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Installation, Operation and Maintenance Instructions

Spindle Type: PKZ 50


Form #329319 (rev.8, March 2004)

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

Warning and Caution Symbols


WARNING: This symbol indicates the potential for serious injury if the instruction is not followed correctly. WARNING: This symbol indicates the potential for electrical shock if the instruction is not followed correctly. IMPORTANT: This symbol indicates the potential for damage to the high-speed spindle or other equipment in the system if the instruction is not correctly followed.

PKZ 50 Outline Drawing


78

PKZ 50 Accessories (ordered separately):


Spindle System Components:
Type PCW 310 frequency converter (or Type PCS 410) Type 7136 / 7137 cooling system

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

5/32 314033 3/16 314034 1/4 314036

Coolant (6 tube) 22.7


21.3

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

329204 329205 329443 329444 329445 329446

Consult factory for arbors not listed

Power Cable

Air Seal (6 tube)

Coolant (6 tube)

Page 2 of 17

Form 329319 PKZ 50 Instructions

1. General Description and Safety


The Type PKZ 50 spindle is a variable-speed, liquid-cooled spindle with an integral AC asynchronous motor. The AC motor requires power from a high frequency converter. A liquid cooling system cools the motor and bearings. The high-precision spindle bearings are permanently grease lubricated.

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!

2. Unpacking, Handling, and Storage


Unpacking and Handling:
Protect the spindle by keeping it in the steel storage box until it is installed. Save the storage box and all of the plastic plugs in the spindle fittings for future storage or shipment. IMPORTANT: Never rest the weight of the spindle on the nose. Never subject the spindle shaft to excessive force that can damage the bearings. Refer to Section 4 for a list of all the standard equipment (wrenches, tubing, cleaning tools and documentation) included with the spindle. Check that all necessary parts are present before starting installation.

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).

Page 3 of 17

Form 329319 PKZ 50 Instructions

3. Spindle Technical Specifications

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)

MOUNTING / WEIGHT Housing Diameter Mount Type Net Weight

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

Form 329319 PKZ 50 Instructions

0 .5 0 0 .4 0 Torque (Nm) 0 .3 0 0 .2 0 0 .1 0 0 .0 0

PKZ 50 Power / Torque Curves (S1-100%)

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.

1 .0 0 0 .7 5 0 .5 0 0 .2 5 0 .0 0 20000 25000 30000 35000 40000 45000 50000 S p e e d (rp m ) T o rq u e (N -m ) P o w e r (k W )

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

Form 329319 PKZ 50 Instructions

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:

Anti-Rotation Bracket Instructions:


Description: The anti-rotation bracket assembly is a two-piece supplemental safety mount used with precise fixed centerline spindles. The bracket provides additional operator protection in case the main machine spindle is accidentally turned on with the precise spindle installed. The Anti-Rotation bracket has been designed to be adaptable to a wide variety of machines. Adaptation and installation of the mount is the responsibility of the user. Some machining of the upper mounting plate will be required in order to mount it to the machine. If machining is required that goes beyond the guidelines and recommendations provided, contact precise for assistance. Installation: The anti-rotation bracket consists of two pieces: an upper mounting plate (called the anti-rotation mount) which attaches to the machine, and the anti-rotation bracket which slides over the spindle connection block (see Figure 5.2 for terminology). The mount is intended to remain permanently attached to the machine. The major dimensions of the mount as supplied are as shown in Figure 5.1. The anti-rotation mount must be bolted to the machine. Consult the machine builder before drilling and tapping mounting holes, or before loosening
Page 6 of 17

66.4 mm

17.5 mm

R 52 mm R 120 mm

Figure 5.1 Anti-rotation mount dimensions (upper mounting plate)

Form 329319 PKZ 50 Instructions

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.

Spindle Connection Block

AntiRotation Mount, #331242

Minimum allowable ass'y height

AntiRotation Bracket, #331241

Figure 5.2 Typical Installation

Contact precise if modifications beyond these guidelines are necessary.

Page 7 of 17

Form 329319 PKZ 50 Instructions

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.

Figure 5.3 Warning Label

To mount PKZ 50 into main machine:


1. Insert the PKZ spindle into the host machine. 2. Slide anti-rotation bracket into dovetail slot in anti-rotation mount, and over the PKZ 50 electrical connection box. Slide bracket in until it locks with spring-loaded ball. At no time should any adjustments be made to the anti-rotation bracket assembly while the spindle or main machine is running! 3. WARNING: The host machine spindle must remain stopped when the PKZ spindle is attached. Rotation of the host machine spindle can cause serious injury to personnel!

