2SP1weeis PDF

2SP1 ECS motor spindle
Operating instructions · 02/2011
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2SP1 ECS Motor Spindle ___________________
Preface
Warning and safety

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information 1
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Design and function 2
Installing and commissioning
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the spindle 3
2SP1 ECS Motor Spindle ___________________

Technical data 4
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Faults in operation 5
Operating Instructions
Maintenance
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instructions/maintenance 6
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Tool clamping systems 7
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Rotary gland (option) 8
A
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Appendix
02/2011
6SN1197-0AD14-0BP1
Legal information
Legal information
Warning notice system
This manual contains notices you have to observe in order to ensure your personal safety, as well as to prevent
damage to property. The notices referring to your personal safety are highlighted in the manual by a safety alert
symbol, notices referring only to property damage have no safety alert symbol. These notices shown below are
graded according to the degree of danger.
DANGER
indicates that death or severe personal injury will result if proper precautions are not taken.
WARNING
indicates that death or severe personal injury may result if proper precautions are not taken.
CAUTION
with a safety alert symbol, indicates that minor personal injury can result if proper precautions are not taken.
CAUTION
without a safety alert symbol, indicates that property damage can result if proper precautions are not taken.
NOTICE
indicates that an unintended result or situation can occur if the corresponding information is not taken into
account.
If more than one degree of danger is present, the warning notice representing the highest degree of danger will
be used. A notice warning of injury to persons with a safety alert symbol may also include a warning relating to
property damage.
Qualified Personnel
The product/system described in this documentation may be operated only by personnel qualified for the specific
task in accordance with the relevant documentation for the specific task, in particular its warning notices and
safety instructions. Qualified personnel are those who, based on their training and experience, are capable of
identifying risks and avoiding potential hazards when working with these products/systems.
Proper use of Siemens products
Note the following:
WARNING
Siemens products may only be used for the applications described in the catalog and in the relevant technical
documentation. If products and components from other manufacturers are used, these must be recommended
or approved by Siemens. Proper transport, storage, installation, assembly, commissioning, operation and
maintenance are required to ensure that the products operate safely and without any problems. The permissible
ambient conditions must be adhered to. The information in the relevant documentation must be observed.
Trademarks
All names identified by ® are registered trademarks of the Siemens AG. The remaining trademarks in this
publication may be trademarks whose use by third parties for their own purposes could violate the rights of the
owner.
Disclaimer of Liability
We have reviewed the contents of this publication to ensure consistency with the hardware and software
described. Since variance cannot be precluded entirely, we cannot guarantee full consistency. However, the
information in this publication is reviewed regularly and any necessary corrections are included in subsequent
editions.
Siemens AG order number: 6SN1197-0AD14-0BP1 Copyright © Siemens AG 2011.

Industry Sector Ⓟ 03/2011 Technical data subject to change
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Preface
Motor documentation
The motor documentation is organized in the following categories:
● General documentation e.g. catalogs
● Manufacturer/service documentation e.g. Operating Instructions and Configuration
Manuals
More information
Information on the following topics is available under the link:
● Ordering documentation/overview of documentation
● Additional links to download documents
● Using documentation online (find and search in manuals/information)
http://www.siemens.com/motioncontrol/docu
Please send any questions about the technical documentation (e.g. suggestions for
improvement, corrections) to the following e-mail address:
docu.motioncontrol@siemens.com
My Documentation Manager
The following link provides information on how to create your own individual documentation
based on Siemens content, and adapt it for your own machine documentation:
http://www.siemens.com/mdm
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The following link provides information on SITRAIN - training from Siemens for products,
systems and automation engineering solutions:
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FAQs
You can find Frequently Asked Questions in the Service&Support pages under Product
Support:
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2SP1 ECS Motor Spindle

Operating Instructions, 02/2011, 6SN1197-0AD14-0BP1 3
Preface
Technical Support
For technical support telephone numbers for different countries, go to:
http://www.siemens.com/automation/service&support
Please refer to our Repair and Service Department for technical questions relating to
service, maintenance and repair:
Company Telephone/Telefax Internet address / E-mail

Weiss Spindeltechnologie Tel.: +49 (0) 9532 9229 347 http://www.weissgmbh.com
Repair and Service Center Fax: +49 (0) 9532 9229 377 mailto:service@weissgmbh.de
D-96126 Maroldsweisach
Internet addresses for drive technology

Internet address for motors: http://www.siemens.com/motors
Internet address for products: http://www.siemens.com/motioncontrol
Internet address for SINAMICS: http://www.siemens.com/sinamics
Standard scope
The scope of the functionality described in this document can differ from the scope of the
functionality of the drive that is actually supplied.
● Other functions not described in this documentation might be able to be executed in the
drive. However, no claim can be made regarding the availability of these functions when
the equipment is first supplied or in the event of servicing.
● The documentation can also contain descriptions of functions that are not available in a
particular product version of the drive. The functionalities of the supplied drive should only
be taken from the ordering documentation.
● Extensions or changes made by the machine manufacturer are documented by the
machine manufacturer.
For reasons of clarity, this documentation does not contain all of the detailed information on
all of the product types. This documentation cannot take into consideration every
conceivable type of installation, operation and service/maintenance.

4 Operating Instructions, 02/2011, 6SN1197-0AD14-0BP1
Table of contents
Preface ...................................................................................................................................................... 3
1 Warning and safety information ................................................................................................................. 9
1.1 General ..........................................................................................................................................9
1.2 Qualified personnel ........................................................................................................................9
1.3 Working on the systems...............................................................................................................10
1.3.1 Mechanical system ......................................................................................................................10
1.3.2 Hydraulic/pneumatic systems ......................................................................................................10
1.3.3 Electrical system ..........................................................................................................................11
1.4 Specific hazards and dangers......................................................................................................11
1.4.1 Danger due to mechanical energy...............................................................................................12
1.4.2 Hazards due to hydraulic/pneumatic energy ...............................................................................12
1.4.3 Hazards due to electrical energy .................................................................................................12
2 Design and function ................................................................................................................................. 13
2.1 Bearings .......................................................................................................................................13
2.2 Lubrication....................................................................................................................................13
2.3 Seal ..............................................................................................................................................13
2.4 Drive.............................................................................................................................................14
2.5 Motor cooling................................................................................................................................14
2.6 Tools ............................................................................................................................................15
2.6.1 General ........................................................................................................................................15
2.6.2 Safety ...........................................................................................................................................16
2.6.3 Permitted balance qualities..........................................................................................................16
2.6.4 Permissible speed........................................................................................................................17
2.6.5 Permissible vibration levels..........................................................................................................18
2.7 Tool clamping system ..................................................................................................................19
2.7.1 Clamp/release tool (tool release unit) ..........................................................................................19
2.7.2 Clamping state sensing................................................................................................................19
2.8 Tool cooling..................................................................................................................................21
2.8.1 Internal tool cooling for the cooling-lubricating medium (option) .................................................21
2.8.2 External tool cooling for the cooling-lubricating medium (option for 2SP120x) ...........................22
2.9 Tool air purge system ..................................................................................................................23
3 Installing and commissioning the spindle................................................................................................. 25
3.1 Commutation angle......................................................................................................................26
3.2 Voltage limiting.............................................................................................................................28
3.3 Conditions for switching on ..........................................................................................................30
3.3.1 Switching-on conditions when operating the spindle under speed..............................................30
3.3.2 Switching-on conditions when changing tools .............................................................................32

Table of contents
3.4 Switch-on procedure ................................................................................................................... 33

3.5 Switch-off procedure ................................................................................................................... 33
4 Technical data ......................................................................................................................................... 35
4.1 Power connection........................................................................................................................ 35
4.2 Overview, supplying the various media ...................................................................................... 37
4.2.1 Cooling water .............................................................................................................................. 38
4.2.2 Compressed air........................................................................................................................... 39
4.2.3 Hydraulic ..................................................................................................................................... 40
4.2.4 Internal tool cooling using the cooling-lubricating medium (option) ............................................ 41
4.2.5 External tool cooling with the cooling-lubricating medium (option for 2SP120x) ........................ 43
4.2.6 Connections for various media ................................................................................................... 44
4.3 Clamping state sensing............................................................................................................... 48
4.4 Rotary encoder, motor measuring system .................................................................................. 51
4.5 Bearing temperature monitoring (option for 2SP120x) ............................................................... 51
4.6 Tool interfaces............................................................................................................................. 52
4.7 Tool interfaces............................................................................................................................. 53
5 Faults in operation ................................................................................................................................... 57
6 Maintenance instructions/maintenance.................................................................................................... 59
6.1 Maintenance plan........................................................................................................................ 59
6.2 Wearing parts.............................................................................................................................. 59
6.3 Storing the spindle in the magazine............................................................................................ 60
7 Tool clamping systems ............................................................................................................................ 61
7.1 Safety instructions....................................................................................................................... 61
7.2 Product description, tool clamping system HSK A63 Type K ..................................................... 61
7.2.1 Mounting the clamping set .......................................................................................................... 64
7.2.1.1 Protective sleeve for sealing socket installation.......................................................................... 65
7.2.1.2 Installation tool HSK A63 Type K................................................................................................ 66
7.2.1.3 Final check HSK A63 Type K...................................................................................................... 66
7.2.1.4 Balancing..................................................................................................................................... 66
7.2.2 Operation..................................................................................................................................... 67
7.2.3 Changing the lip seal in the clamping set ................................................................................... 68
7.2.4 Broken gripper segment.............................................................................................................. 68
7.2.5 Maintenance................................................................................................................................ 69
7.2.6 Spare parts list ............................................................................................................................ 71
7.2.6.1 O-rings and lip seal parts ............................................................................................................ 71
7.2.6.2 Rotary gland................................................................................................................................ 71
7.2.7 Troubleshooting HSK A63........................................................................................................... 72
7.3 Product description of holding clamping set HSK A63 Type C................................................... 73
7.3.1 Mounting the clamping set .......................................................................................................... 75
7.3.1.1 Protective sleeve for sealing socket installation.......................................................................... 76
7.3.1.2 Final check HSK A63 Type C ..................................................................................................... 77
7.3.1.3 Balancing..................................................................................................................................... 77
7.3.2 Operation..................................................................................................................................... 78

Table of contents
7.3.3 Changing the lip seal in the clamping set ....................................................................................79

7.3.4 Broken gripper segment...............................................................................................................79
7.3.5 Maintenance.................................................................................................................................80
7.3.6 Spare parts list .............................................................................................................................82
7.3.6.1 O-rings and lip seal parts .............................................................................................................82
7.3.7 Troubleshooting HSK A63-Type C ..............................................................................................83
7.4 Product description, tool clamping system SK40/CAT40/BT40...................................................84
7.4.1 Installing the clamping set............................................................................................................86
7.4.1.1 Final check ...................................................................................................................................87
7.4.1.2 Balancing .....................................................................................................................................87
7.4.2 Operation .....................................................................................................................................87
7.4.3 Broken gripper segment...............................................................................................................88
7.4.4 Maintenance.................................................................................................................................88
7.4.5 Spare parts list .............................................................................................................................89
7.4.6 Fault finding SK40/CAT40/BT40..................................................................................................90
8 Rotary gland (option) ............................................................................................................................... 91
8.1 Maintaining the rotary gland.........................................................................................................91
8.2 Replacing the rotary gland ...........................................................................................................91
8.3 Timing diagram for the rotary gland.............................................................................................93
A Appendix.................................................................................................................................................. 95
A.1 Dimension drawings.....................................................................................................................95
A.2 Parameter and machine data - setting data...............................................................................102
A.2.1 SINAMICS S120 ........................................................................................................................102
A.2.2 SIMODRIVE 611 universal/digital ..............................................................................................105
A.3 Declaration of conformity ...........................................................................................................109
A.4 Service workshops.....................................................................................................................110
Index...................................................................................................................................................... 111

Table of contents

Warning and safety information 1
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 have access to these
operating instructions and clearly understand them.
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 GmbH has the exclusive copyright 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 are responsible in ensuring that the spindle unit is only operated when it is in a perfect
condition.
WARNING
Modifications and changes
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 Qualified personnel

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.
The operator is responsible for ensuring that no unauthorized personnel work on/with the
spindle unit. Any person in the users 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 user/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.

