HSD ES779 User manual

Translation of the original instructions
ENGLISH
Serial number
ES779, ES789
Electrospindle
Assembly instructions
Edition.Revision 2.1
H5801H0118

Information about the publication
HSD S.p.A. © - H5801H0118.fm120718
3
Information about the publication
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.
Code Issue Code of previous issue
H5801H0118 2 H5803H0005
Revision Description of updates
0 (02/2017) new document
1 (05/2018)
Revision paragraphs 1.3, 1.6, 2.4, 2.5.2, 3.4, 3.5, 4.1, 5.5.2, 5.5.5, 5.6, 5.7, 5.7.3,
5.8.1, 6.1.5, 7.4, 7.8, 7.8.5, 7.10, 8.1.8, 9.1, 9.1.20, 9.3.1, 9.3.4, 9.4.2, 9.4.3,
appendix A, B.
Paragraphs added 3.5.2, 3.5.6, 3.5.8, 3.5.9, 3.5.10, 3.5.15, 3.5.16, 3.5.17, 3.5.18,
3.5.22, 3.5.23, 3.5.24, 5.9.

Information about the publication
4
HSD S.p.A. © - H5801H0118.fm120718

Table of contents
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Table of contents
Preliminaries
1 Preliminary information
Introduction ................................................................................................................. 15
1.1 Scope of the manual ........................................................................................................ 15
1.2 Symbols used in the manual ............................................................................................ 16
1.3 Documents supplied with the product .............................................................................. 16
EC Declaration of Conformity ..................................................................................... 17
1.4 Identification of the manufacturer and of the product ....................................................... 18
1.5 Orders and requests for information ................................................................................ 18
1.6 Glossary ........................................................................................................................... 18
1.7 Warranty ........................................................................................................................... 20
2 Safety information
2.1 Safety regulations ............................................................................................................ 21
2.2 Safety warnings for the fitting and use of tools ................................................................ 21
2.3 Safety warnings for maintenance ..................................................................................... 22
2.4 Risks associated with the use of the product ................................................................... 23
Magnetic dangers ....................................................................................................... 23
2.4.1 Prohibitions and risks associated with improper handling and/or use ........................... 24
2.4.2 Residual risks ................................................................................................................ 25
2.5 Signs fixed to the product ................................................................................................. 26
2.5.1 Danger signs ................................................................................................................. 26
2.5.2 Mandatory signs ............................................................................................................ 26
Descriptions
3 Technical specifications and main parts
3.1 General product description ............................................................................................. 29
3.2 Workable materials .......................................................................................................... 29
3.3 Applications ...................................................................................................................... 30
3.4 General overview and main parts .................................................................................... 31
3.4.1 ES779, with free cables, with fixing grooves ................................................................. 31

