kessler电主轴说明书

Assembly InstructionsGrinding spindleModel E13811BArticle number 000.633.533Serial number ______________Date of delivery ______________Original Assembly Instructions - GermanAll other languages are a translation of the original.Franz Kessler GmbHFranz-Kessler-Strasse 2 • 88 422 Bad BuchauTelephone: +49 (0)7582 / 809-0 • Fax: +49 (0)7582 / 809-170e-mail: franz-kessler@franz-kessler.de • web: http://www.franz-kessler.deOI 000.654.990_EN Created: 10/2010ContentsDeclaration of incorporation (5)1. About these assembly instructions (6)Scope of delivery (6)2. For your safety (7)General (7)Designated use (7)Non-authorised usage (7)Product identification (7)Important operating instructions (7)Operator's responsibility (8)Qualified technical staff (9)Work on the electrical system (9)Work on the hydraulic system (9)Personal protective equipment (9)Information about warning notices (10)Warning symbols (10)Warning levels (10)Damage to property (11)Other symbols used (11)Safety instructions (12)Danger due to electrical voltage (12)Danger due to hydraulic fluid (12)Danger due to compressed air (13)Danger of environmental pollution (13)3. Transport (14)4. Storage (15)5. Assembly (16)General informations (16)Installation position (16)Standard assembly information (16)Sequence for assembly (16)Electrical system: (17)Connection with plug (17)Possible plug connections (18)Frequency converter (20)Torque motor drive (21)Operating mode (21)Connection sensor system (22)Temperature sensor for motor coil (22)Motor shut-down temperature (22)Cooling connection (24)Motor cooling (24)Manufacturers of chemical additives for cooling water (26)Pneumatic connection (if applicable) (27)Compressed air (27)Bearings (if applicable) (28)Oil-air lubrication (if applicable) (28)Connection process oil-air lubrication system (30)Connection process spindle to oil separator (30)Lubricant recommendation (30)6. Commissioning (33)Carrying out commissioning (33)Start-up cycle (34)7. During operation (35)Ensuring cooling agent flow rate (if applicable) (35)Checks to be made during operation: (35)Tool and tool holder (if applicable) (35)Important operating instructions (36)Protecting bearings from external influences (36)Clamp with spring-return mechanism (36)Spindles with hollow clamping cylinders (37)Spindles with grease-lubricated bearings (37)8. Maintenance (38)Maintenance plan (39)Bearing maintenance (41)Service life greased bearings (41)9. Replacing parts (42)Replacing pulse transmitter (42)Replacing bearings (42)Replacing rotary union (42)Tool clamping system (42)Replacing clamping set (42)Wear and spare parts list (42)10. Decommissioning (44)Sequence for decommissioning (45)Disassembly (46)Disposal (46)11. Connections (47)12. Troubleshooting (48)13. Service and Support (49)KESSLER China (49)KESSLER USA (49)Declaration of incorporationfor partly completed machinery pursuant to the Machinery Directive 2006/42/EC, Annex II BWe the manufacturer:Franz Kessler GmbH, Franz-Kessler-Strasse 2, 88422 Bad Buchau (Germany),hereby declare that for the following product:Grinding spindleType: E13811BMaterial number 000.633.533• the following essential health and safety requirements in accordance with Annex I of the Machinery Directive have been applied and are complied with:1.1.2, 1.1.3, 1.1.5, 1.3.2, 1.3.4, 1.3.9, 1.5.1, 1.5.2, 1.5.3, 1.5.4, 1.5.5, 1.5.6, 1.5.8, 1.5.9,1.5.10, 1.5.11, 1.7.1, 1.7.2, 1.7.3, appendix VI.• The relevant technical documentation described in Annex VII B has been prepared.• In response to a reasoned request by national authorities the relevant technical documentation can be provided in writing.• The following person is authorised to compile the relevant technical documentation: Franz Kessler GmbH, Franz-Kessler-Strasse 2, 88422 Bad Buchau• The product further conforms to the requirements of the following EC directives:• Low Voltage Directive 2006/95/EC• Further, we declare that the following harmonized standards pursuant to the Low Voltage Directive have been applied.