Warning and safety information
1.3 Working on the systems
1.3 Working on the systems
WARNING
Only appropriately trained specialist personnel may work on and with the spindle unit.
The appropriate operating instructions must be carefully observed.
1.3.1 Mechanical system
WARNING
All work must 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 operating
instructions must be carefully and precisely observed.
1.3.2 Hydraulic/pneumatic systems
WARNING
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.
Pressure reservoirs 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!

1.4 Specific hazards and dangers
1.3.3 Electrical system
WARNING
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.
If the terminal box is open, it is not permissible that the spindle shaft rotates (the motor can
generate a voltage at the terminals).
DANGER
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.

1.4.1 Danger due to mechanical energy
CAUTION
Depending on the tool diameter and the speed, the tool is subject to extremely high
centrifugal forces. 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 is it permissible that the highest spindle unit speed is exceeded.
Under no circumstances may fingers be inserted into the tool interface.
1.4.2 Hazards due to hydraulic/pneumatic energy
WARNING
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.
1.4.3 Hazards due to electrical energy
DANGER
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.

Design and function 2
Detailed technical data on the functions described below are provided in Chapter Technical
data (Page 35).
2.1 Bearings
High precision spindle bearings are used for the 2SP1 motor spindle. 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
tensioning. The bearings have excellent smoothing running characteristics and the lowest
level of roughness.
2.2 Lubrication
The bearings of 2SP1 motor spindles have 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.

Design and function
2.4 Drive
2.4 Drive
An integrated built-in motor drives the 2SP1 motor spindle. This built-in motor has a high
torque and its rotor is directly mounted onto the tool spindle. This built-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, precision rotary encoder, they are admirably suited for both closed-loop
speed and position controlled operation.
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 heat loss
of 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 heat 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 or 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 providing the
appropriate cooling water.
It is not permissible that the cooling water intake temperature drops below the ambient
temperature in order to avoid condensation inside the spindle.

Design and function
2.6 Tools
2.6 Tools
2.6.1 General
WARNING
Rotation of the workspindle without a clamped tool is prohibited at all times.
A maximum of 1000 rpm is 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 the tool is inserted. Even minute amounts of
contamination will cause radial eccentricity and out-of-balance conditions.
If machining is performed with inner tool cooling, you must use tools with a flexible coolant
supply pipe! If this is not possible, then it must be guaranteed that the coolant feed can be
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;
short tools result in lower bearing stressing. This means that the tools must be clamped so
that their effective length is as short as possible.

Design and function
2.6 Tools
2.6.2 Safety
CAUTION
Depending on the tool diameter and speed, the tool is subject to extremely high centrifugal
forces.
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.
For this reason, only balanced tools are permitted that are used in enclosed and secured
working areas (see Chapter Permitted balance qualities (Page 16)).
2.6.3 Permitted balance qualities
CAUTION
The balance quality of the tool being used is decisive for the machining result.
Only precisely balanced tools with balance quality Q 6.3 are permitted. 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 and 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.

Design and function
2.6 Tools
2.6.4 Permissible speed

The ratio between length L and diameter Ø for the utilized tools must not exceed 3:1.
Likewise, the total mass of the tool insert must be under 4.5 kg.
7RROKROGHU
7RROLQVHUW
Figure 2-1 Length-diameter ratio of the tool
WEISS spindles are designed such that with these tools the critical speeds are higher than
the maximum spindle speed.
If tools are used whose dimensions deviate from these specifications, then the permissible
speed must be calculated.
In addition to the speed being limited by the critical speeds of the spindle/tool system,
attention must also be paid to the fact that the technological data of the machining process
could limit the speed.

Design and function
2.6 Tools
2.6.5 Permissible vibration levels

The maximum permissible radial vibration velocity is limited to the following values over the
complete speed range:
3 mm/s in no-load operation

6 mm/s in continuous operation
10 mm/s briefly (max. 5 sec)
For the axial vibration velocity, half of the values apply.
In the 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 (machining-end value A, drive-end value B) are documented in the
respective acceptance report.
If the balance quality is subsequently measured in the field, the measurement must be
performed using a high-precision-balanced tool (Q ≤ 2.5). The vibration value determined
when accepted is used as a nominal quantity (refer to the acceptance report).
The field measurements can be performed on the outside diameter of the mounting flange or
on the freely-accessible spindle nose.
When it is installed it is possible that vibration velocities are measured that deviate from
those in the acceptance report due to the influence of the machine tool.
CAUTION
For safety reasons, vibration levels 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.

Design and function
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 at 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 has reached the tool change position, the tool is held in the change position with a
defined force (see Chapter Product description of holding clamping set HSK A63 Type C
(Page 73)).
2.7.1 Clamp/release tool (tool release unit)

The tool is released using a tool release unti at the spindle housing. By applying pressure,
the tool release 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 over, the tool release unit is
moved back again.
Available connections:
● Clamping the tool
● Releasing the tool
Note
As a result of the spindle design, the spindle shaft moves slightly in the axial direction
while the tool is being changed.
2.7.2 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:
2SP120x analog clamping state sensing

● Sensor S1 to specify the draw bar position as analog signal indicates the respective
clamping state: clamped, clamped without tool, and released. The exact spindle-specific
values can be taken from the relevant acceptance report. This cannot be used to safely
sense a jammed tool!
● Sensor S4 is adjusted so that it supplies a signal if there is a safe clearance between the
release unit and the spindle shaft.

Design and function
2SP120x digital clamping state sensing

● Sensor S1 is adjusted so that for a tool in compliance with the standard, it supplies the
"draw bar in released position" signal. This cannot be used to safely sense a jammed
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 either no tool or an excessively small tool, the "no tool
or no tool in compliance with the standard" signal is supplied.
● Sensor S4 is adjusted so that when the tool release unit is retracted from the shaft, a
signal is output.
2SP125x digital clamping state sensing

● Sensor S1 (optional) is adjusted so that for a tool in compliance with the standard, it
supplies the "draw bar in released position" signal. This cannot be used to safely sense a
jammed 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 (optional) is adjusted so that for either no tool or an excessively small tool, the
"no tool or no tool in compliance with the standard" signal is supplied.
WARNING
For safety reasons, all of the sensors available at the spindle must be connected and
evaluated. It is not necessary to adjust the sensors - and in fact this is strictly prohibited!

Design and function
2.8 Tool cooling
2.8 Tool cooling
2.8.1 Internal tool cooling for the 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.
supply pipe!
Coolant leaks inherent for this mechanical arrangement are drained through a hole in the
rotary gland housing without back pressure. That is, the drain pipe is always routed so that it
falls away from the rotary gland (see Chapter Replacing the rotary gland (Page 91)).
The rotary gland is only conditionally 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 - this rule
applies both when under pressure and under no pressure.
Note
Avoid pressure spikes and pressure fluctuations!
In particular, pressure spikes can occur if an incompressible medium (e.g. cooling-lubricating
medium) 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 valve so that the pressure spikes occurring under
the specific installation conditions do not exceed the normal permissible operating pressure.
The operating pressure must be established in stages.
Closing valves can also cause the permissible pressure to be exceeded (pressure surges
when closing).
The permissible pressure can also be exceeded if an incompressible medium (e.g. coolant)
is subjected to additional pressure by a stroke movement in an enclosed space. Remedy:
Venting!

Design and function
2.8 Tool cooling
2.8.2 External tool cooling for the cooling-lubricating medium (option for 2SP120x)
The 2SP120x 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 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.

Design and function
2.9 Tool air purge system

The tool air purge system is available with/without inner tool cooling. Compressed air is used
as cleaning medium (see under "Technical Data"; Chapter ).
When the tool is changed, the purge air must clean the tool interface in order to ensure that
the tool is safely and smoothly guided through the interface. The purge air is fed from the
end of the spindle through the draw bar up to the tool taper.
The purge air must be appropriately conditioned outside the spindle in order to fulfill the
cleaning function.
2SP120x
The supply is established using a separate connection at the back of the spindle.
NOTICE
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.
2SP125x
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, it must be ensured that there is no cooling-lubricating medium (no
hydrostatic head) in the cooling system by appropriately purging it.
NOTICE
It is not permissible to change a tool when the cooling-lubricating medium is under pressure
(no hydrostatic head) in the spindle! Failure to comply with this requirement could result in
damage to the spindle!

Design and function

Installing and commissioning the spindle 3
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 ChapterConnections for various media (Page 44)).
● For horizontal mounting arrangements, the spindle must be mounted so that the relief
and drain holes of the spindle face downwards (see Chapter Connections for various
media (Page 44)).
● 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 (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 see Tools (Page 15)).
● Never raise the spindle unit at the shaft nor place it down on the shaft face or tool
interface!
● Orientation of the spindle to change a tool is only possible in normal operation after
passing the reference mark (at least 1 shaft revolution).
This is the reason that switching-on and switching-off the spindle in the tool change state
is critical.

Installing and commissioning the spindle
3.1 Commutation angle
NOTICE
With synchronous spindles, the angle must be determined or entered when the spindle is
first commissioned or when the spindle is replaced!
The "installed" permanent magnetic field of the rotor must be synchronized with the
electrically generated magnetic field of the stator. This enables the two magnetic fields of the
stator and rotor to be optimally superimposed on one another.
This "synchronization angle" relative to the zero mark of the encoder system can be
measured and saved in the converter (commutation angle offset).
Determining the commutation angle offset for SIMODRIVE

1. Set P1011.12 = 1
2. Set P1011.13 = 0
3. Carry out a HW RESET
4. Set P1017.0 = 1
5. Activate the pulse and controller enable
6. Move the axis over the zero mark (e.g. enter a low nset)
7. --> the angle offset is automatically entered in P1016
8. --> fault 799 (save FEPROM and HW RESET required) is displayed
9. Back up FEPROM and carry out HW RESET
If the angle is already known (e.g. final acceptance report), then this value should be used to
check the value that has been determined.
Note
Deviations > 5°
For deviations > 5°, the authorized technical personnel of the manufacturer must be
contacted.
When the spindle is switched on again, the angle entered in P1016 is used after the zero
mark is crossed.

