SCHUNK HSA Series User instructions

Translation of Original Operating Manual
Special chuck HSA 2-jaw chuck / 3-jaw chuck
HSA 160 (88001862, 88021732, 88029313, 88035481, 88037348, 88039738, 88036995)
HSA 160/2 (88026206, 88029240, 88036160, 88041389)
HSA-NZ 170/2 (88027365)
HSA 180/2 (88036423)
HSA 200 (88002843, 88002909, 88002958, 88004159, 88018669, 88020485, 88026696, 88028474,
88028566, 88039479, 88039429)
HSA 250 (88018463, 88018469, 88019551)
HSA 250/2 (88028004, 88034564)
HSA 265 (88003413, 88003473)
HSA 315 (88037992, 88040302)
HSA 315/2 (88029693)
HSA 400 (88026570)
HSA 630/2 (88019966)
Assembly and Operating Manual
Superior Clamping and Gripping

Imprint
2
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Imprint
Copyright:
This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely
supplied to our customers and operators of our products and forms part of the product.
This documentation may not be duplicated or made accessible to third parties, in particu-
lar competitive companies,
without our prior permission.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 88040302-en
Edition: 02.00 |22/02/2016|en
© SCHUNK GmbH & Co. KG
All rights reserved.
Dear customer,
congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for
the highest precision, top quality and best service.
You are going to increase the process reliability of your production and achieve best
machining results –to the customer's complete satisfaction.
SCHUNK products are inspiring.
Our detailed assembly and operation manual will support you.
Do you have further questions? You may contact us at any time –even after purchase.
Kindest Regards
Your H.-D. SCHUNK GmbH & Co.
Spanntechnik KG
Lothringer Str. 23
D-88512 Mengen
Tel. [phone]
Fax [phone]
[email protected]
www.schunk.com

Table of contents
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3
Table of contents
1
General .................................................................................................................... 4
1.1
Warnings................................................................................................................... 4
1.2
Applicable documents .............................................................................................. 5
2
Basic safety notes..................................................................................................... 6
2.1
Intended use............................................................................................................. 6
2.2
Not intended use...................................................................................................... 6
2.3
Notes on particular risks........................................................................................... 7
2.4
Notes on safe operation......................................................................................... 10
2.4.1
Substantial modifications............................................................................ 13
2.5
Personnel qualification........................................................................................... 13
2.6
Organizational measures........................................................................................ 13
2.7
Using personal protective equipment.................................................................... 14
2.8
2-jaw chuck............................................................................................................. 14
3
Warranty................................................................................................................. 15
4
Torques per screw ................................................................................................... 15
5
Scope of delivery ..................................................................................................... 16
6
Technical data ......................................................................................................... 17
6.1
Calculation of the clamping force based on the speed:......................................... 17
6.2
Grades of Accuracy................................................................................................. 18
6.3
Permissible imbalance............................................................................................ 18
7
Assembly................................................................................................................. 19
7.1
Pre-assembly measures.......................................................................................... 19
7.2
Assembly of the HSA chuck .................................................................................... 19
8
Chuck function ........................................................................................................ 22
8.1
Functional principle................................................................................................ 22
8.2
Replacement or renewal of jaws............................................................................ 23
8.3
Disassembly and assembly of the Chuck................................................................ 23
9
Maintenance ........................................................................................................... 26
9.1
Lubrication.............................................................................................................. 26
9.2
Maintenance intervals............................................................................................ 26
9.3
Changing the top jaws ............................................................................................ 26
10
Disposal .................................................................................................................. 27
11
Parts lists................................................................................................................. 28
12
Drawings ................................................................................................................. 30

General
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General
This operating manual is an integral component of the product and
contains important information on safe and proper assembly,
commissioning, operation, care, maintenance and disposal. This
manual must be stored in the immediate vicinity of the product
where it is accessible to all users at all times.
Before using the product, read and comply with this manual,
especially the chapter “Basic safety notes”.(2, Page 6)
If the product is passed on to a third party, these instructions must
also be passed on.
Illustrations in this manual are provided for basic understanding of
the product and may differ from the actual product design.
We accept no liability for damage resulting from the failure to
observe and comply with this operating manual.
Warnings
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Danger for persons.
Non-compliance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons.
Ignoring a safety note like this can lead to irreversible injury and
even death.
CAUTION
Dangers for persons.
Non-observance can cause minor injuries.
1
1.1

