SCHUNK ROTA FSW User instructions

Chuck quick-change
ROTA FSW
Assembly and Operating Manual
Translation of Original Operating
Manual

Imprint
2 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
Imprint
Copyright:
This manual is protected by copyright. The author is SCHUNK GmbH & Co. KG. All rights
reserved.
Technical changes:
We reserve the right to make alterations for the purpose of technical improvement.
Document number: 1456065
Version: 01.00|05/04/2023|en
Dear Customer,
Thank you for trusting our products and our family-owned company, the leading technology
supplier of robots and production machines.
Our team is always available to answer any questions on this product and other solutions. Ask
us questions and challenge us. We will find a solution!
Best regards,
Your SCHUNK team
Customer Management
Tel. [phone]
Fax [phone]
[e-mail]
Please read the operating manual in full and keep it close to the product.

Table of Contents
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 3
Table of Contents
1 General ............................................................................................. 5
1.1 About this manual............................................................................... 5
1.1.1 Presentation of Warning Labels ..................................................... 5
1.1.2 Applicable documents ................................................................. 6
1.1.3 Sizes........................................................................................ 6
1.2 Warranty ........................................................................................... 6
1.3 Scope of delivery................................................................................. 6
2 Basic safety notes ................................................................................ 7
2.1 Intended use...................................................................................... 7
2.2 Not intended use ................................................................................ 7
2.3 Constructional changes......................................................................... 7
2.4 Spare parts ........................................................................................ 8
2.5 Environmental and operating conditions.................................................. 8
2.6 Personnel qualification ........................................................................ 8
2.7 Personal protective equipment .............................................................. 9
2.8 Notes on safe operation........................................................................ 10
2.9 Transport........................................................................................... 10
2.10 Malfunctions ...................................................................................... 10
2.11 Disposal ............................................................................................ 11
2.12 Fundamental dangers .......................................................................... 11
2.12.1 Protection during handling and assembly ....................................... 11
2.12.2 Protection during commissioning and operation ............................... 12
2.12.3 Protection against dangerous movements ....................................... 12
2.12.4 Notes on particular risks .............................................................. 13
3 Technical data ..................................................................................... 16
3.1 Precision classes ................................................................................. 16
3.2 Permissible imbalance ......................................................................... 16
4 Torques per screw ................................................................................ 17
5 Mounting ........................................................................................... 18
5.1 Installing and connecting ..................................................................... 18
5.2 Checking the spindle nose for mounting the chuck quick-change.................. 19
5.3 Assembly of the ROTA FSW Chuck quick-change .......................................... 20
5.3.1 Assembly of the ROTA FSW Chuck quick-changes with a reducing or
extension flange ........................................................................
20
5.3.2 Assembly of the ROTA FSW Chuck quick-change with a direct mount ...... 21
5.4 Assembly of the flexible adapter to the draw tube/drawbar.......................... 22
5.4.1 Assembling the retainer ring and draw tube adapter to the clamping
device .....................................................................................
23

Table of Contents
4 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
5.5 Assembly of the clamping device and the ROTA FSW chuck quick-change......... 24
6 Function ............................................................................................ 26
6.1 Function of the ROTA FSW Chuck quick-change........................................... 26
6.2 Handling the ROTA FSW Chuck quick-change ............................................. 26
6.3 Functional testing ............................................................................... 28
7 Commissioning .................................................................................... 29
8 Maintenance ....................................................................................... 31
8.1 Lubrication ........................................................................................ 31
8.2 Maintenance instructions...................................................................... 32
8.3 Period of maintenance ......................................................................... 33
8.4 Storing the ROTA FSW Chuck quick-change ................................................ 34
8.5 Disassembling and assembling the ROTA FSW Chuck quick-change ................. 34
9 Spare parts ......................................................................................... 36
10 Assembly drawing ................................................................................ 37

General
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 5
1 General
1.1 About this manual
This manual contains important information for a safe and
appropriate use of the product.
This manual is an integral part of the product and must be kept
accessible for the personnel at all times.
Before starting work, the personnel must have read and
understood this operating manual. Prerequisite for safe working
is the observance of all safety instructions in this manual.
In addition to these instructions, the documents listed
under }1.1.2 [/6] are applicable.
NOTE: The illustrations in this manual are intended to provide a
basic understanding and may deviate from the actual version.
1.1.1 Presentation of Warning Labels
To make risks clear, the following signal words and symbols are
used for safety notes.
DANGER
Dangers for persons!
Non-observance will inevitably cause irreversible injury or death.
WARNING
Dangers for persons!
Non-observance can lead to irreversible injury and even death.
CAUTION
Dangers for persons!
Non-observance can cause minor injuries.
NOTICE
Material damage!
Information about avoiding material damage.