Determining the pole position identification / commutation angle for SINAMICS

1. Select a power unit (Motor Module) and select the (closed-loop) control type "Speed
control with encoder".
2. Select the 2SP1 motor spindle in the motor selection list; then press the "Continue" key.
3. Select a speed encoder (hollow-shaft incremental encoder, 1 Vpp); then press the "Enter
data" key.
4. The pole position identification routine provides coarse synchronization. The encoder has
a zero mark, therefore, after the zero mark has been crossed, the pole position can be
automatically adjusted to the zero mark position (fine synchronization). The zero mark
position must be electrically adjusted (p0431). Fine synchronization is recommended
(p0404.15 = 1), as it avoids measurement spread and allows the determined pole position
to be automatically checked.
5. "Pole position identification" must be selected in the encoder data screen under coarse
synchronization. "Zero marks" should be selected for fine synchronization. The other
fields are already pre-assigned. The "Saturation-based 1st + 2nd harmonic" is selected
and acknowledged using "Pole position ID parameter".
6. The 2SP1 spindle configuration has been completed once the Wizards have been
completed and data has been downloaded into the drive. The correct pole position
identification technique (p1980) is pre-assigned with the motor-specific identification
currents (p0325, p0329) and their selection (p1982).
7. Before determining the commutation angle offset, the control sense of the drive should be
checked, i.e. for motor clockwise rotation, the encoder must supply positive speed actual
values in r0061.
8. The correct commutation angle offset (p0431) should be determined by selecting p1990 =
1. In the expert list, switch-on the drive using the commissioning tool (control panel) (PLI
is performed) p1990 = 1. Then enter a low speed setpoint. After the zero mark has been
crossed for the first time, the determined commutation angle offset is automatically
entered into p0431. Alarm A07971 is output during the determination routine. p1990 is
automatically set to the value of 0 at the end of the measurement.
9. The automatically determined value in p0431 should be subject to a plausibility check.
Several techniques are recommended in the parameter description for p1990 (see
SINAMICS S120/S150 List Manual LH1).
If the angle is already known (e.g. final acceptance report), then this value should be used to
check the value that has been determined.
Note
Deviations > 5°
For deviations > 5°, the authorized technical personnel of the manufacturer must be
contacted.

3.2 Voltage limiting
Function description
For 2SP1 motor spindles using synchronous motors with EMF V = 820 V up to 2000 V
(Vrms = 570 V to 1400 V) voltage protection is required in order to limit the converter DC link
voltage if a fault develops.
If the line voltage fails at maximum motor speed or if the drive converter pulses are canceled
as a result of the power failure, the synchronous motor regenerates at high voltage back into
the DC link. The voltage protection detects a DC link voltage that is too high (DC > 820 V)
and short-circuits the 3 motor supply cables. The energy remaining in the motor is converted
into heat as a result of the short-circuit and causes the motor to quickly brake.
Voltage limiting modules

For SINAMICS S120, the following can be used as voltage protection:
● the VPM (Voltage Protection Module) or
● the IVP function (Internal Voltage Protection) in conjunction with
– a CSM for secure voltage supply and
– and a Braking Module with the appropriate braking resistor
For SIMODRIVE 611, the following can be used as voltage protection:
● the VPM (Voltage Protection Module)
Integration and system prerequisites of the IVP function

The IVP function is only capable of functioning in conjunction with SINAMICS S120 booksize
and/or SINUMERIK solutionline. Available as standard function from software release 2.5
and higher
System prerequisites
● SINAMICS S120 booksize (6SL31xx-xxxxx-xxxx3), software release 2.5
● Line Module capable of regenerative feedback with a regenerative power that, as a
minimum, corresponds to the maximum S1 power used.
● Adequately dimensioned Motor Module with Imax > 1.8x motor short-circuit current
● Additional DC link-buffered 24 V supply (CSM) to supply the control and Motor Modules
● Braking Module with braking resistor
For detailed information, see the SINAMICS S120 /FH1/ Function Manual

Integration and system prerequisites of the VPM

The VPM can only function in conjunction with SINAMICS S120 booksize or SIMODRIVE
611 universal/digital HRS. The VPM must be installed between the motor and drive system
(at a maximum distance from the drive system of 1.5 m). Use shielded motor feeder cables.
System prerequisites
● SINAMICS S120 booksize (6SL31xx-xxxxx-xxxx3)
● SIMODRIVE 611 universal/digital HRS
● SINUMERIK 840D sl from software release 1.3 and higher

3.3 Conditions for switching on
3.3.1 Switching-on conditions when operating the spindle under speed

The control and monitoring of the switch-on and switch-off operations at the spindle and its
supply equipment is realized via the central machine control. The switch-on and operating
conditions for safe spindle operation are listed in the following.
Motor
Cooling ON
Motor temperature < Maximum value
Sealing air
Supply pressure (measured at the spindle) in the setpoint range (see Chapter Connections
for various media (Page 44))
2SP120x
Analog clamping state sensing
Analog sensor S1
Enable for spindle start 2 - 4 V 1)
1) The specified values of the analog sensor are nominal values.
NOTICE
When setting, the actual values should be taken from the spindle acceptance report! In
order to ensure safe spindle operation, the various conditions should be monitored during
operation using the sensor. After the switch-on conditions are present, wait times must be
maintained before the spindle is allowed to rotate (see the Configuration Manual).

Tool release unit sensing
Digital sensor S4
Spindle start 1 1)
1) Do not maintain the release pressure at the tool release unit.
Digital clamping state sensing
S1 S2 S3
Enable for spindle start 1) 0 1 0
Tool release unit sensing
Digital sensor S4
Spindle start 1
NOTICE
In order to ensure safe spindle operation, the various conditions should be monitored
during operation using the sensor. After the switch-on conditions are present, wait times
must be maintained before the spindle is allowed to rotate (see the Configuration Manual).
2SP125x
Clamping state sensing
S1 S2 S3
Enable for spindle start 1) 0 1 0
NOTICE

3.3.2 Switching-on conditions when changing tools
2SP120x
Analog clamping state sensing
Analog sensor S1
Tool change 2 - 4 V 1)
1) The specified values of the analog sensor are nominal values.
NOTICE
When setting, the actual values should be taken from the spindle acceptance report! In
order to ensure safe spindle operation, the various conditions should be monitored during
operation using the sensor. After the switch-on conditions are present, wait times must be
maintained before the spindle is allowed to rotate (see the Configuration Manual).
S1 S2 S3
Enable for tool change 1) 1 0 0
1) Enable for a tool change means that the draw bar is in the "tool released position"
2SP125x
S1 S2 S3
Enable for tool change 1) 1 0 0
1) Enable for a tool change means that the draw bar is in the "tool released position"
NOTICE

3.4 Switch-on procedure
3.4 Switch-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, then ready for operation
Also see chapter Storing the spindle in the magazine (Page 60).
3.5 Switch-off procedure
Speed Braking down to standstill

Motor cooling OFF after 3 minutes
Sealing air OFF after 3 minutes

3.5 Switch-off procedure

Technical data 4
4.1 Power connection
Synchronous spindle
Table 4- 1 Power connection, synchronous spindle
Phase Designation at the spindle Conductor designation

U1 U 1
V1 V 2
W1 W 3
PE PE gy/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
into the machine control.
Induction motor spindle (2SP125x-8xxx)
Table 4- 2 Power connection, induction motor spindle
Phase Designation at the spindle Conductor designation

U1 1
V1 2
A1/UVW
W1 3
PE gy/ye
U2 1
V2 2
A2/UVW
W2 3
PE gy/ye
When commissioning, it must be ensured that the individual phases are correctly connected
and the spindle direction of rotation must be checked (the count direction of the rotary
encoder defines the standard direction of rotation, see ChapterRotary encoder, motor
measuring system (Page 51).

Technical data
4.1 Power connection
Pin assignment of the power connector
Table 4- 3 Pin assignment of the connector
2SP1202 connector size 1.5 2SP1204 connector size 3

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: 8 : 8
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Technical data
4.2 Overview, supplying the various media
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Technical data
4.2.1 Cooling water
Table 4- 4 Cooling water connections
2SP120 2SP125 Comment

Connection fitting Connector for hose ∅ G1/2" (inner thread) for hose ∅ On the spindle side
12/10 mm 9 mm
Connection code I = motor cooling ON I = motor cooling ON On the spindle side
II = motor cooling OFF II = motor cooling OFF
Permitted tightening torque [Nm] -- max. 100 Nm
NOTICE
The feeder lines and hoses to the connections must be flexible and strain relieved. Rigid
pipe connections are not permissible.
Only use PU/PA connecting hose quality for the connectors of the 2SP120x spindle.
The cooling water must be conditioned in order to maintain the correct functioning of the
cooling system on the spindle side (refer to the following Table).
Table 4- 5 Conditioning the cooling water
Value
Min. incoming temperature No moisture condensation
Max. incoming temperature Without de-rating: 25 °C
With derating, see the table below: 40 °C
Quantity 10 l/min
Max. hydrostatic pressure 5 bar
Max. particle size 100 μm
Recommended anti-corrosion agents max. 25 % Clariant, Antifrogen or Tyfocor
CAUTION
Cooling with flowing water from drinking water or usage water systems – or with cooling-
lubricating medium is not permitted.
The cooling water temperature must be set corresponding to the ambient temperature so
that moisture condensation does not occur.
The S1 power (continuous duty) of the spindle depends on the incoming temperature of the
cooling water. For incoming temperatures of up to 25 °C, the S1 power specified in the data
sheet is reached. The S1 power is reduced above a cooling water inlet temperature of 25 °C
(see table below).

Technical data
Table 4- 6 Reduced S1 power as a function of the cooling-water temperature
Incoming temperature [°C] Reduction factor

25 1
35 0,95
40 0,90
4.2.2 Compressed air

All of the connections are compressed air feed connections (inlet). The compressed air
which has been used is discharged to the environment.
Table 4- 7 Compressed air connections for 2SP120
Pneumatic cylinder Blocking air Taper cleaning air

Function Release tool, air Clamp tool, air inlet Air inlet Taper cleaning air
inlet inlet
Connection fitting (on the 1 x G3/8" 1 x G1/8" Radial: G1/8" G1/4"
spindle side) (inner thread) for (inner thread) for (inner thread) (inner thread) for
hose hose Axial: ∅ 5.0 mm hose
∅ ≥ 8 mm ∅ ≥ 8 mm (provide a 6 x 2 mm ∅ ≥ 8 mm
O ring) for hose
∅ ≥ 8 mm
Connection code (on the spindle VIIa VIIIa V IX
side) 1)
Perm. tightening torque 30 Nm 20 Nm 20 Nm 40 Nm
1) Connection code, also refer to chapter dimension drawings
Table 4- 8 Compressed air connections for 2SP125
Pneumatic cylinder Blocking air Taper cleaning air

Function Release tool, air Clamp tool, air inlet Air inlet Taper cleaning air
inlet inlet
Connection fitting (on the M16 x 1.5 G1/8" Radial: G1/8" G1/4"
spindle side) (inner thread) for (inner thread) for (inner thread) for (inner thread) for
hose hose hose hose
∅ ≥ 8 mm ∅ ≥ 8 mm ∅ ≥ 8 mm ∅ ≥ 8 mm
Connection code (on the spindle X XI V IXa
side) 1)
Perm. tightening torque 30 Nm 20 Nm 20 Nm 40 Nm

Technical data
NOTICE
In addition to the different minimum requirements placed on the supply of the compressed air
functions, the conditions, listed in Table "Conditioning" must be maintained.
Table 4- 9 General conditioning of the compressed air
Min. air inlet temperature [°C] Ambient temperature

Max. air inlet temperature 35 °C
Max. residual water content 0.12 g/m3
Max. residual oil content 0.01 mg/m3
Max. residual dust 0.1 mg/m3
Table 4- 10 Conditioning
Minimum pressure [pa] Maximum pressure [pa] Max. particle size [μm]
Pneumatic cylinder 5⋅ 105 (5 bar) 10 ⋅ 105 (10 bar) 50
Blocking air 2,5 ⋅ 105 (2.5 bar) 3⋅ 105 (3 bar) 8
Taper cleaning air 5 ⋅ 105 (5 bar) 6 ⋅ 105 (6 bar) 50
4.2.3 Hydraulic
All of the connections only comprise a hydraulic fluid feed.
Table 4- 11 Technical data to control the hydraulics of the hydraulic cylinder
Hydraulic cylinder
Function Release tool Clamp tool
Connection fitting (on the spindle side) G1/4" G1/4"
Connection code (on the spindle side) 1) VII VIII
Perm. tightening torque 40 Nm 40 Nm
Release/clamping pressure 50 to 80 bar
Max. particle size 100 μm
NOTICE

Technical data
4.2.4 Internal tool cooling using the cooling-lubricating medium (option)
Table 4- 12 Connecting the internal tool cooling
Cooling-lubricating Leakage drain

medium inlet
Connection fitting (on the spindle side) G1/4" (inner thread) G1/8" (inner thread)
Connection code (on the spindle side) For 2SP120: X IV
For 2SP125: IXb
Permissible tightening torque [Nm] 40 20
CAUTION
It is not permissible to use a rigid pipe connection.