General
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5
NOTICE
Material damage
Information about avoiding material damage.
WARNING
Warning about hand injuries
WARNING
Warning about hot surfaces
Applicable documents
General terms of business
Calculation of the jaw centrifugal forces
("Technology" chapter in the lathe chuck catalog)
The above mentioned documents can be downloaded at
www.de.schunk.com.
1.2

Basic safety notes
6
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Basic safety notes
Improper handling, assembly and maintenance of this product may
result in risk to persons and equipment if this operating manual is
not observed.
Report any failures and damage immediately and repair without
delay to keep the extent of the damage to a minimum and prevent
compromising the safety of the product.
Only use original SCHUNK spare parts.
Intended use
The chuck is used to clamp workpieces on machine tools and other
suitable technical facilities, paying particular attention to the
technical data specified by the manufacturer. The technical data
specified by the manufacturer must never be exceeded.
The product is intended for industrial use.
Intended use also means that the user has read and understood
this operating manual in its entirety, especially the chapter “Basic
safety notes”.
The maximum RPM of the chuck and the required clamping force
must be determined by the user for the respective clamping task
based on the applicable standards and technical specifications of
the manufacturer.
(See also “Calculations for clamping force and RPM” in the chapter
“Technical data”). (6, Page 17)
Not intended use
The product is not being used as intended if, for example,
•It is used as a press, a punch, a chuck, a load-handling device or
as lifting equipment.
•It is used in working environments that are not permissible.
•Workpieces are not clamped properly, paying particular
attention to the clamping forces specified by the manufacturer.
•People work on machines or technical equipment that do
not comply with the EC Machinery Directive 2006/42/EC,
in violation of the applicable safety regulations.
2
2.1
2.2

Basic safety notes
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7
•The technical data for use of the product specified by the
manufacturer are exceeded.
Notes on particular risks
This product may pose a danger to persons and property if, for
example:
•It is not used as intended;
•It is not installed or maintained properly;
•The safety and installation instructions, local applicable
safety and accident prevention regulations or the EC Machinery
Directive are not observed.
DANGER
Possible risk of fatal injury to operating personnel due to the
workpiece falling down or being flung out in the event of a
power failure!
In the event of a power failure, the chuck's clamping force may
fail immediately and the workpiece may be released in an
uncontrolled manner. This poses a risk of death or injury to
the operating personnel and can result in serious damage to the
system.
•Due to the carried out and documented danger assessment
and risk evaluation, the machine manufacturer and its
operator have to ensure that appropriate measures have
been taken in order to maintain the clamping force of the
chuck until the machine's standstill, and to secure the
workpiece correspondingly (e.g. via a crane or a suitable
hoist).
•The machines and facilities must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against possible mechanical hazards.
2.3

Basic safety notes
8
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DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the chuck fails because the technical data have been
exceeded and a workpiece is released or parts fly off!
•The technical data specified by the manufacturer for using the
chuck must never be exceeded.
•The chuck may only be used on machines and facilities that
fulfill the minimum requirements of the EC Machinery
Directive 2006/42/EC; specifically, they must have effective
technical measures to protect against possible mechanical
hazards.
DANGER
Possible risk of fatal injury to operating personnel from clothing
or hair being caught on the chuck and being dragged into the
machine
Loose clothing or long hair may become caught on projecting
parts of the chuck and be drawn into the machine.
•The machines and facilities must fulfill the minimum
requirements of the EC Machinery Directive 2006/42/EC;
specifically, they must have effective technical measures to
protect against possible mechanical hazards.
•Always wear tight-fitting clothing and a hairnet when working
on the machine and the chuck.
WARNING
Risk of injury due to dropping the chuck during transport,
installation or removal.
•Take special care in the danger zone when transporting,
installing or removing the chuck.
•Note the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-handling
equipment.

