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Contents
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. General Description and Safety .................... pg. 3 Unpacking, Handling, and Storage................ pg. 3 Spindle Technical Specifications................... pg. 4 Standard Equipment...................................... pg. 5 Mounting........................................................ pg. 6 Electrical Connections ................................... pg. 9 Liquid Cooling Connection ............................ pg. 11 Bearing Lubrication Connection .................... pg. 12 Labyrinth Air Seal Connection....................... pg. 12 SRP 6 Collets ................................................ pg. 13 Spindle Start-up and Operation..................... pg. 13 Maintenance .................................................. pg. 16 Renewal Service............................................ pg. 17 Warranty ........................................................ pg. 17
30
Power Cable
SRP 6 Collets:
3mm 4mm 316773 316774 316775 316776 3/32 1/8 314031 314032
145.7 159.7
80 h5
5mm 6mm
Mounting Arbors:
329447 Erickson #30 (1/2 13) Erickson #40 (5/8 11) Erickson #45 (3/4 10) Erickson #50 (1 8) Cat. V-flange Size 40 (5/8 11) Cat. V-flange Size 45 (3/4 10) Cat. V-flange Size 50 (1 8) BT 30 (Japan V-flange) (special applications only) BT 35 (Japan V-flange) BT 40 (Japan V-flange) BT 50 (Japan V-flange) 329200 329201 329202 329203
32.5
Top view
Power Cable
Coolant (6 tube)
Page 2 of 17
WARNING: Read all operating instructions carefully before operating the spindle, including the separate Safety Instruction (form #329139). It is absolutely necessary that all of the installation and safety requirements are understood and provided for before operating the spindle!
Storage:
Before storing the spindle, drain the coolant passages and blow clean with compressed air. A small quantity of rust inhibitor can be added into the coolant passages (the fittings marked WATER only!) and blown through with compressed air. Plug coolant fittings immediately after coolant is drained. Plug all other air fittings immediately after the tubing is disconnected. Clean spindle housing and protect with light oil or rust preventative (do not spray anything near spindle nose!). IMPORTANT: Store spindle in the original storage container in a dry, temperature-controlled environment. High humidity and temperature changes can cause condensation and internal spindle damage. Do not rest the weight of spindle on the shaft. Spindle shaft must be rotated a few turns every 3 months to prevent bearing damage. Use "new spindle" warm up procedure when spindle is re-started after storage of more than 2 weeks (see Section 11).
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TYPE
MOTOR Speed Range Torque (S1 100%) Power (S1 100%) Frequency Range Voltage Range Maximum Amperage Motor Type SPINDLE DRIVE Drive Type BEARINGS Bearings Mounting Lubrication Bearing labyrinth air seal SHAFT DATA Runout Accuracy Stiffness Balance Quality SPINDLE COOLING Cooling TOOL CLAMPING Collets SENSORS Motor Protection CONNECTIONS
PKZ 50
15,000 50,000 rpm 0.25 N-m [2.2 in-lbs] 1.3 kW [1.74 hp] at 50,000 rpm 250 - 833 Hz 45 - 150 VAC 5.8 amps at full torque AC asynchronous, 2-pole, 3-phase induction motor precise PCW 310 frequency converter (or Type PCS 410) Four (4) angular-contact, high-precision bearings, ABEC 7/9 precision Front and rear duplex sets, mounted in O arrangement with shaft length compensation to provide constant spring pre-load Permanent grease lubrication 0.2 bar [3 psi] positive air pressure at bearing seal to prevent bearing contamination 2 m [0.00008] maximum radial runout in spindle taper. Radial: 30 N/m [169,000 lb/in] Axial: 25 N/m [141,000 lb/in] 1 mm/sec maximum allowable vibration velocity at maximum speed (measured radially on spindle housing at front and rear bearings) Liquid (1 part Dowtherm SR1 to 2 parts distilled water) circulation through spindle housing using precise type 7136 / 7137 cooling system. precise SRP 6 collets (6 mm, 1/4" maximum collet capacity) PTC thermistor in stator liquid cooling (2 x 6mm tubes) labyrinth air seal (1 x 6mm tube) power cable (1 meter length with connector)
80 mm h5 Interchangeable mounting arbors. (Type 9080 plane mount can also be used for permanent mounting). 4.5 kg [10 lb] without mounting arbor
Page 4 of 17
0 .5 0 0 .4 0 Torque (Nm) 0 .3 0 0 .2 0 0 .1 0 0 .0 0
1 .5 0 1 .2 5 Power (kW)
Quantity 1 pc. 1 pc. 6 pcs. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 1 pc. 2 pcs. 1 pc.
