Page 1 Translation of the original instructions ES779, ES789 Electrospindle Assembly instructions Edition.Revision 2.1 H5801H0118 ENGLISH Serial number...
Page 3 This manual has been prepared by the manufacturer to be used by customers only and it contains information protected by copyright. It must not be photocopied or reproduced in any form, either fully or in part, without the prior written consent of the manufacturer. HSD S.p.A. © - H5801H0118.fm120718...
Page 5: Table Of Contents
Descriptions Technical specifications and main parts General product description ..................... 29 Workable materials ......................29 Applications ........................30 General overview and main parts ..................31 3.4.1 ES779, with free cables, with fixing grooves ..............31 HSD S.p.A. © - H5801H0118TOC.fm120718...
Page 6 220/380V 250Hz ...................... 45 3.5.4 Technical datasheet asynchronous ES779 10/12kW 380V 500Hz ....... 46 Parameters of equivalent electrical network ES779 10/12kW 380V 500Hz ....47 3.5.5 Technical datasheet asynchronous ES779 12/13kW 380V 500Hz ....... 48 Parameters of equivalent electrical network ES779 12/13kW 380V 500Hz ....49 3.5.6...
Page 7 Transport and packing ..................... 90 Lifting .......................... 91 Unpacking ........................91 Storage ..........................92 Installation and commissioning Preliminary installation checks ..................93 Preparing the factory services ..................93 Environmental work requisites ..................93 Mechanical connections ....................94 HSD S.p.A. © - H5801H0118TOC.fm120718...
Page 8 5.4.3 Threaded service holes ....................95 5.4.4 Tool-change system ...................... 95 Pneumatic connections ....................96 5.5.1 Compressed air specifications for HSD products ............97 5.5.2 Pneumatic connection points ..................98 Pneumatic connection examples ................99 5.5.3 Pneumatic cylinder ...................... 100 5.5.4...
Page 9 Checking and adjusting the HSK collet ejection position ..........125 Tool-holder cone ......................126 7.5.1 Installation of the HSD 0804H0009 screw dowel in the ISO30 DIN69871 cone ..127 7.5.2 General recommendations regarding tool holder cones ..........127 Tool ..........................128 7.6.1...
Page 10 Bearings ........................156 Replacing components Replacing the shaft kit ....................158 Replacing the encoder reader ..................168 Models with an HSD square-wave encoder ............. 168 Models with a Lenord-Bauer sinusoidal encoder ............. 168 Replacing and adjusting the sensors ................169 9.3.1 Identifying and accessing the sensors ................
Page 11 Table of contents Appendices Troubleshooting Problems, causes and solutions ..................189 Spare parts Tools for collet HSK assembly .................. 194 Disposal Customer service Customer service ......................197 HSD S.p.A. © - H5801H0118TOC.fm120718...
Page 13 Preliminaries...
Page 15: Preliminary Information
In order to prevent incorrect operation that could constitute a hazard for personnel and/or cause damage to the product, all the documents supplied must be read and fully understood. HSD (or its representative), from here on the manufacturer, cannot be held responsible or legally liable for any damage resulting from incorrect use of the documentation.
Page 16: Symbols Used In The Manual
Check that all the documents listed above are present on delivery of the product. If necessary, further copies can be obtained on request from the manufacturer. Annexes (if included). These contain additional information that completes and/or replaces the information in the document with which they are enclosed. HSD S.p.A. © - h0101k01a.fm120718...
Page 17: Ec Declaration Of Conformity
QUE HAN SIDO APLICADAS LAS PARTES PERTINENTES DE LAS SIGUIENTES NORMAS ARMONIZADAS: EN 60034-1:2010+AC:2010, EN 60204-1:2006+A1:2009+AC:2010. Luogo e data / Place and date / Ort und Datum / Procuratore Speciale Lieu et date / Lugar y fecha: Special Attorney Sonderbevollmächtiger Fondé de pouvoir extraordinaire Mandatario Especial HSD S.p.A. © - h0101k01a.fm120718...
Page 18: Identification Of The Manufacturer And Of The Product
DOWEL 69871 CONE of connection. 0804H0009 Tool-holder cone connection system, described in standard DIN 69893. The electrospindle carries a plate similar to the one shown alongside, indicating the type of connection. DIN 69893 CONE HSD S.p.A. © - h0101k01a.fm120718...
Page 19 Scheduled product the same as that provided for by the manufacturer at the moment of maintenance its introduction onto the market. The maintenance is carried out by means of programmed adjustments, repairs, part replacements, etc.. HSD S.p.A. © - h0101k01a.fm120718...
Page 20: Warranty
The warranty will be rendered null and void if the buyer fails to inform HSD S.p.A. in writing and in detail, the nature of any conformity defects encountered in the product within 15 days of the identification of said defect.
Page 21: Safety Information
Safety information The product will operate in safety if it is installed and used by qualified personnel in compliance with the recommendations and instructions provided in this manual or supplied by HSD's technical engineers at the time of installation. Tampering with the safety devices to perform unforeseen operation causes the onset of serious danger to the operator.
Page 22: Safety Warnings For Maintenance
The use of the product, and of the machine on which it is installed, must always be in compliance with safety regulations in force in each country. At the end of all maintenance interventions, take care to replace all guards, fixing them into place with the relevant mechanical locking devices. HSD S.p.A. © - h0115k01a.fm120718...
Page 23: Risks Associated With The Use Of The Product
Risks associated with the use of the product HSD is not responsible for installations performed by persons who are unqualified and/or for installations that do not comply with the conditions stated in this manual. The equipment must only be fitted on machinery. The manufacturer must perform the risk analysis before putting the machine into service.
Page 24: Prohibitions And Risks Associated With Improper Handling And/Or Use
Incorrect electrical installation, such as the inversion of phases, represents improper use of the product and is therefore not allowed. It is not allowed to violate or avoid the prescriptions contained in this manual. HSD S.p.A. © - h0115k01a.fm120718...
Page 25: Residual Risks
The product has been analysed in compliance with Directive 2014/35/EU in order to identify possible risk sources. The risks that remain (residual risks) and the relative countermeasures are highlighted in the relative sections of this manual. HSD S.p.A. © - h0115k01a.fm120718...
Page 26: Signs Fixed To The Product
DANGER, HOT SURFACES! High temperature component, risk of burning. Wear suitable protective clothing. 2.5.2 Mandatory signs The general mandatory signs are described below. USER MANUAL! It is compulsory to read the whole user manual before performing any operations. HSD S.p.A. © - h0115k01a.fm120718...
Page 27: Descriptions
Descriptions...
Page 29: Technical Specifications And Main Parts
To machine different material, contact HSD Customer Service. The use of the product with other materials may pose a serious danger for the operator. The use of the product on other materials may damage it.
Page 30: Applications
3 Technical specifications and main parts Applications Some examples of intended applications are: boring and milling; other machining operations, milling/boring to produce doors and windows; moulding. For other applications, contact HSD Customer Service. HSD S.p.A. © - h0102k01a.fm120718...
Page 31: General Overview And Main Parts
3 Technical specifications and main parts General overview and main parts 3.4.1 ES779, with free cables, with fixing grooves Bore Ø30 H8 depth 4 14 Tool holder description Positioning bore Ø60 H8 depth 6 4 bores M5 thread depth 6...
Page 32: Es779, With Free Cables, With Fixing Bores
3 Technical specifications and main parts 3.4.2 ES779, with free cables, with fixing bores Support surface Positioning bore Ø60 H8 6 fixing bores M8 thread depth 6 depth 12 6 inlet/outlet holes for compressed air and fluids 18 Encoder compartment Positioning bore Ø8 H7...
