Jäger Chopper 1500 HSK S5A User manual

Manual
Chopper 1500 HSK S5A
High Frequency Spindle
Pneumatic taper change

Item no. 11503005, Revision 072 ( 36 )
Identification of HF spindle
Spindle type
Pmax S6-60%
Item no. .... Serial no.
Rated rotation speed
Serial no.
Item no.
Power data
Spindle type
S1-100%
As we always ensure that our HF spindles are at the cutting edge of techno-
logical 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 prohibited with-
out the express written approval of Alfred Jäger GmbH.

Item no. 11503005, Revision 07 3 ( 36 )
Contents:
Translation of the original manual
1 Preliminary information 5
1.1 Purpose of the manual.......................................................5
1.2 Explanation of symbols used........................................... 5
2 Transport and packaging 6
2.1 Scope of supply of HF spindle.........................................6
2.1.1 Optional accessories..............................................6
2.1.2 Documentation supplied.....................................6
2.2 Packaging of HF spindle.................................................... 6
3 Designated use 7
3.1 Permissible types of machining...................................... 7
3.2 Permissible materials..........................................................7
4 Safety instructions 8
4.1 Safe working.......................................................................... 9
4.2 Shutdown of HF spindle..................................................10
4.3 Installation and maintenance........................................10
4.4 Modification and repair ...................................................10
4.5 Improper operation ..........................................................10
5 Technical description 11
5.1 Connections of HF spindle .............................................11
5.2 Electrical connection ........................................................12
5.3 Cooling ..................................................................................12
5.4 Sealing air .............................................................................13
5.5 Taper cleaning ....................................................................13
5.6 Pneumatic tool change....................................................13
5.7 Cylinder vent .......................................................................13
6 Technical Specifications 14
6.1 Dimensions ..........................................................................15
6.2 Technical data sheet (KL 3502, AC motor) ................16
6.2.1 Performance Diagram........................................ 17
6.3 Wiring diagram...................................................................18
6.4 Motor protection PTC 130°C..........................................19
6.5 ESD protection....................................................................19
6.6 Air-borne noise emissions ..............................................20
7 Operating location 20
8 Installation 21
8.1 Installing the HF spindle..................................................21
8.2 Diameter of media supply line......................................21
8.3 Compressed air...................................................................22
8.3.1 Air purity classes (ISO 8573-1)..........................22
8.3.2 Setting the sealing air .........................................22
8.3.3 Setting values.........................................................23
9 Commissioning 23
9.1 Running-in schedule..........................................................23
9.2 Daily start-up ........................................................................24
9.3 Shutdown signal .................................................................24
9.4 Commissioning after storage .........................................24
10 Tool change 25
10.1 Clockwise ...............................................................................25
10.2 pneumatic taper change..................................................25
10.2.1 Automatic hollow shank taper tool clamp
.....................................................................................26
10.3 Tool changing station (optional accessory) ..............27
10.3.1 pneumatic taper change ...................................27
10.3.2 Installing the changing station........................27
10.3.3 Maintenance...........................................................27
11 Tools for high speed cutting 28
12 Maintenance 29
12.1 Ball bearings .........................................................................29
12.2 Daily cleaning.......................................................................29
12.2.1 Before commencing work.................................29
12.2.2 With every tool change ......................................30
12.3 In the case of storage.........................................................30
12.4 Monthly maintenance.......................................................30
12.5 Long periods of storage ...................................................30
12.6 Maximum storage time.....................................................30
13 Dismantling 31
13.1 Disposal and environmental protection ....................31
14 Service and repairs 31
14.1 Service partners...................................................................31
14.2 Malfunctions.........................................................................32
15 Declaration of Incorporation 35

Contents:
Item no. 11503005, Revision 074 ( 36 )

Preliminary information
Item no. 11503005, Revision 07 5 ( 36 )
1 Preliminary information
The high frequency spindle (HF spindle) is a high quality precision tool for
high speed machining.
1.1 Purpose of the manual
The manual is an important component of the HF spindle.
ÜStore the manual carefully.
ÜMake the manual available to all persons who work with the HF spindle.
ÜRead the documentation supplied in full.
ÜBefore carrying out any work, read the corresponding section 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.
uMeasure to avert the danger.
WARNING
Dangerous situation!
May result in serious injury or death.
uMeasure to avert the danger.
CAUTION
Dangerous situation!
May result in minor to moderate injury.
uMeasure to avert the danger.
Note
May result in material damage. This warning symbol is not a warning for per-
sonal injury.
Tip
Tips indicate useful information for users.

