1. Introduction
This manual provides detailed instructions for the installation, operation, and maintenance of the RATTMMOTOR 4.5KW ATC Spindle BT30 Air Cooled Spindle Motor and its accompanying 5.5KW Fuling Brand Inverter. This system is designed for high-precision applications in CNC Lathe Routers, woodworking machinery, and polishing industries, offering automatic tool change capabilities and efficient air cooling.
2. Package Contents
The package includes the following components:
- 1 x 4.5KW BT30 ATC Air Cooled Spindle Motor (220V or 380V, 24000rpm, 15A, 3-phase, 800Hz, 4pcs bearing)
- 2 x Aviation plugs
- 1 x BT30-ER25 Tool Holder with pull stud
- 1 x 5.5KW Fuling Brand Inverter VFD (220V)
- An English user manual will be sent via email.
3. Technical Specifications
3.1. Spindle Motor Specifications
| Parameter Name | Value |
|---|---|
| Spindle Model | RTM120x103-30-24Z/4.5 |
| Voltage | 220V / 380V (Optional) |
| Maximum Speed | 24000rpm |
| Rated Frequency | 800Hz |
| Electric Current | 15A |
| Motor Pole | 4P |
| Rated Power (S1) | 4.5KW |
| Peak Power (S6) | 5.4KW |
| Rated Torque | 3.5Nm |
| Peak Torque | 4.2Nm |
| Spindle Blowing Dust/Seal Gas Pressure | 0.2-0.25 MPa |
| Spindle Gas Seal Gas Flow | 65±10 L/min (When on Working) |
| Cooling Water Pressure | ≥0.25 MPa |
| Cooling Water Flow | ≥2.5 L/min |
| Cooling Water Temperature | 24-28 °C |
| Spindle Static State Pulse | ≤3 µm |
| Spindle Vibration | ≤1.0 mm/s |
| Spindle Assembly Method | Bottom mounting (6-M8) |
| Motor Windings Pressure Test | 1000V/1 minute withstanding Voltage test |
| Tool Interface | BT30 |
| Fitment | Woodworking machinery, polishing industry, etc. |
3.2. Fuling VFD Inverter Specifications
| Parameter Name | Value |
|---|---|
| Model | DZB312 Series |
| Power | 5.5KW |
| Input Voltage | 1-phase AC220V±15% or 3-phase AC220V±15% |
| Output Power Range | AC220V 3-phase |
| Output Frequency | 0-1000Hz |
| Input Frequency | 47-63Hz, power factor ≥95% |
| Control Mode | Non-PG vector control, V/F control |
| Operation Instruction Source | Panel, terminal, RS485 communication |
| Given Frequency Source | Panel figure, analog quantity, RS485 serial communications, multi-speed simple PLC, PID, etc. |
| Overload Capacity | 130% rated current for 60s, 150% rated current for 3s |
| Carrier Frequency | 1.0kHz-15.0kHz (automatically adjusted) |
| Frequency Resolution | 0.01Hz (digital), 0.1% of highest frequency (analog) |
| Torque Elevation | Manual torque can elevate 0-30% |
| Inching Operation | Frequency range: 0.0Hz - Max output frequency; Inching acceleration/deceleration time: 0-3600.0s |
| PLC & Multistage Speed | Up to 8 segments running |
| Automatic Voltage Regulation | Maintains constant output voltage during grid voltage fluctuation |
3.3. Product Characteristic Curves
4. Safety Warnings
- Always ensure proper grounding of all components.
- Disconnect power before performing any maintenance or wiring changes.
- Ensure all safety devices are installed and working correctly before operating the spindle.
- Do not operate the spindle if it becomes excessively hot. Stop operation and consult support.
- Wear appropriate personal protective equipment (PPE) during operation.
5. Setup and Installation
5.1. Spindle Installation
The spindle features a built-in asynchronous motor and automatic tool change device. It is designed for bottom mounting using 6-M8 fasteners.
5.2. Wiring Connections
Refer to the following diagrams and instructions for proper wiring:
5.2.1. Power Supply, Thermal, and Fan Connections
The main power connector and fan connectors are integrated. Ensure correct polarity and secure connections.