Page 33: Es789, With Free Cables, With Fixing Grooves
10 20 Tool holder description accessories 12 Motor cable positioning 2 bores* for tool Serial (or register) lubricant-coolant outlet number 13 Sensors area M6 or G1/8”, depending on the version; check the technical data sheet. HSD S.p.A. © - h0102k01a.fm120718...
Page 34: Es789, With Free Cables, With Fixing Bores
14 Sensors area Serial (or register) number Shaft 15 Cylinder 6 fixing bores M8 thread 16 Sensor cable positioning 24 Tool holder description depth 12 M6 or G1/8”, depending on the version; check the technical data sheet. HSD S.p.A. © - h0102k01a.fm120718...
Page 35: Variations With Hsd Electric Connectors
3 Technical specifications and main parts 3.4.5 Variations with HSD electric connectors Button for manual tool 4 through fixing bores Hydraulic/Pneumatic release Ø8.5 connectors 14 HSD electric connector Serial (or register) 6 fixing bores M8 thread number depth 12 15 Encoder compartment...
Page 36: Variations With Mil Standard Electric Connectors
6 2 bores *for tool Electric connectors (MIL lubricant-coolant outlet standard) Nose Button for manual tool Hydraulic/Pneumatic release Shaft connectors HSK collet M6 or G1/8”, depending on the version; check the technical data sheet. HSD S.p.A. © - h0102k01a.fm120718...
Page 37: Variations With Configurable Power Supply Terminal Board 220/380V
Box of electrical connections Cover with gasket Configurable terminal board for electrical connection of the 380V star or 220V Electric connectors (MIL standard) delta Area of hydraulic/pneumatic connectors Button for manual tool release Electric connector (encoder) HSD S.p.A. © - h0102k01a.fm120718...
Page 38: Variations With Fluid Distributor
3 Technical specifications and main parts 3.4.8 Variations with fluid distributor Drainage Rotary fluid distributor inlet for lubrication Fluids distributor coolant fluid inside the tool and for tool Nose holder cone cleaning air HSD S.p.A. © - h0102k01a.fm120718...
Page 39: Variations With Floating Or Fixed Piston
3 Technical specifications and main parts 3.4.9 Variations with floating or fixed piston Floating piston Fixed piston 3.4.10 ES779 with manual tool change (ES779 collet) 6 fixing bores M8 thread depth 16 Pressurisation air inlet Positioning bore Ø8 H7 depth 10 Nose Shaft ER32 collet seat Thread M40, step 1.5, for ring nut...
Page 40: Features And Performance
3 Technical specifications and main parts Features and performance 3.5.1 Technical datasheet asynchronous ES779 10/12kW 380kW 250Hz with motor rating plate H1423H0216 Motor rating plate ES 779L 4P 12,00kW H1 H1423H0216 Flussigkeitsgekuhlt Liquid cooling HSD S.p.A www.hsd.it ASYNCHRONOUS Ta:20 °...
Page 41: Parameters Of Equivalent Electrical Network Es779 10/12Kw 380Kw 250Hz
3 Technical specifications and main parts Parameters of equivalent electrical network ES779 10/12kW 380kW 250Hz with motor rating plate H1423H0216 Electrical parameters (SP.120.080.45) Potenza nominale / rated power / nennleistung (S1) P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1)
Page 42: With Motor Rating Plate Fnz4102319
3 Technical specifications and main parts 3.5.2 Technical datasheet asynchronous ES779 10/12kW 380V 250Hz with motor rating plate FNZ4102319 Motor rating plate ES779 4P 10 kW Flüssigkeitsgekühlt Liquid cooling FNZ4102319 ASYNCHRONOUS HSD S.p.A. www.hsd.it Ta:20 ° 3-PHASE MOTOR Via della Meccanica, 16 Ins.Cl.
Page 43: Parameters Of Equivalent Electrical Network Es779 10/12Kw 380V 250Hz
3 Technical specifications and main parts Parameters of equivalent electrical network ES779 10/12kW 380V 250Hz with motor rating plate FNZ4102319 Electrical parameters (SP.119.080.46.AL) Potenza nominale / rated power / nennleistung (S1) P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1)
Page 44: Technical Datasheet Asynchronous Es779 10/12Kw 220/380V 250Hz
3 Technical specifications and main parts 3.5.3 Technical datasheet asynchronous ES779 10/12kW 220/380V 250Hz Motor rating plate ES 779L 4P 10,00kW FNZ4101425 Liquid cooling Flussigkeitsgekuhlt HSD S.p.A www.hsd.it ASYNCHRONOUS Ta:20 ° 3-PHASE MOTOR Via della Meccanica,16 ES 779L 4P 10,00kW DREHSTROM- Ins.Cl.
Page 45: Parameters For Equivalent Electrical Network Asynchronous Es779 10/12Kw 220/380V 250Hz
3 Technical specifications and main parts Parameters for equivalent electrical network asynchronous ES779 10/12kW 220/380V 250Hz Electrical parameters (SP.120.080.4O) Potenza nominale / rated power / nennleistung (S1) P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1) 21.5 37.2 P0305 P1103 P161...
Page 46: Technical Datasheet Asynchronous Es779 10/12Kw 380V 500Hz
3 Technical specifications and main parts 3.5.4 Technical datasheet asynchronous ES779 10/12kW 380V 500Hz Motor rating plate ES 779L 4P 12,00kW H1 H1423H0212 Liquid cooling Flussigkeitsgekuhlt HSD S.p.A www.hsd.it ASYNCHRONOUS ° Ta:20 3-PHASE MOTOR Via della Meccanica,16 Ins.Cl. F DREHSTROM-...
Page 47: Parameters Of Equivalent Electrical Network Es779 10/12Kw 380V 500Hz
3 Technical specifications and main parts Parameters of equivalent electrical network ES779 10/12kW 380V 500Hz Electrical parameters (SP.120.080.44) Potenza nominale / rated power / nennleistung (S1) P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1) 26.4 P0305 P1103...
Page 48: Technical Datasheet Asynchronous Es779 12/13Kw 380V 500Hz
3 Technical specifications and main parts 3.5.5 Technical datasheet asynchronous ES779 12/13kW 380V 500Hz* Motor rating plate ES 779L 4P 13,00kW H1 H1423H0240 Liquid cooling Flussigkeitsgekuhlt HSD S.p.A www.hsd.it ASYNCHRONOUS ° Ta:20 3-PHASE MOTOR Via della Meccanica,16 Ins.Cl. F DREHSTROM-...
Page 49: Parameters Of Equivalent Electrical Network Es779 12/13Kw 380V 500Hz
3 Technical specifications and main parts Parameters of equivalent electrical network ES779 12/13kW 380V 500Hz Electrical parameters (120.080.44.PAR) Potenza nominale / rated power / nennleistung (S1) P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1) 31.5 P0305 P1103...
Page 50: Technical Datasheet Synchronous Es779 12/14.4Kw 357Hz
3 Technical specifications and main parts 3.5.6 Technical datasheet synchronous ES779 12/14.4kW 357Hz Motor rating plate ES779L 6P 12 kW Flüssigkeitsgekühlt Liquid cooling FNZ4102351 SYNCHRONOUS HSD S.p.A. www.hsd.it Ta:20 ° 3-PHASE MOTOR Via della Meccanica, 16 DREHSTROM- Ins.Cl. F 61122...
