6D machining spindle
• Magnetic bearings
• Integrated SIGMA automatic clamping cartridge
LeviSpin R140
Installation Manual
Change history
Version Date Comment
7226.20B.0 2016-10 Initial approval
2017-11 Name changed from LeviSpin to LeviSpin Q110 in the entire document
7229.20B.0 2019-08 Name changed from LeviSpin Q110 to LeviSpin R140 in the entire document
2019-09 New design data added.
2019-11 Second approval
2020-02 Change of name to KEBA Industrial Automation Germany GmbH
2020-09 Workpiece spindle added
7229.20B.1-00 2020-11 Spindle version with Hall sensor added
7229.20B.1-01 2023-12 Minor changes made
Subject to technical change without notice
The content of our documentation was compiled with the greatest care and attention,
and based on the latest information available to us.
We should nevertheless point out that this document cannot always be updated simulta-
neously with the ongoing technical development of our products.
Information and specications may be subject to change at any time. Please obtain infor-
mation on the latest version in our documentation portal.
Overview
The LeviSpin R140 is available in two models (see order code). The differences are
shown in the following matrix:
Tool spindle Workpiece spindle
Order no. LS-R140-0xxx LS-R140-0xx1 LS-R140-1xxx
Clamping tool (Sigma) For tools (drills, milling cutters, etc.) For workpieces
Rotary union (GAT) Yes No
Figure
•
•
LeviSpin R140 6D Machining Spindle
Installation Manual
ID no.: 7229.20B.1-01
Date: 2023-12
THIS DOCUMENTATION IS TO BE KEPT!
The German version of this document is the original version, versions in all
other languages have been translated from the original text.
2
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Table of contents
1 General ........................................................................................5
1.1 Goal of this document ........................................................................................... 5
1.2 Prerequisite ........................................................................................................... 5
1.2.1 Qualication ................................................................................................... 5
1.2.2 Knowledge required ......................................................................................5
1.3 Reference documents ........................................................................................... 5
1.4 Order code ............................................................................................................ 6
1.5 Pictograms ............................................................................................................ 6
1.6 Disclaimer .............................................................................................................. 7
1.7 Disposal ................................................................................................................. 7
1.8 Support & Service ................................................................................................. 7
1.9 Rating plate ........................................................................................................... 7
1.10 Scope of supply..................................................................................................... 7
2 Safety ..........................................................................................9
2.1 O v e r v iew ............................................................................................................... 9
2.2 General safety precautions .................................................................................... 9
2.3 Personal safety precautions .................................................................................. 9
2.4 Hazards due to mechanical energy ....................................................................... 9
2.5 Measures for your safety ....................................................................................... 10
2.6 General safety instructions and warnings .............................................................. 11
2.7 Intended use of the spindle ................................................................................... 12
2.7.1 Repairs ........................................................................................................ 12
2.7.2 Maintenance ................................................................................................ 12
2.8 Foreseeable misuse .............................................................................................. 12
3
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
2.9 Declaration of incorporation .................................................................................. 13
2.10 Responsibility ........................................................................................................ 13
2.10.1 Measures taken by the operating organisation (residual risk): ...................... 14
3 Mounting (installation) of the spindle ........................................... 15
3.1 Introduction ........................................................................................................... 15
3.1.1 Notes for installation and operation ............................................................. 15
3.1.2 Fastening the spindle ................................................................................... 16
3.2 Electromagnetic compatibility ................................................................................ 16
3.2.1 Earthing ....................................................................................................... 16
3.2.2 Shielding, general ........................................................................................ 16
3.2.3 Additional EMC measures: .......................................................................... 17
3.2.4 Electrostatic charging of the shaft ............................................................... 17
3.3 Tool/workpiece spindle comparison ...................................................................... 17
3.4 Dimensions of the spindle...................................................................................... 18