Basic safety notes
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9
CAUTION
Danger of slipping and falling in case of dirty environment
where the chuck is used (e.g. by cooling lubricants or oil).
•Make sure the work environment is clean before beginning
assembly and installation tasks.
•Wear suitable safety shoes.
•Observe the safety and accident prevention regulations
during operation of the chuck, especially in connection with
machining centers and other technical equipment.
CAUTION
Danger of limbs being crushed by opening and closing of the
chuck jaws during manual loading and unloading or when
replacing moving parts.
•Do not reach between the jaws.
•Wear safety gloves.
•Observe the safety and accident prevention regulations
during operation of the chuck, especially in connection with
machining centers and other technical equipment.
CAUTION
Risk of burns due to workpieces with high temperatures.
•Wear protective gloves when removing the workpieces.
•Automatic loading is preferred.
CAUTION
Risk of damages due to incorrect choice of clamping position for
chuck jaws on workpiece.
If an incorrect clamping position is chosen for the chuck jaws on
workpiece, the base and the top jaws may be damaged.
•The T-nuts combine the top jaws with the base jaws and they
should never protude over the base jaws in radial direction.
•The outer diameter of the screwed top jaws must not exceed
the outer diameter of the chuck by more than 10%.

Basic safety notes
10
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CAUTION
Hazard from vibration due to imbalanced rotating parts and
noise generation.
Physical and mental strains due to imbalanced workpieces and
noise during the machining process on the clamped and rotating
workpiece.
•Ensure the chuck's axial and concentric runout.
•Check options for remedying imbalances on special top jaws
and workpieces.
•Reduce the speed.
•Wear hearing protection.
Notes on safe operation
•The machine spindle may only be started up when clamping
pressure has built up in the cylinder and clamping has followed
in the permitted work area.
•Unclamping may only be possible when the machine spindle
has come to a standstill.
•If the clamping energy fails, the workpiece must remain firmly
clamped until the spindle is shut down and the workpiece is
secured.
•The technical safety requirements in the respective operating
instructions must be observed exactly.
Functional test
After installation of the chuck, its function must be checked prior
to start-up.
Two important points are:
•Clamping Force! The clamping force of the chuck must be
achieved at max. operating force/pressure.
•Stroke control! The stroke of the clamping piston must allow a
safety zone at the front and rear end position. The machine
spindle may only be started when the clamping piston has
passed through the safety zone. Only limit switches that meet
the requirements for safety limit switches specified in DIN EN
60204-1 may be used.
2.4

Basic safety notes
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11
When determining the necessary clamping force to machine a
workpiece, take the centrifugal force acting on the chuck jaws into
account (according to VDI 3106).
If the chuck jaws are changed, adjust the stroke control to the new
situation.
Speed
DANGER
Possible risk of fatal injury to operating personnel if the chuck's
top speed is exceeded and a workpiece is released or parts fly
off.
If the machine tool or technical equipment can reach a higher
speed than the chuck's top speed, a reliable speed limiter must
be installed and proof must be provided that the speed limiter is
effective.
Maintenance instructions
The chuck's reliability and safety can only be guaranteed if the
operator complies with the manufacturer's maintenance
instructions.
•For lubrication, we recommend our tried and tested special
grease, LINO MAX. Unsuitable lubricants can have a negative
impact on the functioning of the chuck (clamping force,
coefficient of friction, wear characteristics).
(For product information about LINO MAX, see the
"Accessories" chapter of the SCHUNK lathe chuck catalog
or contact SCHUNK).
•Use a suitable high-pressure grease gun to ensure that you
reach all the greasing areas.
•To ensure correct distribution of the grease, move the clamping
piston to its end positions several times, lubricate again, and
then check the clamping force.
•We recommend checking the clamping force using a clamping
force tester before starting a new production run and between
maintenance intervals. "Only regular checks can guarantee
optimal safety."
•The clamping force should always be measured in the state of
the chuck as used for the current clamping situation. If top jaws
with clamping steps are used, measuring must be performed in
the same step as for the respective clamping task. In the event
of high operating speeds, clamping force losses must be