Page 51: Parameters For Equivalent Electrical Network Synchronous Es779 12/14.4Kw 357Hz
3 Technical specifications and main parts Parameters for equivalent electrical network synchronous ES779 12/14.4kW 357Hz Electrical parameters (120.060.61.PAR.12) Tipologia motore / motor type / motor typologie P0300 Corrente nominale / rated current / nennstrom (100 K)(S1) P0305 MD1103 Potenza nominale / rated power / nennleistung (S1)
Page 52: Technical Datasheet Asynchronous Es779 13.5/16.2Kw 380V 400Hz
3 Technical specifications and main parts 3.5.7 Technical datasheet asynchronous ES779 13.5/16.2kW 380V 400Hz Motor rating plate ES 779L 4P 16,20kW H1 H1423H0378 Liquid cooling Flussigkeitsgekuhlt HSD S.p.A www.hsd.it ASYNCHRONOUS ° Ta:20 3-PHASE MOTOR Via della Meccanica,16 Ins.Cl. F DREHSTROM-...
Page 53: Parameters Of Equivalent Electrical Network Asynchronous Es779 13.5/16.2Kw 380V 400Hz
3 Technical specifications and main parts Parameters of equivalent electrical network asynchronous ES779 13.5/16.2kW 380V 400Hz Electrical parameters (SP.120.080.4S) Potenza nominale / rated power / nennleistung (S1) 13.5 P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1) P0305 P1103...
Page 54: Technical Datasheet Asynchronous Es779 15/18Kw 380V 400Hz
3 Technical specifications and main parts 3.5.8 Technical datasheet asynchronous ES779 15/18kW 380V 400Hz Motor rating plate ES779 4P 15 kW Flüssigkeitsgekühlt Liquid cooling FNZ4102245 ASYNCHRONOUS HSD S.p.A. www.hsd.it Ta:20 ° 3-PHASE MOTOR Via della Meccanica, 16 DREHSTROM- Ins.Cl. F...
Page 55: Parameters Of Equivalent Electrical Network Asynchronous Es779 15/18Kw 380V 400Hz
3 Technical specifications and main parts Parameters of equivalent electrical network asynchronous ES779 15/18kW 380V 400Hz Electrical parameters (SP.119.080.47.AL) Potenza nominale / rated power / nennleistung (S1) P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1) P0305 P1103...
Page 56: Technical Datasheet Asynchronous Es779 15/18Kw 380V 434Hz
3 Technical specifications and main parts 3.5.9 Technical datasheet asynchronous ES779 15/18kW 380V 434Hz Motor rating plate HSD S.p.A. www.hsd.it ES779 4P 15kW Via della Meccanica,16 Liquid cooling FNZ4101846 61122 Pesaro (PU) (Italy) IEC 60034-1 ASYNCHRONOUS 3-PHASE MOTOR 24000 MAX RPM...
Page 57: Parameters Of Equivalent Electrical Network Asynchronous Es779 15/18Kw 380V 434Hz
3 Technical specifications and main parts Parameters of equivalent electrical network asynchronous ES779 15/18kW 380V 434Hz Electrical parameters (SP.119.080.41) Potenza nominale / rated power / nennleistung (S1) P0307 P1130 P160 Corrente nominale / rated current / nennstrom (S1) P0305 P1103...
Page 58: Technical Datasheet Synchronous Es779 22/25Kw 530Hz
3 Technical specifications and main parts 3.5.10 Technical datasheet synchronous ES779 22/25kW 530Hz Motor rating plate ES779L 6P 22 kW Flüssigkeitsgekühlt Liquid cooling FNZ4102231 SYNCHRONOUS HSD S.p.A. www.hsd.it 3-PHASE MOTOR Via della Meccanica, 16 DREHSTROM- 61122 PESARO (Italy) SYNCHRONMOTOR S6 60%...
Page 59: Parameters For Equivalent Electrical Network Synchronous Es779 22/25Kw 357Hz
3 Technical specifications and main parts Parameters for equivalent electrical network synchronous ES779 22/25kW 357Hz Electrical parameters (SP.120.060.61) Tipologia motore / motor type / motor typologie P0300 Corrente nominale / rated current / nennstrom (100 K)(S1) P0305 MD1103 Potenza nominale / rated power / nennleistung (S1)
Page 60: Technical Datasheet Asynchronous Es789 11/13.5Kw 380V 350Hz
13.3 Rated efficiency 0.86 Power factor cos Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. Discontinued. HSD S.p.A. © - h0102k01a.fm120718...
Page 61: Parameters Of Equivalent Electrical Network Asynchronous Es789 11/13.5Kw 380V 350Hz
P0322 P1146 P174 / Maximaldrehzahl Fattore di potenza / power factor / P0308 nennleistungsfactor Moment of inertia of the rotor 2.5E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 62: Technical Datasheet Asynchronous Es789 15/17Kw 380V 400Hz
15.9 18.8 Rated efficiency Power factor cos Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. Discontinued. HSD S.p.A. © - h0102k01a.fm120718...
Page 63: Parameters Of Equivalent Electrical Network Asynchronous Es789 15/17Kw 380V 400Hz
P0322 P1146 P174 / Maximaldrehzahl Fattore di potenza / power factor / P0308 nennleistungsfactor Moment of inertia of the rotor 2.5E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 64: Technical Datasheet Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate Fnz4101253
The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. Discontinued. Replaced by another version. Refer to paragraph 3.5.15 “Technical datasheet asynchronous ES789 15/18kW 380V 300Hz with motor rating plate FNZ4101851”. HSD S.p.A. © - h0102k01a.fm120718...
Page 65: Parameters Of Equivalent Electrical Network Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate Fnz4101253
P0322 P1146 P174 / Maximaldrehzahl Fattore di potenza / power factor / 0.87 P0308 nennleistungsfactor Moment of inertia of the rotor 3.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 66: Technical Datasheet Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate H1423H0228
The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. Discontinued. Replaced by another version. Refer to paragraph 3.5.16 “Technical datasheet asynchronous ES789 15/18kW 380V 300Hz with motor rating plate FNZ4101847”. HSD S.p.A. © - h0102k01a.fm120718...
Page 67: Parameters Of Equivalent Electrical Network Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate H1423H0288
P0322 P1146 P174 / Maximaldrehzahl Fattore di potenza / power factor / 0.87 P0308 nennleistungsfactor Moment of inertia of the rotor 3.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 68: Technical Datasheet Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate Fnz4101851
19.5 Rated efficiency 0.84 Power factor cos 0.87 Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. HSD S.p.A. © - h0102k01a.fm120718...
Page 69: Parameters Of Equivalent Electrical Network Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate Fnz4101851
/ Maximaldrehzahl Gain factor Xh-Characteristic Fattore di potenza / power factor / 0.83 P0308 nennleistungsfactor Moment of inertia of the rotor 3.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate HSD S.p.A. © - h0102k01a.fm120718...
Page 70: Technical Datasheet Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate Fnz4101847
19.5 Rated efficiency 0.84 Power factor cos 0.87 Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. HSD S.p.A. © - h0102k01a.fm120718...
Page 71: Parameters Of Equivalent Electrical Network Asynchronous Es789 15/18Kw 380V 300Hz With Motor Rating Plate Fnz4101847
/ Maximaldrehzahl Gain factor Xh-Characteristic Fattore di potenza / power factor / 0.83 P0308 nennleistungsfactor Moment of inertia of the rotor 3.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 72: Technical Datasheet Asynchronous Es789 15/18Kw 380V 400Hz With Motor Rating Plate Fnz4101849
35.5 Rated efficiency 0.84 Power factor cos 0.83 Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. HSD S.p.A. © - h0102k01a.fm120718...
