Keba LeviSpin 6D Spindle Installation Installation guide

Brand: Keba

Model: LeviSpin 6D Spindle Installation

Type: Installation guide

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

7229.20B.1-02 2024-01 Technical data of Pre-assembled cables moved to "LeviSpin system description"

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 specications 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.1-02

Date: 2024-01

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.

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Table of contents

1 General ........................................................................................5

1.1 Goal of this document ........................................................................................... 5

1.2 Prerequisite ........................................................................................................... 5

1.2.1 Qualication ................................................................................................... 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 ................................................................................................................. 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

Table of contents

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Table of contents

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

3.2.5 Magnetic shielding ....................................................................................... 17

3.3 Dimensions of the spindle...................................................................................... 17

3.4 Motor cooling ........................................................................................................ 18

3.4.1 Coolant ........................................................................................................ 18

3.4.2 Coolant temperature .................................................................................... 18

3.5 Bearings (contact-free magnetic bearings) ............................................................ 19

3.5.1 Emergency bearings .................................................................................... 19

3.6 Tool clamping system ............................................................................................ 19

3.6.1 Clamping state sensor ................................................................................. 19

3.6.2 Clamping states ...........................................................................................20

3.7 Axial shaft play ...................................................................................................... 20

Table of contents

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Table of contents

4 Electrical installation ................................................................... 21

4.1 Overview of connections ....................................................................................... 21

4.2 Pre-assembled cables ........................................................................................... 21

4.3 Electrical connections on the spindle .................................................................... 22

4.3.1 Specication, Hall sensor (X6) ...................................................................... 23

4.4 Drive controller ...................................................................................................... 23

5 Commissioning ..........................................................................25

5.1 O pe r a t i o n............................................................................................................... 25

5.2 Stopping the spindle .............................................................................................. 25

A Appendix ...................................................................................27

A.1 Technical data ....................................................................................................... 27

A.2 Ambient conditions ................................................................................................ 29

A.3 Data sheets, pre-assembled cables ...................................................................... 29

Glossary ............................................................................................ 31

General

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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 verication 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 sufcient training.

yAn internal procedure is to be prepared.

1.2.1 Qualication

yOnly qualied 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

specied 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

LeviSpin system description 7229.20B.x PDF contains technical data

Pre-assembled cables

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

7171.20B.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

General

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

General

1.4 Order code

The article designation provides information on the spindle model supplied. The

signicance 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

tbd 0

Type of connection:

Robotics

Machine tool

Encoder type:

Sin/Cos

SinCos plus Hall

tbd 0

Stall torque 1/10 Nm:

5.3 Nm

tbd 0

Rated speed:

12000 1/min

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.

(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.

General

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

General

1.9 Rating plate

On the rating plate for the spindle you will nd:

18000 rpm

30°C

2020

39 kg

3~ Mot

cos 

Ins. cl

IP23/65

IEC60034-1

LS-R140-0000-0000

KEBA Industrial Automation

Germany GmbH

35633 Lahnau

www.keba.com

Year

SN: 205512345

Art.No.

287 V15 A12000 rpm

nmax

6,3 kW 0,98

Uind

400 Hz 265 V

max. coolant temp.

7229.0000.0

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 certied disposal organisation with scrapping.

1.8 Support

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

NOTE:

You will nd information about our services on our web site tecnical support.

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Safety

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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 specication 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 briey.

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.

Safety

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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".

Safety

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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.

Safety

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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 specic

application area are followed.

NOTE:

The magnetic bearings in the spindle are only to be operated using

LeviOnejunior 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 “3.4 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.

Safety

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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 specic 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

Safety

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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.

Mounting (installation) of the spindle

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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 sufcient 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

sufcient cooling air) to prevent impermissible heating of the spindle. Do not

operate the spindle without cooling, even briey!

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

Mounting (installation) of the spindle

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

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 insufcient. We therefore

recommend using the metal housing on the connector for the screen connection.

Mounting (installation) of the spindle

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Mounting (installation) of the spindle

3.3 Dimensions of the spindle

52,3

83,50

HSK-E32

ø140 h9

(-0,100)

175

182

140,20

17,20

492

179,50

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.

3.2.3 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.

Mounting (installation) of the spindle

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Mounting (installation) of the spindle

3.4 Motor cooling

Water cooling is intended to be used for the motor. You will nd the connection

specications 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.

3.4.1 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 purication is

recommended.

Item Description Connection Figure

A Inlet G1/8

52,3

X4.2

X4.1

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)

3.4.2 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.

Mounting (installation) of the spindle

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Mounting (installation) of the spindle

3.6 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”).

3.6.1 Clamping state sensor

The tool system is equipped with an inductive distance sensor manufactured by

BALLUFF.

52,3

X4.2

X4.1

(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

X4.1

(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.

3.5 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”).

3.5.1 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

Mounting (installation) of the spindle

LeviSpin R140 Installation Manual

ID no.: 7229.20B.1-02 Date: 2024-01

Mounting (installation) of the spindle

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

3.6.2 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.

3.7 Axial shaft play

The maximum axial shaft play available depends on several factors such as the

frequency or tool and should be determined individually for each process.

100

110

120

130

140

150

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

maximum axial sha� play

Ampl itude [µm]

Frequency [Hz]

Figure 3.6 Maximum shaft play (characteristic without process shown)

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Keba LeviSpin 6D Spindle Installation Installation guide

Keba LeviSpin 6D Spindle Installation Installation guide

Keba LeviSpin 6D Spindle Installation Installation guide

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