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Service and repairs

Item no. 10406166, Revision 03

43 ( 48 )

14

Service and repairs

DANGER: Electric shock.

Electric shock can lead to severe burns and life-threatening injuries.

Take measures to prevent hazards caused by electrical energy (for details re-
fer e.g. to the regulations issued by the VDE and the local 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 of partners can be found on the following website.

http://www.alfredjaeger.de/de/spindel-servicepartner.html

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Содержание 10406166

Страница 1: ...Manual F100 H636 101 K0 5RW2V High Frequency Spindle Hydraulic taper change ...

Страница 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...

Страница 3: ...talla tion 17 6 Technical Specifications 18 6 1 Dimensions 19 6 2 Technical data sheet KL8513 AC Motor 20 6 2 1 Performance Diagram 21 6 3 Wiring diagram 22 6 4 Motor protection KTY 84 130 26 6 5 Motor protection PTC 130 C 27 6 6 Tool change monitoring 27 6 7 Air borne noise emissions 28 7 Operating location 28 8 Installation 29 8 1 Installing the HF spindle 29 8 2 Diameter of media supply line 30...

Страница 4: ...ents Translation of the original manual 12 6 Maximum storage time 41 13 Dismantling 42 13 1 Disposal and environmental protection 42 14 Service and repairs 43 14 1 Service partners 43 14 2 Malfunctions 44 15 Declaration of Incorporation 47 ...

Страница 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...

Страница 6: ...Check the high frequency spindle for completeness upon delivery 2 1 1 Service set q Felt cleaning taper 2 1 2 Optional accessories Available on request q Frequency converter q Chiller q Collet grease q Further accessories on request Only approved accessories have been tested for operational safety and func tionality Ü Do not use any other accessories this may invalidate any warranty claims and com...

Страница 7: ...l 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 2 Permissible materials The HF spindle has been developed only for the following materials q Metals such as alloys cast metals etc q Sintered mat...

Страница 8: ...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...

Страница 9: ...use 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 bala...

Страница 10: ...uency converter of detecting the shutdown signal from the shaft and forwarding this to the machine controller for evaluation 4 3 Internal coolant supply DANGER Due to explosion Flammable flow media or hydrocarbons may ignite and trigger explosions u Ensure that no flammable flow media are used u Ensure that no hydrocarbons are used Exception Heat transfer oils within the permissible temperature ra...

Страница 11: ...y 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 5 Modification and repair Modifications or alterations to the HF spindle are only permitted after prior consultation with Alfred Jäger GmbH Only the service partners liste...

Страница 12: ...motor phases 1b Electrical connection for Tool taper monitoring PTC KTY 1c Electrical connection for Vector control 2 Cooling water G 1 4 3a Sealing air front G 1 8 3b Sealing air rear M5 4 Taper cleaning G 1 4 7 Hydraulic system for tool change cylinder forward M10x1 8 Hydraulic system for tool change cylinder back M10x1 11 Internal coolant supply G 1 4 12 Leakage G 1 4 ...

Страница 13: ...life through heat dissipation Heat is 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 31 section The sealing air prevents foreign bodies such as chips and liquid...

Страница 14: ...yed Ü Only use tools and tool holders that are suitable for internal coolant sup ply Ü Make sure that the cooling lubricant used conforms to the current specifi cations in legislation and from the trade associations Ü Make sure that compressed air is not applied to the internal coolant supply in the case of a rotating shaft Otherwise the sealing surfaces of the inter nal coolant supply will be dam...

Страница 15: ...media of the following classes Ä Class 5 according to ISO 4406 1999 code 17 15 12 Ä or class 8 according to NAS 1638 5 7 3 Avoiding pressure peaks Pressure peaks mainly occur when an incompressible medium e g cooling lu bricant collides at high speed with a closed or almost closed hole This impact may cause the pressure to increase to many times the permitted pressure Ü Select the duty cycle of th...

Страница 16: ... line by means of the relief hole The leakage quantity depends on the following factors q Cooling lubricant and its viscosity q Installation position of the internal coolant supply q Routing of the supply line q Position of the cooling lubricant valve and of the non return valve and or 3 2 way valve 5 8 1 Internal coolant supply vertical installation Example of design Leakage Leakage Screw in dept...

