Zimmer HF150-003, Installation And Operating Instruction

Page 1: ...www zimmer group de INSTALLATION AND OPERATING INSTRUCTION HF150 003 Motor spindle DDOC00746 THE KNOW HOW FACTORY ...

Page 2: ... and maintain it in a state of constant readiness and efficiency operating personnel require in depth training from our experts These installation and operating instructions are a constituent part of the operating instructions of the machine in which this incomplete machine is installed and shall be kept available for operating personnel to use at all times in accordance with the Machinery Directi...

Page 3: ...EN 2020 10 22 DDOC00746 Glossary Abbreviation Explanation HTS Hollow taper shank MSDS Material safety datasheets PTC Positive temperature coefficient thermistor SBT Silicon based thermistor MQL Minimum quantity lubrication MQCL Minimum quantity cooling lubrication Handling instructions Ö Consequences or additional information of an instruction Bulleted list 1 Bulleted list 2 ...

Page 4: ... 9 Installation 14 9 1 Safety notes 14 9 2 General installation information 15 9 3 Installing the motor spindle 15 9 4 Installing the attachment part 16 9 5 Installing the power supply 17 9 6 Installing the electrical connections 18 9 7 Installing the fluid connections 19 9 8 Installing the cooling system 19 9 8 1 Cooling duct connections 21 9 8 2 Requirements for the screw on surface 21 9 8 3 Coo...

Page 5: ...e 31 12 1 Safety note 31 12 2 Cleaning agents 32 12 3 Definitions of maintenance work 32 12 3 1 Visual inspection of the motor spindle 32 12 3 2 Inspection of the motor spindle 32 12 3 3 Maintenance of the motor spindle 32 12 3 4 Overhaul of the motor spindle 32 12 4 Maintenance plan 33 13 Disassembly for decommissioning 34 14 Decommissioning and disposal 34 15 Cleaning preservation 34 16 Storage ...

Page 6: ... health of people Ignoring these notices can result in serious injury or death You absolutely must comply with the described measures for avoiding these dangers Ö The warning symbols are assigned according to the type of danger WARNING This notice warns of a situation that is potentially hazardous to personal health Ignoring these notices can result in serious injury or damage to health You absolu...

Page 7: ...hment equipment may damage the product Ö Do not use any chains or steel cables Ö Use only tested lifting belts with sufficient load capacity 3 2 Transportation data CAUTION Improper transportation Improper handling of the transportation box will cause transport damage to the motor spindle Ö Do not tilt the transportation box Ö Avoid powerful vibrations and impacts NOTICE Transportation temperature...

Page 8: ...indle cannot be actuated by mistake Modifications to the motor spindle such as adding drilled holes or threads may be made only with prior approval from Zimmer GmbH The specified maintenance intervals are to be observed also refer to the Maintenance section When the motor spindle is used under extreme conditions the maintenance interval must be adapted Use of the motor spindle under extreme condit...

Page 9: ...ng production methods Machining with geometrically defined cuts dry machining DIN 8589 0 for non abrasive materials Drilling counterboring reaming DIN 8589 2 Milling DIN 8589 3 Grinding DIN 8589 0 The motor spindle is used to hold and drive cutting tools Permitted materials Wood Plastics Light metals non ferrous metals or comparable materials Any other or more extensive use is improper Zimmer GmbH...

Page 10: ...p XXX XXX am an XXX XXX ao ap 7 2 Functional description The product is directly driven by a three phase motor The product is operated by means of a frequency converter An inductive proximity switch is installed for speed sensor monitoring and standstill monitoring optional a sin cos 1Vss The heat created by the motor must be discharged by a suitable cooling system The product features correspondi...

Page 11: ...housing 2 Unit interface front side optional bl Piston housing intermediate flange with sensors 3 Spindle neck bm Motor spindle housing 4 HSK taper bn Installation positions with connecting thread 5 HSK clamping set bo Display with LED display 6 HSK plane face bp Coolant connections 7 Power supply bq Pneumatic connections 8 Plug housing br PE connection ground conductor bs Sealing air connection o...

Page 12: ...lder is detected by a sensor and is transmitted to the machine control system as digital signals Refer to the specifications for the technical design of the sensors Three clamping states are available Clamped without tool Clamped with tool Tool unclamped The circuit diagram of the clamping states is provided on the technical datasheet 8 3 Standstill monitoring DANGER Risk of fatal injury and mater...

Page 13: ... encoder and their control system Ö It must not be possible for any person to be able to stand inside the safety device or to enter it while the motor spindle is rotating Risk of fatal injury and damage to the product when operating without signals from the speed sensor The speed signal must be generated from the installed sine cosine encoder with two independent speed signals Otherwise there is a...

