Jäger FS80-H445.106 S29A2W2/2V User manual

Manual
FS80-H445.106 S29A2W2/2V
High Frequency Spindle
Pneumatic taper change

Item no. 13404005-02, Revision 012 ( 40 )
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,
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 prohibited with-
out the express written approval o Nakanishi Jaeger GmbH.

Item no. 13404005-02, Revision 01 3 ( 40 )
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
6 Technical Specifications 14
6.1 Dimensions..........................................................................15
6.2 Technical data sheet (KL3601 , DC-Motor)...............16
6.2.1 Performance Diagram........................................17
6.3 Wiring diagram...................................................................18
6.4 Motor protection Pt1000................................................20
6.5 Tool change monitoring.................................................21
6.6 Speed and position sensor (MiniCoder)....................22
6.6.1 Technical Specifications....................................22
6.7 ESD protection....................................................................22
6.8 Air-borne noise emissions..............................................23
7 Operating location 23
8 Installation 24
8.1 Installing the HF spindle .................................................24
8.2 Diameter of media supply line .....................................25
8.3 Cooling water......................................................................25
8.3.1 Quality of cooling water....................................25
8.3.2 Setting the cooling..............................................25
8.4 Compressed air...................................................................26
8.4.1 Air purity classes (ISO 8573-1).........................26
8.4.2 Setting the sealing air ........................................26
8.4.3 Setting values........................................................27
9 Commissioning 27
9.1 Running-in schedule ........................................................27
9.2 Daily start-up.......................................................................28
9.3 Shutdown signal................................................................28
9.4 Commissioning after storage........................................28
10 Tool change 29
10.1 Clockwise and counter-clockwise ...............................29
10.2 Pneumatic taper change ................................................30
10.2.1 Automatic hollow shank taper tool clamp
....................................................................................30
10.3 Tool changing station (optional accessory).............31
10.3.1 pneumatic taper change...................................31
10.3.2 Installing the changing station.......................31
10.3.3 Maintenance..........................................................31
11 Tools for high speed cutting 32
12 Maintenance 33
12.1 Ball bearings........................................................................33
12.2 Daily cleaning .....................................................................33
12.2.1 Before commencing work ................................33
12.2.2 With every tool change .....................................33
12.2.3 Every time the clamping device is changed
....................................................................................34
12.3 In the case of storage.......................................................34
12.4 Monthly maintenance .....................................................34
12.5 Long periods of storage..................................................34
12.6 Maximum storage time...................................................34
13 Dismantling 35
13.1 Disposal and environmental protection...................35
14 Service and repairs 35

Item no. 13404005-02, Revision 014 ( 40 )
Contents:
Translation of the original manual
14.1 Service partners..................................................................35
14.2 Malfunctions........................................................................36
15 Declaration of Incorporation 39

Preliminary information
Item no. 13404005-02, Revision 01 5 ( 40 )
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. 13404005-02, Revision 016 ( 40 )
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
qTool taper
qFelt cleaning taper
qTransport packaging
ÜCheck the high frequency spindle for completeness upon delivery.
2.1.1 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.
2.1.2 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. 13404005-02, Revision 01 7 ( 40 )
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 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.
qMetals (such as alloys, cast metals etc.)
qSintered materials
qPlastics
qWood
qGraphite
qStone (marble, etc.)
qPaper and cardboard
qCircuit boards
qGlass and ceramic
ÜContact Nakanishi Jaeger GmbH if other materials are to be machined.

Safety instructions
Item no. 13404005-02, Revision 018 ( 40 )
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. 13404005-02, Revision 01 9 ( 40 )
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. 13404005-02, Revision 0110 ( 40 )
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 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 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 Nakanishi Jaeger GmbH.
Only the service partners listed in the “Service and repair [}35]” 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. 13404005-02, Revision 01 11 ( 40 )
5 Technical description
5.1 Connections of HF spindle
1a
3
2
1c 8
7
24
1a Electrical connection for: motor phases, sensors
1c Electrical connection for: Vector control
2Cooling water G 1/8"
3Sealing air G 1/8"
4Taper cleaning G 1/8"
7Pneumatics for tool change (cylinder forward) G 1/8"
8Pneumatics for tool change (cylinder back) G 1/8"

Technical description
Item no. 13404005-02, Revision 0112 ( 40 )
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
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.

