Jäger F100-H636.101 K0,5RW2V User manual

Manual
F100-H636.101 K0,5RW2V
High Frequency Spindle
Hydraulic taper change

Item no. 10406166, Revision 032 ( 48 )
Identification of HF spindle
Spindle type
Pmax S6-60% S1-100%
Item no. .... Serial no.
Rated rotation speed
Serial no.
Item no.
Power data
Spindle type
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. 10406166, Revision 03 3 ( 48 )
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 Service set..................................................................6
2.1.2 Optional accessories..............................................6
2.1.3 Documentation supplied.....................................6
2.2 Packaging of HF spindle.................................................... 7
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 Internal coolant supply....................................................10
4.4 Installation and maintenance........................................11
4.5 Modification and repair ...................................................11
4.6 Improper operation ..........................................................11
5 Technical description 12
5.1 Connections of HF spindle .............................................12
5.2 Electrical connection ........................................................13
5.3 Cooling ..................................................................................13
5.4 Sealing air .............................................................................13
5.5 Taper cleaning ....................................................................13
5.6 Hydraulic tool change......................................................13
5.7 Internal coolant supply....................................................14
5.7.1 Cooling lubricant ................................................. 14
5.7.2 Filtering the cooling lubricant ........................ 15
5.7.3 Avoiding pressure peaks................................... 15
5.8 Leakage .................................................................................16
5.8.1 Internal coolant supply, vertical installation
.................................................................................... 16
5.8.2 Internal coolant supply, horizontal installa-
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
8.3 Cooling water.......................................................................30
8.3.1 Quality of cooling water.....................................30
8.3.2 Setting the cooling...............................................31
8.4 Hydraulic tool change.......................................................31
8.5 Compressed air....................................................................31
8.5.1 Air purity classes (ISO 8573-1)..........................31
8.5.2 Setting the sealing air .........................................32
8.5.3 Setting values.........................................................32
9 Commissioning 33
9.1 Running-in schedule..........................................................33
9.2 Daily start-up ........................................................................33
9.3 Shutdown signal .................................................................34
9.4 Commissioning after storage .........................................34
10 Tool change 35
10.1 Clockwise and counter-clockwise.................................35
10.2 hydraulic taper change.....................................................36
10.2.1 Automatic hollow shank taper tool clamp
.....................................................................................36
10.3 Workflow................................................................................37
10.3.1 Hydraulic workflow..............................................37
10.3.2 Electrical workflow...............................................38
10.3.3 Signals.......................................................................38
11 Tools for high speed cutting 39
12 Maintenance 40
12.1 Ball bearings .........................................................................40
12.2 Daily cleaning.......................................................................40
12.2.1 Before commencing work.................................40
12.2.2 With every tool change ......................................41
12.3 In the case of storage.........................................................41
12.4 Monthly maintenance.......................................................41
12.5 Long periods of storage ...................................................41

Item no. 10406166, Revision 034 ( 48 )
Contents:
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

Preliminary information
Item no. 10406166, Revision 03 5 ( 48 )
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. 10406166, Revision 036 ( 48 )
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
qService set
qTransport packaging
ÜCheck the high frequency spindle for completeness upon delivery.
2.1.1 Service set
qFelt cleaning taper
2.1.2 Optional accessories
Available on request:
qFrequency converter
qChiller
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.
2.1.3 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.

Designated use
Item no. 10406166, Revision 03 7 ( 48 )
2.2 Packaging of HF spindle
All transport packaging materials can be recycled in appropriate disposal facil-
ities.
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. 10406166, Revision 038 ( 48 )
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. 10406166, Revision 03 9 ( 48 )
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. 10406166, Revision 0310 ( 48 )
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 [}18].
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 and the taper cleaning 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 Internal coolant supply
DANGER: Due to explosion.
Flammable flow media or hydrocarbons may ignite and trigger explosions.
uEnsure that no flammable flow media are used.
uEnsure that no hydrocarbons are used.
Exception:
Heat-transfer oils within the permissible temperature range.
uNote the safety data sheet of the oil that is used.
WARNING: Risk of injury due to flying parts.
If excessive pressure is applied to the internal coolant supply, connection ca-
bles may fly off.
uDo not connect the internal coolant supply to a pipe system with an ex-
cessive level of pressure.
WARNING: Risk of burns.
If the flow media exceed the maximum permissible temperature, the seals
may be damaged. This causes the internal coolant supply to leak and hot
media may escape.
uDo not route flow media with excessive temperatures through the inter-
nal coolant supply.

