ES721 ISO40 7 kW NL - HSD

HSD 

MECHATRONIC 

D I V I S I O N 

HSD S.p.A. 

Registered office: 

via della meccanica, 16 

loc. Chiusa di Ginestreto 

61122 Pesaro (PU) ITALY 

ES794 

Factory headquarters: 

p.le Alfio De Simoni, sn 

61122 Pesaro (PU) ITALY 

Ph.: (+39) 0721 205 211 

Fax: (+39) 0721 205 247 

E-mail: supporthsd@hsd.it 

web: www.hsd.it 

5801H0066 

EN Rev.01 

Instruction manual


Table of contents 

§ 1 DOCUMENTS SUPPLIED WITH THE PRODUCT........................................................4 

§ 2 DOCUMENT INFORMATION........................................................................................4 

§ 3 CUSTOMER ASSISTANCE SERVICE..........................................................................4 

§ 4 TERMS OF WARRANTY ..............................................................................................5 

§ 5 WARNINGS AND SAFETY PRECAUTIONS ................................................................6 

5.1 Distribution of this manual ....................................................................................................... 6 

5.2 General safety symbols ........................................................................................................... 6 

5.3 Risks associated with the electrospindle ................................................................................. 7 

5.4 Risks associated with improper use and handling................................................................... 7 

5.5 Risks specific to maintenance ................................................................................................. 8 

§ 6 TRANSPORT, PACKAGING, UNPACKING, STORAGE .............................................9 

6.1 Warnings.................................................................................................................................. 9 

6.2 Dimensions and weights.......................................................................................................... 9 

6.3 Transport and Packaging Conditions....................................................................................... 9 

6.4 Unpacking Procedure .............................................................................................................. 9 

6.5 Storage .................................................................................................................................. 10 

§ 7 TECHNICAL SPECIFICATIONS .................................................................................11 

7.1 Characteristics and performance........................................................................................... 11 

§ 8 DIMENSIONS AND MAIN PARTS ..............................................................................13 

8.1 Connections........................................................................................................................... 13 

8.1.1 DPC & encoder version................................................................................................... 13 

8.1.2 Direct liquid coolant coupling & S3 sensor version.......................................................... 15 

8.1.3 Deublin distributor, encoder & lateral connections .......................................................... 17 

§ 9 INSTALLAZIONE ........................................................................................................19 

9.1 Utility supplies in the factory .................................................................................................. 19 

9.2 Fixing ..................................................................................................................................... 19 

9.3 Hydraulic connections............................................................................................................ 19 

9.4 Motor cooling ......................................................................................................................... 19 

9.5 Internal tool cooling................................................................................................................ 20 

9.5.1 Direct coupling................................................................................................................. 20 

9.5.2 Deublin distributor ........................................................................................................... 20 

9.5.3 Controlled loss water distributor (DPC) ........................................................................... 20 

9.6 External tool cooling .............................................................................................................. 22 

9.7 Compressed air specifications............................................................................................... 23 

9.8 Pneumatic connections.......................................................................................................... 24 

9.9 Example of compressed air circuits ....................................................................................... 24 

9.9.1 Tool-holder changing circuit ............................................................................................ 24 

9.9.2 Pressurization circuit ....................................................................................................... 24 

9.10 automatic cone cleaning...................................................................................................... 25 

9.11 Electrical connectors............................................................................................................ 26 

§ 10 OPERATION .............................................................................................................27 

10.1 General precautions ............................................................................................................ 27 

10.2 Running in............................................................................................................................ 27 

10.3 Warming up ......................................................................................................................... 27 

10.4 Tool locking and release...................................................................................................... 27 

10.5 Automatic cleaning of the spindle shaft cone housing......................................................... 28 

10.6 Pressurising......................................................................................................................... 28 

10.7 Proximity sensors ................................................................................................................ 28 

10.7.1 Specifications of proximity sensors ............................................................................... 28 

5801H0066 en Rev.01 2/48


10.7.2 Electrospindle states and corresponding sensor S1, S2, S5 outputs............................ 29 

10.7.3 S3 sensor “shaft idle” (optional)..................................................................................... 29 

10.8 Thermal alarm...................................................................................................................... 29 

10.9 Encoder (optional) ............................................................................................................... 30 

10.9.1 Standard HSD TTL rectangular encoder..................................................................... 30 

10.10 Choice of toolholder cone.................................................................................................. 31 

10.11 Choice of tool..................................................................................................................... 32 

10.12 What to do if the tool is blocked on the piece being worked.............................................. 32 

§ 11 ORDINARY MAINTENANCE ....................................................................................34 

11.1 Daily maintenance ............................................................................................................... 35 

11.1.1 Checking and Cleaning the tool holder seat and the tool holder cone .......................... 35 

11.1.2 Protection of the tool holder seat................................................................................... 35 

11.2 Biweekly Maintenance......................................................................................................... 36 

11.2.1 Clean the tool holder cone with ethyl alcohol ................................................................ 36 

§ 12 REPLACEMENT OF COMPONENTS .......................................................................37 

12.1 Replacement and adjustment of the sensor group .............................................................. 38 

12.1.1 Description of the sensor unit........................................................................................ 38 

12.1.2 Replacement and adjustment of the sensor unit ........................................................... 39 

12.1.3 Sensor S1 adjustment ................................................................................................... 39 



§ 13 DISPOSING OF THE PRODUCT ..............................................................................42 

§ 14 LIST OF SPARE PARTS...........................................................................................43 

§ 15 TROUBLESHOOTING ..............................................................................................44 

§ 16 DECLARATION OF INCORPORATION ...................................................................47 

5801H0066 en Rev.01 3/48


§ 1 DOCUMENTS SUPPLIED WITH THE PRODUCT 

The documentation supplied with the product includes: 

� Manufacturer's declaration as provided for by Appendix IIB of Directive 2006/42/CE. 

� Product test certificate. 

� This manual, containing the instructions and warnings governing transport, installation, use 

and maintenance and final disposal of the product. 

i 

Check that all the above-mentioned documents are present at the moment the product is 

delivered. Copies can be obtained on request from HSD S.p.A. 

§ 2 DOCUMENT INFORMATION 

This manual has been written by the Electrospindle department of the Technical Office at HSD 

S.p.A. for use by all the installers, operators and service engineers who work with the 

electrospindle. 

ISSUED BY 

HSD S.p.a 


CODE REVISION APPROVED BY 

Via della Meccanica, 16; 

Loc. Chiusa di Ginestreto 

61122 PESARO (PU) ITALY 


P.le A. de Simoni, sn 


5801H0066 00 UTE008/05 

List of updates 

Revision Modified paragraph Description 

00 (22.07.2009) - - - New document 

01 (29.07.2010) - - - General revision 

This manual is delivered as an essential part of the electrospindle and at the time of revision was 

the most up to date documentation on the product. For updates please visit our web sites or call 

HSD Customer Assistance Service (see above) 

This document is an English translation of the original manual HSD H5801H0066 written in Italian. 

In the case of any discrepancies between this translation and the original Italian document, 

reference should be made to the original version available on web site www.hsd.it, or from HSD 

Customer Assistance Service (see above). 

§ 3 CUSTOMER ASSISTANCE SERVICE 

HSD S.p.A. 


Via della Meccanica 16 




P.le A. De Simoni, sn 


Tel. (+39)0721.205.211 

Fax (+39)0721.205.247 

E-mail supporthsd@hsd.it 

Web www.hsd.it 


Deutschland GmbH 

Brückenstrasse 32 

D-73037 Göppingen DEUTSCHLAND 

Tel. +49(0)7161 / 956660 

Fax +49(0)7161 / 9566610 

E-mail supporthsddeut@hsddeutschland.de 

Web www.hsddeutschland.de 

HSD USA Inc. 