The piping must be free of any tension and pressure as well as bending and torsional
torque. The piping may not be subject to tensile stress – neither when pressurized nor
under a no-pressure condition.
The piping may not exert any torsion on the connection fitting of the cooling-lubricating
medium feed. Flexible hoses with the appropriate loop must be used to make the
connection.
NOTICE
Small cooling-lubricating medium leaks will occur in operation, especially when tools are
being changed. The leaked cooling-medium fluid is collected in the cooling-lubricating
medium gland from where it can drain. Any leaked fluid must be able to freely drain from
the pipes.
The data in the following table apply for the cooling-lubricating medium flow when the spindle
is being operated.
Table 4- 13 Data of the cooling-lubricating medium gland
Value Comment
Max. pressure 50 105 Pa (50 bar)
Max. speed 18000 rpm Also under no pressure
conditions
Max. particle size 50 μm Cooling-lubricating medium
acc. to ISO 4406 (-/16/13)
Max. cooling-lubricating medium temperature 40 °C
Max. flow rate 54 l/min Dependent on the pressure

Technical data
Value Comment
Pressure loss 2,7 105 Pa
(2.7 bar)
Frictional torque 0.3 Nm
The frictional torque of the cooling-lubricating medium gland means that its temperature
increases and reduces the available maximum torque.
Table 4- 14 Permissible media for the internal tool cooling
Operation with cooling-lubricating The flow must be guaranteed

medium
Operation with a minimum quantity of Mixture, maximum 5 bar
cooling-lubricating medium Lubricating medium percentage, minimum 10 ml/h
Lubrication must be guaranteed
2/2 way valve must permit unrestricted flow (due to
possible separation) (e.g. ball-type valve)
Cooling-lubricating medium and compressed air may
never be simultaneously applied to the MQL system
Dry machining without compressed air The line must be vented; there may be no residual
pressure
When changing a tool, to clean the tool cone/nose at standstill, compressed air can be fed-in
through the integrated cooling-lubricating medium gland.
CAUTION
The cooling-lubricating medium must be conditioned so that pressure peaks in the feeder
line are avoided. The maximum permissible pressure may never be exceeded – even
during pressure peaks.
The integrated cooling-lubricating medium gland is not suitable to feed-in hydraulic fluids
and compressed air while the spindle is rotating.
Only suitable tools with a through hole which allows the cooling-lubricating medium to be
discharged may be used when feeding-in cooling-lubricating medium for internal tool
cooling; there must always be a transfer pipe to connect the tool to the clamping system so
that no fluid is lost.
If unsuitable tools are used, then the grease is flushed-out of the tool gripper and,
depending on the pressure, can cause failure of the spindle or the rotary gland.

Technical data
4.2.5 External tool cooling with the cooling-lubricating medium (option for 2SP120x)
Table 4- 15 Connection for the external tool cooling (for 2SP120)
Connection, cooling-lubricating medium inlet

Axial Radial
Connection fitting (on the spindle side) Hole Ø 8.8 mm prepared for O G1/4" (inner thread)
ring 11 x 2 mm
Connection code (on the spindle side) 1) XI XI
Perm. tightening torque - 40 Nm
Cooling-lubricating medium outlet via adjustable 6 spray nozzles, adjustable from 0-30 °
spray nozzles (standard)
Cooling-lubricating medium outlet through threaded Threaded holes 8 x G1/4"
holes for customer-specific spray nozzles (option)
CAUTION
It is not permissible to use a rigid pipe connection. The piping must be free of any tension
and pressure as well as bending and torsional torque.
The piping may not be subject to tensile stress – neither when pressurized nor under no-
pressure conditions. The piping may not exert any torsion on the connection fitting of the
cooling-lubricating medium feed.
Flexible hoses with the appropriate loop must be used to make the connection.
The data in the following table apply for the cooling-lubricating medium flow when the spindle
is being operated.
Table 4- 16 Data of the external tool cooling with cooling-lubricating medium
Value Comment
Max. pressure 5 · 105 Pa (5 bar)
Max. particle size 50 μm Cooling-lubricating medium
acc. to ISO 4406 (-/16/13)
Max. cooling-lubricating medium temperature 40 °C
Max. flow rate Dependent on the
pressure
CAUTION
The cooling-lubricating medium must be conditioned so that pressure peaks are avoided.
The maximum permissible pressure may not be exceeded.

Technical data
4.2.6 Connections for various media
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Technical data
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Technical data
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Technical data
4.3 Clamping state sensing
2SP120x
Analog draw bar sensing
Sensor S1 See Chapter Dimension drawings (Page 95), Fig. A-3 Spindle
2SP120x-1, connection designations and connection conditions
Draw bar in the release 9 - 10 V
position
Tool clamped 2-4V
Tool too small 1-2V
No tool <1V
Those values are nominal values only. The actual values should be taken from the particular spindle
acceptance report!
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
Sensor S4 See Chapter Dimension drawings (Page 95), Fig.

A-3 Spindle 2SP120x-1, connection designations
and connection conditions
Sensor S4 is adjusted so that it supplies a signal if there is a safe clearance between the release unit
and the spindle shaft.

Technical data
Digital status sensing
Sensor S1 (optional) See Chapter Dimension drawings (Page 95), Fig.

released position" signal.
This cannot be used to safely detect jammed tools!

CAUTION:
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!

Sensor S3 is adjusted so that for either no tool or an excessively small tool it supplies a signal.
Digital tool release unit sensing

Sensor S4 is adjusted so that it supplies a signal if there is a safe clearance between the release unit
and the spindle shaft.

Technical data
2SP125x
Digital status sensing

released position" signal.
This cannot be used to safely detect jammed tools!



Technical data
4.4 Rotary encoder, motor measuring system
4.4 Rotary encoder, motor measuring system

The spindle is equipped with a hollow-shaft incremental encoder.
Table 4- 17 Technical data
Signals sin-cos signal (A+, A-, B+, B-)

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.
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 Configuration
Manual or catalog).
4.5 Bearing temperature monitoring (option for 2SP120x)

The PT100 resistance sensor is used to monitor the bearing temperature. Corresponding
PT100 signal evaluation units must be used for the evaluation.
These are connected using a free cable end at the flange.

Technical data
4.6 Tool interfaces
4.6 Tool interfaces
Table 4- 18 Tool interfaces
HSK A63 SK40 CAT40 BT40

Pull-in force 18 +5.4/-1.9 kN 8 +1.6/-0.8 kN 8 +1.6/-0.8 kN 8 +1.6/-0.8 kN
Reference gauge 10.5 ±0.1 mm 93.6 ±0.1 mm 82.9 ±0.1 mm 99.7 ±0.1 mm
Standards HSK A63: DIN 69893-1 Form A, ISO 12164-1/2, Type A

SK40 non-symmetrical: DIN 69871/69872, ISO 7388/1/2, Type A
CAT40 non-symmetrical: ANSI B5.50-78, ISO 7388/1/2, Type B
BT40 non-symmetrical: 30°, MAS 403-1982, BT/PT30°, Version E1
BT40 non-symmetrical: 45°, MAS 403-1982, BT/PT45°, Version F1
Table 4- 19
HSK A63 SK40 CAT40 BT40

Pull-in force 18 +5.4/-1.9 kN 8 +1.6/-0.8 kN 8 +1.6/-0.8 kN 8 +1.6/-0.8 kN
Reference 10.5 ±0.1 mm 93.6 ±0.1 mm 82.9 ±0.1 mm 99.7 ±0.1 mm
gauge
Standards HSK A63: DIN 69893-1 Form A, ISO 12164-1/2, Type A

SK40 non-symmetrical: DIN 69871/69872, ISO 7388/1/2, Type A
CAT40 non-symmetrical: ANSI B5.50-78, ISO 7388/1/2, Type B
BT40 non-symmetrical: 30°, MAS 403-1982, BT/PT30°, Version E1
BT40 non-symmetrical: 45°, MAS 403-1982, BT/PT45°, Version F1
NOTICE
supply pipe! If this is not possible, then it must be guaranteed that the coolant feed can be
stopped.

Technical data
4.7 Tool interfaces
4.7 Tool interfaces

%
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Figure 4-9 SK40
-
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Figure 4-10 CAT40

Technical data
4.7 Tool interfaces
(
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Figure 4-11 BT40, 30°
(
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Figure 4-12 BT40, 45°

Technical data
4.7 Tool interfaces
I O
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Figure 4-13 HSK A63

Technical data
4.7 Tool interfaces

Faults in operation 5
If faults occur during operation, then the spindle unit should be handled according to the
following priorities.
Definition, priority levels
DANGER
Priority 1
A critical situation involving death or severe injury has occurred. Immediately stop the
spindle.
WARNING
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.
Priorities
Table 5- 1 Priority levels depending on the fault
Fault Priority
Motor Switch-off temperature; thermo-sensor responds Priority 1
Pre-alarm temperature; thermo-sensor responds Priority 2
Cooling not on Priority 2
Clamping state sensing No tool clamped Priority 1
Tool release unit sensing Tool release unit not retracted Priority 1
Release pressure available at the tool release unit Priority 1
For sealing air Pressure too low Priority 2

Faults in operation

Maintenance instructions/maintenance 6
6.1 Maintenance plan
Weekly
● Clean the spindle unit. Do not direct jets of steam, compressed air directly at the seals.
● Visually check that glands, plugs/caps are tight and are not leaking.
● Visually check the tool grippers for damage and accumulated dirt and that it is adequately
lubricated
Yearly
● 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 3 years.
Note
For maintaining the tool clamping system, for HSK A63 Type K, see Chapter
Maintenance (Page 69), for HSK A63 Type C, see Chapter Maintenance (Page 80) and
for SK40, see Chapter Maintenance (Page 88).
6.2 Wearing parts

Parts that are subject to natural wear include:
● Spindle bearings (see Technical Support, )
● Tool clamping system (see Chapter Spare parts list (Page 71))
● Rotary gland (see Chapter Rotary gland (Page 71))
● Hydraulic or pneumatic cylinder (see Technical Support, )

Maintenance instructions/maintenance
6.3 Storing the spindle in the magazine
6.3 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 °C and 35 °C.
Vibration is not permitted.
For storage times over a year, the quality of the lubricant can deteriorate due to
environmental effects. We recommend that the spindle is checked in one of our Service
workshops (Page 110).
When removed from storage, the spindle must not be immediately operated at full speed. A
new run-in procedure is required (for this, see Chapter Switch-on procedure (Page 33)).