Technical description
Item no. 13404005-02, Revision 01 13 ( 40 )
5.4 Sealing air
For guidelines on air quality,
see "Air purity classes (ISO
8573-1) [}26]" 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) [}26]" 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 Pneumatic tool change
For guidelines on air quality,
see "Air purity classes (ISO
8573-1) [}26]" 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.

Technical Specifications
Item no. 13404005-02, Revision 0114 ( 40 )
6 Technical Specifications
Bearings Hybrid ball bearing (pcs) 3
Lifetime lubricated maintenance free
Power values
Liquid cooled
Pmax./5s S6-60% S1-100%
Rated power 6,6 5 3,8 [kW]
Torque 1,4835 1,218 0,8 [Nm]
Voltage 311,2 275 291 [V]
Current 15,36 12,6 9,5 [A]
Motor data Motor technology 3-phase synchronous drive
(no brushes or sensors)
Frequency 1.500 Hz
Motor poles (pairs) 2
Rated rotation speed 45.000 rpm
Acceleration/braking value
Per second
10 000 rpm
(other values by consultation)
Characteristics Speed sensor Vector control
Toothed wheel Teeth = 128
Module = 0,3
Motor protection Pt1000
Housing Stainless steel
Housing diameter 80 mm
Flange diameter 120 mm
Pitch circle
Ø 94 mm (6 x Ø 6,6 )
for screws: M6
Ø 110 mm (6 x M4 )
Cooling Liquid cooled
Ambient temperature + 10°C … + 45°C
Sealing air
Protection category
(sealing air turned on) IP54
Taper cleaning
ESD protection insulated led out
Tool change Pneumatic taper change
Tool Holder HSK-E 25
Tool change monitoring inductive

Technical Specifications
Item no. 13404005-02, Revision 01 15 ( 40 )
2 positions clamped, ejected
Clamping range up to 10 mm
Clockwise and anticlockwise
Connector plug
15-pin
(SpeedTEC)
Motor phases
17-pin
Sensors
Weight ~ 6 kg
Inner taper run out < 1 µ
Axial run-out < 1 µ
6.1 Dimensions

Technical Specifications
Item no. 13404005-02, Revision 0116 ( 40 )
6.2 Technical data sheet (KL3601 , DC-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 DCM 52/34/35-4E
Rated power 3,7 kW
Rated rotation speed 45.000 rpm
Cooling Liquid cooled
Motor protection Pt1000
Winding resistance 0,313 Ω
Measured values: S1-100%
Rated rotation speed 5.000 10.000 15.000 20.000 25.000 30.000 35.000 40.000 45.000 rpm
Frequency 167 333 500 667 833 1.000 1.167 1.333 1.500 Hz
Rated power 0,422 0,837 1,256 1,678 2,095 2,518 2,932 3,352 3,750 kW
Torque 0,8 0,8 0,8 0,8 0,8 0,8 0,8 0,8 0,8 Nm
Voltage 45 75 105 133 163 192 216 242 291 V
Current 8,5 8,5 8,7 8,9 8,8 9,2 9,3 9,4 9,5 A
Measured values: S6-60%
Rated rotation speed 5.000 10.000 15.000 20.000 25.000 30.000 35.000 40.000 45.000 rpm
Frequency 167 333 500 667 833 1.000 1.167 1.333 1.500 Hz
Rated power 0,630 1,215 1,898 2,446 3,186 4 4,272 4,624 5,038 kW
Torque 1,206 1,161 1,209 1,168 1,218 1,163 1,166 1,104 1,069 Nm
Voltage 52 82 113 142 175 201 228 254 275 V
Current 11,5 11,3 11,8 11,9 12,6 12,3 12,3 12 12 A