3764 SW, 30 th Avenue 

Hollywood, Florida 33312 USA 

Phone no. (+1) 954 587 1991 

Fax (+1) 954 587 8338 

E-mail supporthsdusa@hsd.it 

Web www.hsdusa.com 


Mechatronic 

Shangai Co. Ltd 

D2, First floor, 207 Taigu Road 

Waigaoquiao Free Trade Zone 

200131, Shangai - China 

Phone no. (+86) 215866 1236 

E-mail sales@hsd-china.cn 

Web www.hsd-china.cn 

5801H0066 en Rev.01 4/48


§ 4 TERMS OF WARRANTY 

HSD S.p.A. guarantees that this electrospindle has been QC passed in testing in the factory. 

All work performed under the terms of the warranty shall be carried out at the premises of HSD 

S.p.A., with carriage at the Customer’s expense. HSD S.p.A. cannot accept any responsibility for 

production losses incurred as a result of work performed under the warranty. 

The warranty does not cover defects caused by the normal use of parts subject to continuous or 

rapid wear (e.g. seals, belts, bearings, etc.). In particular HSD S.p.A. offers no guarantee as to the 

duration of bearings, since bearing wear depends on various factors including: tool balancing 

precision, type of machining operation, impacts and/or mechanical stress in excess of the 

manufacturer’s declared limits. 

HSD S.p.A. declines all responsibility for non-compliance of the electrospindle caused by failure to 

follow the precautions and instructions given in this manual or by improper use or handling of the 

electrospindle. The Customer has the right to replacement of all parts shown to be defective, unless 

the said defects are caused by unauthorized tampering, including the fitting of non-original HSD 

spare parts and/or the replacement of parts not described or authorized in this manual unless 

authorized beforehand and in writing by HSD S.p.A.. 

In no case shall HSD S.p.A. or its suppliers accept any responsibility for damage (including damage 

to the unit, damage incurred for lost production and income, down-time in manufacturing, loss of 

information or other economic losses) deriving from the use of HSD products, even if HSD has been 

advised of such risks in advance. 

The warranty becomes automatically null and void if the Customer fails to notify HSD S.p.A. in 

writing of any faults found in the electrospindle within 15 days of their occurrence. The warranty 

likewise becomes null and void if the Customer fails to permit the seller to perform all necessary 

checks and tests, and if, when the seller requests the return of a defective part, the Customer fails 

to do so within two weeks of the request. 

Dimensioned drawings and photographs are provided only for information purposes and to 

facilitate understanding of text. 

HSD S.p.A. has a policy of constant development and improvement, and reserves the right to 

make functional and stylistic modifications to its products, to change the design of any functional or 

accessory part, and to suspend manufacturing and supply without notice and without obligation to 

third parties. Furthermore, HSD S.p.A. reserves the right to make any structural or functional 

change to the units, and to change the supply of spare parts and accessories without any prior 

notice. 

5801H0066 en Rev.01 5/48


§ 5 WARNINGS AND SAFETY PRECAUTIONS 

5.1 DISTRIBUTION OF THIS MANUAL 

This manual contains important instructions and precautions, and must accompany the 

electrospindle at all times since it is essential for the safe operation of the electrospindle. 

Keep this manual safe, and ensure that all persons involved with the electrospindle know of it and 

have access to it. 

The safety precautions contained herein are designed to ensure the safety of all persons 

exposed to the residual risks associated with the electrospindle. 

The instructions contained herein provide information necessary for the correct operation of the 

electrospindle, as required by the manufacturer. 

If any information given in this manual is found to be in conflict with applicable safety regulations, 

contact HSD S.p.A. on +39 0721 205 211 to request the necessary corrections and/or adaptations. 

Make sure that you read and fully understand all the documentation supplied with the 

electrospindle to avoid incorrect operation of the unit and unnecessary risks of personal injury. 

Keep this manual in a suitable place near the machine, where it will always be readily available to 

operators for consultation. 

i 

IMPORTANT: The information given in this manual is essential to ensure that the 

electrospindle is installed and used safely and correctly. 

5.2 GENERAL SAFETY SYMBOLS 

In this manual, important instructions or precautions are marked with the following symbols: 

i 

Indicates a procedure, practice or other analogous 

measure that if not observed or correctly followed, 

can result in personal injury. 

Indicates an operational procedure, practice or other 

analogous measure that if not observed or correctly 

followed, can damage or completely destroy the 

product. 

Indicates information of particular general interest that 

must not be ignored. 

5801H0066 en Rev.01 6/48


5.3 RISKS ASSOCIATED WITH THE ELECTROSPINDLE 

HSD does not and can not know how end users will install their electrospindles. The 

installer or Customer must therefore perform risk assessment specific to each installation 

and application. 

It is also the responsibility of the installer to ensure that adequate guards are provided to prevent 

accidental contact with moving parts. 

The installer and the operator must also bear in mind other types of risk, particularly those 

associated with foreign bodies, explosive, inflammable, toxic or high temperature gasses. 

Risks associated with maintenance operations must also be guarded against. Maintenance must 

be performed in conditions of maximum safety, and only with the electrospindle fully stationary and 

switched off. 

Once the electrospindle has been installed in the way decided upon by the installer and/or 

Customer, the machine becomes a “finished machine” as defined for the purposes of the 

Machinery Directive. Overall risk assessment must therefore be performed on the finished 

machine and a declaration of conformity produced in compliance with Appendix IIA of the 

2006/42/CE Machinery Directive. 

5.4 RISKS ASSOCIATED WITH IMPROPER USE AND HANDLING 

� Never impede the functioning of, remove, modify or in any way interfere with any safety device, 

guard, or control of individual parts or of the electrospindle as a whole. 

� Never place your hands, arms, or any other part of your body near moving machinery. 

� Do not use the electrospindle in atmospheres or environments where there is a risk of 

explosion. 

� Unless you are duly authorized, never attempt to repair faults or electrospindle malfunctions 

and never interfere in any way with the electrospindle’s operation or installation. 

� On completion of servicing work for which guards, covers, or any other protections have been 

removed, always make sure that they have been correctly and securely replaced and are fully 

functional before re-starting the electrospindle. 

� Keep all protection and safety devices in perfect working order. Also make sure that all warning 

labels and symbols are correctly positioned and perfectly legible. 

� When troubleshooting the electrospindle always adopt all the safety precautions listed in this 

manual for the purpose of preventing injury or damage to persons and things. 

� After adjusting any mechanical part, make sure that you fully tighten all screws, bolts or ring 

nuts you may have slackened or removed. 

� Before you start the electrospindle, make sure that all the safety devices are installed and 

perfectly functional. Do not start the electrospindle if this is not the case, but immediately inform 

the person responsible for machine safety or your direct superior. 

� Make sure that you have and use all the personal protective equipment (PPE) required by law. 

Do not wear loose or hanging clothing (ties, wide sleeves, etc.). 

� Never use tool holders of different types to those specified in this manual. To do so could 

damage the tool holder cone or lead to unsafe tool holder locking. 

5801H0066 en Rev.01 7/48


5.5 RISKS SPECIFIC TO MAINTENANCE 

� Take great care not to cut yourself on the tools while servicing or cleaning the electrospindle. 

Ideally, tools should be removed prior to these operations. 

� Rotating parts may continue to spin under the effect of inertia even when the electrospindle 

has been switched off. Make absolutely sure that the spindle is not spinning before accessing 

it. 

� Perform all scheduled maintenance as described in this manual. Failure to do so may lead to 

mechanical failures and breakage through wear or inadequate maintenance. 

WARNING! 

� Make absolutely sure that the tool in the electrospindle has stopped 

rotating before commencing any maintenance operation! 

� Disconnect the electrospindle from the mains power supply before 

commencing any maintenance operation! 

� It is strictly forbidden to clean the electrospindle while it is functioning! 