• EN 60034-1, Rating and performance• EN 60034-5, Degrees of protection• EN 60034-6, Methods of cooling• EN 60034-9, Noise limits• EN 60204-1, Safety of machinery• The partly completed machinery mentioned above may not be commissioned independently, but only after being installed in a predetermined machine or plant. Commissioning of the partly completed machinery is prohibited until the machine or plant in which the partly completed machinery is installed meets the requirements of the Machinery Directive 2006/42/EG.1. About these assembly instructionsThe copyright on these assembly instructions remains with Franz Kessler GmbH. They may not be copied, distributed or made accessible to others either in part or in full without permission.At the time of publication the information provided in these assembly instructions complied with technical standards. Subject to change without notice. We reserve the right to make alterations without notice.The original assembly instructions are provided in German. All other languages are a translation of the original.Contents of these assembly instructionsThese assembly instructions contain information on the conditions which must be met so that the partly completed machinery can be installed correctly without impairment to safety and health. Abbreviations used for connections refer to the dimension sheet in the appendix to these instructions. The abbreviations consist of letters and numbers, e.g. H21.The dimension sheet can be supplied as a PDF file and printed out larger at any time for better legibility. The PDF file can be requested from the Department for Technical Documentation. Technical specifications can be found in the technical data sheet or in the dimension sheet in the appendix to these assembly instructions.Scope of deliveryThe scope of delivery includes the following:• Spindle 000.633.533• Assembly instructions MA 000.654.989_DE (German)• Assembly instructions MA 000.654.990_EN (English)• Assembly instructions MA 000.660.807_RO (Romanian)• Technical data sheet• Dimension sheet• Parameter list2. For your safetyGeneralThe spindle is a high-speed, high-frequency electro spindle for grinding/milling. The high-frequency spindle is provided with a threaded tool mount.The spindle operates at a maximum speed of 120.000 rpm. The spindle is driven by a high-frequency three-phase AC motor.The spindle is designed in such a way that it can be operated safely and with a high degree of reliability after correct installation of electrical power, coolant, cooling lubricant, hydraulic system, pneumatic system and sensor system as well as correct programming of the motor control. The condition for this is that all technical parameters defined in these assembly instructions are observed at all times while taking the specified tolerances into account.The contents of these assembly instructions were compiled to the best of our knowledge und belief. However, it is possible that not all information which may be required for safe operation or which must be observed by the operator is available. If you have any questions, please contact our technical sales department.Designated useThe spindle is specially adapted for installation in machining centres. The spindle is exclusively designed to hold tools, to place them in a defined position and to them there during machining.Do not make changes to the spindle or its components. Dangers may arise from alterations or non-authorised use for which the existing protective equipment is not sufficient. This can lead to damage to property, serious injury or death.Non-authorised usageThe spindle is not authorised for:• operation in environments where there is danger of explosion,• operation under water,• operation outdoors.Any use other than the designated use is improper use and is not permitted.Product identificationThe identification data and technical characteristics are engraved on type plate of the spindle.Important operating instructions• In these assembly instructions the spindle will also be referred to as a unit.• Gross weight of the spindle: approx. 7 kg.• Maximum speed: 120,000 rpm.• A temperature monitoring device must always be connected.Operator's responsibilityRead these assembly instructions before assembly and commissioning, and follow the warning and safety instructions carefully. In addition to these instructions, the instructions attached to the unit must also be observed.Knowledge of these assembly instructions is essential for avoiding accidents and ensuring fault-free operation. Failure to observe the warning and safety instructions can result in injury or danger to life. Failure to observe important information is likely to lead to inferior production quality, frequent operational faults and damage to the unit, for which we as the manufacturer cannot accept liability.The operator must ensure:• that the unit is only assembled and used according to the designated use;• that