3.5 Motor cooling ........................................................................................................ 18
3.5.1 Coolant ........................................................................................................ 18
3.5.2 Coolant temperature .................................................................................... 19
3.6 Bearings (contact-free magnetic bearings) ............................................................ 19
3.6.1 Emergency bearings .................................................................................... 19
3.7 Tool clamping system ............................................................................................ 20
3.7.1 Clamping state sensor ................................................................................. 20
3.7.2 Clamping states ........................................................................................... 20
3.8 Axial shaft play ...................................................................................................... 21
4
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
4 Electrical installation ...................................................................23
4.1 Overview of connections ....................................................................................... 23
4.2 Pre-assembled cables ........................................................................................... 23
4.3 Electrical connections on the spindle .................................................................... 24
4.3.1 Specication, Hall sensor (X6) ...................................................................... 25
4.4 Drive controller ...................................................................................................... 25
5 Commissioning ..........................................................................27
5.1 O pe r a t i o n............................................................................................................... 27
5.2 Stopping the spindle .............................................................................................. 27
A Appendix ...................................................................................29
A.1 Technical data ....................................................................................................... 29
A.2 Ambient conditions ................................................................................................ 31
A.3 Data sheets, pre-assembled cables ...................................................................... 31
A.3.1 Pre-assembled motor cable (X3) .................................................................32
A.3.2 Pre-assembled encoder cable (X2) ..............................................................32
A.3.3 Pre-assembled cable for magnetic bearing sensors 1 (X4.1) .......................33
A.3.4 Pre-assembled cable for magnetic bearing sensors 2 (X4.2) ....................... 33
A.3.5 Pre-assembled cable for magnetic bearing sensors 1 (X4.1*) ......................34
A.3.6 Pre-assembled cable, bearing electronics (X5) ............................................ 34
A.3.7 Speed extraction for LeviOne junior ............................................................. 35
A.3.8 Hall sensor cable (X6) ..................................................................................35
Glossary ............................................................................................ 37
5
General
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
General
1 General
The product DVD from KEBA Industrial Automation Germany GmbH contains the
complete documentation for the related product series. The documentation for a spindle
includes the installation manual, CAD drawing, installation manual for the clamping
cartridge, as well as other descriptions.
1.1 Goal of this document
The documentation describes the 6D machining spindle. This spindle is intended to
be used in machine tools for the verication of various applications. The installation
manual forms part of the spindle and contains important information about installation,
operation and service. The documentation is aimed at all persons who are tasked with
the mounting, installation and commissioning of the spindle.
1.2 Prerequisite
The operating organisation is responsible for the following points:
yThe documentation on the spindle is to be stored so it is legible, accessible at all times and for
the entire life of the product.
yFor the work on your product it is important that the documentation, in particular the warning and
safety instructions in this installation manual are read and understood.
yThe specialist personnel are to receive sufcient training.
yAn internal procedure is to be prepared.
1.2.1 Qualication
yOnly qualied personnel who have been instructed about installation, commissioning,
maintenance and repair are allowed to work on the spindle to prevent injuries and damage.
yThe responsibility for installation, commissioning, maintenance and repair must be clearly
specied by the user and observed.
1.2.2 Knowledge required
yNational health and safety regulations (e.g. DGUV V3 in Germany)
yInstallation, commissioning, maintenance and repair of the spindle
ySafety of machinery (EN6800….)
All work in other areas, for example transport, storage and disposal is only allowed to be
undertaken by trained personnel.
NOTE
This installation manual is valid for the spindle:
Type LS-R140-0000-0000-(...).
1.3 Reference documents
Document Number Format Comment
Data sheet LeviSpin R140 tool spindle 7229.05B.x PDF
Data sheet LeviSpin R140 workpiece spindle 7229.06B.x PDF
Operation Manual LeviOne junior
Magnetic Bearing Electronics
7171.00B.x PDF
Installation/Operating Manual Automatic
Clamping Cartridge Tool
FI-ASS-32-B3
Date: 02-06-2017 PDF Sigma
Installation/Operating Manual Collet Chuck
for Workpiece
FI-ASS-32-B6
Date: 09-09-2020 PDF Sigma
Rotodisk Installation Guide Date: 10-2016 PDF
GAT® Gesellschaft für
Antriebstechnik mbH
Rotodisk Operating Instructions Date: 11-2016 PDF
Table 1.1 Reference documents
6
General
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
General
1.4 Order code
The article designation provides information on the spindle model supplied. The
signicance of the individual characters of the order code is given below.