5801H0066 en Rev.01 8/48


§ 6 TRANSPORT, PACKAGING, UNPACKING, STORAGE 

6.1 WARNINGS 

� The lifting and handling of the product may create hazardous situations for the persons 

involved; we therefore recommend that the instructions given by HSD S.p.A. are observed and 

that only suitable tools are used. 

� The erection and installation operations must always be carried out only by specialised 

technicians. 

� We recommend that all lifting and handling operations of the product or its parts be carried out 

with great care, avoiding collisions that could compromise the proper function or damage coated 

parts. 

The responsibility for selecting the most suitable lifting equipment (ropes, straps 

or chains, etc.) lies with the user, paying attention to safety and functionality such 

as lifting capacity, relative to the weight indicated on the packaging and on the 

label of the product. 

6.2 DIMENSIONS AND WEIGHTS 

� Weight of the packed product: is indicated on the packaging. 

� Linear dimensions of the packed product: are indicated on the documents accompanying 

the product. 

6.3 TRANSPORT AND PACKAGING CONDITIONS 

6.4 UNPACKING PROCEDURE 

The product is shipped protected by a covering of 

VCI plastic and expanded foam, packed in a 

wooden crate or case of special cardboard. 

The figure below shows a few methods of lifting 

the packed product (using ropes and using a 

fork-lift truck; in the latter case, ensure that during 

lifting the centre of gravity of the crate is always 

between the two forks). 

The examples shown are only indications as it is 

not possible to determine in advance all the 

possible configurations with which it is possible to 

lift a product manufactured by HSD S.p.A.. 

Check the integrity of the seals on the 

packaging before opening the packaging 

If the product is packed in a wooden crate, insert a 

screwdriver under the locking hook. Open the hook, paying 

attention not to damage the packaging and its contents. 

If the product is packed in a cardboard case, remove the 

strip of adhesive tape, paying attention not to damage the 

packaging and its contents. 

Do not lift the product by pulling on the part of the electric fan, in order not to 

damage the guard. 

i The expanded foam and plastic cover can be disposed of as plastic material. 

5801H0066 en Rev.01 9/48


6.5 STORAGE 

If the product is to be stored, it must be protected against the weather, moisture, dust and 

aggressive atmospheric and environmental agents. 

It is therefore necessary: 

� To carry out periodic checks to ensure the good condition of the general protection; 

� To manually rotate the shaft (roughly once a month) to maintain optimum lubrication of the 

bearings. 

STORAGE TEMPERATURE: from -5° C (+23° F) to +55° C (+131° F) 

RELATIVE HUMIDITY (NON-CONDENSING): from 5% to 55% 

The storage time limit of HSD electrospindles is 12 months. 

After this time-limit the product must be inspected by an authorized HSD service. 

i Please contact HSD Customer care service if you need more information 

(see chapter § 3). 

5801H0066 en Rev.01 10/48


§ 7 TECHNICAL SPECIFICATIONS 

7.1 CHARACTERISTICS AND PERFORMANCE 

Tensione nominale (*) Nennspannung (*) Rated voltage (*) V 380 380 

Frequenza nominale Nennfrequenz 

Nominale 

Rated frequency Hz 200 400 

Velocità nominale Geschwindigkeit Rated speed rpm 6000 12000 

Tipo di servizio Betriebsart Duty type S1 cont S6 60% S1 cont S6 60% 

Potenza nominale Nennleistung Rated power kW 6 7.2 6 7.2 

Coppia nominale Nenndrehmoment Rated torque Nm 9.5 11.4 4.8 5.8 

Corrente nominale Nennstrom Rated current A 12.6 15.0 12.6 15 

Rendimento nominale � Nennwirkungsgrad � Rated efficiency � 0.85 

Fattore di potenza cos � Leistungsfaktor cos � Power factor cos � 0.85 

Numero di poli Polzahl Number of poles 4 

Classe di isolamento Isolierklasse Insulation class F 

Raffreddamento a liquido / Flüssigkeit / 

Tipo di raffreddamento Kühlungstyp Type of cooling 

Liquid cooling 

Peso versione Gewicht Version Weight of LONG 

NASO LUNGO LANG NASE 

[(*) von Inverter 

NOSE variant 

[(*) fornita da inverter] geliefert] [(*) from inverter] 

kg ~ 35 

5801H0066 en Rev.01 11/48


Toolholder locking springs 4000 N 

Volume = 0,17 Liters (10 cu in) 

Pneumatic piston 

Pmin = 6 bar (145 PSI) 

Pmax = 7 bar (174 PSI) 

130 L/min @ 4 bar e 20°C (360 NL/min) 

Pressurization air consumption 

Cone cleaning air consumption 

DPC Controlled loss water distributor 

(depending on model) 

Encoder 

(optional) 

200 L/min @ 4 bar , 20°C (320 NL/min) 

(Only during the tool change cycle) 

HSD patented 

S1: “toolholder locked” sensor � (present) 

S2: “toolholder unlocked” sensor � (present)� 

S3: “shaft idle” sensor (optional) - 

S4: “HSK” sensor � (not present) 

S5: “piston in safe condition” sensor � (present) 

Thermal switch 130°C (266°F) 

Type of cooling Liquid 

� HSD TTL line driver , rectangular wave 

654 count/rev , zero index 

feed voltage 12 - 24 Volt DC 

Toolholder 

ISO 40 – special ISO 40 

(depending on model) 

Toolholder expulsion 0,4 ÷ 0,6 mm 

5801H0066 en Rev.01 12/48


§ 8 DIMENSIONS AND MAIN PARTS 

See the technical data sheet supplied with the electrospindle. 

8.1 CONNECTIONS 

i The images below are illustrative. 

8.1.1 DPC & encoder version 

Ref. Description 

Power and Thermal switch connector 

Data 

1 ( 3 Ph + 2 Thermal bimetallic NC 100°C ) L. = 1 m 

2 Encoder connector L. = 1 m 

3 Coolant inlet 4 l/min min. 

4 Coolant outlet 4 l/min min. 

5 Toolholder release air inlet 6-7 bar 

6 Air inlet for pressurization of spindle 2 bar 

7 Air inlet for pressurization of distributor 2 bar 

8 DPC water discharge x 

9 Internal water inlet / toolholder cleaning 4 bar 

10 S1 Drawbar sensor x 

11 S2 Tool out sensor x 

12 S5 Piston back sensor x 

8 

8 

5 

5801H0066 en Rev.01 13/48 

11 

12 

8 

8


Long nose 

Short nose 

= = 

170 

76,5 

76,5 

170 

== 

76 

76 

6 

10,5 

n°6 fori fissaggio O 

n°6 holes 

6 

10,5 

n°6 fori fissaggio O 

n°6 holes 

430 

5801H0066 en Rev.01 14/48 

517 

3 4 

1 

3 4 

2 

1 

2 

10 

7 

10 

9 

7 

9


8.1.2 Direct liquid coolant coupling & S3 sensor version 



Data 


2 S3 Sensor “shaft idle” L. = 0.1 m 









8 

7 

5 

5801H0066 en Rev.01 15/48 

9 

10


76 

76 

6 

6 

n°2 fori per movimentazione M 

n°2 handling holes 

n°6 fori fissaggio 

n°6 holes 

O 10.5 

3 

400 

1 2 

5801H0066 en Rev.01 16/48 

4 

Raccordo dritto G 1/8 tubo 8 

Straight fitting G 1/8 Ø8


8.1.3 Deublin distributor, encoder & lateral connections 



Data 


2 S3 Sensor “shaft idle” L. = 0.1 m 









8 

5 

5801H0066 en Rev.01 17/48 

10 

9


+0 

-0,054 

O 105 h8 

O 88.5 

O 57 

76 76 

1,6 

143.03 

128.5 

134 

0 6 12 93.5 

6 

137.8 

38 

9 

128.5 218.5 238.5 308.5 317.5 390 415 

108.5 

415 

333.5 369 406 

236.8 

131.5 100 72 

Avanzamento del Deublin in fase di espulsione 

Deublin movement during tool holder ejection 

5801H0066 en Rev.01 18/48 

3 

N°6 FORI PER FISSAGGIO 

N°6 HOLES 

172 70 

O 10.5 

1 

4 

2 

Deublin 1116-555-463 

(NOT INCLUDED) 

104 

O 

N°6 M 6 

DEPTH 10 mm 

132 

6


§ 9 INSTALLAZIONE 

HSD S.p.a. does not and cannot know the methods adopted by the user to install 

the spindles. It is therefore the responsibility of the installer or end user to carry 

out a risk analysis for each specific installation type and the methods adopted. 