Страница 17: ...nes can always be connected to the relief holes in the 6 o clock position at the lowest point Ü Remove the sealing plugs that protect the connections against damage and contamination during transportation Ü Instead of these sealing plugs install the appropriate hose fittings Ü Install the corresponding hoses in the hose fittings Ü Route the leakage hose with a falling gradient so that the leakage ...

Страница 18: ... 2 Rated rotation speed 36 000 rpm Acceleration braking value Per second 10 000 rpm other values by consultation Characteristics Speed sensor Vector control Toothed wheel Teeth 148 Module 0 3 Motor protection PTC 130 C KTY 84 130 Housing Stainless steel Housing diameter 100 mm Flange diameter 144 mm Pitch circle dia 132 mm 12 x Ø 6 5 for screws M6 Cooling Liquid cooled Ambient temperature 10 C 45 ...

Страница 19: ... inductive 3 positions clamped unclamped ejected Clamping range up to 16 mm Clockwise and anticlockwise Coupler plug 5 pin ECTA 133 Cable length 0 5 m motor phases 12 pin ECTA 133 17 pin Cable length 0 5 m sensors Weight 16 kg Inner taper run out 1 µ Axial run out 1 µ 6 1 Dimensions ...

Страница 20: ...Speed 4 185 9 242 14 271 19 299 24 328 29 191 35 062 rpm Frequency 167 333 500 667 833 1 000 1 200 Hz Rated power 1 898 4 546 6 6 8 5 10 014 9 944 9 548 kW Torque 4 332 4 698 4 442 4 187 3 931 3 253 2 695 Nm Voltage 89 170 240 310 380 380 380 V Current 24 8 25 7 24 8 23 9 23 1 22 6 21 7 A Cos φ 0 84 0 80 0 79 0 78 0 77 0 79 0 79 Measured values S6 60 Rated rotation speed 5 000 10 000 15 000 20 000...

Страница 21: ...12 9 8 13 16 136 16 01 15 281 kW Torque 6 12 6 846 6 712 6 579 6 445 5 341 4 41 Nm Voltage 89 170 240 310 380 380 380 V Current 38 38 38 38 38 38 4 38 2 A Cos φ 0 9 0 84 0 82 0 81 0 79 0 79 0 77 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 gre...

Страница 22: ...ide phase U phase V phase W Spindel U V W gn ge 0 2mm sw 0 2mm bl 0 2mm br 0 2mm Stator 1 2 3 PE 4 sw 1 2 5 mm sw 2 2 5 mm sw 3 2 5 mm gn ge 2 5 mm 1 Perschewski 24 03 16 1 29031170 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...

Страница 23: ...s PNP output output 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm KTY JCP Kabelabgang WK PTC KTY 12x0 14mm PTC Induktiver Sensor inductive sensor Induktiver Sensor inductive sensor Induktiver Sensor inductive sensor schwarz black blau blue schwarz black blau blue schwarz black braun brown braun brown braun brown rot red blau blue blau blue ...

Страница 24: ... Kabelplan S12 12x0 14mm A B E F G C D H J K L M 23 07 2015 J A H K B G M L C F E D K H G M F D L PTC PTC J KTY 3x A B 3x C KTY E 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm 0 14 mm gelb yellow braun brown grün green rot red blau blue schwarz black Spindelstecker S12 ECTA 133 Spindle plug S12 ECTA 133 Steuerleitung control cable violett purple weiß white...

Страница 25: ... 0 25 mm UA UA UB 0 25 mm 0 25 mm 0 25 mm 0 25 mm UN 0 25 mm GND 1 2 5 9 10 11 12 13 14 16 3 4 6 7 8 17 15 Schield von 1 Kabelstecker SA17 11 10 9 8 7 6 5 4 3 2 12 14 1 13 17 16 15 12 11 10 1 2 16 9 8 6 7 5 15 14 4 rosa pink rot red blau blue grau grey braun brown Sense Sense weiss white schwarz black grün green gelb yellow Kabelstecker SA17 Cable plug SA17 Zahnradgeber GEL 2442 Precision encoder ...

Страница 26: ...ance Ω Temp error C F K min Type max K 0 32 0 75 474 498 522 6 07 10 50 0 77 514 538 563 5 98 20 68 0 75 555 581 607 5 89 25 77 0 74 577 603 629 5 84 30 86 0 73 599 626 652 5 79 40 104 0 71 645 672 700 5 69 50 122 0 70 694 722 750 5 59 60 140 0 68 744 773 801 5 47 70 158 0 66 797 826 855 5 34 80 176 0 64 852 882 912 5 21 90 194 0 63 910 940 970 5 06 100 212 0 61 970 1000 1030 4 90 110 230 0 60 102...

