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
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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
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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
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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
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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