Page 73: Parameters Of Equivalent Network Asynchronous Es789 15/18Kw 380V 400Hz With Motor Rating Plate Fnz4101849
/ Maximaldrehzahl Gain factor Xh-Characteristic Fattore di potenza / power factor / P0308 nennleistungsfactor Moment of inertia of the rotor 2.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 74: Technical Datasheet Asynchronous Es789 15/18Kw 220/380V 400Hz With Motor Rating Plate Fnz4101850
52 61.4 53.7 60.6 51.9 62.3 43.3 51.9 Rated efficiency 0.85 Power factor cos 0.83 Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. HSD S.p.A. © - h0102k01a.fm120718...
Page 75: Parameters Of Equivalent Network Asynchronous Es789 15/18Kw 220/380V 400Hz With Motor Rating Plate Fnz4101850
Maximaldrehzahl Gain factor Xh-Characteristic Fattore di potenza / power factor / nennleistungsfactor P0308 Moment of inertia of the rotor 2.8E-3 2.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 76: Technical Datasheet Asynchronous Es789 15/18Kw 380V 400Hz With Motor Rating Plate Fnz4100709
The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. Discontinued. Replaced by another version. Refer to paragraph 3.5.17 “Technical datasheet asynchronous ES789 15/18kW 380V 400Hz with motor rating plate FNZ4101849”. HSD S.p.A. © - h0102k01a.fm120718...
Page 77: Parameters Of Equivalent Electrical Network Asynchronous Es789 15/18Kw 380V 400Hz With Motor Rating Plate Fnz4100709
P0322 P1146 P174 / Maximaldrehzahl Fattore di potenza / power factor / 0.87 P0308 nennleistungsfactor Moment of inertia of the rotor 3.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 78: Technical Datasheet Asynchronous Es789 15/18Kw 220/380V 400Hz With Motor Rating Plate Fnz4100809
The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. Discontinued. Replaced by another version. Refer to paragraph 3.5.18 “Technical datasheet asynchronous ES789 15/18kW 220/380V 400Hz with motor rating plate FNZ4101850”. HSD S.p.A. © - h0102k01a.fm120718...
Page 79: Parameters Of Equivalent Electrical Network Asynchronous Es789 15/18Kw 220/380V 400Hz With Motor Rating Plate Fnz4100809
P0322 P1146 P174 Maximaldrehzahl Fattore di potenza / power factor / nennleistungsfactor 0.87 0.87 P0308 Moment of inertia of the rotor 3.8E-3 3.8E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 80: Technical Datasheet Asynchronous Es789 16/18Kw 380V 267Hz
The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. Discontinued. Replaced by another version. Refer to paragraph 3.5.22 “Technical datasheet asynchronous ES789 16/19.2kW 380V 300Hz”. HSD S.p.A. © - h0102k01a.fm120718...
Page 81: Parameters Of Equivalent Electrical Network Asynchronous Es789 16/18Kw 380V 267Hz
P0322 P1146 P174 / Maximaldrehzahl Fattore di potenza / power factor / P0308 nennleistungsfactor Moment of inertia of the rotor 2.5E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 82: Technical Datasheet Asynchronous Es789 16/19.2Kw 380V 300Hz
19.5 14.5 17.5 Rated efficiency Power factor cos Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. HSD S.p.A. © - h0102k01a.fm120718...
Page 83: Parameters Of Equivalent Electrical Network Asynchronous Es789 16/19.2Kw 380V 300Hz
/ Maximaldrehzahl Gain factor Xh-Characteristic Fattore di potenza / power factor / 0.78 P0308 nennleistungsfactor Moment of inertia of the rotor 2.9E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 84: Technical Datasheet Asynchronous Es789 18/21.5Kw 380V 333Hz
43.1 Rated efficiency 0.92 Power factor cos 0.78 Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. HSD S.p.A. © - h0102k01a.fm120718...
Page 85: Parameters Of Equivalent Electrical Network Asynchronous Es789 18/21.5Kw 380V 333Hz
/ Maximaldrehzahl Gain factor Xh-Characteristic Fattore di potenza / power factor / 0.77 P0308 nennleistungsfactor Moment of inertia of the rotor 2.7E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 86: Technical Datasheet Asynchronous Es789 25/30Kw 380V 333Hz
Rated current Rated efficiency 0.92 Power factor cos 0.78 Number of poles Insulation class Cooling Liquid Weight The maximum speed is specified in the “MAX RPM” box of the motor rating plate affixed to the product. HSD S.p.A. © - h0102k01a.fm120718...
Page 87: Parameters Of Equivalent Electrical Network Asynchronous Es789 25/30Kw 380V 333Hz
/ Maximaldrehzahl Gain factor Xh-Characteristic Fattore di potenza / power factor / 0.78 P0308 nennleistungsfactor Moment of inertia of the rotor 2.7E-3 P0341 P1117 P159 Collegamento / circuit connection / schaltungsart See product motor rating plate. HSD S.p.A. © - h0102k01a.fm120718...
Page 89: Transport, Packing, Unpacking, Storage
Do not approach with data support (for ex. discs, credit cards, company cards), electronic circuits, clocks or other equipment which is sensitive to the rotor. Clearly mark the storage place with danger signs, in compliance with the packaging of the integrated motors! HSD S.p.A. © - h0103k01a.fm120718...
Page 90: Dimensions And Weights
In some cases the product can be packed as requested by the customer. Furthermore, it is necessary that during transport the following environmental conditions are observed: Transport temperature -25°C ÷ +60°C (-13°F ÷ +140°F) Non condensing relative humidity 5% ÷ 55% HSD S.p.A. © - h0103k01a.fm120718...
Page 91: Lifting
Do not lift the product by grasping the electric fan and/or plastic parts, as this could damage the guard. Do not rest the product on the electrospindle shaft. The foam rubber and plastic wrapping should be disposed of as plastic material. HSD S.p.A. © - h0103k01a.fm120718...
Page 92: Storage
-5°C ÷ +55°C (23°F ÷ +131°F) Non condensing relative humidity 5% ÷ 55% The maximum storage period, before the product must be controlled by the manufacturer's authorised personnel is of 12 months. For further information, contact Customer Service. HSD S.p.A. © - h0103k01a.fm120718...
Page 93: Installation And Commissioning
Max. relative humidity : 50% (40°C/104°F). Operating altitude: from 0 up to 1000 metres a.s.l. The motor power could decrease if this is air cooled and if the machine is installed at high altitudes. Maximum altitude: 3000 metres a.s.l.. HSD S.p.A. © - h0104k01a.fm120718...
Page 94: Mechanical Connections
Use screws of resistance class 8.8 or higher. For the tightening torque, refer to the class used and the manufacturer's indications. The screws must be tightened with a torque wrench. The torque value is very important. HSD S.p.A. © - h0104k01a.fm120718...
Page 95: Fixing Via Bores
The tool-holder magazine must position the cones with the tolerance levels shown in the figure. Spindle shaft ISO 30 Tool holder cone ISO 30 HSK spindle shaft HSK Tool holder cone ^ 0,2 D 0,4 C a 0,2 A n 0,2 B HSD S.p.A. © - h0104k01a.fm120718...
Page 96: Pneumatic Connections
The pneumatic connection operations must be performed by specialised and suitably trained personnel. Before starting to make a pneumatic connection, check that the upstream valve is closed and the system has been vented. HSD S.p.A. © - h0104k01a.fm120718...
