Operating Instructions

2SP1 spindle units

© 2007

Edition 01/07
Operating Instructions for Spindle Units Type 2SP1… 0

Table of Contents
1 WARNING AND SAFETY INFORMATION 1
1.1 GENERAL 1
1.2 DISCLAIMER OF LIABILITY 1
1.3 CORRECT USE 1
1.4 ORGANIZATIONAL INFORMATION 1
1.5 WORKING ON THE SYSTEM 2
1.6 SPECIFIC HAZARDS AND DANGERS 3
2 DESIGN AND FUNCTION 4
2.1 BEARING DESIGN 4
2.2 LUBRICATION 4
2.3 SEAL 4
2.4 DRIVE 4
2.5 MOTOR COOLING 5
2.6 TOOLS 5
2.7 TOOL CLAMPING SYSTEM 7
2.8 TOOL RELEASE UNIT 7
2.9 CLAMPING STATE SENSING 8
2.10 INNER TOOL COOLING USING A COOLING-LUBRICATING MEDIUM (OPTION) 9
2.11 EXTERNAL TOOL COOLING WITH COOLING-LUBRICATING MEDIUM 9
2.12 TOOL AIR PURGE SYSTEM 9
3 INSTALLING AND OPERATING THE SPINDLE 11
3.1 POWER-ON CONDITIONS 12
3.2 POWER-ON PROCEDURE 15
3.3 POWER-OFF PROCEDURE 15
4 FAULTS IN OPERATION 16
5 MAINTENANCE INFORMATION 17
5.1 MAINTENANCE SCHEDULE 17
5.2 PARTS SUBJECT TO WEAR 17
5.3 STORING THE SPINDLE IN THE MAGAZINE 17
6 TECHNICAL DATA 18
6.1 POWER CONNECTION 18
6.2 SEALING AIR 18
6.3 MOTOR COOLING 19
6.4 TOOL RELEASE UNIT 19
6.5 INNER TOOL COOLING USING A COOLING-LUBRICATING MEDIUM (OPTION) 20
6.6 EXTERNAL TOOL COOLING WITH COOLING-LUBRICATING MEDIUM (OPTION FOR
2SP120...) 20
6.7 TOOL AIR PURGE SYSTEM 20
6.8 CLAMPING STATE SENSING 21
6.9 ROTARY ENCODER, MOTOR MEASURING SYSTEM 22
6.10 STORAGE TEMPERATURE MONITORING PT100 (OPTION FOR 2SP120...) 23
6.11 TOOL INTERFACES 23
6.12 TOOL INTERFACES 24
7 TOOL CLAMPING SYSTEMS 26
7.1 SAFETY INFORMATION 26
7.2 PRODUCT DESCRIPTION, TOOL CLAMPING SYSTEM HSK-A63 TYPE K 27
7.3 PRODUCT DESCRIPTION OF HOLDING CLAMPING SET HSK A63-TYPE C 37
7.4 PRODUCT DESCRIPTION, TOOL CLAMPING SYSTEM SK 40 47
8 ROTARY GLAND (OPTIONAL) 53
8.1 REPLACING THE ROTARY GLAND 53
8.2 MAINTAINING THE ROTARY GLAND 54
9 APPENDIX 54
Operating Instructions for Spindle Units Type 2SP1… 1

1 WARNING AND SAFETY INFORMATION

1.1 GENERAL
Faults at the motor spindle can only be avoided and disturbance-free operation secured by
being knowledgeable about the information in these Operation Instructions. This is the
reason that it is extremely important that all of the relevant personnel clearly understand
these Operating Instructions.
These Operating Instructions address personnel involved with the installation, operation
and monitoring of the equipment. These Operating Instructions include regulations and
technical drawings that may neither be completely nor partially copied, communicated or
passed-on for competitive purposes. The WEISS company has the exclusive copyrights for
these Operating Instructions.
The operator is responsible for immediately reporting any changes that occur relating to
the spindle unit that could have a potential negative impact on the safety.
Users and operating companies are responsible in ensuring that the spindle unit is only
operated when it is in a perfect condition.
It is expressly prohibited to make any modifications and changes that could influence the
safety of the spindle unit.
The local safety and accident prevention regulations always apply when operating the
spindle unit.
1.2 DISCLAIMER OF LIABILITY
The contents of this document have been checked. However, deviations cannot be
completely ruled-out so that we cannot accept any liability for the information contained in
the document and that it is absolutely correct. Data in this document is reviewed regularly
and any necessary corrections will be included in the following Edition. We are grateful for
any recommendations for improvement.

Technical data subject to change.

1.3 CORRECT USE
The spindle unit represents state-of-the-art technology and is operationally safe and
reliable. However, the spindle unit can represent a hazard if it is not correctly used in line
with the specifications.
The spindle unit has been exclusively designed and constructed to mill metals. This
excludes radioactive or combustible metals. If the spindle unit is used to machine any
other material, then this is not considered to be correct use. The WEISS company is not
liable for any damage incurred due to incorrect use. The company operating the spindle is
exclusively responsible for the risk unless this use has been explicitly approved released by
WEISS in writing.
Correct use also means that the installation/uninstallation/reinstallation, commissioning,
operating and maintenance conditions specified by WEISS are adhered to.
Cutting values and cutting parameters for both tools and materials cannot be guaranteed
as cutting values are very dependent on the structural design of the machine tool and the
tools and materials that are being used. The spindle unit has clearly specified technical
data such as speed, power and torque.
The machine tool manufacturer is exclusively responsible for the milling process. It is the
responsibility of the machinery construction OEM to evaluate the milling results.

1.4 ORGANIZATIONAL INFORMATION

Only authorized, appropriately trained personnel who have received the appropriate
instructions may operate, service and repair the spindle unit. These personnel must have
received special, in-depth training and instructions about possible hazards and dangers.
Operating Instructions for Spindle Units Type 2SP1… 2

The operator/operating company is responsible for ensuring that no unauthorized

personnel work on/with the spindle unit. Any person in the operating company's facility
that is involved with installing/uninstalling/reinstalling, commissioning, operating and
maintaining the spindle unit must have read and understood the complete operating
instructions and especially this Chapter. We recommend that the operating company has
this confirmed in writing.
Responsibilities for installing/uninstalling/reinstalling, commissioning, operating and
maintenance must be clearly assigned to specific personnel. This allocation of
responsibilities must be carefully maintained. This then ensures that from the safety
perspective, there is no confusion in understanding who is responsible for what.

1.5 WORKING ON THE SYSTEM

1.5.1 Basic information

Only appropriately trained specialist personnel may work on and with the spindle unit.
The appropriate Operating Instructions must be carefully observed.

1.5.2 Mechanical system

Any work may only be carried out with the spindle unit at an absolute standstill.
During this work, the following must be absolutely excluded:
That media under pressure are present
That electrical voltages are present
That the spindle unit can move
For any work involving installing/uninstalling/reinstalling, commissioning, operating,
converting, adapting and maintenance, the shutdown procedures specified in the
Operation Instructions must be carefully and precisely observed.

1.5.3 Hydraulic/pneumatic systems

All of the systems must be first brought into a no-pressure condition and must be secured
so that they cannot be accidentally switched-in again.
For any work involving installing/uninstalling/reinstalling, commissioning, operating,
converting, adapting and maintenance, the shutdown procedures specified in the
Operation Instructions must be carefully and precisely observed.
Pressurized accumulators are equipped with safety valves. These safety valves are
permanently set and sealed. It is absolutely prohibited to change the settings of these
valves as this could result in potential death or serious injury!

1.5.4 Electrical system

Before carrying-out any electrical work, the machine and peripheral devices must be
disconnected from the line supply and must be locked-out to ensure that power is not
accidentally re-connected.
If it is absolutely necessary to carry out work on equipment that is under voltage (live
equipment), then a second trained technician must be deployed that can intervene if an
emergency situation occurs.
For any work involving installing/uninstalling/reinstalling, commissioning, operating,
converting, adapting and maintenance, the shutdown procedures specified in the
Operation Instructions must be carefully and precisely observed.
Operating Instructions for Spindle Units Type 2SP1… 3

1.6 SPECIFIC HAZARDS AND DANGERS

In spite of being correctly used, when a spindle unit is operated, users or third-parties can
be exposed to situations which could result in death or severe bodily injury. The
subsequent safety and hazard information and instructions must be carefully observed and
maintained at all times.
If these information and instructions are not carefully observed, this can result in death or
severe personal injury.

