Kessler TSM User manual

Assembly instructions
with operating and maintenance information
Torque motor
Type:
TSM,TMS
TMU, TMI
HTM, HTMx
HTMe, STMx
Art. no.:
see type plate/data sheet
Serial no.:
see type plate/data sheet

Torque motor
Assembly instructions
Franz Kessler GmbH
Franz-Kessler-Straße 2
88422 Bad Buchau, Germany
Tel.: [phone]
Fax: [phone]
E-Mail: [email protected]iz
Web: http://www.kessler-group.biz
Created:
24.04.2015
Issue:
09.06.2021 / bbe
Assembly instructions:
000.624.690_EN
Original Assembly Instructions - German
All other languages are a translation of the original.
These assembly instructions include operating and maintenance information
READ BEFORE USE!
KEEP FOR FUTURE USE!

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Contents
1About these assembly instructions........................................................................ 7
1.1 Product designation .............................................................................................. 7
1.2 Importance of these assembly instructions.................................................. 7
1.3 Scope of delivery .................................................................................................... 8
2For your safety ............................................................................................................... 9
2.1 Designated use........................................................................................................ 9
2.2 Non-authorised usage.......................................................................................... 9
2.3 Protection class IP54 ............................................................................................. 9
2.4 Operator's responsibility....................................................................................10
2.5 Qualified technical staff......................................................................................11
2.5.1 Work on the electrical system..................................................................11
2.5.2 Work on the hydraulic system .................................................................11
2.6 Personal protective equipment.......................................................................11
2.7 Information about warning notices...............................................................12
2.7.1 Warning symbols ..........................................................................................12
2.7.2 Warning levels................................................................................................12
2.7.3 Damage to property....................................................................................13
2.7.4 Other symbols used.....................................................................................13
2.8 Safety instructions................................................................................................14
2.8.1 Danger due to electrical voltage.............................................................14
2.8.2 Danger due to electromagnetic fields ..................................................15
2.8.3 Danger due to cooling agent...................................................................15
2.8.4 Danger to the environment from operating fluids..........................16
3Product information...................................................................................................17
4Transport and storage...............................................................................................18
4.1 Transport..................................................................................................................18
4.1.1 Protection during transport......................................................................18
4.1.2 Packaging upon delivery............................................................................18
4.1.3 Unpacking........................................................................................................18
4.1.4 Transport with lifting eye bolts................................................................20
4.2 Storage .....................................................................................................................21
4.2.1 Storage time ...................................................................................................21
4.2.2 Environmental conditions..........................................................................21
4.2.3 Corrosion protection ...................................................................................21
4.2.4 Protection from damage............................................................................22
4.2.5 Storage of components with permanent magnets..........................23
5Assembly........................................................................................................................24

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5.1 Important notice...................................................................................................24
5.1.1 Environmental conditions..........................................................................24
5.1.2 Specific dangers ............................................................................................24
5.2 Motor design..........................................................................................................25
5.2.1 Stator.................................................................................................................25
5.2.2 Rotor..................................................................................................................25
5.2.3 Rotor shaft.......................................................................................................26
5.2.4 Housing ............................................................................................................26
5.3 Installation...............................................................................................................27
5.3.1 Preparing for installation ...........................................................................27
5.4 Electrical system....................................................................................................29
5.4.1 Electrical interface.........................................................................................29
5.5 Thermal motor protection.................................................................................31
5.5.1 Circuit diagram thermal motor protection..........................................31
5.5.2 Electrostatic discharge................................................................................32
5.5.3 Protective measures for the temperature sensor.............................33
5.5.4 Protective measures KTY 84-130 / PT 1000-sensor.........................33
5.5.5 Motor shut-down temperature ...............................................................33
5.5.6 PT1000 sensor................................................................................................33
5.5.7 KTY 84-130/PT 1000 sensor......................................................................34
5.5.8 Bimetal temperature sensor .....................................................................34
5.5.9 PTC thermistor temperature sensor.......................................................35
5.5.10 Connection example .................................................................................36
5.6 Hydraulic system...................................................................................................37
5.6.1 Important specifications for hydraulic lines........................................37
5.6.2 Avoid wear of hydraulic components ...................................................38
5.7 Cooling system......................................................................................................39
5.7.1 Required line diameter ...............................................................................39
5.7.2 Connection data............................................................................................40
5.7.3 Important specifications for the cooling agent.................................40
5.7.4 Protective measures.....................................................................................41
5.7.5 Using system cleaner...................................................................................41
5.7.6 Cooling system settings.............................................................................42
5.7.7 Anti-corrosion agent ...................................................................................43
5.7.8 Cooling diagram............................................................................................44
6Commissioning............................................................................................................45
6.1 Preparation..............................................................................................................45
6.1.1 Check connections and peripheral devices.........................................45