Basic safety notes
12
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accounted for due to the centrifugal force acting on the
chuck jaws. The operating clamping force must in this case be
determined by means of dynamic measurement.
•Move the clamping piston through to its end position several
times after 500 clamping strokes, at the latest. (This moves the
lubricant back to the surfaces of the force transmission. This
means that the clamping force is retained for longer).
Safety notes for servicing
Follow all the applicable legal norms for health and safety during
servicing. Use suitable personal protective equipment, especially
protective gloves, goggles and safety boots, paying particular
attention to the operating system and hazard assessment.
DANGER
Possible risk of fatal injury to operating personnel due to
chuck failure if the servicing instructions for the chuck are
disregarded!
The servicing instructions specified by the manufacturer must be
complied with to ensure safe operation of the chuck.
Work must be carried out by qualified specialist personnel with
the relevant safety training.
Use of special chuck jaws
When using special chuck jaws, please observe the following rules:
•The chuck jaws should be designed to be as light and as low as
possible. The clamping point must be as close as possible to the
chuck face (clamping points at a greater distance lead to great-
er surface pressure in the jaw guidance and can significantly
reduce the clamping force).
•Do not use welded jaws.
•If for constructional reasons the chuck jaws in special design
are heavier than the top jaws assigned to the clamping device,
greater centrifugal forces must be accounted for when defining
the required clamping force and the recommended speed.
•Screw the jaw mounting screws into the bore holes furthest
apart.

Basic safety notes
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13
•The maximum recommended speed may only be operated in
conjunction with maximum actuating force and only with the
chuck in optimal, fully functioning condition.
•If the chuck is involved in a collision, it must be subjected to a
crack test before using it again. Replace damaged parts with
original SCHUNK spare parts.
•Replace the chuck jaw mounting screws if there are signs of
wear or damage. Only use screws with a quality of 12.9.
Substantial modifications
No substantial modifications may be made to the chuck.
If the operator carries out a substantial modification to the
chuck, the product shall no longer conform to the EC Machinery
Directive 2006/42/EC.
Personnel qualification
Assembly and disassembly, commissioning, operation and repair of
the chuck may be performed only by qualified specialists who have
been instructed with respect to safety.
All persons who are assigned to operate, maintain and repair our
chuck must have access to the operating manual, especially the
chapter “Fundamental safety instructions”. We recommend that
the operator create in-house safety operating instructions.
Persons in training may be assigned to machines and technical
equipment in which a chuck is mounted only if they are under the
constant guidance and supervision of qualified specialists.
Organizational measures
Obeying the rules
Via suitable organizational measures and instructions, the
operator must ensure that the relevant safety rules are obeyed
by the persons asked to operate, maintain and repair the chuck.
2.4.1
2.5
2.6

Basic safety notes
14
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Checking the behavior of personnel
The operator must at least occasionally check that the personnel
are behaving in a safety conscious manner and are aware of the
potential hazards.
Danger signs
The operator must ensure that the signs concerning safety and
hazards mounted on the machine where the chuck is mounted are
clearly legible and are observed.
Faults
If a fault occurs on the chuck and this fault endangers safety or if
a problem is suspected due to production characteristics, the
machine tool where the chuck is mounted must be immediately
stopped and remain shut down until the fault has been located
and remedied. Only allow specialists to remedy faults.
Spare parts
Only ever use original SCHUNK spare parts.
Environmental regulations
Comply with the applicable legal norms when disposing of waste.
Using personal protective equipment
When using this product, you must comply with the relevant
health and safety at work rules and you must use the required
personal safety equipment (minimum: category 2).
2-jaw chuck
The values for the total clamping force, recommended speed and
actuating force are embossed on the chuck body.
The base jaws are aligned in the front stroke position. The top jaws
only align after 10 mm of piston stroke.
Only parts that are flat in the clamping direction or on which
compensation is only expected in the jaw guidance direction can
be clamped.
2.7
2.8

