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Service and repairs

Item no. 10405047-06, Revision 02

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.

https://www.nakanishi-jaeger.com/en/contact/service-partners

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Содержание Z80-H536.08 S8RW3

Страница 1: ...Manual Z80 H536 08 S8RW3 High Frequency Spindle Pneumatic taper change ...

Страница 2: ...velopment 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 Nakanishi Jaeger 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 prohibi...

Страница 3: ... Motor 18 6 2 1 Performance Diagram 19 6 3 Wiring diagram 20 6 4 Motor protection PTC 160 C 21 6 5 Tool change monitoring 21 6 6 Displacement measuring system Ott Jakob 22 6 6 1 Technical Specifications 22 6 6 2 Signals 23 6 6 3 Installation 23 6 6 4 Scaling 24 6 7 Air borne noise emissions 25 7 Operating location 26 8 Installation 27 8 1 Installing the HF spindle 27 8 2 Diameter of media supply l...

Страница 4: ...0 12 2 2 With every tool change 40 12 2 3 Every time the clamping device is changed 41 12 3 In the case of storage 41 12 4 Monthly maintenance 41 12 5 Long periods of storage 41 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: ...ection 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 ...

Страница 6: ...es Available on request q Spindle holder q Frequency converter q Chiller q Controller 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...

Страница 7: ...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 Nakanishi Jaeger 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 m...

Страница 8: ...s 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 Ob...

Страница 9: ...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 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 ba...

Страница 10: ...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...

Страница 11: ... 8 7 12 12 12 12 11 1a Electrical connection for motor phases 1b Electrical connection for Tool taper monitoring 2 Cooling water G 1 8 3 Sealing air G 1 8 4 Taper cleaning G 1 8 7 Pneumatics for tool change cylinder forward G 3 8 8 Pneumatics for tool change cylinder back G 1 4 11 Internal coolant supply G 1 8 12 Leakage 5 x M5 ...

Страница 12: ...s 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 29 section The sealing air prevents foreign bodies such as chips and liquids e g emul sions from entering the H...

Страница 13: ...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 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 c...

Страница 14: ...ause 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 cause excessive pressure fluid hammer Excessive pressures may also occur when pressure is additionally applied to an incompressible medium e g cooling lubricant in a closed space...

Страница 15: ...ngle at least 15 Ü Route away the leak to avoid backing up 5 8 2 Internal coolant supply horizontal installation Example of design Leakage Leakage Screw in depth 1 High Frequency Spindle max 6 mm 2 Internal coolant supply max 6 mm Ü Position the HF spindle so that all leakage lines can always be connected to the relief holes in the 6 o clock position at the lowest point Ü Remove the sealing plugs ...

Страница 16: ...es pairs 2 Rated rotation speed 36 000 rpm Acceleration braking value Per second 10 000 rpm other values by consultation Characteristics Motor protection PTC 160 C Housing Stainless steel Housing diameter 80 mm Cooling Liquid cooled Ambient temperature 10 C 45 C Sealing air Protection category sealing air turned on IP54 Taper cleaning Internal coolant supply Internal coolant supply 150 bar 38 l mi...

Страница 17: ...Technical Specifications Item no 10405047 06 Revision 02 17 48 Weight 12 kg Inner taper run out 1 µ Axial run out 1 µ 6 1 Dimensions Clamping range ...

Страница 18: ...8 910 23 868 28 294 32 727 33 616 rpm Frequency 167 333 500 667 833 1 000 1 167 1 200 Hz Rated power 0 766 1 671 2 641 3 398 4 043 4 621 4 731 4 696 kW Torque 1 88 1 82 1 8 1 72 1 62 1 56 1 38 1 34 Nm Voltage 86 154 228 297 366 365 360 359 V Current 10 10 10 10 10 10 10 10 A Cos φ 0 25 0 41 0 57 0 67 0 71 0 8 0 83 0 83 Measured values S6 60 Rated rotation speed 5 000 10 000 15 000 20 000 25 000 30...

Страница 19: ... 2 333 3 842 5 425 6 871 6 893 6 698 6 608 kW Torque 2 41 2 86 2 93 2 94 2 87 2 43 2 07 2 01 Nm Voltage 81 151 217 286 351 348 341 339 V Current 14 15 15 15 15 16 16 16 A Cos φ 0 93 0 91 0 89 0 88 0 88 0 9 0 9 0 89 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...

