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Service and repairs

Item no. 10408017, Revision 05

48 ( 52 )

14.2

Malfunctions

The list below can be used to quickly investigate and eliminate faults.

HF spindle not rotating

Cause

Troubleshooting

No
power supply

Check the frequency converter.

Check the machine.

Check all electrical connections.

Check all wires in the motor cable.

Activate the Start/Reset button.

Thermal protection has
been activated

Wait until the HF spindle has cooled down.

Check the frequency converter for error messages. If no
messages are illuminated, start the frequency converter.

(See also “Spindle becomes hot

Frequency converter
has
shut down

Check the error messages in the frequency converter man-
ual.

Tool change
initiated

Turn off the pneumatic system for the tool change.

HF spindle becomes hot

Cause

Troubleshooting

Insufficient cooling

Check the power of the chiller.

Check the water level of the chiller.

Check the connections and the cooling hoses.

Check the cooling circuit.

Check the chiller for error messages.

Phase missing

Check all wires in the motor cable for cable breaks.

Machining too heavy

Check the rotational direction of the HF spindle.

Check the rotational direction of the tool.

Check the tool for damage.

Reduce the machining load intensity.

Frequency converter
incorrectly set

Compare the values for the HF spindle with the set values
on the frequency converter.

Содержание F120-H824.11 S11RW2V

Страница 1: ...Manual F120 H824 11 S11RW2V High Frequency Spindle Pneumatic 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: ... 18 6 1 Dimensions 19 6 2 Motor data 20 6 2 1 Performance Diagram 21 6 2 2 Equivalent circuit diagram data 21 Parameter 22 6 3 Wiring diagram 23 6 4 Motor protection Pt1000 26 6 5 Motor protection PTC 130 C 27 6 6 Tool change monitoring 28 6 7 Speed and position sensor MiniCoder 29 6 7 1 Technical Specifications 29 6 8 Air borne noise emissions 30 7 Operating location 30 8 Installation 31 8 1 Inst...

Страница 4: ...th 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 Declaration of Incorporation 51 ...

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: ...ccessories Available on request q Spindle holder 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 compensation claims for damages Ü If the spindle holder is to be produced in house it is essential to cont...

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: ...ical connection for motor phases 1b Electrical connection for Tool taper monitoring PTC Pt1000 1c Electrical connection for Vector control 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 11 Internal coolant supply G 1 8 12 Leakage M5 ...

Страница 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 33 section The sealing air prevents foreign bodies such as chips and liquids e g emul sions from entering the HF ...

Страница 14: ...ol 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 5 7 1 Cooling lubricant Ü Do not use pure or distilled water Ä Such water causes immediate corrosion on bare parts which is often un noticeable at first but later leads to serious corrosion damage Ü Only use coo...

Страница 15: ...iding 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 the valve so that the peaks in pressure that occur not exceed the normally permitted operating pressure Closing valves may also ...

Страница 16: ...tect the HF spindle from damage 5 8 1 Internal coolant supply vertical installation Example of design Leakage Leakage Screw in depth 1 High Frequency Spindle max 6 mm 2 Internal coolant supply max 6 mm 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 co...

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: ...0 Hz Motor poles pairs 2 Rated rotation speed 24 000 rpm Acceleration braking value Per second 10 000 rpm other values by consultation Characteristics Speed sensor Vector control Toothed wheel Teeth 256 Module 0 3 Motor protection PTC 130 C Pt1000 Housing Stainless steel Housing diameter 120 mm Flange diameter 144 mm Pitch circle dia 132 mm 12 x Ø 6 5 for screws M6 Cooling Liquid cooled Ambient te...

Страница 19: ...oring inductive 3 positions clamped unclamped ejected Clamping range up to 20 mm Clockwise and anticlockwise Coupler plug 5 pin ECTA 133 motor phases 12 pin ECTA 133 17 pin sensors Weight 27 kg Inner taper run out 1 µ Axial run out 1 µ 6 1 Dimensions Clamping range of spindle holder Clamping range of flange ...

