Summary of Contents for Jäger F100-H636.01 K0,5RW2
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Manual F100-H636.01 K0,5RW2 High Frequency Spindle Hydraulic taper change...
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Identification of HF spindle Spindle type Item no. Serial no. Spindle type Item no..Serial no. Pmax S6-60% S1-100% Rated rotation speed Power data 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.
Contents: Translation of the original manual Motor protection KTY 84-130 ......... 25 Preliminary information 5 Motor protection PTC 130°C ........... 26 Purpose of the manual............ 5 Tool change monitoring........... 26 Explanation of symbols used........... 5 Air-borne noise emissions .......... 27 Transport and packaging 6 Operating location...
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Contents: Translation of the original manual 12.6 Maximum storage time ........... 41 Dismantling 42 13.1 Disposal and environmental protection .... 42 Service and repairs 43 14.1 Service partners.............. 43 14.2 Malfunctions................ 44 Declaration of Incorporation 47 4 ( 48 ) Item no. 10406064, Revision 03...
Preliminary information Preliminary information The high frequency spindle (HF spindle) is a high quality precision tool for high speed machining. Purpose of the manual The manual is an important component of the HF spindle. Ü Store the manual carefully. Ü Make the manual available to all persons who work with the HF spindle.
Transport and packaging Transport and packaging Avoid strong vibrations or impacts during transportation, as these could dam- age the ball bearings of the HF spindle. Ü Any damage reduces the accuracy of the HF spindle. Ü Any damage restricts the functionality of the HF spindle. Ü...
Designated use Packaging of HF spindle All transport packaging materials can be recycled in appropriate disposal facil- ities. 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.
Safety instructions 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: If it is installed by untrained personnel. If it is used incorrectly. If it is not used in accordance with its intended use.
Safety instructions 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.
Safety instructions The tool cutting diameter (X) must not be greater than the maximum clamping range (Y). Ü Always clamp the tool so that it is as short as possible. Ü Keep the dimension (Z) small. Ä (Y) See section: Technical Specifications 18].
Safety instructions 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. Observe 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.
Technical description Technical description Connections of HF spindle 11 4 Electrical connection for: motor phases Electrical connection for: Tool taper monitoring, PTC, KTY Cooling water G 1/4" Sealing air G 1/8" Taper cleaning G 1/4" Hydraulic system for tool change (cylinder forward) M10x1 Hydraulic system for tool change (cylinder back) M10x1...
Technical description Electrical connection The HF spindle may only be operated with a frequency converter (FC). Ü Check whether the current, voltage, and frequency data of the HF spindle match the raw data for the frequency converter. Ü Use a motor supply line that is as short as possible. Ü...
Technical description 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.
Technical description 5.7.2 Filtering the cooling lubricant Unfiltered flow media with a particle size in excess of 60 µm lead to increased wear. Ü Use 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.
Technical description 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: If the internal coolant supply is operated in the lower pressure range. If the pressure of the cooling medium builds up slowly.
Technical description 5.8.2 Internal coolant supply, horizontal installation Leakage Screw-in depth High Frequency Spindle max. 6 mm 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...
Technical Specifications Technical Specifications Bearings Hybrid ball bearing (pcs) Lifetime lubricated maintenance free Power values Pmax / 5 s S6-60% S1-100% Liquid cooled Rated power 16,1 11,5 [kW] Voltage Current 38,4 28,5 25,7 Motor data 3-phase asynchronous drive Motor technology (no brushes or sensors) Frequency 1.200 Hz...
Technical Specifications Technical data sheet (KL8513 , AC-Motor) The power values (S1, S6, S2) Motor type ACM 82/50/80-4E are valid for sinusoidal cur- Rated power 10 kW rents and voltages. The power values of the HF Rated rotation speed 36.000 rpm spindle are dependent on the Cooling Liquid cooled...
Technical Specifications Motor protection KTY 84-130 Silicon temperature sensor For temperatures greater than 200°C, Technical Specifications the current must be Icont = 2 mA. Sensor resistance R100 970 W … 1030 W Temperature range -40°C / +300°C Current max. 10 mA cont Ambient tem- Temp.
Technical Specifications 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. Technical Specifications M135 Type = 0 … 40°C) V Max. operating voltage 30 V –...
Technical Specifications Air-borne noise emissions CAUTION: Noise has an impact on health. Only operate the HF spindle if you are wearing hearing protection. Item no. 10406064, Revision 03 27 ( 48 )
Operating location 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. Clamp 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.
Installation Installation Before installation: Ü Check the HF spindle for damage and ensure that it is complete. If the HF spindle has been stored for a long period: Ü Carry out all steps in the Commissioning after storage section. Installing the HF spindle Complete the following steps in sequence to install the HF spindle: Ü...
Installation Diameter of media supply line Ü The nominal size of the media supply lines can be found in the following table: Medium Compressed air 2.8 mm " 4 mm " Compressed air 4 mm " 6 mm " Compressed air 6 mm "...
