HSD ES779, ES789 Instruction Manual

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Page 1

HSD

MECHATRONIC

DIVISION

Instruction Manual

H5803H0005_EN

Rev. 03

06/2008

ES779 - ES789

HSD S.p.A.

Head Office

Via della Meccanica, 16 61100 Pesaro (PU) Italy Tel. +39 0721 439638 Fax +39 0721 441608 Tax Code No. 02196600965 VAT No. IT 01376450415

Customer Service

Via della Meccanica, 16 61100 Pesaro (PU) Italy Loc. Chiusa di Ginestreto Tel. +39 0721 439638 Fax +39 0721 441608 E-mail: [email protected] Web: www.hsd.it

Page 2

Information on the publication

Document code Revision Approval Date of issue

H5803H0005 03 UTE 011 / 02 07 / 2008

List of Updates

Revision Modified

sections

00 of 06 / 2002 --- First edition

01 of 09 / 2005 --- General Revision

02 of 11 / 2007 Cover

§ 3.1.4, 3.1.5

§ 4.2

§ 4.2.8

§ 4.6

§ 4.9, 4.10

§ 6.4

§ 8.1

§ 8.2

§ 8.3.11

§ 8.3.12, 8.3.13

§ 11

03 of 07 / 2008 §4.6.1 Updated air specifications section

Description of modifications

Updated images ES775 removed, out of production Views with new bore positions updated Equivalent electric networks added Technical card and electric network equivalent to 13.5 kW model added Missing pneumatic connections added Electrical connections with HSD mounting plate and MIL connectors added Clamping force of A/E 63 hooks added Shaft kit replacement: procedure and notes about spare parts Procedure for encoder reader replacement added Gauges to adjust A/E 63 added Adjustment procedure S1 and S4 with kit updated Spare part list updated

This publication is the English translation of the original Italian version of the manual HSD H5803H0005.

In case of discrepancies between this translation and the original version, refer to the original version in Italian.

The updated version of this manual is available at HSD website or at the HSD Customer Service (see page 111).

Manual prepared by the HSD Documentation Department with FrameMaker 7.0

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Index

1 Preliminary Information ............................................................................7

1.1 Documents supplied with the product ....................................................... 7

1.2 Purpose of the manual .............................................................................. 7

1.3 Symbols used in the manual .................................................................. 7

1.4 Risks associated with the use of the product ............................................ 8

1.4.1 Risks associated with incorrect use and/or operation ............................ 8

1.4.2 Specific risks during product maintenance ............................................ 9

1.4.3 Residual risks ......................................................................................... 9

1.5 Information on the product ........................................................................ 9

1.5.1 Purpose of the product ........................................................................... 9

1.5.2 Range of applications ............................................................................. 9

1.5.3 EC marking and identification of the product .......................................... 9

1.6 Glossary ................................................................................................. 10

1.7 Warranty ................................................................................................. 11

2 Transport, packaging, unpacking, storage ...........................................12

2.1 Warnings ................................................................................................. 12

2.2 Dimensions and weights ......................................................................... 12

2.3 Transport and Packaging Conditions ...................................................... 12

2.4 Unpacking Procedure ............................................................................. 13

2.5 Storage ................................................................................................... 13

3 Technical specifications ........................................................................14

3.1 Main parts ............................................................................................... 15

3.1.1 ES779 non connectorised, with fixing bores ...................................... 15

3.1.2 ES779 non connectorised, with fixing grooves ................................... 16

3.1.3 ES789 non connectorised, with fixing bores ...................................... 17

3.1.4 ES789 non connectorised, with fixing grooves ................................... 18

3.1.5 ES779 Collet, non connectorised ....................................................... 19

3.1.6 Variations for versions with electrical connectors of HSD type ........... 20

3.1.7 Variations for versions with MIL standard electrical connectors ......... 21

3.1.8 ES789 variations with distributor .......................................................... 22

3.1.9 Variations with floating piston or fixed piston ........................................ 23

3.2 Characteristics and performance ............................................................ 24

3.2.1 ES779 12kW with 500Hz (15,000 rpm) rated frequency ..................... 24

3.2.2 ES779 12kW DP with 250Hz (7,500 rpm) rated frequency ................. 26

3.2.3 ES779 13kW with 500Hz (15,000 rpm) rated frequency .................... 28

3.2.4 ES779 13.5kW with 400Hz (12,000 rpm) rated frequency ................... 30

3.2.5 ES789 18kW with 267Hz (8,000 rpm) rated frequency ....................... 32

3.2.6 ES789 18kW DP with 300Hz (9,000 rpm) rated frequency ................. 34

3.2.7 ES789 17kW with 400Hz (12,000 rpm) rated frequency .................... 36

3.2.8 ES789 13.5kW with 350Hz (10,500 rpm) rated frequency ................. 38

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Index

4 Installation and commissioning.............................................................40

4.1 Dimensional drawings ............................................................................. 40

4.2 Preliminary checks before installation .................................................... 40

4.3 Preparation of the auxiliary systems of the plant .................................... 40

4.4 Mechanical connections ......................................................................... 41

4.4.1 Resting surface ................................................................................... 41

4.4.2 Tool change system ............................................................................ 41

4.4.3 Fastening of models with “fixing bores” ................................................ 41

4.4.4 Fastening of models with “fixing grooves” ............................................ 41

4.4.5 “Collet” model fastening ....................................................................... 42

4.4.6 Threaded service bores ........................................................................ 42

4.5 Fluids distributor .................................................................................... 42

4.6 Pneumatic connections ........................................................................... 43

4.6.1 Specifications for compressed air to be supplied to HSD products ...... 43

4.6.2 Automatic cleaning of the tool holder cone .......................................... 46

4.6.3 Internal pressurisation .......................................................................... 46

4.7 Hydraulic connections and specifications of the cooler ......................... 47

4.7.1 Specifications of the cooler ................................................................... 47

4.7.2 Hydraulic connection points .................................................................. 47

4.8 Pneumatic/hydraulic connections of models with distributor .................. 50

4.9 Electrical connections of models with free cables .................................. 51

4.9.1 ES779 and ES789 Power Cables ........................................................ 51

4.9.2 Sensor Cables (all motors) ................................................................. 52

4.9.3 Encoder cables (Optional) ................................................................... 52

4.10 Electrical connections of models with HSD connectors .......................... 53

4.10.1 Power connector diagram .................................................................... 53

4.10.2 Signal connector diagram ..................................................................... 54

4.11 Electrical connections of models with military connectors ...................... 55

4.11.1 Power connector diagram (standard MIL) ............................................ 55

4.11.2 Signal connector diagram (standard MIL) ............................................ 55

4.11.3 Encoder connector diagram ................................................................. 56

4.12 Tool release button ................................................................................. 57

4.12.1 Electric diagram for manual tool holder release ................................... 57

5 General checks after installation ...........................................................58

5.1 Checks before the start-up ..................................................................... 58

5.1.1 Pneumatic circuit .................................................................................. 58

5.1.2 Hydraulic circuit .................................................................................... 58

5.1.3 Electrical circuit ................................................................................... 58

5.1.4 Programming the inverter ..................................................................... 58

5.2 Checks during initial starting ................................................................... 59

6 Use and Adjustment................................................................................60

6.1 Environmental Conditions ....................................................................... 60

6.2 Running-in .............................................................................................. 60

6.3 Preheating .............................................................................................. 60

6.4 Tool holder locking and ejection device .................................................. 61

6.4.1 Tool holder cone ................................................................................... 62

6.4.2 Installation of the tie-rod HSD 0804H0009 in the cone ISO30 DIN69871 .

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6.4.3 General recommendations relating to tool holder cones ...................... 63

6.5 Tool ......................................................................................................... 63

6.5.1 Speed limits regarding the tool ............................................................. 64

6.6 Sensors ................................................................................................... 67

6.6.1 Technical characteristics of the inductive sensors ................................ 67

6.6.2 States of the electrospindle and corresponding outputs of the inductive sensors 67

6.6.3 Description of the inductive sensors ..................................................... 68

6.6.4 Use and technical characteristics of the thermal alarm ........................ 69

6.7 Encoder (optional) .................................................................................. 70

6.7.1 General description .............................................................................. 70

6.7.2 Technical specifications of the HSD Square Wave encoder ............... 71

6.7.3 Technical specifications of the Lenord+Bauer Square Wave encoder 72

6.7.4 Technical specifications of the Lenord+Bauer Sinus Wave encoder .... 73

Index

7 Scheduled maintenance ......................................................................79

7.1 Daily maintenance .................................................................................. 80

7.1.1 Checking and cleaning the tool holder seat and the tool holder cone 80

7.1.2 Protection of the tool holder seat .......................................................... 81

7.2 Biweekly Maintenance ............................................................................ 81

7.2.1 Clean the tool holder cone with ethyl alcohol ....................................... 81

7.3 Monthly maintenance .............................................................................. 82

7.3.1 Lubrication of the HSK collet ................................................................ 82

7.3.2 Check of functionality collet HSK ......................................................... 82

7.4 Bearings .................................................................................................. 82

8 Replacement of components .............................................................83

8.1 Replacement of the Shaft Kit .................................................................. 84

8.2 Replacement of the encoder reader ....................................................... 94

8.3 Replacement and adjustment of the sensor group ................................. 95

8.3.1 Access to the sensors .......................................................................... 95

8.3.2 Identification of the sensors ................................................................. 95

8.3.3 Sensor wiring ..................................................................................... 96

8.3.4 Description of the sensor unit ............................................................... 96

8.3.5 Replacement and adjustment of the sensor unit ................................. 97

8.3.6 Sensor S1 adjustment (for all models) ................................................ 98

8.3.7 S2 sensor adjustment for ISO models .................................................. 99

8.3.8 Sensor S2 adjustment for HSK models ............................................. 100

8.3.9 Sensor S3 adjustment (for all models) ............................................... 101

8.3.10 Adjustment of S4 sensor (present only in models HSK) .................. 101

8.3.11 Kit of adjustment gauges for HSK sensors S1 and S4 ....................... 102

8.3.12 Adjustment of S1 using the kit ............................................................ 104

8.3.13 Adjustment of S4 using the kit ............................................................ 105

9 Disposal of the product .......................................................................106

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Index

10 Troubleshooting ...................................................................................107

11 List of spare parts..................................................................................110

12 Customer Service ..................................................................................111

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1 Preliminary Information

1.1 Documents supplied with the product

The documentation supplied with the product consists of:

 Manufacturer's Declaration complying with Annex IIB of Directive 2006/42/EC

 Product inspection certificate

 This manual, containing the warnings and instructions for transport, installation, operation,

maintenance and disposal of the product.

Check that all the documents listed above are present at the time of delivery of the product; if necessary, request a new copy from HSD S.p.A.

1.2 Purpose of the manual

The manual forms an integral part of the product and must therefore accompany the product; if this is not the case, the product loses one of its essential safety requirements.

The manual must be handled with care, distributed and made available to all persons concerned.

The purpose of the warnings is to protect the safety of the persons exposed to the residual risks.

The instructions provide tips on the proper behaviour for the correct use of the product as intended by the manufacturer.

In the event that contradictions are discovered between these instructions and the safety standards, please contact HSD S.p.A. for any corrections and/or amendments.

In order to avoid incorrect operation that could result in danger for persons and/or damage to the product, it is important to read and understand all the documentation accompanying the product.

It is important to keep this manual in a suitable place and always within reach for consultation.

The information contained in the manual is indispensable for safe operation of the product in accordance with its intended use.

1.3 Symbols used in the manual

Indicates a procedure, practice or any other similar measure that, if not observed or correctly followed, may cause personal injuries.

Indicates an operational procedure, practice or any other similar measure that, if not observed or correctly followed, can damage or completely destroy the product.

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Indicates information of particular general interest that must not be ignored.

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1.4 Risks associated with the use of the product

HSD S.p.A. is not acquainted, and cannot be acquainted with the conditions of installation of the product, so the installer or end user must carry out an analysis of the risks, relating specifically to the mode and typology of installation.

It is, however, the responsibility of the party conducting the installation to guarantee an adequate degree of protection against the risk of accidental contact with moving parts and elements.

The installer and user must also bear in mind other types of risk, in particular those arising from the presence of foreign bodies and from the transport of explosive, inflammable or toxic gases at high temperatures.

Furthermore, consideration must be given to the risks inherent in the maintenance operations, that must be carried out under conditions of maximum safety by isolating the product and with the tool at a standstill.

At the end of the choices and according to the product installation mode defined and employed by the installer and/or the client, the final machine may be considered a “self-contained machine” in the sense of the Machine Safety Directive. A complete assessment of the risks must be carried out and a declaration of conformity must be drawn up on the basis of Annex IIA of Directive 2006/ 42/EC.

1.4.1 Risks associated with incorrect use and/or operation

Disconnecting, removing, modifying or in any other way deactivating any safety, protection or monitoring device or individual parts of the product as a whole is absolutely forbidden.

 Do not place your hands, arms or any other parts of the body in the vicinity of moving parts.

 Use of the product in atmospheres with an explosion risk is forbidden.

 It is forbidden for an unauthorised operator to eliminate possible defects or faults in the

function or the product and/or to change the type of operation and installation.

 After carrying out any special operations involving the removal of guards, barriers or other

protective devices, install these again before restarting the machine and check that they are correctly positioned and functioning efficiently.

 All the protective and safety devices must be maintained in a perfect and efficient condition at

all times. The warning and danger signs must be kept in clearly legible conditions at all times and must not be removed.