15000
4. Standard Equipment
Standard Equipment:
The standard equipment included with the spindle will be the wrenches, tubing, cleaning tools, and instructions / documentation. Using the following lists, check that all equipment is present before proceeding with spindle installation.
Item PKZ 50 Standard Equipment Description #061423 17 mm open end wrench #176051 collet assembly tool #176535 M5 socket head cap screw (only if mounting arbor is not attached) #176991 Warranty registration card #307423 spanner wrench #314032 1/8 collet #314036 1/4 collet #327930 4 mm hex key wrench #329139 Safety Instruction sheet #329219 Operating Instructions (this manual) #329268 O-ring, 44 mm (only if mounting arbor not attached) #329284 outline drawing #329302 Warning label #329492 5 micron filter-regulator for labyrinth air seal #330646 6mm tubing adapters for cooling system #330985 Anti-rotation bracket and instructions
Page 5 of 17
5. Mounting
WARNING: To protect the operator from potentially serious injury from rotating or flying parts, it is the reponsibility of the machine operator to: 1. NEVER turn main machine spindle on when using the PKZ 50! For CNC machines, make sure that all of the spindle start codes have been removed from CNC programs. 2. Properly install the supplied Anti-Rotation Bracket to the host machine. 3. Engage and use the Anti-Rotation bracket as an additional safety device whenever the PKZ 50 is used. Before mounting PKZ 50 into the main machine, make sure that the supplied #330985 anti-rotation bracket has been properly installed on machine. Complete instructions for installing and using the Anti-Rotation Bracket are provided below, and additionally provided with the bracket:
66.4 mm
17.5 mm
R 52 mm R 120 mm
any existing bolts for the purpose of mounting the anti-rotation mount. Machining of the mount contour to match the machine and mounting hole placement is left to the discretion of the machine end-user. The inner 52 mm radius and outer 120 mm radius should not be machined, in order to preserve the dovetail length. Before beginning machining the mount, make sure that the mount will not interfere with any tool-changing arms, tooling, or fixturing. The positioning of the anti-rotation mount should also be checked in advance to be certain it is not in a position too low for the anti-rotation bracket to be able to enclose the spindle connection block. If the supplied anti-rotation mount will not reach an acceptable mounting surface, then a spacer block can be added. Total block height (anti-rotation mount plus spacer block) must not exceed 120 mm in order to maintain necessary stability. A minimum of two mounting holes are required. The recommended minimum hole diameter is [6 mm]. A counterbore is also required so that the contact surface of the anti-rotation mount remains unobstructed to allow the anti-rotation bracket to fit properly. If necessary, the #331241 anti-rotation bracket (bottom piece) may be machined for clearance. If this is done, the completed bracket assembly must reach at least halfway down the side of the spindle connection block. Only machine the bracket height if necessary. Do not alter the side walls that capture the spindle connection block.
Page 7 of 17
As an additional safety reminder, affix the supplied warning label (Fig. 5.3) in a location on the machine or on the PKZ 50 spindle within the view of the operator.
4. Make sure that the spindle nose is protected during the mounting steps.
Page 8 of 17
6. Electrical Connections
Power / Thermistor Cable:
The PKZ 50 spindle is supplied with a 5-meter [16 ft] combined power / thermistor cable with Amphenol 5+10 plug. The spindle power connector is wired as shown in Figure 6.1. The integral 3-phase, 2-pole AC asynchronous motor must be driven by and connected to a precise frequency converter, or a similar high quality variable speed AC drive.