Transport and packaging
Item no. 11503005, Revision 076 ( 36 )
2 Transport and packaging
Avoid strong vibrations or impacts during transportation, as these could dam-
age the ball bearings of the HF spindle.
ÜAny damage reduces the accuracy of the HF spindle.
ÜAny damage restricts the functionality of the HF spindle.
ÜAny damage shortens the service life of the HF spindle.
2.1 Scope of supply of HF spindle
The following parts are supplied with the HF spindle:
qHigh Frequency Spindle
qTransport packaging
ÜCheck the high frequency spindle for completeness upon delivery.
2.1.1 Optional accessories
Available on request:
qFrequency converter
qTool taper
qFelt cleaning taper
qCollet grease
qFurther accessories on request.
Only approved accessories have been tested for operational safety and func-
tionality.
ÜDo not use any other accessories – this may invalidate any warranty claims
and compensation claims for damages.
2.1.2 Documentation supplied
The documents listed below are supplied with the HF spindle:
qManual
qThe declaration of incorporation is part of the manual.
qInspection protocol
ÜCheck 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.

Designated use
Item no. 11503005, Revision 07 7 ( 36 )
3 Designated use
The HF spindle is an “incomplete machine” in accordance 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.
qCutting
qDrilling
qEngraving
qGrinding
ÜContact 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.
qMetals (such as alloys, cast metals etc.)
qSintered materials
qPlastics
qWood
qGraphite
qStone (marble, etc.)
qPaper and cardboard
qCircuit boards
qGlass and ceramic
ÜContact Alfred Jäger GmbH if other materials are to be machined.

Safety instructions
Item no. 11503005, Revision 078 ( 36 )
4 Safety instructions
The high frequency spindle is a state of the art product and is safe to operate.
However, the HF spindle may pose a risk in the following cases:
qIf it is installed by untrained personnel.
qIf it is used incorrectly.
qIf it is not used in accordance with its intended use.
The high frequency spindle may only be installed, commissioned, and main-
tained by specialist personnel.
Definition: Specialist personnel are persons who are familiar with the assem-
bly, installation, commissioning, and operation of the product and have the
relevant qualifications for their area of activity. The operator must closely con-
trol the responsibility, training, and monitoring of these personnel.
DANGER: Due to explosion.
HF spindles are not approved for use in areas at risk of explosion. Use in such
areas may result in explosions.
uDo 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.
uOperate the HF spindle only if it is installed in the machine or system in a
fixed manner.
Note: Adhere to the limit values.
uObserve the limit values specified in the technical data.
Note: Take account of the machine.
uObserve the manual of the machine in which the HF spindle is installed.
uObserve all safety instructions specified by the machine manufacturer.
uEnsure that the machine does not cause any hazards (e.g. uncontrolled
movements). Do not install the HF spindle in the machine until this has
been done.
Note. Do not damage the HF spindle.
uAny damage reduces the accuracy of the HF spindle.
uAny damage restricts the functionality of the HF spindle.
uAny damage shortens the service life of the HF spindle.

Safety instructions
Item no. 11503005, Revision 07 9 ( 36 )
4.1 Safe working
Observe all safety instructions set out in the manual, the applicable national
accident prevention regulations, and the valid company work, operation, and
safety guidelines.
DANGER: Due to flying parts.
Tools that are not clamped correctly will be flung away by the centrifugal
forces that occur during machining.
uUse the full clamping depth of the clamping system.
uClamp the tool securely.
DANGER: Due to flying parts.
If the wrong rotational direction is used, the clamping system releases and
the tool is flung away.
uIt is essential to adhere to the rotational direction of the HF spindle.
WARNING: Risk of injury due to flying parts.
The HF spindle operates at high speeds which may cause chips to fly out
with great force.
uNever remove the protective devices of the machine or system.
uAlways wear protective goggles during work.
Exampleofdesign: Inserting the
shank
Note: Ensure functionality.
uNever operate the HF spindle without a clamped tool shank.
If no tool shank is clamped:
qThe clamping system is damaged by the centrifugal forces.
qThe clamping system is shifted.
qThe balance of the HF spindle is affected.
qThe bearing is damaged.
ÜTake the relevant measures to protect against splashes and spray accord-
ing to the type of machining, the type of material being machined, and the
type of tool selected.
ÄObserve the manual of the machine in which the HF spindle is installed.
ÜObtain the maximum circumferential speeds of the tools used from the
tool supplier.
Single-point tools are not suitable for high speed cutting.
If they are required for production reasons:
ÜOnly use a balanced tool.
ÄDIN ISO 1940
ÄBalance grade 2,5

