SERVICE MANUAL
Contents
1. 11 Daily R risIri PEOCBOllre usi oe et pd e ot Getae br dau 11 Abbreviated Run in Procedure for a Spindle with 1 2 2 hours of Idle 11 zype Pic E 12 Ambient Conditions 2 0 044000 00 12 LUBRICATION ec t 13 Grease LubriCallon eo oe I enc eO eite 13 PAW ONT AMG AMON pesce CE EE 13 Air Quality Specification for Air Oil 244 40404040 14 setup RECOMMENAA OMS ENSE 14 Procedure to connect the air oil lubrication 15 e MERE E 16 cg a say 17 FAI PUGO EN 17 Air Quality Specification for Air Purge 17 Procedure to Connect the Air Purge System 18 EG alr IG EN tied ate tv sa 19 Recommendations for Spindles Arranged with Bearing 0 5 19 Positive Internal Pressure PIP 2 4 300000 20 Air Quality Requirements 2 tee e Rie ne 20 Procedure to Connect a Positive Internal Air Purge PIP2. 21 SETCO AirShield SAS and USAS temi redes 22 Procedure to Connect the SETCO AirShield SAS and USAS 24 VIBRATION MEASUREMENT reiten renean eet 25 Instrumentation and orco er 25 Testing Rages d als 26 Vibration 5 eR RR 26 Magnet Mounted Transducer 444 124444440 26 Stud Mounted semet ei 26 Data Collections e 27 Baseline Signatut edet reiten tee etse te ende Oen ee een 28 ELECTRICAL CONNECTIONS tore toten ente reto teles 29 Supply Disconnecting 29 HYDRAULIC AND PNEUMATIC ACCESSORIES cesses 30 ug Publication No R 0007 5 final 27 2008 elo cmm C C C 31 Coolant Requirements General 31 Setup Recommendations oec ioter ie oet t bt e PON UE Dade cit 32 B aring M 32 Clustered Spindle 34 TRANSPORTING AND OPERATING CONDITIONS 35 Ambient Conditions
3. 35 Ambient Conditions 35 PERIODIC MAINTENANGQGE a Gov ain ER Tua 36 Coolant Management Laufe adus pd 36 Belt ene 37 ate 38 Drawbar Maintenance ER 38 Dry Floor and Tunnel Guarding poer dt epe o oc 38 General Considerations x oes edet n 39 TROUBLESHOOTING roro tette ote tetro detto cbe eser ere 40 PRODUCT SUPP OR iiit 41 SETCO Service Locations 2 ped 41 Notes Publication No R 0007 5 final 27 2008 SAFTEY PRECAUTION WARNING DISCONNECT ELECTRICAL POWER WHEN PERFORMING MAINTENANCE OR SERVICE ON EQUIPMENT THIS INCLUDES WHEN ADJUSTING OR CHANGING TOOLS WHEN MAKING MECHANICAL ADJUSTMENTS WHEN PERFORMING MAINTENANCE WORK OR PERFORMING ANY SERVICE TO THE SPINDLE WHEN REMOVING ANY GUARD WHEN REMOVING BELTS OR PULLEYS TO AVOID INJURY ELECTRICL POWER MUST BE OFF WHEN PERFORMING MAINTENANCE OR SERVICE ON EQUIPMENT DANGER MAIN POWER MUST BE OFF SERIOUS PERSONAL INJURY IS ALWAYS A HAZARD IN AN INDUSTRIAL ENVIRONMENT EXTREME CAUTIO
4. 12 13 REFER AIR OIL LUBRICATION UNIT MANUFACTURER S INSTALLATION PROCEDURES FOR MORE COMPLETE INSTRUCTIONS Mount panel in a convenient location near the spindle assembly for accessible service Make all required electrical connections Select monitoring time Select lubrication cycle time Make all required pneumatic connections Set pressure regulator for the pump and the air oil mixing blocks Fill reservoir with oil Install lube lines to lube bearing ports but do not connect Purge the system Start the air oil lubrication system AIR OIL LUBRICATION MUST BE STARTED A MINIMUM OF 15 MINUTES PRIOR TO STARTING THE SPINDLE ASSEMBLY AND MUST REMAIN ON FOR A MINIMUM OF 5 MINUTES AFTER THE SPINDLE HAS STOPPED AND THE COOLANT HAS STOPPED DRIPPING Check the oil lines to ensure that oil has reached the bearing inlets Connect lube lines to bearing lube ports Start the spindle assembly 15 Publication R 0007 5 final 27 2008 Oil Lubrication OIL LUBRICATION is the more common method of lubricating the gearbox of a precision gear driven spindle assembly A typical gear driven spindle assembly will have the spindle output bearings grease lubricated while the gear train input bearings and idler bearings will be oil lubricated REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING AND OR THE SPINDLE NAMEPLATE FOR THE RECOMMENDED OIL LUBRICATION SPECIFICATIONS USED IN THE PRECISION SPINDLE ASSEMBLY