Tool clamping systems 7
7.1 Safety instructions
NOTICE
The following points must always be carefully observed:

 Rotation of the workspindle without a clamped tool is prohibited at any time.
 A maximum of 1000 rpm is allowed for positioning purposes only (tool change).
 Only use tools that are in a perfect operating condition!
 Only use tools that are designed and intended for this tool clamping system (carefully
observe the standard companion dimension drawing)!
 Tools may only be inserted when the drive spindle is at a standstill!
 Observe the maintenance intervals!
 Only precisely balanced tools with balance quality Q 6.3 are permitted to be used.
7.2 Product description, tool clamping system HSK A63 Type K
Function
A spring assembly draws the draw bar together with the clamping taper into the spindle. In
so doing, the clamping taper spreads the clamp outwards until this is in contact with the tool
and clamps the tool 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 (400%
clamping force). The tool is only released after tool breakage due to the mechanical
interlocking.
If pressure is applied to the tool 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 is ready to accept a new tool.
Order No.: 95.600.001.3.6 for Weiss Spindeltechnologie GmbH

Tool clamping systems
(TXLSPHQWQXPEHU[[[[[[[[SOHDVH
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Figure 7-1 HSK A63 Type K tool clamping system

Dimensions
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Figure 7-2 Dimensions, HSK A63 Type K
Features
● The tool grippers can be shifted in parallel
● High static and dynamic stiffness

7.2.1 Mounting the clamping set

● 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 A63: 95.601.169.4.1
from Weiss Spindeltechnologie GmbH
Apply grease to the contact surfaces

 METAFLUX paste 70-8508
or
 KLÜBER paste ME 31-52
[[ Never mix/combine different grease types!
Engage the tool gripper segments 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 device and

retain using a rubber ring; introduce the complete
unit; apply a blow to the auxiliary dowel and locate
) the gripper; remove the rubber ring


Apply grease to the clamping taper

or
Never mix/combine different grease types!
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!
5HIHUHQFH Adjust the clamping taper to the reference gauge

JDXJH 5HOHDVHSRVLWLRQ Reference gauge = 10.5 ±0.1 mm
Tighten the lock nut

Tightening torque:
HSK A63: 30 Nm
0$
7.2.1.1 Protective sleeve for sealing socket installation

Not included in the scope of delivery!
Size A63/B80/E63/F80
Order No. of Weiss 95.601.169.4.1
Spindeltechnologie GmbH

7.2.1.2 Installation tool HSK A63 Type K

To more easily install the tool grippers. Not included in the scope of delivery!
7.2.1.3 Final check HSK A63 Type K

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
Inspect after approximately 100 clamping strokes
5HIHUHQFHJDXJH In the released position:

Check the reference gauge
Check the lock nut using the clamped tool
7.2.1.4 Balancing
The complete system must be balanced with the clamping system installed and with a
clamped tool! For balance quality, see DIN ISO 1940 Part 1.

7.2.2 Operation
NOTICE
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!
&RQFHQWULFLW\WROHUDQFH Recommended concentricity tolerance when

changing the tool and the maximum contact force
at the clamping taper:
Nominal size: A63
Concentricity (øG): 0,8
Contact force, max.: 3.6 kN
Recommended: Position sensing of draw bar

To minimize wear on the sealing ring, the coolant tube should have the following
characteristics at the clamping set/tool transition.
● Able to easily move through a minimum angle (in accordance with ISO 12164-1)
● Ground
NOTICE
Operation with cooling-lubricating medium
Operation with cooling-lubricating medium is only permitted if steps are taken to ensure
that it can flow freely. This is the reason that a tool with a cooling medium pipe and a
machining tool with a through hole must be used. Otherwise, there is a danger that the
spindle will be flooded or the seals will be damaged by pressure spikes.
The maintenance intervals must be maintained!

7.2.3 Changing the lip seal in the clamping set

The ring does not have to be removed to disassemble the lip seal; the ring only has to be
replaced if damaged.
Remove the defective lip seal from the clamping

unit using either a suitable hook or pliers
5LQJ /LSVHDO
Press the lip seal into a kidney shape and install;

carefully observe the installation position
Using a blunt object, press the seal against the

walls and then bring into the final position using a
mandrel
7.2.4 Broken gripper segment

If a gripper segment breaks, the complete gripper unit must be replaced (we recommend
replacing the entire clamping set)!

7.2.5 Maintenance
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:
● 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)
Note
To be observed:
The re-lubrication interval depends on how much grease the clamping set loses.
Reasons for grease loss:
 Defective seal in the clamping taper
 A medium that dissolves grease is used
 A jet of cleaning fluid has been applied directly to the clamping set etc.
● 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)
If the pull-in force is less than 70% of the nominal value, then the following measures
should be taken in the subsequent sequence:
1. Re-lubricate and re-check the pull-in force
2. Replace the gripper and re-check
3. Completely replace the tool clamping system
● Annually or, at the latest, after 500,000 tool changes
– Replace the lip seal

Grease paste
Table 7- 1 Designation and order numbers of the lubricants
Designation Quantity Order No.

METAFLUX grease paste No. 70-85081) 4g 0.929100.012
KLÜBER grease paste ME 31-52 10 g 06.21001.014
1) First grease lubrication, when first equipped
NOTICE
Only use grease from the same company.

It is not permissible to mix greases from different manufacturers.
Table 7- 2 Manufacturer addresses
Company / address Telephone/Telefax Internet address

Metaflux AG Tel.: +41-61-851 0800 http://www.metaflux.com
Industriestraße 11 Fax: +41-61-851 0808
CH-4313 Möhlin
Klüber Lubrication München KG Tel.: +49 (0) 89 7876-0 http://www.Klueber.com
Postfach 701047 Fax: +49 (0) 89 7876-333
D-81310 München

7.2.6 Spare parts list
7.2.6.1 O-rings and lip seal parts

Figure 7-3 Spare parts
Table 7- 3 Weiss Spindeltechnologie GmbH order numbers
Brass sleeve Lip seal O-rings

Clamping unit 1 2 3 4
A63 95.600.001.3.6 95.600.850.4.1 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
7.2.6.2 Rotary gland
Rotary gland, 50 bar (optional) 95.250.037.2.0

Rotary gland, 80 bar (optional) 95.250.022.3.0

7.2.7 Troubleshooting HSK A63
Fault Possible 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 set
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 during Broken gripper, clamping taper or draw bar
machining Broken tool shaft
Broken springs
Pull-in force too low
Loss of clamping force Clamping set is operating in a dry condition
We recommend that the clamping force is
measured.

7.3 Product description of holding clamping set HSK A63 Type C
Function
See Chapter Product description, tool clamping system HSK A63 Type K (Page 61).
Weiss Spindeltechnologie GmbH order number (extraction force 270 N): 95.600.052.2.6 V02
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.
Acceleration in various 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 that act 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 latching clamping set is only permissible for tools with a total
weight (tool holder and tool) less and equal to 5 kg.
NOTICE
Vertical applications with a holding clamping set are not permitted!
For horizontal arrangements, observe the wear

on the contact points due to tilting of the tool!

Dimensions
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Figure 7-4 Dimensions, HSK A63 Type C
Features
● The tool grippers can be shifted in parallel
● High static and dynamic stiffness
● Positively-driven
● High wear resistance
● Holding the tool in the released position

7.3.1 Mounting the clamping set

● 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 A63: 95.601.169.4.1
Apply grease to the contact surfaces

or
Engage the tool gripper segments into the spacer

ring and gripper retaining cone surfaces (ensure
the same number!)
Apply grease to the clamping taper

or

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!

Adjust the clamping taper to the reference gauge
Tighten the lock nut

0$
Tightening torque (MA):
A63/B80/E63/F80: 30 Nm
7.3.1.1 Protective sleeve for sealing socket installation

Not included in the scope of delivery!

7.3.1.2 Final check 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
Check after approximately 100 clamping strokes

Check the reference gauge
Check the lock nut using the clamped tool
7.3.1.3 Balancing

7.3.2 Operation
NOTICE
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!
Recommended concentricity tolerance when

Koaxialitätstoleranz
changing the tool and the max. contact force at
the clamping taper:
Nominal size: A63
Concentricity (øG): 0,8
Contact force, max.: 3.6 kN
Recommended: Position sensing of draw bar

To minimize wear on the sealing ring, the coolant tube should have the following
characteristics at the clamping set/tool transition.
● Able to easily move through a minimum angle (in accordance with ISO 12164-1)
● Ground
NOTICE
Operation with cooling-lubricating medium
Operation with cooling-lubricating medium is only permitted if steps are taken to ensure
that it can flow freely. This is the reason that a tool with a cooling medium pipe and a
machining tool with a through hole must be used. Otherwise, there is a danger that the
spindle will be flooded or the seals will be damaged by pressure spikes.
The maintenance intervals must be observed!

7.3.3 Changing the lip seal in the clamping set

The ring does not have to be removed to disassemble the lip seal; the ring only has to be
replaced if damaged.
Remove the defective lip seal from the clamping

unit using either a suitable hook or pliers
5LQJ /LSVHDO
Press the lip seal into a kidney shape and install;

carefully observe the installation position
Using a blunt object, press the seal against the

walls and then bring into the final position using a
mandrel


7.3.5 Maintenance
● Weekly
– Check the lip seal in the clamping taper (visual inspection)
Note
To be observed:
The re-lubrication interval depends on how much grease the clamping set loses.
Reasons for grease loss:
 Defective seal in the clamping taper
 A medium that dissolves grease is used
 A jet of cleaning fluid has been applied directly to the clamping set etc.
● Every six months or, at the latest, after 200,000 tool changes
– Check the pull-in force (our recommendation: Use the power check)
● Annually or, at the latest, after 500,000 tool changes
– Replace the lip seal

Grease paste

NOTICE


CH-4313 Möhlin
Postfach 701047 Fax: +49 (0) 89 7876-333
D-81310 München
Tool for reapply grease paste in the installed state (clamped without tool):
Order No. for the brush (HSK A50 up to A100) from Weiss Spindeltechnologie GmbH:
06.16001.001

7.3.6.1 O-rings and lip seal parts

Figure 7-5 Spare parts
Brass sleeve Lip seal O-rings

Clamping unit 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

7.3.7 Troubleshooting HSK A63-Type C

Worn clamping set
position
Leaky rotary gland
Insufficient hydraulic pressure
Micro-corrosion at the centering
machining Broken tool shaft
Broken springs
Pull-in force too low
In the holding position, the tool falls out of the Tool is pushed out by purge air
spindle When purging, the tool is pushed out of the
spindle
Axis acceleration too high
Release velocity too high
Clamping set worn - retention force is too low
measured.

7.4 Product description, tool clamping system SK40/CAT40/BT40
Function
A spring assembly draws the tool into the workspindle through a spline gear, a draw bar and
a gripper. As a result of the spline gear, the holding force is a multiple number of times
higher than the pull-in force when the tool is drawn in. The tool is firmly clamped even if the
power fails. The tool is released using the release units.
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 passed, the gripper automatically opens.
The tool is automatically ejected by the draw bar. The tool clamping system is ready to
accept a new tool.
Table 7- 8 Order designations of the SK 40 clamping system from Weiss Spindeltechnologie GmbH
Designation Order No.

Item 100, gripper with holder
Gripper with holder, SK-40-A1-2 (DIN 69871 / ISO-A) 95.101.216.3.2
Gripper with holder, SK-40-B1-2 (OTT-RILLE) 95.101.234.3.2
Gripper with holder, SK-40-C1-2 (ASME / ANSI B5.50 / ISO-B) 95.101.233.3.2
Gripper with holder, SK-40-E1-2 (MAS 30°) 95.101.485.3.2
Gripper with holder, SK-40-F1-2 (MAS 45°) 95.101.486.3.2

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Figure 7-6 Tool clamping system SK 40/CAT 40/BT 40

7.4.1 Installing the clamping set

● Tools required for installation:
Installation tool for SK/CAT/BT tool grippers; Order No. from Weiss Spindeltechnologie
GmbH: 95.102.388.9.2
● Check
– Clean the spindles and installed parts
– Check that all of the parts are undamaged
– Grease the tool gripper and clamping head
Screw the gripper with holder onto the draw bar
5HIHUHQFHJDXJHs Adjust the gripper with holder to the reference

,QWKHUHOHDVHGSRVLWLRQ gauge
0 $ 1P Attach the gripper with holder using the lock nut.
+ROG
Tightening torque (MA) = 18 Nm
Table 7- 9 Reference gauge
Code Standard Reference gauge

±0.10 mm
A1 DIN 69 871/69 872 93.6 mm
B1 DIN 2080 91.4 mm
C1 ANSI B 5.50 82.9 mm
E1 MAS 403-1982 P40T-2 99.7 mm
F1 MAS 403-1982 P40T-1 99.7 mm

7.4.1.1 Final check
Check after approximately 100 clamping strokes
5HIHUHQFHJDXJHs In the released position:

,QWKHUHOHDVHG Check the reference gauge
SRVLWLRQ
0 $ 1P Check the lock nut using the clamped tool
7.4.1.2 Balancing
7.4.2 Operation
NOTICE
● Tools may only be inserted when the drive spindle is at a standstill!