 When looking for the cause of any fault or malfunction of the product, take all the precautions

described in the instruction manual in order to avoid personal injury or damage to equipment.

 Remember to tighten all screws, bolts or ring nuts of all mechanical elements to be adjusted or

set-up.

 Before starting the product, ensure that all the safety devices are installed and in proper

working order; if this is not the case, it is absolutely forbidden to start the product and the person responsible for internal safety or the head of maintenance must be informed immediately.

 The operator must be equipped with Personal Protective Equipment (PPE) in accordance with

the provisions of the laws in force; wearing loose clothes and various accessories (ties, wide sleeves, etc.) is forbidden.

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1.4.2 Specific risks during product maintenance

To safely operate an HSD product fitted on the machine, refer to the manual of the machine itself.

 Disconnect the product from the main power supply before carrying out any maintenance

operations!

 Even when the product is disconnected from the power supply, the rotating parts (and moving

parts in general) can nevertheless move, due to their inertia; before carrying out maintenance operations therefore, check that the moving parts of the product are at a standstill.

1.4.3 Residual risks

The product has been analysed on the basis of Directive 2006/42/EC in order to identify possible sources of risk. The risks that still remain (residual risks) and the respective countermeasures are described in the relevant sections of this manual.

1.5 Information on the product

1.5.1 Purpose of the product

The product is part of a machine intended to be assembled to or incorporated into other parts of machinery or machines in order to create a machine according to Directive 2006/42/EC.

It is forbidden to set the product into operation before the machine into which it is to be incorporated complies with the provisions of Directive 2006/42/EC and subsequent amendments.

1.5.2 Range of applications

The product has been designed to carry out milling and boring operations in the field of wood and its derivatives, plastic, fibre, aluminium, and light machining operations on other metals.

1.5.3 EC marking and identification of the product

The EC marking plate and the serial number represent the only elements to identify the product acknowledged by HSD S.p.A. The user of the product is obliged to maintain the integrity of these signs.

In the 3 “Technical specifications” section you can see the EC marking plate, along with its position and that of the Serial Number of the product.

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1.6 Glossary

ISO 30

HSK

Value of the balancing of a rotating object in accordance with standard ISO 1940/1,

Level or class

of dynamic

balancing

Rated voltage

Rated

frequency

Nominal

characteristics

Service S1

Service S6

Torque and

Power

Coolant

Scheduled

maintenance

indicated by the letter G. Low values for G indicate a higher degree of balancing; the maximum balancing precision is G=0.4. G takes on discrete values in relation to multiples of 2.5 (G=0.4 G=1 G=2.5 …).

Maximum supply voltage.

Minimum frequency corresponding to the maximum value for the supply voltage.

All the various rated values reached in relation to the rated frequency.

Operation under constant load, with a duration sufficient to allow the motor to attain a thermal equilibrium. The corresponding abbreviation is S1. (Standard IEC EN 60034-1)

Sequence of identical operating cycles, each comprising a period of operation under constant load and a period of operation without load while maintaining the rotational speed; there is no rest period. The corresponding abbreviation is S6, followed by the percentage ratio between the period of operation under load and the length of the cycle.

Example: S6 40%

(40% period of operation with load, 60% period of operation in rotation but without load) (Standard IEC EN 60034-1)

Providing a precise physical definition of torque and power would be going beyond the scope and possibility of this manual. Nevertheless the torque can be roughly correlated to the force with which the tool contacts the piece being machined (and with equal torque, the force increases as the diameter of the tool decreases). Power, on the other hand, is proportional to the torque and the rotational speed and determines the maximum machining speed (taking into consideration the performance of the tool, the characteristics of the material being machined and the type of machining).

Fluid, liquid or gas (including air) by means of which the heat is transferred from the spindle to the atmosphere.

All the activities intended to maintain the operating and functioning conditions of the product as provided for by HSD S.p.A. at the moment of its launch on the market; it is carried out through scheduled operations to adjust, repair and replace parts.

CONE ISO30

DIN 69871

CONE HSK - DIN 69893

60 W×()

CNm()

-----------------------------

2 π× rpm×

Tool holder cone hooking system, described by the standard DIN 69871.

The electrospindle has a plate similar to that shown in the next image, indicating

TIE-ROD HSD

0804H0009

Tool holder cone hooking system, described by standard DIN 69893.

The electrospindle has a plate similar to that shown in the next image, indicating the type of mounting.

the type of mounting.

C = Torque W = Power rpm = revolutions per minute

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1.7 Warranty

HSD S.p.A. guarantees that the product has been inspected at its plant with a positive result.

Works under warranty shall be performed free at the HSD S.p.A. facilities, transport at the customer's expense; HSD S.p.A. shall not be liable for termination of production during the warranty period.

The warranty does not cover faults due to normal wear of those parts which, by their nature, are subject to rapid and continuous wear (e.g. gaskets, belts, bearings, etc.). In particular, HSD S.p.A. gives no guarantee as to the service life of the bearings, as this depends on various factors including: the degree of balancing of the tools, the types of machining operation, collisions and/or mechanical stresses beyond the values indicated by the manufacturer.

HSD S.p.A. accepts no liability for faults in the conformity of the product caused by a failure to observe the instructions contained in the instruction manual, or due to incorrect operation or handling of the product. The buyer shall therefore have a right to replacement of parts found

to be defective only if the faults have not been caused by tampering with the product namely by installing non-original HSD spare parts not provided for and not authorised in the present manual, and in all cases without the prior written approval of HSD S.p.A.

On no account shall HSD S.p.A. or its suppliers be responsible for damage (including but not limited to damage to the physical integrity of the product or damages due to loss or reduced earnings, stoppages in production, loss of information or other economic losses) resulting from the use of HSD products, even in cases where HSD S.p.A. has been warned of the possibility of such damage.

and/or by replacement of components

The buyer's warranty shall be voided if HSD S.p.A. is not notified in detail in writing of the nature of any faults discovered in the product within 15 days of the fault being discovered. The buyer's warranty shall also be voided in the event that he does not allow the seller to carry out any requested inspections or if the seller requests the defective parts to be returned to the works and the buyer fails to return them within two weeks of the request.

Measured drawings and photographs are provided purely as reference examples for a simpler understanding of the text.

In line with its policy of continuous development and advancement of the product, the company reserves the right to modify either its functional or aesthetic characteristics, to vary the design of any functional element or accessory, or to suspend production and delivery; this without undertaking to give notice to anyone and without incurring any other obligation. In addition, HSD S.p.A. reserves the right to make any structural or functional modification, as well as modifications to the supply of spare parts and accessories, without the obligation to communicate these changes to anyone and for any reason.

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2 Transport, packaging, unpacking,

2 Transport, packaging, unpacking, storage

2.1 Warnings

 Lifting and handling the product may create hazardous situations for the persons involved; we

therefore recommend that the instructions given by HSD S.p.A. are observed and that only suitable tools are used.

 The installation and assembly operations must always be carried out by specialised

technicians only.

 We recommend that all lifting and handling operations of the product or its parts be carried out

with great care, avoiding collisions that could compromise the proper functioning, or damage coated parts.

The user is responsible for selecting the lifting equipment (ropes, straps or chains, etc.) considered most suitable in terms of both functionality and lifting capacity, with regard to the weight indicated on the packaging and on the product label.

2.2 Dimensions and weights

 Product crate for shipment:

- the gross weight is specified on the packaging;

- the packaging linear dimensions are specified in the documents supplied with the product.

 Unpacked product:

- the weight (according to the version) is indicated in chapter 3 “Technical specifications”;

- dimensional drawings are available upon request at the customer service.

2.3 Transport and Packaging Conditions

The product is shipped protected by a covering of VCI plastic and expanded foam, packed in a wooden crate or case of special cardboard. The figure below shows a few methods of lifting the packed product (using ropes and using a forklift truck; in the latter case, ensure that during lifting the centre of gravity of the crate is always between the two forks).

The examples shown are only indications, as it is not possible to determine in advance all the possible configurations for lifting a product manufactured by HSD S.p.A.

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2 Transport, packaging, unpacking,

2.4 Unpacking Procedure

Before opening the package, check that the seals on the package are not broken

If the product is packed in a wooden crate, insert a screwdriver under the locking hook. Lever it open, paying attention not to damage the packaging and its contents.

If the product is packed in a cardboard case, remove the strip of adhesive tape, paying attention not to damage the package and its contents.

Do not lift the product by holding it from the electric fan section (if provided), in order not to damage the guard.

Do not rest the product on the spindle shaft .

The expanded foam and plastic cover can be disposed of as plastic material.

2.5 Storage

If the product is to be stored, it must be protected against the weather, moisture, dust and aggressive atmospheric and environmental agents.

It is therefore necessary:

 to carry out periodic checks to ensure the good general condition of conservation;

 to manually rotate the shaft (roughly once a month) to maintain optimum lubrication of the

bearings.

STORAGE TEMPERATURE: from -5°C (+23°F) to +55°C (+131°F)

RELATIVE HUMIDITY (NON-CONDENSING): from 5% to 55%

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3 Technical specifications

ES779

ES789

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3.1 Main parts

3.1.1 ES779 non connectorised, with fixing bores

3 Technical specifications

1 Resting surface 9

6 bores for compressed air

and fluid inlet / outlet H8 bore Ø60, depth 6

for positioning H7 bore Ø8, depth 10

for positioning 2 M6 bores for tool

lubricant-coolant outlet

6 Shaft 14 Sensor area 22 EC marking plate

6 M8 bores, thread depth

12 for fastening H8 bore Ø60, depth 6

for positioning

H7 bore Ø8, depth 10 for positioning

10 Nose 18 Encoder compartment

11 HSK collet 19

6 M5 bores

for accessories

13 Engine cable passage 21 Resting surface

15 Cylinder 23 Serial number

16 Sensor cable passage 24 Description of tool holder

6 M8 bores, thread depth

12 for fastening

4 through bores Ø8.5 for fastening

20 Framework

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3.1.2 ES779 non connectorised, with fixing grooves

3 Technical specifications

1 H8 bore Ø30, depth 4 8

4 M5 bores, thread depth 6

for accessories

3 6 M5 bores for accessories 10

4 Nose 11 Shaft 18 Sensor area 5 HSK collet 12 Cylinder 19 Sensor cable passage 6 Resting surface 13 EC marking plate 20 Encoder compartment

6 bores for compressed air

and fluid inlet / outlet

H8 bore Ø60, depth 6 for positioning

H7 bore Ø8, depth 10 for

positioning 2 M6 bores for tool

lubricant-coolant outlet

14 Description of tool holder 21 Framework

15 Serial number

16 Fixing groove

17 Engine cable passage

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3.1.3 ES789 non connectorised, with fixing bores

3 Technical specifications

2 1

1 Resting surface 9

6 bores for compressed air

and fluid inlet / outlet H8 bore Ø60, depth 6

for positioning H7 bore Ø8, depth 10

for positioning 2 M6 bores for tool

lubricant-coolant outlet

6 Shaft 14 Sensor area 22 EC marking plate

6 M8 bores, thread depth

12 for fastening H8 bore Ø60, depth 6

for positioning

H7 bore Ø8, depth 10 for positioning

10 Nose 18 Encoder compartment

11 HSK collet 19

6 M5 bores

for accessories

13 Engine cable passage 21 Resting surface

15 Cylinder 23 Serial Number

16 Sensor cable passage 24 Description of tool holder

6 M8 bores, thread depth

12 for fastening

4 through bores Ø8.5 for fastening

20 Framework

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3.1.4 ES789 non connectorised, with fixing grooves

3 Technical specifications

1 12

1 Resting surface 8

6 bores for compressed air

and fluid inlet / outlet H8 bore Ø60, depth 6

for positioning H7 bore Ø8, depth 10

for positioning 2 M6 bores for tool

lubricant-coolant outlet

6 Shaft 13 Sensor area 20 Description of tool holder 7 H8 bore Ø30, depth 4 14 Cylinder 21 Serial number

4 M5 bores, thread depth 6 for accessories

9 Nose 16 Fixing groove

10 HSK collet 17 Encoder compartment

6 M5 bores

for accessories

12 Engine cable passage 19 EC marking plate

15 Sensor cable passage

18 Framework

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3.1.5 ES779 Collet, non connectorised

3 Technical specifications

6 M8 bores, thread depth

16 for fastening

2 Pressurisation air inlet 8 Resting surface 14 Serial number

H7 bore Ø8, depth 10

for positioning

4 Nose 10

5 Shaft 11

6 ER32 collet seat 12

M40 thread, 1.5 step

for ring nut

9 Engine cable passage 15 Slot for CH34 wrench

H8 bore Ø60, depth 6 for positioning

2 bores for coolant inlet / outlet

Fixing groove (one per side)

13 EC marking plate

16 Framework

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3.1.6 Variations for versions with electrical connectors of HSD type

3 Technical specifications

1 Button for manual tool unlocking 10 Description of tool holder

2 Serial number 11 EC marking plate

3 2 M6 bores for tool lubricant-coolant outlet 12 Sensor area

4 Nose 13 Hydraulic/pneumatic connectors

5 Shaft 14 HSD electrical connector

6 HSK collet 15 Encoder compartment

4 through bores Ø8.5

for fastening

8 6 M8 bores, thread depth 12 for fastening 17 Framework

9 6 M5 bores for accessories 18 Cylinder

H8 bore Ø60, depth 6

for positioning

031-it_Parti.fm

HSD S.p.A.