PKZ 50 SPINDLE
MOTOR (3-PHASE)
THERMISTOR
1 1
2 3 4 2 3 4 "A" Block
GREEN
YELLOW
3
"B" Block
CONNECTOR (5 + 10)
Figure 6.1 PKZ 50 Wiring Diagram WARNING: Do not attempt any electrical connection before reading the operating and maintenance instruction provided with the frequency converter. Refer to the operating and maintenance instructions provided with the precise frequency converter for installation and operation information.
WARNING: Never connect the spindle when the frequency converter is on! Always disconnect the main power supply before making any connections. The combination cable also contains connection for the spindle thermistor. A thermistor is wound into the motor stator to protect the motor in case of high stator temperature. If the stator temperature exceeds 130C, the thermistor will signal the frequency converter to stop the spindle, and an error message will be displayed on the precise frequency converter.
Page 9 of 17
Electrical Connections:
The PKZ 50 electrical connections will be slightly different depending upon which precise frequency converter is used and if a flow switch is used. However, the basic connections are described in the diagram below:
Always disconnect mains power supply BEFORE making any spindle connections! Connect male Amphenol 5 + 10 connector from spindle to the mating connector on frequency converter. Tighten all four screws securely.
If optional flow switch is used, connect the 5-meter interlock cable from flow switch (with male 5-pin plug) to mating receptacle on frequency converter. (#176699 bypass plug must be installed into flow switch receptacle)
10
A
If optional flow switch is not used, connect #176699 bypass plug to mating receptacle on frequency converter.
PKZ 50 LIQUID COOLING REQUIREMENTS Required flow rate: Heat load: Allowable coolant temperature: Required coolant mixture: 0.35 liters/min [0.1 gal/min] 240 W at 100% motor load 24C +/- 6C [75F +/- 11F]
1 part Dowtherm SR1 to 2 parts distilled water
The spindle motor and bearings are cooled using liquid coolant circulation. The precise Type 7136 / 7137 Cooling System is normally supplied with the PKZ 50 spindle (See Figure 7.1). Read the operating and maintenance instructions provided with the Type 7136 / 7137 Cooling System for installation and operation.
Operation:
IMPORTANT: Cooling water must be circulating before starting the spindle. Failure to provide the necessary cooling will result in bearing failure and motor overheating.
Connection instructions:
IMPORTANT: Follow all of the installation instructions provided in the cooling system operating instructions. Do not place cooling system near heat generating equipment, in dusty or contaminated locations, or in unventilated cabinets. If the Type 7136 / 7137 cooling system is used, install the two #330646 fittings (6mm tubing) supplied with the spindle. One fitting must be installed in the pump output. The other fitting must be installed in the return port. If the optional flow switch box is used, then follow the instructions provided with flow switch box for proper installation. The coolant tubes should be kept as short as possible and without kinks. Remove and save the plugs in the coolant fittings on the spindle. Connect the coolant tubes (6 mm) to the coolant fittings on the spindle. It does not matter which spindle fittings is IN or OUT. If tube lengths greater than 5 m [16 ft] are used, or if the spindle is more than 1.5 m [60"] above the pump, then check the flow rate. To measure flow rate, disconnect the return
Page 11 of 17 Form 329319 PKZ 50 Instructions
coolant tube at the cooling unit and time the flow into a measuring container. Flow rate must be at least 0.35 liters/min [0.1 gal/min] for full power operation. IMPORTANT: The cooling system must be filled with a mixture of 1 part Dowtherm SR1 (#328970) rust inhibitor and 2 parts clean distilled water. Do not use automotive anti-freeze as coolant. Check coolant level in sight glass again after starting cooling system filling the coolant lines. Add additional coolant to reservoir if needed.
Air Consumption:
Operation:
The PKZ 50 spindle is equipped with a labyrinth air seal feature, which provides a positive air pressure seal at the spindle nose to help prevent contaminants from entering the front bearings. Cleanliness of the air supply is critical to prevent damaging the bearings.