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6.1.2 Limiting maximum current........................................................................46
7During operation.........................................................................................................47
7.1 Monitoring of media supply.............................................................................47
7.2 Coolant flow ...........................................................................................................47
7.3 Temperature sensor at coil end ......................................................................47
7.4 Operation of the motor......................................................................................48
7.4.1 Torques.............................................................................................................48
7.5 Oscillation speeds of the motor......................................................................50
7.5.1 Permitted oscillation speed while running idle.................................50
7.5.2 Increased vibrations.....................................................................................50
8Maintenance.................................................................................................................51
8.1 Electrical system....................................................................................................52
8.2 Cooling system......................................................................................................53
9Repairs ............................................................................................................................56
9.1 Wear and replacement parts list.....................................................................56
10 Decommissioning......................................................................................................57
10.1 Sequence for decommissioning...................................................................58
10.2 Disassembly..........................................................................................................59
10.3 Disposal..................................................................................................................59
11 Fault correction...........................................................................................................60
11.1 Fault diagnosis ....................................................................................................60
11.1.1 General faults...............................................................................................60
12 Error report...................................................................................................................62
13 Connections.................................................................................................................63
14 EC declaration of conformity.................................................................................64
15 Service and support..................................................................................................65
15.1 KESSLER Germany..............................................................................................65
15.2 KESSLER USA........................................................................................................65
15.3 KESSLER China.....................................................................................................66
15.4 KESSLER Taiwan..................................................................................................66
15.5 KESSLER Russia....................................................................................................66
16 Revision index .............................................................................................................67
17 Index ...............................................................................................................................68

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Assembly instructions

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1 About these assembly instructions
1About these assembly instructions
The copyright on these assembly instructions remains with Franz Kessler GmbH.
They may not be copied, distributed or made accessible to others either in part or
in full without permission.
At the time of publication the information provided in these assembly instructions
complied with technical standards. Subject to change without notice. We reserve
the right to make alterations without notice.
The original assembly instructions are provided in German. All other languages are
a translation of the original.
1.1 Product designation
Torque motor: Article number –see data sheet
The product will be referred to as a unit throughout the documentation.
1.2 Importance of these assembly instructions
These assembly instructions are important for your safety. Read these assembly
instructions carefully before starting any work.
Ensure that a copy of these assembly instructions is always available for
reference.
Ensure that a copy of these assembly instructions is available during the service
life of the unit.
A replacement copy of the assembly instructions can be obtained from our sales
department. Contact details can be found in the section “Service and Support”.
Contents of these assembly instructions
These assembly instructions contain information on the conditions which must be
met so that the partly completed machinery can be installed correctly without
impairment to safety and health.
Abbreviations used for connections refer to the dimension sheet. The abbreviations
consist of letters and numbers, e.g. SE-H21.
The dimension sheet can be supplied as a PDF file and printed out larger for better
legibility. The PDF file can be requested from your sales partner.
Technical specifications can be found in the technical data sheet or in the
dimension sheet.