1.6.1 Hazards due to mechanical energy

Depending on the tool diameter and the speed, extremely high centrifugal forces occur at
the tool. This is the reason that only the most precisely balanced tools may be used whose
maximum speeds and circumferential velocities lie above the max. spindle speed. For tools
with a high mass and/or high extended length (long cantilever length), it is possible that
the spindle - tool system can reach its natural frequency therefore destroying the
bearings. This could mean that the tool or parts of the tool could be flung-out with an
extremely high kinetic energy.
The parts and components mounted and installed in the spindle under spring pressure can
be flung-out at a high speed if incorrectly mounted and installed. This is the reason that
the spindle may only be opened-up by appropriately trained personnel.
Under no circumstances can the highest spindle unit speed be exceeded.
Under no circumstances may fingers be inserted into the tool interface.

1.6.2 Hazards due to hydraulic/pneumatic energy

If damage is identified at pressure hoses and lines as well as glands - such as leaks or
worn areas - then the spindle unit must be immediately stopped and powered-down no
matter how slight the apparent damage. Operation may only be resumed if the problems
and defects have been completely removed.
If media at high pressure escape, then this can result in injury, explosion and fire.

1.6.3 Hazards due to electrical energy

When incorrectly handled, electricity can be potentially hazardous resulting in death or
severe personal injury!
It is not permissible that the spindle unit is operated with terminal boxes, connectors or
electrical cabinets open.
After any electrical installation work or service/maintenance work, the protective measures
used must be carefully tested. This also applies for the clamped state displays for the
tools. Tools could be flung-out at an extremely high speed if the display indicates an
incorrect value.
Operating Instructions for Spindle Units Type 2SP1… 4

2 DESIGN AND FUNCTION

Detailed technical data on the functions described below are provided in Chapter
"Technical data".
2.1 BEARING DESIGN
High precision spindle bearings are used for the 2SP1 motor spindle shaft. They offer
excellent precision and are designed for the loads that occur at high speeds. Hybrid
bearings are used for spindle types that operate at even higher speeds. Special
significance was placed on the ruggedness of the bearings. They have proven themselves
over many years in applications - from JOB-shop environments up to three-shift operations
in series production.
The high precision spindle bearings accept the radial and axial forces from the process
without any play. Thermal loading of the spindle shaft has no effect on the mechanical
tensile forces. The bearings have excellent smoothing running characteristics and the
lowest level of roughness.
2.2 LUBRICATION
The bearings of 2SP1 motor spindles have a permanent grease lubrication. Re-greasing is
not required.
2.3 SEAL
The bearings are equipped with an integrated seal. On the spindle drive end, the seal to
the operating area is supported using the spindle's own sealing air system.
The sealing air must have been conditioned so that it is clean and dry. The optimum air
quantity is obtained at the specified input pressure at the spindle. A pressure switch is
necessary in order to check this air flow.
It is not permissible that spray water or other liquids are directly pointed at the sealing
gap (labyrinth seal) or openings in the spindle.
In order to prevent foreign bodies from being drawn-through the spindle, it is not
permissible that there is a pressure difference between the drive and drive-out sides of the
spindle.
Note:
In order to achieve the specified bearing lifetime, it is absolutely necessary that the
sealing air system is correctly operated.
2.4 DRIVE
An integrated build-in motor drives the 2SP1 motor spindle. This build-in motor has a high
torque and its rotor is directly mounted onto the tool spindle. This build-in motor is
available both as synchronous and induction motor. The electric power is only fed to the
stationary outer jacket of the motor. The rotating inner part of the motor does not require
any electrical power. Both synchronous and induction motors can be installed. When it
comes to designing the machines, in order to graduate the power requirement between
the two different diameters, either a long or a short design of the drive package can be
selected. These motors are available in various speed classes. The induction motor version
has been designed so that the torque can be adapted to the machining situation for both
operating modes - star circuit and delta circuit configurations. The operating company can
select the most suitable circuit configuration (either star or delta). The motors are
designed for high-speed load changes and they quickly follow changing torque demands.
In conjunction with the integrated, precise rotary encoder, they are admirably suited for
both closed-loop speed and position controlled operation.
Operating Instructions for Spindle Units Type 2SP1… 5

2.5 MOTOR COOLING

2SP1 motor spindles have integrated ducts to liquid-cool the stationary stator of the drive
motor. The stator that draws the electric drive power represents the main source of power
loss in the form of heat in the spindle unit. This is the reason that the cooling system is
extremely closely coupled to the stator of the drive motor from a thermal standpoint.
However, the sources of power losses that are some distance away are also adequately
cooled as a result of the integrated cooling ducts. The spindle unit must be supplied with
the cooling medium through a feed and return line. The cooling-medium absorbs the
power loss of the spindle and as a result its temperature increases. The cooling medium is
cooled-down to the original intake temperature outside the spindle using an external
cooling or heat exchanger system. The cooling and heat exchanger system is the
responsibility of the machinery construction OEM. The necessary cooling-medium pressure
in the intake line must be established using an external pump; the user must ensure an
adequate cooling quantity by appropriately providing the cooling water.
It is not permissible that the cooling water intake temperature drops below the ambient
temperature in order to avoid the formation of condensation water inside the spindle.

2.6 TOOLS

2.6.1 General
Rotation of the workspindle without a clamped tool is prohibited at any time.
A maximum of 1000 rpm are allowed within one revolution (tool change) for positioning
purposes only.

Only tools equipped with a suitable interface and whose peripheral speed or rotational
speed is permitted for the maximum spindle speed can be used.

The joint surfaces must be free of dirt before using the tool. Even minute amounts of
contamination will cause radial eccentricities and out-of-balance conditions.

If machining is performed with open-circuit tool cooling, you must use tools with a
movable coolant delivery tube! If this is not possible, you must always ensure that the
coolant feed is stopped.

The resonant frequencies of the spindle holder and spindle must always lie above the
speed permitted for the particular tool. As a result of a clamped tool, resonant frequencies
can be noticeably and undesirably reduced.
The danger associated with reducing the resonant frequencies is especially critical for:
Long tools
Heavy tools
Tools with a large radius
Generally, the best smooth running characteristics are achieved when short tools are
used; when short tools are used, then these result in lower bearing stressing. This means
that the tools must be clamped so that their effective length is as short as possible.

2.6.2 Safety
Depending on the tool diameter and speed, extremely high centrifugal forces occur at the
tool.
For tools with a high mass and/or high extended length (long cantilever length), it is
possible that the spindle/tool system reaches its natural frequency therefore destroying
the bearings.
This could mean that the tool or parts of the tool could be flung-out with an extremely
high kinetic energy.
Operating Instructions for Spindle Units Type 2SP1… 6

For this reason, only balanced tools in enclosed and secured working areas are permitted
to be used. (see 2.6.3)

2.6.3 Permitted balance qualities

The machining result especially depends on the balance quality of the tool being used.
Only precisely balanced tools with balance quality Q 6.3 are permitted to be used.
Otherwise, a safety hazard exists!
Standards to be carefully observed and fulfilled:
VDI Directive 2056
DIN EN ISO 15641

The system must be balanced after inserting a tool insert in the tool holder. It is not
permissible to individually balance the tool insert and tool holder without balancing the
complete assembly.

Tool wear can have a noticeable negative impact on the balance quality. If vibration and
noise levels increase while the tool is being used, then the tool should be checked for
wear and then carefully re-balanced.

2.6.4 Permissible speed

The length-to-diameter ratio (L:Ø) for the utilized tools must not exceed 3:1. Likewise, the
total mass of the tool unit must be under 4.5 kg.

WEISS spindles are designed such that with these tools the critical speeds are greater
than the maximum spindle speed.

If tools are used whose dimensions deviate from these specifications, the permissible
speed must be calculated.

In addition to the critical speeds of the spindle/tool system, attention must also be paid to
the technological data of the machining process for limiting the speed.
Operating Instructions for Spindle Units Type 2SP1… 7

2.6.5 Permissible vibrations

The maximum permissible radial vibration speed over the entire speed range is limited to:

3 mm/s in no-load operation

6 mm/s in continuous operation
10 mm/s Transient (maximum of 5 sec)

For the axial vibration speed, these values are each divided in half.

In its acceptance test, the Weiss spindle was balanced with a reference tool to ≤ 1 mm/s
in no-load operation. Based on VDI 2056, the acceptance test is performed on the spindle
in its uninstalled state.
The measured values (work-end value A, drive-end value B) are documented in the
respective acceptance report.

If the balance quality is measured subsequently in the field, the measurement must be
performed using a high-precision-balanced tool (Q≤2.5). The vibration value calculated
during the acceptance test is the benchmark for this. (See the relevant acceptance
report.)
The field measurements can be performed on the outside diameter of the mounting flange
or on the freely-accessible spindle nose.

In its installed state, the spindle is influenced by the machine tool. Under certain
circumstances, this causes vibration speeds to be measured that deviate from the above.

For safety reasons, vibrations greater than 10 mm/s are not permitted even if the results
of the machining operation are okay.
The spindle must be shut down immediately.