General
6 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
1.1.2 Applicable documents
lGeneral terms of business *
lCatalog data sheet of the purchased product *
lCalculation of the jaw centrifugal forces, "Technology" chapter
in the lathe chuck catalog *
lQuick guide
The documents labeled with an asterisk (*) can be downloaded
from schunk.com.
1.1.3 Sizes
This operating manual applies to the following sizes:
lFSW 220-A8
lFSW 290-A11
lFSW 400-A15
1.2 Warranty
The warranty period is 24 months from works delivery, 250 000
clamping cycles* of the flexible adapter and the draw tube
adapter when used as intended under the following conditions:
lObserve the applicable documents, }1.1.2 [/6]
lObserve the ambient conditions and operating
conditions, }2.5 [/8]
lObserve the specified maintenance and lubrication
intervals, }8 [/31]
Parts touching the workpiece and wear parts are not included in
the warranty.
* A cycle consists of a complete clamping process ("Open" and
"Close").
1.3 Scope of delivery
1 Chuck quick-change ROTA FSW
1 Clamping device and machine-specific attachment
1 Actuation key
1 Eye bolt
1 Assembly tool
1 Assembly and Operating Manual
1 Short operating manual

Basic safety notes
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 7
2 Basic safety notes
2.1 Intended use
The product acts exclusively as an interface between the machine
spindle and clamping device in the machine tool.
lThe product may only be used within the scope of its technical
data, }3 [/16].
lThe product is intended for industrial and industry-oriented
use.
lAppropriate use of the product includes compliance with all
instructions in this manual.
The maximum speed of the design and the maximum actuating
force of the clamped clamping device must be determined by the
operator for each clamping task in accordance with the valid
standards or technical specifications of the manufacturer.
2.2 Not intended use
The product is not being used as intended if, for example,
lthe clamping device is not positioned and clamped properly
in the chuck quick-change.
lthe intended use of the clamping device is ignored. (See the
Assembly and Operating Manual of the respective clamping
device.)
lit is used under working environment conditions that are not
permissible.
lThe technical data for use of the product specified are
exceeded. }3 [/16]
lif the product is used for machines or clamping devices for
which it was not intended.
lif the product is operated without protective equipment.
2.3 Constructional changes
Implementation of structural changes
By conversions, changes, and reworking, e.g. additional threads,
holes, or safety devices can impair the functioning or safety of
the product or damage it.
lStructural changes should only be made with the written
approval of SCHUNK.

Basic safety notes
8 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
2.4 Spare parts
Use of unauthorized spare parts
Using unauthorized spare parts can endanger personnel and
damage the product or cause it to malfunction.
lUse only original spare parts or spares authorized by SCHUNK.
2.5 Environmental and operating conditions
Required ambient conditions and operating conditions
Incorrect ambient and operating conditions can make the
product unsafe, leading to the risk of serious injuries,
considerable material damage and/or a significant reduction to
the product's life span.
lMake sure that the product is used only in the context of its
defined application parameters, }3 [/16].
lMake sure that the product is a sufficient size for the
application.
lOnly use high-quality cooling emulsions with anti-corrosive
additives during processing.
2.6 Personnel qualification
Inadequate qualifications of the personnel
If the personnel working with the product is not sufficiently
qualified, the result may be serious injuries and significant
property damage.
lAll work may only be performed by qualified personnel.
lBefore working with the product, the personnel must have
read and understood the complete assembly and operating
manual.
lObserve the national safety regulations and rules and general
safety instructions.