● When the tool is inserted, it is important to make sure that the tool must be pushed back
before the clamping operation has been completed!
● Observe the maintenance intervals!


7.4.4 Maintenance
● Weekly
● Every six months or. at the latest. after 200.000 tool changes
– Check the pull-in force (recommendation: Use the power check)
● after 4000 operating 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.
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, service should be performed after 4000 operating
hours.
Note
For bearings with "lifetime lubrication", the bearings should be changed at the latest after
3 years, otherwise, uncontrolled failures cannot be completely excluded.

Grease paste

NOTICE


CH-4313 Möhlin
Postfach 701047 Fax: +49 (0) 89 7876-333
D-81310 München
SK40 Standard 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

7.4.6 Fault finding SK40/CAT40/BT40

Incorrect gripper installed (tool standard)
Large amount of dirt in the gear
Tool draw bolts either incorrect or faulty
position
Loss of clamping force
Leaky rotary gland
Insufficient release pressure
Micro-corrosion at the steep-angle taper
machining 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
measured.

Rotary gland (option) 8
8.1 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 4000 hours.
The rotary gland should be replaced, at the latest, after three years use, as otherwise,
unpredictable failures cannot be completely excluded.
8.2 Replacing the rotary gland

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

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

Rotary gland (option)
8.2 Replacing the rotary gland
Installing the rotary gland
NOTICE
The device may only be manually installed! Never apply any hammer blows to the rotary
gland! Otherwise the rotary gland could be pre-damaged.
NOTICE
The maximum pressure applied to the rotary gland must not exceed the maximum
permissible pressure for the rotary gland! The pressure must be checked before installation
and during operation!
1. Carefully insert the new rotary gland into its bore. In so doing, carefully observe the
position of the octagon at the connecting element.
2. Insert the clamping element into the groove and clamp using screws (MA = 13 Nm).
3. Re-attach the lines for the cooling-lubricating medium feed and leakage.
4. After switching-on the cooling-lubricating medium supply, visually check all the
connections to ensure that they are tight and there are no leaks.
Figure 8-1 Installing the rotary gland
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Figure 8-2 Connecting the leakage drain

8.3 Timing diagram for the rotary gland
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Figure 8-3 Timing diagram, rotary gland

Operation with cooling-lubricating The flow must be guaranteed

medium Possible at speeds 0 to n (with the exception of tool change)
Operation with a minimum quantity Mixture, maximum 5 bar
of cooling-lubricating medium Lubricating medium percentage, minimum 10 ml/h
Lubrication must be guaranteed
2/2 way valve must permit unrestricted flow (due to possible
separation) (e.g. ball-type valve)
MMKS (minimum quantity cooling-lubricating medium) system
may never be simultaneously
switched-in with the cooling-lubricating medium or compressed
air
Dry machining, compressed air The line must be vented; there may be no residual pressure
* Dry machining, compressed air Operation with compressed air is only permissible
 up to a speed of max. 10,000 rpm,
 at max. 5 bar and
 only alternating with wet machining
Spindle overpressure (sealing air) Not permissible

Appendix A
A.1 Dimension drawings
Note
Siemens AG reserves the right to change the motor dimensions as part of design
improvements without prior notification. The dimension drawings, provided in this
documentation, can go out-of-date.
Current dimension drawings can be requested at no charge from your local Siemens office.
Table A- 1 Dimension table for 2SP120x-1 spindle
MLFB Speed Motor Release Moment A A* B Power

[rpm] unit: of inertia [mm] [mm] [mm] connector,
[kgm2] optional
2SP1202-1HA3x-1xx2 15000 1FE082-4WP51 Hydraulic 0.015 617 572 236 Size 1.5
2SP1202-1HA2x-1xx2 15000 1FE082-4WP51 Pneumatic 0.015 735 692 236 Size 1.5
2SP1202-1HB3x-2xx2 18000 1FE082-4WN51 Hydraulic 0.015 617 572 236 Size 1.5
2SP1202-1HB2x-2xx2 18000 1FE082-4WN51 Pneumatic 0.015 735 692 236 Size 1.5
2SP1204-1HA3x-1xx2 15000 1FE084-4WT51 Hydraulic 0.023 717 672 336 Size 3
2SP1204-1HA2x-1xx2 15000 1FE084-4WT51 Pneumatic 0.023 835 792 336 Size 3
2SP1204-1HB3x-2xx2 18000 1FE084-4WP51 Hydraulic 0.023 717 672 336 Size 3
2SP1204-1HB2x-2xx2 18000 1FE084-4WP51 Pneumatic 0.023 835 792 336 Size 3
Dimension A* without rotary gland

Appendix
Figure A-1 Spindle 2SP120x-1

Appendix
Figure A-2 Spindle 2SP120V-1, spindle nose and spindle connections

Appendix
Figure A-3 Spindle 2SP120x-1, connection designations and connection conditions

Appendix
Table A- 2 Dimension table for spindle 2SP125x-1
MLFB Interface Motor type A [mm] B [mm] B* [mm] C [mm] C* [mm]

2SP1253-1xxxx-xxxx SK/BT/CAT 40 Synchronous 305.0 71.3 114.3 775.3 818.3
2SP1255-1xxxx-xxxx SK/BT/CAT 40 Synchronous 405.0 71.3 114.3 775.3 818.3
2SP1253-1xxxx-xxxx HSK A63 Synchronous 305.0 71.3 114.3 775.3 818.3
2SP1255-1xxxx-xxxx HSK A63 Synchronous 405.0 71.3 114.3 775.3 818.3
2SP1253-8xxxx-xxxx SK/BT/CAT 40 Induction 305.0 71.3 114.3 775.3 818.3
2SP1255-8xxxx-xxxx SK/BT/CAT 40 Induction 405.0 71.3 114.3 775.3 818.3
2SP1253-8xxxx-xxxx HSK A63 Induction 305.0 71.3 114.3 775.3 818.3
2SP1255-8xxxx-xxxx HSK A63 Induction 405.0 71.3 114.3 775.3 818.3
Dimension B* and C* without rotary gland

Appendix
Figure A-4 Spindle 2SP125x-1

Appendix
Connection designations and connection conditions for spindle 2SP125x-1

I G1/2" ∅9 mm Motor cooling/bearing cooling inlet Medium: Water
II G1/2" ∅9 mm Motor cooling/bearing cooling inlet pressure: Max. 5 bar
Quantity: 10 l/min
Additives: 25% CLARIANT Antifrogen N
V G1/8" ∅5 mm Sealing air inlet Pressure: 1.5 to 3 bar
VI G1/8" ∅5 mm Sealing air outlet Filter mesh: 8 μm
Air quantity: 1 to 1.5 Nm3/h
IXa G1/4" Air purge max. 6 bar
IXb G1/4" Cooling-lubricating medium max. 50 bar
IV G1/8" Leakage, rotary gland
X M16 x 1.5 Release tool 5 to 6 bar
XI G1/8" Clamp tool/unload 5 to 6 bar
Release Release piston area 311 cm2

unit Clamp piston area 159 cm2
Force at 5 bar min. 13 kN
Max. air usage per cycle when resetting with air 846 cm3
Max. air usage per cycle when resetting with spring 559 cm3
XXX engraved Weiss spindle number acc. to parts list (-002 etc. )
Speed refer to Table
Mounting position Horizontal/vertical
Running precision Radial 3 μm
Moment of inertia of all rotating parts xxx kgm2
Pull-in force SK 40 = 8 kN
HSK A63 = 18 kN
Rotary encoder, Siemens Sensor head sin/cos 1 Vpp Order No.: 6FX2001-6AA11-0AA0
Measuring wheel 256 pulses/rev Order No.: 6FX2001-6RB01-4GA0
Cable assembly Order No.: 6FX2001-6KC10-1CA0
Sensors Order No.: BALLUFF BES 516-325-E5-C-S4 / Siemens 3RG4012-3AG33

S1 Draw bar position/release position
S2 Draw bar position/clamped with tool
S3 Draw bar position/clamped without tool

Appendix
A.2 Parameter and machine data - setting data
A.2.1 SINAMICS S120
Table A- 3 Parameter setting data for 2SP120x
SINAMICS S120 2SP1204- 2SP1204- 2SP1202- 2SP1202-

Voltages, phase-to-phase, otherwise phase values 1HBx-2DF2 1HAx-1DF2 1HBx-2DF2 1HAx-1DF2
Motor type - - P0300 291 291 291 291
Motor code number - - P0301 29104 29103 29102 29101
Rated motor current IN A P0305 79,0 60,0 42,0 30,0
Rated motor power PN kW P0307 35,0 26,4 15,5 12,0
Rated motor speed nN rpm P0311 4300 3000 3500 2700
Rated motor torque MN Nm P0312 78 84 42 42
Pole pair No. p - P0314 2 2 2 2
Torque constant kt Nm/A P0316 0,92 1,27 0,9 1,25
Voltage constant ke V/1000* P0317 70 97 74 98
rpm
Motor locked rotor current I0 A P0318 79,0 60,0 42,0 30,0
Motor static torque M0 Nm P0319 78 84 42 42
Motor short-circuit current Ik A P0320 64,0 46,0 29,0 23,0
Maximum motor speed nmax rpm P0322 18000 15000 18000 15000
Max. motor current Imax A P0323 160,0 120,0 84,0 60,0
Breakdown torque reduction factor kred % P0326 80 80 75 75
Optimum load angle αopt ° P0327 105 105 105 105
Reluctance torque factor krelu mH P0328 0,7 1.2 6,3 4,2
Current, rotor position identification - A P0329 40 30 21 15
Motor limiting current Ilimit A P0338 160,0 120,0 84,0 60,0
Motor moment of inertia J kgm² P0341 0,023 0,023 0,015 0,015
Speed at the start of field weakening nfs rpm P0348 6100 4400 5700 4300
Armature resistance Ra Ω P0350 0,085 0,165 0,255 0,46
Direct axis inductance Ld mH 3,00 5,80 7,00 11,60
Quadrature axis inductance Lq mH P0356 3,40 6,40 7,20 12,50
Current controller adaptation, lower - A P0391 0 0 0 0
limit
Current controller adaptation, upper - A P0392 32 24 16,8 12
limit
Current controller adaptation, - % P0393 15 15 15 15
reduction factor
Encoder pulse number, motor - Inc/rev P0408 256 256 256 256
measuring system
Motor temperature alarm threshold - °C P0604 150 150 150 150
Shutdown limit, motor temperature - °C P0605 160 160 160 160

Appendix
Table A- 4 Parameter setting data for 2SP125x, standard and reduced
SINAMICS S120 2SP1255-1HBx- 2SP1255-1HAx- 2SP1253-1HBx- 2SP1253-1HAx-