Designation LS - R 140 - 0 0 0 0 - 0 0 0 1
Spindle type:
LeviSpin LS
Design (motor area):
Round R
Edge dimensions (motor area):
140 mm
140
Model:
Tool spindle
Workpiece spindle
0
1
tbd 0
Type of connection:
Robotics
Machine tool
0
1
Encoder type:
Sin/Cos
SinCos plus Hall
0
1
tbd 0
Stall torque 1/10 Nm:
5.3 Nm
0
tbd 0
Rated speed:
12000 1/min
1
Table 1.2 Type code, LeviSpin
1.5 Pictograms
The pictograms used in this installation manual signify the following for the user:
NOTE
Useful information or reference to other documents.
1.
(digit)
ACTION TO BE TAKEN
Action undertaken by the user or the system.
You will nd the pictograms used in this installation manual for "safety instructions and
warnings" in chapter 2 Safety.
7
General
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
General
NOTE:
You will nd information about our services on our web site www.keba.com in
"Service".
1.9 Rating plate
On the rating plate for the spindle you will nd:
18000 rpm
nn
m
30°C
2020
39 kg
3~ Mot
cos
Un
Ins. cl
F
IP23/65
IEC60034-1
I
n
LS-R140-0000-0000
KEBA Industrial Automation
Germany GmbH
35633 Lahnau
www.keba.com
Year
SN: 205512345
Art.No.
Pn
fn
287 V15 A12000 rpm
nmax
6,3 kW 0,98
Uind
400 Hz 265 V
max. coolant temp.
7229.0000.0
S1
Order code
Technical data
Year of production
Figure 1.1 Rating plate (example LeviSpin R140)
1.10 Scope of supply
The scope of supply includes, depending on the spindle type ordered:
yLeviSpin R140 spindle
yClamping cartridge (already installed)
yRotary union with connection box (already installed)
yYou will nd documentation in our documentation portal
1.6 Disclaimer
Following the documentation on the products from KEBA Industrial Automation Germany
GmbH is a prerequisite:
yFor safe operation.
yTo achieve stated performance features and product characteristics.
KEBA does not accept any liability for injuries, damage or nancial losses that result from
the failure to follow the documentation.
1.7 Disposal
Follow the applicable national regulations! If necessary, dispose of individual parts,
depending on their characteristics and national regulations, e.g. as:
yElectrical waste
yPlastic
yMetal
Or engage a certied disposal organisation with scrapping.
1.8 Support & Service
Address: KEBA Industrial Automation Germany GmbH
Gewerbestrasse 5-9
35633 Lahnau
Internet: www.keba.com
E-mail: [email protected]
Telephone: +49 6441 966-0
Fax: +49 6441 966-137
8
General
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
General
9
Safety
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Safety
2 Safety
2.1 Overview
Our spindles are state-of-the-art and comply with recognised safety regulations. Despite
correct use and operation, hazards may arise for the life and limb of the user. In this
chapter:
yWe provide information on residual risks and hazards that can emanate from our product even if
used as intended.
yWe warn about foreseeable misuse.
yWe refer to the necessary care and measures to be taken to prevent risks and minimise hazards.
2.2 General safety precautions
The spindle is only allowed to be installed and operated indoors (see climatic conditions
in chapter 6 Appendix).
Limits for the speed, position and temperature of the spindle must be monitored and
observed by the operating organisation.
The limits for the speed and temperature of the tools based on the specication must be
below the limits for the spindle. These aspects must be monitored and observed by the
organisation operating the overall machine.
2.3 Personal safety precautions
The following personal protective equipment (PPE) is stipulated during work on the
spindle:
yGloves for protection against hot surfaces and sharp edges/corners.
yProtective earwear if there is increased noise
yAccess authorisation to the room where installed only after detailed training and provision of an
internal procedure
ySafety glasses for protection against ying chips during the machining process.