IMPORTANT: 1. The air supply must be clean and dry. It is the responsibility of the user to make sure that the air supply does not contain a high degree of water or oil vapor. If water/oil regularly collects in the filter bowl, a water/oil removal system must be installed in the air line or the bearings may be damaged! 2. The labyrinth air seal air pressure (0.2 bar) must be ON before grinding or cutting fluid is turned on, during operation of the spindle, and during spindle cleaning. The air pressure should be left on for 15 minutes after the spindle has stopped, to prevent ingress of dust and coolant as the spindle interior is cooling. 3. Do not exceed 0.2 bar [3 psi] air pressure! Excessive pressure will damage the bearings.
Connection instructions:
Connect the supplied 6 mm tubing (5 meter maximum length) to the fitting on the spindle as shown in Figure 9.1. Connect the other end to the 6 mm quick connect fitting on the supplied 5 micron filter / regulator. Adjust pressure to 0.2 bar (3 psi). Never exceed 0.3 bar (3 psi)! Too much pressure will damage the grease in the bearings!
Page 12 of 17
A shut-off valve (or 2-way solenoid valve) should be provided in the air supply for ON/OFF control of the labyrinth AIR SEAL.
5-micron filter/regulator Adjust to 0.2 bar 6 mm tubing Input air supply Air Seal
disassembly
cap
collet nut
WARNING: Make sure that the collet and collet nut are installed correctly, as shown in Figure 10.1. An incorrectly installed collet will not tighten properly. Serious injury to personnel can result from tools flying out of an improperly tightened collet! Never start the spindle without proper safety guards in place to protect against flying tools. Always wear safety glasses with side shields. Use the supplied #061423 17 mm open-end wrench to lock the spindle shaft. Use the supplied #307423 spanner wrench to tighten and loosen the collet. Never tighten collets unless a tool shank is inserted, to avoid damaging the collet! Tool shank size must be within +/- .01mm [0.0004"] of nominal collet size to maintain the accuPage 13 of 17 Form 329319 PKZ 50 Instructions
racy and clamping power of the collet. After clamping a tool, check runout before operating. Runout should not exceed 0.025mm [0.001"] T.I.R. at tool point. Specific tools and applications may require lower runout, so only use this as a starting point. Excessive tool runout creates a potential risk of injury from tool breakage due to high imbalance forces and/or high vibration or cutting forces. WARNING: Always accelerate the spindle up to speed slowly and cautiously, after mounting a new tool. Stop the spindle immediately if you detect any unusual vibration or noise. Noticeably higher levels of spindle vibration and/or noise can indicate a potentially dangerous situation with risk of serious injury to personnel due to tool breakage, and/or tools flying out of the spindle. Never start the spindle without proper safety guards in place to protect against flying tools. Always wear safety glasses with side shields.
Safety checklist:
WARNING:
To avoid injury, always check these safety items before operating the spindle:
1. Make sure that all of the following operating instructions have been read, understood, and properly followed before operating the spindle: Safety Instruction Manual (Form #329139 bright yellow sheet) PKZ 50 manual Frequency converter and cooling system manuals 2. Wear safety glasses with side shield or goggles at all times. 3. Install and engage the Anti-Rotation bracket. 4. Check to make sure that the main machine spindle will not start or rotate after the PKZ 50 has been installed. 5. Make sure that suitable high-strength safety guards are in place to shield the operator from all rotating parts. 6. Remove all wrenches from spindle nose. 7. Make sure that any tool installed into the spindle nose (cutting tool, grinding arbor, grinding wheel, toolholder, etc.) is dynamically balanced and structurally designed for the intended operating speed. Contact the manufacturer of the tool if necessary, and consult ANSI-B7-1 for guidelines concerning grinding wheels. Never operate a tool above the manufacturers maximum safe operating speed rating!
Page 14 of 17
WARNING:
1. Never turn on main machine spindle with PKZ 50 installed! 2. Always check tool runout before operating. Tools with high runout can break at high speeds! 3. Always increase spindle speed slowly and cautiously after mounting a new tool. Stop spindle immediately if you notice any unusual noise or vibration. 4. Always true grinding wheels at low speed first before increasing to operating speed. 5. Never continue to operate spindle if you notice excessive noise, chatter, or poor surface finish. High levels of vibration can cause tool failure and/or spindle damage. Adjust cutting parameters accordingly to reduce vibration. 6. Avoid excessive tool lengths. In general, avoid using tools with length to diameter ratios greater than 5:1. Contact precise for analysis of any untested tools before operating! 7. Never operate at or above a speed that produces a natural frequency! It is possible that a natural frequency can occur within the spindles speed range if long tooling is installed. Operating the spindle at the natural frequency will result in high levels of vibration, and may cause tooling breakage and/or projectiles! Contact precise for analysis of any questionable or untested tooling before operating.