2.7 TOOL CLAMPING SYSTEM

An integrated clamping system is used to clamp the tool.
The tool is clamped using a spring-loaded column that is part of the clamping system.
The tool is released using a tool release unit in the spindle housing. When it is actuated, it
overcomes the pre-tension in the spring-loaded column and the draw bar including the
tool is pushed-out of the shaft.
The clamping set is equipped with a holding function for the tool. As soon as the
clamping set reaches the tool change position, the tool is held with a
defined force in the change position. (see 7.3.5.1)

2.8 TOOL RELEASE UNIT

The tool is released using a tool release unit at the spindle housing. By applying pressure,
the unit is shifted forwards against the draw bar and releases the clamping system
interlocking and therefore the tool. After it has been released, the tool must be held using
a suitable mechanism. When the pressure changes, the unit is shifted back again.
Available connections: - Clamp tool
- Release tool
Note:
As a result of the spindle design, the spindle shaft moves slightly in the axial direction
while the tool is being changed.
Operating Instructions for Spindle Units Type 2SP1… 8

2.9 CLAMPING STATE SENSING

Sensors integrated in the spindle are used to sense the position of the draw bar and tool
release unit. The following sensors can be used for evaluation and monitoring:

2SP120… analog clamping state sensing

Sensor S1 for the analog specification of the draw bar position indicates the respective
clamping state: clamped, clamped without tool, and released.
The exact spindle-specific values can be obtained from the relevant acceptance report.
Sensor S4 is adjusted so that it supplies a signal if there is a safe clearance between the
release unit and the spindle shaft.

2SP120...digital clamping state sensing

Sensor S1 is adjusted so that for a tool in compliance with the standard,
it supplies the "Draw bar in the released position" signal.
This cannot be used to safely sense a clamped tool!

Sensor S2 is adjusted so that for a clamped tool, in compliance with the standard,
it supplies the "Tool clamped" signal. It must be guaranteed that the spindle can only start
when the sensor S2 has switched. If this is not the case, then there is a potential danger
of personal injury and machine damage due to tool parts that are flung-out at high speed!

Sensor S3 is adjusted so that for a too small tool or no tool, it supplies the "no tool or no
tool in compliance with the standard" signal.

Sensor S4 is adjusted so that when the tool release unit is retracted from the shaft, a
signal is output.

2SP125... digital clamping state sensing

Sensor S1 (option) is adjusted so that for a tool in compliance with the standard,
it supplies the "Draw bar in the released position" signal.
This cannot be used to safely sense a clamped tool!

Sensor S2 is adjusted so that for a clamped tool, in compliance with the standard,
it supplies the "Tool clamped" signal. It must be guaranteed that the spindle can only start
when the sensor S2 has switched. If this is not the case, then there is a potential danger
of personal injury and machine damage due to tool parts that are flung-out at high speed!

Sensor S3 (option) is adjusted so that for an excessively small tool or no tool, it supplies
the "no tool or no tool in compliance with the standard" signal.

For safety reasons, all of the sensors available at the spindle

must be connected-up and evaluated.
It is not necessary to adjust the sensors - and in fact this is
strictly prohibited !
Operating Instructions for Spindle Units Type 2SP1… 9

2.10 INNER TOOL COOLING USING A COOLING-LUBRICATING MEDIUM (OPTION)

The 2SP1 motor spindle is optionally available with the inner tool cooling function. In this
case, a cooling-lubricating medium (this comprises an emulsion of water and an oil
additive) is fed through a rotary gland from the rear shaft end through the spindle shaft to
the tool. The user must appropriately condition and provide this cooling-lubricating
medium in order to guarantee the service lifetime of the rotary gland.
If machining is performed with inner tool cooling, you must use tools with a movable
coolant delivery tube!
Coolant leaks inherent for this mechanical arrangement are drained through a hole in the
rotary gland housing without back pressure. That is, the leakage connecting line is always
routed so that it falls away from the rotary gland. (see figure in 8.1)
The rotary gland is suitable for running under dry conditions.
Do not connect any compressed air while the spindle is rotating.
Use flexible hoses/lines. It is not permissible to use rigid pipe connections. Always route
hoses and lines in arcs. The hose may not place a strain on the rotary gland neither when
it is pressurized or not pressurized.
Note

Avoid pressure spikes and pressure fluctuations!

In particular, pressure spikes can occur if an incompressible medium (e.g., coolant) strikes
a closed or nearly closed hole at high velocity This impact can cause an increase in
pressure reaching a multiple of the permissible pressure.
The user must select the on duration of the armature so that the pressure spikes occurring
in the specific installation conditions do not exceed the normal permissible operating
pressure.
The operating pressure must be built up in stages.
Closing armatures can also cause the permissible pressure to be exceeded (closing
impacts).
The permissible pressure can also be exceeded if an incompressible medium (e.g.,
coolant) is subjected to additional pressure by a stroke motion in an enclosed space.
Remedy: Venting!

2.11 EXTERNAL TOOL COOLING WITH COOLING-LUBRICATING MEDIUM

(Option for Spindle 2SP120...)

The 2SP120... motor spindle is optionally available with the "external tool cooling"
function. The cooling-lubricating medium (this comprises an emulsion of water and an oil
additive) can be fed with a maximum pressure of 5 bar to a ring with 6 openings via a
connection at the spindle flange. The cooling-lubricating medium is discharged through
these openings which, depending on the option selected, are equipped with 6 adjustable
nozzles or 8 threaded holes.
Flexible hoses must be used to connect the cooling-lubricating medium. It is not
permissible to use rigid pipe connections.
The user must appropriately condition this cooling-lubricating medium so that the nozzles
remain free and don't become blocked.

2.12 TOOL AIR PURGE SYSTEM

The tool air purge system is available with/without inner tool cooling. Compressed air is
used as cleaning medium (see 6.7).
When the tool is changed, the purge air cleans the tool interface in order to ensure that
the tool is safely and smoothly guided through the interface.
The purge air must be appropriately conditioned outside the spindle in order to fulfill the
cleaning function.
Operating Instructions for Spindle Units Type 2SP1… 10

The purge air is fed from the end of the spindle through the draw bar up to the tool taper.

2SP125…
The air is fed through a separate connection, or when the inner tool cooling option is
used, through the rotary gland.
Prior to each tool change, you must make sure that the water column of the coolant is
sufficiently purged.
Do not perform a tool change with a coolant column present in the spindle. Failure to
comply with this requirement could result in damage to the spindle.

2SP120…
The supply line is made via a separate connection on the back of the spindle.

An on-off valve in the supply line must be used to ensure that the purge air is only applied
while a tool is being changed with the spindle stationary and that the cooling-lubricating
medium for the inner tool cooling is not fed-in.
Operating Instructions for Spindle Units Type 2SP1… 11

3 INSTALLING AND OPERATING THE SPINDLE

The spindle is a precision product. This is the reason that it must be extremely carefully
handled and must be kept very clean both when installing as well as in operation.

• In order to achieve the required characteristics of the spindle unit also in the machine,
the following basic rules must be carefully observed when installing the spindle:

• Only cranes/lifting equipment with the appropriate load handling capability may be used
to transport the spindle unit.

• The spindle unit may only be attached to the lifting equipment using ring bolts located
at the threads provided.

• The screw plugs at the various spindle unit openings (for media etc.) must be removed.
(see Appendix, Connection diagrams)

• For horizontal mounting arrangements, the spindle must be mounted so that the relief
and drain holes of the spindle are facing downwards. (see Appendix, Connection
diagrams)

• Before connecting-up the supply hoses/lines, these must be carefully cleaned. Under no
circumstances may foreign bodies and dirt enter the inside of the spindle. We
recommend that supply hoses/lines are purged using media of the specified quality.

• Before mounting, make sure that all of the joint surfaces are clean.

• Force must not be applied to the spindle when it is being mounted in the spindle
housing. If force is applied, this could damage the spindle.

• Never use compressed air to clean the spindle and parts of it.

• Do not directly point a jet of cooling medium onto the sealing gap at the spindle nose
(labyrinth seal).

• Do not directly point a jet of cooling medium onto the relief hole of the sealing air.

• Before using a tool, check that it is suitable (also refer to 2.6).

• Never raise the spindle unit at the shaft nor place it down on the shaft face or tool
interface!

• It is only possible to orientate the spindle for a tool change in the closed-loop controlled
mode after passing the reference mark (at least one shaft revolution).
This is the reason that it is a critical operation when powering-up and powering-down
the spindle in the tool change state.
Operating Instructions for Spindle Units Type 2SP1… 12

3.1 POWER-ON CONDITIONS

3.1.1 Commutation angle

With synchronous spindles, the angle must be calculated when the spindle is first
commissioned and entered when the spindle is replaced.

