Attentions for handling

Attentions for handling

CHECKLIST – Installation and starting after Spindle Repair Service

  • The spindle must be installed and operated by persons only who are familiar with this product and qualified for the corresponding work.
  • It is up to the customer to guarantee that the responsibilities and the personnel qualifications are fixed and respected clearly with regard to installation and starting of the spindle.
  • Any person who is commissioned with installation and starting of the spindle must have read and understood this present instruction manual.
  • All safety connections in or at the spindle have to be connected with its proper control device. It is not permitted not to connect them or built an “electric bridge” in-between.

bullet Spindles with grease lubrication

For spindles with grease lubrication please observe the following points :

  • Damage to the bearings do mostly result from impurities (e.g. dirt, dust, water etc.); this can also cause a destruction of the grease lubrication.
  • External supplied air, for sealing air (Air seal) or overpressure, has to be absolutely clean. Water and oil have to be filtered from the air.
  • Air supply is realized with a fog lubricator LAG / LFE. Water and oil separator necessary!
  • If spindles with grease lubrication have been stored for a long time, please make sure before starting that a running-in period of 1-2 hours at low speed has to be arranged. In order to avoid a shift of the grease the spindles have to be run-in every 3 month following the instructions for first start-up. Afterwards they have to run for about 2-3 hours. Bearing-cage noise may occur, which will stop after a certain time of running of the spindle. It is not a sign of broken bearings.
  • Spindles that have been stored for more than 2 years without having been operated have to be disassembled. The bearings have to be lubricated with new grease. Please contact DEUSCHLE!

bullet Spindles with oil lubrication

Before the first start-up please check the spindle including all peripheral devices in the following order:

  • Damage to the bearings do mostly result from impurities (e.g. dirt, dust, water etc.); this can also cause a destruction of the grease lubrication.
  • The pre-lubrication time before spindle start-up has to be observed and followed
  • The supply of oil has to be assured (hereby please check the oil flow directly on the spindle by taking off the hose on the „oil in“ hose for a short time and letting the oil drop into a white cloth)

bullet First Start-up of the spindle CHECKLIST

Before the first start-up please check the spindle including all peripheral devices in the following order :

  • If oil lubrication: Check each oil pipe and clean it properly
  • If oil lubrication: Check each plastic pipe and cut the hose end properly 90°
  • If oil lubrication: Check the air supply device (function etc.)
  • Check the air pressure needed at spindle side and adjust if necessary (not at manometer)
  • Check the quality of the cooling liquid (cooling additive necessary?)
  • Check coolant flow in Liter/min
  • Check direction of rotation when starting spindle – correct?
  • Check the correct sealing air pressure
  • Check all tools for concentricity of clamping
  • Make sure that by turning the main switch of the machine sealing air is active
  • Let the spindle run for about 15 minutes with 10 % of the maximum speed. Then speed up the machine step by step for about 1 hour and let it run for another hour. If the temperature exceeds 55 ° C switch off the spindle and let it cool down. Repeat the procedure until the grease is distributed. Check the spindle for vibrations. In case please balance the tool holder with tools in dynamic condition.
  • Are the tools dynamically balanced with balancing quality G  2.5 at nominal speed
    of the tool? Please refer also to its guideline DIN ISO 1940-1/2.

bullet Daily Start-up of the spindle (Cold room condition < 20°C)

  • The spindle has to be started up according to the mentioned instructions after a stand still duration of more than four months. (See above).
    In order to exclude thermic distortion caused by fluctuation in temperature during the storage, do not start up the spindle in normal start-up time (8-15 seconds) to maximum speed while it is cold. A warming up to half of the speed for about 15 minutes is useful. When the spindle reached the operating temperature it can be normally accelerated and braked (8-15 seconds).
    A warming up with reduced speed is always necessary with temperatures below 15°C at the spindle housing to bring the spindle to operating temperature.

bullet Working Condition

  • The working conditions of the spindle need to be observed continuously in order to avoid damages in the spindle itself. This guarantees a long life span and a clam run. If changes to the original standard described in this instruction manual occur the spindle has to be shut down immediately in order to avoid further damages.
  • These changes might be: The spindle shows visible changes, Strong vibrations or problems during the working process, Abnormal noise, A defect of peripheral devices

bullet Avoiding Speed Ranges

  • Due to the constructive design the spindle has different resonant frequency ranges. These resonant frequency ranges are much higher than the maximum speed. Using multi-cutting tools the stimulate frequency is brought nearby the resonant frequency. This area of the resonant frequency have to be avoided. The avoiding speed ranges are to be asked at the spindle manufacturer.