Page 97: Compressed Air Specifications For Hsd Products
If the machine has a lubricated air circuit, this must be isolated from the dry air circuit feeding the product by means of non-return valves. Install the filters shown in the following figure as close as possible to the HSD product. 1. Main compressed air supply 2.
Page 98: Pneumatic Connection Points
Straight quick connection couplings are supplied for Ø6 mm tubes. The pneumatic supply must never exceed the value stated in the technical data. For this reason, a pressure regulator must always be fitted on the supply line. HSD S.p.A. © - h0104k01a.fm120718...
Page 99: Pneumatic Connection Examples
The use of two solenoid valves in series (instead of one) reduces the risk of malfunctioning. Even though these malfunctions are quite infrequent, due to their possible serious nature, the adoption of a redundancy principle is recommended. HSD S.p.A. © - h0104k01a.fm120718...
Page 100: Pneumatic Cylinder
If this is not the case, check the efficiency of the pneumatic circuit and check the connections. Consumption Compressed air at 4 bar, 20°C (58 PSI, 68°F) Equivalent volume at 1 Atm, 20°C (68°F) 10÷15 litres/minute - 0.35÷0.53 cfm 40÷60 litres/minute - 1.4÷2.1 cfm HSD S.p.A. © - h0104k01a.fm120718...
Page 101: Automatic Tool-Holder Cone Cleaning
5. keep the cone cleaning air jet active until the tool change procedure has been completed; 6. before starting the shaft turning, close the cone cleaning air jet and, if the machining operation requires it, open the supply of coolant fluid into the inside of the tool. HSD S.p.A. © - h0104k01a.fm120718...
Page 102: Cooler Specifications And Hydraulic Connections
For the cooling circuit, use demineralised water (minimum 75% volume) with 10% of ethylene glycol and anti-corrosion additives. The gaskets isolating the fluid circuits inside HSD products are manufactured in NBR: use additives that do not degrade this material. In concentrations above 15%, even the ethylene glycol can damage the seals.
Page 103: Hydraulic Connection Points
Lubricant/coolant outlet outside the tool - line “A” M6x8 M6x8 Lubricant/coolant inlet outside the tool - line “B” 6 mm G1/8”* Lubricant/coolant outlet outside the tool - line “B” M6x8 M6x8 Straight quick connection couplings are supplied for Ø6 mm tubes. HSD S.p.A. © - h0104k01a.fm120718...
Page 104: Fluid Distributor Connections
In normal applications, the valves (5) are open in mutually exclusive mode, i.e. never at the same time: one is opened only when the other has already closed. Other procedures are not excluded, but must be carefully evaluated by the application designer. HSD S.p.A. © - h0104k01a.fm120718...
Page 105: Rotary Fluid Distributor Fitted By The User
For further information please refer to the documentation supplied by the rotating joint manufacturer. 5.7.1 Rotary fluid distributor fitted by the user Refer to the specific dimensional drawings of your own electrospindle, and the documentation supplied by the fluid distributor manufacturer. HSD S.p.A. © - h0104k01a.fm120718...
Page 106: Rotary Distributor For Liquids
CAUTION: always verify that the maximum allowed values for the fluid distributor are always compatible with the maximum allowed values for the electrospindle that uses it. For more information, refer to the specific dimensional drawings of your own electrospindle and the documentation supplied by the fluid distributor manufacturer. HSD S.p.A. © - h0104k01a.fm120718...
Page 107: Electrical Connections
<1000 V; phase voltage rise time measurement >200 ns. Power supply distribution must comply with the voltage limits established by the manufacturer. Check the values while the entire system is running. HSD S.p.A. © - h0104k01a.fm120718...
Page 108: Versions With Free Cables
PTC 2*** Blue Blue PT 1**** PT 2**** White White Thermal motor alarm - bi-metallic NC (normally closed) switch. Thermal motor alarm KTY 84-130. Thermal motor alarm PTC 130. **** Thermal motor alarm PT 1000. HSD S.p.A. © - h0104k01a.fm120718...
Page 109: Power Wiring - Versions With Configurable Star (380V) Or Delta (220V) Connection
For example, the following diagram shows a connection that can be converted from start to delta and vice versa by means of a terminal board. The circuit indicated here is merely an example. INVERTER Electric star connection INVERTER Electric delta connection HSD S.p.A. © - h0104k01a.fm120718...
Page 110: Sensor Wiring - Versions Without Sensor S5
ISO versions: sensor S1 output; HSK versions: sensor S1+S4 output Grey Sensor S2 output Sensor S3* output Orange Sensor S5 output White +24V sensor S1 Yellow +24V sensor S2 Blue +24V sensor S3* Purple +24V sensor S5 Shield Shield Present in certain versions only. HSD S.p.A. © - h0104k01a.fm120718...
Page 111: Wiring Of Thermal Probe On Front Bearings
V-Sense Purple KTY+* thermal motor alarm KTY 84-130 Beige KTY-* thermal motor alarm KTY 84-130 Screen Shield Present in certain versions only. A voltage level higher than the one specified may damage the encoder reader. HSD S.p.A. © - h0104k01a.fm120718...
Page 112: Versions With Hsd Electrical Connectors
5 Installation and commissioning 5.8.2 Versions with HSD electrical connectors The position of the electrical connectors is shown in paragraph 3.4.5 “Variations with HSD electric connectors”. The connectors are housed in a junction box, also known as a "fixed mounting plate".
Page 113: Signal Connector Diagram (Fixed Part)
For HSK versions only: sensor S1 output A+ encoder* A- encoder* B- encoder* 0V encoder* Z+ encoder* Electricity supply** to encoder* B+ encoder* Z- encoder* Present in certain versions only. For the encoder supply voltage, refer to the electrospindle technical datasheet. HSD S.p.A. © - h0104k01a.fm120718...
Page 114: Versions With Mil Electrical Connectors
Not used Earth Motor phase W Not used Thermal alarm* Thermal alarm* Motor phase U Motor phase V Not used On the Technical Datasheet, check the type of thermal alarm fitted on your own model. HSD S.p.A. © - h0104k01a.fm120718...
Page 115: Signal Connector Diagram (Fixed Part)
Encoder connector diagram (fixed part) This connector is only present in versions fitted with an encoder. DESCRIPTION user side view Electricity supply* Screen Not used For the encoder supply voltage, refer to the electrospindle technical datasheet. HSD S.p.A. © - h0104k01a.fm120718...
Page 116: Configurable Power Supply Terminal Board 220/380V
When the button is pressed, the button power supply pin is connected to the button output pin (see “Signal connector diagram (fixed part)” paragraphs on page or page 115, depending on the type of connector). HSD S.p.A. © - h0104k01a.fm120718...
Page 117: Example Of A Wiring Diagram For Manual Tool-Holder Release
For example, the following diagram shows the connections to be made by the user. The circuit indicated here is merely an example. Ref. Description Pin +24V power supply to button, HSD connector Pin +24V power supply to button, MIL connector 7 / G...
Page 118: Programming The Inverter
The maximum continuous current set on the inverter must correspond to the rated current value indicated on the motor rating plate. Contact the manufacturer if it is considered necessary to check the other parameters of the inverter. HSD S.p.A. © - h0104k01a.fm120718...
Page 119: General Post-Installation Checks
The progress of the tool holder cone ejection must be as specified in section 7.4 “Tool-holder locking and ejection device”. 6.1.3 Hydraulic connections The hydraulic circuit and liquids used must meet the specifications and instructions in paragraph 5.6 “Cooler specifications and hydraulic connections”. HSD S.p.A. © - h0105k01a.fm120718...