Installation 8.3.2 Setting the cooling Ü Observe the following values for liquid cooling: Hose diameter (*) Min. DN 5.5 Feed temperature Min. 20°C Volumetric flow Min. 1.5 l/min Return temperature Max. 40°C (*) Use cooling hoses that are impermeable to UV light. Hydraulic tool change Ü...
Installation 8.5.2 Setting the sealing air For guidelines on air quality, The adjustment value for the sealing air depends on the hose diameter and see "Air purity classes (ISO length. 8573-1) 31]" section. Ü Hose diameter: DN 4 Ü The setting value can be found in the following diagram. Ü...
Commissioning Commissioning DANGER: Due to flying parts. If the speed is selected incorrectly, the HF spindle or the tool may be de- stroyed and their fragments may be flung out. Note the maximum speed for the selected tool. Note the maximum speed for the HF spindle. The maximum permissible speed of the HF spindle for commissioning / processing is always the lowest...
Commissioning Daily start-up Proceed as follows to preheat the grease lubrication of the bearing and to protect it: Ü Operate the HF spindle with a clamped tool (without machining). Ä Approx. 2 minutes. Ä At maximum 50 % of the maximum permissible speed. (See Commissioning 33] section)
Tool change Tool change CAUTION: Danger of being drawn in by rotating shaft. If the shaft is still rotating, fingers and hands may be drawn in and crushed. Only change the tool if the shaft is at a standstill. Note: Ensure functionality. Never operate the HF spindle without a clamped tool shank.
Tool change Ü Make sure that the shaft of the HF spindle has come to an absolute stand- still. Ü Switch on the hydraulics 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.
Tool change 10.3 Workflow 10.3.1 Hydraulic workflow HF spindle shutdown signal from machine controller. (Speed = 0 for HF spindle with differential magneto resistor) (Frequency = 0 and time delay of at least 2-3 sec for HF spindle without differential magneto resistor) Connection Fluid Compressed...
Tool change 10.3.2 Electrical workflow Tool taper Hydraulics on Clamped Released Ejected No signal Signal No signal inserted Signal No signal No signal Inserted No signal No signal Signal clamped 10.3.3 Signals Inputs Description Signal Action Cylinder back. Released Clamping system released. Do not start signal No tool taper inserted in tool mount...
Tools for high speed cutting Tools for high speed cutting DANGER: Due to flying parts. If the wrong direction of rotation is used, the tool is damaged when load is applied. The centrifugal forces cause the broken part to be flung out. Only use tools with the correct direction of rotation for the HF spindle.
Maintenance Maintenance Only specialist personnel may perform maintenance on the spindle. The HF spindle must be shut down before any maintenance work. Ü Make sure that the shaft of the HF spindle has come to an absolute stand- still. Ü Before carrying out any work, read the corresponding section of the man- ual carefully again.
Maintenance 12.2.2 With every tool change Ü Clean the inner taper of the HF spindle shaft. The inner taper must be free of chips and contamination. Ü Clean the tool taper. Ü Clean the collet and the collet mount. Ü Apply a light greasy film to the taper of the collet after cleaning.
Dismantling Dismantling Proceed as follows to remove the HF spindle: Ü Completely disconnect the power supply. Ü Completely disconnect the media supply (air and liquid). Ü Switch the hydraulics off fully. Ü Make sure that the shaft of the HF spindle has come to an absolute stand- still.
Service and repairs 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).
Service and repairs 14.2 Malfunctions The list below can be used to quickly investigate and eliminate faults. HF spindle not rotating Cause Troubleshooting Check the frequency converter. Check the machine. Check all electrical connections. power supply Check all wires in the motor cable. Activate the Start/Reset button.
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Service and repairs HF spindle becomes loud Cause Troubleshooting Only use balanced tools. (Also see the "Tools for high speed cutting [} 39]" section.) Tool unsuitable Check the tool for damage. Replace damaged tool. HF spindle is not Only use spindle holders from the original accessories or clamped truly or is dis- holders produced according to the tolerances specified by torted...
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Service and repairs HF spindle vibrates/ Cause Troubleshooting oscillates Only use balanced tools. (Also see the "Tools for high speed cutting [} 39]" section.) Tool unsuitable Check whether the tool is suitable for the application. Check the tool for damage. Replace damaged tool. Remove all contamination between the tool taper and shaft of the HF spindle.
Tel. +49 (0) 60029123 -0 hereby declare that the product, Product High Frequency Spindle Type F100-H636.01 K0,5RW2 Serial no. See last page of manual as far as possible from the supplied, complies with the essential requirements of the Machinery Directive 2006/42/EC.
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Norcross, GA 30071 GERMANY Alfred Jäger YouTube channel Scan this QR code with the Jäger app or +49 (0)6002-9123-0 +1 (770) 674-4480 any QR code scanner. sales@alfredjaeger.de office@jaegerspindles.com www.alfredjaeger.de www.alfredjaeger.de/en Serial number Type F100-H636.01 K0,5RW2 Item no. 10406064 Revision Date 05.10.2021 Language...