all relevant laws, directives and rules for safety, prevention of accidents andenvironmental protection are observed;• that the necessary constructive safety and protection devices and appropriate warning notices are fitted;• that work is only carried out by sufficiently qualified and instructed technical staff;• that the assembly instructions and associated documentation are available to personnel whowork on the machine, and that they have been read and understood;• that the necessary personal protective equipment according to employment protection laws is provided and used;• that no constructional changes are made;• that stated maintenance intervals and tasks are observed.Qualified technical staffWork on the unit must be carried out strictly by qualified technical staff. The staff must have read and understood these assembly instructions.Qualified technical staff are staff who are familiar with the installation, assembly, commissioning and operation of the product and have the required qualifications such as:• qualified training, experience and appropriate instruction;• knowledge of observation of relevant standards, regulations, accident prevention regulations and operational conditions;• the ability to recognise and avoid possible dangers;• adequate safety and protective equipment;• first-aid training.Work on the electrical systemWork on the electrical system may only be carried out by qualified electricians or by trained technical staff under control and supervision of an electrician in accordance with electrotechnical rules.Work on the hydraulic systemWork on the hydraulic system may only be carried out by technical staff with additional skills and experience with hydraulic systems.Personal protective equipmentPersonal protective equipment in accordance with employment protection laws must be provided and used when working on the unit.Minimum requirements for protective equipment:• Protective clothing• Safety shoes• Protective gloves• Protective gogglesInformation about warning noticesTo emphasise safety relevant procedures in these assembly instructions the following warning notices apply. Warning notices consist of a signal word and a warning sign. If appropriate, prohibiting signs are used.Warning symbolsFollowing is a list of warning symbols used. They warn about the risk of injury. To avoid injury ordeath comply with all measures which are marked with a warning symbol.This warning symbol warns about the risk of injury.This warning symbol warns about the risk of injury from electric shock.This warning symbol warns about the risk of injury from hydraulic fluid and coolant.This warning symbol warns about the risk of injury from compressed air.This warning symbol warns about the risk of injury from suspended loads.This warning symbol warns about the risk of injury from crushing or becoming trapped.Warning levelsThe warning notices are graded by the seriousness of the danger. DANGER!Warns about dangers which will lead to irreversible injuries or death. Non-compliance with the warning notice will result in irreversible injuries or death!WARNING! Warns about dangers which can lead to serious injuries or death. Non-compliance with the warning notice can result in serious injuries ordeath.CAUTION!Warns about dangers which can lead to injuries. Non-compliance withthe warning notice can result in injuries.Damage to propertyNOTICE! Warns about possible damage to property. Non-compliance with thenotices can result in damage to property.Other symbols usedA prohibiting sign denotes a prohibited action, e.g. Entry for personswith pacemakers prohibited.Safety instructionsObserve the following safety instructions in order to avoid danger to persons or the environment.Danger due to electrical voltageAcute danger of injury or to life from electric shock! Electric shock can result in the following: cardiac arrest, respiratory arrest, neural damage, burns and consequential injury such as broken bones. Before working on the unit: (1) disconnect from mains,(2) ensure that power cannot be switched on again, (3) check that no electrical current is flowing, (4) earth and short-circuit,(5) shield, cover or otherwise isolate (adjacent) parts or components which are electrically live. In addition:connect the protective earth conductor; earth the housing;on assembly: first connect the earthing cable, then the power supply; on disassembly: first disconnect the power supply, then the earthing cable; ensure correct fit of