Page 120: Electrical Connections
The tool change cycle must only take place with the shaft stopped. Check the correct operation of the cooling system. With the tool holder inserted and without performing machining operations, perform the preheating cycle described in paragraph “Warm-up”. HSD S.p.A. © - h0105k01a.fm120718...
Page 121: Adjustment And Maintenance
Adjustment and Maintenance...
Page 123: Operation And Regulation
Only in the case of the first start-up after storage or machine downtime over four months, anticipate the pre-heating cycle by a preliminary phase of 2 minutes at 5000rpm. Failure to enable the warm-up cycle causes irreversible damage. HSD S.p.A. © - h0106k01a.fm120718...
Page 124: Tool-Holder Locking And Ejection Device
70% of the minimum value. Dropping below this level means exposure to serious danger for the operator as well as the risk of damaging the product. The tool ejection and change operations must take place with the shaft stopped. HSD S.p.A. © - h0106k01a.fm120718...
Page 125: Checking And Adjusting The Hsk Collet Ejection Position
If the collet must be adjusted, check the calibration and, if necessary, calibrate the sensors again. To do this, refer to paragraph 9.3 “Replacing and adjusting the sensors”. HSD S.p.A. © - h0106k01a.fm120718...
Page 126: Tool-Holder Cone
It is forbidden to use tool holders that do not comply with the above conditions. Non compliance with these instructions can lead to a risk of breakage or an imperfect coupling of the tool holder cone, with the resulting risks for the user. HSD S.p.A. © - h0106k01a.fm120718...
Page 127: Installation Of The Hsd 0804H0009 Screw Dowel In The Iso30 Din69871 Cone
LOCTITE 243, or according to the manufacturer's instructions if an alternative equivalent product is used). The use of non-original HSD screw dowels, or their incorrect installation, may cause the tool-holder cone to be suddenly ejected. Pay attention to the dosage of the thread-locker liquid. Excessive quantities may unintentionally obstruct holes and/or adversely affect the operation.
Page 128: Tool
The balance quality grade is that recommended in the preceding paragraphs. If the position of the centre of gravity "G" is unknown, it can be calculated following the simplified procedure described in paragraph “Calculating the centre of gravity for the tool+tool-holder assembly”. HSD S.p.A. © - h0106k01a.fm120718...
Page 129: Calculating The Centre Of Gravity For The Tool+Tool-Holder Assembly
; Aluminium: 2100 Kg/m 3. Elementary formulae for calculating the centre of gravity; Cylindrical segment (possibly hollow): G position : b = Volume : V = (R - r ) h Mass : m = Vd HSD S.p.A. © - h0106k01a.fm120718...
Page 130 : m = Vd 4. Obtain the position of the centre of gravity of the assembly, starting with the centres of gravity of the individual parts (the reference faces for the measurement of "b" are in yellow) HSD S.p.A. © - h0106k01a.fm120718...
Page 131: Procedure For Reading The Graphs
4. If the weight or the distance of G is higher than that provided for by the manufacturer, it is the user's responsibility to evaluate the maximum safe operating speed case by case. If it is thought that the tool may be too large and could damage the electrospindle, contact the Assistance Service. HSD S.p.A. © - h0106k01a.fm120718...
Page 132 EXAMPLE 2 If a milling cutter pack that can be assimilated to a cylinder of length L=160mm and with a total weight of 4.5kg is to be used on an ES779 HSK short-nose: 1. b=h/2=160/2=80mm; 2. The tool can be assimilated to a single elementary part (cylinder), therefore X=b=80 mm;...
Page 133: Graph Used To Define The Maximum Machining Speed
7 Operation and regulation Graph used to define the maximum machining speed Centre of gravity curves for ES779 HSK short-nose 24000 22000 X = 70 20000 X = 90 18000 X = 110 16000 X = 130 14000 12000 10000...
Page 134: Procedure To Follow If The Tool Becomes Jammed In The Piece Machining Operation In Progress
If this procedure is not followed, the tool holder will drag the locking system (collet/screw dowel) with it until the cone is released. After which, the collet will move back violently due to the force exerted by the spring and could cause damage. HSD S.p.A. © - h0106k01a.fm120718...
Page 135 ISO collet (or pre-inserted nut) Screw dowel The arrows indicate the direction in which the locking system returns after having freed the cone Point at which the collet will hit the shaft Screw dowel breakage HSD S.p.A. © - h0106k01a.fm120718...
Page 136 Point at which the screw dowel will hit the safety ring nut Safety ring nut Cracking of the safety ring nut The red arrows indicate the direction in which the locking system returns after having freed the cone HSD S.p.A. © - h0106k01a.fm120718...
Page 137: Sensors
Sensor S1: “tool holder coupled” signal The signal from 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 coupling command. HSD S.p.A. © - h0106k01a.fm120718...
Page 138: Sensor S1+S4: "Hsk Cone Locked In The Correct Position" Signal
(“ON” or “OFF”). Sensor S5: “piston backward” signal Sensor S5 is only present in certain versions. It checks the position of the piston. The piston must be fully backwards (sensor ON) to allow the spindle to rotate. HSD S.p.A. © - h0106k01a.fm120718...
Page 139: Technical Characteristics Of The Inductive Sensors
Tool holder cone properly locked, but piston not STOPPED or completely retracted MOVING** Collet closed but with no tool holder cone STOPPED Present in certain versions only. Depending on the operational status of the machine. HSD S.p.A. © - h0106k01a.fm120718...
Page 140 This status will damage the product, because the piston comes into contact with the rotating shaft. If it is detected, stop the rotation, inspect the machine and remove whatever is MOVING preventing the piston from retracting completely. HSD S.p.A. © - h0106k01a.fm120718...
Page 141: Sensor Calibration
If the shaft stops while the tool is being pushed against the piece being machined, the spindle bearings may break. If the tool is not immediately moved away from the piece and the rotation stopped, there is a risk of burning out the stator or damaging the bearings. HSD S.p.A. © - h0106k01a.fm120718...
Page 142: Thermal Alarm Temperature Thresholds
NC (normally closed) Power supply 48 V Current 1.6 A MAX Switching cycles 10000 Cycles Contact interruption time < 1 ms Contact resistance (according to MIL R 5757) < 50 m Isolation voltage 2 kV HSD S.p.A. © - h0106k01a.fm120718...
Page 143: Technical Features Of The Ptc Thermistor
+ 5K >1330 <2.5 V Resistance at T + 15K >4000 <7.5 V - pulsed Behaviour of the KTY 84-130 probe Temperature (°C) Resistance (Ohm) Temperature (°C) Resistance (Ohm) 1000 1062 1127 1194 1262 1334 1407 HSD S.p.A. © - h0106k01a.fm120718...
Page 144: Pt 1000 Probe Performance
Its behaviour is described in the following table: Temperature (°C) Resistance (Ohm) Temperature (°C) Resistance (Ohm) 80.31 123.24 84.27 127.08 88.22 130.9 92.16 134.71 96.09 138.51 142.29 103.9 146.07 107.79 149.83 111.67 153.58 115.54 157.33 119.4 161.05 HSD S.p.A. © - h0106k01a.fm120718...
Page 145: Encoders
(A inverted and B inverted) in phase quadrature; it also provides the Zero and inverted Zero signals (see the figures below The signals are shown on the outside, as explained in section 5.8 “Electrical connections”. The following encoder models are available: Lenord+Bauer “square wave” encoder; Lenord+Bauer sinusoidal wave encoder. HSD S.p.A. © - h0106k01a.fm120718...