2.4 Hazards due to mechanical energy
Very high centrifugal forces occur at the tool depending on the tool diameters and the
speed. For this reason, only very nely balanced tools are allowed to be used and these
tools must have a max. speed or peripheral speed above the max. spindle speed.
If tools with a high mass and/or large projection length are used, it is possible that the
spindle-tool system may reach its resonant frequency and the bearings therefore fail. The
tool or parts of it can be thrown out with high kinetic energy.
The parts installed in the spindle with spring preload (e.g. the clamping cartridge) can be
thrown out at high velocity if installed incorrectly. The spindle is therefore only allowed to
be opened by trained personnel.
The highest permissible speed of the spindle unit is not allowed to be exceeded under
any circumstances, also not briey.
Warning! Risk of injury due to crushing of the hand during a tool change!
Carelessness can result in crushing, bone fractures or cuts to
the hand.
Under no circumstances is it allowed to reach into the tool receptacle with the ngers.
10
Safety
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Safety
2.5 Measures for your safety
NOTE:
The spindle is only allowed to be installed and put into operation if the related
documents have been read fully and understood.
For your own safety and for the safe function of your device, please be sure to observe
the following points:
Follow the safety instructions:
yFollow safety instructions and warnings in the documentation related to the spindle and other
devices.
Electric drives are dangerous:
yDue to electrical voltages in the low voltage range
yDue to rotating parts
yDue to hot components and surfaces
Protection against magnetic and/or electromagnetic elds during
installation and operation
yPersons tted with heart pacemakers, metallic implants or hearing aids, etc. must not be allowed
access to the following areas:
− Areas in the immediate vicinity of electrical equipment!
− Areas where electronic components and drive controllers are installed, repaired and operated!
− Areas where motors are installed, repaired and operated! Motors with permanent magnets
pose particular hazards.
During installation observe the following:
NOTE:
It is a prerequisite that the operating organisation is already familiar with the
subject of "high-frequency drives" as a result of attending an appropriate
training course or from reading literature.
yComply with connection conditions and technical data as per the
documentation and the rating plate!
yComply with standards and directives on electrical installation, such as
cable cross-section, shielding, etc.!
yDo not touch electronic components or contacts! Electrostatic discharge
can harm people and destroy components!
yTake protection measures and use protective devices as per the applicable
regulations (e.g. EN 60204 or EN 61800-5-1)!
yObserve "device earthing" protection measure!
Ambient conditions
yPay attention to the information about the transport, storage and correct
operation of the spindle stated in the installation manual in "chapter 6
Appendix".
11
Safety
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Safety
Warning! Risk of injury due to crushing during installation!
Carelessness during installation can result in crushing, bone
fractures or cuts.
Please pay attention to "Personal safety precautions"
Warning! Mortal danger due to magnetic and/or electro-
magnetic elds for persons with heart pacemakers!
Persons tted with heart pacemakers, metallic implants,
hearing aids, etc. must not be allowed access to the following
areas:
• Areas where drive systems are installed, repaired and operated.
• Areas where motors are installed, repaired and operated.
• Motors with permanent magnets pose a particular hazard!
Further protective measures are to be taken by the operating organisation.
NOTE:
The pictograms may also be used on their own with the signal word in this
document. However, they apply in the same way as the complete warning.
2.6 General safety instructions and warnings
Hazards may emanate from our products (motor/devices). For this reason follow the
safety instructions and warnings in this document.
Danger! Risk of injury due to electrical power!
Carelessness will result in serious injuries or death. The motor/
the spindle is operated with dangerously high voltages.
For this reason, never connect or disconnect connectors while in operation. It is imperative
attention is paid to the correct earthing of the spindle housing.
Danger! Risk of injury due to rotating parts!
Carelessness will result in serious injuries or death.
Follow safety instructions and warnings in this document.
Warning! Risk of injury due to hot surfaces!
Carelessness may result in serious burns.
Follow safety instructions and warnings in this document.
Caution! Damage to the components (device, motor or spindle) due to
incorrect operation!
Carelessness may result in damage. Follow safety instructions
and warnings in this document.