Страница 20: ... Technologie Blatt 1 1 0 Projekt Nr Version Nr Zeichn Nr Hr Fischer Alfred Jäger GmbH Siemensstraße 8 61239 Ober Mörlen 29027070 Flanschstecker FS18 0 75 mm U W 0 14 mm 0 14 mm 0 25 mm 0 25 mm 0 25 mm B A W V U PE 1 2 3 4 5 6 7 8 9 10 11 12 grün gelb green yellow PTC PTC V Stator Stator rot red blau blue weiss white rot red blau blue Spindelstecker FS18 Spindle plug FS18 Spindelerkennung nach Beda...

Страница 21: ...st 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 160 5 C 550 Ω 1330 Ω 4 kΩ 6 5 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 contr...

Страница 22: ...during rotation q The sensor electronics convert the signal from the sensor into an analog output signal Ä 4 20 mA 2 10 V q The output signal can be analyzed digitally with the position controller ac cessory 6 6 1 Technical Specifications Operating voltage dependent on RB 15 18 VDC 18 30 VDC Burden RB 250 Ω 500 Ω Current consumption max 70 mA Measurement range with target ring Ø 8 10 with target r...

Страница 23: ...itive to any electromagnetism Ä For example linear drives motor power cable HF technology etc q The analog current signal can be transmitted over long distances Ä Cable length max 50 m q The Ott Jakob position controller can only evaluate the current signal Voltage signal The voltage signal is dependent on the total resistance Ü Take the following factors into account Ä Line resistance Ä Internal ...

Страница 24: ...Technical Specifications Item no 10405047 06 Revision 02 24 48 6 6 4 Scaling Displacement Current Voltage 0 mm 4 mA 2 V 25 mm with target ring Ø 8 10 15 mm with target ring Ø 5 20 mA 10 V ...

Страница 25: ...Technical Specifications Item no 10405047 06 Revision 02 25 48 6 7 Air borne noise emissions CAUTION Noise has an impact on health u Only operate the HF spindle if you are wearing hearing protection ...

Страница 26: ...eeds 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 con...

Страница 27: ...responding 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 u...

Страница 28: ...ality 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 ...

Страница 29: ...n air quality see Air purity classes ISO 8573 1 29 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 ...

Страница 30: ...wing values Taper cleaning 4 5 6 bar Pneumatic system for tool change 5 0 8 0 bar 8 5 Setting the internal coolant supply 1 Internal cooling as required M5 Max 10 bar 2 Internal cooling as required M5 Max 10 bar 3 Compressed air 10 bar n 0 rpm 4 Cooling lubricant Max 150 bar Min 1 bar 5 Vent 6 Leakage Must be present at the connection of the internal coolant supply ...

Страница 31: ...Fit the electronics in line with this Ü Secure the housings with two screws Ä See illustration for the drill hole pattern 8 6 1 Wiring of measuring system The sensor is pre assembled in the unclamp unit and connected to the sensor electronics Ü Do not shorten the sensor cable since the measuring system was cali brated with this cable length Ü Do not kink the cable There is a connector at the outpu...

Страница 32: ...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 load minutes Max load Ü Put the HF spindle into operation with a clamped tool without machinin...

Страница 33: ...ding 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 40 section Ü...

Страница 34: ... 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 t...

Страница 35: ...ount 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 Inser...

Страница 36: ...tic 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 Bef...

Страница 37: ...ion 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 c...

Страница 38: ...tart 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 s...

Страница 39: ...e 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 te...

Страница 40: ...urately 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 commenc...

Страница 41: ...orizontal 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 ...

Страница 42: ...tion 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 Dis...

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 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 chill...

Страница 45: ...the spindle holder manually q Do not use technical aids to clamp the HF spindle Bearings damaged q Contact Nakanishi Jaeger 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 34 and Mainte nance 40 sections Lack of pressure q Check the connections for compresse...

Страница 46: ...for damage q Replace damaged tool Contamination q Remove all contamination between the tool taper and shaft of the HF spindle Observe all points in the Tool change 34 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 loo...

Страница 47: ...5 5 1 5 6 1 5 8 1 5 9 1 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 ...

Страница 48: ...len GERMANY 49 0 6002 9123 0 sales anakanishi jaeger com www nakanishi jaeger com Serial number Type Z80 H536 08 S8RW3 Item no 10405047 06 Revision 02 Date 01 09 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 nakanishi jaeger com en ...

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