plug connections;ensure that there is no strain on cables during transport, assembly and operation; work may only be carried out by a qualified electrician;when working on the electrical system ensure that a second technical person is present who can switch of the power supply in an emergency;only run the unit when the terminal box, switch cabinet etc. are shut.Danger due to hydraulic fluidDanger to health and the environment due to hydraulic fluid. Hydraulic fluid can become up to 80 °C hot and be under high pressure.Contact with hydraulic fluid can cause allergic reactions, skin and eye irritation, injuries and scalding.Hydraulic fluid can cause environmental damage.Before working on the hydraulic system, ensure that the power supply is switched off, and that the unit is free of electrical current.Before working on the hydraulic system, ensure that the system is free of pressure. To reduce pressure safely, slowly turn out the vent screw (approx. 1/2 revolution). Avoid lengthy skin contact with hydraulic fluid. Wear protective clothing, protective gloves and protective goggles.Use suitable collection devices for leaking hydraulic fluid. Dispose of hydraulic fluid in an environmentally compatible manner.Danger due to compressed airDanger of injury due to escaping compressed air or whirling tubing. Escaping compressed air can cause skin and eye injuries.An escaping air jet can cause swarf and other particles to be whirled through the air which can result in eye injuries.Loose pressurised tubing can whirl about and result in injuries.Before working on the pneumatic system ensure that the power supply is switched off, and that the pneumatic system is free of pressure. Use personal protective equipment.Danger to health and the environment due to cooling agents. Contact with cooling agents can cause allergic reactions, skin, eye and respiratoryirritation.Cooling agents can cause environmental damage.Before working on the cooling system ensure that the power supply is switched off, and that the cooling system is free of pressure.Avoid lengthy skin contact with cooling agents. Wear protective clothing, protective gloves and protective goggles.Use suitable collection devices for leaking cooling agents. Dispose of cooling agents in an environmentally compatible manner.Danger of environmental pollutionDanger to the environment from operating fluids! Operating fluids such as lubricating grease, hydraulic fluid, cooling agent, cleaning fluid etc. must not be allowed to enter the ground, the water supply or the sewer system. The smallest amount of these fluids can cause damage to health or the environment. Use suitable containers for collection, storage, transport and disposal so that no danger for persons or the environment can arise.3. TransportTransport may only be carried out by qualified technical staff or a specialised company.4. StorageNOTICE! NOTICE! Risk of damage from incorrect storage!• Incorrect storage can result in corrosion of the unit or damage to the bearings.Observe the following instructions for storage time, environmental conditions and protection against bearing damage.Storage timeThe maximum storage time is 18 months.Make a note of the date put into storage and the unit's identification.Additional rust protection measures are required for storage times over 7 days.Environmental conditionsThe temperature of the unit may not exceed 45 °C during storage.The storage area must have as constant a temperature as possible, between 4 °C and 45 °C. The storage area must be dry and free of dust and dirt. Storage outdoors is not permitted.To prevent condensation, the temperature must not fall below the dewpoint.Protection against bearing damageExposure of the unit to shock or vibrations can result in bearing damage in the form of standstill marks.• Vibrations of max. 0.1 mm/s are permitted for a storage time of up to 6 months.• Vibrations of max. 0.08 mm/s are permitted for a storage time of up to a maximum of 18 months.• If necessary store the unit on a base which isolates against vibration.Long storage times can result in standstill corrosion in the bearings.