It is furthermore the responsibility of the installer to ensure that there is sufficient 

protection against accidental contact with moving parts. 

The installer and user must also take all the necessary precautions to prevent 

other types of risk, particularly those deriving from foreign bodies entering the 

equipment, contact with explosive, flammable, toxic or high temperature gases. 

Risks relating to maintenance operations must also be taken into consideration. 

Maintenance must be performed in conditions of maximum safety, with 

electrospindle power switched off and with no risk of tool movement. 

9.1 UTILITY SUPPLIES IN THE FACTORY 

All preparation work for installation of the electrospindle is the responsibility of the Customer (e.g. 

the provision of electricity and compressed air lines, etc.). 

The electrical power line to the electrospindle must have sufficient capacity. Connection to the 

supply network must be performed by qualified electricians. The Customer is responsible for the 

entire electrical supply as far as the electrospindle connectors. 

The Customer's attention is drawn to the need to ensure that all safety aspects relating to the 

grounding of the electrospindle are complied with. 

The ground system must furthermore comply with the standards applicable in the country or state 

of installation and must be checked regularly by qualified electricians. 

9.2 FIXING 

(See figures of chapter § 8) 

To fix the electrospindle directly onto the machinery use n°8 M8 stainless steel screws. 

To fix an electrospindle equipped with the fixing support use n°8 M10 stainless steel screws and 

n°2 reference pins. 

9.3 HYDRAULIC CONNECTIONS 

See the figures in chapter § 8 for the location and sizes of connections. 

See the following sections of this chapter for fluid specifications. 

9.4 MOTOR COOLING 

The Customer must provide an adequate cooling circuit, with a housing around the spindle for 

coolant circulation. 

The designer of the machine on which the electrospindle is installed is also responsible for the 

design and implementation of the cooling system. The following table indicates the minimum 

values that must be respected: 

Minimum flow 5 liters / minute 

Cooler set temperature 25±3°C 

Max. coolant temperature 40°C 

Min. inside diameter of delivery and return lines 10 mm 

Use water with 10% ethylene glycol and anti-corrosion additives. 

5801H0066 en Rev.01 19/48


Ethylene glycol concentrations over 15% may damage the NBR gaskets of the 

product. 

HSD recommends the use of ‘ARTIC-FLU-5’ (order code: H2161H0022) after testing it internally. 

ARTIC-FLU-5 is a premixed ready-to-use liquid coolant. The coolant contains monoethylene glycol 

and ecologically formulated corrosion inhibitors without amines, nitrates or phosphates and 

guarantees protection for approximately one year. ARTIC-FLU-5 prevents the formation of rust, 

limescale and foam deposits as well as the hardening, cracking and swelling of the rubbers and 

couplings. It also complies with various international standards, including CUNA NC 956-16. 

9.5 INTERNAL TOOL COOLING 

9.5.1 Direct coupling 

In the back of the electrospindle is positioned a direct connection of the tool liquid coolant (see 

chapter § 8 ). 

9.5.2 Deublin distributor 

The electrospindle is prepared for the installation of the Deublin distributor. 

i 

See the use and maintenance manual of the Deublin distributor for the installation of the 

component. 

9.5.3 Controlled loss water distributor (DPC) 

The cooling water reaches the tool through a controlled loss water distributor called “DPC” (HSD 

patented). The exceeding water is drained out of the DPC. Drainage varies according to the water 

flow through the tool: the less water comes out through the tool, the more water is drained out of 

the DPC. 

Drained water comes out from the DPC by gravity, so it’s important to follow the instruction above 

to have a correct and complete drainage: 

For the correct functioning of the DPC and to avoid damages to the 

electrospindle observe the following indications. 

� For the internal tool cooling use tap water, or water of equal 

characteristics. 

� Process the cooling water by a 25 µm filter. Service regularly the filter, 

as instructed by the manufacturer, and replace it as it loses its filtering 

capability. 

� Feed the DPC by a flow of water of 10 liter/minute (0,35 CFM). 

� Ensure that the drain holes (see chapter § 8 ) of the controlled loss 

distributor are always free to drain. 

� In case any tube is connected to the DPC draining holes, it must be 

downward oriented. Tubes must remain downward oriented even when 

the machine moves the electrospindle (see following figure). 

� Tilt the electrospindle only in direction of the draining holes. (see 

following figure). 

5801H0066 en Rev.01 20/48


DPC 

5801H0066 en Rev.01 21/48 

!


9.6 EXTERNAL TOOL COOLING 

For the external tool cooling use water with the following specifications: 

� Index of aggressiveness (I.A) = 11-12 

� Electrical conductivity: not more than 600 microS/cm 

� Turbidity not above 20 mg/l 

� Chlorides not above 300 mg/l 

i 

Only an accurate analysis will tell if the water used for the machining process has the 

required physical characteristics. 

Do not use products containing sodium chloride (NaCl), which cause corrosion 

(rust). 

When using the HSD “Water flange” optional part, do not use de-scaling products 

in the external tool cooling circuit. De-scaling products will damage the watertightness 

of the “Water flange” unit. 

Never direct liquid or air jets to 

the pressurized labyrinth seal, 

because infiltrations damage the 

internal parts of the spindle. 

Do not direct liquid or air jets 

into the electrospindle when the 

tool-holder is not clamped in, as 

they could dirt the coupling 

surface of the taper fit or they 

could get dirt into the 


1 Coupling surface. 

2 Labyrinth seal. 

1 2 

5801H0066 en Rev.01 22/48


9.7 COMPRESSED AIR SPECIFICATIONS 

Introduce compressed air of a purity in accordance with ISO 

IMPORTANT: 8573-1, classes 2 4 3, i.e.: 

� class 2 for the solid particles: size of the solid particles < 1 µm 

� class 4 for the humidity: dew-point < 3°C (37.4°F) 

� class 3 for the total oil: concentration of oil < 1 mg / m 3 

Missing to follow the above mentioned specification might cause damage to the product. 

Warranty is denied if pollutant traces are found during servicing. 

As an example, a possible implementation of the above mentioned specification could be 

i made by the following instructions. 

� Use nonreturn valve to separate the circuit of the dry air from the circuit of the lubricate 

air (if present). 

� Install the filters shown in the figure below as near as possible to the electrospindle. 

� As filter efficiency is less than 100%, it’s important to feed the compressed air circuit of 

the CNC machinery with air properly processed. 

As an example, put in point (1) of figure below air of a purity in accordance with ISO 

8573-1, classes 7 6 4, i.e.: 

o Class 7 for the solid particles: 

size of the solid particles < 40 µm; 

concentration of solid particles < 10mg/m 3 ; 

o Class 6 for the humidity: 

dew-point < 10°C; 

o Class 4 for the total oil: 

concentration of oil < 5 mg/m 3 . 

� At the end of the working day, unload the pneumatic circuit, to let the automatic 

discharge of the liquids accumulated in the filter cups. 

� Service regularly the filters, as instructed by the manufacturers, and replace them as 

they lose their filtering capabilities (at least once or twice a year). 

