SCHUNK HSA Series User instructions

Translation of Original Operating Manual

Special chuck HSA 2-jaw chuck / 3-jaw chuck

HSA 160 (88001862, 88021732, 88029313, 88035481, 88037348, 88039738, 88036995)

HSA 160/2 (88026206, 88029240, 88036160, 88041389)

HSA-NZ 170/2 (88027365)

HSA 180/2 (88036423)

HSA 200 (88002843, 88002909, 88002958, 88004159, 88018669, 88020485, 88026696, 88028474,

88028566, 88039479, 88039429)

HSA 250 (88018463, 88018469, 88019551)

HSA 250/2 (88028004, 88034564)

HSA 265 (88003413, 88003473)

HSA 315 (88037992, 88040302)

HSA 315/2 (88029693)

HSA 400 (88026570)

HSA 630/2 (88019966)

Assembly and Operating Manual

Superior Clamping and Gripping

Imprint

01.00| |en

Imprint

This manual remains the copyrighted property of SCHUNK GmbH & Co. KG. It is solely

supplied to our customers and operators of our products and forms part of the product.

This documentation may not be duplicated or made accessible to third parties, in particu-

lar competitive companies,

without our prior permission.

Technical changes:

We reserve the right to make alterations for the purpose of technical improvement.

Document number: 88040302-en

Edition: 02.00 |22/02/2016|en

Dear customer,

congratulations on choosing a SCHUNK product. By choosing SCHUNK, you have opted for

the highest precision, top quality and best service.

You are going to increase the process reliability of your production and achieve best

machining results –to the customer's complete satisfaction.

SCHUNK products are inspiring.

Our detailed assembly and operation manual will support you.

Do you have further questions? You may contact us at any time –even after purchase.

Kindest Regards

Your H.-D. SCHUNK GmbH & Co.

Spanntechnik KG

Lothringer Str. 23

D-88512 Mengen

Tel. +49–7572-7614-0

Fax +49-7572-7614-1099

[email protected]

www.schunk.com

Table of contents

01.00| |en

Table of contents

General .................................................................................................................... 4

1.1

Warnings................................................................................................................... 4

1.2

Applicable documents .............................................................................................. 5

Basic safety notes..................................................................................................... 6

2.1

Intended use............................................................................................................. 6

2.2

Not intended use...................................................................................................... 6

2.3

Notes on particular risks........................................................................................... 7

2.4

Notes on safe operation......................................................................................... 10

2.4.1

Substantial modifications............................................................................ 13

2.5

Personnel qualification........................................................................................... 13

2.6

Organizational measures........................................................................................ 13

2.7

Using personal protective equipment.................................................................... 14

2.8

2-jaw chuck............................................................................................................. 14

Warranty................................................................................................................. 15

Torques per screw ................................................................................................... 15

Scope of delivery ..................................................................................................... 16

Technical data ......................................................................................................... 17

6.1

Calculation of the clamping force based on the speed:......................................... 17

6.2

Grades of Accuracy................................................................................................. 18

6.3

Permissible imbalance............................................................................................ 18

Assembly................................................................................................................. 19

7.1

Pre-assembly measures.......................................................................................... 19

7.2

Assembly of the HSA chuck .................................................................................... 19

Chuck function ........................................................................................................ 22

8.1

Functional principle................................................................................................ 22

8.2

Replacement or renewal of jaws............................................................................ 23

8.3

Disassembly and assembly of the Chuck................................................................ 23

Maintenance ........................................................................................................... 26

9.1

Lubrication.............................................................................................................. 26

9.2

Maintenance intervals............................................................................................ 26

9.3

Changing the top jaws ............................................................................................ 26

Disposal .................................................................................................................. 27

Parts lists................................................................................................................. 28

Drawings ................................................................................................................. 30

General

01.00| |en

General

This operating manual is an integral component of the product and

contains important information on safe and proper assembly,

commissioning, operation, care, maintenance and disposal. This

manual must be stored in the immediate vicinity of the product

where it is accessible to all users at all times.

Before using the product, read and comply with this manual,

especially the chapter “Basic safety notes”.(2, Page 6)

If the product is passed on to a third party, these instructions must

also be passed on.

Illustrations in this manual are provided for basic understanding of

the product and may differ from the actual product design.

We accept no liability for damage resulting from the failure to

observe and comply with this operating manual.

Warnings

To make risks clear, the following signal words and symbols are

used for safety notes.

DANGER

Danger for persons.

Non-compliance will inevitably cause irreversible injury or death.

WARNING

Dangers for persons.

Ignoring a safety note like this can lead to irreversible injury and

even death.

CAUTION

Dangers for persons.

Non-observance can cause minor injuries.

1.1

General

01.00| |en

NOTICE

Material damage

Information about avoiding material damage.

WARNING

Warning about hand injuries

WARNING

Warning about hot surfaces

Applicable documents

General terms of business

Calculation of the jaw centrifugal forces

("Technology" chapter in the lathe chuck catalog)

The above mentioned documents can be downloaded at

www.de.schunk.com.

1.2

Basic safety notes

01.00| |en

Basic safety notes

Improper handling, assembly and maintenance of this product may

result in risk to persons and equipment if this operating manual is

not observed.

Report any failures and damage immediately and repair without

delay to keep the extent of the damage to a minimum and prevent

compromising the safety of the product.

Only use original SCHUNK spare parts.

Intended use

The chuck is used to clamp workpieces on machine tools and other

suitable technical facilities, paying particular attention to the

technical data specified by the manufacturer. The technical data

specified by the manufacturer must never be exceeded.

The product is intended for industrial use.