Safety instructions
Item no. 10406166, Revision 03 11 ( 48 )
CAUTION: Risk of injury due to emerging medium.
During work on the internal coolant supply, the medium may come into con-
tact with skin or eyes.
uObserve the safety instructions for the flow medium that is used.
CAUTION: Risk of injury due to emerging medium.
If unsuitable hoses are used, they may become porous or burst.
uTo connect the internal coolant supply to the machine, choose suitable
hoses with specifications that match the application.
uUse hoses that are approved for the medium.
uUse hoses that are approved for the maximum system pressure of the
machine.
uUse hoses that are approved for the maximum temperature of the
medium.
4.4 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.
4.5 Modification and repair
Modifications or alterations to the HF spindle are only permitted after prior
consultation with Alfred Jäger GmbH.
Only the service partners listed in the “Service and repair [} 43]” section are
authorized to open and repair the HF spindle.
Only approved accessories have been tested for operational safety and func-
tionality.
4.6 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. 10406166, Revision 0312 ( 48 )
5 Technical description
5.1 Connections of HF spindle
3b8
221c
3a1b1a
712
11 4
1a Electrical connection for: motorphases
1b Electrical connection for: Tool taper monitoring, PTC, KTY
1c Electrical connection for: Vector control
2Cooling water G 1/4"
3a Sealing air (front) G 1/8"
3b Sealing air (rear) M5
4Taper cleaning G 1/4"
7Hydraulic system for tool change (cylinder forward) M10x1
8Hydraulic system for tool change (cylinder back) M10x1
11 Internal coolant supply G 1/4"
12 Leakage G 1/4"

Technical description
Item no. 10406166, Revision 03 13 ( 48 )
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.
5.3 Cooling
Liquid cooling keeps the HF spindle at a constant temperature during opera-
tion.
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 + 45° C as this shortens the service life of the
bearing.
uCheck 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 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
For guidelines on air quality,
see "Air purity classes (ISO
8573-1) [}31]" section.
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.
5.6 Hydraulic tool change
The tool change or tool taper change is performed hydraulically.
During this, a mechanism is operated inside the HF spindle which clamps, re-
leases, or ejects the tool taper or collet.

Technical description
Item no. 10406166, Revision 0314 ( 48 )
5.7 Internal coolant supply
The internal coolant supply cools the tool and the HF spindle.
The tool coolant is routed internally through the HF spindle and tool, and
emerges at the interface of the clamped tool. The coolant lubricates the tool
at the same time.
Note: Unsuitable tool.
Tools without an internal hole are not suitable for internal coolant supply.
uIt 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.
ÜOnly use tools and tool holders that are suitable for internal coolant sup-
ply.
ÜMake sure that the cooling lubricant used conforms to the current specifi-
cations in legislation and from the trade associations.
ÜMake 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 damaged.
5.7.1 Cooling lubricant
CAUTION: Danger due to hydraulic oil spraying out.
If the internal coolant supply is used for hydraulic oil, the internal coolant
supply may be damaged and hydraulic oil may be sprayed out at high pres-
sure.
uDo not use hydraulic oils.
ÜOnly use cooling lubricants that comply with the following guidelines:
Cutting oil
Temperature of the medium min. +3°C
Ambient temperature min. +3°C

Technical description
Item no. 10406166, Revision 03 15 ( 48 )
5.7.2 Filtering the cooling lubricant
Unfiltered flow media with a particle size in excess of 60 µm lead to increased
wear.
ÜUse a filter upstream of the internal coolant supply that filters out particles
that are bigger than 60 μm from the medium.
The greater the number of particles in the flow medium, the greater the wear
on the internal coolant supply.
ÜEnsure that the residual dirt load complies with the following specifica-
tions:
Ämax. 100 mg/l
ÄAluminum machining: max. 50 mg/l.
ÜUse media of the following classes:
ÄClass 5 according to ISO 4406:1999 code 17/15/12
Äor 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.
ÜSelect 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 due to a
stroke motion.
ÜRemedy: ventilation.