Page 21

HSD

3.1.7 Variations for versions with MIL standard electrical connectors

3 Technical specifications

1 EC marking plate 10 6 M5 bores for accessories 2 Electrical connector (encoder) 11 Electrical connectors (standard MIL) 3 Serial number 12 Hydraulic/pneumatic connector zone

2 M6 bores for tool lubricant-coolant

outlet

5 Nose 14 Encoder compartment 6 Shaft 15 Sensor area 7 HSK collet 16 Cylinder

4 through bores Ø8.5

for fastening

9 6 M8 bores, thread depth 12 for fastening 18 Button for manual tool unlocking

13 Framework

H8 bore Ø60, depth 6

for positioning

031-it_Parti.fm

HSD S.p.A.

Page 22

HSD

3.1.8 ES789 variations with distributor

3 Technical specifications

12 13

1 EC marking plate 11 Electrical connectors (standard MIL) 2 Electrical connector (encoder) 12 Fluids distributor 3 Serial number 13 Hydraulic/pneumatic connector zone

2 M6 bores for tool lubricant-coolant

outlet

5 Nose 15 Encoder compartment 6 Shaft 16 Sensor area

4 through bores Ø8.5

for fastening

8 6 M8 bores, thread depth 12 for fastening 18

9 6 M5 bores for accessories 19 Button for manual tool unlocking

10 HSK collet

031-it_Parti.fm

14 Framework

17 Cylinder

H8 bore Ø60, depth 6 for positioning

HSD S.p.A.

Page 23

HSD

3.1.9 Variations with floating piston or fixed piston

1 Floating piston 2 Fixed piston

3 Technical specifications

031-it_Parti.fm

HSD S.p.A.

Page 24

HSD

H1423H0212 Rev.03 (SP.120.80.44)

Tensione nominale (*)

Nennspannung (*) Rated voltage (*)

310 380 380 380 380 380 380

Frequenza nominale Nennfrequenz

Rated frequency

400 500 600 733 800 833 933

Velocità nominale

Nominale

Geschwin digkeit

Rated speed

rpm

12000 15000 18000 22000 24000 25000 28000

Tipo di se rvizio

Betriebsart

Duty type

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

Potenza nominale

Nennleistung Rated power

8,4

6,7

7,2

6,6

4,6

4,7

Coppia nominale

Nenndrehmoment Rated torque

9,6

6,4

7,6

5,3

6,4

3,7

2,7

2,9

1,8

2,5

1,6

Corrente nominale

Nennstrom Rated current

37,5

26,4

31,5

18,6

13,7

12,5

Rendimento nominale

Nennwirkungsgrad η Rated efficiency

0,85

Fattore di potenza cos

Leistungsfaktor cos ϕ Power factor cos

0,85

Numero di poli

Polzahl Number of poles

Classe di isolamento

Isolierklasse Insulation class

Tipo di raffreddamento

Kühlungstyp Type of cooling

Raffreddamento a liquido / Flüssigkeit / Liquid cooling

Peso versione

NASO CORTO

Gewicht Version

KURZE NASE

Weight of SHORT

NOSE variant

Peso versione

NASO LUNGO

Gewicht Version

LANG NASE

Weight of LONG

NOSE variant

[(*) fornita da inverter ]

[(*) von Inverter

geliefert]

[(*) from inver ter]

Versioni disponibili - Verfügbare Versionen - Available models

ATTACCO PORTAUTENSILE CUSCINETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

TOOL HOLDER FRONT BEARINGS REAR BEARINGS MAX SPEED

HSK A63

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC 18000rpm

HSK E63

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC 18000rpm

HSK F63

CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL

22000rpm

HSK E40 - F50

CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL

24000rpm

HSK F63

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC

25000rpm

HSK E40 - F50

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC

28000rpm

3.2 Characteristics and performance

3.2.1 ES779 12kW with 500Hz (15,000 rpm) rated frequency

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 25

HSD

Equivalent electrical network SP.120.80.44

Rated power (S1/Cont) kW 10

Rated current (S1/Cont) A26.4

Rated voltage V380

Rated speed rpm 11,810

Rated frequency Hz 400

No-load line voltage V300

No-load current A7.5

Stator resistance (20°C) Ohm 0.11

Rotor resistance (20°C) Ohm 0.16

Stator leakage reactance Ohm 0.9

Rotor leakage reactance Ohm 1.9

Main field reactance Ohm 23

Field weakening initial speed rpm 15,000

Motor maximum speed rpm 28,000

Power factor 0.85

Rotor moment of inertia kg 1.5E-03

Connection Y/D Y

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 26

HSD

H1423H0216 Rev.05 (SP.120.080.45)

Tensione nominale (*)

Nennspannung (*) Rated voltage (*)

380 380 380 380 380 380 380 380

Frequenza nominale Nennfrequenz

Rated frequency

250 367 400 600 733 800 833 933

Velocità nominale

Nominale

Geschwin digkeit

Rated speed

rpm

7500 11000 12000 18000 22000 24000 25000 28000

Tipo di se rvizio

Betriebsart

Duty type

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

Potenza nominale

Nennleistung Rated power

9,5

11,4

7,9

4,6

5,5

3,6

4,3

3,1

3,7

1,6

1,9

Coppia nominale

Nenndrehmoment Rated torque

12,7

15,3

8,7

10,4

7,6

9,1

4,2

4,8

2,4

1,4

1,7

1,2

1,4

0,55

0,65

Corrente nominale

Nennstrom Rated current

22,6

27,1

21,5

25,8

17,8

20,4

13,6

16,3

8,5

10,2

5,2

6,2

Rendimento nominale

Nennwirkungsgrad η Rated efficiency

0,83

Fattore di potenza cos

Leistungsfaktor cos ϕ Power factor cos

0,8

Numero di poli

Polzahl Number of poles

Classe di isolamento

Isolierklasse Insulation class

Tipo di raffreddamento

Kühlungstyp Type of cooling

Raffreddamento a liquido / Flüssigkeit / Liquid cooling

Peso versione

NASO CORTO

Gewicht Version

KURZE NASE

Weight of SHORT

NOSE variant

Peso versione

NASO LUNGO

Gewicht Version

LANG NASE

Weight of LONG

NOSE variant

[(*) fornita da inverter ]

[(*) von Inverter

geliefert]

[(*) from inver ter]

Versioni disponibili - Verfügbare Versionen - Available models

ATTACCO PORTAUTENSILE CUSCINETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

TOOL HOLDER FRONT BEARINGS REAR BEARINGS MAX SPEED

HSK A63

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC

18000rpm

HSK E63

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC

18000rpm

HSK F63

CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL

22000rpm

HSK F63

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC

25000rpm

HSK E40 - F50

ACCIAIO / STAHL / STEEL ACCIAIO / STAHL / STEEL

12000rpm

HSK E40 - F50

CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL

24000rpm

HSK E40 - F50

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC

28000rpm

HSK E40 - F50

CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC

28000rpm

3.2.2 ES779 12kW DP with 250Hz (7,500 rpm) rated frequency

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 27

HSD

Equivalent electrical network SP 120.80.45

Rated power (S1/Cont) kW 10

Rated current (S1/Cont) A24

Rated voltage V380

Rated speed rpm 7,250

Rated frequency Hz 250

No-load line voltage V354

No-load current A11

Stator resistance (20°C) Ohm 0.26

Rotor resistance (20°C) Ohm 0.24

Stator leakage reactance Ohm 1.1

Rotor leakage reactance Ohm 1.78

Main field reactance Ohm 17

Field weakening initial speed rpm 7,500

Motor maximum speed rpm

Power factor 0.8

Rotor moment of inertia kg 1.1E-03

Connection Y/D Y

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 28

HSD

3.2.3 ES779 13kW with 500Hz (15,000 rpm) rated frequency

H1423H0240 Rev.01 (SP.120.80.44.Par)

Tensione nominale (*)

Frequenza nominale Nennf requenz

Velocità nominale

Tipo di servizio

Potenza nominale

Coppia nominale

Corrente nominale

Rendimento nominale η

Fattore di potenza c os ϕ

Numero d i poli

Classe di isolamento

Tipo di raffreddamento

Peso versione

NASO CORTO

Peso versione

NASO LUNG O

[(*) fornita da inverter]

Nennspannung (*) Rated voltage (*)

Geschwindigkeit

Nennleistung Rated power

Nenndrehmoment Rated t orque

Nennwirkungsgrad η Rated efficiency

Leistungsfaktor cos ϕ Power factor cos

Isolierklasse Insulation cl ass Kühlungstyp Type of cooling

Gewicht Version

KURZE NASE

Gewicht Version

LANG NASE

[(*) von Inverter

geliefert]

Rated frequency

Nominale

Betriebsart Duty type

Nennstrom Rated current

Polzahl Number of poles

Rated speed

Weight of SHORT

NOSE variant

Weight of LONG

NOSE variant

[(*) from inverter]

V 310 380 380 380 380 380 380

400 500 600 733 800 833 933

rpm 12000 15000 18000 22000 24000 25000 28000

cont

60%

cont

60%

cont

60%

cont

60%

cont

60%

cont

10 12 12 13 12 13 7 8,4 6,7 7,2 5 6,6 4,6 4,7

Nm 8 9,6 7,6 8,2 6,4 6,9 3 3,7 2,7 2,9 1,8 2,5 1,6 1,6

A 31 37,5 31,5 34,1 31 33,6 20 24 18,6 20 13,7 18 12 12,5

Raffreddamento a liquido / Flüssigkeit / Liquid cooling

kg 26

0,8

0,85

4 F

60%

cont

60%

Versioni disponibili - Verfügbare Versionen - Available models

ATTACCO PORTAUTENSILE CUSCINETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

TOOL HOLDER FRONT BEARINGS REAR BEARINGS MAX SPEED

HSK F63 CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL 22000rpm

HSK F63 CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC 25000rpm HSK E40 - F50 CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL 24000rpm HSK E40 - F50 CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC 28000rpm

032-it_Sp-Elet.f.fm

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

HSD S.p.A.

Page 29

HSD

Equivalent electrical network SP 120.80.44 par

Rated power (S1/Cont) kW 12

Rated current (S1/Cont) A31.5

Rated voltage V380

Rated speed rpm 11,810

Rated frequency Hz 400

No-load line voltage V300

No-load current A7.5

Stator resistance (20°C) Ohm 0.11

Rotor resistance (20°C) Ohm 0.16

Stator leakage reactance Ohm 0.9

Rotor leakage reactance Ohm 1.9

Main field reactance Ohm 23

Field weakening initial speed rpm 15,000

Motor maximum speed rpm 28,000

Power factor 0.85

Rotor moment of inertia kg 1.5E-03

Connection Y/D Y

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 30

HSD

3.2.4 ES779 13.5kW with 400Hz (12,000 rpm) rated frequency

H1423H0378 Rev.00 (SP. 120.080.4S)

Tensione nominale (*)

Frequenza nominale Nennfrequenz

Velocità nominale

Tipo di servizio

Potenza nominale

Coppia nominale

Corrente nominale

Rendimento nominale η

Fattore di potenza cos ϕ

Numero di poli

Classe di isolamento

Tipo di raffreddamento

Peso versione

NASO CORTO

Peso versione

NASO LUNGO

[(*) fornita da inverter]

Versioni disponibili - Verfügbare Versionen - Available models

ATTACCO PORTAUTENSILE CUSCI NETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

TOOL HOLDER FRONT BEARINGS REAR BEARINGS MAX SPEED

HSK A63

Nennspannung (*) Rated voltage (*)

Nominale

Geschwindigkeit

Betriebsart Duty type

Nennleistung Rated power

Nenndrehmoment Rated torque

Nennstrom Rated current

Nennwirkungsgrad η Rated efficiency

Leistungsfaktor cos ϕ Power factor cos

Polzahl Number of poles Isolierklasse Insulation class Kühlungstyp Type of cooling

Gewicht Version

KURZE NASE

Gewicht Version

LANG NASE

[(*) von Inverter

geliefert]

CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL

Rated frequency

Rated speed

Weight of SHORT

NOSE variant

Weight of LONG

NOSE variant

[(*) from inverter]

380 380 380 380

400 600 667 800

12000 18000 20000 24000

rpm

cont

60%

cont

13,5 16,2 13,5 16,2 11,5 13,8 7,5 9

10,7 12,9 7,2 8,6 5,5 6,6 3,0 3,6

29,0 35,0 29,0 35,0 25,0 30,0 16,5 19,8

60%

0,85 0,82

Raffreddamento a liquido / Flüssigkeit / Liquid cooling

cont

60%

18000rpm

cont

60%

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 31

HSD

Equivalent electrical network SP 120.80.4S

Rated power (S1/Cont) kW 13.5

Rated current (S1/Cont) A29

Rated voltage V380

Rated speed rpm 11,830

Rated frequency Hz 400

No-load line voltage V 369.56

No-load current A5.6

Stator resistance (20°C) Ohm 0.18

Rotor resistance (20°C) Ohm 0.13

Stator leakage reactance Ohm 2.1

Rotor leakage reactance Ohm 1.3

Main field reactance Ohm 37.6

Field weakening initial speed rpm 12,000

Motor maximum speed rpm 24,000

Power factor 0.82

Rotor moment of inertia kg

Connection Y/D

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 32

HSD

3.2.5 ES789 18kW with 267Hz (8,000 rpm) rated frequency

HSD S.p.A www.hsd.it Via della Meccanica,16 61100 PESARO (Italy)