Explanation:
When synchronous motors are operated, the "built-in" permanent magnetic field of the
rotor must be synchronized with the electrically generated magnetic field of the stator.
This is necessary to enable the optimum superimposition of the two magnetic fields of the
stator and rotor.

This 'synchronization angle' relative to the zero mark of the encoder system can be
measured and saved in the converter. (Commutation angle offset)

For Simodrive, the angle is determined as follows:

Set P1011.12=1
Set P1011.13=0
Carry-out a HW RESET.
Set P1017.0=1
Activate the pulse and controller enable
Move axis over the zero mark (e.g., specify small nset)
Æ The angle offset is automatically entered in P1016
Æ Fault 799 (save FEPROM and HW RESET required) appears
Back up FEPROM and perform HW RESET

If the angle is already known (e.g., final acceptance certificate), the measured value
should be checked against this value.
For discrepancies of more than 5°, consult the manufacturer.
When the spindle is switched on again, the angle entered in P1016 is used after the zero
mark is crossed.
Operating Instructions for Spindle Units Type 2SP1… 13

3.1.2 Power-on conditions for operation of the spindle under speed

The control and monitoring of the power-on and power-off operations at the spindle and
its supply equipment is realized via the central machine control. The power-on and
operating conditions for safe spindle operation are listed in the following.

Motor

Cooling ON
Motor temperature < Maximum value

Sealing air

Supply pressure In the setpoint range

2SP120...
Analog clamping state sensing

Analog sensor S1
Enable for
1)
Spindle start 2-4V
1)
The specified values of the analog sensor are nominal values.
When setting, the actual values should be taken from the spindle acceptance certificate!
In order to ensure safe spindle operation, the various conditions should be monitored
during operation using the sensor. After the power-on conditions are present, delay times
must be maintained before the spindle is allowed to rotate (refer to the Engineering
Guide).

Tool release unit sensing

Digital sensor S4
Spindle start 1 1)
1)
Do not maintain the release pressure at the tool release unit.

2SP120...
Digital clamping state sensing

S1 S2 S3
Enable for
Spindle start 1) 0 1 0
1)
Do not maintain the release pressure at the tool release unit.

Tool release unit sensing

Digital sensor S4
Spindle start 1) 1
1)
In order to ensure safe spindle operation, the various conditions should be monitored
during operation using the sensor. After the power-on conditions are present, delay times
must be maintained before the spindle is allowed to rotate (refer to the Engineering
Guide).
Operating Instructions for Spindle Units Type 2SP1… 14

2SP125...
Clamping state sensing

S1 S2 S3
Enable for
1)
Spindle start 0 1 0
1)
Do not maintain the release pressure at the tool release unit.

In order to ensure safe spindle operation, the various conditions should be monitored
during operation using the sensor. After the power-on conditions are present, delay times
must be maintained before the spindle is allowed to rotate (refer to the Engineering
Guide).

3.1.3 Power-on conditions for tool change

2SP120...
Analog clamping state sensing

Analog sensor S1
1)
Tool change 2-4V
1)
The specified values of the analog sensor are nominal values.
When setting, the actual values should be taken from the spindle acceptance certificate!
In order to ensure safe spindle operation, the various conditions should be monitored
during operation using the sensor. After the power-on conditions are present, delay times
must be maintained before the spindle is allowed to rotate (refer to the Engineering
Guide).

2SP120...
Digital clamping state sensing

S1 S2 S3
Enable for
Tool change1) 1 0 0
1)
An enable signal for a tool change means that the draw bar is in the "tool released
position".

2SP125...
Digital clamping state sensing

S1 S2 S3
Enable for
Tool change1) 1 0 0
1)
An enable signal for a tool change means that the draw bar is in the "tool released
position".

In order to ensure safe spindle operation, the various conditions should be monitored
during operation using the sensor. After the power-on conditions are present, delay times
must be maintained before the spindle is allowed to rotate (refer to the Engineering
Guide).
Operating Instructions for Spindle Units Type 2SP1… 15

3.2 POWER-ON PROCEDURE

Motor cooling ON
Sealing air ON
Spindle motor ON

A new, shorter run-in period is required after the spindle has not been used for more than
a week.

This must be carried-out according to the following guidelines:

25% maximum speed 5 min. operating time

50% maximum speed 5 min. operating time
75% maximum speed 5 min. operating time, ready to operate

See also 5.3

3.3 POWER-OFF PROCEDURE

Speed Braking down to standstill

Motor cooling OFF after 3 minutes
Sealing air OFF after 3 minutes
Operating Instructions for Spindle Units Type 2SP1… 16

4 FAULTS IN OPERATION

If faults occur during operation, then the spindle unit should be handled according to the
following priorities.

Priority 1:
A critical situation involving death or severe injury has occurred.
Immediately stop the spindle!

Priority 2:
A situation has occurred that means that the spindle can no longer be operated in a non-
critical situation.
Power-down the spindle unit.

Motor

Shutdown temperature
Priority 1
Thermo-sensor responds
Pre-warning temperature
Priority 2
Thermo-sensor responds
Cooling not on Priority 2

Clamping state sensing

No tool clamped Priority 1

Tool release unit sensing

Release unit not retracted Priority 1

Release pressure present at the release
Priority 1
unit

For sealing air

Pressure too low Priority 2

Operating Instructions for Spindle Units Type 2SP1… 17

5 MAINTENANCE INFORMATION

5.1 MAINTENANCE SCHEDULE

Weekly
Clean the spindle unit. Do not point jets of steam, compressed air directly at the seals.
Visually check that glands, plugs/caps are tight and are not leaking.

Annually
Ensure that the motor cooling system is free and not blocked
Replace the anti-corrosion agent.
The optional rotary gland is maintenance-free. However, in order to secure a high degree
of availability we recommend that the rotary gland is replaced at the latest after three
years.

Note:

For information on maintenance of the tool clamping system, see 7.2.8, 7.3.9, and 7.4.4.

5.2 PARTS SUBJECT TO WEAR

Parts that are subject to natural wear include:
• Spindle bearings,
• Tool clamping system,
• Rotary gland,
• Hydraulic and/or pneumatic cylinders.
5.3 STORING THE SPINDLE IN THE MAGAZINE
The spindle must be stored in the original packaging. The storage location must be dry
and free of dust and dirt. The temperature should be between 10 and 35°C.
Oscillations and vibrations are not permitted.

For storage times over a year, the quality of the lubricant can deteriorate due to ambient
effects. We recommend that the spindle is checked in one of our service workshops.

When removed from storage, the spindle must not be immediately operated at full speed.
A new run-in procedure is required (also refer to "Power-on procedure" in the Chapter
"Installing and operating the spindle").
Operating Instructions for Spindle Units Type 2SP1… 18

6 TECHNICAL DATA

6.1 POWER CONNECTION

6.1.1 Synchronous spindle (2SP120...; 2SP125.-1...)

Phase Designation at the spindle Conductor designation
U1 U 1
V1 V 2
W1 W 3
PE PE Gn/Ye

When synchronous motors are operated, the commutation angle must be calculated
during the initial commissioning or obtained from the acceptance report. This must then
be entered in the machine control.
6.1.2 Induction spindle (2SP125.-8...)
Phase Designation at the spindle Conductor designation
U1 1
V1 2
A1 / UVW
W1 3
PE Gn/Ye
U2 1
V2 2
A2 / UVW
W2 3
PE Gn/Ye

During commissioning, you must ensure that the individual phases are connected correctly
and check the direction of rotation of the spindle (the default direction of rotation is
determined by the count direction of the rotary encoder).

6.1.3 Terminal assignment of the power connector (2SP120...)

2SP 1202 Gr.1,5 2SP 1204 Gr.3

6.2 SEALING AIR

Sealing air input Connection V
G1/8“ (∅ 5 mm)
Pressure 2.5 - 3 bar
Filtration grade 8 µm
Min. sealing air temperature Ambient
Max. sealing air temperature 35° C
Max. residual water content 0.12 g/m3
Max. residual oil content 0.01 g/m3
Max. residual dust 0.1 mg/m3
Operating Instructions for Spindle Units Type 2SP1… 19

6.3 MOTOR COOLING

2SP120... 2SP125...
Water inlet Connector I Connector I
Connector
G1/2’’ (∅ 9 mm)
for hose 12/10
Water outlet Connector II Connector II
Connector
G1/2’’ (∅ 9 mm)
for hose 12/10
Water with max. 25% anti-corrosion
Cooling medium
agent
Pressure Max. 5 bar
Quantity 10 l/min
Filtration grade 100 µm
CLARIANT Antifrogen N,
Anti-corrosion agent Tyfocor,
or comparable anti-corrosion agent

For the connectors of the 2SP120... spindle, only use connecting hoses in a PU/PA
quality!!