Страница 27: ... 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 130 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...

Страница 28: ...erates at high speeds 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 hole pattern of the HF spindle and hole pattern of the mounting surface in the machine match Ä Check the ...

Страница 29: ...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 hydraulics 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 beari...

Страница 30: ... mm 5 16 15 mm 19 32 10 Hydraulics 9 5 mm 3 8 17 4 mm 11 16 6 Cooling lubricant 6 4 mm 1 4 13 4 mm 17 32 8 Cooling lubricant 8 mm 5 16 15 mm 19 32 8 3 Cooling water 8 3 1 Quality of cooling water Distilled water causes 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...

Страница 31: ...n Return temperature Max 40 C Use cooling hoses that are impermeable to UV light 8 4 Hydraulic tool change Ü Use only hydraulic oil with the following properties DIN 51524 ISO 6743 HLP 46 8 5 Compressed air 8 5 1 Air purity classes ISO 8573 1 Solid impurities Class 3 Filter grade at least 5 µm for solids Water content Class 4 Max pressure dew point 3 C Total oil content Class 3 Max oil content 1 m...

Страница 32: ...ing when turn ing on the machine This protects the HF spindle even when it is stationary Lowest sealing air supply Dry machining Medium sealing air supply Machining with spray water Highest sealing air supply Machining with hose water 8 5 3 Setting values For guidelines on air quality see Air purity classes ISO 8573 1 31 section Ü Keep to the following values Taper cleaning 4 5 6 bar Hydraulic sys...

Страница 33: ...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 load minutes Max load Ü Put the HF spindle into operation with a clamped tool without machining for approx 10 minutes Ü The speed in this case should be no more than 20 of the maximum per missible speed for the HF spindle Ä See definition Max permissible s...

Страница 34: ...rom 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 40 section Ü Operate the HF spindle at a maximum of 50 of the max permissible speed for approx 5 minutes Ä See Commissioning 33 section Ü Operate the HF spindle for approx 2 ...

Страница 35: ...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...

Страница 36: ...all times u Check the tool taper mount It must be free of damage and clean when switching to the HF spindle Ü Make sure that the shaft of the HF spindle has come to an absolute stand still Ü Switch on the hydraulics 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 tool up to...

Страница 37: ...Caution No rotation without clamped tool Tool clamped signal HF spindle is ready for use No Connection on off Compressed air on off Fluid 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 Internal coolant supply off 11 Taper cleaning on 4 Hydraulics for tool change on Cylinder forward 7 Perform tool change Taper cle...

Страница 38: ... 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 state...

Страница 39: ... HF spindle for commissioning processing is always the lowest specified speed Note Unsuitable tool Tools without an internal hole are not suitable for internal coolant supply u It is essential to switch off the internal coolant supply if tools without an internal hole are being used for production reasons If this is not done the HF spindle will be damaged or destroyed Ü Only use tools that are tec...

Страница 40: ...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 jets to clean the HF spindle This could cause contaminat...

Страница 41: ...cs Ü Store the HF spindle in horizontal 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 sha...

Страница 42: ...ls 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 Do not discharge oils into wastewat...

Страница 43: ...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...

Страница 44: ... Frequency converter has shut down q Check the error messages in the frequency converter man ual Tool change initiated q Switch off the hydraulics 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 f...

Страница 45: ...ntamination q Remove all contamination between the tool taper and shaft of the HF spindle Observe all points in the Tool change 35 and Mainte nance 40 sections Lack of pressure q Check the connections for the hydraulics q Check the lines for the hydraulics q Check the hydraulic circuit q Check the settings of the hydraulics for the tool change No ventilation q Check whether both connections of the...

Страница 46: ...serve all points in the Tool change 35 and Mainte nance 40 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...

Страница 47: ... 6 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 M...

Страница 48: ...39 Ober Mörlen GERMANY 49 0 6002 9123 0 sales alfredjaeger de www alfredjaeger de Serial number Type F100 H636 101 K0 5RW2V Item no 10406166 Revision 03 Date 29 11 2021 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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