380V

W k

267Hz

8000 rpm

continuous

ES 789L 4P 18,00kW H1

Liquid cooling

1818

1616

Flussigkeitsgekuhlt

ASYNCHRONOUS 3-PHASE MOTOR

DREHSTROM-

ASYNCHRONMOTOR

H1423H0211

Ta:20°C

Ins.Cl. F

Peak Power

Spitzenleistung

19 kW - 25,5 Hp

1010

16 kW-21,5 Hp

8888

18181822

22000

UL-MH26206

2222

5,2222

5,5, 4,

4,3333

4,4,

PEAK CURRENT

120 A 500 ms 145 A 15 ms 170 A 5 ms

34,5 A

S6 60% 18 kW-24,1 Hp

Poles: 4

= 0,7

Cos

= 0,8

IP 54 36 Kg

42 Kg

rpm

m x 1

rprp

m m

x 1000000000000

x 1x 1



10 18

8888

1010

MMMMAAAAXXXX RRRRPPPPMMMM

18000

IEC 60034-1

H1423H0211 Rev.02 (2120H0120)

Tensione nominale (*)

Frequenza nominale Nennfrequenz

Velocità nominale

Tipo di servizio

Potenza nominale

Coppia nominale

Corrente no minale

Rendimento nominale η

Fattore di potenza cos ϕ

Numero di p oli

Classe di isolamento

Tipo di raffreddamento

Peso versione

NASO LUNGO

Peso versione con

DISTRIBUT ORE

[(*) fornita da inverter]

ATTACCO PORTAUTENSILE CUSCINETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

TOOL HOLDER FRONT BEARINGS REAR BEARINGS MAX SPEED

Nennspan nung (*) Rated voltage (*)

Geschwindigkeit

Betriebsa rt Duty type

Nennleistung Rat ed power

Nenndrehmoment Rated torque

Nennstrom Rated current

Nennwirkungsgrad η Rated efficiency

Leistungsfaktor cos ϕ Power factor cos

Isolierklasse Insulation class Kühlungstyp Type of cooling

Gewicht V ersion

LANGE NASE

Gewicht V ersion

DISTRIBUTOR

[(*) von Inverter

geliefert]

HSK F63 CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL 18000rpm HSK F63 CRONIDUR / CHROMEX CERAMICI / KERAMIK / CERAMIC 22000rpm

Rated frequency

Nominale

Polzahl Number of poles

Rated speed

Weight of LONG

NOSE variant

DISTRIBUTOR

[(*) from inverter]

V 380 380 380 380

Hz 267 333 600 733

rpm 8000 10000 18000 22000

cont

60%

cont

60%

cont kW 16 18 16 18 8 10 4,3 5,2 Nm 19 21,5 15,3 17,2 4.2 5,3 1,9 2, 3

A 34,5 45 34,5 45 18 26 8 11

0,8

0,7

4 F Raffreddamento a liquido / Flüssigkeit / Liquid cooling

kg 36

Weight of

variant

60%

cont

60%

032-it_Sp-Elet.f.fm

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

HSD S.p.A.

Page 33

HSD

Equivalent electrical network SP 120.150.4A

Rated power (S1/Cont) kW 16

Rated current (S1/Cont) A34.5

Rated voltage V380

Rated speed rpm 7,810

Rated frequency Hz 267

No-load line voltage V266

No-load current A11

Stator resistance (20°C) Ohm 0.12

Rotor resistance (20°C) Ohm 0.2

Stator leakage reactance Ohm 1

Rotor leakage reactance Ohm 1.7

Main field reactance Ohm 19

Field weakening initial speed rpm 8,000

Motor maximum speed rpm 18,000

Power factor 0.8

Rotor moment of inertia kg 0.0025

Connection Y/D Y

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 34

HSD

3.2.6 ES789 18kW DP with 300Hz (9,000 rpm) rated frequency

HSD S.p.A www.hsd.it Via della Meccanica,16 61100 PESARO (Italy)

380V

rpm x 1 000

300Hz

9000 rpm

continuous

15 kW-20,1 Hp

31,6 A

S6 60% 18 kW-24,1 Hp

Poles: 4

M = 0,8

Cos

= 0,8

IP 54 Kg 36 Kg

ES 789L 4P

Flussigkeitsgekuhlt

13,1



IEC 60034-1

18,00

ASYNCHRONOUS 3-PHASE MOTOR

DREHSTROM-

ASYNCHRONMOTOR

kW H1

H1423H0228

Liquid cooling

Ta:20°C

Ins.Cl. F

Peak Power

Spitzenleistung

13,5

14 18

21,8 kW-29,2 Hp

9,8

5,5

3,8

MAX RPM

18000 22000 24000

UL-MH26206

4,1

H1423H0228 Rev.02 (SP.120.150.4E)

Tensione nominale (*)

Frequenza nominale Nennfrequenz

Velocità nominale

Tipo di servizio

Potenza nominale

Coppia nominale

Corrente nominale Rendimento nominale Fattore di potenza cos

Numero di poli

Classe di isolamento

Tipo di raffreddamento

Peso versione

NASO LUNGO

[(*) fornita da inverter]

Nennspannung (*) Rated voltage (*)

Geschwindigkeit

Nennleistung Rated power

Nenndrehmoment

Nennwirkungsgrad K Rated efficiency

Leistungsfaktor cos M Power factor cos

Isolierklasse Insulation class Kühlungstyp T ype of cooling

Gewicht Version

LANGE NASE

[(*) von Inverter

geliefert]

Rated frequency

Nominale

Betriebsart Duty type

Nennstrom Rated current

Polzahl Number of poles

Rated speed

Rated torque

Weight of LONG

NOSE variant

[(*) from inverter]

V 255 380 380 380 380 380

Hz 200 300 467 600 733 800

rpm 6000 9000 14000 18000 22000 24000

contS660% S1contS660% S1cont kW 12 13,1 15 18 12 13,5 9 9,8 5,5 6 3,8 4,1 Nm 19,1 20,9 15,9 19,1 8,2 9,2 4,8 5,2 2,4 2,6 1,5 1,6

A 36,8 41,3 31,6 38,7 29,1 32,8 24,3 26,4 16,2 17,6 11,1 12,2

0,8

4 F

kg 36

60% S1contS660% S1contS660%

Raffreddamento a liquido / Flüssigkeit / Liquid cooling

cont S660%

Versioni disponibili - Verfügbare Versionen - Available models

ATTACCO PORTAUTENSILE CUSCINETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

TOOL HOLDER FRONT BEARINGS REAR BEARINGS MAX SPEED

HSK F63 CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL 18000rpm HSK F63 CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC 22000rpm HSK F63 CERAMICI / KERAMIK / CERAMIC CERAMICI / KERAMIK / CERAMIC 24000rpm

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 35

HSD

Equivalent electrical network SP 120.150.4E

Rated power (S1/Cont) kW 15

Rated current (S1/Cont) A33

Rated voltage V380

Rated speed rpm 8,880

Rated frequency Hz 300

No-load line voltage V373

No-load current A6.4

Stator resistance (20°C) Ohm 0.13

Rotor resistance (20°C) Ohm 0.14

Stator leakage reactance Ohm 1.7

Rotor leakage reactance Ohm 1.26

Main field reactance Ohm 34

Field weakening initial speed rpm 9,000

Motor maximum speed rpm 24,000

Power factor 0.8

Rotor moment of inertia kg 3.8E-03

Connection Y/D Y

032-it_Sp-Elet.f.fm

HSD S.p.A.

Page 36

HSD

3.2.7 ES789 17kW with 400Hz (12,000 rpm) rated frequency

H1423H0245 Rev.01 (SP.120.150.45)

Tensione nominale (*)

Frequenza nominale Nennfrequenz

Velocità nominale

Tipo di servizio

Potenza nominale

Coppia nominale

Corrente nominale

Rendimento nominale η

Fattore di potenza cos ϕ

Numero d i poli

Classe di isolamento

Tipo di raffreddamento

Peso versione

NASO LUNG O

[(*) fornita da inverter]

Nennspannung (*) Rate d voltage (*)

Geschwindigkeit

Nennleistung Rated power

Nenndrehmoment Rated torqu e

Nennwirkungsgrad η Rat ed efficiency

Leistungsfaktor cos ϕ Power factor cos

Isolierklasse Insulation class

Kühlungstyp Ty pe of cooling

Gewicht Version

LANGE NASE

[(*) von Inverter

geliefert]

Rated frequency

Nominale

Betriebsart Duty type

Nennstrom Rated current

Polzahl Number of poles

Rated speed

Weight of LONG

NOSE variant

[(*) from inverter]

V 380 380 380 380

Hz 400 500 733 833

rpm 12000 15000 22000 25000

kW 15 17 15 17 7 8,5 5,5 6, 6

Nm 12 13,5 9,6 10,8 3 3,6 2,1 2,5

A 34 38 34 38 16,5 20 15,9 18,8

0,8

4 F Ra ffreddamento a liquido / F lüssigk eit / Liquid cooling

kg 36

cont

60%

cont

60%

cont

60%

cont

60%

ATTACCO PORTAUTENSILE CUSCINETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

TOOL HOLDER FRONT BEARINGS REAR BEARINGS MAX SPEED

HSK F63 CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL 22000rpm HSK F63 CRONIDUR / CHROMEX CERAMICI / KERAMIK / CERAMIC 25000rpm

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

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Equivalent electrical network SP 120.150.45

Rated power (S1/Cont) kW 15

Rated current (S1/Cont) A34

Rated voltage V380

Rated speed rpm 11748

Rated frequency Hz 400

No-load line voltage V364

No-load current A9.5

Stator resistance (20°C) Ohm 0.09

Rotor resistance (20°C) Ohm 0.13

Stator leakage reactance Ohm 0.61

Rotor leakage reactance Ohm 1.8

Main field reactance Ohm 27.9

Field weakening initial speed rpm 12000

Motor maximum speed rpm

Power factor 0.8

Rotor moment of inertia kg 2.5E-03

Connection Y/D Y

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3.2.8 ES789 13.5kW with 350Hz (10,500 rpm) rated frequency

H1423H0246 Rev.01 (SP.120.150.49)

Tensione nominale (*)

Frequenza nominale Nennfrequenz

Velocità nominale

Tipo di servizio

Potenza nominale

Coppia nominale

Corrente nominale

Rendimento nominale η

Fattore di potenza cos ϕ

Numero d i poli

Classe di isolamento

Tipo di raffreddamento

Peso versione

NASO LUNG O

[(*) fornita da inverter]

ATTACCO PORTAUTENSILE CUSCINETTI ANTERIORI CUSCINETTI POSTERIORI VELOCITÀ MASSIMA

WERKZEUGHALTER VORDERE LAGER HINTERE LAGER MAX. DREHZAHL

Nennspannung (*) Rate d voltage (*)

Geschwindigkeit

Betriebsart Duty type

Nennleistung Rated power

Nenndrehmoment Rated torque

Nennstrom Rated current

Nennwirkungsgrad η Rat ed efficiency

Leistungsfaktor cos ϕ Power factor cos

Isolierklasse Insulation class Kühlungstyp Ty pe of cooling

Gewicht Version

LANGE NASE

[(*) von Inverter

geliefert]

Rated frequency

Nominale

Polzahl Number of poles

Rated speed

Weight of LONG

NOSE variant

[(*) fro m inverter]

V 380 380 380 380

Hz 233 350 733 833

rpm 7000 10500 22000 25000

cont

60%

cont

60%

cont

60%

kW 8 9,6 11 13,5 5 6 3,5 4,2

Nm 10,9 13,1 10 12,3 2,2 2,6 1,3 1,6

A 27,5 33 26 32,5 13,3 16 9, 5 11

0,86

0,7

4 F Raffreddament o a liquido / Flüssigkeit / Liquid cooling

kg 36

cont

60%

TOOL HOLDER FRONT BEARINGS REAR BEARING S MAX SPEED

HSK F63 CERAMICI / KERAMIK / CERAMIC ACCIAIO / STAHL / STEEL 22000rpm HSK F63 CRONIDUR / CHROMEX CERAMICI / KERAMIK / CERAMIC 25000rpm

The maximum value of rated current “S1/cont” is used to set the parameter of the “maximum direct current” of the inverter

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Equivalent electrical network SP 120.150.49

Rated power (S1/Cont) kW 11

Rated current (S1/Cont) A27.5

Rated voltage V380

Rated speed rpm 10,350

Rated frequency Hz 350

No-load line voltage V380

No-load current A6.0

Stator resistance (20°C) Ohm 0.14

Rotor resistance (20°C) Ohm 0.22

Stator leakage reactance Ohm 1.1

Rotor leakage reactance Ohm 1.8

Main field reactance Ohm 38

Field weakening initial speed rpm 10,500

Motor maximum speed rpm 20,000

Power factor 0.8

Rotor moment of inertia kg 25E-03

Connection Y/D Y

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4 Installation and commissioning

4.1 Dimensional drawings

Dimensional drawings are available upon request at HSD customer service.

4.2 Preliminary checks before installation

Before carrying out any operation, CHECK:

 that no part of the product has suffered knocks or damage during the transport and/or

handling;

 that connectors are not damaged.

4.3 Preparation of the auxiliary systems of the plant

It is the responsibility of the customer to have the auxiliary systems of the plant ready (e.g. electrical system, air, etc.). The electric power line must have the necessary transmission power. Connection to the electric mains network may only be carried out by qualified persons.

The Customer is responsible for the whole electric power supply to the product up to the connectors. The user must ensure all the safety conditions necessary for the earthing of the product. The earthing system must conform to the standards in force in the country of installation and must be inspected at regular intervals by qualified personnel.

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4.4 Mechanical connections

The supporting structure to which the product will be secured must be sufficiently stable for the weight of the product and for the type of machining operation to be carried out.

4.4.1 Resting surface

The surface on which the electrospindle is to be fitted must have a flatness less than 0.02 mm.