Basic safety notes
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 9
The following personal qualifications are necessary for the
various activities related to the product:
Trained electrician Due to their technical training, knowledge and experience,
trained electricians are able to work on electrical systems,
recognize and avoid possible dangers and know the relevant
standards and regulations.
Qualified personnel Due to its technical training, knowledge and experience,
qualified personnel is able to perform the delegated tasks,
recognize and avoid possible dangers and knows the relevant
standards and regulations.
Instructed person Instructed persons were instructed by the operator about the
delegated tasks and possible dangers due to improper behaviour.
Service personnel of
the manufacturer
Due to its technical training, knowledge and experience, service
personnel of the manufacturer is able to perform the delegated
tasks and to recognize and avoid possible dangers.
2.7 Personal protective equipment
Use of personal protective equipment
Personal protective equipment serves to protect staff against
danger which may interfere with their health or safety at work.
lWhen working on and with the product, observe the
occupational health and safety regulations and wear the
required personal protective equipment.
lObserve the valid safety and accident prevention regulations.
lWear protective gloves to guard against sharp edges and
corners or rough surfaces.
lWear heat-resistant protective gloves when handling hot
surfaces.
lWear protective gloves and safety goggles when handling
hazardous substances.
lWear close-fitting protective clothing and also wear long hair
in a hairnet when dealing with moving components.

Basic safety notes
10 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
2.8 Notes on safe operation
Incorrect handling of the personnel
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
lAvoid any manner of working that may interfere with the
function and operational safety of the product.
lUse the product as intended.
lObserve the safety notes and assembly instructions.
lDo not expose the product to any corrosive media. This does
not apply to products that are designed for special
environments.
lEliminate any malfunction immediately.
lObserve the care and maintenance instructions.
lObserve the current safety, accident prevention and
environmental protection regulations regarding the product's
application field.
2.9 Transport
Handling during transport
Incorrect handling during transport may impair the product's
safety and cause serious injuries and considerable material
damage.
lWhen handling heavy weights, use lifting equipment to lift
the product and transport it by appropriate means.
lSecure the product against falling during transportation and
handling.
lStand clear of suspended loads.
2.10 Malfunctions
Behavior in case of malfunctions
lImmediately remove the product from operation and report
the malfunction to the responsible departments/persons.
lOrder appropriately trained personnel to rectify the
malfunction.
lDo not recommission the product until the malfunction has
been rectified.
lTest the product after a malfunction to establish whether it
still functions properly and no increased risks have arisen.

Basic safety notes
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 11
2.11 Disposal
Handling of disposal
The incorrect handling of disposal may impair the product's
safety and cause serious injuries as well as considerable material
and environmental harm.
lFollow local regulations on dispatching product components
for recycling or proper disposal.
2.12 Fundamental dangers
General
lObserve safety distances.
lNever deactivate safety devices.
lBefore commissioning the product, take appropriate
protective measures to secure the danger zone.
lDisconnect power sources before installation, modification,
maintenance, or calibration. Ensure that no residual energy
remains in the system.
lIf the energy supply is connected, do not move any parts by
hand.
lDo not reach into the open mechanism or movement area of
the product during operation.
2.12.1 Protection during handling and assembly
Incorrect handling and assembly
Incorrect handling and assembly may impair the product's safety
and cause serious injuries and considerable material damage.
lHave all work carried out by appropriately qualified
personnel.
lFor all work, secure the product against accidental operation.
lObserve the relevant accident prevention rules.
lUse suitable assembly and transport equipment and take
precautions to prevent jamming and crushing.
Incorrect lifting of loads
Falling loads may cause serious injuries and even death.
lStand clear of suspended loads and do not step into their
swiveling range.
lNever move loads without supervision.
lDo not leave suspended loads unattended.

Basic safety notes
12 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
2.12.2 Protection during commissioning and operation
Falling or violently ejected components
Falling and violently ejected components can cause serious
injuries and even death.
lTake appropriate protective measures to secure the danger
zone.
lNever step into the danger zone during operation.
2.12.3 Protection against dangerous movements
Unexpected movements
Residual energy in the system may cause serious injuries while
working with the product.
lSwitch off the energy supply, ensure that no residual energy
remains and secure against inadvertent reactivation.
lNever rely solely on the response of the monitoring function
to avert danger. Until the installed monitors become effective,
it must be assumed that the drive movement is faulty, with its
action being dependent on the control unit and the current
operating condition of the drive. Perform maintenance work,
modifications, and attachments outside the danger zone
defined by the movement range.
lTo avoid accidents and/or material damage, human access to
the movement range of the machine must be restricted. Limit/
prevent accidental access for people in this area due through
technical safety measures. The protective cover and protective
fence must be rigid enough to withstand the maximum
possible movement energy. EMERGENCY STOP switches must be
easily and quickly accessible. Before starting up the machine
or automated system, check that the EMERGENCY STOP system
is working. Prevent operation of the machine if this protective
equipment does not function correctly.