1 From compressed air circuit. 

2 Pre-filter 5 µm. 

3 Anti-oil filter 0,1 µm. 

4 To the electrospindle. 

1 4 

2 

5801H0066 en Rev.01 23/48 

3


9.8 PNEUMATIC CONNECTIONS 

i 

See the figures in paragraph 8.1 for the location and sizes of connections. 

See paragraph 7.1 for air consumptions. 

9.9 EXAMPLE OF COMPRESSED AIR CIRCUITS 

9.9.1 Tool-holder changing circuit 

electrospindle 

cilinder 

( S ) 

( R ) 

5-2 monostable valve 

The cylinder of this electrospindle is single-acting. 

4 

2 

1 5 

3 

hoses : Ø 8x6 Minimum 

two step air-cleaning kit 

step 1 : 5 μm filter 

step 2 : 0,1 μm oil remover 

If not supplied is advisable to insert a security valve with open at 2.5/3 Bar 

between the cylinder and 5-2 monostable valve. 

9.9.2 Pressurization circuit 

pressione 4 Bar 

pressure 

regulator 

hoses : Ø 6x4 Minimum 

( P ) 

6 Bar 

Pressurization inlet 

pressure switch 

4 Bar 

two step air-cleaning kit 

step 1 : 5 μm filter 

step 2 : 0,1 μm oil remover 

The internal pressurisation pneumatic circuit prevents harmful particles from entering the 


5801H0066 en Rev.01 24/48 

6 Bar 

The pressurisation air must be present even when the electrospindle is at a 

standstill and the machine is switched on. It must be present also when cleaning 

or servicing the machinery, to prevent dust from other machining areas entering 

the spindle. 

Check with the spindle at standstill that there is a uniform outlet of air around the spindle shaft 

(pressurisation); if this is not the case, check the efficiency of the pneumatic circuit and the 

tightness of the connections.


9.10 AUTOMATIC CONE CLEANING 

1. 6 bar air inlet 

1 2. water inlet for internal tool cooling 

3. to be connected to the “water to the tool” inlet (see paragraph 8.1 ) 

( T ) 

3 

2 

Figure aside shows an example of a compressed air circuit for automatic 

cone cleaning. During the tool change phase, water delivery is stopped 

and compressed air is delivered instead to blow out any dirt which may 

have built up. (NOTE: The cone must still be checked and cleaned on a 

regular basis as instructed in section § 11 on spindle maintenance). 

5801H0066 en Rev.01 25/48


9.11 ELECTRICAL CONNECTORS 

See the figures in chapter § 8 for the location of connections. 

D 

C 

E 

F 

A 

B 

Power connector 

(optional) 

A Motor phase “U” 

B Motor phase “V” 

C Motor phase “W” 

D Ground PE 

E Thermal switch for motor protection (*) 

F Thermal switch for motor protection (*) 

(*) E and F are the two terminals of a normally 

closed (ON) switch, which opens when the motor 

reaches a dangerous temperature. 

Sensor wiring 

1 

4 1 +Vcc 

3 3 0 V 

4 Output 

100 

5801H0066 en Rev.01 26/48 

G 

H A 

F 

K J 

E 

B 

D 

C 

Encoder connector 

(optional) 

A A + 

B A – 

C B – 

D GND 

E Z + 

F +Vcc 12 V DC ÷ 24 V DC �10% 

G Not used 

H Not used 

J B + 

K Z – 

Cable length : 1m 

Proximity sensor assembly 

PNP N.O. 

with M8 three-pin plug 

for sensor: S2, S3 (optional), 

S5 

Proximity sensor assembly 

PNP N.C. 

with M8 three-pin plug 

for sensor: S1


§ 10 OPERATION 

10.1 GENERAL PRECAUTIONS 

HSD S.p.A. has inspected and checked its electrospindles under the standard ambient conditions 

(CEI EN 60034-1:2006-05). 

Contact HSD S.p.A. for information on the possibility of applications in special ambient conditions. 

When machining, never allow non-cutting rotating parts (spindle shaft, toolholder etc.) to come into 

contact with the piece being machined. 

Accidental contact of this sort leads to a risk of serious damage to the electrospindle and injury to 

the operator. 

10.2 RUNNING IN 

The electrospindle is supplied already run-in and ready for installation. The factory running-in cycle 

includes careful testing of all controls and signals in simulated work cycles. 

10.3 WARMING UP 

When you power up the machine at the beginning of each day, allow the electrospindle to warm up 

slowly, to allow the bearings to reach a uniform operating temperature with consequent uniform 

expansion of the raceways. 

To warm up, run the spindle at the following speeds for the times specified: 

50% of max rated speed for 2 min. 



Repeat this cycle every time the machine is switched off for any length of time, to bring the 

electrospindle back up to operating temperature gradually and uniformly. 

While the machine operating, the spindle can reach high temperatures. 

Be very careful not to touch it without due precautions. 

i Preheating is carried out without tool holder. 

10.4 TOOL LOCKING AND RELEASE 

The tool is mechanically locked by springs. 

The tool is released by means of a single acting piston actuated by compressed air at 6 bar. 

ELECTROSPINDLE MODEL AXIAL FORCE OF SPRINGS AXIAL FORCE ON TOOL 

HOLDER 

ISO 40 / ISO 40 Special 4000 N +/- 10% 4000 N +/- 10% 

To prevent the toolholder from sticking, remove it after machining. 

Always protect the internal parts of the spindle: 

lock in a clean and ambient-temperature toolholder when the spindle is not 

machining. 

5801H0066 en Rev.01 27/48


The axial force exerted on the tool holder by the locking system is guaranteed 

to be constant for a minimum of 2,000,000 tool changing cycles 

1 Tool Changing Cycle = Tool Locked / Tool Released / Tool Locked 

All HSD electrospindles have a mechanical reactionm system that neutralises the 

axial force of the piston on the shaft during the tool changing phase, thus 

guaranteeing the integrity of the precision bearings. 

10.5 AUTOMATIC CLEANING OF THE SPINDLE SHAFT CONE HOUSING 

The tapered housing of the spindle shaft must always be kept perfectly clean and free from dust, 

grease, coolant, oil, metal particles, corrosion and scaling. 

The compressed air system shown in section 9.10 automatically cleans the cone during tool 

changes. This cleaning is not sufficient on its own, however. Regular cleaning must be performed 

as instructed in chapter § 11 on maintenance. 

10.6 PRESSURISING 

Compressed air must be ISO 8573-1, classes 2 4 3 compliant ( see section 9.7 ) 

There are two pressurizing circuits inside the electrospindle. The purpose of these is to prevent dirt 

from entering. Compressed air is distributed to two separate areas: 

1. Front mechanical labyrinth: Compressed air is forced out through the ports in the spindle 

nose area. 

2. Tool cooling water distributor: Compressed air prevents water from entering the draw bar 

and release cylinder area. Any water which does get through is drained out through drain holes 

provided for the purpose. 

10.7 PROXIMITY SENSORS 

The electrospindle is fitted with three normally open (NO) and one normally closed (NC) PNP 

proximity sensors: 

� S1 : DRAW BAR SENSOR (TOOLHOLDER LOCKED) 

� S2 : FORWARD PISTON SENSOR (TOOLHOLDER UNLOCKED) 

� S3 (optional): SHAFT IDLE SENSOR 

� S5 : BACKWARD PISTON SENSOR (PISTON IN SAFE CONDITION, AWAY FROM 

ROTATING PARTS) 

10.7.1 Specifications of proximity sensors 

Supply voltage 10 � 30 V (DC) 

Maximum load 200 mA 

Current absorbed without load � 10 mA 

Nominal reading distance 0,8 mm 

i 

The “ON” condition of the sensor corresponds to the output equal to the supply voltage; 

the “OFF” condition corresponds to an output of 0V. 