4.4.2 Tool change system

The tool holder magazine must position cones with the following precision:

 ISO: spindle shaft/tool holder cone concentricity: 0.2 mm;

 HSK: spindle shaft/tool holder cone concentricity: 0.7 mm

spindle shaft/tool holder stop surface perpendicularity: 0.1 mm.

ISO HSK

1 Spindle shaft ISO

r 0,02

-A-

a A0,2

-B-

1 3

-C-

a C0,7

n B0,1

2 Tool holder cone ISO

3 Spindle shaft HSK

4 Tool holder cone HSK

4.4.3 Fastening of models with “fixing bores”

To fit the machine electrospindle, choose any of the resting surfaces shown in figures of section 3

“Technical specifications”, with the corresponding fixing and positioning bores.

In particular, if the surface chosen has fixing bores either of the through or the threaded type, simply use all the fixing bores of one type only.

In connectorised models, there is only one resting surface.

4.4.4 Fastening of models with “fixing grooves”

To fit the machine electrospindle, use 2 side grooves and positioning bores in the resting surface (see figures in section 3 “Technical specifications”).

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4.4.5 “Collet” model fastening

To fasten the machine electrospindle, alternatively use 2 side grooves or threaded bores in the resting surface; for the correct positioning, use 2 bores with specific tolerance on the resting surface (see the figure in section 3.1).

4.4.6 Threaded service bores

There are six M5 threaded bores on the electrospindle nose to mount some accessories. In models with “fixing grooves”, moreover, there are 4 M5 threaded bores on the surface opposite to the resting surface.

(See figures in section 3 “Technical specifications”).

In “Collet” models, there are no service threaded bores.

4.5 Fluids distributor

Only for non connectorised versions: the interface surface that creates the connection between the compressed air circuits/cooling liquids circuits and the electrospindle must be made so as to prevent leaks and contamination between the various ducts.

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4.6 Pneumatic connections

4.6.1 Specifications for compressed air to be supplied to HSD products

Inject compressed air with a purity rating complying with ISO 8573-1, types 2, 4, 3, i.e:

• Type 2 for solid particles: size of solid particles < 1 µm.

• Type 4 for humidity: dew point < 3°C (37.4°F).

• Type 3 for total oil: oil concentration < 1 mg/m

Failure to comply with these specifications may result in electrospindle malfunction. The warranty is not valid if pollutants are found during repair operations.

As an example, the above mentioned specifications can be implemented by following the indications below:

 If a lubricated air circuit is present in the machine, it should be isolated from the dry

air circuit (to be used by the electrospindle) by means of non-return valves.

 The filters indicated in the diagrams of the following figures should be installed as

near the electrospindle as possible.

 taking into account the fact that the efficiency of the filters is <100%, it is essential

that the machine be fed with properly treated air; As a general guide, and for the circuits illustrated below, inject compressed air with a purity rating complying with ISO 8573-1, types 7, 6, 4, i.e.:

• Type 7 for solid particles: solid particle size < 40 µm; solid particle concentration < 10mg/m3;

• Type 6 for humidity: dew point < 10°C;

• Type 4 for total oil: oil concentration < 5 mg/m3.

 At the end of the working day, empty the pneumatic system to enable the automatic

purging of filters.

 Carry out regular maintenance operations of the filters according to the

manufacturer's indications, and replace them when they are saturated and lose effectiveness (approximately every 6/12 months).

1. Mains power supply.

1 4

2. Pre-filter 5 µm.

3. De-oiling filter 0.1 µm.

4. To the HSD product.

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Figure 1 : pneumatic connection points

Ø 5

Ø 4

ø4

ø5

2 1

versions with “fixing bores”

versions with connectors

versions with “fixing grooves”

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Figure 2 : indicative pneumatic layout

ø8/6mm

5 µ

0,1 µ

ø8/6mm

1 Air inlet for pressurisation and cone cleaning 4 bar (58 PSI) 2 Air inlet and outlet for tool holder unlocking 10 bar (145 PSI) 3 Line lead-in 10 bar (145 PSI)

Air filtration and purification stage for 99.97% at 0.1 µµm

(as an example: pair of condensate separation filters with automatic draining; first stage at 5 µµm and second at 0.1µµm, with a purification capacity of 99.97% at 0.1 µµm)

5 Pressure regulator set to 4 bar (58 PSI) 6 Pressure gauge

Pair of 3-way monostable solenoid valves

(use solenoid valves suitable for the pressures employed)

8 Possible pressure multiplication system

The use of two electric valves in series instead of just one reduces the possibility of malfunctioning. Although such malfunctioning is very rare, the seriousness sometimes means the application of the redundancy principle.

THE CIRCUIT SHOWN IS PURELY INDICATIVE

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IMPORTANT:

 In order to guarantee the reliable function of the electrospindle, and in particular of the

precision bearings, it is absolutely essential to avoid the possibility of contamination of the dry air circuit with oil from the lubricated air circuit (if installed) or from the compressor.

 Keep the dry air circuit and lubricated air circuit completely separate and independent; where

this is not possible, take every measure necessary to prevent an abnormal flow-back of lubricated air, for example using non-return valve upline of the oiler and tapping the dry air for the electrospindle upline of these valves.

 Purely as an example and not as a limitation we should point out that such back-flows may

cause fluctuations in pressure, for example during the starting and stopping phases of the machine or compressor, or fluctuations in the mains voltage, faults in the compressor, etc.

4.6.2 Automatic cleaning of the tool holder cone

The tool holder cone and its tapered mounting on the spindle shaft is automatically cleaned by a jet of compressed air during the tool changing phase. This procedure protects the coupling surfaces against deposits of contaminants. The state of the coupling surfaces must be checked at regular intervals, along with their level of

cleanliness, as described in section 7 “Scheduled maintenance”.

The jet of cleaning air is active for the whole time that the collet is open.

4.6.3 Internal pressurisation

The internal pressurisation prevents harmful particles from entering the electrospindle. Pressurisation circuit must be fed with air compressed at the pressure indicated in Figure 2.

The pressurisation air must be present even when the electrospindle is at a standstill and the machine is switched on, so that no dust from other machining areas can come into the spindle.

With the spindle at standstill, check there is a uniform outlet of air around the spindle shaft (pressurisation); if this is not the case, check the efficiency of the pneumatic circuit and the tightness of the connections.

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4.7 Hydraulic connections and specifications of the cooler

The gaskets that isolate the fluid circuits inside the electrospindle are made of NBR (nitrile rubber): use only additives that do not degrade this material.

For the cooling circuit use water with 10% ethylene glycol and anticorrosion additives.

Upon request, HSD supplies “ARTIC-FLU-5” (order No.: H2161H0022). ARTIC-FLU-5 is a premixed coolant ready for use, tested by HSD S.p.A. It contains ethylene glycol and corrosion inhibitors with an ecological formula without amines, nitrates or phosphates, and guarantees protection against corrosion for roughly 1 year. ARTIC-FLU-5 prevents the formation of rust, scale and foam deposits, as well as the hardening, cracking or swelling of the seals and sleeves. It complies with various international standards, including CUNA NC 956-16.

4.7.1 Specifications of the cooler

Electrospindle power From 0 to 12 kW From 13 to 20 Cooling capacity 1,600 W 3,400 W Minimum flow rate 5 litres/minute 5 litres/minute

Type of coolant

Temperature of the cooler set

Water + 10% Ethylene Glycol + corrosion inhibitors

+25+/-3°C (+77+/-5°F) +25+/-3°C (+77+/-5°F)

Water + 10% Ethylene Glycol + corrosion inhibitors

4.7.2 Hydraulic connection points

The following figures illustrate the hydraulic connection points according to correspondence shown in this table:

1 Engine coolant inlet 2 Engine coolant outlet 3 First lubricant-coolant inlet for tool 4 First lubricant-coolant outlet for tool 5 Second lubricant-coolant inlet for tool (*) 6 Second lubricant-coolant outlet for tool (*)

(*) present only in some versions.

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Figure 3 : hydraulic connections for ES779 with fixing bores

ø6

Figure 4 : hydraulic connections for ES779 with fixing grooves

ø6

Figure 5 : hydraulic connections for ES789 with fixing bores

ø6 M6

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Figure 6 : hydraulic connections for ES789 with fixing grooves

ø6

5 2

ø6 M6

Figure 7 : hydraulic connections for all the other models with electrical connections

ø6

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4.8 Pneumatic/hydraulic connections of models with distributor

1 Air inlet for tool changing (8x6 pipe 10 bar) 2 Air inlet for pressurisation (4x2 pipe 6 bar) 3 4 bores for safety drainage 4 Air inlet for tool cooling and cone cleaning (G1/8) 5 Tool coolant inlet; oil-water mix (G1/4)

Specifications of the distributor

Inlet air maximum pressure 20 bar Inlet pressure drop 350 (NL/min)/1 bar Filtration degree < 50 microns Coolant inlet maximum pressure 80 bar Dry running Possible

The cooling water reaches the tool through a fluid rotating distributor

Pipes connecting to distributor safety drainage must be oriented downwards. Pipes must remain oriented downwards even when the machine moves the electrospindle (see the following figure).

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4.9 Electrical connections of models with free cables

1 Enconder and Sensor cable outlet (*) 2 Power and Thermal Alarm cable outlet

(*)The encoder is optional

The electrical power supply to the electrospindle MUST be provided via inverter.

4.9.1 ES779 and ES789 Power Cables

Colour Description

Red U Motor Phase Black V Motor phase White W Motor Phase Yellow/green : Motor Earth Grey Thermal alarm Grey Thermal alarm

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4.9.2 Sensor Cables (all motors)

Colour Description

White +24 V DC Sensor S1 Green 0 V Sensor S1 Brown OUTPUT Sensor S1 Yellow +24 V DC Sensor S2 Pink 0 V Sensor S2 Grey OUTPUT Sensor S2 Blue +24 V DC Sensor S3 Black 0 V Sensor S3 Red OUTPUT Sensor S3

(1)

Violet Beige Orange

(2)

+24 V DC Sensor S4 0 V Sensor S4

(2)

Sensor S4 OUTPUT

(1)

Only HSK versions: weld “OUTPUT Sensor S1” to the Brown conductor

(2)

Only HSK versions

(2)

Only HSK versions:

the welding specified in note “(1)” of the previous table connects S1 and S4 in series. This eliminates the false signals of S4 in the phases when it is not important.

4.9.3 Encoder cables (Optional)

Colour Description

Brown B + Blue B Yellow A + Green A Black 0V Grey Z + Red Vcc (*) White Z -

(*) +5 V DC or +12 V DC according to model

Check power supply voltage of the Encoder model before connecting and feeding it so as not to damage electronic circuits.

100-it_Con-Elet.fm

The cables of the Sensors and Encoder ARE NOT “high-flexibility” ones. If the application requires it, use “high-flexibility” cables for the connections.

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4.10 Electrical connections of models with HSD connectors

4.10.1 Power connector diagram

PIN DESCRIPTION

THERMAL PROTECTIVE DEVICE: bimetallic normally-closed (NC) switch to be

connected in series to the machine alarm or the inverter alarm. 48V DC MAX; 1.6A MAX

: in common with PIN 7

3 not used 4 Motor U phase

THERMAL PROTECTIVE DEVICE (see PIN

6 Motor V phase

: in common with PIN 2

8 Motor W phase 9 Not used

Use cables of not less than 6 mm

1 mm

minimum (or at least AWG18) for the odd ones

(or at least AWG10) for the even PINS, and

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4.10.2 Signal connector diagram

Use cables of not less than 0.35 mm

PIN DESCRIPTION 1 sensor S2 (collet open) OUTPUT 2 S1+ S4 sensor series (tool locked) OUTPUT 3 S3 sensor (stopped shaft) OUTPUT (S3 optional) 4 +24V DC power to S1, S2, S3 5 +24V DC power to push-button LIGHT BULB 6 0V power supply to S1, S2, S3 7 +24V DC power supply to BUTTON 8 PUSH-BUTTON OUTPUT 9 Not used 10 Not used 11 0V power supply to BUTTON and LIGHT BULB 12 Not used 13 Not used 14 S1 sensor (tool present) OUTPUT 15 A + (ENCODER optional) 16 A - (ENCODER optional) 17 B - (ENCODER optional) 18 0V (optional ENCODER power supply) 19 Z + (ENCODER optional) 20 VCC (optional ENCODER power supply) 21 B + (ENCODER optional) 22 Z - (ENCODER optional) (*) +5 V DC or +12 V DC according to model

(or at least AWG22)

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4.11 Electrical connections of models with military connectors

4.11.1 Power connector diagram (standard MIL)

PIN DESCRIPTION

A U Motor phase B V Motor phase C W Motor phase

D U Motor phase

THERMAL PROTECTIVE DEVICE: bimetallic normally-closed (NC) switch to be

connected in series to the machine alarm or the inverter alarm. 48V DC MAX; 1.6A MAX

F THERMAL PROTECTIVE DEVICE (see PIN E)

4.11.2 Signal connector diagram (standard MIL)

PIN DESCRIPTION

A sensor S2 (collet open) OUTPUT

B S1+ S4 sensor series (tool locked) OUTPUT C S3 sensor (stopped shaft) OUTPUT (S3 optional) D +24V DC power to S1, S2, S3

E +24V DC power to push-button LIGHT BULB

F 0V power supply S1, S2, S3, S4 G +24V DC power supply to BUTTON H PUSH-BUTTON OUTPUT

J 0V power to BUTTON and LIGHT BULB

M S1 sensor (tool insert) OUTPUT

N THERMAL PROTECTIVE DEVICE

P THERMAL PROTECTIVE DEVICE

K-L

O,P-T

Not used

100-it_Con-Elet.fm

Contacts of the thermal probe can be found in the power connector or in the signals connector according to the electrospindle model. For the correct pin-out of connectors, see the dimensional drawing of the spindle concerned

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4.11.3 Encoder connector diagram

PIN DESCRIPTION

A A + B A -

C B - D 0V power to ENCODER

E Z +

F VCC ENCODER power supply (*)

J B + K Z -

(*) +5 V DC or +12 V DC according to model

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4.12 Tool release button

The position of the button is shown in section 3.1

The button on the electrospindle can be used to manually command the release of the tool holder: so that by keeping the button pressed the tool is expelled and the collet remains open until the button is released again.