5.2.2. Proximity Switch and Push Button Switch Connections
The spindle includes two sensors for tool change signals (0-24V, PNP). One sensor responds to the broach knife signal when the knife handle is hung, and the other responds to the loose knife signal when the knife jaws are open.
5.2.3. Inverter Wiring
Connect the VFD to the spindle and power source as follows:
- Powering the Inverter: Connect L1, L2, and L3 (or L1, L2 for single-phase input) to R, S, and T terminals respectively.
- Spindle Connections: Connect VFD U, V, W to Spindle U, V, W terminals.
- Speed Control: To speed up the spindle, connect the terminal DCM to S1. For analog speed control, connect the VFD's analog output to the CSMIO Analog port.
5.3. Air Sealing and Cooling System
The spindle uses a forced cooling mode for the motor and bearings. Coolant flows through a cycle watercourse to maintain thermal equilibrium. An external cooling device is recommended to maintain a constant coolant temperature.
- Fan Cooling: The rear fan system must be started when the spindle rotates. The fan requires a 12V supply voltage.
- Air Sealing Control (AS): To prevent water or impurities from entering the spindle, a gas sealing device is used. This must be started simultaneously with the machine and requires multi-stage filtration.
- Compressed Gas Quality Requirements:
- Oil content: <0.01mg/m³
- Solid particle: <5µm
- Pressure dew point: <7.5°C (0.7MPa)
6. Operating Instructions
6.1. Running-in Program
Before initial use or after a long period of inactivity, the spindle must undergo a slow running-in process:
- Start the spindle at 25% of its maximum speed for half an hour.
- Increase the speed to 50% of the maximum speed and run for 15 minutes.
- Finally, increase to the maximum speed.
Important: Monitor the spindle temperature throughout this process. The spindle will get warm but should not be too hot to touch. If it becomes excessively hot, stop operation immediately and contact customer service.
6.2. Automatic Tool Change (ATC) Operation
The spindle features an automatic tool change mechanism. The tool clamping method uses a BT30 shank form.
The ATC system uses sensors to detect tool presence and status. Ensure these sensors are correctly wired and calibrated for reliable tool changes.
7. Maintenance
- Lubrication: The spindle bearings use grease-lubricated angular contact bearings, designed for lifelong lubrication within their service life. No regular lubrication is typically required.
- Cooling System: Regularly check the cooling fan for obstructions and ensure it is operating correctly. Verify that the coolant flow and pressure meet the specified requirements (≥0.25 MPa pressure, ≥2.5 L/min flow, 24-28 °C temperature).
- Air Sealing: Ensure the air sealing system is functioning to prevent contaminants from entering the spindle. Check the quality of compressed air regularly to meet the specified oil content, solid particle, and pressure dew point requirements.
- Temperature Monitoring: The spindle has a built-in PTC 140 temperature sensor for motor temperature protection. Monitor this to prevent overheating.
8. Troubleshooting
- Spindle Overheating: If the spindle becomes excessively hot during operation, immediately stop the machine. Check the cooling fan, coolant flow, and air sealing system for any issues. Refer to the PTC140 temperature sensor parameters for diagnostic information.
- Tool Change Malfunctions: Verify the wiring and functionality of the proximity switches. Ensure the tool holders are correctly seated and the pneumatic system for tool clamping/unclamping is operating at the correct pressure (0.5-0.6 MPa for intake air, 0.35-0.45 MPa for return air).
- Inverter Errors: Consult the Fuling Inverter user manual for specific error codes and troubleshooting steps. Ensure all parameters are set correctly as per the spindle's requirements.
9. User Tips
- The product typically comes as a single unit including the spindle, inverter, and tool holder.
- This is an air-cooled ATC spindle motor, meaning it uses air for cooling and has an automatic tool change function.
10. Warranty and Support
The 5.5KW Fuling Brand Inverter comes with a 2-year warranty. For any issues or questions not covered in this manual, please contact your seller or the manufacturer's support team. Provide detailed information and any relevant photos to assist with troubleshooting.