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Manual

KS2-06/80

High Frequency Spindle

Pneumatic direct change

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Summary of Contents for KS2-06/80

Page 1: ...Manual KS2 06 80 High Frequency Spindle Pneumatic direct change ...

Page 2: ...evelopment we reserve the right to make technical modifications and variations from the exact design described in the manual The text in this manual has been compiled with the utmost care However Al fred Jäger GmbH cannot assume any legal responsibility or liability of any kind for incorrect information and any consequences thereof Translations and reproductions including of extracts are prohibite...

Page 3: ...perating location 19 8 Installation 20 8 1 Installing the HF spindle 20 8 2 Diameter of media supply line 21 8 3 Cooling water 21 8 3 1 Quality of cooling water 21 8 3 2 Setting the cooling 21 8 4 Compressed air 22 8 4 1 Air purity classes ISO 8573 1 22 8 4 2 Setting the sealing air 22 8 4 3 Setting values 23 9 Commissioning 23 9 1 Running in schedule 23 9 2 Daily start up 24 9 3 Shutdown signal 2...

Page 4: ...tion of the man ual carefully again 1 2 Explanation of symbols used To enable quick classification of information this manual uses visual aids in the form of symbols and text markings Notes are marked with a signal word and a colored box DANGER Dangerous situation Results in serious injury or death u Measure to avert the danger WARNING Dangerous situation May result in serious injury or death u Me...

Page 5: ... spindle q High Frequency Spindle q Collet q Service set q Transport packaging Ü Check the high frequency spindle for completeness upon delivery 2 1 1 Service set q Collet grease q Felt cleaning taper q Cylinder brush with eyelet q Ejector pin q O ring q Collet screw in tool 2 1 2 Optional accessories Available on request q Spindle holder q Frequency converter q Chiller q Further accessories on re...

Page 6: ...e with the Machinery Directive and cannot perform any function independently The HF spindle can only be operated in conjunction with a machine tool and a frequency con verter 3 1 Permissible types of machining The HF spindle has been developed only for the following types of machining q Cutting q Drilling q Engraving q Grinding Ü Contact Alfred Jäger GmbH if other types of machining are required 3...

Page 7: ...are not approved for use in areas at risk of explosion Use in such areas may result in explosions u Do not use the HF spindle in potentially explosive atmospheres DANGER Due to flying parts The HF spindle operates at high speeds and may therefore be flung away by these u Operate the HF spindle only if it is installed in the machine or system in a fixed manner Note Adhere to the limit values u Obse...

Page 8: ...chips to fly out with great force u Never remove the protective devices of the machine or system u Always wear protective goggles during work Example of design Inserting the shank Note Ensure functionality u Never operate the HF spindle without a clamped tool shank If no tool shank is clamped q The clamping system is damaged by the centrifugal forces q The clamping system is shifted q The balance ...

Page 9: ...this to the machine controller for evaluation 4 3 Installation and maintenance Ü Carry out installation cleaning and maintenance work only after shutting down the HF spindle and after the shaft has come to a standstill Ü Install all safety and protective devices of the machine immediately after completing work 4 4 Modification and repair Modifications or alterations to the HF spindle are only perm...

Page 10: ...whether the current voltage and frequency data of the HF spindle match the raw data for the frequency converter Ü Use a motor supply line that is as short as possible Ü Adjust the speed of the HF spindle using the FC Ü Refer to the frequency converter manual for further information The FC detects the following operating states of the HF spindle depending on the version q HF spindle rotating q HF s...

Page 11: ...spindle on the housing 5 4 Sealing air For guidelines on air quality see Air purity classes ISO 8573 1 22 section The sealing air prevents foreign bodies such as chips and liquids e g emul sions from entering the HF spindle Ü Check that air escapes at the front between the housing and the rotating parts of the HF spindle 5 5 Pneumatic tool change For guidelines on air quality see Air purity classe...

Page 12: ...s Frequency 1 333 Hz Motor poles pairs 1 Rated rotation speed 80 000 rpm Acceleration braking value Per second 10 000 rpm other values by consultation Characteristics Speed sensor Differential magneto resistor TTL Number of signals 6 Motor protection PTC 160 C Housing Stainless steel Housing diameter 61 9 mm Cooling Liquid cooled Ambient temperature 10 C 45 C Sealing air Protection category sealin...

Page 13: ...Technical Specifications Item no 10302006 Revision 10 13 36 6 1 Dimensions Clamping range ...

Page 14: ...8 424 28 411 38 256 48 223 58 211 67 382 76 328 rpm Frequency 167 333 500 667 833 1 000 1 167 1 333 Hz Rated power 0 115 0 231 0 338 0 455 0 561 0 671 0 868 0 943 kW Torque 0 13 0 12 0 11 0 11 0 11 0 11 0 12 0 12 Nm Voltage 75 113 143 166 185 205 215 212 V Current 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5 A Cos φ 0 27 0 37 0 44 0 51 0 57 0 61 0 72 0 78 Measured values S6 60 Rated rotation speed 10 000 20 00...