Warranty / Torques per screw
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15
Warranty
If the product is used as intended, the warranty is valid for
12 months from the date of delivery from the production facility
under the following conditions:
•Observe the applicable documents (1.2, Page 5)
•Observe the environmental and operating conditions.
•Observation of the maximum clamping cycles(6, Page 17)
•Observe the mandatory maintenance and lubrication
intervals.(9, Page 26)
Parts touching the work piece and wearing parts are not part of
the warranty.
Torques per screw
Tightening torques for mounting screws used to clamp the
chuck on lathes or other suitable technical equipment
(screw quality 10.9)
Screw size
M6
M8
M10
M12
M14
M16
M18
M20
M22
M24
M27
M30
Admissible torque
MA(Nm)
13
28
50
88
120
160
200
290
400
500
1050
1500
Tightening torques for mounting screws used to attach top jaws
onto the chuck (screw quality 12.9)
Screw size
M6
M8
M10
M12
M14
M16
M20
M24
Torque MA(Nm)
16
30
50
70
130
150
220
450
3
4

Scope of delivery
16
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Scope of delivery
1
HSA power chuck in the version ordered
HSA 160
(Id-No. 88001862, 88021732, 88029313, 88035481, 88037348,
88039738, 88036995)
HSA 160 –2-jaw chuck
(Id-No. 88026206, 88029240, 88036160, 88041389)
HSA-NZ 170 –2-jaw chuck
(Id-No. 88027365)
HSA 180 –2-jaw chuck
(Id-No. 88036423)
HSA 200
(Id-No. 88002843, 88002909, 88002958, 88004159, 88018669,
88020485, 88026696, 88028474, 88028566, 88039479, 88039429)
HSA 250
(Id-No. 88018463, 88018469, 88019551)
HSA 250 –2-jaw chuck
(Id-No. 88028004, 88034564)
HSA 265
(Id-No. 88003413, 88003473)
HSA 315
(Id-No. 88037992, 88040302)
HSA 315 –2-jaw chuck
(Id-No. 88029693)
HSA 400
(Id-No. 88026570)
HSA 630 –2-jaw chuck
(Id-No. 88019966)
1
Intermediate flange (Item 10)
Fastening screws –Chuck on mounting and mounting on spindle.
HSA 160, HSA 160/2, 200, 250, 315, 400 and 630/2:
T-nuts with screws, or groove combinations with 2 screws
(Item 14)
4
1
HSA-NZ 170, HSA 180/2:
Screws for mounting
Set of top jaws
2
HSA 315/2:
Screws DIN EN ISO 4762 (for mounting the top jaws)
1
Operating manual
5

Technical data
01.00| |en
17
Technical data
For the technical data for the chucks, refer to the enclosed
drawings.
Balancing:
The HSA chuck is balanced in accordance with DIN ISO 1940.
For balancing, a balancing grade of G 6.3 is selected and the mass
and maximum recommended speed of the chuck are used as
reference values. It applies to self-centering clamping using the
bushing.
Warranty and maximum clamping cycles
Length of warranty
12 Months
Maximum clamping cycle number
300 000 Cycles
Calculation of the clamping force based on the speed:
ΣS = a · F ± 0.00001096 · (M · r + K) · n2
Total clamping force = Static clamping force ± Loss of centrifugal
force
The loss of centrifugal force must not exceed 50% of the static
clamping force.
±:
Minus (–) applies to O.D. clamping and plus (+) to I.D. clamping
ΣS:
Total clamping force in N
M:
Mass of all top jaws with T-nuts and screws in kg
r:
Distance from chuck center to center of gravity of top jaws
in mm
K:
K =
K =
K =
K =
K =
K =
K =
K =
K =
K =
K =
K =
Constant for the base jaw
3077.0 on HSA 630/2
460.2 on HSA 400
630.0 on HSA 315
646.0 on HSA 315/2
401.2 on HSA 265
293.8 on HSA 250
196.0 on HSA 250/2
84.2 on HSA 200
83 on HSA 180/2
46.6 on HSA-NZ 170/2
69.5 on HSA 160
46.3 on HSA 160/2
6
6.1