12
Safety
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Safety
2.7 Intended use of the spindle
The spindle with magnetic bearings is intended for installation in electrical systems
or machines. It is powered from a drive controller that must be designed for motor
frequencies up to 400 Hz. Commissioning, i.e. start-up of intended operation, is
prohibited, unless it has been ascertained that the entire machine complies with the
provisions of the applicable directives.
These include the Machinery Directive 2006/42/EC, the Low Voltage Directive 2014/35/
EU, the EMC Directive 2014/30/EU. EN 60204-1 (Safety of machinery) is also to
be followed. It is imperative the applicable regulations and standards in the specic
application area are followed.
NOTE:
The magnetic bearings in the spindle are only to be operated using
LeviOnejunior magnetic bearing electronics of type 52LJ008 from KEBA.
The usage of magnetic bearing electronics from another manufacturer is not
allowed.
NOTE:
The organisation operating the system must provide suitable cooling to
prevent impermissible heating of the spindle (see chapter “3.5 Motor cooling”).
The spindle must be operated with a comprehensive protection concept. This protection
is not entirely included in the scope of supply.
Caution! Damage to the components (device, motor or spindle) due to
unsuitable protection devices!
Carelessness or incorrect operation may result in damage.
Due to the high operating frequencies, earth faults may cause short circuit currents that are not
detected by the usual protection devices; however these currents can cause res, damage or
injuries.
Caution! Damage to the spindle due to incorrect handling!
The spindle is only allowed to be used and put into operation
in conjunction with the components "LeviOne junior magnetic
bearing electronics", "drive controller ServoOne" and suitable
water cooling.
The cooling water for the spindle must meet the corresponding technical requirements.
2.7.1 Repairs
Repairs may only be carried out by authorised repair workshops. Unauthorised repairs
could lead to injuries and damage. The warranty will be rendered void.
2.7.2 Maintenance
The user has the obligation to prepare a maintenance schedule for the system.
The sequence of the individual maintenance tasks must be stated in this schedule.
Corresponding precautionary measures are to be taken before and during the
dismantling of the spindle.
2.8 Foreseeable misuse
yThe spindle is not intended for installation in vehicles or mobile equipment. This usage is
considered usage in extraordinary environmental conditions and is not allowed.
yThe spindle is not intended for installation in environments with damaging oils, acids, gases,
vapours, dusts, radiation, etc.
yThe spindle is not approved as a generator of high-frequency onboard networks for which it is
not designed.
13
Safety
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Safety
2.10 Responsibility
The spindle meets the requirements of IEC 60034-1
NOTE:
Electrical components such as motor, spindle and drive units are, in principle,
not fail-safe. The installer and/or organisation operating the machine or system
are/is responsible for ensuring that the spindle is rendered safe if a component
fails.
In the section on "Electrical equipment of machines", the standard EN 60204-1 "Safety
of machinery" stipulates safety requirements for electrical drives and controllers. They
are intended to protect personnel and machinery, and to maintain the machine or plant
concerned in correct working order, and must be observed.
The organisation operating the machine must ensure the maximum spindle speed is not
exceeded under any circumstances.
The EMERGENCY STOP function shuts down the supply of electrical power to the
entire installation or part of the installation as per EN 60204-1. It may be appropriate to
provide an emergency stop function that maintains individual components, e.g. magnetic
bearings, in operation or initiates specic safety sequences to protect against danger.
Emergency stop means stopping a process or a movement. We recommend the supply
of electrical power is not disconnected from the magnetic bearing electronics before the
speed is less than 3 Hz, even if there is a fault.
The design of such a measure is assessed by means of a risk analysis of the machine or
system, including the electrical equipment, according to EN ISO 14121 and according
to EN ISO 13849-1 "Safety of machinery - Safety-related parts of control systems" by
selecting the circuit category.
2.9
Declaration of incorporation
14
Safety
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Safety
2.10.1 Measures taken by the operating organisation (residual risk):
yProvide protective cover
yTrain personnel
yPrepare internal procedure
yConnection only by specialist personnel
yCheck earth connection for correct function before commissioning as per VDE 0100; prepare
report on measurement
NOTE:
Earthing is only provided by the motor cable connected.
yMonitor the limits (speed; temperature)
yEvaluate clamping state monitoring.
yProvide personal protective equipment (PPE).
yPay attention to information about permissible bearing, transport and operating temperatures.