Страница 20: ...Measured values S1 100 Rated rotation speed 1 800 5 000 10 000 12 000 15 000 24 000 rpm Speed 1 447 4 596 9 605 11 612 14 422 23 114 rpm Frequency 60 167 333 400 500 800 Hz Rated power 1 87 6 5 13 2 15 7 18 16 7 kW Torque 12 33 13 59 13 22 13 01 12 04 7 07 Nm Voltage 70 170 320 380 380 380 V Current 38 1 39 7 38 9 38 5 38 35 2 A cos φ 0 76 0 73 0 72 0 72 0 82 0 84 Measured values S6 60 Rated rotat...

Страница 21: ... 23 64 kW Torque 21 37 21 07 20 72 20 53 17 39 10 13 Nm Voltage 75 175 325 380 380 380 V Current 55 55 55 55 55 55 A cos φ 0 85 0 8 0 79 0 79 0 83 0 8 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 specified values due to the ha...

Страница 22: ...ent 21 5 Arms p0322 Maximum speed 24 000 rpm p0326 Stalling torque correction factor 100 p0335 Cooling type Liquid cooled p0341 Moment of inertia 0 003247 kgm p0348 Field weakening operating speed VDC 600V 13 398 rpm p0350 Stator resistance cold strand 0 184 Ω p0353 Series inductance strand 0 mH p0354 Rotor resistance cold 0 156 Ω p0356 Stator stray inductance 0 282 mH p0358 Rotor stray inductance...

Страница 23: ...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...

Страница 24: ... BK BU 3 4 PNP Spindelstecker S12 ECTA S13 spindle plug S12 ECTA S13 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 29030070 g f e d c b a 4 5 6 1 3 2 a b c d e f g Bl Übersetzungen V...

Страница 25: ...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 hineinlegen not connected isolate...

Страница 26: ...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 ...

Страница 27: ...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...

Страница 28: ...o the machine controller q Tool taper monitoring using inductive proximity switch Signals Tool clamped Tool released Tool ejected HF spindle HF spindle HF spindle Ready to operate Not ready to operate Not ready to operate Operating voltage range 10 30 VDC UL Class 2 Switching distance Sn 2 0 mm Short circuit and reverse po larity resistant PNP BK 4 BU 3 BN 1 Z Output 0 V BN brown BK black BU blue ...

Страница 29: ...hnical 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 synchronization USp1 USp2 0 9 1 1 Supply voltage UB 5 VDC 5 Power consumption without load 0 3 W Cable lengt...

Страница 30: ... range of spindle holder Ü Make sure that the correct spindle holder for the HF spindle is fitted in the machine Clamping range of flange 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 number and sizes of the mounting screws optional acces sories Ü Check the connecting hoses for damage Ü Check the connecting cables for ...

Страница 31: ...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...

Страница 32: ...lity 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 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 v...

Страница 33: ... air quality see Air purity classes ISO 8573 1 33 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...

Страница 34: ...es on air quality see Air purity classes ISO 8573 1 33 section Ü Keep to the following values Taper cleaning 4 5 6 bar Pneumatic system for tool change 6 0 bar Internal coolant supply Max 80 bar Max 10 l min Cooling lubricant MQL oil mist Max 10 bar MQL minimum quantity lubrication ...

Страница 35: ...0 rpm 5 bar Above 10 000 rpm No pressure 4 Minimum quantity cooling lubrication Max 5 bar 5 Cooling lubricant Max 80 bar 6 Vent G1 8 7 Leakage 5 x M5 Ü Keep lines short Ü Do not exceed the pressures specified above Ü Avoid pressure pulsation Ä Max 5 bar Ü Avoid pressure peaks Low pulsation delivery of media 2 bar by the pump increases the service life of the cooling lubricant system components and...

Страница 36: ...entrifugal 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 load minutes Max load Ü Put the HF spindle into operation with a clamped tool without machining...

Страница 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 ...

Страница 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...

Страница 39: ...nt It must be free of damage 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 ...

Страница 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...

Страница 41: ...n 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 Pneumatic system for tool change on Cylinder forward 7 Perform tool change Taper cle...

Страница 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...

Страница 43: ... 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 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...

Страница 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...

Страница 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 ...

Страница 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...

Страница 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...

Страница 49: ...ice 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 pneumatic circuit q Check the setting of the compressed air for the tool chang...

Страница 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...

Страница 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 Mac...

Страница 52: ...239 Ober Mörlen GERMANY 49 0 6002 9123 0 sales alfredjaeger de www alfredjaeger de Serial number Type F120 H824 11 S11RW2V Item no 10408017 Revision 05 Date 30 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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