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Jäger Z100-H642.15 S11W2 Manual

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Z100-H642.15 S11W2
High Frequency Spindle
Pneumatic taper change

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Summary of Contents for Jäger Z100-H642.15 S11W2

  • Page 1 Manual Z100-H642.15 S11W2 High Frequency Spindle Pneumatic taper change...
  • Page 2 Identification of HF spindle Spindle type Item no. Serial no. Spindle type Item no..Serial no. Pmax S6-60% S1-100% Rated rotation speed Performance 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.

  • Page 3: Table Of Contents

    Contents: Translation of the original manual 6.8.2 Technical Specifications ........ 27 Preliminary information  5 Speed and position sensor (TTL, optional accessory) Purpose of the manual ............ 5 .................... 28 Explanation of symbols used ..........  5 6.9.1 Toothed wheel............ 28 Transport and packaging  6 6.9.2 Technical data (TTL, x8) ........
  • Page 4 Contents: Translation of the original manual 10.4.1 Pneumatic workflow........... 41 10.4.2 Electrical workflow .......... 42 10.4.3 Signals.............. 42 Tools for high speed cutting  43 Maintenance  44 12.1 Ball bearings ................ 44 12.2 Daily cleaning .............. 44 12.2.1 Before commencing work ........ 44 12.2.2 With every tool change........ 44 12.2.3 Every time the clamping device is changed .................. 45 12.3...

  • Page 5: Preliminary Information

    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.

  • Page 6: Transport And Packaging

    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...

  • Page 7: Documentation Supplied

    Transport and packaging 2.1.2 Documentation supplied The documents listed below are supplied with the HF spindle: Manual The declaration of incorporation is part of the manual. Inspection protocol Ü Check that the documentation supplied is complete when the spindle is delivered.

  • Page 8: Designated Use

    Designated use 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.

  • Page 9: Safety Instructions

    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.

  • Page 10: Safe Working

    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.

  • Page 11: Shutdown Of Hf Spindle

    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  14].

  • Page 12: Technical Description Connections Of Hf Spindle

    Technical description Technical description Connections of HF spindle Electrical connection for: motor phases Electrical connection for: Tool taper monitoring, PTC, Pt1000 Electrical connection for: Vector control (optional accessory) Electrical connection for: Eddy current sensor (optional accessory) Cooling water G 1/4" Sealing air G 1/8"...

  • Page 13: Electrical Connection

    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...

  • Page 14: Technical Specifications Dimensions

    Technical Specifications Technical Specifications Bearings Hybrid ball bearing (pcs) Lifetime lubricated maintenance free Temperature monitoring Pt1000 Power values Pmax./5s S6-60% S1-100% Liquid cooled Rated power 16,1 11,5 [kW] Torque 6,85 5,19 [Nm] Voltage Current 38,4 28,5 25,7 Motor data 3-phase asynchronous drive Motor technology (no brushes or sensors) Frequency...
  • Page 15 Technical Specifications 3 positions clamped, unclamped, ejected Clamping range up to 13 mm Clockwise and anticlockwise 5-pin (ECTA 133) motor phases Coupler plug 12-pin (ECTA 133) sensors Weight ~ 15 kg Inner taper run out < 1 µ Axial run-out < 1 µ Dimensions (*) = Clamping range Item no.

  • Page 16: Motor Data

    Technical Specifications Motor data The power values (S1, S6, S2) Spindle characteristic curve KL 8510 are valid for sinusoidal cur- Motor technology AC Motor rents and voltages. The power values of the HF Motor type ACM 82/50/80-4E spindle are dependent on the Rated power 10 kW frequency converter used and...