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3.4.2 ES779, with free cables, with fixing bores ..................................................................... 32
3.4.3 ES789, with free cables, with fixing grooves ................................................................. 33
3.4.4 ES789, with free cables, with fixing bores ..................................................................... 34
3.4.5 Variations with HSD electric connectors ....................................................................... 35
3.4.6 Variations with MIL standard electric connectors .......................................................... 36
3.4.7 Variations with configurable power supply terminal board 220/380V ............................ 37
3.4.8 Variations with fluid distributor ....................................................................................... 38
3.4.9 Variations with floating or fixed piston ........................................................................... 39
3.4.10 ES779 with manual tool change (ES779 collet) ............................................................ 39
3.5 Features and performance ............................................................................................... 40
3.5.1 Technical datasheet asynchronous ES779 10/12kW 380kW 250Hz
with motor rating plate H1423H0216 ............................................................................. 40
Parameters of equivalent electrical network ES779 10/12kW 380kW 250Hz
with motor rating plate H1423H0216 ....................................................................... 41
3.5.2 Technical datasheet asynchronous ES779 10/12kW 380V 250Hz
with motor rating plate FNZ4102319 ............................................................................. 42
Parameters of equivalent electrical network ES779 10/12kW 380V 250Hz
with motor rating plate FNZ4102319 ....................................................................... 43
3.5.3 Technical datasheet asynchronous ES779 10/12kW 220/380V 250Hz ........................ 44
Parameters for equivalent electrical network asynchronous ES779 10/12kW
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 Technical datasheet synchronous ES779 12/14.4kW 357Hz ........................................ 50
Parameters for equivalent electrical network synchronous ES779 12/14.4kW 357Hz 51
3.5.7 Technical datasheet asynchronous ES779 13.5/16.2kW 380V 400Hz ......................... 52
Parameters of equivalent electrical network asynchronous ES779 13.5/16.2kW 380V 400Hz 53
3.5.8 Technical datasheet asynchronous ES779 15/18kW 380V 400Hz ............................... 54
Parameters of equivalent electrical network asynchronous ES779 15/18kW 380V 400Hz 55
3.5.9 Technical datasheet asynchronous ES779 15/18kW 380V 434Hz ............................... 56
Parameters of equivalent electrical network asynchronous ES779 15/18kW 380V 434Hz 57
3.5.10 Technical datasheet synchronous ES779 22/25kW 530Hz ........................................... 58
Parameters for equivalent electrical network synchronous ES779 22/25kW 357Hz .. 59
3.5.11 Technical datasheet asynchronous ES789 11/13.5kW 380V 350Hz ............................ 60
Parameters of equivalent electrical network asynchronous ES789 11/13.5kW 380V 350Hz 61
3.5.12 Technical datasheet asynchronous ES789 15/17kW 380V 400Hz ............................... 62
Parameters of equivalent electrical network asynchronous ES789 15/17kW 380V 400Hz 63
3.5.13 Technical datasheet asynchronous ES789 15/18kW 380V 300Hz
with motor rating plate FNZ4101253 ............................................................................. 64
Parameters of equivalent electrical network asynchronous ES789 15/18kW
380V 300Hz with motor rating plate FNZ4101253 .................................................. 65
3.5.14 Technical datasheet asynchronous ES789 15/18kW 380V 300Hz
with motor rating plate H1423H0228 ............................................................................. 66
Parameters of equivalent electrical network asynchronous ES789 15/18kW
380V 300Hz with motor rating plate H1423H0288 .................................................. 67

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3.5.15 Technical datasheet asynchronous ES789 15/18kW 380V 300Hz
with motor rating plate FNZ4101851 ............................................................................. 68
Parameters of equivalent electrical network asynchronous ES789 15/18kW
380V 300Hz with motor rating plate FNZ4101851 .................................................. 69
3.5.16 Technical datasheet asynchronous ES789 15/18kW 380V 300Hz
with motor rating plate FNZ4101847 ............................................................................. 70
Parameters of equivalent electrical network asynchronous ES789 15/18kW
380V 300Hz with motor rating plate FNZ4101847 .................................................. 71
3.5.17 Technical datasheet asynchronous ES789 15/18kW 380V 400Hz
with motor rating plate FNZ4101849 ............................................................................. 72
Parameters of equivalent network asynchronous ES789 15/18kW
380V 400Hz with motor rating plate FNZ4101849 .................................................. 73
3.5.18 Technical datasheet asynchronous ES789 15/18kW 220/380V 400Hz
with motor rating plate FNZ4101850 ............................................................................. 74
Parameters of equivalent network asynchronous ES789 15/18kW
220/380V 400Hz with motor rating plate FNZ4101850 ........................................... 75
3.5.19 Technical datasheet asynchronous ES789 15/18kW 380V 400Hz
with motor rating plate FNZ4100709 ............................................................................. 76
Parameters of equivalent electrical network asynchronous ES789 15/18kW
380V 400Hz with motor rating plate FNZ4100709 .................................................. 77
3.5.20 Technical datasheet asynchronous ES789 15/18kW 220/380V 400Hz
with motor rating plate FNZ4100809 ............................................................................. 78
Parameters of equivalent electrical network asynchronous ES789 15/18kW
220/380V 400Hz with motor rating plate FNZ4100809 ........................................... 79
3.5.21 Technical datasheet asynchronous ES789 16/18kW 380V 267Hz ............................... 80
Parameters of equivalent electrical network asynchronous ES789 16/18kW 380V 267Hz 81
3.5.22 Technical datasheet asynchronous ES789 16/19.2kW 380V 300Hz ............................ 82
Parameters of equivalent electrical network asynchronous ES789 16/19.2kW 380V 300Hz . 83
3.5.23 Technical datasheet asynchronous ES789 18/21.5kW 380V 333Hz ............................ 84
Parameters of equivalent electrical network asynchronous ES789 18/21.5kW 380V 333Hz . 85
3.5.24 Technical datasheet asynchronous ES789 25/30kW 380V 333Hz ............................... 86
Parameters of equivalent electrical network asynchronous ES789 25/30kW 380V 333Hz 87
4 Transport, packing, unpacking, storage
4.1 Warnings .......................................................................................................................... 89
4.2 Dimensions and weights .................................................................................................. 90
4.3 Transport and packing ..................................................................................................... 90
Lifting .......................................................................................................................... 91
4.4 Unpacking ........................................................................................................................ 91
4.5 Storage ............................................................................................................................ 92
5 Installation and commissioning
5.1 Preliminary installation checks ......................................................................................... 93
5.2 Preparing the factory services .......................................................................................... 93
5.3 Environmental work requisites ......................................................................................... 93
5.4 Mechanical connections ................................................................................................... 94