Page 146: Technical Characteristics Of The Lenord+Bauer Square Wave Encoder
Signals output TTL electrical levels compatible (0V, +5V line driver) A voltage level higher than the one specified (5V ±5%) may damage the encoder reader. Signals of the Lenord+Bauer Square Wave encoder Period Phase displacement (D=T/4) HSD S.p.A. © - h0106k01a.fm120718...
Page 147: Technical Characteristics Of The Lenord+Bauer Sine Encoder
A voltage level higher than the one specified (5V ±5%) may damage the encoder reader. Key to the figures below Period (360° electric) Phase displacement (D=T/4) A diff (A) - (A-) B diff (B) - (B-) Z diff (Z) - (Z-) HSD S.p.A. © - h0106k01a.fm120718...
Page 148: Progressive Trend Of Signal A
= (A+) – (A–) diff 0,500 0,000 -0,500 Temporal trend of signal B 3,000 2,500 2,000 B– 1,500 = (B+) – (B–) diff 1,000 0,500 0,000 -0,500 Displacement of signals A and B 2,75 2,25 HSD S.p.A. © - h0106k01a.fm120718...
Page 149: Progressive Trend Of Signal Z
7 Operation and regulation Progressive trend of signal Z 3.00 2.75 2.50 2.25 2.75 2.50 2.25 2.00 1.00 = (Z+) – (Z–) diff 0.75 0.50 0.25 -0.25 HSD S.p.A. © - h0106k01a.fm120718...
Page 150: Temporal Trend Of The Differential Signals
For information on how to use the rotating joints, please refer to the warnings in section 5.7 “Fluid distributor connections” and to the documentation supplied by the rotating joint manufacturer. Particular attention must be given to the importance of the fluid delivery start-up and stoppage procedures. HSD S.p.A. © - h0106k01a.fm120718...
Page 151: Maintenance
All personnel taking part in the maintenance operations must be in full visual contact with each other in order to be able to signal any dangers that may arise. HSD S.p.A. © - h0107k01a.fm120718...
Page 152: Scheduled Maintenance
Imperfect cleaning can lead to serious consequences for the user's safety, the wear of the electrospindle and the tool-holder, and the accuracy and efficiency of the machining operation. HSD S.p.A. © - h0107k01a.fm120718...
Page 153: Protect The Tool-Holder Seat
The tool holder to be removed may be hot! use gloves! 8.1.3 Drain the pneumatic circuit filters Frequency: DAILY At the end of each work shift, discharge the compressed air circuit to allow the automatic filter cleaning system that protects the HSD product to function. HSD S.p.A. © - h0107k01a.fm120718...
Page 154: Clean The Tool-Holder Cone With Alcohol
Check the condition of the power supply and signal wires and make sure that the connectors are tight. Check that there are no leaks from the pipes and fittings of the cooling and compressed air circuits. HSD S.p.A. © - h0107k01a.fm120718...
Page 155: Lubricate The Hsk Collet
(checking the tool holder axial force). Check operation of the collet, as indicated. Failure to check operation of the collet can cause serious danger to the operator as well as damage the said product. HSD S.p.A. © - h0107k01a.fm120718...
Page 156: Replace The Coolant
8.1.10 Replace the pneumatic circuit filters Frequency: ACCORDING TO THE MANUFACTURER'S INSTRUCTIONS Perform regular maintenance on and replace the filters of the pneumatic circuit feeding the HSD product in line with the filter manufacturer's instructions. 8.1.11 Bearings...
Page 157: Replacing Components
S.p.A. spare parts described in this section of the manual are used. Any other type of intervention is not allowed and will invalidate the warranty. When the collet needs replacing, you are advised to have the job carried out at a HSD repair centre or by specialised HSD personnel.
Page 158: Replacing The Shaft Kit
The shaft kits include a shaft, bearings, rotor, screw dowel and coupling system. To find the sprindle kit designed for your own model, let the HSD sales office know the serial number of the spindle; this number is usually printed on the front flange or the front of the casing (see paragraph 3.4 “General overview and main...
Page 159 Remove the 4 fixing screws that hold the electrospindle casing in place. There is also a thin layer of silicone fixing the casing to the electrospindle, but a slight force is enough to remove it. HSD S.p.A. © - h0108k01a.fm120718...
Page 160 9 Replacing components Description Picture Remove the 8 hex screws (2 on each corner) of the cylinder unit. Open the cylinder unit, paying attention to the cable highlighted in the figure. Remove the 4 springs. HSD S.p.A. © - h0108k01a.fm120718...
Page 161 (upper figure) and piston screw dowel (lower figure) are not worn or damaged in any way (in this case, the replacement of the shaft kit alone is not sufficient; the electrospindle has to be sent to HSD service). HSD S.p.A. © - h0108k01a.fm120718...
Page 162 Remove the eight 5x10 screws (“B”) around the screw dowel. Move the two screws in the oval holes radially outwards (direction “C”), then tighten them so they are blocked in this position. HSD S.p.A. © - h0108k01a.fm120718...
Page 163 DO NOT use the holes indicated by (C) (the inner ones). Carefully pull the shaft kit out by a few centimetres. FOR VERSIONS WITH AN ENCODER: using the inspection window, make sure the encoder wiring isn't entangled. HSD S.p.A. © - h0108k01a.fm120718...
Page 164 Make sure the three ORM 0080-15 rings indicated in the figure by “A”, and the ORM 0050-15 ring indicated by “B”, are fitted and in good condition. NB: the hole “B” is not present on certain models. HSD S.p.A. © - h0108k01a.fm120718...
Page 165 Picture VERSIONS WITH A HSD ENCODER: Disconnect the connector “C”. VERSIONS WITH ENCODER L+B: Disconnect the 3 connectors indicated in the figure. Remove the shaft kit. Clean the support surfaces and grease the bearing seats. HSD S.p.A. © - h0108k01a.fm120718...
Page 166 Partly insert the new shaft kit. Make sure the pressurisation air hole on the shaft is aligned with the one on the flange. VERSIONS WITH AN HSD ENCODER: Connect the connector “C”. VERSIONS WITH ENCODER L+B: Connect the 3 connectors.
Page 167 To ensure optimum machining precision after replacing the shaft kit, you are advised to reset the axis affected by the modification (the one parallel to the spindle shaft). HSD S.p.A. © - h0108k01a.fm120718...
Page 168: Replacing The Encoder Reader
If the encoder reader needs to be replaced, follow the shaft kit disassembly procedure as far as point 12, then proceed as follows: Models with an HSD square-wave encoder Loosen the two optic reader fixing screws and carefully raise the reader out of its seat.
Page 169: Replacing And Adjusting The Sensors
Identifying and accessing the sensors Figure 10: sensor unit Figure 11: sensor connection Electric connector Calibrated position Numbered label Bracket and block Pre-inserted nut Sensor unit Sensor Screw Eccentricity between the nut and sensor, for adjustment HSD S.p.A. © - h0108k01a.fm120718...
Page 170 510 (or an equivalent product) on the edge of the casing. Figure 12: ES779 Figure 13: ES789 Figure 14: versions with distributor Figure 15: ES779 and ES789 Versions with a fixed piston Versions with a floating piston Versions with a floating piston not set up for use of S5 Sensor S4 is only present in HSK versions.
Page 171: Sensor Wiring
Output Black ON / OFF paragraph 5.8.1 “Versions with Blue free cables”. Sensor S4 is only present in HSK versions. Sensors S3 and S5 are only present in certain versions. HSD S.p.A. © - h0108k01a.fm120718...