Page 15 of 17 Form 329319 PKZ 50 Instructions
IMPORTANT: Follow these additional operating points to avoid damaging the spindle system:
1. Always protect the spindle nose from impact and contamination to avoid damage to the high precision bearings. 2. Never point a coolant stream directly at the spindle nose, particularly when the spindle is stopped. 3. If a vacuum scavenge system is used, always position the suction port lower than the spindle face to prevent pulling dust into the labyrinth area. 4. Only use precise Type SRP 6 collets. 5. Replace all damaged collets.
12. Maintenance
Spindle:
Clean regularly with a vacuum; never use compressed air! A complete cleaning of the spindle front end should be done regularly by carefully wiping away chips and dirt. For dusty applications, use a vacuum to remove the dust as it is loosened. IMPORTANT: Make sure that the labyrinth air seal is ON when cleaning the spindle nose. Never use compressed air for cleaning the spindle. Clean the collet and collet nut after every tool removal. The collet must be absolutely dirtfree to maintain accuracy. Make sure collet slots are clean. Lightly oil the collet and collet nut. Damaged and dirty collets / collet nuts will impair the performance of the spindle and may lead to damage. Clean or replace these parts as needed.
Cooling system:
Check cooling system fluid level periodically and add distilled water as needed to replace evaporation loss. Replace loss due to spillage with 1 part Dowtherm SR1 and 2 parts distilled water. After 5 years (maximum time), drain cooling system, flush with clean water, and refill with 1 part Dowtherm SR1 to 2 parts distilled water. Check cooling system reservoir periodically for build-up of algae or slime. Drain, flush, and refill system immediately if build-up is noticed. Refer to environmental guidelines in your area for disposal of old coolant. Consult the Material Safety Data Sheet included with Dowtherm SR1. Clean pump strainer monthly to prevent blockage and poor flow rate (see figure 12.1). Clean heat exchanger fins when dirty to maintain effective heat transfer. Refer to the Type 7136 / 7137 operating and maintenance instructions for further maintenance points.
Page 16 of 17
14. Warranty
We warrant our products against defects in material and workmanship and also against defects in design of the products to meet the product's intended purpose if experienced during the first 12 months from the date of invoice by precise. Under the warranty, we shall repair or replace products or components which prove to our satisfaction to have been defective as to material, workmanship or design and which have not been misused, altered, or carelessly handled. In order to take advantage of this warranty, the complaint must be immediately submitted in writing, and the product must be returned, not dismantled, shipped prepaid and within the warranty period, to the precise factory. We reserve the right to decline responsibility under this warranty where repairs have been made or attempted by others, where the product has been used for a purpose other than its intended purpose, or where the customer has not complied with the Operating and Maintenance Instructions supplied with each product. This warranty is limited to the repair or replacement of the product or component proven defective and shall not extend to any damages, actual or consequential, which may be caused by the defective product. We reserve the right to make structural changes in the product without prior notice. This warranty is exclusive, and is in lieu of all other guarantees or warranties whether written, oral or statutory, and, except as expressly provided in this statement as to the intended purpose of the product, is in lieu of the implied warranty or merchantability and the implied warranty of fitness for a particular purpose.
The Precise Corporation 3715 Blue River Ave. P.O. Box 085000 Racine, WI 53408-5000 USA Phone: +1 (262) 632-6173 Fax: +1 (262) 632-6730 e-mail: precise@precise-corp.com www.precise-corp.com
Precise Przisionsspindeln GmbH Am Wallgraben 2 D-42799 Leichlingen, Germany Postfach 1461 D-42785 Leichlingen Telefon: +49 (0 21 75) 9 71 0 Telefax: +49 (0 21 75) 9 71 99, 9 71 97 e-mail: precise@precise.de www.precise.de