Colibri Sander BLO 80 2 1 C 30 User Manual

Manual Book:

BLO 80 2.1 C 30

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Characteristics

In most respects aerostatic bearings are ideally suited for use in high-speed machines. Their low
friction provides high mechanical efficiency and minimizes bearing heating problems.

They are quiet and smooth running and do not add to sound and vibration levels of the machine in
the way that high-speed ball bearing do.

Applications

One of the most important fields of application of aerostatic bearings is undoubtedly on machine tools
where the range of machine tool application is very wide.

lmost all of the benefits result from three properties of aerostatic bearings: low friction, precise axis
definition, and the absence of wear. In comparison with spindles with ball or roller bearings, the lower
level of vibration of aerostatic bearings is an important advantage. This is particularly true in relation
to the production of good work piece geometry and surface finish, and in ensuring long life of the
cutting tool, drill or grinding wheel.

erostatic bearings have been employed in machines driven by most types of electric motors and
most types of turbines. They have also been employed in a wide range of machine tool spindles
driven by various types of belts and flexible couplings. In all these cases the driving torque is evenly
and smoothly applied, excepting the case of driving by means of a belt, the drive does not apply large
loads to the bearings. Aerostatic bearings are most successful when operating under these
conditions. They are much less likely to be successfully applied to machines with pulsating drives,
which impose large internal loads on the bearings.

Advantages

CONTENTS

1. Fundamental Safety Instructions. 3

2. Warranty notice. 5

3. Attention – Daily Check Before starting the spindle 6

4. System general description. 7

5. Aerostatic Spindle Label. 7

6. Installing the spindle. 8

7. Removing the spindle from the machine. 9

8. Specification for High – Speed Air Spindle. 10

9. Electrical Motor Specification. 11

10. Brushless DC Motor 12

11. Diagrams:
a) Torque & Power Vs. Rotation Speed 13
b) Final Velocity Vs. Torque & Acceleration Time & External Inertia 13
c) Radial Stiffness Vs. Air Pressure. 14
d) Axial Stiffness Vs. Air Pressure. 14
e) Radial Load Capacity Vs. Air Pressure. 14
f) Axial Load Capacity Vs. Air Pressure. 14
g) No Load Deceleration 14
h) Mechanical Friction Losses. 14
i) Voltage constant 15
j) Current Vs rotation speed 15
k) Torque Vs rotation speed 15
l) Vibration Speed Vs. Rotation Speed. 15
m) Vibration Amplitude Vs. Rotation Speed. 15
n) Power Vs. Current & Rotation Speed. 15

12. Raw Materials Data. 16

13. Spindle Modes. 17

14. Spindle Balancing 18

15. Electrical System. 22

16. Thermistor – 104GT-1. 23

17. Description of a Spindle Testing. 24

18. Cooling Water Sealing & Flow Test Circuit. 25

19. Failure, Cause, Prevention 26

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FUNDAMENTAL SAFETY INSTRUCTIONS

1. Basic operation and designated use of the machine.

1.1 The machine has been built in accordance with state of the art standards and recognized safety
rules. Nevertheless, its use may constitute a risk to life and limb of the user and of the third
parties, or cause damage to the machine and to other material property.

1.2 The machine must only be used in technically perfect conditions in accordance with its designated
use and the instructions set out in the operation manual. Only safety-conscious persons who are
fully aware of the risks involved in operation the machine should operate it. Any functional
disorders, especially those affecting the safety the safety of the machine, should therefore be
rectified immediately.

1.3 The machine is designed exclusively for drilling, grinding and milling operations. Using the

machine for purposes other than those mentioned above is considered contrary to its designated
use. The manufacturer cannot be held liable for any damage resulting from such use. The risk of
such misuse lies entirely with the user. Operating the machine within the limits of its designated
use also involves observing the instructors set out in the operation manual and complying with the
inspection and maintenance directives.

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. Organizational measures.

2.1 The operating instructions must always be at hand at the place of use of the machine.

2.2 In addition to the operating instructors, observe and instruct the user in all other generally
applicable legal and other mandatory regulations relevant to accident prevention and
environmental protection. Those compulsory regulations may also deal with the handling of
hazardous substances, issuing and/of wearing personal protective equipment.