6.4 TOOL RELEASE UNIT

2SP120...
Design Pneumatic Hydraulic
Pressure input, to release Connector VII Connector VII
G1/4’’ G1/4’’
Pressure input, to clamp Connector VIII Connector VIII
G1/8’’ G1/4’’
Release pressure 5-6 bar 50 - 80 bar
Clamping pressure 5-6 bar 50 - 80 bar

2SP125...
Design Pneumatic
Pressure input, to release Connector X
1 x M16x1.5
Pressure input, to clamp Connector XI
1 x G1/8’’
Release pressure 5-6 bar
Clamping pressure 5-6 bar
Operating Instructions for Spindle Units Type 2SP1… 20

6.5 INNER TOOL COOLING USING A COOLING-LUBRICATING MEDIUM (OPTION)

2SP120... 2SP125...
Cooling-lubricating medium intake Connector X Connector IXb
G1/4’’ G1/4’’
Leakage Connector IV
G1/8’’
Suitable for cooling-lubricating medium Emulsion of water and oil additive
Filtration grade according to ISO 4406 -/16/13, 50 µm
Maximum of 50 bar / optionally, maximum
Cooling-lubricating medium pressure
of 80 bar
Cooling-lubricating medium temperature Max. 70 °C
Flow quantity 50 bar:55 l/min 80 bar:72 l/min

6.6 EXTERNAL TOOL COOLING WITH COOLING-LUBRICATING MEDIUM

(OPTION FOR 2SP120...)
2SP120...
Cooling-lubricating medium intake Connector XI
G1/4’’ (radial) or,
8.8 mm diameter (axial) for O ring 11x2
Suitable for cooling-lubricating medium Emulsion of water and oil additive
Cooling-lubricating medium pressure Max. 5 bar
Cooling-lubricating medium temperature Max. 70 °C

6.7 TOOL AIR PURGE SYSTEM

2SP120… 2SP125…
Connector IX Connector IXa
G1/4’’
Pressure 5-6 bar
Filtration grade 50 µm
Max. residual water content 0.2 g/m3
Max. residual oil content 0.1 g/m3
Max. residual dust 0.1 mg/m3
Operating Instructions for Spindle Units Type 2SP1… 21

6.8 CLAMPING STATE SENSING

2SP120…

Analog draw bar sensing

Balluff
Sensor S1
BAW M18ME-UAC50B-BP03
Draw bar in the release position 9 - 10 V
Tool clamped 2-4V
Tool too small 1-2V
No tool <1 V
Those values are nominal values only.
The actual values should be taken from the particular spindle acceptance certificate!
Sensor S1 is adjusted so that for tools in compliance with the standard, it supplies the
"draw bar in released position" signal. This cannot be used to safely detect jammed
tools!
Supply voltage, 24 V DC +/-20%

Digital tool release unit sensing

Balluff
Sensor S4
BES M08MI-PSC15B-BP03
Sensor S4 is adjusted so that it supplies a signal if there is a safe clearance between the
release unit and the spindle shaft.
Supply voltage, 24 V DC +/-20%

2SP120…

Digital draw bar sensing

Balluff
Sensor S1 (optional)
BES M08MI-PSC15B-BP03
Sensor S1 is adjusted so that for tools in compliance with the standard it supplies the
"draw bar in the released position" signal.
This cannot be used to safely detect jammed tools!
Supply voltage, 24 V DC +/-20%

Balluff
Sensor S2
BES M08MI-PSC15B-BP03
Sensor S2 is adjusted so that for clamped tools in compliance with the standard, it
supplies a correct signal. It must be guaranteed that the spindle can only start when the
sensor S2 has switched. If this is not the case, then there is a potential danger of
personal injury and machine damage due to tool parts that are flung-out at high speed!
Supply voltage, 24 V DC +/-20%

Balluff
Sensor S3 (optional)
BES M08MI-PSC15B-BP03
Sensor S3 is adjusted so that it supplies a signal if either a tool is being used that is too
small or no tool at all.
Supply voltage, 24 V DC +/-20%
Operating Instructions for Spindle Units Type 2SP1… 22

Digital tool release unit sensing

Balluff
Sensor S4
BES M08MI-PSC15B-BP03
Sensor S4 is adjusted so that it supplies a signal if there is a safe clearance between the
release unit and the spindle shaft.
Supply voltage, 24 V DC +/-20%

2SP125...

Digital draw bar sensing

SIEMENS 3RG4012-3AG33
Sensor S1 (optional)
BES 516-325-E5-C-S4
Sensor S1 is adjusted so that for tools in compliance with the standard it supplies the
"draw bar in the released position" signal.
This cannot be used to safely detect jammed tools!
Supply voltage, 24 V DC +/-20%

SIEMENS 3RG4012-3AG33
Sensor S2
BES 516-325-E5-C-S4
Sensor S2 is adjusted so that for clamped tools in compliance with the standard, it
supplies a correct signal. It must be guaranteed that the spindle can only start when the
sensor S2 has switched. If this is not the case, then there is a potential danger of
personal injury and machine damage due to tool parts that are flung-out at high speed!
Supply voltage, 24 V DC +/-20%

SIEMENS 3RG4012-3AG33
Sensor S3 (optional)
BES 516-325-E5-C-S4
Sensor S3 is adjusted so that it supplies a signal if either a tool is being used that is too
small or no tool at all.
Supply voltage, 24 V DC +/-20%

6.9 ROTARY ENCODER, MOTOR MEASURING SYSTEM

The spindle is equipped with a hollow-shaft incremental encoder

Sin-Cos signal (A+, A-, B+, B-)

Signals
1 reference signal per revolution (R+, R-)
Signal level 1 Vpp (difference signal)
Pulse number 256 signals / revolution

The sin-cos signal is suitable for fine interpolation. The reference signal supplies one pulse
at each shaft revolution and allows the shaft angle to be referenced. For a synchronous
motor, the reference pulse indicates the positive zero crossover of phase U (with a
clockwise rotating field). The encoder interface is electrically and functionally compatible
to SIEMENS SIMODRIVE 611 drive converters.

Ensure that the wiring complies with EMC requirements and that a continuous shielding
concept is implemented.

The encoder is connected through a 17-pin flange-mounted socket. Pre-assembled cables

should be used to connect the encoder to the drive converter (refer to the Planning
Guide).
Operating Instructions for Spindle Units Type 2SP1… 23

6.10 STORAGE TEMPERATURE MONITORING PT100 (OPTION FOR 2SP120...)

The PT100 resistance sensor is used for:

• Monitoring of bearing temperature

• Compensation for thermal-related length increase of the spindle

Corresponding PT100 signal evaluators must be used for the evaluation.

These are connected via an available cable head on the flange.

6.11 TOOL INTERFACES

HSKA63 SK40 / CAT40 / BT40

SK40-asymmetrical
DIN 69871 / 69872
ISO 7388/1/2 Type A

CAT40-asymmetrical
ANSI B5.50-78
ISO 7388/1/2 Type B
DIN 69893-1 Form A
Relevant standards BT40 asymmetrical
ISO 12164-1/2 style A
BT40, 30°
MAS 403-1982,BT/PT30°
Version E1

BT40 asymmetrical
BT40, 45°
MAS 403-1982,BT/PT45°
Version F1
Pull-in force 18.000 +5.4/-1.9 N 8,000 +1.6/-0.8 N
Reference gauge 10.5 +/- 0.1 mm 93.6 +/- 0.1 mm
Reference gauge BT 40 - 99.7 +/- 0.1 mm
Reference gauge CAT 40 - 82.9 +/- 0.1 mm

Note:
If machining is performed with inner tool cooling, you must use tools with a movable
coolant delivery tube! If this is not possible, you must always ensure that the coolant feed
is stopped.
Operating Instructions for Spindle Units Type 2SP1… 24

6.12 TOOL INTERFACES

SK 40

A B C
±0.25 ±0.25
ISO 40 44.45 94.25 88.25

CAT 40

A J K
±0.3 ±0.3
CAT 40 44.45 84.50 79.25

BT / PT 30°

BT / PT

A I F
±0.25 ±0.25
BT/PT30 44.45 100.35 93.35
°

BT / PT 45°
Operating Instructions for Spindle Units Type 2SP1… 25

A E F
±0.25 ±0.25
BT/PT45 44.45 100.35 93.35
°

HSK A63
Operating Instructions for Spindle Units Type 2SP1… 26

7 TOOL CLAMPING SYSTEMS

7.1 SAFETY INFORMATION

¾ The following points must always be carefully observed:

¾ Rotation of the workspindle without a clamped tool is prohibited at any time.

A maximum of 1000 rpm are allowed for positioning purposes only (tool change).
¾ Only use tools that are in a perfect operating condition!

¾ Only use tools that are designed and intended for this tool clamping system (carefully
observe the standard companion dimension drawing)!