Safety instructions
Item no. 11503005, Revision 0710 ( 36 )
The tool cutting diameter (X) must not be greater than the maximum
clamping range (Y).
ÜAlways clamp the tool so that it is as short as possible.
ÜKeep the dimension (Z) small.
Ä(Y) See section: Technical Specifications [}14].
4.2 Shutdown of HF spindle
The procedure for shutting down the high frequency spindle for installation
and maintenance work is as follows:
ÜCompletely disconnect the power supply.
ÜCompletely disconnect the media supply (air and liquid).
ÜMake sure that the shaft of the HF spindle has come to an absolute stand-
still.
If the HF spindle is being shut down to be cleaned:
ÜReconnect only the sealing air.
Tip: Forward the data to the controller.
uUse the option on the frequency converter of detecting the shutdown
signal from the shaft and forwarding this to the machine controller for
evaluation.
4.3 Installation and maintenance
ÜCarry out installation, cleaning, and maintenance work only after shutting
down the HF spindle and after the shaft has come to a standstill.
ÜInstall 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 permitted after prior
consultation with Alfred Jäger GmbH.
Only the service partners listed in the “Service and repair [} 31]” section are
authorized to open and repair the HF spindle.
Only approved accessories have been tested for operational safety and func-
tionality.
4.5 Improper operation
The high frequency spindle is only safe to operate for its designated use.
ÜObserve the safety instructions in all sections of the manual to prevent
hazards to persons, the environment, the machine, or the HF spindle itself.
Failure to observe the safety instructions may invalidate any warranty claims
and compensation claims for damages.

Technical description
Item no. 11503005, Revision 07 11 ( 36 )
5 Technical description
5.1 Connections of HF spindle
741
3
8
1Electrical connection
3Sealing air M5
4Taper cleaning G 1/8"
7Pneumatic system for tool change G 1/8"
8Cylinder vent
Sound absorber (may only be removed if necessary!) G 1/8"

Technical description
Item no. 11503005, Revision 0712 ( 36 )
5.2 Electrical connection
The HF spindle may only be operated with a frequency converter (FC).
ÜCheck whether the current, voltage, and frequency data of the HF spindle
match the raw data for the frequency converter.
ÜUse a motor supply line that is as short as possible.
ÜAdjust the speed of the HF spindle using the FC.
ÜRefer to the frequency converter manual for further information.
The FC detects the following operating states of the HF spindle, depending on
the version:
qHF spindle rotating.
qHF spindle too hot.
qHF spindle at a standstill, etc.
The FC forwards the operating states of the HF spindle to the machine con-
troller.
Note: Connect the SpeedTEC quick locking connector.
uFor the combination SpeedTEC connector plug/SpeedTEC cable plug:
uRemove the O ring on the SpeedTEC connector plug.
5.3 Cooling
The HF spindle does not require extra cooling. The HF spindle is equipped
with integrated air ventilation.
Note: Extension of the service life through heat dissipation.
Heat is produced during operation of the HF spindle. The temperature of the
HF spindle should not exceed + 55° C as this shortens the service life of the
bearing.
uCheck the temperature of the HF spindle on the housing.

Technical description
Item no. 11503005, Revision 07 13 ( 36 )
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.
ÜCheck that air escapes at the front between the housing and the rotating
parts of the HF spindle.
5.5 Taper cleaning
Taper cleaning prevents chips and liquids from entering the shaft during a
tool change and causing contamination and damage to the inner taper and
the clamping system.
The taper cleaning is integrated in the pneumatics system for the tool change.
This means that no additional connections are required.
5.6 Pneumatic tool change
For guidelines on air quality,
see "Air purity classes (ISO
8573-1) [}22]" section.
The tool change or tool taper change is performed pneumatically.
During this, a mechanism is operated inside the HF spindle which clamps, re-
leases, or ejects the tool taper or collet.
5.7 Cylinder vent
The cylinder takes in air when clamping the taper/tool. This air must be clean
and dry.
Only if necessary:
ÜRemove the sound absorber.
ÜFit the relevant hose fitting in place of the sound absorber.
ÜFit the relevant hose to the hose fitting.
ÜSelect the length of the hose so that its free end protrudes out of the hose
fitting far enough that no dirt or moisture can be taken into the hose.