Characteristics of the button Bulb characteristics

Rated voltage (DC) 24V Rated voltage (DC) 24V

Maximum current 100 mA Rated power 0.7W

Rated current 29 mA

4.12.1 Electric diagram for manual tool holder release

 When the spindle is rotating, a control system must disable the command arriving

from the button.

 The activation of the button must only be possible with the spindle idle.

 The tool locking/release operation via this button must only be carried out with

the machine in MANUAL working mode (not AUTOMATIC).

 The tool could be ejected at high speed if the safety conditions described above

are not respected.

7 - 8

PINS 7 and 8 of the SIGNALS connector

B Tool release button

Pressure switch that, in the event of

low pressure, does not allow the release of the tool holder

Safety check

(zero speed device)

E CNC

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5 General checks after installation

5.1 Checks before the start-up

5.1.1 Pneumatic circuit

 Pneumatic circuit pipes must have the diameter specified in section 4.6 “Pneumatic

connections”. Input compressed, dry and filtered air, according to the specifications indicated

in the same section;

 for the connections, check any labels on the product and refer to section 4.6 “Pneumatic

connections”;

 compressed air must always be present, even when the electrospindle is stopped: check (with

the electrospindle stopped and tool holder installed) that a uniform and continuous flow of air comes out from the labyrinth on the spindle nose;

 the cone cleaning air must be present during tool changing;

 The expulsion progress of the tool-holder cone must be that indicated in section 6.4 “Tool

holder locking and ejection device”.

5.1.2 Hydraulic circuit

 The liquids used must respect the specifications and warnings in section 4.7 “Hydraulic

connections and specifications of the cooler”.

5.1.3 Electrical circuit

 The earthed cable of the product (indicated in section 4.8 and 4.10) must be

connected to the earthed cable of the machine;

 the thermal safety switch must activate a procedure for protecting against the

overheating of the coils of the electrospindle (see section 6.6.4).

5.1.4 Programming the inverter

 The maximum voltage set on the inverter must correspond to the rated value indicated on the

motor rating plate.

 The set frequency value at which the maximum voltage (rated frequency) is to be attained

must correspond to the value indicated on the motor rating plate.

 The maximum speed set on the inverter must correspond to the value indicated on the motor

rating plate.

 The maximum direct current supplied to the inverter must correspond to the rated current

indicated on the motor rating plate.

 If it is considered necessary to check the other parameters of the inverter, please contact HSD

S.p.A.

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5 General checks after installation

5.2 Checks during initial starting

Start the electrospindle only if the sensors confirm the following conditions simultaneously:

Sensor 1 ON Tool-holder cone attached

Sensor 1 + Sensor 4 (*) ON (*) HSK cone blocked in the correct position (*)

Sensor 2 OFF Collet closed

(*) HSK versions only

The “ON” condition of the sensor corresponds to the output equal to the supply voltage. The “OFF” condition of the sensor corresponds to an output of 0V.

It is forbidden to start the electrospindle without the tool holder installed.

 the control sensors must intervene according to the logic described in section 6.6;

 the tool changing cycle may only start when the shaft is at a standstill;

 with the tool holder inserted, and without machining, carry out the preheating cycle described

in section 6.3.

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6 Use and Adjustment

6.1 Environmental Conditions

HSD S.p.A. has inspected and tested its products in accordance with standard environmental conditions(CEI EN 60034-1:2006-05). Contact HSD S.p.A. for information on the possibility of applications in special environments.

6.2 Running-in

Before being packed, the product was subjected to an automatic running-in cycle to guarantee the correct distribution of the lubricant (long-life grease) on the races of the bearings, and to run in the spheres and races of the bearings themselves. If present, also the reducers and servomotors are run in, and dynamic tests are carried out on the inner pneumatic and hydraulic circuits. The running-in cycle also includes a strict inspection of all the command and signalling elements, simulating various types of operating cycle on the test bench.

6.3 Preheating

HSD S.p.A. uses high-precision angular contact bearing pairs, pre-loaded and lubricated for life with special grease for high speeds. When the machine is switched on for the first time every day, allow the electrospindle to perform a brief preheating cycle in order to allow the bearings to gradually attain a uniform operating temperature, and hence to obtain a uniform expansion of the bearing races and the correct preload and rigidity.

The following cycle is recommended, with tool holder inserted, but without machining operations:

 50% of the maximum rated speed for 2 minutes.

 75% of the maximum rated speed for 2 minutes.

 100% of the maximum rated speed for 1 minute.

The preheating cycle should also be performed every time that the machine is inoperative long enough for the electrospindle to cool down to room temperature.

Only in cases of the first start-up after storage or machine shutdown for more than four months, allow the machine to run for 2 minutes at 5,000 rpm before proceeding with the preheating cycle.

While the machine is operating, the spindle can reach high temperatures. Be very careful not to touch it without due precautions.

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6.4 Tool holder locking and ejection device

The blocking and expulsion of the tool-holder are achieved by the double-acting movement of a pneumatic piston, activated with compressed air of the pressure indicated in section 4.6

“Pneumatic connections”.

The tool-holder cone expulsion must be around 0.5 mm - 0.9 mm for versions ISO and around 0.5 mm - 0.6 mm for versions HSK.

The tool-holder is blocked mechanically by elastic springs that develop an axial force equal to:

ELECTROSPINDLE

MODEL

ES779 HSK E40-F50 2,300 ± 10% 6,800 ± 10%

ES779 HSK A/E 63 6,300 ± 10% 18,000 ± 10% ES779 HSK F63 3,430 ± 10% 11,000 ± 10% ES789 HSK F63 3,430 ± 10% 11,000 ± 10%

The axial force exerted on the tool-holder by the blocking system is guaranteed constant for a minimum duration of 2,000,000 cycles of tool change

1 tool changing cycle = tool blocked / tool released / tool blocked

All HSD electrospindles have a mechanical reaction system that neutralises the axial force of the piston on the shaft during the tool changing phase, thus guaranteeing the integrity of the precision bearings.

AXIAL FORCE

OF THE SPRINGS

AXIAL FORCE ON

TOOL HOLDER

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6.4.1 Tool holder cone

CONE ISO30

DIN69871

 The geometry of the conicity must respect standard DIN69871 for ISO30 cones, and standard

DIN69893 for HSK cones.

 The tool holder cone ISO30 must have an AT3 precision rating;

 Avoid the presence of plugs, slots, or other forms affecting the dynamic balancing of the tool

holder;

 At the maximum rated speed of the electrospindle, the level of dynamic balancing must be G =

2.5 or better (ISO1940 standard);

 The balancing must be carried out with the tool holder assembled (cone, mill collet, ring nut,

tool);

 The tie-rod (also known as the shank) of the cone ISO30 must only be the one supplied by

HSD (code 0804H0009).

TIE-ROD HSD

0804H0009

HSK CONE

DIN69893

6.4.2 Installation of the tie-rod HSD 0804H0009 in the cone ISO30 DIN69871

• Carefully clean the tie-rod and the tie-rod housing in the cone ISO30.

• Cover the thread of the tie-rod with high resistance, thread-blocking liquid (LOCTITE 270 or another equivalent

• Tighten the tie-rod to the cone with a torque of 62 Nm.

• Leave the cone to rest, to allow the thread-blocking liquid to adhere (12 hours with LOCTITE 270, or depending on the manufacturer's indications if using an alternative, equivalent

thread-blocker).

The use of non-original HSD tie-rods, or incorrect installation, may cause the tool holder cone to be thrown out.

product).

It is forbidden to use ISO or HSK tool holders not conforming to the conditions described above; failure to observe these instructions represents a source of risk, damage or incorrect hooking of the tool holder cone, with serious risks for the user.

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6.4.3 General recommendations relating to tool holder cones

IMPORTANT:

 The choice of tool holder is a determining factor for safety purposes.

 The conical surfaces of the tool holder and of its housing on the shaft/spindle must be kept

thoroughly clean in order to permit secure mounting (see section 7 “Scheduled maintenance”).

 During machining operations, be sure to avoid any contact between the non-cutting rotating

parts and the piece being machined.

 The seat of the tool holder cone must always be protected against any impurity that may come

in: use a closing device or a tool holder cone.

 At the end of the working day, always remove the tool holder cone from the electrospindle, to

avoid any problem of it sticking. Close the seat of the tool holder by means of a tool holder cone that is clean and at room temperature.

 Do not set the electrospindle in rotation without the tool holder installed. In particular, for the

HSK models, the rotation of the electrospindle without its tool holder jeopardises the balancing and the working of the collet.

6.5 Tool

The tools must have a degree of dynamic balancing of G = 2.5 or better (standard ISO1940).

OBSERVE THE MAXIMUM ROTATIONAL SPEED (rpm) SPECIFIED BY THE TOOL MANUFACTURER.

Depending on the type and quality of the machining operation to be performed and the material used, it is the responsibility of the user to decide whether to operate with a lower speed (NEVER HIGHER) than that specified by the tool manufacturer.

When selecting the tool, it is essential to pay attention to the following recommendations:

 Always use properly sharpened tools, locking them correctly in the respective tool holder.

 Never use deformed or damaged tools, tools with missing parts or tools that are not perfectly

balanced.

 Before inserting the tool in the respective collet, always check that all the surfaces are free

from damage and thoroughly cleaned.

 The essential conditions for using a tool at high speed are:

- compact, short and light tool

- accurate and with some blocked inserts with a high safety degree

- balanced and symmetrically coupled with the tool holder

- with cutting edges near the rotation axis

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6.5.1 Speed limits regarding the tool

As an example, the charts on the following pages show the maximum rotation speed of the electrospindle when empty, on the basis of the weight of the TOOL+TOOL HOLDER assembly (including ring nut and mill collet if present), and, furthermore, depending on the distance between the nose of the electrospindle and the centre of gravity “G” of the tool+tool holder assembly.

Next to each chart there is the tool+tool holder assembly that was envisaged as assembled in the spindle shaft to calculate the curves.

The mass of the tool+tool holder assembly was applied to the centre of gravity “G”, highlighted in the drawing.

Some possible positions of the centre of gravity “G” were considered, and for each position a curve has been drawn on the chart.

The degree of balancing is that recommended in the previous paragraphs.

The charts on the following pages are approximate, i.e. they do not take into account (because HSD S.p.A. cannot know this piece of information) the machining operation parameters, the specific characteristics of the tool used by the customer, or the particular type of material being machined: it is the user's responsibility to evaluate each time the maximum speed that allows him to work safely.

Procedure for reading the charts

5. Identify the chart relating to your electrospindle;

6. On the basis of the distance “X” between the spindle nose and the centre of gravity “G” of the tool+tool holder assembly, choose one of the curves. If the “X” measured on your electrospindle does not appear on the chart, choose the curve associated with the “X” that is the next measurement bigger (see example);

7. Corresponding to the weight of the tool+tool holder assembly, read the value of the maximum speed.

EXAMPLE

On an ES789 HSK a tool+tool holder assembly with an overall weight of 4.5 kg (including the ring nut and mill collet) is to be used; the distance between the spindle nose and the centre of gravity “G” of the tool+tool holder assembly is “X”=120 mm:

1. The chart relating to this particular electrospindle is “ES789 HSK” on page 66;

2. With no specific curve for “X”=120 mm, it is necessary to refer to the yellow curve associated with “X”=130 mm;

3. Corresponding to the weight of 4.5 kg, you can read the maximum speed, when empty, of 10,000 rpm.

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ES779 HSK Short Nose

X = 110

X = 90

X = 130

X = 70

0 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6

24000

180-it_Max-rpm.fm (19-01-09)

22000

20000

DO NOT EXCEED THE MAXIMUM ROTATIONAL SPEED (rpm) SPECIFIED BY THE TOOL MANUFACTURER!

18000

16000

14000

12000

HSD S.p.A.

10000

8000

6000

4000

2000

Page 66

HSD

ES789 HSK

X = 130

X = 70

X = 110

X = 90

22000

180-it_Max-rpm.fm (19-01-09)

20000

DO NOT EXCEED THE MAXIMUM ROTATIONAL SPEED (rpm) SPECIFIED BY THE TOOL MANUFACTURER!

18000

16000

14000

12000

HSD S.p.A.

10000

8000

6000

4000

0 1 1,5 2 2,5 3 3,5 4 4,5 5 5,5 6 6,5

2000

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6.6 Sensors

The electrospindle is equipped with inductive sensors for monitoring its status, and a “thermal alarm” to protect the electric coils.

NAME INFORMATION OF THE SIGNAL S1 Tool holder cone attached S2 Collet open - Tool released S3 (*) Shaft idle (*) S1+S4 (**) HSK cone blocked in the correct position (**) Thermal alarm Motor overheated: stop the electrospindle!