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1 About these assembly instructions
1.3 Scope of delivery
Torque motor
Assembly instructions German
Assembly instructions English
Assembly instructions, additional languages in accordance with technical data sheet

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Assembly instructions
2 For your safety
2For your safety
The unit is designed in such a way that it can be operated safely and with a high
degree of reliability after correct installation of electrical power, coolant, cooling
lubricant, hydraulic system, pneumatic system and sensor system as well as correct
programming of the motor control. The condition for this is that all technical
parameters defined in these assembly instructions are observed at all times while
taking the specified tolerances into account.
The contents of these assembly instructions were compiled to the best of our
knowledge and belief. However, it is possible that not all information which may be
required for safe operation or which must be observed by the operator is available.
If you have any questions, please contact our technical sales department.
2.1 Designated use
Motor type
Torque motor
Type of construction
synchronous
Installation position
horizontal and vertical
The motor is a specially adapted unit for installation in machining centres. After
installation, the motor is used as a drive for machine tool axes, preferably rotary
axes.
Do not make alterations to the motor or its components. Dangers may arise from
alterations or non-authorised use for which the existing protective equipment is
not sufficient. This can lead to death, injury or property damage.
2.2 Non-authorised usage
Any use other than the designated use is improper use and is not permitted.
The unit is not authorised for the following uses:
•processing of foodstuffs of any kind
•operation in environments where there is a danger of explosion
•operation outdoors
•use in mines
2.3 Protection class IP54
The unit is designed with protection class IP54. Complete protection against the
ingress and escape of dust and liquids is not provided.
See also DIN EN 60034-5.

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2 For your safety
2.4 Operator's responsibility
Read these assembly instructions before assembly and commissioning, and follow
the warning and safety instructions carefully. In addition to these assembly
instructions, the instructions attached to the unit must also be observed.
Knowledge of these assembly instructions is essential for avoiding accidents and
ensuring fault-free operation. Failure to observe the warning and safety instructions
can result in death, injury or property damage.
Failure to observe important information is likely to lead to inferior production
quality, frequent operational faults and damage to the unit, for which we as the
manufacturer cannot accept liability.
The operator must ensure the following points
•The unit must never be allowed in the vicinity of external magnetic fields or be
allowed to come into contact with them.
NOTICE
There is a risk of damage to the unit or impairment in the functions
of the unit from powerful external magnetic fields.
The unit is supplied in a demagnetised state. This demagnetised state may
be destroyed if the unit is adversely affected by magnetic fields.
Avoid contact with external magnetic fields to prevent a re-
magnetization.
•The unit may only be assembled and used according to the designated use.
•All relevant laws, directives and rules for safety, prevention of accidents and
environmental protection must be observed.
•The necessary constructive safety and protection devices and appropriate
warning notices must be fitted.
•Work may only be carried out by sufficiently qualified and instructed technical
staff.
•The assembly instructions must be available to the personnel who work on the
machine and they must have been read and understood before commencing
work.
•The necessary personal protective equipment according to employment
protection laws must be provided and used.
•It is forbidden to make constructional changes.
•Stated maintenance intervals and tasks must be observed.

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2 For your safety
2.5 Qualified technical staff
Work on the unit must be carried out strictly by qualified technical staff. The staff
must have read and understood these assembly instructions.
Qualified technical staff is staff who are familiar with the installation, assembly,
commissioning and operation of the product. The qualified staff must have the
following qualification and knowledge:
•Qualified training and work experience.
•Knowledge of the relevant standards, regulations, accident prevention
regulations and operational conditions.
•The ability to recognize and avoid possible dangers.
•Use of adequate safety and protective equipment.
•First-aid training.
2.5.1 Work on the electrical system
Work on the electrical system may only be carried out by qualified electricians or
by trained technical staff under control and supervision of an electrician in
accordance with electro technical rules.
2.5.2 Work on the hydraulic system
Work on the hydraulic system may only be carried out by technical staff with
additional skills and experience with hydraulic systems.
2.6 Personal protective equipment
Personal protective equipment in accordance with employment protection laws
must be provided and used when working on the unit.
Minimum requirements for protective equipment:
•Protective clothing
•Safety shoes
•Protective gloves
•Protective goggles
•Ear protection
•Face mask