5801H0066 en Rev.01 28/48


10.7.2 Electrospindle states and corresponding sensor S1, S2, S5 outputs 

STATE S1 S2 S5 

Toolholder unlocked, collet open OFF ON OFF 

Collet closed without toolholder OFF OFF ON 

Tool-holder locked 

and piston in safe position 

ON OFF ON 

The shaft of the electrospindle can only be rotated when the state is “Tool-holder 

locked and piston in safe position”; if the outputs of S1 or S5 move to “OFF”, stop 

the rotation of the shaft of the electrospindle. 

10.7.3 S3 sensor “shaft idle” (optional) 

Sensor S3 supplies two “ON” pulses and two “OFF” pulses at each rotation of the shaft, as shown 

in the figure below. 

0 

Image 10-1 output S3 sensor 

+ 24 V 

For the electrical specifications see section 10.7.1 . 

For the installation follow paragraph 12.1 and make sure to obtain the output illustrated in the 

Image 10-1. 

10.8 THERMAL ALARM 

A normally closed switch is installed inside the motor. The switch opens if the motor reaches a 

temperature likely to cause damage. Monitor the state of this switch via the wiring described in 

section 9.11 and stop the electrospindle if the switch opens (OFF). 

If the shaft stops while the tool is being pressed against the workpiece, this may 

damage the spindle bearings. If an excessive amount of time is taken to move the 

tool away from the workpiece and stop the rotation, there is a risk of burning-out 

the stator. 

5801H0066 en Rev.01 29/48 

1 

0 V 

giri 

rev


10.9 ENCODER (OPTIONAL) 

The encoder provides information on spindle angle, rotation speed, and rotation direction. 

10.9.1 Standard HSD TTL rectangular encoder 

SPECIFICATION VALUE 

Rated feed power: 12 V DC ÷ 24 V DC �10% 

Consumption: 

Operating 

temperature 

Max. operating 

altitude: 

Signal input: 

Signal output: 

99 mA con 12 V DC 

51 mA con 24 V DC 

0° C ÷ 70° C 

(32° F ÷ 158° F) 

2000 m (6500ft) 

654 pulses per revolution 

and zero signal 

TTL compatible electrical 

levels 

(0V, +5V line driver) 

5801H0066 en Rev.01 30/48 

A 

B 

A 

B 

Z 

Z 

D 

T 

5 V 

0 V 

5 V 

0 V 

5 V 

0 V 

5 V 

0 V 

5 V 

0 V 

5 V 

0 V


10.10 CHOICE OF TOOLHOLDER CONE 

� The geometry of the ISO conicity must conform to DIN69871 standard (see Image 10-2), 

for the special version follow the product specifications (see Image 10-3); 

� Avoid the presence of plugs, slots, or other forms affecting the dynamic balancing of the 

tool holder 

� The degree of dynamic balancing must be G = 2.5 or better (standard ISO1940); 

� Balancing is performed with the tool holder assembled (cone, mill collet, ring nut, tool). 

63 

O 

12 

O 

CONO/CONE ISO 40 

ISO/DIS 7388/1 

DIN 69871 

30° 

O 6.35 

Image 10-2 – ISO 40 Standard 

49.3 

35 

M 16 

15° 

O 6.35 

Image 10-3 – ISO 40 Special 

Codolo/Pull Stud 

standard HSD 

code: H080706700 

The pull stud (also referred to as retention knob) must be HSD article code 

H080706700. 

It is strictly forbidden to install pull studs of any type other than the HSD typeapproved 

article specified above. Failure to comply can lead to breakage or 

ineffective locking of the toolholder and EXTREMELY SERIOUS RISKS FOR 

THE OPERATOR. 

When cleaning the cone, make sure that the pull stud is screwed firmly into 

the toolholder. 

5801H0066 en Rev.01 31/48 

61 

44 

O 

Codolo/Pull Stud 

standard HSD 

code: H080706700


10.11 CHOICE OF TOOL 

The following requirements must be respected when choosing a tool: 

1. Only use perfectly sharp tools. Make sure that they are locked firmly in the toolholder. 

2. Never use bent, damaged, incomplete, or imperfectly balanced tools. 

3. Always make sure that the surfaces of the tool are clean and undamaged before fitting it in the 

collet. 

Never operate tools beyond the rated speed punched on them or that 

specified by the manufacturer. 

10.12 WHAT TO DO IF THE TOOL IS BLOCKED ON THE PIECE BEING WORKED 

In the models with an ISO type tool hooking, if the machine goes into emergency 

mode or stops with the tool blocked on the piece being worked, do not move the 

spindle along the Z axis! 

X 

Z 

If possible, release the piece manually and then carry out the tool changing manually. 

If this is not possible, proceed in the following way: 

1. Supply air to the tool changing circuit 

2. Slowly move the spindle away from the piece, moving it along the Z axis until the collet 

opens (“ON” output of sensor S2) 

3. Check the collet spindle has been freed from the collet 

4. Move the spindle completely away from the piece being worked 

5. Remove the blocked tool manually. 

If these procedures are not observed, the tool holder will drag the locking system (collet/tie-rod) 

with it until the collet spindle is freed; owing to the force of the spring, the collet will then shoot back 

violently, perhaps breaking the tie-rod. 

5801H0066 en Rev.01 32/48 

Y


1 2 3 4 

5 6 

UTENSILE BLOCCATO 

UTENSILE RILASCIATO 

IMPATTO 

N. Description 

1 ISO collet spindle 

2 Spindle shaft 

3 ISO collet (or bush) 

4 Tie-rod 

The arrows show the direction in 

which the locking system moves 

after freeing the collet spindle 

Point in which the collet 

5 

knocks against the shaft 

6 Breakage of the tie-rod 

5801H0066 en Rev.01 33/48


§ 11 ORDINARY MAINTENANCE 

i 

i 

To safely operate an electrospindle installed on the machine, refer to the manual 

of the machine itself. 

The punctual respect of the scheduled maintenance is essential in order to 

maintain the conditions of use and working planned by HSD S.p.A. when the 

product was put onto the market. 

The frequency has been calculated on the basis of a working week of 5 days, each of 8 

working hours, under normal environmental working conditions. 

Bearings are lubricated for life and do not require further greasing. 

Read this section carefully before carrying out any maintenance operation on the electrospindle. 

The safety regulations during the maintenance of the electrospindle must take into account that: 

� maintenance and/or lubrication operations must only be carried out by trained and qualified 

personnel, duly authorised by the technical management of the plant, in accordance with 

the safety directives and standards in force, using tools, instruments and products suitable 

for this work; 

� during maintenance works, it is obligatory to wear suitable clothing, such as close-fitting 

overalls, safety shoes, strictly avoiding wide garments or items with protruding parts; 

� during maintenance works, we recommend that the machine be cordoned off and the signs 

indicating “MACHINE MAINTENANCE” posted. 

During any maintenance operations, the electrospindle must be: 

� disconnected and isolated from the electric power supply; 

� the tool must be strictly at a standstill (not rotating). 

The maintenance manager must appoint a team of persons in order to guarantee proper coordination 

among the team members and the maximum safety of the persons exposed to danger. 

All persons involved in the maintenance operations must be in full visual contact for signalling 

possible dangers. 

5801H0066 en Rev.01 34/48


11.1 DAILY MAINTENANCE 

11.1.1 Checking and Cleaning the tool holder seat and the tool holder cone 

The contact surfaces between the tool holder and the tool holder seat must be kept clean in order 

to guarantee safe hooking. 

Image 11-1 

1 

Image 11-2 

Conical surfaces 

(in black) 

At the start of the work day, check that the surfaces shown in figures are thoroughly clean, with no 

traces of dust, grease, cooling liquid, oil, metal particles or machining residues, nor signs of 

oxidisation or scale; 

if necessary, wipe with a soft, clean cloth. 

