HSD ES915 User Manual

Instructions for use
HSD
MECHATRONIC
DIVISION
5801H0056
EN
Rev.02
5801H0056 Rev.02 __________________________________________________________ 1/181
ES884 – ES888
ES915
ES919 – ES929 – ES939
ES983 – ES988

HSD ES915 Specifications

General

Brand	HSD
Model	ES915
Category	Tools
Language	English

Summary

Preliminary Information

Risks Associated with Use

Highlights risks during electrospindle operation, including contact with moving parts and environments.

Risks Associated with Incorrect Use and Operation

Details hazards from improper operation, modification, or bypassing safety devices.

Specific Risks During Maintenance

Technical Specifications

Technical Cards ES884

Presents detailed technical specifications and performance data for the ES884 model.

Technical Cards ES888

Provides detailed technical specifications and performance data for the ES888 model.

Technical Cards ES915

Lists detailed technical specifications and performance data for the ES915 model.

Technical Cards ES919

Presents detailed technical specifications and performance data for the ES919 model.

Technical Cards ES929

Lists detailed technical specifications and performance data for the ES929 model.

Technical Cards ES939

Provides detailed technical specifications and performance data for the ES939 model.

Technical Cards ES983

Lists detailed technical specifications and performance data for the ES983 model.

Installation and Initial Start-Up

Mechanical Connections

Covers the mechanical aspects of installing the electrospindle, including positioning and fixing.

Tool Change System

Fixing Electrospindles (Rectangular Framework)

Pneumatic Connections

Covers pneumatic connection requirements, including air purity and circuit diagrams.

Air Purity

Hydraulic Connections and Cooler Specifications

Electrical Connections

Explains how to connect power and signal cables to the electrospindle connectors.

Button for Manual Command of Tool Release

General Checks After Installation

Checks Before Start-Up

Lists essential checks for positioning, pneumatic, electrical connections, and inverter programming.

Pneumatic Connections Checks

Inverter Programming

Guides on setting inverter parameters like voltage, frequency, speed, and current.

Start-Up Checks

Specifies checks before initial operation, including sensor signals and tool-holder insertion.

Use and Adjustment

Tool-Holder Locking and Expulsion Device

Details the pneumatic piston mechanism for tool-holder locking and expulsion.

Tool-Holder Cone

General Recommendations for Tool-Holder Cones

Tool

Discusses tool requirements, particularly dynamic balancing, for high-speed electrospindle operation.

Speed Limits

Emphasizes observing maximum rotational speed specified by the tool manufacturer.

Maximum Speed and Tool Shape

Explains how tool weight, assembly, and center of gravity affect maximum safe operating speed.

Procedure for Reading Charts

Explains how to use charts to determine the maximum safe operating speed based on tool parameters.

ES915 HSK F63 Long Nose Speed Chart

Chart showing maximum speed limits for ES915 electrospindles with HSK F63 long nose.

ES929 ISO30 Short Nose Speed Chart

Chart illustrating maximum speed limits for ES929 electrospindles with ISO30 short nose.

ES929 ISO30 Long Nose Speed Chart

Chart displaying maximum speed limits for ES929 electrospindles with ISO30 long nose.

ES929 HSK F63 Short Nose Speed Chart

Chart showing maximum speed limits for ES929 electrospindles with HSK F63 short nose.

ES929 HSK F63 Long Nose Speed Chart

Chart illustrating maximum speed limits for ES929 electrospindles with HSK F63 long nose.

ES915 ISO30 Short Nose Speed Chart

Chart displaying maximum speed limits for ES915 electrospindles with ISO30 short nose.

ES919, ES939 ISO30 Short Nose Speed Chart

Chart showing maximum speed limits for ES919/ES939 electrospindles with ISO30 short nose.

ES919, ES939 ISO30 Long Nose Speed Chart

Chart illustrating maximum speed limits for ES919/ES939 electrospindles with ISO30 long nose.

ES919, ES939 HSK F63 Short Nose Speed Chart

Chart displaying maximum speed limits for ES919/ES939 electrospindles with HSK F63 short nose.