Voltages, phase-to-phase, otherwise phase values 1xx2 0xx2 1xx2 0xx2
Stand. Red. Stand. Red. Stand. Red. Stand. Red.
Motor type - - P0300 291 291 291 291 291 291 291 291
Motor code number - - P0301 29108 29107 29106 29105
Rated motor current IN A P0305 120,0 102,0 95,0 85,0 68,0 60,0 53,0 45,0
Rated motor power PN kW P0307 53,4 47,0 46,3 40,0 35,0 30,0 26,0 22,5
Rated motor speed nN rpm P0311 3000 3000 2600 2560 3300 3600 2500 2700
Rated motor torque MN Nm P0312 170 150 170 150 100 80 100 80
Pole pair No. p - P0314 2 2 2 2 2 2 2 2
Torque constant kt Nm/A P0316 1,34 1,34 1,55 1,7 1,24 1,36 1,62 1,77
Voltage constant ke V/1000* P0317 94 94 116 116 93 93 121 121
rpm
Motor locked rotor current I0 A P0318 120,0 102,0 95,0 85,0 68,0 60,0 53,0 45,0
Motor static torque M0 Nm P0319 170 150 170 150 100 80 100 80
Motor short-circuit current Ik A P0320 97,0 97,0 78,0 78,0 58,0 58,0 45,0 45,0
Maximum motor speed nmax rpm P0322 15000 15000 10000 10000 15000 15000 10000 10000
Max. motor current Imax A P0323 240,0 240,0 190,0 170,0 136,0 120,0 106,0 90,0
Breakdown torque kred % P0326 80 70 80 70 80 70 80 70
reduction factor
Optimum load angle αopt ° P0327 110 105 110 105 110 105 110 105
Reluctance torque factor kTrelu mH P0328 2,5 2,5 4,8 3,9 5,2 4,2 8,7 7,1
Current, rotor position - A P0329 48 48 34 34 24 24 18 18
identification
Motor limiting current Ilimit A P0338 240,0 240,0 190,0 170,0 136,0 120,0 106,0 90,0
Motor moment of inertia J kgm² P0341 0,055 0,055 0,055 0,055 0,037 0,037 0,037 0,037
Speed at the start of field nfs rpm P0348 4600 4600 3600 3600 4500 4500 3500 3500
weakening
Armature resistance Ra Ω P0350 0,065 0,065 0,1 0,1 0,13 0,13 0,23 0,23
Direct axis inductance Ld mH 2,62 2,62 4,10 4,10 4,40 4,40 7,40 7,40
Quadrature axis Lq mH P0356 3,00 2,62 4,70 4,10 4,90 4,40 8,40 7,40
inductance
Current controller - % P0391 48 48 38 38 27,2 27,2 21,2 21,2
adaptation, lower limit
Current controller - % P0392 240 240 190 190 136 136 106 106
adaptation, upper limit
Current controller - % P0393 20 20 20 20 20 20 20 20
adaptation, reduction
factor
Encoder pulse number, - °C P0408 256 256 256 256 256 256 256 256
motor measuring system
Motor temperature alarm - °C P0604 150 150 150 150 150 150 150 150
threshold
Shutdown limit, motor - °C P605 160 160 160 160 160 160 160 160
temperature

Appendix
Table A- 5 Parameter setting data for 2SP125x, star/delta
SINAMICS S120 2SP1255-8HAx- 2SP1255-8HAx- 2SP1253-8HAx- 2SP1253-8HAx-

Voltages, phase-to-phase, otherwise phase values 1xx2 0xx2 1xx2 0xx2
Y Δ Y Δ Y Δ Y Δ
Motor type - - P0300 191 191 191 191 191 191 191 191
Motor code number - - P0301 - - 19103 19104 - - 19101 19102
Rated motor voltage VN V P0304 360 370 360 370 400 400 400 400
Rated motor current IN A P0305 28,8 27,5 28,8 27,5 27,0 27,5 27,0 27,5
Rated motor power PN kW P0307 11,7 11,7 11,7 11,7 13,20 13,20 13,20 13,20
Power factor cosΦ - P0308 0,830 0,760 0,830 0,760 0,840 0,790 0, 840 0,790
Rated motor fN Hz P0310 29,3 61,6 29,3 61,6 64,4 136,0 64,4 136,0
frequency
Rated motor speed nN rpm P0311 800 1800 800 1800 1800 4000 1800 4000
Rated torque MN Nm P0312 140 62.1 140 62.1 70 31.5 70 3 1.5
No-load current I0 A P0320 13,4 15,6 13,4 15,6 10,8 14,2 10,8 14,2
Maximum speed nmax rpm P0322 15000 15000 10000 10000 15000 15000 10000 10000
Breakdown torque Mbreak, red - P0326 80 80 80 80 100 100 100 100
reduction factor
Motor moment of J kgm² P0341 0, 055 0, 055 0, 055 0,055 0, 037 0, 037 0,037 0,037
inertia
Speed at the start of nfe rpm P0348 970 1980 970 1980 1800 4000 1800 4000
field weakening
Stator resistance R1K Ω P0350 0,537 0,179 0,537 0,179 0,361 0,120 0,361 0,120
(20°C)
Rotor resistance R2K Ω P0354 0,471 0,157 0,471 0,157 0,384 0,128 0,384 0,128
(20 °C)
Stator leakage L1leak mH P0356 3,81 1,53 3,81 1,53 2,2 0,88 2,2 0,88
inductance
Rotor leakage L2leak mH P0358 3,66 1,36 3,66 1,36 1,77 0,67 1,77 0,67
inductance
Magnetizing L1H mH P0360 74,96 33,33 74,96 33,33 50,66 18,37 50,66 18,37
inductance
Pole pair No. p - - 2 2 2 2 2 2 2 2
Encoder pulse - Inc/rev P0408 256 256 256 256 256 256 256 256
number, motor
measuring system
Motor temperature - °C P0604 150 150 150 150 150 150 150 150
alarm threshold
Shutdown limit, motor - °C P0605 170 170 170 170 170 170 170 170
temperature

Appendix
A.2.2 SIMODRIVE 611 universal/digital
Table A- 6 Machine data - setting data for 2SP120x
SIMODRIVE 611 universal/digital 2SP1204- 2SP1204- 2SP1202- 2SP1202-

Voltages, phase-to-phase, otherwise phase values 1HBx-2DF2 1HAx-1DF2 1HBx-2DF2 1HAx-1DF2
Motor code number - - MD1102 2957 2956 2955 2954
Encoder pulse number, motor - Inc/rev MD1005 256 256 256 256
measuring system
Activate PE MSD - - MD1015 1 1 1 1
Current, rotor position - % MD1019 25 25 25 25
identification
PWM frequency fPWM Hz MD1100 4000 3200 4000 3200
Rated motor current IN A MD1103 79,0 60,0 42,0 30,0
Max. motor current Imax A MD1104 160,0 120,0 84,0 60,0
Pole pair No. - - MD1112 2 2 2 2
Torque constant kt Nm/A MD1113 0,92 1,27 0,9 1,25
Voltage constant ke V/1000* MD1114 70 97 74 98
rpm
Armature resistance Ra Ω MD1115 0,085 0,165 0,255 0,46
Direct axis inductance Ld mH - 3,00 5,80 7,00 11,60
Quadrature axis inductance Lq mH MD1116 3,40 6,40 7,20 12,50
Motor moment of inertia J kgm² MD1117 0,023 0,023 0,015 0,015
Motor locked rotor current I0 A MD1118 79 60 42 30
Motor limiting current Ilimit A MD1122 160 120 84 60
Optimum load angle αopt ° MD1128 105 105 105 105
Motor short-circuit current Ik A MD1136 64 46 29 23
Speed at the start of field nfs rpm MD1142 6100 4400 5700 4300
weakening
Breakdown torque reduction kred % MD1145 80 80 75 75
factor
Maximum motor speed nmax rpm MD1146 18000 15000 18000 15000
Reluctance torque factor krelu mH MD1149 0,7 1,2 6,3 4,2
Current controller adaptation, - % MD1180 0 0 0 0
lower limit
upper limit
reduction factor
Current controller adaptation ON - - MD1183 1 1 1 1
Rated motor speed nN rpm MD1400 4300 3000 3500 2700
Motor temperature alarm - °C MD1602 150 150 150 150
threshold
Shutdown limit, motor - °C MD1607 160 160 160 160
temperature
Rated motor torque MN Nm - 78 84 42 42
Rated motor power PN kW - 35,0 26,4 15,5 12,0

Appendix
Table A- 7 Machine data - setting data for 2SP125x, standard and reduced
SIMODRIVE 611 universal/digital 2SP1255- 2SP1255-1HAx- 2SP1253-1HBx- 2SP1253-1HAx-

Voltages, phase-to-phase, otherwise phase values 1HBx-1xx2 0xx2 1xx2 0xx2
Stand. Red. Stand. Red. Stand. Red. Stand. Red.
Motor code number - - MD1102 2953 2952 2951 2950
Encoder pulse - Inc/rev MD1005 256 256 256 256 256 256 256 256
number, motor
measuring system
Activate PE MSD - - MD1015 1 1 1 1 1 1 1 1
Current, rotor position - % MD1019 15 20 15 20 15 20 15 20
identification
PWM frequency fPWM Hz MD1100 3200 3200 3200 3200 3200 3200 3200 3200
Rated motor current IN A MD1103 120,0 102,0 95,0 85,0 68,0 60,0 53,0 45,0
Max. motor current Imax A MD1104 240,0 240,0 190,0 170,0 136,0 120,0 106,0 90,0
Pole pair No. p - MD1112 2 2 2 2 2 2 2 2
Torque constant kt Nm/A MD1113 1,34 1,34 1,55 1,7 1,24 1,36 1,62 1,77
Voltage constant ke V/1000* MD1114 94 94 116 116 93 93 121 121
rpm
Armature resistance Ra Ω MD1115 0,065 0,065 0,1 0,1 0,13 0,13 0,23 0,23
Direct axis inductance Ld mH - 2,62 2,62 4,10 4,10 4,40 4,40 7,40 7,40
Quadrature axis Lq mH MD1116 3,00 2,62 4,70 4,10 4,90 4,40 8,40 7,40
inductance
Motor moment of J kgm² MD1117 0,055 0,055 0,055 0,055 0,037 0,037 0,037 0,037
inertia
Motor locked rotor I0 A MD1118 120,0 102,0 95,0 85,0 68,0 60,0 53,0 45,0
current
Motor limiting current Ilimit A MD1122 240,0 240,0 190,0 170,0 136,0 120,0 106,0 90,0
Optimum load angle αopt - MD1128 110 105 110 105 110 105 110 105
Motor short-circuit Ik A MD1136 97,0 97,0 78,0 78,0 58,0 58,0 45,0 45,0
current
Speed at the start of nfs rpm MD1142 4600 4600 3600 3600 4500 4500 3500 3500
field weakening
Breakdown torque kred % MD1145 80 70 80 70 80 70 80 70
reduction factor
Maximum motor speed nmax rpm MD1146 15000 15000 10000 10000 15000 15000 10000 10000
Reluctance torque krelu mH MD1149 2,5 2,5 4,8 3,9 5,2 4,2 8,7 7,1
factor
Current controller - % MD1180 20 20 20 20 20 20 20 20
adaptation, lower limit
adaptation, upper limit
adaptation, reduction
factor
Current controller - - MD1183 1 1 1 1 1 1 1 1
adaptation ON
Rated motor speed nN rpm MD1400 3000 3000 2600 2560 3300 3600 2500 2700
Motor temperature - °C MD1602 150 150 150 150 150 150 150 150
alarm threshold
Shutdown limit, motor - °C MD1607 160 160 160 160 160 160 160 160
temperature