Technical Specifications
Item no. 13404005-02, Revision 01 17 ( 40 )
Measured values: S2-Pmax./5 s
Rated rotation speed 5.000 10.000 15.000 20.000 25.000 30.000 35.000 40.000 45.000 rpm
Frequency 167 333 500 667 833 1.000 1.167 1.333 1.500 Hz
Rated power 0,756 1,518 2,328 3,107 3,869 4,510 5,183 5,889 6,625 kW
Torque 1,459 1,479 1,484 1,484 1,480 1,437 1,414 1,406 1,407 Nm
Voltage 57 93 125 158 191 222 255 284 311 V
Current 15 15,2 15,4 15,2 15,3 15 15 14,8 14,8 A
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. 13404005-02, Revision 0118 ( 40 )
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).
UA-
SIN-
1.Spur
UN+N
GND
+5V
VCC_FB
+/-5%
UB+
COS-
2.Spur
UA+
SIN+
1.Spur
UB-
COS+
2.Spur
UN-N
Sense
Zahnradgeber GEL 244
encoder GEL 244
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
Spindelstecker FS17 (S10) Vektor
spindle plug FS17 (S10) Vektor
'P'
GN 0,25 mm²
wird nicht benötigt, isoliert hineinlegen
not connected, isolated
YE 0,25 mm²
BK 0,25 mm²
WH 0,25 mm²
BN 0,25 mm²
GY 0,25 mm²
BU 0,25 mm²
RD 0,25 mm²
PK 0,25 mm²
2.0
1
Perschewski
16.03.17
1
29022570
g
f
e
d
c
b
a
456
13 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. Nakanishi Jaeger GmbH untersagt
Datum
Gepr.
Bearb.
Norm
Projekt Nr.:
Version Nr.:Zeichn.Nr.:
von
Blatt
DIN 61346Flanschstecker FS17 (S10) KEB

Technical Specifications
Item no. 13404005-02, Revision 01 19 ( 40 )
U
V
W
Stator
KTY/
*PT1000
ESD
PNP
Induktiver Näherungsschalter
Inductive proximity switch
PNP
Induktiver Näherungsschalter
Inductive proximity switch
A
B
C
PE
7
8
9
1
2
3
4
5
10
6
Spindel
BN 1 mm²
BU 1 mm²
BK 1 mm²
GNYE 0,75 mm²
BN/*RD 0,14 mm²
WH/*WH 0,14 mm²
0,14 mm²
0,14 mm²
D
BN 0,14 mm²
BU 0,14 mm²
0V
0V
+Us
+Us
Signal gespannt
signal clamped
Signal ausgeworfen
signal ejected
BK 0,14 mm²
BN 0,14 mm²
BU 0,14 mm²
BK 0,14 mm²
Kabelstecker htec15 (S29)
male cable connector htec15 (S29)
Kundenseite
customer side
Phase U
Phase V
Phase W
PE Schutzleiter
protective earth
contact by touch (ESD)
Induktiver Näherungsschalter+
Inductive proximity switch +
Induktiver Näherungsschalter-
Inductive proximity switch -
2.0
Signal gespannt
signal clamped
Signal ausgeworfen
signal ejected
ESD
contact by touch (ESD)
78
9
10
1
Perschewski
03.05.17
1
29046371
g
f
e
d
c
b
a
456
13 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. Nakanishi Jaeger GmbH untersagt
Datum
Gepr.
Bearb.
Norm
Projekt Nr.:
Version Nr.:Zeichn.Nr.:
von
Blatt
DIN 81346Pinbelegung 15pol htec (S29) 2xWK/ESD

Technical Specifications
Item no. 13404005-02, Revision 0120 ( 40 )
6.4 Motor protection Pt1000
2-wire connection
Platinum temperature sensor
Design according to:
qDIN EN 60751
qAccuracy class B
Technical Specifications
Temperature/resistance correlation (series of basic values)
Resistance R/ohm
Temperature t/°C
t90/°C (*) Resistance at temperature t90/°C [Ω]
0123456789
01000 1004 1008 1012 1016 1020 1023 1027 1031 1035
10 1039 1043 1047 1051 1055 1059 1062 1066 1070 1074
20 1078 1082 1086 1090 1094 1097 1101 1105 1109 1113
30 1117 1121 1125 1128 1132 1136 1140 1144 1148 1152
40 1155 1159 1163 1167 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 1457
120 1461 1464 1468 1472 1476 1480 1483 1487 1491 1495
130 1498 1502 1506 1510 1513 1517 1521 1525 1528 1532
140 1536 1540 1543 1547 1551 1555 1558 1562 1566 1570
150 1573 1577 1581 1585 1588 1592 1596 1599 1603 1607
160 1611 1614 1618 1622 1625 1629 1633 1637 1640 1644
170 1648 1651 1655 1659 1663 1666 1670 1674 1677 1681
180 1685 1689 1692 1696 1700 1703 1707 1711 1714 1718
(*) Rounded values