ES919, ES939 HSK F63 Long Nose Speed Chart

Chart showing maximum speed limits for ES919/ES939 electrospindles with HSK F63 long nose.

ES983 HSK E63 Long Nose Speed Chart

Chart illustrating maximum speed limits for ES983 electrospindles with HSK E63 long nose.

ES888/988 ISO 30 Short Nose Speed Chart

Chart displaying maximum speed limits for ES888/ES988 electrospindles with ISO30 short nose.

ES888/988 ISO 30 Long Nose Speed Chart

Chart showing maximum speed limits for ES888/ES988 electrospindles with ISO30 long nose.

ES888/988 HSK F63 Short Nose Speed Chart

Chart illustrating maximum speed limits for ES888/ES988 electrospindles with HSK F63 short nose.

ES888/988 HSK F63 Long Nose Speed Chart

Chart displaying maximum speed limits for ES888/ES988 electrospindles with HSK F63 long nose.

What to Do if Tool is Blocked

Provides procedures for handling situations where the tool becomes blocked during operation.

Sensors

Describes the electrospindle's sensors for status monitoring and thermal alarm protection.

Sensor Status Modes and Outputs

Explains the output states of sensors (S1, S2, S3, S4, S5) for different electrospindle conditions.

Thermal Alarm Use and Characteristics

Explains the thermal alarm's function and technical characteristics for stator coil protection.

Maintenance

Scheduled Maintenance

Cleaning Tool-Holder Cone and Spindle Shaft Housing

Details daily cleaning procedures for tool-holder cones and spindle shaft housings.

Replacing Components

Replacing Shaft Kit (Models ES884, ES888)

Instructions for replacing the shaft kit in ES884 and ES888 models, including disassembly.

Disassembly Procedure (ES884, ES888 Shaft Kit)

Assembly Procedure (ES884, ES888 Shaft Kit)

Replacing Shaft Kit (Models ES915, ES919, ES929, ES988)

Instructions for replacing the shaft kit in ES915, ES919, ES929, ES988 models, including disassembly.

Disassembly Procedure (ES915/919/929/988 Shaft Kit)

Assembly Procedure (ES915/919/929/988 Shaft Kit)

Replacing Shaft Kit (Model ES919 Encoder)

Instructions for replacing the shaft kit in ES919 models equipped with an encoder.

Disassembly Procedure (ES919 Encoder Shaft Kit)

Assembly Procedure (ES919 Encoder Shaft Kit)

Replacing Shaft Kit (Model ES939)

Instructions for replacing the shaft kit in ES939 models.

Replacing Shaft Kit (Model ES939 with Encoder)

Cylinder Unit Disassembly (ES939 with Encoder)

Replacing Encoder Readers

Replacing Sensors

Wiring Sensors (ISO30, Single-Acting Piston)

Wiring Sensors (HSK, Single-Acting Piston)

Wiring Sensors (ISO30, Double-Acting Piston)

Wiring Sensors (HSK, Double-Acting Piston)

Replacing the Sensor Unit

Adjusting Sensor S1 (ISO and HSK)

Calibration procedure for sensor S1, with recommendations for HSK versions using a kit.

Adjusting Sensor S2 (ISO Versions)

Adjusting Sensor S2 (HSK Versions)

Adjusting Sensor S3 (ISO and HSK)

Adjusting Sensor S4 (HSK Versions Only)

Kit of Gauges for Sensors S1/S4 HSK F63

Kit of Gauges for Sensors S1/S4 HSK E63

Troubleshooting

The Electrospindle Does Not Rotate

Troubleshooting steps for issues where the electrospindle fails to rotate.

The Tool-Holder is Not Locked

Diagnoses and solutions for when the tool-holder is not properly locked.

The Tool-Holder is Not Expelled

Troubleshooting steps for when the tool-holder fails to be expelled.

Lack of Pressurisation

Sensor Output Issues

Diagnoses and solutions when sensors do not provide the required output.

Electric Fan Malfunction

Electrospindle Overheating

Addresses causes and solutions for electrospindle overheating issues.

Performance Below Specifications

Vibrations of the Electrospindle