Basic safety notes
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 13
2.12.4 Notes on particular risks
DANGER
Possible risk of fatal injury to operating personnel if a jaw
breaks or if the ROTA FSW chuck quick-change or the clamping
device fails because the technical data has been exceeded and
a workpiece is released or parts fly off.
lThe technical data specified by the manufacturer for using
the ROTA FSW chuck quick-change must never be exceeded.
lThe ROTA FSW chuck quick-change may only be used on
machines and equipment that fulfill the minimum
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
possible mechanical hazards.
DANGER
Possible risk of fatal injury to operating personnel due to ROTA
FSW chuck quick-change failure if the maintenance and
servicing instructions for the ROTA FSW chuck quick-change and
the toolholder are disregarded!
lThe servicing instructions specified by the manufacturer must
be complied with to ensure safe operation of the ROTA FSW
chuck quick-change.
lWork must be carried out by qualified specialist personnel
with the relevant safety training.
DANGER
Possible risk of fatal injury to operating personnel from
clothing or hair being caught on the ROTA FSW chuck quick-
change and/or clamping device and being dragged into the
machine.
Loose clothing or long hair may become caught on projecting
parts of the ROTA FSW chuck quick-change or clamping device
and be drawn into the machine.
lThe machines and equipment must fulfill the minimum
requirements of the EC Machinery Directive; specifically, they
must have effective technical measures to protect against
potential mechanical hazards.
lAlways wear tight-fitting clothing and a hairnet when
working on the machine and the ROTA FSW chuck quick-
change or clamping device.

Basic safety notes
14 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
WARNING
Risk of injury due to dropping the ROTA FSW chuck quick-
change during transport, installation or removal
lTake special care in the danger zone when transporting,
installing or removing the ROTA FSW chuck quick-change or
clamping device.
lNote the relevant load securing regulations for working safely
with cranes, ground conveyors, lifting gear and load-
handling equipment.
CAUTION
Risk of slipping or falling if the ROTA FSW chuck quick-change's
operational environment is not clean (e.g. contaminated with
cooling lubricants or oil).
lEnsure that the working environment is clean before starting
assembly and installation work.
lWear suitable safety boots.
lFollow the safety and accident-prevention regulations when
operating the ROTA FSW chuck quick-change, especially when
working with machine tools and other technical equipment.
CAUTION
Danger of limbs being crushed when manually attaching the
ROTA FSW chuck quick-change and assembling and dismantling
the clamping device.
lUse a crane to install the ROTA FSW chuck quick-change and
clamping device.
lWear personal protective equipment.
lDo not reach between the spindle nose and the ROTA FSW
chuck quick-change.
lDo not reach between the ROTA FSW chuck quick-change and
clamping device.
lFollow the safety and accident-prevention regulations when
operating the ROTA FSW chuck quick-change, especially when
working with machine tools and other technical equipment.

Basic safety notes
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 15
CAUTION
Risk of burns due to workpieces with high temperatures.
lWear protective gloves when removing the workpieces and
the clamping device.
lAutomatic loading of workpieces and clamping devices is to
be preferred.
CAUTION
Danger of damage due to incorrectly set clamping positions of
the clamping slides when changing the clamping devices.
If an incorrect clamping position is chosen for the clamping slides
relative to the clamping device, the ROTA FSW chuck quick-
change and clamping device may be damaged.
lEnsure that the clamping slides are locked/unlocked securely
before or after changing the clamping devices with the ROTA
FSW chuck quick-change.
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.
lEnsure that the ROTA FSW chuck quick-change and the
clamped clamping device run true, both radially and axially.
lCheck options for remedying imbalances on special top jaws
on the clamping device and workpieces.
lReduce the speed.
lWear hearing protection.