  • Page 17: Performance Diagram

    Technical Specifications Measured values: S2-Pmax./5 s Rated rotation speed 5 000 10 000 15 000 20 000 25 000 30 000 42 000 Speed 3 796 8 945 13 933 18 921 23 909 28 625 39 955 Frequency 1 000 1 400 Rated power 2,433...
  • Page 18 Technical Specifications Note: Damage due to incorrect performance data. The values of the parameters relate exclusively to the motor. HF spindle values: See tables S1-100%, S6-60% and S2-Pmax. Parameter Meaning Value Unit p0304 Rated voltage (phase-phase) Vrms p0305 Rated current 22,5 Arms p0307...
  • Page 19 Technical Specifications Parameter Meaning Value Unit Desaturation speed 40.082 Main inductance at maximum speed 4,472 Saturation factor 1,187 Tilting torque reduction factor 58,09 (**) Additional parameters Heidenhain Item no. 10406075, Revision 01 19 ( 52 )

  • Page 20: Wiring Diagram

    Technical Specifications 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). Gerätestecker FS5 (S11) spindle plug FS5 (S11) Spindel Stator BN / *RD / **RD / ***BN 0,2mm²...
  • Page 21 Technical Specifications Spindelstecker S12 (ECTA) (S13) spindle plug S12 (ECTA) (S13) 0,14mm² output 0,14mm² 0,14mm² output 0,14mm² output 0,14mm² 0,14mm² 0,14mm² Widerstand 220Ω resistor 0,14mm² 0,14mm² 0,25mm² RD/ *BN PT1000/ *KTY 0,25mm² WH/ *WH Kundenseite customer side (3x) Induktiver Näherungsschalter + Inductive proximility switch + Feldplatte Signal signal transmitter...

  • Page 22: Circuit Diagram (Optional Accessory)

    Technical Specifications 6.3.1 Circuit diagram (optional accessory) Order number 1-003 Spindelstecker FS17 (S10) Vektor spindle plug FS17 (S10) Vektor Zahnradgeber GEL 244 encoder GEL 244 2.Spur 0,25 mm² COS- +/-5% 0,25 mm² VCC_FB 0,25 mm² 0,25 mm² 1.Spur 0,25 mm² SIN- 1.Spur 0,25 mm²...
  • Page 23 Technical Specifications 6.3.2 Circuit diagram (optional accessory) Order number 1-010 Spindelstecker FS17 (S10) Vektor Zahnradgeber GS04T08 Mis spindle plug FS17 (S10) Vektor encoder GS04T08 Mis 2.Spur COS- 0,25 mm² +/-5% 0,25 mm² 0,25 mm² 0,25 mm² 1.Spur SIN- 0,25 mm² 1.Spur SIN+ 0,25 mm²...

  • Page 24: Motor Protection Pt1000

    Technical Specifications Motor protection Pt1000 Platinum temperature sensor Design according to: DIN EN 60751 Accuracy class B 2-wire connection Technical Specifications Temperature/resistance correlation (series of basic values) /°C (*) Resistance at temperature t /°C [Ω] 1000 1004 1008 1012 1016 1020 1023 1027...

  • Page 25: Motor Protection Ptc 150°C

    Technical Specifications Motor protection PTC 150°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 –...

  • Page 26: Speed Sensor (Digital Differential Magneto Resistor)

    Technical Specifications Speed sensor (digital differential magneto resistor) Trouble-free evaluation requires good wiring. Ü Use twisted and shielded cables. Ü Connect the HF spindle based on the connection example shown below. Note: Resistor (Rx). If the resistor (Rx*) is already integrated in the evaluation unit (FC): Only connect signal and ground.

  • Page 27: Speed And Position Sensor (Sinusoid, Optional Accessory)

    Technical Specifications Speed and position sensor (sinusoid, optional accessory) Order number 1-003 The MiniCoder scans a target wheel (toothed wheel) made from ferromag- netic material. The magnetic field of the built-in encoder is modulated by the moving target wheel. Sample illustration: Toothed wheel The sensor detects the change in magnetic field and converts this into a si- nusoidal output signal.

  • Page 28: Speed And Position Sensor (Ttl, Optional Accessory)

    Technical Specifications Speed and position sensor (TTL, optional accessory) Order number 1-010 The MiniCoder scans a target wheel (toothed wheel) made from ferromag- netic material. The magnetic field of the built-in encoder is modulated by the moving target wheel. Sample illustration: Toothed wheel The sensor detects the change in magnetic field and converts this into a square-wave output signal (TTL).