For cleaning the surfaces indicated, use soft, clean cloths; 

NEVER USE abrasive instruments such as wire wool, metal scrapers, emery cloth, 

acids or other aggressive elements. 

At the end of the working day, clean the surfaces shown in Image 11-1 and Image 

11-2 with a soft, clean cloth; inadequate cleaning may result in serious 

consequences for the operator's safety, for the wear of the electrospindle and tool 

holder, for the precision and efficiency of the machining operation. 

Do not direct jets to the area of the 

pressurized sealing labyrinth because 

infiltrations damage the electrospindles 

internal parts. 

Do not direct jets inside the electrospindle 

when the tool holder is not hooked since the 

coupling surface, together with the tool 

holder, may get dirty or machining residues 

may get into the electrospindle. 

1. Coupling surface 

2. Labyrinth sealing 

1 2 

Image 11-3 

11.1.2 Protection of the tool holder seat 

The tool holder seat must always be protected against the impurities that may come in and could 

damage, oxidise or in any other way harm the contact surfaces: never leave the electrospindle 

without a tool holder cone inserted. 

The cone used for protection must not have through bores. 

In order to avoid sticking, remove the tool holder installed on the electrospindle 

and replace it with a clean tool holder at room temperature after major machining 

operations as well as at the end of the working day, in order to protect the inside 

of the electrospindle from the external environment. 

The tool holder to be removed may be hot! Use gloves! 

5801H0066 en Rev.01 35/48


11.2 BIWEEKLY MAINTENANCE 

11.2.1 Clean the tool holder cone with ethyl alcohol 

Carefully clean the contact surfaces of the tool holders (shown in Image 11-1 and Image 11-2) with 

a soft, clean cloth dipped in ethyl alcohol. 

5801H0066 en Rev.01 36/48


§ 12 REPLACEMENT OF COMPONENTS 

Inside the electrospindle, there is a pre-loaded spring with a force of hundreds of 

kilograms. This spring is attached to a tie-rod that may be thrown out violently if 

the electrospindle is dismantled by personnel who have not been sufficiently 

trained. 

Carry out only the operations described in this manual, paying close attention to 

the instructions given; for further information, contact HSD S.p.A. Customer 

Service. 

Observe the safety precautions for maintenance given on page Errore. Il segnalibro 

non è definito.. 

Only the adjustment and replacement operations with original HSD S.p.A. spare 

parts described in this section of the manual are permitted. 

Any other type of operation is not permitted and will invalidate the product 

warranty. 

5801H0066 en Rev.01 37/48


12.1 REPLACEMENT AND ADJUSTMENT OF THE SENSOR GROUP 

For the position of sensors see the paragraph 8.1 . 

12.1.1 Description of the sensor unit 

The sensors are pre-assembled in calibrated bushes to allow simple insertion to the right depth in 

the electrospindle. It is therefore important to correctly identify the sensor to be replaced: for this 

reason, both the sensors installed on the electrospindle and those supplied as spare parts bear a 

numbered label (Image 12-1). 

Confusion of the sensors will result in damage to the moving parts. 

1 

Image 12-2 

Sensor fastening through bracket 

Image 12-1 

5801H0066 en Rev.01 38/48 

9 

3 

6 

8 

4 

7 2 

Ch 12 

Image 12-3 

Sensor fastening through block 

1 Electrical connector 6 Calibrated position 

2 Eccentricity marking 7 Bracket or block 

3 Bush 8 Sensor unit 

4 Sensor 9 Screw 

Eccentricity between 

5 

regulation sensor 

bush and 

5


12.1.2 Replacement and adjustment of the sensor unit 

i 

For the replacement and adjustment of the sensors shown in this paragraph (and those 

to follow), always refer to Image 12-1; Image 12-2; Image 12-3 of the previous 

paragraph. 

1. Remove screw “9” that blocks the bracket or block “6” of the sensor unit “8” to be replaced; 

2. unthread the faulty sensor unit from its seat, and disconnect its electrical connector “1”; 

3. connect the electrical connector of the new sensor unit to the correspondingly numbered 

connector of the spindle; 

4. check the functioning of the new sensor by bringing it into contact with a metallic mass; 

5. Insert the new sensor unit in the empty seat; 

6. reposition the bracket “7” and lock the screw “9” again without tighten it completely, so that 

the sensor unit can rotate; 

7. rotate the sensor unit a few degrees at a time, until you obtain the outputs requested in the 

paragraphs immediately below; 

8. tighten the screw “9” by blocking the sensor unit with an open-end spanner so as to 

maintain the calibration carried out. 

12.1.3 Sensor S1 adjustment 

After replacing the sensor unit as described in section 12.1.2 , adjust it as follows: 

1. do not tighten the sensor completely until an accurate adjustment has been performed; 

2. attach the tool holder cone and ensure that the output of S1 is “ON”; if the output is “OFF”, 

rotate the sensor unit until it becomes “ON”; 

3. the sensor “4” is eccentric in relation to the bush “3” that contains it: rotate the bush slowly 

in the direction that takes the sensor away from the tool holder; 

stop immediately when the output of the sensor becomes ”OFF”; 

4. carefully rotate the bush back by about 15° - 20°, so that the output of the sensor returns to 

“ON”; 

5. rotate the shaft manually, and check that the signal remains “ON” for the whole rotation; 

6. tighten fixing screw “9”; 

7. release the tool holder by powering the piston at the pressure indicated in the section 8.1 

and check that in this condition (collet open) the output of S1 is “OFF”; 

8. release the pressure at the piston and allow the collet to close without tool holder: in this 

condition, the output of S1 must be “OFF” for the whole rotation of the shaft; 

9. if points (7) and (8) are not satisfied repeat the procedure from the start, making an even 

slighter rotation movement at point (4);; 

10. if points (7) and (8) are satisfied, make a cycle of 10 tool changes; 

11. at the end of the cycle, check that the conditions in the following table are satisfied: 

CONDIZIONE OUTPUT S1 

tool holder locked ON (*) 

missing tool holder 

with closed collet 

collet open 

(tool holder ejected) OFF 

OFF (*) 

(*) for the whole rotation of the shaft 

12. if the conditions of the table are not satisfied, repeat the procedure from the beginning; 

13. if the conditions of the table are satisfied, perform a cycle of 100 tool changes with the 

machine, using the maximum possible number of different tool holders.; 

14. At the end of the cycle, check that the conditions in the table under point (11) are satisfied: 

if this is the case, the regulation procedure for S1 is complete; if this is not the case, 

repeat the procedure from the beginning. 

5801H0066 en Rev.01 39/48




1. correctly attach a tool holder before beginning the adjustment of the sensor; 

2. check that, in this state, the output of S2 is “OFF”; if the output is “ON”, rotate the sensor 

unit until it becomes “OFF”; 

3. feed the cylinder by means of a one-way pressure regulator initially set at 0 bar (0 PSI); 

4. increase the feed pressure by steps of 0.1 bar (1.5 PSI) so as to move the piston slowly 

forward and, at the same time, check that the output of S2 is “OFF”; 

5. as long as the tool holder is firmly blocked, the output of S2 must be “OFF”; 

if the output changes during the movement of the piston, slightly rotate the sensor unit until 

the output returns to “OFF”; 

6. when the tool holder begins to slacken (but is not yet free to fall), the output of S2 must still 

be “OFF” (if necessary, rotate the sensor unit); 

7. when you reach the feed pressure at which the tool holder is finally free to fall, increase the 

pressure by another 0.2 bar (3 PSI) and block the pressure regulator; 

8. rotate the sensor unit so that, in this state, the output of S2 becomes “ON”; 

9. perform a cycle of 10 tool changes; 

10. at the end of the cycle, check that the steps from (1) to (8) are satisfied without the need 

to ever rotate the sensor; 

11. if the outputs requested are not satisfied, repeat the entire procedure from the start; 

12. if the outputs requested are satisfied, perform a cycle of 100 tool changes with the 

machine, using the maximum possible number of different tool holders; 

13. at the end of the cycle, check that the steps from (1) to (8) are satisfied without the need 

to ever rotate the sensor; 

14. if the outputs requested are not satisfied, repeat the entire procedure from the start; 

15. if the outputs requested are satisfied, the regulation procedure for S2 is complete. 