¾ Tools may only be inserted when the drive spindle is at a standstill!

¾ Observe the maintenance intervals!

¾ Only precisely balanced tools with balance quality Q 6.3 are permitted to be used.
Operating Instructions for Spindle Units Type 2SP1… 27

7.2 PRODUCT DESCRIPTION, TOOL CLAMPING SYSTEM HSK-A63 TYPE K

7.2.1 Function
A spring assembly draws the draw bar
Specify device no.
95.xxx.xxx.x.x together with the clamping taper into the
for questions spindle. In so doing, the clamping taper
order spreads the clamp outwards until this is in
contact with the tool and clamps the tool
Draw bar with the spindle.
When clamping, the spring force is
increased 300% using the two gripper
retaining cones (10° and 30°) therefore
applying a clamping force to the tool.
The tool will only become loose after it
has been subject to a massive overload
Spring assembly (400% clamping force). The tool is only
released after tool breakage due to the
mechanical interlocking. If pressure is
applied to the release unit, the draw bar
moves in the opposite direction and the
clamp opens. The tool is ejected towards
the end of the release stroke.
The tool clamping system can now accept
a new tool.

Draw

Spacer

Tool gripper

Clamping taper
Operating Instructions for Spindle Units Type 2SP1… 28

7.2.2 Dimensions

7.2.3 Features

• Parallel shifting of grippers

• High static and dynamic rigidity

Order No.
95.600.001.3.6
Operating Instructions for Spindle Units Type 2SP1… 29

7.2.4 Mounting the clamping unit

• Clean the inner spindle contour
• Check whether all of the edges are appropriately rounded-off
• Apply grease to the O rings

Introduce the spacer ring into the spindle

bore; check to ensure that it can move
freely

Assemble the O ring on the draw bar,

protective sleeve is optionally available:
HSK A 63: 95.601.169.4.1

Apply grease to the contact surfaces

- METAFLUX paste 70-8508
or
- KLÜBER paste ME 31-52
Never mix/combine different grease types!
6x / 7x

Latch/engage the tool gripper segments

6x / 7x into the spacer ring and gripper retaining
cone surfaces (ensure the same number!)

When using the assembly device:

Locate the tool gripper segments on the
1 device and retain using a rubber ring;
2 introduce the complete unit; apply a blow
F
3 to the auxiliary dowel and locate the
gripper; remove the rubber ring

Apply assembly grease to the clamping

taper
Operating Instructions for Spindle Units Type 2SP1… 30

Screw the clamping taper, pre-assembled

with seal, protective ring and lock nut
onto the draw bar up to the maximum
reference gauge; do not screw any further
as this will damage the O ring on the draw
bar!

E. M. Adjust the clamping taper to the reference

Lösestellung! gauge
R.G. = 10.5 +/- 0.1 mm

Tighten the lock nut

Tightening torque:
A63: 30 Nm

MA

7.2.4.1 Protective sleeve for sealing socket installation

Not included in delivery!

Size Order numbers

A63 / B80 / E63 / F80 95.601.169.4.1

7.2.4.2 Installation tool HSK A63 Type K

For easier installation of tool grippers / not included in delivery!

Size Order numbers

A63 / B80 / E63 / F80 95.601.114.3.1
Operating Instructions for Spindle Units Type 2SP1… 31

7.2.4.3 Final inspection of HSK

The following must be checked based on the drawing:

• Max. stroke (corresponds to clamping stroke with a reserve)

• Ejection distance

• Whether the clamping stroke plus a reserve has been provided for the clamped
tool

Inspections after approximately 100 clamping strokes

In the released position:

Check the reference gauge

Check the lock nut

using the clamped tool

7.2.4.4 Imbalances
The complete system must be balanced with built-in clamping system and clamped tool.
For balance quality, see DIN ISO 1940 Part 1
Operating Instructions for Spindle Units Type 2SP1… 32

7.2.5 Operation of HSK A63-TYPE C

No rotation without a clamped tool!

The tool may only be inserted when the

drive spindle is at a standstill!
The tool must be inserted up to the
contact surface of the clamping taper!
Otherwise, clamping errors can occur!

Our recommendation for the concentricity

Koaxialitätstoleranz tolerance when changing the tool and the
maximum contact force at the clamping
taper is presented in the following table:

Nominal size A 63
Concentricity (øG) 0.8
Contact force, max. [kN] 3.6

We recommend: Position sensing of draw bar

To minimize wear on the sealing ring, the coolant tube should exhibit the following
characteristics at the clamping set/tool transition.

• Minimally ground with low-friction angular movability

(in accordance with ISO/DIS 12164-1)

Operation with coolant is only permitted if steps are taken to ensure that the coolant can
flow freely. For this reason, a tool with a coolant tube and a cutting tool with a pass-
through must be used. Otherwise, there is a danger that the spindle will be flooded or the
seals will be damaged by pressure spikes.

Observe the maintenance intervals!

Operating Instructions for Spindle Units Type 2SP1… 33

7.2.6 Changing the lip seal in the clamping unit

The ring does not have to be removed to disassemble the lip seal; it only has to be
replaced if damaged.

Remove the defective lip seal from the

clamping unit using either a suitable hook
or pliers

Ring Lip seal

Press the lip seal into a kidney shape and
install; carefully observe the mounting
position

Using a blunt object, press the seal

against the surface
and using a dowel, bring into the final
position

7.2.7 Breakage of a gripper segment

If a gripper segment breaks, the complete gripper unit must be replaced (we recommend
replacing the entire clamping set)!
Operating Instructions for Spindle Units Type 2SP1… 34

7.2.8 Maintenance

¾ Maintenance intervals
The following checks and work must be carried out at the specified intervals to allow
smooth disturbance-free operation of the tool clamping system and to fulfill the warranty
conditions:
¾ Weekly
• Check the lip seal in the clamping taper (visual inspection)
• Check the tool gripper for damage and accumulated dirt and that it is adequately
lubricated (visual inspection)

The following should be carefully noted:

The re-lubrication interval depends on how much grease is being removed from
the clamping set.

Reason why grease could be removed:

o Defective seal in the clamping taper
o Medium that dissolves grease
o A jet of cleaning fluid is applied directly to the clamping unit etc.
o We recommend METAFLUX Moly-Spray No. 70-82 for quickly re-
greasing the clamping set without having to disassemble the clamp
¾ Every six months or, at the latest, after 200,000 tool changes
• In the released position: Check the reference gauge
• Counter-lock using a clamped tool
• Check the pull-in force (our recommendation: use power check)
If the pull-in force is less than 70% of the nominal value, then the following
measures should be taken in the subsequent sequence:
o Re-lubricate and re-check the pull-in force
o Replace the gripper and re-check
o Completely replace the tool clamping system
¾ Annually or, at the latest, after 500,000 tool changes
• Replace the lip seal
Operating Instructions for Spindle Units Type 2SP1… 35

7.2.9 Lubricants for the HSK clamping unit

Bezeichnung Quantity Bestellnummer

* METAFLUX grease paste No. 4g 0.929100.012
70-8508
METAFLUX-Moly-Spray No. 70-82 400 ml 06.21001.010
KLÜBER grease paste ME 31-52 10 g 06.21001.014
KLÜBER-Spray ALTEMP Q NB 50 400 ml 06.21001.015
* Greased for the first time and when first equipped

Please note: Only use grease/lubricant from the same company; it is not permissible to
mix greases/lubricants!

METAFLUX
Metaflux AG
Industriestraße 11
CH-4313 Möhlin
Tel.: +41-61-851 08 00
Fax: +41-61-851 08 08

TECHNO-SERVICE GmbH
Detmolder Straße 515
D-33605 Bielefeld
Tel.: (05 21) 9 24 44 –0
Fax: (05 21) 20 74 32

KLÜBER
Klüber Lubrication München KG
Postfach 701047
D-81310 München
Tel.: (0 89) 78 76 –0
Fax: (0 89) 78 76 -333
Operating Instructions for Spindle Units Type 2SP1… 36

7.2.10 Spare parts list

7.2.10.1 O rings and lip seal parts

12 3 4

Lip seal O rings

Clamping unit 1 2 3 4
95.600.001.3.6 95.600.850.4.1 0.926030.103 0.926010.156 0.926010.164
A 63
12.0x18.5x4.5 12.0x1.5 13.87x3.53
Material: Viton, Härte 80
SHORE A

7.2.10.2 Rotary gland

Rotary gland, 50 bar (optional) 95.250.037.2.0

Rotary gland, 50 bar (optional) 95.250.022.3.0

7.2.11 Troubleshooting HSK-A63

Fault Cause
Tool has not been correctly clamped Incorrect reference gauge
Lock nut has become loose (released)
Faulty inner tool contour
Broken spring (the stroke is too short)
Worn clamping unit
Tool is inadequately fed
Purge air presses the tool out of the tool
change position
Tool isn't released Defective tool release unit seal
Leaky rotary gland
Insufficient release pressure
Micro-corrosion at the centering
Spring chamber full of oil
Tool is either released or becomes loose Broken gripper, clamping taper or draw
during machining bar
Broken tool shaft
Broken springs
Pull-in force too low
Loss of tension force Clamping unit is operating in a dry state
We recommend that the clamping force is
measured.
Operating Instructions for Spindle Units Type 2SP1… 37

7.3 PRODUCT DESCRIPTION OF HOLDING CLAMPING SET HSK A63-TYPE C

7.3.1 Function (see 7.2.1 and additional holding function 7.3.5.1)

7.3.2 Dimensions

7.3.3 Features

• Parallel shifting of grippers

• High static and dynamic rigidity
• Positively-driven
• High wear resistance
• Retention of tool in the released position

Auszugskraft Order No.