(*) Not present in some versions (**) Only in HSK versions

6.6.1 Technical characteristics of the inductive sensors

Proximity sensors PNP normally open (NO) Supply voltage 10 - 30V (DC) Maximum load 200 mA Power consumption when OFF <10 mA Nominal detection distance 0.8 mm

6.6.2 States of the electrospindle and corresponding outputs of the inductive sensors

The “ON” condition of the sensor corresponds to the output equal to the supply voltage; the “OFF” condition corresponds to an output of 0V.

STATE S1 S2 S3 (*) S1+S4 (**)

Collet open

(Tool-holder cone ejected)

Tool holder cone

correctly locked

Collet closed but tool holder cone

missing

(*) Not present in some versions (**) HSK versions only (***) Depending on the operating status of the machine

For HSK versions there is one further status of the electrospindle, in which the tool-holder cone is attached, but not correctly positioned on the stop as regards the surface of the HSK hooking system. This situation is indicated by the output:

S1 S1+S4

ON OFF

OFF ON IDLE OFF

IDLE or

ON OFF

OFF OFF IDLE OFF

This condition is dangerous: if it arises, stop the rotation or the tool change procedure, check the machine and remove whatever is preventing the correct hooking-up of the HSK tool-holder.

STARTED UP

(***)

The shaft of the electrospindle can only be rotated in the “Tool holder cone correctly locked” status; if the outputs of S1 or S1+S4 move to “OFF”, stop the rotation of the shaft of the electrospindle.

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6.6.3 Description of the inductive sensors

Sensor S1: “Tool holder attached” signal

The signal of sensor S1 indicates the presence of the tool holder cone in the closed collet.

Ignore output S1 during the period from the tool release command to the tool hooking command.

Sensors S1+S4: “HSK cone blocked in correct position” signal

The S1+S4 signal is present only in HSK versions.

Sensors S1 and S4 are connected in sequence (section 8.3.3). Sensor S1 checks that the HSK tool holder cone is present in the closed collet, then activates the reading of sensor S4. If activated by S1, S4 checks that the stop surfaces of the tool holder cone and the HSK hooking system are correctly in contact.

The output is “ON” only if both conditions have been checked.

Ignore the output of S1+S4 during the period from the tool release command to the tool hooking command.

Sensor S2: “Collet open” signal

Signal S2 is relevant during the tool changing cycle: it signals the opening of the collet and the possibility to continue to the next phase of the tool change cycle.

Sensor S3: “Shaft idle” signal

Sensor S3 supplies two “ON” pulses and two “OFF” pulses at each rotation of the shaft, as shown in the figure below.

OFF

giri - rev

Above a certain rotation speed, the output of S3 may appear to be permanently “ON”, only returning to a regular status when the speed drops below this threshold. This phenomenon is not a malfunction and depends on the performance of the CNC.

Ignore the signal S3 during the tool changing phase, as it may appear to be in either of the two statuses (“ON” or “OFF”)

The S3 signal is not present in certain versions.

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6.6.4 Use and technical characteristics of the thermal alarm

The electrospindle is equipped with a normally closed bimetallic switch installed in the electric windings of the stator. If a temperature is reached that is harmful for the electric windings, the switch open and the alarm to which it is connected must stop the machining operation; the contact closes automatically when the temperature drops and returns to safe values. The bimetallic switch must be connected to the machine alarm or the inverter alarm, as shown in section 4.9.

Technical characteristics of the bimetallic switch:

Power supply 48V DC MAX Current 1.6A MAX Switching cycles 10,000 cycles Contact breaking time < 1 ms Contact resistance (according to MIL R 5757) < 50mΩ Insulation voltage 2 kV

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6.7 Encoder (optional)

6.7.1 General description

The encoder codes in an incremental system the registered position data with A and B, A negated and B negated signals, in phase quadrature; it also provides Zero and Zero negated signals (see following figures

).Signals are taken outside as shown in section 4.9.3 “Encoder cables (Optional)”.

There are three models of encoder available:

 HSD “Square Wave” type;

 Lenord+Bauer “Square Wave” type;

 Lenord+Bauer “Sinusoidal” type.

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6.7.2 Technical specifications of the HSD Square Wave encoder

SPECIFICATION VALUE

Rated supply voltage 12 V DC ÷ 24 V DC +/- 10%

Consumption

Operating temperature 0° C ÷ 70° C (+32° F ÷ 158° F) Max. operating height 2,000 m (6,500 ft) Signal input: 400 pulses per rev + zero reference Signal output: TTL-level compatible (0V, +5V line driver)

A voltage over the specified (24V ±10%) may damage the encoder reader

Signals of the HSD Square Wave encoder

99 mA at 12 V DC 51 mA at 24 V DC

T Period

D Phase Difference

(D=T/4)

5 V

0 V

5 V

0 V

5 V

0 V

5 V

0 V

5 V

0 V

5 V

5 V 0 V

0 V

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6.7.3 Technical specifications of the Lenord+Bauer Square Wave encoder

SPECIFICATION VALUE

Rated supply voltage 5 V DC +/- 5% Operating temperature -30° C ÷ +85° C (-22° F ÷ +185° F) Max. operating height 2,000 m (6,500 ft)

Signal input:

Signal output: TTL-level compatible (0V, +5V line driver)

Signals of the Lenord+Bauer Square Wave encoder

1024 pulses per rev + zero reference (256 pulses multiplied x4 internally)

5 V

0 V

5 V 0 V

5 V

T Period

D Phase Difference

(D=T/4)

A voltage over the specified value (5V ±5%) may damage the encoder reader

0 V

5 V 0 V

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6.7.4 Technical specifications of the Lenord+Bauer Sinus Wave encoder

SPECIFICATION VAL U E

“U” rated supply voltage 5 V DC +/- 5% Operating temperature -30° C ÷ 85° C (-22° F ÷ 185° F) Max. operating height 2,000 m (6,500 ft) Signal input: 256 pulses per rev + zero reference

500 mV peak-to-peak with average value “U ref.”=U/2

A B Signal output:

A B signal phase difference 90° (a quarter of period)

Z signal output:

1 V peak-to-peak as signal difference with average value “U ref.” (see following figures)

500 mV of peak according to rest value U ref. ±80mV

1 V of peak as signal difference with rest value U ref.160mV= 2.34V (see following figures)

A voltage over the specified value (5V ±5%) may damage the encoder reader

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A signal temporal performance:

2,75

2,5

2,25

A-

2,75

2,5

2,25

3,25

2,75

2,5

A diff= (A) - (A-)

2,25

1,75

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B signal temporal performance:

2,75

2,5

2,25

B-

2,75

2,5

2,25

3,25

2,75

2,5

B diff= (B) - (B-)

2,25

1,75

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Z signal temporal performance:

2,75

2,5

2,25

Z+

Z-

2,75

2,25

3,5

3,25

2,75

2,5

Z dif f= (Z) - (Z-)

2,25

1,75

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A and B signal phase difference

2,75

2,5

2,25

A and B negated signal phase difference

2,75

2,5

2,25

A-

B-

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Differential signal temporal performance:

TPeriod D Phase Difference

A diff. (A) - (A-) B diff. (B) - (B-) Z diff. (Z) - (Z-)

(D=T/4)

Differential negated signal temporal performance:

3,25

2,75

2,5

2,25

1,75

1,5

A diff-

B diff-

Z diff-

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7 Scheduled maintenance

To safely operate an electrospindle installed on the machine, refer to the specific manual of the machine.

The punctual respect of the scheduled maintenance is essential in order to maintain the conditions of use and working planned by HSD S.p.A. when the product was put onto the market.

The frequency has been calculated on the basis of a working week of 5 days, each of 8 working hours, under normal environmental working conditions.

Read this section carefully before carrying out any maintenance operation on the electrospindle. The safety regulations during the maintenance of the electrospindle must take into account that:

 maintenance and/or lubrication operations must only be carried out by trained and qualified

personnel, duly authorised by the technical management of the plant, in accordance with the safety directives and standards in force, using tools, instruments and products suitable for this work;

 during maintenance works, it is obligatory to wear suitable clothing, such as close-fitting

overalls, safety shoes, strictly avoiding wide garments or items with protruding parts;

 during maintenance works, we recommend that the machine be cordoned off and the signs

indicating “MACHINE MAINTENANCE” posted.

During any maintenance operations, the electrospindle must be:

 disconnected and isolated from the electric power supply;

 the tool must be strictly at a standstill (not rotating).

The maintenance manager must appoint a team of persons in order to guarantee proper coordination among the team members and the maximum safety of the persons exposed to danger. All persons involved in the maintenance operations must be in full visual contact for signalling possible dangers.

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7 Scheduled maintenance

7.1 Daily maintenance

7.1.1 Checking and cleaning the tool holder seat and the tool holder cone

The contact surfaces between the tool holder and the tool holder seat must be kept clean in order to guarantee safe hooking.

At the start of the work day, check that the surfaces shown in figures 8 and 11 are thoroughly clean, with no traces of dust, grease, cooling liquid, oil, metal particles or machining residues, nor signs of oxidisation or scale; if necessary, wipe with a soft, clean cloth.

Figure 8 : ISO tool holder

Figure 10 : HSK tool holder

Figure 9 : ISO tool holder seat

Figure 11 : HSK tool holder seat

1 2

(1) Conical

surfaces (in black)

(2) Stop

surfaces (in grey, only HSK)

For cleaning the surfaces indicated, use soft, clean cloths; NEVER USE cloth, acids or other aggressive elements.

abrasive instruments such as wire wool, metal scrapers, emery

At the end of the working day, clean the surfaces shown in figures 8 to 11

with a soft, clean cloth; inadequate cleaning may result in serious consequences for the operator's safety, for the wear of the electrospindle and tool holder, for the precision and efficiency of the machining operation.

Do not direct jets of compressed air inside the tool holder seat if the tool holder cone is missing, or if the tool holder cone fitted has through bores (Figure 12).

Figure 12 :

NO!

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7 Scheduled maintenance

7.1.2 Protection of the tool holder seat

The tool holder seat must always be protected against the impurities that may come in and could damage, oxidise or in any other way harm the contact surfaces: never leave the electrospindle

without a tool holder cone inserted.

The cone used for protection must not have through bores.

To avoid sticking, remove the tool-holder installed on the electrospindle and replace it with a protective closing device, both after heavy machining operations and at the end of the working day. The protective closing device must be another clean tool-holder, at room temperature, or one of the protective closings appropriately created by HSD and illustrated in figures 13 to 15. The tool holder to be removed may be hot! Use gloves!

Figure 13 Rubber cover code H1401H0010

φ100 mm

Figure 14 ISO30 protective cone code H1707H0030

Figure 15 HSK F63 protective cone, coded H1707H0031

7.2 Biweekly Maintenance

7.2.1 Clean the tool holder cone with ethyl alcohol

 For all the versions:

• carefully clean the contact surfaces of the tool holders (shown in figure 8 and10) with a soft,

clean cloth dipped in ethyl alcohol;

 Only for HSK versions:

• after cleaning with ethyl alcohol, spray the tapered surfaces with KLÜBER LUSIN

PROTECT G 31, and distribute the product uniformly using a clean, dry cloth;

• allow the product to dry before using the tool holder again.

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7 Scheduled maintenance

7.3 Monthly maintenance

7.3.1 Lubrication of the HSK collet

In order to maintain the proper efficiency of the HSK collet over a long period of time, it must be lubricated every month with grease:

METAFLUX-Fett-Paste No. 70-8508

or alternatively

METAFLUX-Moly-Spray No. 70.82

USE ONLY THE GREASES INDICATED ABOVE. Other products are not compatible with those used by HSD S.p.A. for the initial lubrication. Greases that are incompatible, mixed or used successively on the same collet form substances harmful to the functioning of the collet, with serious consequences for safety.

Proceed as follows:

 spread the grease in the gap between the segments of the collet and the ejector (Figure 16),

using a clean, thin, plastic tool;

Figure 16

(1) Segment

(2) Ejector

 carry out roughly ten tool changes to distribute the grease uniformly;

 remove the tool holder from the spindle shaft and remove any visible remains of grease with a

clean cloth. Excessive grease is harmful as it can collect chips or other machining residues, soiling the collet, the tapered surfaces and the stop surfaces. These areas must be kept as clean as possible in order to guarantee the safety of the operator, the precision of the machining operation, and to reduce wear on the spindle and tool holder cone.

7.3.2 Check of functionality collet HSK

Frequency :6 months or 200000 tool changes

 Control the expulsion limit (see limit “ B1” in table 1, pag 100)

 Through a blocked tool tighten the dowel in the expeller

 Check the tightening strength (using Power Check).

If the tightening force is inferior of 70 % of the nominal value, it is necessary to effect the following operations:

• grease again , and check again the tightening force

• change the collet and check again

• change completey the thightening device

7.4 Bearings

Do not carry out any work on the bearings as these are lubricated for life with a special grease for high speed and REQUIRE NO FURTHER LUBRICATION.

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8 Replacement of components

To safely operate an electrospindle installed on the machine, refer to the specific manual of the machine.

Inside the electrospindle, there is a pre-loaded spring with a force of hundreds of kilograms. This spring is attached to a tie-rod that may be thrown out violently if the electrospindle is dismantled by personnel who have not been sufficiently trained.

Carry out only the operations described in this manual, paying close attention to the instructions given; for further information, contact HSD S.p.A. Customer Service.

Observe the safety precautions for maintenance given on page 79.

Only the adjustment and replacement operations with original HSD S.p.A. spare parts described in this section of the manual are permitted. Any other type of operation is not permitted and will invalidate the product warranty.