Technical data
18
01.00| |en
F:
Actuating force in N
n:
Speed in rpm
a:
Static chuck constant:
1.94 on HSA-NZ 170
2.00 on HSA 160, 180/2, HSA 200
2.40 on HSA 265, HSA 250, HSA 250/2, HSA 400
2.30 on HSA 315
2.50 on HSA 315/2
Maximum distance from front face of chuck to center of
workpiece (reach):
HSA 160:
HSA 160/2:
HSA-NZ 170/2:
HSA 180/2:
HSA 200:
HSA 250:
HSA 250/2:
HSA 265:
HSA 315:
HSA 315/2:
HSA 400:
HSA 630/2:
30 mm
30 mm
35 mm
35 mm
46 mm
46 mm
46 mm
46 mm
55 mm
55 mm
75 mm
100 mm
(Greater jaw distances after consultation with clamping
technology technical sales team)
Grades of Accuracy
Tolerances for run-out accuracy and axial run-out accuracy
correspond to the Technical Supply Terms for lathe chucks as
per DIN ISO 3089.
Permissible imbalance
The permissible imbalance for lathe chucks is quality class
G 6.3 as per DIN ISO 1940-1.
6.2
6.3

Assembly
01.00| |en
19
Assembly
The specified item numbers for the corresponding individual
components relate to the enclosed drawings or to the Drawings
chapter (12, Page 30).
Pre-assembly measures
Carefully lift the product (e.g. using suitable lifting gear) from the
packaging.
CAUTION
Danger of injury due to sharp edges and rough or slippery
surfaces
Use personal protective gear, especially safety gloves.
Check the delivery for completeness and for transport damage.
Assembly of the HSA chuck
•Check the machine spindle nose and ready-machined inter-
mediate flange for radial and axial run-out. The permissible
limit is 0.005 mm in accordance with DIN 6386 and ISO 3089.
•The contact surface must be chamfered and completely clean
at the bore holes.
•Unscrew the cylindrical screws (Item 18) and remove the guide
bushing (Item 4, 11, or 13).
•Actuate the clamping cylinder to slide the draw tube to the
front position (see illustration: "Mounting the chuck")
HSA 160, 160/2, NZ 170/2, 180/2, 200, 250, 250/2, 265, 315,
315/2 and 400:
•Screw the intermediate flange (Item 10) onto the spindle using
the screws (Item 19).
•Move the guide part (Item 5) to the front position.
•Raise the chuck in front of the spindle lug using an assembly
belt or eye bolt until it is flush with the center of the spindle.
7
7.1
7.2

Assembly
20
01.00| |en
•Screw the power chuck onto the draw tube as far as it will go.
(Make sure that the draw tube thread is flush.)
The HSA 160,160/2, HSA-NZ 170/2,180/2, HSA 250, HSA 250/2
and HSA 400 is screwed onto the draw bar using the screw
(Item 15). (The screw must also be flush with the draw bar
thread.
•The chuck is screwed onto the intermediate flange (spindle)
using the screws (Item 17).
The run-out can be aligned as follows: Slightly loosen the
screws (Item 17). Fit a dial gauge on the cylindrical surface of
the chuck body (Item 1). Align the run-out using the set-screws
(Item 23). Tighten the screws (Item 17) alternately.
HSA 630/2:
•Lift the chuck with the flange screwed on (Item 10) in front of
the spindle lug using an eye bolt until it is flush with the center
of the spindle. The bore holes for the screws (Item 17) should
be flush with the threaded holes in the spindle.
•Screw onto the draw bar using the screw (Item 15). (The screw
(Item 17) must also be flush with the draw rod thread.)
•Slightly tighten the screws (Item 17) alternately. Also slightly
tighten the screws (Item 19).
•The run-out can be aligned as follows: Place a dial gauge on
the cylindrical surface of the chuck body (Item 1). Adjust the
set-screws (Item 23) to align the run-out. Securely tighten
the screws (Item 17 and 19) alternately.
Tighten the fastening screws, quality class 10.9, using a torque
wrench. (See "Screw tightening torques" chapter (4, Page 15)).
On no account tighten the Allen key with an extension pipe or
with hammer blows.
All HSA chuck types:
•Fit the guide bushing for the compensating clamping (Item 4)
or self-centering clamping (Item 13) using the screws (Item 18).