  • Page 29: Eddy Current Sensor (Sgs, Optional Accessory)

    Technical Specifications 6.10 Eddy current sensor (SGS, optional accessory) Order number 1-001 6.10.1 Measurement principle The displacement measurement system operates without contact on the basis of an eddy current. An electromagnetic coil field induces eddy currents and this causes the resis- tance of the built-in coil to change.

  • Page 30: Eddy Current Sensor (Analog, Optional Accessory)

    Technical Specifications 6.11 Eddy current sensor (analog, optional accessory) Order number 1-007 6.11.1 General data Measurement distance 0 … 2 mm < 0.001 mm (static) Resolution < 0.005 mm (dynamic) Repeat accuracy < 0.02 mm Circuit diagram Linearity deviation ± 100 µm Temperature drift ±...

  • Page 31: Air-Borne Noise Emissions

    Technical Specifications 6.13 Air-borne noise emissions CAUTION: Noise has an impact on health. Only operate the HF spindle if you are wearing hearing protection. Item no. 10406075, Revision 01 31 ( 52 )

  • Page 32: Operating Location

    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.

  • Page 33: Installation

    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...

  • Page 34: Diameter Of Media Supply Line

    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 "...

  • Page 35: Compressed Air

    Installation Compressed air 8.4.1 Air purity classes (ISO 8573-1) Class 3 Solid impurities Filter grade at least 5 µm for solids Class 4 Water content Max. pressure dew point +3 °C Class 3 Total oil content Max. oil content 1 mg/m 8.4.2 Setting the sealing air For guidelines on air quality,...

  • Page 36: Setting Values

    Commissioning 8.4.3 Setting values For guidelines on air quality, Ü Keep to the following values: see "Air purity classes (ISO Taper cleaning 4,5 - 6 bar 8573-1)  35]" section. Pneumatic system for tool change ≥ 6,0 bar 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.

  • Page 37: Daily Start-Up

    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  36] section)

  • Page 38: Tool Change

    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.

  • Page 39: Pneumatic Taper Change

    Tool change 10.2 Pneumatic taper change DANGER: Due to flying parts. The taper cleaning could build up air pressure in the hollow shank taper dur- ing the tool taper change. This air pressure flings out the hollow shank taper in the case of sudden release. Always switch off the taper cleaning when the hollow shank taper is ap- prox. 1-2 mm away from the contact surface.

  • Page 40: Tool Changing Station (Optional Accessory)

    Tool change 10.3 Tool changing station (optional accessory) During a tool change, the HF spindle moves into the changing station with the clamped tool. Ü Note the following values when producing the changing station in order to compensate for the ejection travel (X): Spring loaded X = 2 - 5 mm Spring force...

  • Page 41: Workflow

    Tool change 10.4 Workflow 10.4.1 Pneumatic 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 Compressed Caution...

  • Page 42: Electrical Workflow

    Tool change 10.4.2 Electrical workflow Tool taper Compressed air on Clamped Released Ejected No signal Signal No signal inserted Signal No signal No signal Inserted No signal No signal Signal clamped 10.4.3 Signals Inputs Description Signal Action Cylinder back. Released Clamping system released.

  • Page 43: Tools For High Speed Cutting

    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.

  • Page 44: Maintenance

    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.

  • Page 45: Every Time The Clamping Device Is Changed

    Maintenance 12.2.3 Every time the clamping device is changed 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 Apply a light greasy film to the taper of the collet after cleaning. Ä...

  • Page 46: Dismantling

    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 Make sure that the shaft of the HF spindle has come to an absolute stand- still.

  • Page 47: Service And Repairs

    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).

  • Page 48: Malfunctions

    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.
  • Page 49 Service and repairs HF spindle becomes loud Cause Troubleshooting Only use balanced tools. (Also see the "Tools for high speed cutting [} 43]" 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...
  • Page 50 Service and repairs HF spindle vibrates/ Cause Troubleshooting oscillates Only use balanced tools. (Also see the "Tools for high speed cutting [} 43]" 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.

  • Page 51: Declaration Of Incorporation

    Tel. +49 (0) 60029123 -0 hereby declare that the product, Product High Frequency Spindle Type Z100-H642.15 S11W2 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.
  • Page 52 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 Z100-H642.15 S11W2 Item no. 10406075 Revision Date 20,02.2023 Language...

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