Technical data
16 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
3 Technical data
Type ROTA FSW 220-A8 290-A11 400-A15
ID 1455788 1455789 1455800
Tightening torque [Nm] 100 150 200
Max. actuating force [kN] 70 133 140
Max. speed of rotation [RPM] 6000 4200 3500
Weight without adapter [kg] 10 20 51
Operating temperature [°C] 15 - 60
Maximum number of clamping cycles of the flexible
adapter and the draw tube adapter
250,000
Maximum number of clamping device changes of
the flexible adapter and the draw tube adapter
5,000
The maximum permissible actuating force and the maximum
permissible RPM for special machining must be calculated by the
user based on the permitted data of the chuck quick-change
ROTA FSW and the mounted clamping device or toolholder.
3.1 Precision classes
Tolerances for axial and radial run-out accuracy correspond to
the Technical Supply Terms per DIN ISO 3089.
3.2 Permissible imbalance
The ROTA FSW/bayonet in ungreased state without an installed
lathe chuck corresponds to balancing grade 6.3 (according to DIN
ISO 21940-1). Residual imbalance risks may arise due to
insufficient rotation compensation being achieved (see DIN EN
1550 6.2 e). This applies in particular to high speeds of rotation,
asymmetrical workpieces or the use of lathe chucks that do not
correspond to balancing grade 6.3, as well as uneven lubricant
application. In order to prevent damage resulting from these
residual risks, the entire rotor is to be dynamically balanced in
accordance with DIN ISO 21940-1.

Torques per screw
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 17
4 Torques per screw
Tightening torques for mounting screws used to clamp the ROTA
FSW Chuck quick-change 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

Mounting
18 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
5 Mounting
5.1 Installing and connecting
WARNING
Risk of injury due to unexpected movements!
If the power supply is switched on or residual energy remains in
the system, components can move unexpectedly and cause
serious injuries.
lBefore starting any work on the product: Switch off the power
supply and secure against restarting.
lEnsure that no residual energy remains in the system.
CAUTION
Danger of injury due to sharp edges and rough or slippery
surfaces
lWear personal protective equipment, particularly protective
gloves.
1. Checking the holder of the ROTA FSW or the intermediate
flange }5.2 [/19]
2. Assembly of the ROTA FSW chuck quick-change }5 [/18]
3. Performing a functional check }6.3 [/28]

Mounting
01.00 | ROTA FSW | Chuck quick-change | en | 1456065 19
5.2 Checking the spindle nose for mounting the chuck
quick-change
For high run-out accuracy of the ROTA FSW chuck quick-change or
the substituted-in clamping device, the machine side must be
aligned before assembly of the ROTA FSW chuck quick-change or
the intermediate flange. To do this, check the contact surfaces on
the spindle for axial and concentric run-out using a dial
indicator (see Fig. "Assembly of the chuck quick-change or
intermediate flange" - A).
There should be a maximum concentricity error in the centering
of the mount of 0.005 mm and a maximum axial run-out error
in the contact surfaces of 0.005 mm. The flat surface of the
spindle must also be checked for flatness using a straight edge.
Make sure that the surface area of the flat surface is chamfered
at the bore holes and is clean.
Assembly of the chuck quick-change or intermediate flange

Mounting
20 01.00 | ROTA FSW | Chuck quick-change | en | 1456065
5.3 Assembly of the ROTA FSW Chuck quick-change
5.3.1 Assembly of the ROTA FSW Chuck quick-changes with a
reducing or extension flange
(Figure "Assembly of the chuck quick-change or intermediate
flange" see chapter "Checking the spindle nose of the holder of
the chuck quick-change" }5.2 [/19])
If the ROTA FSW chuck quick-change is screwed on with an
intermediate flange, the following points must be observed:
lTo mount the ROTA FSW chuck quick-change with a reducing
or extension flange on the machine spindle with a short
taper, a corresponding intermediate flange is fastened to the
spindle nose.
lBefore assembly of the intermediate flange, remove any dirt
or chips from the machine spindle and from the centering
mount and contact surface of the flange.
lAn intermediate flange produced by the user must be fully
machined on the machine spindle and balanced and aligned
before assembly of the ROTA FSW chuck quick-change.
lAfter assembly, ensure that the flange is in contact with the
entire surface.
lThen, as described in chapter "Checking the spindle nose of
the holder of the chuck quick-change" }5.2 [/19], check the
radial and axial runout (see fig. "Assembly of the chuck
quick-change or the intermediate flange" – B)
After aligning the intermediate flange, the ROTA FSW chuck
quick-change is assembled. Remove any impurities on the
intermediate flange and the contact surfaces of the ROTA FSW
chuck quick-change.
WARNING
Risk of injury if the ROTA FSW chuck quick-change falls during
transport or assembly.
lUse a crane to assemble the ROTA FSW chuck quick-change.
This can be fastened on the eye bolt provided (see Fig. 2
"Assembly of the chuck quick-change or intermediate flange"
– C). The eye bolt is included in the scope of delivery.
Before commissioning the chuck quick-change ROTA FSW, the
eye bolt on the circumference must be removed.