8 Replacement of components

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8.1 Replacement of the Shaft Kit

SPARE SHAFT KIT

Spare shaft kits are available, to install in case of bearing wear. The shaft kit has a shaft, bearings already run in, rotor, tie-rod and coupling system. To obtain a shaft kit suitable for your own model, inform the HSD commercial office about the spindle serial number The serial number is usually stamped on the front flange or the framework front part (see section 3.1 “Main parts”)

In model ES789 with distributor for tool internal cooling, the shaft kit cannot be replaced.Contact HSD Customer Service

Follow the instructions indicated below to replace the shaft kit.

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Op. Description Image

If the electrospindle is provided with encoder, remove the small cover indicated in figure. Check that the OR2081 is not worn or missing.

Remove the 4 fixing screws of the electrospindle casing.

The casing is fixed to the electrospindle framework through a light silicone layer: simply apply a light force to remove the casing.

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Op. Description Image

Remove the 8 hexagonal head screws (2 for each angle) of the cylinder unit.

Open the release cylinder unit, paying attention to the cable indicated in figure.

Remove the 4 springs.

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Op. Description Image

Check that the six OR2025 indicated in figure are not damaged or missing.

Check that the cone release cylinder (upper figure) and the piston tie-rod (lower figure) are not worn or damaged: in this case, only the shaft kit must be replaced, but the electrospindle should be sent to HSD customer service.

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Op. Description Image

Screw two 5x16 screws in two oval bores (“A”) near the piston tie-rod, but do not fully tighten them.

Remove the eight 5x10 screws (“B”) around the tie-rod.

Radially move both screws in the oval bores (direction “C”) outwards and tighten them so as to block them in that position.

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Op. Description Image

From the front part of the electrospindle (“nose”), remove the eight 5x20 screws that fix the shaft [figure alongside, (C)].

To extract the shaft kit, use two headless, flat end screws (UNI

5923), M5x20 or longer.

Insert the screws in the bores indicated with (B) (the outer bores, one on each side).

DO NOT use the bores marked with (C) (those inside).

Carefully take out the shaft kit by some centimetres.

FOR VERSIONS WITH ENCODER: Check, from the window, that the Encoder wiring does not get entangled.

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Op. Description Image

Check that the 3 ORM 0080-15 indicated in figure “A” and the ORM 0050-15 indicated in “B” are not damaged or missing.

NOTE: in some models, bore “B” is not present.

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Op. Description Image

VERSIONS WITH HSD ENCODER:

Disconnect the connector “C”.

VERSIONS WITH L+B ENCODER:

Disconnect the three connectors indicated in figure.

13 Remove the shaft kit.

Clean resting surfaces and grease bearing seats.

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Op. Description Image

Insert the new shaft kit partially.

Be careful when aligning the bore for pressurisation air passage of the shaft with that on the flange.

16 VERSIONS WITH HSD

ENCODER: Connect the connector “C”.

VERSIONS WITH L+B ENCODER: Check the three connectors.

FOR ALL VERSIONS WITH ENCODER:

Insert the shaft kit completely into the electrospindle by slightly pulling the encoder wiring through the window; position the wiring and the encoder connector so as not to cause interference with rotating parts.

18 Insert the shaft completely into the

electrospindle being careful with the OR shown in point “11”.

19 Refit removed parts in points 9, 8,

4, 3 and 1.

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Op. Description Image

Carry out sensor calibration as described in section 8.3

“Replacement and adjustment of the sensor group”.

Refit the upper cover casing of the electrospindle being careful not to damage sensors.

Use Loctite 510 or an equivalent product on the casing edge.

To ensure maximum accuracy in machining operations, it is recommended to set to zero the axis affected by the modification in the machine (axis parallel to spindle shaft)

Summary of OR used in the shaft kit:

• OR 2081

• OR 2025

• ORM 0080-15

• ORM 0050-15

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8.2 Replacement of the encoder reader

In case the encoder reader must be replaced, follow the shaft kit removal procedure until point “12” and proceed as follows:

Models of HSD Square Wave encoder:

 loosen the two fixing screws of the optical reader,

 delicately lift the reader from its seat,

 carefully slide the reader from the encoder disk being careful not to scratch it,

 more delicately, position the new reader and slot it into its seat,

 lock the two fixing screws,

 check that, by rotating the shaft, the encoder disk is at the same distance from both ends of

the optical reader fork,

 follow backwards the shaft kit assembly procedure.

Models with Lenord-Bauer sinusoidal encoder

 unlock the two fixing screws,

 unlock the screw fixing the reader earth cable to the flange,

 remove the faulty reader,

 place the new reader in its seat keeping it at distance from the toothed wheel,

 lock the two screws without tightening them fully,

 interpose the thickness spacer between the toothed wheel and the new reader,

Place the thickness spacer between the toothed wheel and the encoder reader BEFORE carrying out other operations. Otherwise, the magnetic component of the reader can be attracted and collide with the toothed wheel, with possible damages to the reader.

 push the reader towards the toothed wheel, moving everything “together”,

 tighten definitively the two fixing screws of the reader,

 slide off the thickness spacer previously placed,

 visually check that, when turning the shaft, the toothed wheel does not touch the reader,

 lock again the screw fixing the reader earth cable to the flange,

 follow backwards the shaft kit assembly procedure.

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8.3 Replacement and adjustment of the sensor group

8.3.1 Access to the sensors

 Refer to figures 17 to 18 to access to sensor zone.

 Unlock the four screws (1).

 Remove the casing (2) according to the direction of the arrow in figure.

The casing is fixed to the electrospindle framework through a light silicone layer: simply apply a light force to remove the casing.

 When refitting the casing (2), pay attention not to damage sensor cables inside. Moreover,

apply Loctite 510 or an equivalent product on the casing edge.

Figure 17: ES779

Figure 18: ES789

Figure 19: ES789 with distributor

8.3.2 Identification of the sensors

Figure 20: ES779 and ES789

S1 S4

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8.3.3 Sensor wiring

(X)

For the colours of the userside, see the table in section 4.10.

Output

(+) Brown + 24V DC

Output Black ON / OFF

(-) Blue 0V

The S1 sensor is present only in HSK versions.

8.3.4 Description of the sensor unit

The sensors are pre-assembled in calibrated bushes to allow simple insertion to the right depth in the electrospindle. It is therefore important to correctly identify the sensor to be replaced: for this reason, both the sensors installed on the electrospindle and those supplied as spare parts bear a

numbered label (see figure below

Confusion of the sensors will result in damage to the moving parts.

Figure 21: sensor unit Figure 22: sensor fixing

1 Electrical connector 6 Calibrated position 2 Numbered label 7 Bracket 3 Bush 8 Sensor unit 4 Sensor 9 Screw

Eccentricity between bush and regulation

sensor

42 5

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8.3.5 Replacement and adjustment of the sensor unit

For the replacement and adjustment of the sensors shown in this paragraph (and those to follow), always refer to figures 21 and 22 of the previous paragraph.

8. remove screw “9” that blocks the bracket “7” of the sensor unit “8” to be replaced;

9. Unthread the faulty sensor unit from its seat, and disconnect its electrical connector“1”.

10. connect the electrical connector of the new sensor unit to the correspondingly numbered connector of the spindle;

11. check the functioning of the new sensor by bringing it into contact with a metallic mass;

12. Insert the new sensor unit in the empty seat;

13. reposition the bracket “7” and lock the screw “9” again without tighten it completely, so that the sensor unit can rotate;

14. rotate the sensor unit a few degrees at a time, until you obtain the outputs requested in the paragraphs immediately below;

15. tighten the screw “9” by blocking the sensor unit with an open-end spanner so as to maintain the calibration carried out.

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8.3.6 Sensor S1 adjustment (for all models)

For HSK models, a kit of gauges and thickness spacers is available for adjustment of S1 and S4 sensors; the kit is described in paragraphs 8.3.11 to

8.3.13.

The use of the kit allows a quicker and more precise adjustment: HSD S.p.A. strongly recommends the use of the kit, given the importance (for safety purposes) of a correct sensor adjustment.

After replacing the sensor unit as described in section 8.3.5, adjust it as follows:

1. do not tighten the sensor completely until an accurate adjustment has been performed;

2. attach the tool holder cone and ensure that the output of S1 is “ON”; if the output is “OFF”, rotate the sensor unit until it becomes “ON”;

3. the sensor “4” is eccentric in relation to the bush “3” that contains it: rotate the bush slowly in the direction that takes the sensor away from the tool holder; stop immediately when the output of the sensor becomes ”OFF”;

4. carefully rotate the bush back by about 15° - 20°, so that the output of the sensor returns to “ON”;

5. rotate the shaft manually, and check that the signal remains “ON” for the whole rotation;

6. tighten fixing screw “9”;

7. release the tool holder by powering the piston at the pressure indicated in the section 4.6

“Pneumatic connections”, and check that in this condition (collet open) the output of S1 is

“OFF”;

8. release the pressure at the piston and allow the collet to close without tool holder: in this condition, the output of S1 must be “OFF” for the whole rotation of the shaft;

9. if points (7) and (8) are not satisfied repeat the procedure from the start, making an even slighter rotation movement at point (4);

10. if points (7) and (8) are satisfied, make a cycle of 10 tool changes;

11. at the end of the cycle, check that the conditions in the following table are satisfied:

CONDITION S1 OUTPUT

tool holder locked

missing tool holder with closed collet

collet open (tool holder ejected)

* for the whole rotation of the shaft

ON *

OFF *

OFF

12. if the conditions of the table are not satisfied, repeat the procedure from the beginning;

13. if the conditions of the table are satisfied, perform a cycle of 100 tool changes with the machine, using the maximum possible number of different tool holders.

14. At the end of the cycle, check that the conditions in the table under point (11) are satisfied: if this is the case, the regulation procedure for S1 is complete; if this is not the case, repeat the procedure from the beginning.

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8.3.7 S2 sensor adjustment for ISO models

After replacing the sensor as described in section 8.3.5, calibrate it as follows:

1. correctly attach a tool holder before beginning the adjustment of the sensor;

2. check that, in this state, the output of S2 is “OFF”; if the output is “ON”, rotate the sensor unit until it becomes “OFF”;

3. feed the cylinder by means of a one-way pressure regulator initially set at 0 bar (0 PSI);

4. increase the feed pressure by steps of 0.1 bar (1.5 PSI) so as to move the piston slowly forward and, at the same time, check that the output of S2 is “OFF”;

5. as long as the tool holder is firmly blocked, the output of S2 must be “OFF”; if the output changes during the movement of the piston, slightly rotate the sensor unit until the output returns to “OFF”;

6. when the tool holder begins to slacken (but is not yet free to fall), the output of S2 must still be “OFF” (if necessary, rotate the sensor unit);

7. when you reach the feed pressure at which the tool holder is finally free to fall, increase the pressure by another 0.2 bar (3 PSI) and block the pressure regulator;

8. rotate the sensor unit so that, in this state, the output of S2 becomes “ON”;

9. perform a cycle of 10 tool changes;

10. at the end of the cycle, check that the steps from (1) to (8) are satisfied without the need to ever rotate the sensor;

11. if the outputs requested are not satisfied, repeat the entire procedure from the start;

12. if the outputs requested are satisfied, perform a cycle of 100 tool changes with the machine, using the maximum possible number of different tool holders;

13. at the end of the cycle, check that the steps from (1) to (8) are satisfied without the need to ever rotate the sensor;

14. if the outputs requested are not satisfied, repeat the entire procedure from the start;

15. if the outputs requested are satisfied, the regulation procedure for S2 is complete.

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8.3.8 Sensor S2 adjustment for HSK models

B1 B2

HSK E25 6.5 6.35 HSK E40/F50 8.5 8.35 HSK A/E/F63 10.5 10.3

(+/- 0.1 mm)

Figure 23: position of the ejector Figure 24: (A) ejector

(B) reference position

After replacing the sensor as described in section 8.3.5, calibrate it as follows:

1. bring the spindle to the “collet open (tool holder ejected)” status by feeding the cylinder with the pressure indicated in section 4.6 “Pneumatic connections”; in these conditions, the position (B) (figure 24) takes on the maximum value;

2. as shown in figures 23 and 24, use a depth gauge to check that the position (B) of the ejector in relation to the spindle nose takes on the value “B1” indicated in table 1; if this is not the case, stop and contact HSD Customer Service;

3. fully discharge the pressure from the cylinder; in these conditions, the position (B) takes on the minimum value;

4. feed the cylinder by means of a one-way pressure regulator initially set at 0 bar (0 PSI);

5. increase the pressure in steps of 0.1 bar (1.5 PSI), so as to slowly move the ejector forwards;

6. stop when position (B) reaches the value “B2”;

7. if necessary, loosen the screw “9” (Figure 22 “: sensor fixing”) of sensor S2;

8. rotate sensor S2 until you find the position supplying the signal “ON” with (B) > B2 and “OFF” with (B) < B2;

9. finally tighten screw “9” completely;

Table 1 : values of (B)

10. perform a cycle of 10 tool changes;

11. at the end of the cycle, check that point (8) has been met without the need to rotate the sensor;

12. if it is necessary to rotate the sensor, repeat the whole procedure from the beginning;

13. if it is not necessary to rotate the sensor, perform a cycle of 100 tool changes with the machine, using the maximum possible number of different tool holders;

14. at the end of the cycle, check that point (8) has been met without the need to rotate the sensor;

15. if it is necessary to rotate the sensor, repeat the whole procedure from the beginning;

16. if it is not necessary to rotate the sensor, the S2 adjustment procedure is complete.

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