2.3 The operations instructions must be supplemented by instructions covering the duties involved in
supervising and notifying special organizations, working sequences or the personal entrust with
the work.

2.4 Personal entrust with the work on the machine must have read the operating instructions and in
particular the chapter on safety before beginning work. Reading the instructions after work is too
late. This applies especially to persons working only occasionally on the machine e.g. during
setting up or maintenance.

2.5 Check whether personal is carrying out the work in compliance with the operation instructions and
paying attention to risks and safety factors.

2.6 For reasons of security, long hair must be tied back or otherwise secured, garment must be close
fitting and no jewelry, such as ring, may be worn. Injury must result from being caught up in the
machinery or from rings catching on moving parts.

2.7 Use protective equipment whenever required by the circumstances or by law.

2.8 Observe all safety instructions and wearing attached to the machine.

2.9 See to it that safety instructions and wearing attached to the machine are always complete and
perfectly legible.

2.10 In the event of safety-relevant modifications or changes in the behavior of the machine during
operation, stop the machine immediately and report the malfunction to the competent person.

2.11 Never make any modifications, additions or conversions, which might affect safety without the
suppliers’ approval. This also applies to the installation and adjustments of safety devices and
valves.

2.12 Spare parts may comply with the technical requirements specified by the manufacturer. Spare
parts from original equipment manufacturers can be rely to do so.

2.13 Never modify the software of programmable control systems.

2.14 Adhere to prescribe intervals or those specified in the operating instructions for routine checks and
inspections.

2.15 For the execution of maintenance work, tools and workshop equipment adapted to the task on
hand are absolutely indispensable.

2.16 A portable fire extinguisher must be placed within immediate reach.

2.17 Observe all fire warning and fire-fighting.

. Selection and qualification of personal-basic responsibilities

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3.1 Any work or and with the machine be executed by reliable personnel only. Statutory minimum age

limits must be observed.

3.2 Employ only trained or instructed stuff and set out clearly the individual responsibility of the

personnel of operation, set-up, maintenance and repair.

3.3 Make sure that only authorized personnel work on or with the machine.

3.4 Define the machine operators’ responsibilities – giving the operator the authority to refuse

instructions by third parties that are contrary to safety.

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3.5 Do not allow persons to be trained or instructed or persons taking part in a general training course

to work on or with the machine without being permanently supervised by an experienced person.

3.6 Work on the electrical system and equipment of the machine must be carried out only by a skilled

electrician or by instructed person under the supervision and guidance of a skilled electrician and
in accordance with electrical engineering rules and regulations.

4.

Safety instructions governing standard operation

4.1 Avoid any operational mode that might be prejudicial to safety.

4.2 Take the necessary precautions to ensure that the machine is used only when in a safe and

reliable state.

4.3 Operate the machine only if all protective and safety oriented devices, such as removable safety

devices, emergency shut-off equipment, sound proofing elements and exhausts, are in place and
fully functional.

4.4 Check the machine at least once per working shift for obvious damaged and defects. Report any

changes (including changes in the machine’s working behavior) to the competent person
immediately. If necessary stop the machine immediately and lock it.

4.5 In the event of malfunction, stop the machine immediately and lock it. Have any defects rectified

immediately.

4.6 During start-up and shutdown procedures, always watch the indicators in accordance with the

operating instructions.

4.7 Before starting up or setting the machine in motion, make sure that nobody is in risk.

4.8 Never switch off or remove suction and ventilation devices when the machine is in operation.

5.

Safety instructions governing special work in conjunction with utilization of the machine

and maintenance and repair during operation; disposal and consumable parts.

5.1 Observe the adjustment, maintenance and inspection activities and intervals set out in the
operation instructions, including information on the replacement if parts and equipment. Skilled
personnel may execute those activities only.

5.2 Brief operation personnel before beginning special operations and maintenance wok, and appoint
a person to supervise the activities.

5.3 If any work concerning the operation, conversing or adjustment of the machine and its safety
oriented devises or any work related to maintenance, inspection and repair always observe the
start-up and shutdown procedures set out in the operating and the information on maintenance
work.

