Jäger Z100-H642.15 S11W2 Manual Download

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Manual

Z100-H642.15 S11W2

High Frequency Spindle

Pneumatic taper change

Summary of Contents for Z100-H642.15 S11W2

Page 1: ...Manual Z100 H642 15 S11W2 High Frequency Spindle Pneumatic taper change ...

Page 2: ...l development 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 prohib...

Page 3: ...igital differential magneto resistor 26 6 8 Speed and position sensor sinusoid optional ac cessory 27 6 8 1 Toothed wheel 27 6 8 2 Technical Specifications 27 6 9 Speed and position sensor TTL optional accessory 28 6 9 1 Toothed wheel 28 6 9 2 Technical data TTL x8 28 6 10 Eddy current sensor SGS optional accessory 29 6 10 1 Measurement principle 29 6 10 2 Technical Specifications 29 6 11 Eddy cur...

Page 4: ...12 2 Daily cleaning 44 12 2 1 Before commencing work 44 12 2 2 With every tool change 44 12 2 3 Every time the clamping device is changed 45 12 3 In the case of storage 45 12 4 Monthly maintenance 45 12 5 Long periods of storage 45 12 6 Maximum storage time 45 13 Dismantling 46 13 1 Disposal and environmental protection 46 14 Service and repairs 47 14 1 Service partners 47 14 2 Malfunctions 48 15 ...

Page 5: ...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 6: ...requency spindle for completeness upon delivery 2 1 1 Optional accessories Available on request q Spindle holder q Frequency converter q Chiller q Collet grease q Hose connections q Motor cable q Control cable q ESD protection q Vector control speed and position sensor q Longitudinal growth monitoring eddy current sensor q Further accessories on request Only approved accessories have been tested f...

Page 7: ...h the HF spindle q Manual q The declaration of incorporation is part of the manual q Inspection protocol Ü Check that the documentation supplied is complete when the spindle is delivered If necessary request a new copy 2 2 Packaging of HF spindle All transport packaging materials can be recycled in appropriate disposal facil ities ...

Page 8: ...hining 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 2 Permissible materials The HF spindle has been developed only for the following materials q Metals such as alloys cast metals etc q Sintered materials q Plastics q Wood q Graphite q Stone marble etc q ...

Page 9: ...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 10: ...ause 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 bal...

Page 11: ...nd forwarding 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...

Page 12: ...or phases 1b Electrical connection for Tool taper monitoring PTC Pt1000 1c Electrical connection for Vector control optional accessory 1d Electrical connection for Eddy current sensor optional accessory 2 Cooling water G 1 4 3 Sealing air G 1 8 4 Taper cleaning G 1 8 7 Pneumatics for tool change cylinder forward G 1 8 8 Pneumatics for tool change cylinder back G 1 8 ...

Page 13: ...produced during operation of the HF spindle The temperature of the HF spindle should not exceed 45 C as this shortens the service life of the bearing u Check the temperature of the HF spindle on the housing 5 4 Sealing air For guidelines on air quality see Air purity classes ISO 8573 1 35 section The sealing air prevents foreign bodies such as chips and liquids e g emul sions from entering the HF ...

Page 14: ...0 Hz Motor poles pairs 2 Rated rotation speed 42 000 rpm Acceleration braking value Per second 10 000 rpm other values by consultation Characteristics Speed sensor Differential magneto resistor TTL Number of signals 6 Vector control Optional accessory Motor protection PTC 150 C Pt1000 Housing Stainless steel Housing diameter 100 80 mm Cooling Liquid cooled Ambient temperature 10 C 45 C Sealing air...

Page 15: ... 01 15 52 3 positions clamped unclamped ejected Clamping range up to 13 mm Clockwise and anticlockwise Coupler plug 5 pin ECTA 133 motor phases 12 pin ECTA 133 sensors Weight 15 kg Inner taper run out 1 µ Axial run out 1 µ 6 1 Dimensions Clamping range ...

Page 16: ...5 000 20 000 25 000 30 000 42 000 rpm Speed 4 185 9 242 14 271 19 299 24 328 29 191 40 934 rpm Frequency 167 333 500 667 833 1 000 1 400 Hz Rated power 1 898 4 546 6 6 8 5 10 014 9 944 9 152 kW Torque 4 332 4 698 4 442 4 187 3 931 3 253 2 135 Nm Voltage 89 170 240 310 380 380 380 V Current 24 8 25 7 24 8 23 9 23 1 22 6 20 8 A cos φ 0 84 0 80 0 79 0 78 0 77 0 79 0 8 Measured values S6 60 Rated rota...

Page 17: ...6 01 14 553 kW Torque 6 120 6 846 6 712 6 579 6 445 5 341 3 478 Nm Voltage 89 170 240 310 380 380 380 V Current 38 38 38 38 38 38 4 38 A cos φ 0 9 0 84 0 82 0 81 0 79 0 79 0 76 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 measured currents may be greater than the spec...