Page 172: Replacing The Sensor Unit
9. Rotate the sensor unit by a few degrees at a time, until the outputs required in the following paragraphs are obtained. 10. Use an open-end spanner to tighten the screw that holds the sensor unit, in order to maintain the calibration. HSD S.p.A. © - h0108k01a.fm120718...
Page 173: Adjusting Sensor S1 For Iso Versions
14. at the end of the cycle, check that the conditions in the table in point (11) have been satisfied. If they are not met , repeat the procedure from the start. If they are met , the S1 adjustment procedure is complete. HSD S.p.A. © - h0108k01a.fm120718...
Page 174: Adjusting Sensors S1 And S4 For Hsk Versions
Gauges - S1 doesn't read (14.29) and S4 (14.13); 0.04 and 0.12 thickness spacers Gauges - S1 reads (18.25), S1 doesn't read (18.29), S4 reads A63 E63 (18.01), and S4 doesn't read (17.97); no thickness spacer HSD S.p.A. © - h0108k01a.fm120718...
Page 175 S1 reads (18.25) Gauge - S1 reads (18.25) S1 doesn't read (18.29) Gauge - S1 doesn't read (18.29) S4 reads (18.01) Gauge - S4 reads (18.01) S4 doesn't read (17.97) Gauge - S4 doesn't read (17.97) HSD S.p.A. © - h0108k01a.fm120718...
Page 176: Using The Adjustment Gauge Kit
8. at the end of the cycle, check that the conditions of the table have been met for the entire 360° shaft rotation. Otherwise, repeat the procedure from the start; 9. if the table conditions have been met, the sensor calibration is complete. HSD S.p.A. © - h0108k01a.fm120718...
Page 177: Adjusting Sensor S2 For Iso Versions
14. at the end of the cycle, check that steps [1] to [8] have been met, without ever needing to turn the sensor ; 15. if the requested output have not been verified, repeat the entire procedure from the beginning; 16. if the requested output have verified, the adjustment procedure of S2 is finished. HSD S.p.A. © - h0108k01a.fm120718...
Page 178: Adjusting Sensor S2 For Hsk Versions
13. at the end of the cycle, check that point [7] is met without needing to move the sensor; 14. if necessary move the sensor, then repeat the entire process from the beginning; 15. if it is not necessary to move the sensor, then the S2 adjustment process is complete. HSD S.p.A. © - h0108k01a.fm120718...
Page 179: Adjusting Sensor S3
8. tighten the screw that fastens the sensor completely; 9. perform 10 "tool-holder ejection (piston forward)" - "piston return (piston backward)” cycles; HSD S.p.A. © - h0108k01a.fm120718...
Page 180 15. if point (14) of the procedure is met, perform 50 "tool-holder ejection (piston forward)" - "piston return (piston backward)” cycles. 16. check the calibration by repeating steps [10] to [15] of this procedure four times. HSD S.p.A. © - h0108k01a.fm120718...
Page 181: Hsk Collet Replacement
9 Replacing components HSK collet replacement To replace the collet, it is recommended to have the operation performed at a HSD repair centre or by HSD qualified personnel. Use suitable Teflon or plastic equipment and tools so as not to compromise the surface precision of the components.
Page 182: Assembling The Hsk Collet In The Spindle
(a): Place the segments of the collet onto the tool and secure them with a rubber ring; insert the complete unit; press the segments of the collet down into position; remove the rubber ring. HSD S.p.A. © - h0108k01a.fm120718...
Page 183 • if the force is still less than 70%, change the collet and check again; • if the force is still less than 70%, change the clamping device completely. HSD S.p.A. © - h0108k01a.fm120718...
Page 184: Check The Hsk Collet After Approximately 100 Locking Operations
• if the force is still less than 70%, change the clamping device completely. Check operation of the collet, as indicated. Failure to check operation of the collet can cause serious danger to the operator as well as damage the said product. HSD S.p.A. © - h0108k01a.fm120718...
Page 185: Tightening The Lockscrew For The Hsk Collet
A32 / B40 / E32 10 Nm A80 / B100 30 Nm A40 / B50 / E40/ F50 15 Nm A100 / B125 50 Nm A50 / B63 / E50/ F63 20 Nm A125 / B160 100 Nm HSD S.p.A. © - h0108k01a.fm120718...
Page 187 Appendices...
Page 189: A Troubleshooting
Adjust the sensor as described in section disconnected or out of 9.3 “Replacing and adjusting the order sensors”. If the sensor is faulty, replace it as described in section 9.3 “Replacing and adjusting the sensors”. HSD S.p.A. © - h0110k01a.fm120718...
Page 190 9.3 “Replacing and adjusting order sensors”. If the sensor is faulty, replace it as explained in paragraph 9.3 “Replacing and adjusting the sensors”. Seized bearings or Contact the manufacturer's assistance components service. HSD S.p.A. © - h0110k01a.fm120718...
Page 191 Check the parameters on the Performance lower The inverter parameters electrospindle plate and in paragraph than specifications are incorrect 3.5 “Features and performance” (in the paragraph relating to your model). HSD S.p.A. © - h0110k01a.fm120718...
Page 192 Check the integrity and efficiency of the The tool holder does pneumatic circuit. not eject Consult the manuals or the suppliers of Tool ejection enabling the machine, the numerical control and denied the inverter that is connected to the electrospindle. HSD S.p.A. © - h0110k01a.fm120718...
Page 193: B Spare Parts
SPARE SHAFT KIT Spare shaft kits are available for installation if the bearings are excessively worn. To obtain the correct shaft kit for the model in question, inform the HSD sales office of the spindle serial number. The serial number is usually stamped on the front flange or on the front of the casing (see paragraph 3.4 “General overview and main...
Page 194: Tools For Collet Hsk Assembly
The list below shows the tools for assembling the HSK collets that can be used for the product. HSK tool Manufacturer code HSK shape/size H3811H1320 A40 / E40 / F50 H3811H1321 A50 / E50 / F63 H3811H1322 A63 / E63 / F80 HSD S.p.A. © - h0111k01a.fm120718...
Page 195: C Disposal
This spring is applied to a screw dowel that can be violently ejected if the electrospindle is dismantled by inadequately trained personnel. Only carry out the operations described in this manual. Follow the instructions scrupulously and in the case of doubt, contact the Manufacturer's Assistance Service. HSD S.p.A. © - h0109k00a.fm120718...
Page 197: D Customer Service
Tel. (+39) 0541 979 001 (+39) 0541 979 050 Service (+39) 0541 979 010 E-mail supporthsd@hsd.it www.hsd.it HSD Deutschland GmbH Brückenstrasse, 32 D-73037 Göppingen, Deutschland Tel. +49(0) 7161 956660 +49(0) 7161 9566610 E-mail sales@hsddeutschland.de www.hsddeutschland.de HSD S.p.A. © - h0112k00a.fm120718...
Page 198 (+86) 21 5161 9991 (+86) 21 5866 1237 E-mail sales@hsd-china.cn www.hsd-china.cn HSD Mechatronics Korea 414 Tawontakra 2, 76 Dongsan-ro, Danwon-gu Ansan-si 15434, South Korea Tel. (+82) 31 380 8161 (+82) 303 3443 8161 E-mail sales@hsdkorea.kr www.hsdkorea.kr HSD S.p.A. © - h0112k00a.fm120718...
Page 200 HSD NEL MONDO HSD WORLDWIDE More Value for Your Machine M E C H A T R O N I C S O L U T I O N S hsd.it hsdusa.com hsddeutschland.de hsd-china.cn hsdkorea.kr...

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