Page 15: ...406 0 648 0 905 1 145 1 397 1 593 1 621 kW Torque 0 17 0 25 0 22 0 23 0 23 0 24 0 24 0 21 Nm Voltage 75 115 144 167 185 207 208 206 V Current 5 6 8 6 8 6 8 7 7 7 7 7 9 A Cos φ 0 29 0 45 0 55 0 64 0 72 0 78 0 82 0 83 Note on operation with static frequency converters For operation with a frequency converter the effective fundamental voltage must correspond to the specified motor voltage The measure...

Page 16: ...D 0 14mm BU 0 14mm YE 0 14mm BK GN 0 14mm U V W 2 4 2 3 7 2 2 7 2 4 7 2 3 7 4 7 7 4 AC3 01 PTC 1 4 2 AC4 AC6 AC7 ACM 26 ACM70 40 50 DC2 DC3 DCM26 DCM44 DCM48 30 60 AC9 01 ACM60 32 ACM70 40 100 DCM60 40 KTY AC8 01 AC9 02 ACM48 30 45 ACM82 50 80 4 DC4 DC5 DCM48 30 90 AC8 02 AC10 01 AC10 02 ACM82 50 80 4E DC9 01 DC8 02 DC9 02 DC8 01 0 5 RD 0 5 GN 0 5 WH 2x 0 14 0 5 RD 0 5 BU 0 5 WH 0 22 BN 0 22 VT 0 ...

Page 17: ...ing to the positive temperature coefficient thermistor temperature TPTC small signal resistance Technical Specifications Type M135 Max operating voltage TA 0 40 C V max 30 V Max measuring voltage TA 25 K TNAT 15 K V Meas max 7 5 V Nominal resistance VPTC 2 5 V RN 250 Ω Insulation test voltage Vis 3 kV Response time ta 2 5 s Operating temperature range V 0 Top 25 180 C Resistance values TNAT ΔT R T...

Page 18: ...tor Rx is already integrated in the evaluation unit FC u Only connect signal and ground Supply voltage U Rx Signal 8 V 220 Ω 1000 mV 8 V 450 Ω 2000 mV 12 V 220 Ω 1000 mV 12 V 680 Ω 3000 mV 15 V 220 Ω 1000 mV 15 V 680 Ω 3000 mV 24 V 220 Ω 1000 mV 24 V 680 Ω 3000 mV Unnecessary if a resistor is integrated in the evaluation unit frequency converter etc Values may differ by 20 depending on the measuri...

Page 19: ...eds which may cause chips to fly out with great force u Never remove the protective devices of the machine or system u Always wear protective goggles during work Example of design Mounting surface Note the following points before installing the HF spindle Ü Make sure that the correct spindle holder for the HF spindle is fitted in the machine Ü Check the connecting hoses for damage Ü Check the conn...

Page 20: ...esponding hoses in the hose fittings Ü Make sure that the connections are flexible and free of strain Ü Seal all connections for compressed air axially in relation to the tightening direction Ü Seal all connections for cooling water axially in relation to the tightening direction Ü If the HF spindle is equipped with sealing air Ä Make sure that no air flow can occur in the bearing area Ä Always us...

Page 21: ... immediate corrosion on bare parts which is often unno ticeable at first but later leads to serious corrosion damage Ü Do not use pure or distilled water Deposits in cooling channels due to unsuitable cooling water prevent the dis sipation of heat Ü Use cooling water with the following properties Drinking water according to 98 83 EC Hardness 1 15 dH PH value 7 9 Additive corrosion protection 20 An...

Page 22: ... air quality see Air purity classes ISO 8573 1 22 section The adjustment value for the sealing air depends on the hose diameter and length Ü Hose diameter DN 4 Ü The setting value can be found in the following diagram Ü To ensure effective control turn on the sealing air and cooling when turn ing on the machine This protects the HF spindle even when it is stationary Lowest sealing air supply Dry m...

Page 23: ...If no tool shank is clamped q The clamping system is damaged by the centrifugal forces q The clamping system is shifted q The balance of the HF spindle is affected q The bearing is damaged Example of design Clockwise Ü Turn the shaft of the spindle at least ten times by hand Ü Before storing and before commissioning only clean the cooling duct with compressed air 9 1 Running in schedule Duration o...

Page 24: ...ing this to the machine controller for evaluation 9 4 Commissioning after storage Ü Do not put the HF spindle into operation until its temperature has adjusted from the temperature of the storage location to the temperature of the us age location Ä The temperature difference between the HF spindle and the usage lo cation should not exceed 10 C Ü Carry out all steps in the Maintenance 29 section Ü ...

