

Page 102: ...p A 0108h02a fm100713 8 4 3 Sensor wiring ES327 air ES330 liquid ES330 Figure 18 Figure 19 Figure 20 S1 S2 1 2 24 V 0 V Out S1 Out S2 S3 3 Out S3 S1 S2 1 2 24 V 0 V Out S1 Out S2 S2 S3 2 3 24 V 0 V Out S2 Out S3 S4 4 Out S4 SC 4 Out SC ...

Page 103: ...8h02a fm100713 103 ES331 ES332 ES370 Figura 21 Figure 22 Figure 23 24 V Brown 0 V Blue Output Black S2 S3 2 3 24 V 0 V Out S2 Out S3 S4 4 Out S4 S2 S5 2 5 Out S2 Out S5 S1 S4 1 4 24 V 0 V Out S1 Out S4 S1 S4 1 4 24 V 0 V Out S1 Out S1 S4 ...

Page 104: ...nsor unit 5 verify the functionality of the new sensor by placing it in contact with a metal object 6 insert the new sensor unit in the empty seat 7 rescrew the screw 1 without tightening it completely so that the sensor unit can rotate 8 adjust the sensor unit so as to obtain the outputs required in the paragraphs immediately below tighten the screw 1 locking the sensor unit so as to maintain the...

Page 105: ...ut 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...

Page 106: ...is not yet free to fall the S2 output must still remain OFF if necessary rotate the sensor unit 7 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 8 rotate the sensor unit so that in this condition the S2 output is ON 9 perform a cycle of 10 tool changes 10 at the end of the cycle ch...

Page 107: ...le shown in point 2 has been satisfied for the entire 360 rotation of the shaft Otherwise repeat the procedure from the start 8 if the table is verified make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders 9 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 ...

Page 108: ... it is possible to adjust sensors without using the kit as described in the preceding paragraphs the manufacturer highly recommends the use of the kit given the importance of ensuring accurate calibration of the sensors for safety reasons The gauges and spacers described in figure 25 and 26 are identified by their thicknesses engraved on the surface or listed on the label of the pack 1 Gauge for r...

Page 109: ... 10 tool changes 7 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 8 if the table is verified make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders 9 at the end of the cycle check that the table shown in point 2 has been ...

Page 110: ...been satisfied for the entire 360 rotation of the shaft Otherwise repeat the procedure from the start 8 if the table is verified make the machine perform a cycle of 100 tool changes using the largest possible number of different tool holders 9 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 fro...

Page 111: ...nents plastic materials lubricants liquid coolants etc must be sorted and separated then disposed of in accordance with the laws applicable in the country of installation 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 ...

Page 112: ...9 Disposal of the product 112 HSD S p A 0109h03a fm100713 ...

Page 113: ...ed Wait for the electrospindle to cool down the thermal switch will reset automatically to allow operation If the thermal switch trips frequently consult item The electrospindle overheats later in this chapter The inverter protection has tripped Consult the manual or contact the manufacturer of the inverter Sensor S1 or sensor S4 HSK only is disconnected or faulty Check the connectors Check the in...

Page 114: ...sensor as described in section 8 4 Replacement and adjustment of the sensor unit The tool holder does not eject Insufficient pressure Check the required pressure values in section 4 6 Pneumatic connections Check the integrity and efficiency of the pneumatic circuit Tool ejection enabling denied Consult the manuals or the suppliers of the machine numerical control or inverter that is connected to t...

Page 115: ...s in the paragraph relating to your model Electrospindle vibrates The tool holder is not balanced Choose a tool holder according to the indications described in section 6 5 1 Tool holder cone The tool is not balanced Choose and use the tool as shown in section 6 6 Tool Dirt between the tool holder cone and shaft spindle Remove the macroscopic impurities and clean as described in section 7 Programm...

Page 116: ...10 Troubleshooting 116 HSD S p A 0110h00a fm100713 ...

Page 117: ... the spindle H6200H0050 Electric flying female connector H5618H0003 Button H566100007 Electric fan liquid ES330 H5664H0052 Sensor S2 H5664H0057 Sensor S3 H5664H0058 Sensor S4 H5664H0065 Pulse counter Sensor H1707H0030 ISO30 cone for protecting the interior of the spindle H1419H0102 Sensor cover gasket ES331 H5664H0056 Sensor S2 H5664H0057 Sensor S3 H5664H0058 Sensor S4 H5638H0016 Movable connector...

Page 118: ...00713 2138A0229 Sensor and encoder movable connectors 2147A0404 Connector join 2450A3847 Flat jet 2450A3902 Stackable segment 1 4 2450A3940 1 8 gas join ES370 H5664H0048 S1 or S4 Sensor H3811H0402 HSK E40 F50 gauge kit for regulating sensors S1 and S4 ...

Page 119: ...the models manufactured gained through special training in our factory who are able to service machines on site The list of the manufacturer s Customer Service Authorised Centres can be seen below HSD S p A HSD DeutschlandGmbH 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 ...

Page 120: ...o Ltd 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 D2 First floor 207 Taigu road Waigaoqiao Free Trade Zone 200131 Shanghai China Phone no 86 215866 1236 E mail sales hsd china cn www hsd china cn ...

Page 121: ......

Page 122: ...50 HSD USA Inc 3764 SW 30th Avenue 33312 Fort Lauderdale FL USA Tel 1 954 587 1991 Fax 1 954 587 8338 supporthsdusa hsd it www hsdusa com HSD Deutschland GmbH Brückenstrasse 32 D 73037 Göppingen Deutschland Tel 49 7161 956660 Fax 49 7161 9566610 supporthsddeut hsddeutschland de sales hsddeutschland de www hsddeutschland de HSD Mechatronic Shanghai Co Ltd D2 First floor 207 Taigu Road Waigaoqiao Fr...

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HSD ES327, Assembly Instructions Manual

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