Warning! Mortal danger due to magnetic and/or electro-
magnetic elds for persons with heart pacemakers!
Persons tted with heart pacemakers, metallic implants,
hearing aids, etc. must not be allowed access to the following
areas:
• Areas where drive systems are installed, repaired and operated.
• Areas where motors are installed, repaired and operated.
• Motors with permanent magnets pose a particular hazard!
Further protective measures are to be taken by the operating organisation.
15
Mounting (installation) of the spindle
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Mounting (installation) of the spindle
3 Mounting (installation) of the spindle
3.1 Introduction
The spindle is a precision product. For this reason, basic issues such as careful handling
and extreme cleanliness are vital during installation and also in operation.
To obtain the assured characteristics of the spindle unit also in the machine, the
following basic rules are to be followed during installation:
yOnly use lifting equipment with sufcient load-bearing force to transport the spindle unit.
yThe spindle unit is only allowed to be lifted at the attachment points with ring screws provided.
yThe sealing plugs in the supply bores on the spindle unit must be removed (see Figure 3.2).
yThe supply lines for the cooling are to be cleaned before connecting. Soiling must not enter
the spindle's internal mechanism. We recommend ushing the supply lines with media of the
stipulated quality.
yIt is to be ensured that all mating surfaces are clean before assembly.
yThe spindle must be installed in the spindle housing without the need to apply force. The
application of force may cause damage to the spindle.
yPlease do not attempt to clean using compressed air.
yCheck tools for suitability before use (see also chapter Tools)
yNever lift the spindle unit at the shaft or set it down on the end of the shaft or tool interface!
3.1.1 Notes for installation and operation
Warning! Risk of injury due to hot surfaces!
Carelessness may result in serious burns.
Note that the spindle housing can reach 80 °C in operation.
Warning! Risk of injury due to crushing of the hand during a tool change!
Carelessness can result in crushing, bone fractures or cuts to the hand.
For this reason, please pay attention to the information in chapter 2.3 "Personal safety
precautions".
NOTE:
The spindle is earthed solely via the connector (3) for the motor power (see
“Figure 4.1 Electrical connections”).
NOTE:
The organisation operating the system must provide suitable cooling (spindle
with cooling water, drive controller and magnetic bearing electronics with
sufcient cooling air) to prevent impermissible heating of the spindle. Do not
operate the spindle without cooling, even briey!
Caution! Damage to the spindle due to incorrect installation conditions!
For this reason:
• There must be no moisture inside or ingress of moisture
• There must not be any aggressive or conductive substance in the ambient air
• The spindle is only allowed to be used indoors
Further information on ambient conditions can be found in chapter 6 Appendix
16
Mounting (installation) of the spindle
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Mounting (installation) of the spindle
3.1.2 Fastening the spindle
The spindle can be installed in any installation position. However, the fastening should be
designed with a large area and so it is torsionally stiff to prevent resonant vibration of the
system.
NOTE:
If the spindle is used for vibration drilling, the machining process causes
the excitation of vibration. For this reason the spindle fastening must be
additionally reinforced using suitable measures.
All dimensions in mm
Figure 3.2 Spindle fastening (examples)
NOTE:
Please ensure that sealing of the leakage connection is reliably prevented, for
details see Figure 3.3 connection E and Rotodisk installation guide.
3.2 Electromagnetic compatibility
This section contains basic information that must be followed during the installation
of the overall system and includes measures on how interference in the area of radio
frequencies can be reduced and the interference immunity of electronic systems can be
increased. Simply following this brief information without ltering, or the usage of lters
without the installation measures listed, will not provide any guarantee of the reliable
operation of the system. The applicable standards, directives and laws are not covered
here, there are only general references to them.
3.2.1 Earthing
For optimal earthing/shielding, only use pre-assembled cables from KEBA for the motor
power, rotary encoder, magnetic bearing sensors and magnetic bearing power. You will
nd further information on the cables in chapter 6 Appendix.