Page 14: ...ndle must be checked for damage in transit after each time it is transported It is absolutely necessary to avoid any vibrations or impact Potential consequences of damage in transit include serious personal injury or significant material damage Risk of injury in case of unexpected movement of the machine or system into which the motor spindle is being installed Switch off the power supply to the m...

Page 15: ...required screw connections in accordance with VDI 2230 Make sure the mounting piece is sufficiently rigid INFORMATION When installing the motor spindle you must ensure that there is sufficient clearance space around the motor spindle Observe the following measures Ensure a sufficient amount of air circulation or cooling Ö Ensure sufficient dimensions for the machining area room size enclosure Ö Pr...

Page 16: ...t carrier With attachment part Without attachment part The mechanical interface is customized to match the specific motor spindle and therefore must not be replaced or mounted to a different motor spindle CAUTION Damage to the motor spindle The customized interface guarantees the function of the product Ö The mechanically customized interface must not be dismantled Material damage and malfunction ...

Page 17: ...le and shielded throughout their entire length If the power supply lines do not have adequate dimensions the motor spindle might have an insufficient supply Ö Fault or damage to the motor spindle INFORMATION The bending radius of the power supply lines must not fall below the minimum value Cables that are hanging freely must be affixed Ö Excessive movement stress or crushing must be avoided Refer ...

Page 18: ...e properly oriented and are not damaged bent Faulty connection of the grounding wire will cause a health hazard and material damage Observe the measures for protection against electrical shock Ö Connect the motor spindle s ground conductor and the machine Ö Personnel may work near the electrical components only if they are properly and sufficiently grounded Personnel are grounded by means of an ES...

Page 19: ...design from the Technical Datasheet To optimally supply the product with the operational media the media are transferred directly via the rear side interface of the product Check the connection pressures and flow rates in accordance with specifications and design your mounting piece accordingly 9 8 Installing the cooling system CAUTION Health hazard due to coolant antifreeze Ö Coolant antifreeze i...

Page 20: ...osits on parts that transfer heat Zimmer GmbH accepts no liability for any resulting malfunctions or damage Zimmer GmbH recommends the use of Cool Core Ready from Motorex SK3301 960 from Rittal or a comparable coolant All trials and test runs were carried out with one of the coolants specified above Incorrect pH value of the coolant The coolant must be changed if the pH value is not between 6 5 an...

Page 21: ...cooling unit with adequate cooling capability Ö The cooling unit must have temperature control Ö Recommended flow temperature of the product 25 C at an ambient temperature of a maximum of 35 C If the difference in temperature is greater than 10 C condensate can form in the product Too great a temperature difference can result in damage to the product At an ambient temperature above 35 C the flow t...

Page 22: ...nt of faulty operation of the KR connection Ö Observe the circuit diagram Ö Observe the tool exchange diagram Material damage from actuation of the KR connection By actuating the KR connection without actuating the A connection at the same time the compressed air can expand in the product in an uncontrolled manner causing damage The product has an integrated cone cleaning system KR connection This...

Page 23: ...ring initial commissioning Inadequate safety conditions result in a health hazard and material damage Removing safety devices during the commissioning of the machine can cause serious injury Ö First bring the machine properly out of operation Immediately after completion of commissioning Ö Return the safety unit to its original or correct condition and inspect it CAUTION Material damage caused by ...

Page 24: ...each instance of commissioning or operation of the motor spindle The motor spindle must never rotate or be operated without having carried out the commissioning test described here Check the tightening torques motor spindle mounting piece Check the power supply lines and connections Check the operating parameters Check the standstill monitoring Check the function clamping force and nominal dimensi...

Page 25: ...te the loosening unit using the machine control system to release the tool Remove the tool or unit from the motor spindle in the axial direction Clean the motor spindle using a clean soft rag Plane face of the tool holder Gap between the quick change tool adapter and the surface of the taper To extend the clamping set actuate the loosening unit by using the machine control system Ö The clamping sy...

Page 26: ...ing operation rotation cannot be ruled out Ö Injury to personnel or material damage may result The analog sensor installed in the motor spindle monitors the clamping states of the tool interface The analog sensor outputs corresponding values as a voltage value V based on the clamping state The motor spindle converts the signal from the analog sensor into digital switching states Possible clamping ...

Page 27: ...stor CAUTION Material damage from inappropriate thermistor settings Operating the motor spindle with a PTC130 thermistor value above 4000 Ω will cause damage to or destruction of the motor spindle Ö Never exceed the PTC130 thermistor value of 4000 Ω Ö If the PTC130 thermistor reaches this value the motor spindle must be stopped immediately The characteristic curve of the PTC130 thermistor shows a ...