Page 25: ... use tools with the correct direction of rotation for the HF spindle Ü Only use tool mounts with the correct HF spindle direction of rotation Ü Set the direction of rotation of the HF spindle on the FC in accordance with the arrow display on the HF spindle 10 2 Pneumatic direct change Tip Ensure concentric run out quality u Keep collet clamping nut contact surface shaft tool taper and tool mount c...

Page 26: ...s during cleaning Ü Clean the inner taper of the shaft with the felt cone from the service set Ü Clean the collet with the brush Ü Apply a light greasy film to the taper of the collet To do this only use the collet grease from the service set Ü Insert a suitable tool shank into the collet Ü Screw the collet as far as possible into the shaft using the screw in tool Ä Tightening torque MA max 1 5 Nm...

Page 27: ...t of the shaft Ü The collet opens Ü Only the tool is deposited in the changing station Tip Fast tool change u Use a tool with a stop ring This means that there is no need to re adjust the immersion depth after each tool change 10 3 2 Installing the changing station Proceed as follows to install the changing station Ü Drill a hole with a suitable diameter Ø D1 H7 for the tool mount Ü Add an M5 thre...

Page 28: ...ound Ü Only use tools with a tool shank diameter that corresponds to the inner di ameter of the collet For example do not use shanks with a diameter of 3 mm in collets for 1 8 3 175 mm Ä Also see the Technical Specifications 12 section Ü Only use tool shanks with a diameter tolerance of h6 Ü Do not use tool shanks with a clamping surface e g Weldon Ü Only use a balanced tool Ä DIN ISO 1940 balance...

Page 29: ...to the openings of the HF spindle 12 2 Daily cleaning To ensure that the HF spindle functions safely and accurately all contact sur faces of the HF spindle the mount for the HF spindle the tool mount and the tool holder must be clean Note Foreign matter reduces the service life u Do not use compressed air to clean the HF spindle u Do not use ultrasonic cleaning on the HF spindle u Do not use steam...

Page 30: ...izontal position Ü Store the HF spindle so that it is protected from moisture dust and other environmental influences Ü Note the following storage conditions Temperature of storage location 10 C 45 C Relative humidity 50 12 4 Monthly maintenance Ü Turn the shaft of the HF spindle at least ten times by hand every four weeks 12 5 Long periods of storage Ü Turn the shaft of the HF spindle at least te...

Page 31: ...lants into wastewater Ü Dispose of cooling media in accordance with local regulations If the HF spindle cannot be dismantled send the HF spindle to Alfred Jäger GmbH Alfred Jäger GmbH shall not assume the costs incurred for shipment and the fees for the recycling facilities 14 Service and repairs DANGER Electric shock Electric shock can lead to severe burns and life threatening injuries Take measu...

Page 32: ...requency converter has shut down q Check the error messages in the frequency converter man ual Tool change initiated q Turn off the pneumatic system for the tool change HF spindle becomes hot Cause Troubleshooting Insufficient cooling q Check the power of the chiller q Check the water level of the chiller q Check the connections and the cooling hoses q Check the cooling circuit q Check the chiller...

Page 33: ...screws of the spindle holder manually q Do not use technical aids to clamp the HF spindle Bearings damaged q Contact Alfred Jäger GmbH service No automatic tool change Cause Troubleshooting Contamination q Remove all contamination between the tool taper and shaft of the HF spindle Observe all points in the Tool change 25 and Mainte nance 29 sections Lack of pressure q Check the connections for com...

Page 34: ...serve all points in the Tool change 25 and Mainte nance 29 sections Frequency converter incorrectly set q Compare the values for the HF spindle with the set values on the frequency converter Machining too heavy q Reduce the machining load intensity Mounting screws are loose q Tighten the screws securely HF spindle damaged q Contact Alfred Jäger GmbH service If the error is not rectified after chec...

Page 35: ... 5 1 7 1 1 7 1 1 1 7 2 1 7 3 1 7 4 The incomplete machinery in its standard design complies furthermore with the following applicable regulations Applicable harmonized standards DIN EN ISO 12100 Safety of machines The machinery is incomplete and must not be put into service until the ma chinery into which it is to be incorporated has been declared in conformity with the provisions of the Machinery...

Page 36: ...e 8 61239 Ober Mörlen GERMANY 49 0 6002 9123 0 sales alfredjaeger de www alfredjaeger de Serial number Type KS2 06 80 Item no 10302006 Revision 10 Date 04 01 2023 Language EN Jaeger Spindles North America Corp 6611 Bay Circle Suite 165 Norcross GA 30071 USA 1 770 674 4480 office jaegerspindles com www alfredjaeger de en ...

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