270 N 95.600.052.2.6 V02

Operating Instructions for Spindle Units Type 2SP1… 38

7.3.4 Mounting the clamping unit

• Clean the inner spindle contour,
• Check whether all of the edges are appropriately rounded-off,
• Apply grease to the O rings

Introduce the spacer ring into the spindle

bore; check to ensure that it can move
freely

Assemble the O ring on the draw bar,

Apply grease to the contact surfaces

METAFLUX-Paste 70-8508
or
KLÜBER-Paste ME 31-52
Never mix/combine different grease types!

Latch/engage the tool gripper segments

into the spacer ring and gripper retaining
cone surfaces (ensure the same number!)

Apply assembly grease to the clamping

taper

Screw the clamping taper, pre-assembled

with seal, protective ring and lock nut onto
the draw bar up to the maximum
reference gauge; do not screw any further
as this will damage the O ring on the draw
bar!
Operating Instructions for Spindle Units Type 2SP1… 39

E.M.
In the released position:
Adjust the clamping taper to the reference
gauge

MA Tighten the lock nut

Tightening torque:
A63 / B80 / E63 / F80: 30 Nm

7.3.4.1 Protective sleeve for sealing socket installation

Not included in delivery!

Size Order numbers

A63 / B80 / E63 / F80 95.601.169.4.1
Operating Instructions for Spindle Units Type 2SP1… 40

7.3.4.2 Final inspection of HSK A63-TYPE C

The following must be checked based on the drawing:

• Max. stroke (corresponds to clamping stroke with a reserve)

• Ejection distance

• Whether the clamping stroke plus a reserve has been provided for the clamped
tool

Inspection after approximately 100 clamping strokes

E.M.
In the released position:
Check the reference gauge

Check the lock nut using the clamped tool

7.3.4.3 Imbalances
The complete system must be balanced with built-in clamping system and clamped tool!
For balance quality, see DIN ISO 1940 Part 1
Operating Instructions for Spindle Units Type 2SP1… 41

7.3.5 Operation of HSK A63-TYPE C

No rotation without a clamped tool!

The tool may only be inserted when the

drive spindle is at a standstill!
The tool must be inserted up to the
contact surface of the clamping taper!
Otherwise, clamping errors can occur!

Our recommendation for the concentricity

Koaxialitätstoleranz tolerance when changing the tool and the
maximum contact force at the clamping
taper is presented in the following table:

Nominal size A 63
Concentricity (øG) 0.8
Contact force, max. [kN] 3.6

We recommend: Position sensing of draw bar

To minimize wear on the sealing ring, the coolant tube should exhibit the following
features at the clamping set/tool transition.

• Minimally ground with low-friction angular movability

(in accordance with ISO/DIS 12164-1)

Operation with coolant is only permitted if steps are taken to ensure that the coolant can
flow freely. For this reason, a tool with a coolant tube and a cutting tool with a pass-
through must be used. Otherwise, there is a danger that the spindle will be flooded or the
seals will be damaged by pressure spikes.

Observe the maintenance intervals!

Operating Instructions for Spindle Units Type 2SP1… 42

7.3.5.1 Holding function

The clamping set is equipped with a holding function for the tool. As soon as the clamping
set has reached the tool change position, the tool is held in the change position with a
defined force. In case of automatic tool change, you must ensure that the tool changer is
suitable for the extraction forces.

Accelerations in the axial directions as well as purge air or coolant for cleaning the tool
produce forces on the tool that can be greater than the retention force and, thus, cause
the tool to be forced out. The user must always take steps to ensure that the forces in
effect are less than the retention force.

Especially fast release cylinders can accelerate the tool to such a degree that the tool
pulse is sufficient to overcome the holding position of the clamping set. The settings for
the release operation must also be adapted to this situation. For vertical applications, the
net weight of the tool itself must always be included in the overall considerations.

Vertical applications with a clamping set with holding capability are not permitted!

In horizontal use, observe wear on the

contact points due to tilting of the tool!
Operating Instructions for Spindle Units Type 2SP1… 43

7.3.6 Changing the lip seal in the clamping unit

The ring does not have to be removed to disassemble the lip seal; it only has to be
replaced if damaged.

Remove the defective lip seal from the

clamping unit using either a suitable hook
or pliers

Ring Nutring

Press the lip seal into a kidney shape and

install; carefully observe the mounting
position

Using a blunt object, press the seal

against the surface
and using a dowel, bring into the final
position

7.3.7 Breakage of a gripper segment

7.3.8 If a gripper segment breaks, the complete gripper unit must be

replaced (we recommend replacing the entire clamping set)!
Operating Instructions for Spindle Units Type 2SP1… 44

7.3.9 Maintenance of HSK A63-TYPE C

¾ Maintenance interval
The following checks and work must be carried out at the specified intervals to allow
smooth disturbance-free operation of the tool clamping system and to fulfill the warranty
conditions:
¾ Weekly
• Check the lip seal in the clamping taper (visual inspection)
• Check the tool gripper for damage and accumulated dirt and that it is adequately
lubricated (visual inspection)

The following should be carefully noted:

The re-lubrication interval depends on how much grease is being removed from
the clamping set.

Reason why grease could be removed:

o Defective seal in the clamping taper
o Medium that dissolves grease
o A jet of cleaning fluid is applied directly to the clamping unit etc.
o We recommend METAFLUX Moly-Spray No. 70-82 for quickly re-
greasing the clamping set without having to disassemble the clamp
¾ Every six months or, at the latest, after 200,000 tool changes
• In the released position: Check the reference gauge
• Counter-lock using a clamped tool
• Check the pull-in force (our recommendation: use power check)
If the pull-in force is less than 70% of the nominal value, then the following
measures should be taken in the subsequent sequence:
o Re-lubricate and re-check the pull-in force
o Replace the gripper and re-check
o Completely replace the tool clamping system
¾ Annually or, at the latest, after 500,000 tool changes
• Replace the lip seal
Operating Instructions for Spindle Units Type 2SP1… 45

7.3.10 Lubricants for the HSK clamping unit

Description Quantity Order no.

* METAFLUX grease paste No. 4g 0.929100.012
70-8508
METAFLUX-Moly-Spray No. 70-82 400 ml 06.21001.010
KLÜBER grease paste ME 31-52 10 g 06.21001.014
KLÜBER-Spray ALTEMP Q NB 50 400 ml 06.21001.015
* Greased for the first time and when first equipped

Please note: Only use grease/lubricant from the same company; it is not permissible to
mix greases/lubricants!

Tool for reapply grease paste in the installed state (clamped without tool):

Description HSK size Order no.

Brush A50 - A100 06.16001.001

7.3.11 Spare parts

7.3.11.1 O rings and lip seal parts for HSK A63 C

Lip seal O rings

Clamping set HSK C 1 2 3 4

A63 95.600.052.2.6 95.602.194.3.1 0.926030.103 0.926010.156 0.926010.164

- 12 x 18.5 x 4.5 12.0 x 1.5 13.87 x 3.53

Material: Viton, hardness 80 SHORE A
Operating Instructions for Spindle Units Type 2SP1… 46

7.3.12 Troubleshooting HSK A63-TYPE C

Fault Cause

Tool has not been correctly clamped Incorrect reference gauge

Lock nut has become loose (released)
Faulty inner tool contour
Faulty inner tool contour
Broken spring (the stroke is too short)
Worn clamping unit
Tool is inadequately fed
Purge air presses the tool out of the tool
change position
Tool isn't released Defective tool release unit seal
Leaky rotary gland
Insufficient hydraulic pressure
Micro-corrosion at the centering
Spring chamber full of oil
Tool is either released or becomes loose Broken gripper, clamping taper or draw
during machining bar
Broken tool shaft
Broken springs
Pull-in force too low
Tool falls out of the spindle in the Tool is pushed out by purge air
retention position
Tool is pushed out of the spindle due to
cleaning
Axis accelerations are too high
Release velocity is too high
Clamping set worn - retention force is too
low
Loss of clamping force Clamping unit is operating in a dry state
We recommend that the clamping force is
measured.
Operating Instructions for Spindle Units Type 2SP1… 47

7.4 PRODUCT DESCRIPTION, TOOL CLAMPING SYSTEM SK 40

7.4.1 Function

A spring assembly draws the tool into the

workspindle through a spline gear, a draw
Plunger bar and a gripper. As a result of the spline
gear, the holding force is a multiple
Spline gear number of times higher than the pull-in
Specify device no. force when the tool is drawn in. The tool
95.xxx.xxx.x.x is firmly clamped even if the power fails.
for questions The tool is released using the release unit.
and orders Pressure is applied to the tool release and
compresses the spring assembly through
studs. The draw bar is pushed in the
direction of the steep-angle taper. As
soon as the control edge has been
Spring assembly passed, the gripper automatically opens.
The tool is automatically ejected by the
draw bar.
The tool clamping system can now accept
a new tool.