Page 28: ...s only while the motor spindle is at a standstill Clamp the tools or units firmly and securely Never exceed the tool manufacturer s maximum specified speed Only use tools and tool holders that comply with the following properties Tool interface with a hollow taper shank in accordance with DIN 69893 6 Balance quality G2 5 DIN ISO 1940 A balance quality of G2 5 to G6 3 DIN ISO 1940 will shorten the ...

Page 29: ... the motor spindle In extreme cases damage to the motor spindle cannot be ruled out Ö Observe the warm up cycle In order to ensure the motor spindle achieves the longest possible life cycle a warm up cycle must be carried out after any standstill period longer than four hours Operate the motor spindle as follows Ö Angular acceleration α 200 rad sec 1 warm up cycle At ambient temperatures above 10 ...

Page 30: ...mum tool weight 6 kg Maximum tool length including holder 280 mm Balancing quality Tool fixture with tool dynamically balanced according to ISO 1940 G2 5 Will shorten the life cycle G2 5 to G6 3 A balance quality above G6 3 according to DIN ISO 1940 will shorten the life cycle signifi cantly and must not be used Above G6 3 Direction of rotation left right Maximum concentricity error 0 02 mm 11 4 3...

Page 31: ...ched back on again Risk of injury caused by falling loads Improper handling of hanging loads can cause serious injuries Note the following points Ö Secure hanging loads by using the provided attachment equipment and set workpieces down before working in the danger zone Ö Wear appropriate personal protective equipment Ö Always keep an adequate safety distance from hanging loads Ö Never walk underne...

Page 32: ...indle The visual inspection merely includes visually inspecting component parts and their function If any irregularities or damage are identified during the visual inspection a more detailed check of the component parts must be carried out 12 3 2 Inspection of the motor spindle The inspection includes checking the motor spindle When performing the inspection the actual status of the motor spindle ...

Page 33: ...e nominal actual dimension pH value of the coolant optional Coolant circuit optional Coolant optional Cooling ducts air ducts in the spindle housing Power supply lines in their entirety Electrical system Grease distribution during recommis sioning Inspection Daily Weekly Monthly Annually Visual inspection Daily Weekly Monthly Annually Cleaning Daily Weekly Monthly Annually As required Maintenance ...

Page 34: ... of its operational phase it can be completely disassembled and disposed of Completely disconnect the motor spindle from the power supply The motor spindle can be disassembled and properly disposed of according to material groups When disposing of it observe the locally applicable environmental regulations and codes and regulations for disposal If it is not possible to properly disassemble and dis...

Page 35: ...The operator must provide for a sufficient storage area Ö The original packaging must not be stacked The motor spindle must be stored in its original packaging or in a similar packaging variant in a closed and dry room that is protected from the weather The following storage and transportation conditions must be complied with Storage conditions Units Values Minimum temperature C 10 Maximum tempera...

Page 36: ...ure too low Check air pressure Increase Release tool air pressure Water in the cleaning air Install water separator Temperature sensor in the motor spindle has responded Cooling system is not switched on Switch on cooling system Cooling system is not functional Check cooling system Motor spindle is overloaded Reduce load Collet chuck status is invalid Motor spindle tool holder or holder on the uni...

Page 37: ...50 003 series 37 Zimmer GmbH Im Salmenkopf 5 77866 Rheinau Germany 49 7844 9138 0 49 7844 9138 80 www zimmer group com EN 2020 10 22 DDOC00746 20 Appendix Technical datasheet HF150 003 xxx Motor datasheet Third party company instructions Röhm HTS clamping set ...

Page 38: ...Hoch See manufacturer s address Rheinau Germany 2020 05 25 Martin Zimmer First name last name Address Place and date of issuance Legally binding signature Managing Partner 22 REACH declaration in terms of the EU Regulation 1907 2006 Name and address of the manufacturer Zimmer GmbH Im Salmenkopf 5 77866 Rheinau Germany 49 7844 9138 0 49 7844 9138 80 www zimmer group com REACH stands for Registratio...

Page 39: ...hinery Functional safety of electrical electronic and programmable electronic control systems DIN EN ISO 10218 2 Industrial robots robot systems and integration DIN EN IOS 13849 Safety of machinery Safety related parts of control systems ISO TS 15066 Human Robot Collaboration A full list of applied standards can be obtained from the manufacturer We also declare that the specific technical document...

Page 40: ...ive 2014 30 EU in their design and the version we put on the market The following harmonized standards have been used DIN EN ISO 12100 2011 03 Safety of machinery General principles for design Risk assessment and risk reduction DIN EN 61000 6 3 EMC Generic standard Emission standard for residential commercial and light industrial environments DIN EN 61000 6 2 EMC Generic standard Immunity for indu...