• The unit must be spun by technical staff every 1-2 months.5. AssemblyThe assembly section contains important information on the connections and the specifications for the required media.Work on the unit must be carried out strictly by qualified technical staff.Electrical system:Work on the electrical system may only be carried out strictly by an electrician.Ensure that a second qualified person is available to disconnect the power supply in the event of an emergency.Possible plug connectionsThis is a selection of possible connections. Please see the drawing, the dimension sheet and/or data sheet for further information.See the dimension sheet in the appendix to these instructions for other plug connections.Type A socketES converter J53terminal connection boardES Regler main terminal connection boardJ - Earth K - U L - V M - W A 12 ( ) - B 24 ( ) - C 11 ( ) - D 23 ( ) - E 25 ( ) - N 14 - U 15 - V 10 ( ) - W 2 - X14-In = electro spindle nominal current (A)( ) If the pins 19 and 20 on the J53 terminal connection board are connected to one another – see ES handbook.Type B socketES converter J53terminal connection boardES converter main terminal connection boardA - EarthB - U R - V ‘Q - WC 2 - F 14 - E 12 ( ) - G 25 ( ) - H 14 - K 15 - L 23 ( ) - M 24 ( ) - N - - P11 ( )-In = electro spindle nominal current (A)( ) If the pins 19 and 20 on the J53 terminal connection board are connected to one another – see ES handbook.Type "Schalt-bau" connec-tionES converter J53 terminalconnection boardES converter main terminal connection board1 - Earth2 - U3 - V4 - W 512 ( ) - 624 ( ) - 7 11 ( ) - 8 23 ( ) - 9 - - 10 25 ( ) - 11 14 - 12 15 - 13 2 - 14 10 ( ) - 1514-In = electro spindle nominal current (A)( ) If the pins 19 and 20 on the J53 terminal connection board are connected to one another – see ES handbook.Type Klingel socketES converter J53terminal connection boardES converter main terminal connection boardearth connection -Earth 1 (output) - U 2 (output) - V 3 (output) - W 4-5-6 (output)- - 1-2-3-4-5-6 (signal)--7 (signal) 10 ( ) -8 (signal) 14 -9 (signal) 14 -10 (signal) 15 -11 (signal) 12 ( ) - 12 (signal) 24 ( ) - 13 (signal) 11 ( ) - 14 (signal) 23 ( ) - 15 (signal) 23 ( ) - 16 (signal)2 ( ) -In = electro spindle nominal current (A) ( ) If the pins 19 and 20 on the J53 terminal connection board are connected to one another – see ES handbook.Frequency converterA frequency converter is not supplied with the spindle.Select a converter which is compatible with the maximum current, voltage and frequency as indicated on the type plate attached to the spindle.Torque motor driveNOTICE! Damage to the torque motor due to excessive voltage loads ispossible.Avoid damage to the torquemotor. Observe the followinginstructions:Electrical system oscillations may occur in the case of drive configurations with controlled feeds, for which direct drives such as torque motors are used. System oscillations can lead to excessive voltage load. Voltage loads must not exceed 2000V peak to peak with a build-up time of 10 kV/µs.Cable length, number of axes and motor size are influencing factors.When operating with a frequency changer with controlled feed, use an HFD* reactor with damping resistor to reduce system oscillations.For example: For example: A Siemens HFD-package consisting of an HFD reactor, a resistor anda wideband line filter.*HFD: High-frequency damping.Operating modeThe motor for the spindle drive is optimised according to DIN EN 60034-1.Torque at S1 (continuous operation)This is a permissible torque which must not be effectively exceeded for load cycles.Torque at S6 (continuous operation with intermittent load)Operation made up of a series of identical loads, each of which consists of operation time with constant load and idle time (without stopping the motor).Current changes have not been taken into account for a temperature change. This type of operation is defined by the duration of the load operation (or the percentage of intermittence) and the total duration of a cycle. The information given in this manual and, in particular, in this section, refers to a percentage of intermittence of 60% and a total duration of the work cycle of 10 minutes.For further information see the drawing and/or data sheet.Torque max.The maximum torque may not be applied for more than 1 second.Torque at standstillAt standstill, different loads occur in the individual phases. These may differ by a factor of up to √2. For this reason, the standstill torque must not exceed max. 0.7x torque at S1.Connection sensor systemThe unit has sensors which influence the control. Only correct connection of these sensors ensures fault-free operation.Work on the electrical system may only be carried out strictly by an electrician.Ensure that a second qualified person is available to disconnect the power supply in the event of an emergency.Hydraulic connectionWork on the hydraulic system must be carried out strictly by qualified technical staff with special knowledge and experience with hydraulic systems.Cooling connectionWork on the cooling system must be carried out strictly by qualified technical staff with special knowledge and experience with hydraulic systems.