5801H0066 en Rev.01 40/48




1. correctly attach a tool holder before beginning the adjustment of the sensor; 

2. supply 6 bar (87 PSI) to the cylinder so as to keep the piston at the upper end stop 

3. position the sensor at the highest position allowed by movement (step 6 section 12.1.2 ) 

[“high” = direction opposed to the tool holder]; 

4. check that, in this condition, the output of S5 is “OFF”; 

5. move the sensor downwards in small steps, until you find the position at which the output of 

S5 becomes “ON”; 

6. slightly move the sensor by another small step downwards; 

7. lock the position of the sensor by tightening screw (3); 

8. carry out 10 cycles of “tool expulsion” - “return to upper end stop”; 

9. bring the piston to the upper end stop; 

10. check that, in this condition, the output of S5 is “ON”; 

11. free the input of the air to return the piston to the upper end stop in the cylinder; 

12. feed the air input for “tool holder ejection” of the cylinder, using a one-way pressure 

regulator initially set at 0 bar (0 PSI); 

13. increase the feed pressure by 0.1 bar (1.5 PSI) steps and, at the same time, rotate the 

shaft manually to check that it rotates freely and is not hampered by dragging against the 

piston; 

14. when the output of S5 becomes “OFF”, the manual rotation of the shaft must still be 

absolutely free; 

15. if the cylinder drags against the shaft when sensor S5 is still “ON”, this means that at point 

[6] of this procedure, the sensor was advanced too far: repeat the whole procedure, making 

much finer movements at point [6]; 

16. if point [14] of the procedure is satisfied, perform 50 “tool ejection” - “return to upper end 

stop” cycles; 

17. check the adjustment, repeating steps [9] to [16] of this procedure four times. 

5801H0066 en Rev.01 41/48


§ 13 DISPOSING OF THE PRODUCT 

Observe the safety precautions for maintenance given on page 34 and 37. 

At the end of the electrospindle's working life it is the Customer’s responsibility to dispose of it 

correctly. 

First of all, clean the unit and separate the various components into mechanical and electrical 

parts. Then separate the component parts according to type of material: electric motors (copper 

windings), metal parts (body, etc.), plastic parts, etc.. Dispose of the various materials in 

compliance with the laws and regulations applicable in the country where the electrospindle has 

been installed. 

5801H0066 en Rev.01 42/48


§ 14 LIST OF SPARE PARTS 

CODE DESCRIPTION 

H5664H0040 Kit S2, S5 inductive sensor 

H5664H0062 Kit S1 inductive sensor 

H5631H0537 Kit S3 inductive sensor 

H6202H0079 Cylinder assembly 

FNZ4100033 Motor plate 

H2161H0022 Cooling fluid ARTIC-FLU-5 (5-litre canister) 

5801H0066 en Rev.01 43/48


§ 15 TROUBLESHOOTING 

PROBLEMS CAUSES REMEDIES 

The electrospindle does 

not turn: 

There is no power 

No tool holder is fitted Fit a tool holder. 

The tool holder not correctly 

seated 

The thermal switch has tripped 

The inverter switch has tripped 

Sensor S1 or sensor S5 are 

disconnected or faulty 

� Check the mains power 

supply. 

� Check all power terminals. 

� Check all electrical cables and 

connections for breaks. 

See “The tool holder is not 

locked” below. 

Wait for the electrospindle to cool 

down and the thermal switch will 

automatically reset. 

If the thermal switch trips 

frequently, see “The 

electrospindle overheats” below. 

Consult the inverter's own manual 

or contact the inverter 

manufacturer. 

� Check the sensor connectors. 

� Check the sensor cables for 

breaks. 

� Contact the HSD technical 

assistance service. 

5801H0066 en Rev.01 44/48


The tool holder is not 

locked: 

The tool holder is not 

ejected: 

There is no air pressure 

inside the electrospindle: 

One of the sensors does 

not give the required 

output: 

There is dirt or foreign bodies 

between the tool holder and the 

spindle shaft housing 

The tool holder cone is not of 

the right type 

There is insufficient air pressure 

to open the collet 

Sensor S2 is disconnected or 

faulty 



or the compressed air system is 

faulty 

A sensor is disconnected or 

faulty 

Remove any large foreign bodies 

and clean the tool holder cone 

and spindle housing as instructed 

in section § 11. 

Choose a tool holder as 

instructed in section § 10. 

� Check the air pressure 

settings in accordance with 

section 8.1 ; 

� Check the compressed air 

system for leaks and pressure 

losses. 

� Check the sensor connectors. 


breaks. 





paragraph 8.1 ; 



losses. 



sections 8.1 ; 



losses; 

� Contact the HSD Technical 

Assistance Service. 

� Check the sensor connectors; 


breaks; 



5801H0066 en Rev.01 45/48


The electrospindle 

overheats: 

Performance below 

specifications: 

The electrospindle 

vibrates: 

The bearings are noisy: 

Cooling problems: 

The machining is taking up too 

much power 

The inverter setup is incorrect 


The tool holder is not balanced 

The tool is not balanced 

There is dirt or foreign bodies 

between the tool holder and the 

spindle shaft housing 


The machining is taking up too 

much power 

� Check cooling circuit 

specifications in section 9.4 ; 

� Check the cooling system for 

leaks and losses or clogging. 

� Contact the HSD Technical 

Assistance Service. 

Reduce the machining power 

requirements. 

Check the specifications of the 

electrospindle on its data label 

and in paragraph 7.1 . 




Choose a tool holder in 

accordance with paragraph § 10. 

Choose a tool in accordance with 

paragraph § 10. 

Remove any large foreign bodies 

and clean the tool holder cone 

and spindle housing as instructed 

in section § 11. 




Reduce the machining power 

requirements. 

The fixing bolts are loose Tighten the fixing bolts. 

The bearings are worn or Contact the HSD technical 

damaged 


The bearings are worn or Contact the HSD technical 

damaged 


5801H0066 en Rev.01 46/48


§ 16 DECLARATION OF INCORPORATION 

Pesaro 29/07/2010 

ELECTROSPINDLE 

MODEL 794 

5801H0066 en Rev.01 47/48



MECHATRONIC 

D I V I S I O N 

HSD S.p.a. 


Via della Meccanica 16 

61122 PESARO (ITALIA) 



P.le A.De Simoni, sn 

61122 PESARO (ITALIA) 

Tel. +39 0721 205 211 

Fax +39 0721 205 247 

E-mail supporthsd@hsd.it 

web www.hsd.it 

HSD Deutschland GmbH 

Brückenstrasse 32 

D-73037 Göppingen (DEUTSCHLAND) 

Tel. +49 07161 956 660 

Fax +49 07161 956 661 0 

E-mail supporthsddeut@hsddeutschland.de 

web www.hsddeutschland.de 

HSD USA Inc. 

3764 SW, 30 th Avenue 

Hollywood, Florida 33312 USA 

Phone no. +1 954 587 1991 

Fax +1 954 587 8338 

E-mail supporthsdusa@hsd.it 

web www.hsdusa.com 

HSD Mechatronic Shangai Co. Ltd. 

D2, First floor, 207 Taigu Road 

Waigaoquiao, Free Trade Zone 

200131, Shangai - CHINA 

Phone no. +86 215 866 1236 

E-mail sales@hsd-china.cn 

web www.hsd-china.cn 

5801H0066 en Rev.01 48/48

ES721 ISO40 7 kW NL - HSD

Create successful ePaper yourself

Delete template?

Save as template?