3.2.2 Shielding, general
Control cables must be laid physically separate from power cables or must be shielded
to prevent the coupling of interference.
Always make all shield connections with low impedance, i.e. with a connection with an
area as large as possible (e.g. connector housing).
The cable shields should be earthed at both ends with a large area connection to
prevent the coupling of interference into control cables for digital signal transmission.
Connecting shields via a pin in a connector (e.g. SUB-D) is insufcient. We therefore
recommend using the metal housing on the connector for the screen connection.
17
Mounting (installation) of the spindle
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Mounting (installation) of the spindle
3.3 Tool/workpiece spindle comparison
The LeviSpin R140 is available in two models (see order code). The differences are
shown in the following matrix:
Tool spindle Workpiece spindle
Order no. LS-R140-0xxx LS-R140-0xx1 LS-R140-1xxx
Clamping tool (Sigma) For tools (drills, milling cutters, etc.) For workpieces
Rotary union (GAT) Yes No
Figure
•
•
3.2.3 Additional EMC measures:
Additional measures should be implemented to reduce further the EMC problems.
yIf control/signal cables and power cables cross, they should cross at an angle of 90°.
ySeparate control and power areas are to be established in the switch cabinet. The drive controller
belongs in the power area. The same applies to all cable entries.
yThe shielding should consist of an E-CU braid with a coverage of at least 85%.
yUnshielded outgoing and return wires are to be twisted together.
3.2.4 Electrostatic charging of the shaft
The spindle shaft is electrically isolated due to the magnetic bearings and can therefore
become charged. The maximum possible charge is, however, below the stipulated limits
as per EN 61800-5-1 and EN 61010 and is therefore harmless.
NOTE:
The capacitance and with it the amount of charge on the shaft can increase
due to the tools clamped. In this situation, it is to be checked by the user
whether the stipulated limits are exceeded and corresponding measures are
necessary. Electrical tool capacitances of < 1 nF are uncritical.
3.2.5 Magnetic shielding
Magnetic elds exceeding 5 mT can occur outside the spindle housing.
To further reduce these stray elds, additional magnetic shielding measures or mechan-
ical adjustments to the holder are required. This can reduce the adhesion of magnetisa-
ble chips.
These measures should be evaluated in detail with KEBA.
18
Mounting (installation) of the spindle
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Mounting (installation) of the spindle
3.4 Dimensions of the spindle
52,3
83,50
HSK-E32
ø140 h9
(-0,100)
ø
175
182
140,20
17,20
492
M8
14
179,50
Z
+
-
H
G
F
X1
All dimensions in mm
For information on item X1, H, G, and F see rotary union connections
Figure 3.1 Dimensional drawing, LeviSpin R140
NOTE:
All spindle models (tool/workpiece spindle) have the same dimensions.
3.5 Motor cooling
Water cooling is intended to be used for the motor. You will nd the connection
specications in chapter 6 Appendix. The spindle temperature is measured in the end
winding on the cable outlet side using a KTY 84. The motor temperature sensor is
designed with basic insulation as per EN 61800-5-1 in relation to the motor winding.
NOTE:
The evaluation electronics in the drive controller connected must also be
designed with basic insulation as per EN 61800-5-1.
3.5.1 Coolant
For the coolant we recommend a mixture of:
Drinking water + corrosion inhibitor (e.g. Thermogard HT)
NOTE:
Chloride ions (Cl- > 100 ppm) and calcium carbonate (CaCO3 > 160 ppm)
contamination in the cooling water is not allowed!
The coolant must be as pure as possible to ensure the channels are not clogged. It there
is a suspended matter concentration of more than 15 mg/dm3, continuous purication is
recommended.
19
Mounting (installation) of the spindle
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Mounting (installation) of the spindle
3.6 Bearings (contact-free magnetic bearings)
The spindle is equipped with two radial magnetic bearings and one axial magnetic
bearing. The usage of lubricants is made unnecessary by these contact-free bearings
and there is no contaminating abrasion. Due to the lack of mechanical bearing wear, a
higher peripheral speed can be achieved with longer service life and less maintenance
effort by using magnetic bearings.