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5.4.1 Receiving structure ....................................................................................................... 94
5.4.2 Fitting the electrospindle ............................................................................................... 94
Fixing via bores .......................................................................................................... 95
Fixing via grooves and brackets ................................................................................. 95
5.4.3 Threaded service holes ................................................................................................. 95
5.4.4 Tool-change system ...................................................................................................... 95
5.5 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 Internal pressurisation ................................................................................................. 100
5.5.5 Automatic tool-holder cone cleaning ........................................................................... 101
5.6 Cooler specifications and hydraulic connections ........................................................... 102
5.6.1 Hydraulic connection points ........................................................................................ 103
5.7 Fluid distributor connections .......................................................................................... 104
5.7.1 Rotary fluid distributor fitted by the user ...................................................................... 105
5.7.2 Rotary distributor for liquids ........................................................................................ 106
5.7.3 Rotary distributor for liquids and dry air ...................................................................... 106
5.8 Electrical connections .................................................................................................... 107
5.8.1 Versions with free cables ............................................................................................ 108
Power wiring - versions for star connection only (380V) .......................................... 108
Power wiring - versions with configurable star (380V) or delta (220V) connection .. 109
Sensor wiring - versions without sensor S5 .............................................................. 110
Sensor wiring - versions with sensor S5 ................................................................... 110
Wiring of thermal probe on front bearings ................................................................. 111
Encoder wiring - version without “V-sense” signal ..................................................... 111
Encoder wiring - version with “V-sense” signal .......................................................... 111
5.8.2 Versions with HSD electrical connectors ...................................................................... 112
Power connector diagram (fixed part) ....................................................................... 112
Signal connector diagram (fixed part) ....................................................................... 113
5.8.3 Versions with MIL electrical connectors ....................................................................... 114
Power connector diagram - 6-pin version (fixed part) ............................................... 114
Power connector diagram - 9-pin version (fixed part) ............................................... 114
Signal connector diagram (fixed part) ....................................................................... 115
Encoder connector diagram (fixed part) .................................................................... 115
Configurable power supply terminal board 220/380V .............................................. 116
5.8.4 Tool release button ....................................................................................................... 116
Example of a wiring diagram for manual tool-holder release .................................... 117
5.9 Programming the inverter ............................................................................................... 118
6 General post-installation checks
6.1 Pre start-up checks ......................................................................................................... 119
6.1.1 Positioning ................................................................................................................... 119
6.1.2 Pneumatic connections ................................................................................................ 119
6.1.3 Hydraulic connections .................................................................................................. 119
6.1.4 Electrical connections ................................................................................................. 120
6.1.5 Programming the inverter ............................................................................................ 120