Page 18: ... p0322 Maximum speed 42 000 rpm p0326 Stalling torque correction factor 100 p0335 Cooling type Liquid cooled p0341 Moment of inertia 0 000676 kgm p0348 Field weakening operating speed VDC 600V 60 178 rpm p0350 Stator resistance cold strand 0 225 Ω p0353 Series inductance strand 0 mH p0354 Rotor resistance cold 0 243 Ω p0356 Stator stray inductance 0 365 mH p0358 Rotor stray inductance 0 352 mH p03...

Page 19: ...em no 10406075 Revision 01 19 52 Parameter Meaning Value Unit Desaturation speed 40 082 rpm Main inductance at maximum speed 4 472 mH Saturation factor 1 187 Tilting torque reduction factor 58 09 Additional parameters Heidenhain ...

Page 20: ...er Fa Alfred Jäger GmbH untersagt Datum Gepr Bearb Norm Projekt Nr Version Nr Zeichn Nr von Blatt DIN 81346 Pinbelegung FS5 S11 ECTA Gerätestecker FS5 S11 spindle plug FS5 S11 Spindel U V W GNYE 0 2mm BK 0 2mm BU 0 2mm BN 0 2mm Stator 1 2 3 PE 4 BN RD RD BN BU GN BU VT BK WH WH WH gn ge 2 5 mm AC 6 01 2 AC 7 01 2 AC 8 01 4 8 2 11 4pol 8 1 11 4pol 3 7 4pol 4 7 2pol 2 7 2pol Motorvarianten Kundensei...

Page 21: ... Vs output 0V BK BU 3 4 PNP Spindelstecker S12 ECTA S13 spindle plug S12 ECTA S13 X1 BN 1 Vs output 0V BK BU 3 4 PNP BN 1 Vs output 0V BK BU 3 4 PNP C RD BN 0 25mm WH WH 0 25mm BN 0 14mm BU 0 14mm BK 0 14mm BK 0 14mm BK 0 14mm PTC BU 0 14mm RD 0 14mm PNP Induktiver Näherungsschalter Inductive proximility switch 1 Perschewski 09 04 18 1 PTC KTY WK FP 29023272 g f e d c b a 4 5 6 1 3 2 a b c d e f g...

Page 22: ...ndle plug FS17 S10 Vektor P 1 Perschewski 16 03 17 1 29022570 g f e d c b a 4 5 6 1 3 2 a b c d e f g Bl Übersetzungen Vervielfältigungen und die Weitergabe an Dritte auch nur auszugsweise ist ohne schriftliche Gehnehmigung der Fa Alfred Jäger GmbH untersagt Datum Gepr Bearb Norm Projekt Nr Version Nr Zeichn Nr von Blatt DIN 61346 Flanschstecker FS17 S10 GN 0 25 mm wird nicht benötigt isoliert hin...

Page 23: ... Fa Alfred Jäger GmbH untersagt Datum Gepr Bearb Norm Projekt Nr Version Nr Zeichn Nr von Blatt DIN 81346 Pinbelegung FS17 S10 Vektor GS04 S M UA SIN NA 1 Spur UN PZ N GND 5V 5 UB COS PB 2 Spur UA SIN PA 1 Spur UB COS NB 2 Spur UN NZ N Sense Zahnradgeber GS04T08 Mis encoder GS04T08 Mis 11 10 7 3 2 1 12 13 E BU 0 25 mm BN 0 25 mm WH 0 25 mm GY 0 25 mm YE 0 25 mm GN 0 25 mm RD 0 25 mm PK 0 25 mm wir...

Page 24: ...7 1171 1175 1179 1182 1186 1190 50 1194 1198 1202 1206 1209 1213 1217 1221 1225 1229 60 1232 1236 1240 1244 1248 1252 1255 1259 1263 1267 70 1271 1275 1278 1282 1286 1290 1294 1298 1301 1305 80 1309 1313 1317 1320 1324 1328 1332 1336 1340 1343 90 1347 1351 1355 1359 1362 1366 1370 1374 1378 1381 100 1385 1389 1393 1396 1400 1404 1408 1412 1415 1419 110 1423 1427 1431 1434 1438 1442 1446 1449 1453 ...

Page 25: ... voltage Vis 3 kV Response time ta 2 5 s Operating temperature range V 0 Top 25 180 C Resistance values TNAT ΔT R TNAT ΔT VPTC 2 5 V R TNAT ΔT VPTC 2 5 V R TNAT 15 K VPTC 7 5 V R TNAT 23 K VPTC 2 5 V 150 5 C 550 Ω 1330 Ω 4 kΩ 6 6 Tool change monitoring Tool taper monitoring indicates the readiness status of the HF spindle to the operator and forwards the corresponding signal to the machine control...

Page 26: ...differential magneto resistor S signal Note Resistor Rx If the resistor 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 freq...

Page 27: ... as of zero speed 6 8 1 Toothed wheel teeth 164 module 0 3 Centering diameter Ø24 M25x1 LH 6 8 2 Technical Specifications Output level 1 VSS as differential signal Output signal 2 sinusoidal signals offset by 90 and their inverse signals short circuit proof Option reference pulse Output frequency 0 200 kHz for a line capacity of 5 nF Offset static 20 mV Amplitude tolerance 20 10 Amplitude synchron...