Technical description
Item no. 10406166, Revision 0316 ( 48 )
5.8 Leakage
Note: Damage to the HF spindle due to leakage.
Cooling lubricant may enter the HF spindle through the bearing of the inter-
nal coolant supply and destroy it:
qIf the internal coolant supply is operated in the lower pressure range.
qIf the pressure of the cooling medium builds up slowly.
uUse leakage monitoring to protect the HF spindle from damage.
If pressure is applied to the internal coolant supply, the seal ring pair inside
the internal coolant supply closes.
If the pressure is deactivated, the mechanical seal opens. The leakage quantity
that emerges is discharged through a separate line by means of the relief hole.
The leakage quantity depends on the following factors:
qCooling lubricant and its viscosity.
qInstallation position of the internal coolant supply.
qRouting of the supply line.
qPosition 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 depth
1High Frequency Spindle max. 6 mm
2Internal coolant supply max. 6 mm
ÜRemove the sealing plugs that protect the connections against damage
and contamination during transportation.
ÜInstead of these sealing plugs, install the appropriate hose fittings.
ÜInstall the corresponding hoses in the hose fittings
ÜRoute the leakage hose with a falling gradient so that the leakage can be
discharged.
ÄAngle: at least 15°.
ÜRoute away the leak to avoid backing up.

Technical description
Item no. 10406166, Revision 03 17 ( 48 )
5.8.2 Internal coolant supply, horizontal installation
Exampleofdesign: Leakage
Leakage Screw-in depth
1High Frequency Spindle max. 6 mm
2Internal coolant supply max. 6 mm
ÜPosition 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).
ÜRemove the sealing plugs that protect the connections against damage
and contamination during transportation.
ÜInstead of these sealing plugs, install the appropriate hose fittings.
ÜInstall the corresponding hoses in the hose fittings
ÜRoute the leakage hose with a falling gradient so that the leakage can be
discharged.
ÄAngle: at least 15°.
ÜRoute away the leak to avoid backing up.

Technical Specifications
Item no. 10406166, Revision 0318 ( 48 )
6 Technical Specifications
Bearings Hybrid ball bearing (pcs) 4
Lifetime lubricated maintenance free
Power values
Liquid cooled
Pmax / 5 s S6-60% S1-100%
Rated power 16,1 11,5 10 [kW]
Voltage 380 380 380 [V]
Current 38,4 28,5 25,7 [A]
Motor data Motor technology 3-phase asynchronous drive
(no brushes or sensors)
Frequency 1.200 Hz
Motor poles (pairs) 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°C
Sealing air
Protection category
(sealing air turned on) IP54
Taper cleaning
Internal coolant supply
Internal coolant supply < 140 bar
< 24,3 l/min
Tool change Hydraulic taper change
Tool Holder HSK-E 40

Technical Specifications
Item no. 10406166, Revision 03 19 ( 48 )
Tool change monitoring 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

Technical Specifications
Item no. 10406166, Revision 0320 ( 48 )
6.2 Technical data sheet (KL8513 , 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 82/50/80-4E
Rated power 10 kW
Rated rotation speed 36.000 rpm
Cooling Liquid cooled
Motor protection PTC 130°C
KTY 84-130
Winding resistance 0,47 Ω
Measured values: S1-100%
Rated rotation speed 5.000 10.000 15.000 20.000 25.000 30.000 36.000 rpm
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 25.000 30.000 36.000 rpm
Speed 4.313 9.269 14.277 19.285 24.293 29.160 35.011 rpm
Frequency 167 333 500 667 833 1.000 1.200 Hz
Rated power 2,122 5,037 7,4 9,6 11,494 11,172 10,712 kW
Torque 4,699 5,189 4,966 4,742 4,518 3,659 3,028 Nm
Voltage 89 170 240 310 380 380 380 V
Current 27,4 28,5 27,8 27 26,3 25,4 24,5 A
Cos φ 0,85 0,81 0,80 0,79 0,78 0,79 0,79