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6.2 Start-up checks .............................................................................................................. 120
Adjustment and Maintenance
7 Operation and regulation
7.1 Environmental conditions ............................................................................................... 123
7.2 Running-in ...................................................................................................................... 123
7.3 Warm-up ........................................................................................................................ 123
7.4 Tool-holder locking and ejection device ......................................................................... 124
7.4.1 Checking and adjusting the HSK collet ejection position ............................................ 125
7.5 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
7.6 Tool ................................................................................................................................ 128
7.6.1 Speed limits ................................................................................................................. 128
Maximum speed and shape of the tool .................................................................... 128
Calculating the centre of gravity for the tool+tool-holder assembly .......................... 129
Procedure for reading the graphs ............................................................................. 131
Graph used to define the maximum machining speed ............................................. 133
7.7 Procedure to follow if the tool becomes jammed in the piece machining operation in progress 134
7.8 Sensors .......................................................................................................................... 137
7.8.1 Description of the inductive sensors ........................................................................... 137
Sensor S1: “tool holder coupled” signal ................................................................... 137
Sensor S1+S4: “HSK cone locked in the correct position” signal ............................. 138
Sensor S2: “collet open” signal ................................................................................ 138
Sensor S3: spindle shaft rotation speed ................................................................... 138
Sensor S5: “piston backward” signal ........................................................................ 138
7.8.2 Technical characteristics of the inductive sensors ....................................................... 139
7.8.3 Electrospindle conditions and corresponding outputs of the inductive sensors .......... 139
7.8.4 Sensor calibration ....................................................................................................... 141
7.8.5 Use and technical characteristics of the thermal alarm ............................................... 141
Thermal alarm temperature thresholds .................................................................... 142
Technical characteristics of the bimetallic switch: .................................................... 142
Technical features of the PTC thermistor ................................................................. 143
Behaviour of the KTY 84-130 probe ......................................................................... 143
PT 1000 probe performance .................................................................................... 144
PTC 100 probe performance .................................................................................... 144
7.9 Encoders ........................................................................................................................ 145
7.9.1 Technical characteristics of the Lenord+Bauer Square Wave encoder ....................... 146
Signals of the Lenord+Bauer Square Wave encoder ............................................... 146
7.9.2 Technical characteristics of the Lenord+Bauer sine encoder ...................................... 147
Progressive trend of signal A ................................................................................... 148
Temporal trend of signal B ........................................................................................ 148
Displacement of signals A and B .............................................................................. 148
Progressive trend of signal Z .................................................................................... 149

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Temporal trend of the differential signals ................................................................. 150
7.10 Rotary fluid distributor .................................................................................................... 150
8 Maintenance
8.1 Scheduled maintenance ................................................................................................ 152
8.1.1 Check and clean the tool-holder seat and tool-holder cone ........................................ 152
8.1.2 Protect the tool-holder seat ......................................................................................... 153
8.1.3 Drain the pneumatic circuit filters ................................................................................ 153
8.1.4 Clean the tool-holder cone with alcohol ...................................................................... 154
8.1.5 Check the coolant ....................................................................................................... 154
8.1.6 Check the connections ................................................................................................ 154
8.1.7 Lubricate the HSK collet .............................................................................................. 155
8.1.8 Check the functioning of the HSK collet ...................................................................... 155
8.1.9 Replace the coolant .................................................................................................... 156
8.1.10 Replace the pneumatic circuit filters ........................................................................... 156
8.1.11 Bearings ...................................................................................................................... 156
9 Replacing components
9.1 Replacing the shaft kit .................................................................................................... 158
9.2 Replacing the encoder reader ........................................................................................ 168
Models with an HSD square-wave encoder ............................................................. 168
Models with a Lenord-Bauer sinusoidal encoder ..................................................... 168
9.3 Replacing and adjusting the sensors ............................................................................. 169
9.3.1 Identifying and accessing the sensors ........................................................................ 169
Sensor wiring ........................................................................................................... 171
9.3.2 Replacing the sensor unit ............................................................................................ 172
9.3.3 Adjusting sensor S1 for ISO versions ......................................................................... 173
9.3.4 Adjusting sensors S1 and S4 for HSK versions .......................................................... 174
Gauge kit for adjusting HSK sensors S1 and S4 ..................................................... 174
Using the adjustment gauge kit ................................................................................ 176
9.3.5 Adjusting sensor S2 for ISO versions ......................................................................... 177
9.3.6 Adjusting sensor S2 for HSK versions ........................................................................ 178
9.3.7 Adjusting sensor S3 .................................................................................................... 179
9.3.8 Adjusting sensor S4 .................................................................................................... 179
9.3.9 Adjusting sensor S5 .................................................................................................... 179
9.4 HSK collet replacement ................................................................................................. 181
9.4.1 Disassembling the HSK collet from the spindle .......................................................... 181
9.4.2 Assembling the HSK collet in the spindle .................................................................... 182
9.4.3 Check the HSK collet after approximately 100 locking operations .............................. 184
9.4.4 Tightening the lockscrew for the HSK collet ................................................................ 185