Page 28: ... is modulated by the moving target wheel q The sensor detects the change in magnetic field and converts this into a square wave output signal TTL q The sensor multiplies the output signal by 8 6 9 1 Toothed wheel teeth 164 module 0 3 Centering diameter Ø24 M25x1 LH 6 9 2 Technical data TTL x8 Supply voltage 5 V 5 load current 60 mA Output signal 2 square wave signals offset by 90 with reference pu...

Page 29: ...ecifications The specified data are valid for a reference temperature of 20 C Measurement range 400 µm Start of measurement range 150 µm Linearity 5 µm Resolution 1 µm Limit frequency analog 20 mV µm Sensitivity q Displacement q Temperature 20 mV µm 0 1 V C Temperature stability q Sensor q Controller 0 01 of measurement range C 0 05 of measurement range C Interfaces q Analog q Digital 0 2 10 VDC o...

Page 30: ...ponse time 1 ms Operating voltage range 15 30 VDC Current consumption max 10 mA without load Output circuit Voltage output Output signal 0 10 VDC Load resistance 3000 Ω short circuit proof reverse polarity proof 6 12 ESD protection optional accessory ESD protection is provided by creating an electrically conductive connection between the rotating shaft of the HF spindle and the motor housing q Dep...

Page 31: ...Technical Specifications Item no 10406075 Revision 01 31 52 6 13 Air borne noise emissions CAUTION Noise has an impact on health u Only operate the HF spindle if you are wearing hearing protection ...

Page 32: ...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 33: ...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 34: ... 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 35: ... air quality see Air purity classes ISO 8573 1 35 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 36: ...thout 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 of the HF spindle is affected q The bearing is damaged 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 of...

Page 37: ...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 44 section Ü ...

Page 38: ...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 10 1 Clockwise and counter clockwise Sample illustration Direction of rotation indication The HF spindle clamping system is designed for clockwise and counter clock wise rotation Ü Only use tools with the correct direction of rotation for th...

Page 39: ...age and clean when switching to the HF spindle Insert the tool up to the contact surface of the clamping taper Ü Make sure that the shaft of the HF spindle has come to an absolute stand still Ü Switch on the compressed air for cylinder forward Ü Remove the tool Ü Clean the inner taper of the tool mount and the inner taper of the shaft with the felt cleaning taper Ü Insert the tool Ä Insert the too...

Page 40: ...ic taper change During a tool change the tool mount is pressed out of the shaft by the cylin der 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 thread Ü Insert the changing station into the hole Ü Secure the changing station using the threaded spindle M5 10 3 3 Maintenance Befo...

Page 41: ... Tool change at the HF spindle Caution No rotation without clamped tool Tool clamped signal HF spindle is ready for use No Connection on off Compressed air Always leave sealing air switched on Even in the case of a tool change This prevents dirt or moisture from entering the HF spindle 3 Taper cleaning on 4 Pneumatic system for tool change on Cylinder forward 7 Perform tool change Taper cleaning o...

Page 42: ...rt HF spindle Clamped signal Cylinder back Clamping system clamped with tool Tool taper inserted in tool mount of HF spindle 1 Start HF spindle when signal 1 Ejected signal Cylinder is extended Clamping system disengaged Tool taper inserted in tool mount of HF spindle Tool taper is not clamped here 0 Do not start HF spindle Note Ensure functionality The released signal shows the user the ready sta...

Page 43: ...may be flung out u Note the maximum speed for the selected tool u Note the maximum speed for the HF spindle u The maximum permissible speed of the HF spindle for commissioning processing is always the lowest specified speed Ü Only use tools that are technically sound 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...

Page 44: ...rately 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 jets to clean the HF spindle This could cause contamination to enter the bearing area 12 2 1 Before commenci...

Page 45: ...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 46: ...tection More than 90 of the materials used in the HF spindle can be recycled alu minum stainless steel steel copper etc The HF spindle may not be disposed of with normal domestic waste Ü Remove all non recyclable materials Ü Dispose of the HF spindle as scrap at an approved recycling facility Ü Follow all rules of the responsible administrative bodies Ü Do not discharge coolants into wastewater Ü ...

Page 47: ...al energy supply companies u Before commencing work switch off the power supply of the HF spindle Note Damage due to electrostatic discharge Do not touch the electrostatic sensitive components of the HF spindle 14 1 Service partners Only certified service partners may open and repair the spindle Failure to comply with this voids any warranty claims and compensation claims for dam ages Ü The list o...

Page 48: ...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 49: ...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 38 and Mainte nance 44 sections Lack of pressure q Check the connections for compressed air q Check the hoses for compressed air q Check the pneumati...

Page 50: ...serve all points in the Tool change 38 and Mainte nance 44 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 51: ...4 1 6 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 Mach...

Page 52: ...1239 Ober Mörlen GERMANY 49 0 6002 9123 0 sales alfredjaeger de www alfredjaeger de Serial number Type Z100 H642 15 S11W2 Item no 10406075 Revision 01 Date 20 02 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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