bullet Storage of the spindle

  • The place of storage has to be dry (max. 55% humidity) and well ventilated
  • Outdoor storage of the spindle is not allowed!
  • In case of storage or transport temperature lower 5°C please make sure that all cooling agents are removed. Otherwise serious damages may occur to the spindle.
  • The permissible storage temperature is –10 C to +55 C.

bullet Service and cleaning

  • General services work on the spindle covers periodical checks and cleaning of the interface between spindle and tool holder (taper surface). The taper surface has to be cleaned at least once a week.
    Cleaning work on the spindle can be carried out only if overpressure/ sealing air is switched on.

bullet Permissible operating conditions

  • The permissible operating temperature range is min. 18 C up to max. 40 C
Disturbance Cause Control check / Recovery
Tool does not clamp properly Splinters, surplus grease or dirt obstruct the clamping action Clean and examine the HSK/ISO tool holders. Check the approx. switch S4
Accuracy to size of the tool holders are off the tolerance Check tool holders or replace it
Tool is positioned insufficiently exactly to the tool holder Adjust tool changer of the machine (see instruction manual of the machine)
Setting dimension of the clamping taper incorrectly, fixing screw is not tighten Adjust it to correct measurement.
Collet worn out or defectively Replace collet
Clamping springs broken, clamping force insufficient; or with another disturbance Send spindle to DEUSCHLE for repair
Tool does not open properly Tool holder got stuck Pressure at the hydraulic device or pneumatic can be damaged. Pls check.
HSK design of the tool holder is damaged or out of the tolerance Check tool holders and change to new one
Hydraulic cylinder loses oil Check hydraulic device and hydraulic pressure
Oil pressure too low (loosen tool) Increasing pressure by 20 bar at the hydraulics aggregate. Attaching again reduce on normal pressure
Fretting corrosion at the cone due to extreme vibrations Rebalance the tool immediately or replace to new tool holder/tool,

***change process parameters***

Oil level too low Refill fine-filtered (!) oil to signed level
Hydraulic cylinder broken or broken for another reason Send spindle to DEUSCHLE for repair
Tool shows problem during working process Clamping system broken,
helical disk spring broken
Draw-In force too low
Replace clamping set or send spindle to DEUSCHLE for repair including 2 or 3 tool holders together
Spindle vibration Tool or tool holder is not balanced sufficiently Balance accord. balancing grade G 2,5
Run out test of the tool shows abnormal values The run out error can be max. 0,01mm at 4 x tool diameter by using testing bar
Error message, tool unclamped Error in the electrical connection Check wires and connection components
Check connector pins and if necessary adjust them again
Clamping set (clamping taper) is not adjusted correctly Check the measure according to ISO and adjust again.
Analog sensor is not correctly programmed Check limit values of the analog sensor and adjust in the PLC / CNC
Clamping system is broken or the cause is unclear Send spindle DEUSCHLE for repair
Error message at tool clamped without tool Error in the electrical connection Check wires and connection components
Analog sensor is not correctly adjusted Check limit values of the analog sensor and adjust in the PLC / CNC
Collet Pin bent or clamping system broken Send spindle DEUSCHLE for repair
Error message, tool clamped Error in the electrical connection Check wires and connection components
Analog sensor is not correctly programmed Check limit values of the analog sensor and adjust in the PLC / CNC
Clamping set is not correctly adjusted Check dimension and if necessary adjust them again
Metal chips, worn tool holder or obstruct the clamping action Clean the HSK/ISO taper of the spindle and the tool
Clamping system is defect or the cause is unclear Check the clamping system or send spindle DEUSCHLE for repair
Spindle does not turn Error in the electrical connection Check wires and connection components
Converter failure Check whether the exit of the converter voltage is out of order. If no, check the voltage wires according to the manual of the converter.
Turn conclusion Examine the difference of the turn resistance. The difference between the individual motor phases may not exceed 0.1 ohms. If the difference is more the spindle must be send back to DEUSCHLE for repair.
Ground fault Ground fault, humidity might be inside of the spindle. Check electrical connection and check for ground fault. If the spindle shows a ground fault even by taking-off the plug, it must be sent to DEUSCHLE for a repair service

Questions? Please contact
Deuschle Korea Ltd.
Tel. +82-31-436-2252 www.deuschle.co.kr

Deuschle Korea Ltd. ㅣ CEO : Woo-Seok Heo, Jonathan Deuschle

104-1112, SK Ventium, 166, Gosan-ro, Gunpo-si, Gyeonggi-do, Korea
Tel : +82-31-436-2252(General), +82-31-436-2253
Fax : +82-31-436-2230 E-mail : office@deuschle.co.kr