5.4 Ensure that the maintenance area is adequately secured.

5.5 If the machine is completely shut-down for maintenance and repair work, it must be secured
against inadvertent starting by:

- Locking the principal control elements and/or

- Attaching the “warning signal” sign to the main switch.

5.6 To avoid the risk of accidents, individual parts and large assemblies being moved for replacement
purposes should be carefully attached to lifting tackle and secured. Use only suitable and
technically perfect lifting gear and suspension systems with adequate lifting capacity. Never work
or stand under suspended loads.

5.7 For carrying out overhead assembly work, always use specially designed or otherwise safety­oriented ladders and working platforms. Never use machine parts as a climbing aid. Wear a safety
harness when carrying out maintenance work at greater heights.

5.8 Keep all hardens, steps, handrails, platforms landing and ladders from dirt.

5.9 Clean the machine especially connections and threaded unions, of any trace of oil, fuel, or
preservative before carrying out maintenance. Never use aggressive detergents. Use lint-free
cleaning rags.

5.10 Before cleaning the machine, cove or tape all openings, which for safety and functional rezones,
must be protected against water, steam, or detergent penetration. Special care must be taken with
electric motors and switchboard cabinets.

5.11 Always tighten any screwed connections that have been loosened during maintenance work.

5.12 Any safety devices removed for set-up, maintenance or repair purpose must be ratified and
checked immediately upon completion of the maintenance work.

5.13 Ensure that all consumable and replaced parts are disposed safely and with minimum

environmental impact.

6.

Warning of special dangers:

6.1 Use only original fuses with the specified current rating. Switch off the machine immediately if
trouble occurs in the electrical systems.

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6.2 Work on the electrical system or equipment may only be carried out by a skilled electrician himself
or by specially instructed personnel under the control and supervision of such electrician and in
accordance with the applicable electrical engineering rules.

6.3 If provided for in the regulations, the power supply to parts of machine, on which inspection,
maintenance and repair work has to be carried out, must be cut off. Before starting any work,
check the de-energized parts for the presents of power and ground or short-circuit in addition to
insulating adjacent live parts and elements.

6.4 The electrical equipment of machine is to be inspected and checked at regular intervals. Defects
such as loose connectors or scorched cable must be rectified immediately.

6.5 Necessary work on live parts and elements must be carried out only in the presence of a second
whom can cut off the power supply in case of danger by actuating the emergency shut-off or main
power switch. Secure the working area with a red-and-white safety tape and a warning sign. Use
insulated tools only.

6.6 Check all lines, hose and screwed connections regularly for leaks and obvious damage. Repair
damage immediately.

6.7 Depress all system sections and pressure pipes to be removed in accordance with the specific
instructions for the unit concerned before carrying out any repair work.

6.8 Compressed air lines must be laid and fitted promptly. Ensure the no connections are

interchanged. The fittings, length and quality of the hoses must comply with the technical
requirements.

7.

Mobile machinery and equipment

7.1 Cut off the external power supply of the machine even if only minor changes of place are envisage.
Properly reconnect the machine to the supply mains before restarting.

7.2 For restarting process only in accordance with the operating instructions.

WARRANTY NOTICE

We warrantee this spindle to be free of material and workshop defects. This warrantee is

conditional upon proper use in the applications of which this spindle is designed to. Warrantee is void if
damaged caused due to improper use, installation, negligence, accident, inadequate maintenance to the
spindle or the machine in which it is installed. This warrant is also void if customer did not follow the
complete manual and caused damage.

In any case of damage, failure analysis will be perform by Plasel to determine the cause of the

failure. Warrant is void if damaged caused by inadequate machine maintenance or improper use ex. Leaky
valves, Z-axis leakage wear, contained air supply, lower/higher air presser, inadequate vacuum, using the
spindle to work on material that is too hard, drilling into anything other then the right material.

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DAILY CHECK BEFORE OPERATING THE SPINDLE

1. For first time installation, look at “Installing the spindle” paragraph.

2. Check air supply (5-6 bar.)

3. Check ventilation exits.

4. Check for free movement of the shaft.

ATTENTION

5. The spindle must be securely clamped to the machine and clea

from any distraction.

6. Check for electric connections and command (community

grounding).

7. Start the spindle.

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SYSTEM GENERAL DESCRIPTION

TOP VIEW SIDE VIEW

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