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2 For your safety
2.7 Information about warning notices
To emphasise safety relevant procedures in these assembly instructions the
following warning notices apply.
Warning notices consist of a signal word and a warning sign. If appropriate,
prohibiting signs are used.
2.7.1 Warning symbols
Following is a list of warning symbols used. They warn about the risk of injury. To
avoid injury or death comply with all measures which are marked with a warning
symbol.
This warning symbol warns about the risk of injury.
This warning symbol warns about the risk of injury from electric shock.
This warning symbol warns about the risk of injury from hydraulic fluid and
coolant.
This warning symbol warns about the risk of injury from compressed air.
This warning symbol warns about the risk of injury from magnets and magnetic
fields.
This warning symbol warns about the risk of injury from suspended loads.
This warning symbol warns about the risk of injury from crushing or becoming
trapped.
2.7.2 Warning levels
DANGER!
Warns about dangers which will lead to irreversible injuries or death. Failure to
observe the warning notice will result in irreversible injuries or death!
WARNING!
Warns about dangers which can lead to serious injuries or death. Failure to
observe the warning notice can result in serious injuries or death.
CAUTION!
Warns about dangers which can lead to injuries. Failure to observe the warning
notice can result in injuries.

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2 For your safety
2.7.3 Damage to property
NOTICE
Warns about possible damage to property. Failure to observe the notices can
result in damage to property.
2.7.4 Other symbols used
Prohibiting signs denote a prohibited action, e.g. Entry prohibited.

This symbol denotes an action to be carried out, numbered if necessary.
•
This symbol denotes a list.
This symbol denotes possible environmental damage.

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2 For your safety
2.8 Safety instructions
Observe the following safety instructions in order to avoid danger to persons or
the environment.
2.8.1 Danger due to electrical voltage
Acute danger of injury or to life from electric shock!
Electric shock can result in the following: Death, cardiac arrest, respiratory arrest,
neural damage, burns and consequential injury such as broken bones.
Work may only be carried out by a qualified electrician.
When working on the electrical system ensure that a second technical person
is present who can switch of the power supply in an emergency.
Before working on the unit:
(1) Disconnect the plant from mains.
(2) Ensure that power cannot be switched on again.
(3) Check that no electrical current is flowing.
(4) Earth and short-circuit.
(5) Shield, cover or otherwise isolate adjacent parts or components which are
electrically live.
In addition:
For transport, installation and operation: Ensure that there is no strain on
cables.
On assembly: First connect the protective earth conductor, then the power
connection.
Ensure that the protective earth conductor is connected.
Ensure that the motor housing is earthed.
Ensure correct fit of plug connections.
Only run the unit when the terminal box and switch cabinet are shut.
On disassembly: First remove the power connection, then the protective earth
conductor.

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2 For your safety
2.8.2 Danger due to electromagnetic fields
There is danger of injury or death due to electromagnetic fields in the
vicinity of permanent magnets!
An acute danger to the life of persons with pacemakers exists in the immediate
vicinity of permanent magnets! Pacemakers are influenced by electromagnetic
fields!
In the immediate vicinity of permanent magnets there is an acute danger of
injury to persons with metal implants or metal parts in their bodies. Magnetic
objects align themselves and are attracted by magnetic fields!
Attracted magnetic objects present a danger of crushing to all body parts.
Handling of permanent magnets is forbidden for persons with pacemakers,
metal implants or metal parts in the body.
Ensure that the danger zone and approach zone around permanent magnets
are equipped with warning signs and that the area is clearly marked.
Ensure that personnel who have access to the danger zone are informed of
the dangers.
2.8.3 Danger due to cooling agent
Danger to health and the environment due to cooling agent!
Cooling agent can become up to 80 °C hot and be under high pressure.
Contact with cooling agent can cause allergic reactions, skin, eye and respiratory
irritation, injuries and scalding.
Cooling agent can cause environmental damage.
Before working on the cooling system, ensure that the power supply is
switched off, and that the unit is free of electrical current.
Before working on the cooling system, ensure that the systems are free of
pressure.
Avoid lengthy skin contact with cooling agent. Wear protective clothing,
protective gloves and protective goggles.
Use appropriate collection devices for leaking cooling agent.
Dispose of cooling agent in an environmentally compatible manner according
to local regulations.