• Solids filter < 100 µm• do not use non-ferrous metal that contains copper in combination with glycol in the cooling circuit• do not use galvanised components in the cooling circuitThe following information can be found in the dimension sheet and data sheet in the appendix to these instructions:• Connection diameter • Flow volume • Pressure• Coolant temperature on inlet:Fig. Cooling diagramProtective measures for the cooling systemThe coolant must consist of an emulsion of water and an anti-rust additive.When installing a closed water cooling circuit, add an anti-corrosion agent with a maximum ratio according to the manufacturer's specifications. Use an anti-freeze agent when temperatures in the operating room fall below freezing point. Ensure that installation and preparation of the cooling water also prevents the following under extreme conditions:• deposits,• corrosion,• freezing of the water.After filling, bleed the cooling circuit.Before commissioning check that the signals for the motor temperature are functioning correctly. Ensure that sufficient coolant flow is available in accordance with specifications.Cooling INCooling OUTManufacturers of chemical additives for cooling waterCompany Address ContactHoughton Lubricor GmbH Werkstrasse 26D-52076 AachenTel.: +49 (0)24 08 - 1 40 60Fuchs Mineralölwerke GmbH Friesheimerstrasse 15D-68169 MannheimTel.: +49 (0)6 21 - 3 70 10Cincinnati Cimcool, Cimcool Division Cincinnati Milacron b.v. Tullastrasse 45D-79108 FreiburgTel.: +49 (0)6 21 - 3 70 10Hebro Chemi GmbH Postfach 30 02 42D -41192Tel.: +49 (0)21 66 - 6 09 90Important conditions for cooling water:• pH: 7 … 8.5• Hardness: 3 … 8 °dH (5 … 15 °f)• Degree of filtration: 25 µmPneumatic connection (if applicable)Work on the pneumatic system must be carried out strictly by qualified technical staff.Bearings (if applicable)Work on the bearings must be carried out strictly by qualified Kessler staff.CAUTION!Danger to health and the environment due to lubricant. • Lubricant can cause damage to health and the environment. Use personal protective equipment. Use collection devices for leaking lubricants.Dispose of lubricants in an environmentally compatible manner.The design of the bearings and lubrication is adapted to the operating requirements. Most high-frequency spindles are equipped with oil-air lubricated bearings. The oil-air lubricant circulatesthrough the spindle in two different circuits in order to lubricate the front and the rear bearings. The number and type of bearings can be found in the drawing and/or data sheet.NOTICE! NOTICE!Bearing failure possible!• Bearing failure can occur after expiration of the service life, or when maintenance instructions are not complied with. Observe maintenance instructionsOil-air lubrication (if applicable)The motor spindle is equipped with spindle bearings, which must be lubricated with oil-air due to the high speeds and the low thermal load to be achieved.Each spindle bearing must be lubricated separately. This means that each bearing must be connected separately to the appropriate dispensing unit (see diagram). Do not connect more than one bearing to each lubrication line.The connection spindle - lubrication unit is made with plastic pipelines. The connection lines (DIN 73378: 1996-02/ NFE standard 49100 - oil durability of lines used) must be at least one metre long and have helical coils with five windings each on the spindle input (diameter approx. 50 mm. The helical coil axis must be horizontal. The helical coils ensure that the bearings are supplied with oil within a short time when restarted. For design reasons, the helical coils for the rear bearing may already be installed in the motor spindle.Connections and lines must be air-tight and water-tight! The smallest of leakages can cause spindle failure due to damaged bearings. Teflon sealing tape must not be used to seal the screw connections. All connections must be flexible!The connections are made by the customer. It must be ensured that the pipelines are cut off at an angle and the transition to the internal motor pipeline is without a gap.。