4. Make sure that the spindle nose is protected during the mounting steps.

To attach mounting arbor to PKZ 50:


Precise PKZ 50 mounting arbors are interchangeable to allow the use of the spindle on various machines. In addition, most PKZ 50 mounting arbors are interchangeable with PKZ 25 mounting arbors for a two-spindle system. Precise PKZ 50 spindles are normally shipped with a mounting arbor factory installed. The procedure for removing and installing a new mounting arbor is as follows: 1. Remove rear spindle connection plate (5 x M5 screws) with the arbor attached. IMPORTANT: Prevent dust and dirt from entering the rear spindle area when exposed. 2. If changing the arbor, remove arbor from connection plate by removing the six M5 socket head cap screws. 3. Clean the mating faces of new mounting arbor and connection plate. Grease O-ring (#115816, 44mm x 1.5mm) and insert into the front end of new mounting arbor. 4. Assemble the mounting arbor to the connection plate using the six M5 socket head cap screws. 5. Clean the mating faces of the connection plate and the PKZ 50 housing. Make sure that the two O-rings in the connection plate (one is on the pilot, and one on the face) are correctly positioned and attach connection plate/arbor to spindle using 5 x M5 screws. 6. Make sure that the spindle nose is protected during the mounting steps.

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Form 329319 PKZ 50 Instructions

6. Electrical Connections
Power / Thermistor Cable:

Refer to: Frequency Converter Operating Instructions

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

outer shield braided shield inner shield


GREEN-YELLOW

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.

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Form 329319 PKZ 50 Instructions

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:

PKZ 50 Power Cable (5m)

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)

Amphenol 5+10 receptacle on frequency converter


5
B

10
A

5-meter interlock cable with plug, from optional flow switch

Interlock receptacle on frequency converter

#176699 bypass plug (supplied with frequency converter)

If optional flow switch is not used, connect #176699 bypass plug to mating receptacle on frequency converter.

Figure 6.2 PKZ 50 Electrical Connection Drawing


Page 10 of 17 Form 329319 PKZ 50 Instructions

7. Liquid Cooling Connection

Refer to: Type 7136 / 7137 Cooling System Operating Instructions

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.

Figure 7.1 Type 7136 / 7137 Cooling System

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.

8. Bearing Lubrication Connection


The ball bearings are permanently grease lubricated and do not require a lubrication connection.

9. Labyrinth Air Seal Connection


PKZ 50 LABYRINTH AIR SEAL REQUIREMENTS Operating pressure: 0.2 bar maximum [3 psi maximum] Air quality: filtered to 5 micron level, free from oil and water (ISO Class 3: max. particle size 5 m, max. particle density 5 mg/m3 , dew point -20 C) 50 liters/min [1.8 CFM]

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!

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Form 329319 PKZ 50 Instructions

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

Figure 9.1 Labyrinth Air Seal Connection

10. SRP 6 Collets


The PKZ 50 spindle uses precise Type SRP 6 collets. Type SRP 6 collets are selfreleasing and therefore must be locked into the collet nut. Use the supplied #176051 collet assembly tool to lock the collet and collet nut together as shown in Figure 10.1.
assembly
cap

disassembly
cap

SRP 6 collet and collet nut assembled


collet nut collet

collet nut

collet nut SRP 6 collet

collet base base

Figure 10.1 SRP 6 Collet and Collet Nut Assembly

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.

11. Spindle Start-up and Operation

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

Form 329319 PKZ 50 Instructions

Spindle Start-up Programs:


IMPORTANT: The spindle must always be warmed-up at low speeds to prevent damaging the high-precision bearings!

New Spindle Start-up:


Use this spindle start-up program for the first start-up for a new spindle, or if the spindle has not operated for 2 weeks or more: 1. Start cooling system. 2. Turn on "Labyrinth Air Seal" air pressure (0.2 bar) 3. Start spindle at minimum speed and check for correct rotation. Stop spindle immediately if rotation is reversed and contact precise for assistance. 4. Warm-up spindle as follows: 25% of maximum speed for 30 minutes 50% of maximum speed for 60 minutes

Daily Spindle Start-up:


Use this spindle start-up program for the daily start-up, or if the spindle has not been idle for more than 2 weeks: 1. Start cooling system. 2. Turn on "Labyrinth Air Seal" air pressure (0.2 bar) 3. Start spindle and warm-up at 25% of maximum speed for 15 minutes

Additional Important Operating Points:

WARNING:

Follow these additional important safety points to avoid possible injury:

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

Figure 12.1 Cooling System Pump Strainer


Form 329319 PKZ 50 Instructions

13. Renewal Service


For any service problem, which requires disassembly of the spindle, or adjustments not covered by these instructions, the spindle should be returned to the nearest precise manufacturing or service facility. Any bearings or other worn parts will be replaced with specification components. Rotating assemblies will be re-balanced to original balance quality. After spindle is renewed, it must pass all mechanical and electrical tests required on new spindles. We highly recommend that the toolholder(s) and collet(s) used with the spindle be returned with the spindle for inspection in the interest of safety. In warranty situations, this is required. If service work is performed by other than a Precise authorized service center, then the entity performing the work assumes product liability for the service work performed.

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

Form: #329319 (March 2004) Page 17 of 17 Form 329319 PKZ 50 Instructions