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2 For your safety
2.8.4 Danger to the environment from operating fluids
Danger to the environment from operating fluids!
Operating fluids such as lubricating grease, hydraulic fluid, cooling agent,
cleaning fluid etc. must not be allowed to enter the ground, the water supply or
the sewer system. The smallest amount of these fluids can cause damage to
health or the environment.
Use suitable containers for collection, storage, transport and disposal so that
no danger for persons or the environment can arise.
Dispose of operating fluid in an environmentally compatible manner
according to local regulations.

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3 Product information
3Product information
Product identification
The unit can be identified by its type plate. The type plate is securely attached and
may not be removed. In addition, the article number and/or serial number are
engraved on the unit.
Product designation
Product name
Torque motor
Model
See data sheet
Article number
See data sheet
Weight
See delivery note

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4 Transport and storage
4Transport and storage
4.1 Transport
Transport may only be carried out by qualified technical staff or a specialised
company.
Read the safety information. See chapter "For your safety".
The gross weight can be found in the chapter "Product information".
DANGER!
Danger of injury or death due to electromagnetic fields in the vicinity of
permanent magnets!
Danger of injury or death for persons with pacemakers, metal implants or metal
parts in the body.
Attracted magnetic objects present a danger of crushing to all body parts.
Handling of permanent magnets is forbidden for persons with pacemakers,
metal implants or metal parts in the body.
Ensure, that the danger zone and approach zone around permanent magnets
is sufficiently equipped with warning signs and that the area is clearly marked.
Ensure that personnel who have access to the danger zone are sufficiently
informed of the dangers.
WARNING!
Danger due to suspended loads!
Falling suspended loads can lead to serious injuries or death.
Do not walk under suspended loads.
Only use lifting gear with sufficient load bearing capacity. Observe the gross
weight.
Secure transport units in position.
When setting the load down, ensure that no persons can be trapped.
Use personal protective equipment.
4.1.1 Protection during transport
During transport protect the unit from the following:
•moisture
•impact
•contamination
•being dropped
4.1.2 Packaging upon delivery
The unit is supplied wrapped in anti-corrosion film in a box. Depending on the
model, the unit may also be secured on a transport frame inside the box.
4.1.3 Unpacking
Check the transport packaging immediately after receipt of goods for external
signs of damage.

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4 Transport and storage
NOTICE
Risk of damage from corrosion
If the unit is unpacked too quickly or exposed to fluctuating temperatures, this
could lead to corrosion and, as a consequence, damage to the unit.
Store the unit for at least 24 hours at a temperature of 23 ±2°C. After this, first
remove the protective foil.
Inspect the unit for external signs of damage. Any damage is to be reported to
the forwarder immediately.
Retain the packaging for return transport for repairs.
NOTICE
Damage to the rotor bandage (fibre composite material) during unpacking
possible.
When unpacking, ensure that the rotor bandage (fibre composite material)
does not become damaged.
Do not open the transport packaging with a knife or other sharp or pointed
object.
Bandage
Rotor

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4 Transport and storage
4.1.4 Transport with lifting eye bolts
The motor is provided with threads for lifting eye bolts.
Only use the lifting eye bolts supplied to transport the unit.
If lifting eye bolts are not included in the scope of delivery we recommend the use
of Star Point VRS lifting eye bolts.
Observe the manufacturer's instructions for use when using rotatable lifting eye
bolts.
CAUTION!
Risk of injury from falling parts!
The rotor is not attached to the stator.
When transporting at least two lifting eye bolts must be attached to both the
rotor and the stator. Otherwise, when being lifted, the rotor and stator can
separate and fall.
Load capacity and direction of pull
Observe the correct load capacity and direction of pull.
max. load capacity for lifting eye bolts
direction of pull is vertical
max. load capacity for lifting eye bolts
direction of pull 0° - 45°
StarPoint VRS © RUD