Technical Specifications
Item no. 11503005, Revision 0714 ( 36 )
6 Technical Specifications
Bearings Steel ball bearing (pcs) 2
Lifetime lubricated maintenance free
Power values
Fan cooled
Pmax / 5 s S6-60% S1-100%
Rated power 3,5 1,9 1,5 [kW]
Voltage 200 200 200 [V]
Current 14 7 6 [A]
Motor data Motor technology 3-phase asynchronous drive
(no brushes or sensors)
Frequency 500 Hz
Motor poles (pairs) 1
Rated rotation speed 30.000 rpm
Acceleration/braking value
Per second
10.000 rpm
(other values by consultation)
Characteristics Motor protection PTC 130°C
Housing Aluminium
Housing diameter 100 mm
T-slots DIN 650-8
Spindle holder integrated
Cooling Fan-cooled
(impeller on shaft)
Heat dissipation Via the housing
Housing temperature < + 55° C
Ambient temperature + 10°C … + 45°C
Sealing air
Protection category
(sealing air turned on) IP54
Taper cleaning
ESD protection
Tool change Pneumatic taper change
Tool Holder HSK-E 25
Clamping range up to 10 mm
Clockwise
Coupler plug 9-pin (SpeedTEC)

Technical Specifications
Item no. 11503005, Revision 07 15 ( 36 )
Weight ~ 7 kg
Inner taper run out < 2 µ
Axial run-out < 2 µ
6.1 Dimensions

Technical Specifications
Item no. 11503005, Revision 0716 ( 36 )
6.2 Technical data sheet (KL 3502, AC motor)
The power values (S1, S6, S2)
are valid for sinusoidal cur-
rents and voltages.
The power values of the HF
spindle are dependent on the
frequency converter used and
may vary from the indicated
values.
Motor type ACM 70/40/50-2
Rated power 1,5 kW
Rated rotation speed 30.000 rpm
Cooling Fan cooled
Motor protection PTC 130°C
Winding resistance 0,63 Ω
Measured values: S1-100%
Rated rotation speed 5,000 10,000 15,000 20,000 25,000 30,000 rpm
Speed 4,600 9,615 14,515 19,390 24,440 29,200 rpm
Frequency 83 167 250 333 417 500 Hz
Rated power 0.25 0.5 0.75 1 1.25 1.5 kW
Torque 0.52 0.5 0.49 0.49 0.49 0.49 Nm
Voltage 45 85 100 133 167 200 V
Current 6 6 6 6 6 6 A
Cos φ 0.73 0.70 0.82 0.87 0.87 0.86
Measured values: S6-60%
Rated rotation speed 5,000 10,000 15,000 20,000 25,000 30,000 rpm
Speed 4,440 9,495 14,360 19,200 24,260 29,250 rpm
Frequency 83 167 250 333 417 500 Hz
Rated power 0.317 0.633 0.95 1.267 1.583 1.9 kW
Torque 0.68 0.64 0.63 0.63 0.62 0.62 Nm
Voltage 45 85 100 133 167 200 V
Current 7 7 7 7 7 7 A
Cos φ 0.84 0.77 0.87 0.90 0.89 0.89

Technical Specifications
Item no. 11503005, Revision 07 17 ( 36 )
Measured values: S2-Pmax./5 s
Rated rotation speed 5,000 10,000 15,000 20,000 25,000 30,000 rpm
Speed 4,260 8,535 13,470 18,060 23,290 28,360 rpm
Frequency 83 167 250 333 417 500 Hz
Rated power 0.45 0.95 1.75 2.333 2.917 3.5 kW
Torque 1.01 1.06 1.24 1.23 1.2 1.18 Nm
Voltage 50 75 110 133 167 200 V
Current 11 12 14 14 14 14 A
Cos φ 0.85 0.93 0.91 0.9 0.9 0.9
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
harmonic content.
6.2.1 Performance Diagram