Magnetic bearing electronics are required to operate the magnetic bearing.
NOTE:
The magnetic bearings in the spindle are only to be operated using magnetic
bearing electronics of type 51LJ008 from KEBA. The usage of magnetic
bearing electronics from another manufacturer is not allowed.
You will nd details on the magnetic bearing electronics in the operation
manual for the magnetic bearing electronics (see “1.3 Reference documents”).
3.6.1 Emergency bearings
Two mechanical emergency bearings are also installed in addition to the magnetic
bearings. They are used at standstill and in emergencies (e.g. failure of the power supply)
and ensure the spindle shaft can coast down safely without damage.
NOTE:
If contact occurs between the rotating shaft with magnetic bearings and the
emergency bearing, this situation is acquired by a counter in the magnetic
bearing electronics. The system outputs a corresponding warning if 70% of
the threshold is reached.
Type Value
Max. shaft play (can be used for machining process)
Radial ± 120 µm
Axial ± 150 µm
The shaft play is dependent on the process and frequency, see “3.8 Axial shaft play”
Table 3.3 Technical data, shaft play
Item Description Connection Figure
A Inlet G1/8
H
G
F
X1
52,3
X4.2
A
B
X2
X3
C
X4.1
X5
X6
B Outlet G1/8
Note:
The sealing plugs for the motor
cooling must be removed before the
connection of cooling lines!
Figure 3.2 Connection of motor cooling (for technical data, see chapter 6 Appendix)
3.5.2 Coolant temperature
The coolant temperature can be between 5 °C and 30 °C. The coolant temperature
should not be more than 10 K below the ambient temperature to prevent the formation
of condensation inside the spindle.
While lling the cooling circuit, attention is to be paid to ensuring there are no circulation
problems due to pockets of air.
20
Mounting (installation) of the spindle
LeviSpin R140 Installation Manual
ID no.: 7229.20B.1-01 Date: 2023-12
Mounting (installation) of the spindle
3.7 Tool clamping system
The spindle is equipped with an automatic clamping cartridge manufactured by SIGMA
of type HSKE32. The installation and operation of this clamping tool is described in a
separate document (see “1.3 Reference documents”).
3.7.1 Clamping state sensor
The tool system is equipped with an inductive distance sensor manufactured by
BALLUFF.
H
G
F
X1
52,3
X4.2
A
B
X2
X3
C
X4.1
X5
X6
(X1) Clamping state sensor
(H) Collet cleaning
(G) Clamp tool
(F) Release tool
Figure 3.3 Position of the clamping state sensor on workpiece spindle (LS-R140-1xxx)
52,3
X4.2
A
B
X2
X3
C
X4.1
X5
X6
H
G
F
D
E
X1
(X1) Clamping state sensor
(H) Taper cleaning air connection
(G) Clamp tool air connection
(F) Release tool air connection
(E) Route leakage connection so that a backup
cannot occur (G1/8)
(D) Inlet (µm lter mesh required) (G1/8)
Figure 3.4 Position of the clamping state sensor, tool spindle (LS-R140-0xxx)
The electrical connection is routed out using a ying lead.
Connection diagram Pin Assignment Function
BN UE DC Supply voltage
24 VDC
BK UA,RL DC Clamping state
WH UA,RT DC Temperature output
BU GND Ground
Figure 3.5 Terminal assignment, clamping state sensor
3.7.2 Clamping states
The clamping states must be evaluated via an ext. controller. The clamping state sensor
used is aligned such that in the "tool clamped" state an analogue value of approx. 5 VDC
is output.
The table below shows the possible state transitions of the tool clamping system.
Threshold Reference value State Rotation allowed
< 3 VDC 0 VDC No tool clamped YES 1)
3 … 8 VDC 5 VDC Tool clamped YES
> 8 VDC 10 VDC Tool ejected No
1) Limited speed for tool positioning
Table 3.4 Tool clamping system states
NOTE:
Rotary movement of the drive shaft is only allowed with a tool insert clamped.
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
Page is loading ...
/