Intended use also means that the user has read and understood

this operating manual in its entirety, especially the chapter “Basic

safety notes”.

The maximum RPM of the chuck and the required clamping force

must be determined by the user for the respective clamping task

based on the applicable standards and technical specifications of

the manufacturer.

(See also “Calculations for clamping force and RPM” in the chapter

“Technical data”). (6, Page 17)

Not intended use

The product is not being used as intended if, for example,

•It is used as a press, a punch, a chuck, a load-handling device or

as lifting equipment.

•It is used in working environments that are not permissible.

•Workpieces are not clamped properly, paying particular

attention to the clamping forces specified by the manufacturer.

•People work on machines or technical equipment that do

not comply with the EC Machinery Directive 2006/42/EC,

in violation of the applicable safety regulations.

2.1

2.2

Basic safety notes

01.00| |en

•The technical data for use of the product specified by the

manufacturer are exceeded.

Notes on particular risks

This product may pose a danger to persons and property if, for

example:

•It is not used as intended;

•It is not installed or maintained properly;

•The safety and installation instructions, local applicable

safety and accident prevention regulations or the EC Machinery

Directive are not observed.

DANGER

Possible risk of fatal injury to operating personnel due to the

workpiece falling down or being flung out in the event of a

power failure!

In the event of a power failure, the chuck's clamping force may

fail immediately and the workpiece may be released in an

uncontrolled manner. This poses a risk of death or injury to

the operating personnel and can result in serious damage to the

system.

•Due to the carried out and documented danger assessment

and risk evaluation, the machine manufacturer and its

operator have to ensure that appropriate measures have

been taken in order to maintain the clamping force of the

chuck until the machine's standstill, and to secure the

workpiece correspondingly (e.g. via a crane or a suitable

hoist).

•The machines and facilities must fulfill the minimum

requirements of the EC Machinery Directive 2006/42/EC;

specifically, they must have effective technical measures to

protect against possible mechanical hazards.

2.3

Basic safety notes

01.00| |en

DANGER

Possible risk of fatal injury to operating personnel if a jaw

breaks or if the chuck fails because the technical data have been

exceeded and a workpiece is released or parts fly off!

•The technical data specified by the manufacturer for using the

chuck must never be exceeded.

•The chuck may only be used on machines and facilities that

fulfill the minimum requirements of the EC Machinery

Directive 2006/42/EC; specifically, they must have effective

technical measures to protect against possible mechanical

hazards.

DANGER

Possible risk of fatal injury to operating personnel from clothing

or hair being caught on the chuck and being dragged into the

machine

Loose clothing or long hair may become caught on projecting

parts of the chuck and be drawn into the machine.

•The machines and facilities must fulfill the minimum

requirements of the EC Machinery Directive 2006/42/EC;

specifically, they must have effective technical measures to

protect against possible mechanical hazards.

•Always wear tight-fitting clothing and a hairnet when working

on the machine and the chuck.

WARNING

Risk of injury due to dropping the chuck during transport,

installation or removal.

•Take special care in the danger zone when transporting,

installing or removing the chuck.

•Note the relevant load securing regulations for working safely

with cranes, ground conveyors, lifting gear and load-handling

equipment.

Basic safety notes

01.00| |en

CAUTION

Danger of slipping and falling in case of dirty environment

where the chuck is used (e.g. by cooling lubricants or oil).

•Make sure the work environment is clean before beginning

assembly and installation tasks.

•Wear suitable safety shoes.

•Observe the safety and accident prevention regulations

during operation of the chuck, especially in connection with

machining centers and other technical equipment.

CAUTION

Danger of limbs being crushed by opening and closing of the

chuck jaws during manual loading and unloading or when

replacing moving parts.

•Do not reach between the jaws.

•Wear safety gloves.

•Observe the safety and accident prevention regulations

during operation of the chuck, especially in connection with

machining centers and other technical equipment.

CAUTION

Risk of burns due to workpieces with high temperatures.

•Wear protective gloves when removing the workpieces.

•Automatic loading is preferred.

CAUTION

Risk of damages due to incorrect choice of clamping position for

chuck jaws on workpiece.

If an incorrect clamping position is chosen for the chuck jaws on

workpiece, the base and the top jaws may be damaged.

•The T-nuts combine the top jaws with the base jaws and they

should never protude over the base jaws in radial direction.

•The outer diameter of the screwed top jaws must not exceed

the outer diameter of the chuck by more than 10%.

Basic safety notes

01.00| |en

CAUTION

Hazard from vibration due to imbalanced rotating parts and

noise generation.

Physical and mental strains due to imbalanced workpieces and

noise during the machining process on the clamped and rotating

workpiece.

•Ensure the chuck's axial and concentric runout.

•Check options for remedying imbalances on special top jaws

and workpieces.

•Reduce the speed.

•Wear hearing protection.

Notes on safe operation

•The machine spindle may only be started up when clamping

pressure has built up in the cylinder and clamping has followed

in the permitted work area.

•Unclamping may only be possible when the machine spindle

has come to a standstill.

•If the clamping energy fails, the workpiece must remain firmly

clamped until the spindle is shut down and the workpiece is

secured.

•The technical safety requirements in the respective operating

instructions must be observed exactly.

Functional test

After installation of the chuck, its function must be checked prior

to start-up.

Two important points are:

•Clamping Force! The clamping force of the chuck must be

achieved at max. operating force/pressure.

•Stroke control! The stroke of the clamping piston must allow a

safety zone at the front and rear end position. The machine

spindle may only be started when the clamping piston has

passed through the safety zone. Only limit switches that meet

the requirements for safety limit switches specified in DIN EN

60204-1 may be used.

2.4

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