Technical Specifications
Item no. 11503005, Revision 0718 ( 36 )
6.3 Wiring diagram
Note: Do not change the ex-works configuration.
Any change may cause overvoltage on the electrical components (e.g. PTC,
differential magneto resistor).
g
f
e
d
c
b
a
4 5 6
1 32
a
b
c
d
e
f
g
Bl.von 1
Ü b e r s e t z u n g e n , V e r vi e l f ä l t i g u n ge n u n d d i e W e i te rg a be a n D r i t te , a u c h n u r a us z ug sw e i se ,
i s t o h n e s c h r i f t l i c h e G e h n e h m i g u n g d e r F a . A l f r e d J ä g e r G m b H u n t e rs ag t
Datum
Gepr.
Bearb.
Norm System Technologie
Blatt 1
1.0
Projekt Nr.:
Version Nr.:
Zeichn.Nr.:
Hr Fischer
Alfred Jäger GmbH
Siemensstraße 8
61239 Ober Mörlen 29025670
Pinbelegung FS9 (S5) PTC
U
W
-A
-D
-B
-C
-G
-E
PTC
Ptc
VStator
Stator
grün-gelb
green-yellow
Spindelstecker FS9M Spindle plug FS9M
Farbe - siehe Tabelle
Color - see chart
Farbe - siehe Tabelle
Color - see chart
Farbe - siehe Tabelle
Color - see chart
Farbe - siehe Tabelle
Color - see chart
Farbe - siehe Tabelle
Color - see chart
0,75 mm²
U
V
W
PIN 3/7-4 pole 4/7-2 pole
2/7-2 pole
2/4-2 pole
3/7-2 pole
AC 7.01-2
PTC+
PTC-
AC 8.01-4
C
B
A
G
blau 0,14mm²
blue 0.14mm²
blau 0,14mm²
blue 0.14mm²
blau 0,14mm²
blue 0.14mm²
rot 0,14mm²
red 0.14mm²
rot 0,14mm²
red 0.14mm²
rot 0,14mm²
red 0.14mm²
blau 0,25mm²
blue 0.25mm²
blau 0,25mm²
blue 0.25mm²
blau 0,25mm²
blue 0.25mm²
weiß 0,20mm²
white 0.20mm²
weiß 0,22mm²
white 0.22mm²
weiß 0,25mm²
white 0.25mm²
braun 0,22mm²
brown 0.22mm²
grün 0,20mm²
green 0.20mm²
lila 0,22mm²
purple 0.22mm²
schwarz 0,5mm²
black 0.5mm²
blau 0,5mm²
blue 0.5mm²
braun 0,5mm²
brown 0.5mm²
blau 0,25mm²
blue 0.25mm²
blau 0,25mm²
blue 0.25mm²
blau 1mm²
blue 1mm²
braun 1mm²
brown 1mm²
schwarz 1mm²
black 1mm²
rot 0,25mm²
red 0,25mm²
rot 0,20mm²
red 0,20mm²
E
-L
-F
-H
Kundenseite
Customer side
Rückseite
Back side
14.10.2013
A
B C
E
G
H
F
L
D
G
L
F
C
B
A D
E
H
PTC-
Motorphase W
Motor phase W
Motorphase V
Motor phase V
Motorphase U
Motor phase U
PE Schutzleiter
PE conductor
Kundenseite
Customer side
PTC+
---
---
---
---
---
---

Technical Specifications
Item no. 11503005, Revision 07 19 ( 36 )
6.4 Motor protection PTC 130°C
PTC thermistor with protective insulation
Characteristic curves for rated response temperatures 90°C to 160°C in accor-
dance with DIN VDE V 0898-1-401.
Positive temperature coefficient
thermistor resistance (RPTC)
according 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 (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 ----
6.5 ESD protection
ESD protection is provided by creating an electrically conductive connection
between the rotating shaft of the HF spindle and the motor housing.
qDepending on the operating time, the electrical resistance of this sliding
contact is <1 kΩ.
qThe wear on the sliding contact is not monitored.

Operating location
Item no. 11503005, Revision 0720 ( 36 )
6.6 Air-borne noise emissions
CAUTION: Noise has an impact on health.
uOnly operate the HF spindle if you are wearing hearing protection.
7 Operating location
DANGER: Due to flying parts.
If the HF spindle is incorrectly attached, it may come loose during operation
and be flung away by the forces that occur.
uClamp the HF spindle firmly.
WARNING: Risk of injury due to flying parts.
The HF spindle operates at high speeds which may cause chips to fly out
with great force.
uNever remove the protective devices of the machine or system.
uAlways wear protective goggles during work.
Exampleofdesign: Mounting
surface
Note the following points before installing the HF spindle:
ÜMake sure that the correct T-slot clamping system for the HF spindle is fit-
ted in the machine.
ÜCheck the connecting hoses for damage.
ÜCheck the connecting cables for damage.
ÜOnly use undamaged hoses and cables.
ÜDo not allow the HF spindle to run in the vicinity of a heat source.