Draw bar

Gripper
Control edge
Operating Instructions for Spindle Units Type 2SP1… 48

7.4.2 Mounting the clamping unit

• Mounting tools required: Mounting tool for SK tool grippers

95.102.388.9.2

• Checking

Are the spindles and parts to be mounted/installed clean?

Are all of the parts in perfect condition and not damaged?
Gripper and clamping head greased?

Screw the gripper with holder onto the draw bar

E.M. ±0,1
in Lösestellung

Adjust the gripper with holder to the reference

gauge

MA = 18 Nm
festhalten

Attach the gripper with holder using the lock

nut.
Tightening torque 18 Nm

Check after the first 100 clamping operations:

Check the reference gauge

Check after the first 100 clamping operations:

Check that the lock nut is tight using a

clamped tool
Operating Instructions for Spindle Units Type 2SP1… 49

Reference gauges

R.G.
Code Standards
+/- 0.10
A1 DIN 69 871 / 69 872 93.6
B1 DIN 2080 91.4
C1 ANSI B 5.50 82.9
I1 MAS 403-1982 P40T-2 99.7
F1 MAS 403-1982 P40T-1 99.7

7.4.2.1 Final inspection

Inspection after approximately 100 clamping strokes

Check the reference gauge

Check the lock nut

using the clamped tool

7.4.2.2 Imbalances
The complete system must be balanced with built-in clamping system and clamped tool!
For balance quality, see DIN ISO 1940 Part 1
Operating Instructions for Spindle Units Type 2SP1… 50

7.4.3 Operation
No rotation without a clamped tool!

• Tools may only be inserted when the drive spindle is at a standstill!

When the tool is inserted, make sure that the tool is pushed back until the clamping
operation is complete!

• Observe the maintenance intervals!

7.4.4 Maintenance

¾ Maintenance intervals
The following checks and work must be carried out at the specified intervals to allow
smooth disturbance-free operation of the tool clamping system and to fulfill the warranty
conditions:
¾ Weekly
• Check the tool gripper for damage and accumulated dirt and that it is adequately
lubricated (visual inspection)

¾ Every six months or, at the latest, after 200,000 tool changes
• In the released position: Check the reference gauge
• Counter-lock using a clamped tool
• Check the pull-in force
(our recommendation: Use the power check)

¾ 4000 hours
The rotary gland is maintenance-free within the specified service interval. Of course this
assumes that you have observed the installation instructions specified in this product
information.
If media are used with hard and fine-grained contaminants (e.g. silicon), then it can be
assumed that there will be an increased seal wear.
The bearings are grease-lubricated; for information on their service life, see Worksheet 3
of the Gesellschaft für Tribologie (GfT) [Society for Tribology]. For applications where a
high degree of availability is necessary, we currently recommend a service interval of 4000
hours. In all cases, bearings that are "lubricated for life" should be changed after 3 years
at the latest. Otherwise, uncontrolled failures cannot be ruled out.
Operating Instructions for Spindle Units Type 2SP1… 51

7.4.5 Lubricants for the SK clamping set

Description Quantity Order no.

* METAFLUX grease paste No. 4g 0.929100.012
70-8508
METAFLUX-Moly-Spray No. 70-82 400 ml 06.21001.010
KLÜBER grease paste ME 31-52 10 g 06.21001.014
KLÜBER-Spray ALTEMP Q NB 50 400 ml 06.21001.015
* Greased for the first time and when first equipped

Please note: Only use grease/lubricant from the same company; it is not permissible to
mix greases/lubricants!

METAFLUX
Metaflux AG
Industriestraße 11
CH-4313 Möhlin
Tel.: +41-61-851 08 00
Fax: +41-61-851 08 08

TECHNO-SERVICE GmbH
Detmolder Straße 515
D-33605 Bielefeld
Tel.: (05 21) 9 24 44 –0
Fax: (05 21) 20 74 32

KLÜBER
Klüber Lubrication München KG
Postfach 701047
D-81310 München
Tel.: (0 89) 78 76 –0
Fax: (0 89) 78 76 -333

7.4.6 Breakage of a gripper segment

Bei Bruch eines Zangensegmentes

Ist der komplette Zangensatz
auszutausschen. Richtige Reihenfolge
der
Segmente beachten!
Operating Instructions for Spindle Units Type 2SP1… 52

7.4.7 Spare parts list

SK 40 Standards Order no. Code No.

DIN 69871 / 69872 ISO 7388/1/2 Type A 95.102.437.2.1 36
DIN 2080 - OTT-Rille 95.102.432.2.1 32
ANSI B5.50 - 78 ISO 7388/1/2 Type B 95.102.436.2.1 35
MAS 403-1982 BT/PT 2 (30°) 95.103.514.2.1 38
MAS 403-1982 BT/PT 1 (45°) 95.103.513.2.1 37
Rotary gland, 50 bar (optional) 95.250.037.2.0

7.4.8 Troubleshooting SK40

Fault Cause
Tool has not been correctly clamped Incorrect reference gauge
Lock nut has become loose (released)
Incorrect gripper used (tool standard)

Broken spring (the stroke is too short)

Large amount of dirt in the gear
Draw bolts either incorrect or faulty
Tool is inadequately fed
Purge air presses the tool out of the tool
change position
Loss of clamping force
Tool isn't released Defective tool release unit seal
Leaky rotary gland
Insufficient release pressure
Micro-corrosion at the steep-angle taper
Spring chamber full of oil
Tool is either released or becomes loose Broken gripper, clamping taper or draw
during machining bar
Draw bolts or steep-angle taper shaft
broken
Tool too long/too short
Broken springs
Pull-in force too low; gear is not in the
working range
Loss of clamping force Clamping unit is operating in a dry state
We recommend that the clamping force is
measured.
Operating Instructions for Spindle Units Type 2SP1… 53

8 ROTARY GLAND (OPTIONAL)

8.1 REPLACING THE ROTARY GLAND

When replacing the rotary gland, you must ensure extreme cleanliness while
disassembling/assembling. This prevents dirt from entering the cooling-medium feeder
lines!

Removing the rotary gland.

Ensure that all of the cooling-medium lines are in a no-pressure condition. Remove any
water from the lines.
Remove the connecting lines for the cooling-lubricating medium feed and leakage drain
holes.
Release the clamping elements of the rotary gland and carefully withdraw the rotary gland
from its bore.

Installing the rotary gland

Carefully insert the new rotary gland into its bore. In so doing, carefully observe the
position of the octagon at the connecting element! It may only be inserted by hand! Never
apply any hammer blows to the rotary gland! This would certainly damage the rotary
gland.
Then, insert the clamping element into the groove and clamp using screws (MA = 13 Nm).
Re-attach the lines for the cooling-medium feed and leakage.
After powering-up the cooling-lubricating medium supply, visually check all the
connections to ensure that they are tight and there are no leaks.

Please note:
The maximum pressure applied to the rotary gland must not exceed the maximum
permissible pressure for the rotary gland!
Please check prior to installation and during operation!

Installing the rotary gland

Operating Instructions for Spindle Units Type 2SP1… 54

Connecting the leakage drain pipe

8.2 MAINTAINING THE ROTARY GLAND

The rotary gland is maintenance-free within the service interval.
However, if media are used with hard and fine-grained contaminants (e.g. silicon), then it
can be assumed that there will be an increased level of seal wear.

The bearings of the rotary gland are greased. For applications where a high degree of
availability is necessary, we recommend a service interval of 4,000 hours. The rotary gland
should be replaced, at the latest, after 3 years use, as otherwise, unpredictable failures
cannot be completely excluded.

9 APPENDIX
• Dimension drawings
• Connection diagrams
• Electrical setting data