Appendix
2SP1255- 2SP1255-1HAx- 2SP1253-1HBx- 2SP1253-1HAx-

1HBx-1xx2 0xx2 1xx2 0xx2
Rated motor torque MN Nm - 170 150 170 150 100 80 100 80
Rated motor power PN kW - 53,4 47,0 46,3 40,0 35,0 30,0 26,0 22,5
Table A- 8 Machine data - setting data for 2SP1253-8HAx, star/delta
SIMODRIVE 611 universal/digital 2SP1253-8HAx-1xx2 2SP1253-8HAx-0xx2

Voltages, phase-to-phase, otherwise phase values
Star (Y) Delta (Δ) Y Δ Y Δ
Motor code number - - MD1102 MD2102 342 343 341 340
Encoder pulse number, - Inc/rev MD1005 MD2005 256 256 256 256
motor measuring system
Rated motor power PN kW MD1130 MD2130 13,2 13,2 13,2 13,2
Rated motor current IN A MD1103 MD2103 27,0 27,5 27,0 27,5
Rated motor voltage UN V MD1132 MD2132 400 400 400 400
Rated motor speed nN rpm MD1400 MD2400 1800 4000 1800 4000
Rated motor frequency fN Hz MD1134 MD2134 64,4 136,0 64,4 136,0
No-load voltage at rated flux U0 V MD1135 MD2135 368 380 368 380
No-load current I0 A MD1136 MD2136 10,8 14,2 10,8 14,2
Stator resistance (20°C) R1K Ω MD1137 MD2137 0,361 0,120 0,361 0,120
Rotor resistance (20°C) R2K Ω MD1138 MD2138 0,384 0,128 0,384 0,128
Stator leakage reactance X1leak Ω MD1139 MD2139 0,891 0,752 0,891 0,752
Rotor leakage reactance X2leak Ω MD1140 MD2140 0,715 0,570 0,715 0,570
Magnetizing reactance X1H Ω MD1141 MD2141 20,5 15,7 20,5 15,7
Speed at the start of field nfe rpm MD1142 MD2142 1800 4000 1800 4000
weakening
Upper speed, Lh - rpm MD1143 MD2143 2700 4900 2700 4900
characteristic
Gain factor, Lh characteristic - % MD1144 MD2144 148 112 148 112
Maximum speed nmax rpm MD1146 MD2146 15000 15000 10000 10000
Pole pair No. p - - - 2 2 2 2
Motor moment of inertia J0 kgm² MD1117 MD2117 0,037 0,037 0,037 0,037
Motor temperature alarm - °C MD1602 MD2602 150 150 150 150
threshold
Power factor cosϕ - - - 0,840 0,790 0,840 0,790
Rated torque MN Nm - - 70 31,5 70 31,5
Breakdown torque reduction Mbreak, red - MD1145 MD2145 100 100 100 100
factor

Appendix
Table A- 9 Machine data - setting data for 2SP1255-8HAxx, star/delta
SIMODRIVE 611 universal/digital 2SP1255-8HAx-1xx2 2SP1255-8HAx-0xx2

Voltages, phase-to-phase, otherwise phase values
Star (Y) Delta (Δ) Y Δ Y Δ
Motor code number - - MD1102 MD2102 347 346 344 345
Encoder pulse number, motor - Inc/rev MD1005 MD2005 256 256 256 256
measuring system
Rated motor power PN kW MD1130 MD2130 11,7 11,7 11,7 11,7
Rated motor current IN A MD1103 MD2103 28,8 27,5 28,8 27,5
Rated motor voltage UN V MD1132 MD2132 360 370 360 370
Rated motor speed nN rpm MD1400 MD2400 800 1800 800 1800
Rated motor frequency fN Hz MD1134 MD2134 29,3 61,6 29,3 61,6
No-load voltage at rated flux U0 V MD1135 MD2135 320 350 320 350
No-load current I0 A MD1136 MD2136 13,4 15,6 13,4 15,6
Stator resistance (20°C) R1K Ω MD1137 MD2137 0,537 0,179 0,537 0,179
Rotor resistance (20°C) R2K Ω MD1138 MD2138 0,471 0,157 0,471 0,157
Stator leakage reactance X1leak Ω MD1139 MD2139 0,701 0,593 0,701 0,593
Rotor leakage reactance X2leak Ω MD1140 MD2140 0,673 0,526 0,673 0,526
Magnetizing reactance X1H Ω MD1141 MD2141 13,8 12,9 13,8 12,9
Speed at the start of field nfe rpm MD1142 MD2142 970 1980 970 1980
weakening
Upper speed, Lh characteristic - rpm MD1143 MD2143 1600 2600 1600 2600
Gain factor, Lh characteristic - % MD1144 MD2144 147 117 147 117
Maximum speed nmax rpm MD1146 MD2146 15000 15000 10000 10000
Pole pair No. p - - - 2 2 2 2
Motor moment of inertia J0 kgm² MD1117 MD2117 0,055 0,055 0,055 0,055
Motor temperature alarm - °C MD1602 MD2602 150 150 150 150
threshold
Power factor cosϕ - - - 0,830 0,760 0,830 0,760
Rated torque MN Nm - - 140 62,1 140 62,1
Breakdown torque reduction Mbreak, - MD1145 MD2145 80 80 80 80
factor red

Appendix
A.3 Declaration of conformity
A.3 Declaration of conformity

Appendix
A.4 Service workshops
A.4 Service workshops
Table A- 10 Service workshops/customer service
Country Address data

Germany Weiss Spindeltechnologie GmbH
A Siemens Company
Birkenfelder Weg 14
96126 Maroldsweisach
Telephone: +49 9532 9229 – 347
Fax: +49 9532 9229 – 377
E-mail: service@WEISSGMBH.de
USA Weiss Spindle Technology, Inc
Repair and Service
Jürgen Beck
7255 Industrial Park Blvd./ Unit K
Mentor Ohio 44060 USA
Telephone: +1 440 946 – 4003
Fax: +1 440 942 – 9056
E-mail: Juergen.Beck@weissgmbh.de
Great Britain SIEMENS Weiss Spindle Service
Dave Ellis
Unit 3A, Brooke Park, Handforth
Creshire SK9 3PR
Telephone: +44 1625 543480
Fax: +44 1625 543488
E-mail: Dave.ellis@siemens.com
Brazil SIEMENS LTDA.
Philipp Hager
Rua Werner Siemens, 111
05069-010 Sao Paulo – SP
Brazil
Telephone: +55 11 383344 – 35
Fax: +55 11 383344 – 34
E-mail: philipp.hager@siemens.com
China SIEMENS FACTORY Automation Engineering Ltd.
SERVICE A&D DEPT.
MOTOR REPAIR
Mr. Zhao Jiang
8/F, A1 Building, No. 9, Jiuxianqiao East Rd.
Chaoyang District,
Beijing, 100016, P.R. China
Telephone: +86 (010) 84597307
Fax: +86 (010) 84597390
E-mail: jiang.zhao@siemens.com
India SIEMENS Ltd. Automation and Drives
Mr. Raghavendra Mutalik
No.84, Keonics Electronic City, Hosur Road
Bangalore 560100, India
Telephone: +91 (080) 41191694
Fax: +91 (080) 41191580
E-mail: raghavendra.mutalik@siemens.com

Index
H
B Hotline, 4
Bearings, 13 Hydraulic
Connections, 40
C
I
Clamping state sensing
Function description, 19 Installing the spindle, 25
Technical data, 48 Internal tool cooling, 21
Clamping state sensors IVP, 28
Conditions for switching on, 30
Commissioning, 25
Compressed air M
Conditioning, 40 Maintenance intervals
Connections, 39 HSK A63 Type C, 80
Conditions for switching on, 30 HSK A63 Type K, 69
Connection SK 40/CAT 40/BT 40, 88
Power connector, 36 Maintenance plan, 59
Connections for the various media (graphics), 44 Media°, 37
Converter setting data
SIMODRIVE 611, 105
SINAMICS S120, 102 P
Cooling, 14
Cooling water Power connection, 35
Conditioning, 38
Connections, 38
R
Rotary encoder, 51
D Rotary gland, 91
Danger notices, 11
Dimension drawings, 95
Drive, 14 S
Safety instructions, 9
Electrical system, 11
E Hydraulic/pneumatic systems, 10
External tool cooling, 22 Mechanical system, 10
Qualified personnel, 9
Seal, 13
F Service & Support, 4
Service workshops, 110
Faults, 57 Supplying the various media, 37
Switch-on procedure, 33

Index
T
Technical data
Power connection, 35
Technical Support, 4
Tool air purge system, 23
Tool clamping system, 19
HSK A63 Type C, 73
HSK A63 Type K, 61
SK40, 84
Tool interfaces
BT40, 54
CAT40, 53
HSK A63, 55
Pull-in force, 52
Reference gauge, 52
SK40, 53
Standards, 52
Tool release unit
Description, 19
Tools, 15
Training, 3
V
Vibration velocity, 18
Voltage limiting, 28
VPM, 28
W
Warning and safety instructions, 9
Wearing parts, 59

Siemens AG Subject to change without prior notice
Industry Sector © Siemens AG 2011
Drive Technologies
Motion Control Systems
P.O. Box 3180
91050 ERLANGEN
GERMANY
www.siemens.com/motioncontrol

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2SP1 ECS motor spindle

Operating instructions · 02/2011

Warning and safety

2SP1 ECS Motor Spindle ___________________

Siemens AG order number: 6SN1197-0AD14-0BP1 Copyright © Siemens AG 2011.

2SP1 ECS Motor Spindle

Company Telephone/Telefax Internet address / E-mail

Internet addresses for drive technology

2SP1 ECS Motor Spindle

2SP1 ECS Motor Spindle

3.4 Switch-on procedure ................................................................................................................... 33

2SP1 ECS Motor Spindle

7.3.3 Changing the lip seal in the clamping set ....................................................................................79

2SP1 ECS Motor Spindle

2SP1 ECS Motor Spindle

1.2 Qualified personnel

2SP1 ECS Motor Spindle

1.3 Working on the systems

1.3.1 Mechanical system

1.3.2 Hydraulic/pneumatic systems

2SP1 ECS Motor Spindle

1.3.3 Electrical system

1.4 Specific hazards and dangers

2SP1 ECS Motor Spindle

1.4.1 Danger due to mechanical energy

1.4.2 Hazards due to hydraulic/pneumatic energy

1.4.3 Hazards due to electrical energy

When incorrectly handled, electricity can be potentially hazardous resulting in death or

2SP1 ECS Motor Spindle

2SP1 ECS Motor Spindle

2.5 Motor cooling

2SP1 ECS Motor Spindle

Rotation of the workspindle without a clamped tool is prohibited at all times.

2SP1 ECS Motor Spindle

2.6.3 Permitted balance qualities

2SP1 ECS Motor Spindle

2.6.4 Permissible speed

Figure 2-1 Length-diameter ratio of the tool

2SP1 ECS Motor Spindle

2.6.5 Permissible vibration levels

3 mm/s in no-load operation

2SP1 ECS Motor Spindle

2.7 Tool clamping system

2.7.1 Clamp/release tool (tool release unit)

2.7.2 Clamping state sensing

2SP120x analog clamping state sensing

2SP1 ECS Motor Spindle

2SP120x digital clamping state sensing

2SP125x digital clamping state sensing

2SP1 ECS Motor Spindle

2.8 Tool cooling

2.8.1 Internal tool cooling for the cooling-lubricating medium (option)

2SP1 ECS Motor Spindle

2SP1 ECS Motor Spindle

2.9 Tool air purge system

2SP1 ECS Motor Spindle

2SP1 ECS Motor Spindle

2SP1 ECS Motor Spindle

3.1 Commutation angle

Determining the commutation angle offset for SIMODRIVE

2SP1 ECS Motor Spindle

Determining the pole position identification / commutation angle for SINAMICS

2SP1 ECS Motor Spindle

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