5. CONTAINED IN THIS DOCUMENT MAY RESULT IN SPINDLE FAILURE PERSONAL INJURY AND OR VOIDING OF THE SPINDLE WARRANTY KEEP ALL UNAUTHORIZED PERSONNEL AWAY FROM SPINDLE ASSEMBLY AND OR ITS COMPONENTS DISCLAIMER The products described in this publication may employ or create hazardous conditions that could through misuse inattention or lack of understanding result in damage to the product or to the equipment or result in personal injury It is imperative therefore that personnel involved in the handling installation maintenance or use of this product read understand and comply to the operation of the product and the contents of this publication This document is based on information available at the time of its publication While efforts have been made to be accurate the information contained herein does not intend to cover all details or variations of the products nor to provide for every possible contingency in connection with handling installation operation or maintenance Features may be described herein which are not present in or on all products SETCO assumes no obligation of notice to holders of this document with respect to changes subsequently made SETCO makes no representation or warranty expressed implied or statutory with respect to and assumes no responsibility for the accuracy completeness sufficiency or usefulness of the information contained herein No warranties of merchantability or fitness for purposes shall a
6. FAILURE TO FOLLOW THIS INSTRUCTION MAY RESULT IN SEAL DAMAGE OR BEARING CONTAMINATION Clear away all accumulating chips and or other contamination from the spindle assembly on a regular periodic basis so that spindle drain holes are not restricted guarding to be designed to prevent coolant from pooling near the spindle drain holes conduit boxes electrical connectors etc Cleaning of the machine with high pressure coolant or steam cleaners must be avoided Spindles are not designed to be subjected to washing when they are not rotating Properly seal all hydraulic pneumatic and electrical connections Seals and gaskets can be susceptible to coolant ingress if not properly secured or if the sealing deteriorates over time All threaded connections and fittings must be sealed with pipe sealant Do NOT use pipe tape Spindle should be rotating at all times while coolant is on Stop all coolant flow before stopping the spindle Start the spindle before starting the coolant If this is not possible as in the case of using a rotating coolant union start the spindle and coolant at the same time 36 setco Belt Tensioning A loose belt will slip and not transmit enough power If the belt has too much tension spindle and motor bearing can be damaged The illustration right shows a typical belt tension instruction plate If this instruction plate is provided a belt tension specification for your spindle a
7. FEDERAL LAW PROHIBITS SHIPMENT OF AN OIL LUBRICATED SPINDLE WITH OIL IN THE RESERVOIR THEREFORE ALL SPINDLES MUST BE PROPERLY FILLED BY THE SPINDLE USER PRIOR TO INSTALLATION Oil fill holes are machined into the spindle gearbox and tagged with OIL FILL nameplates The gearbox should be filled to the proper oil level and monitored using the visual sight gauge provided on the spindle housing REFER TO THE SPINDLE OUTLINE ASSEMBLY FOR THE NUMBER SIZE AND LOCATION OF THE OIL FILL HOLES REFER TO THE SPINDLE OUTLINE ASSEMBLY FOR OIL TYPE SPECIFICATIONS SETCO recommends that the gearbox oil be changed every 1000 hours of operation FAILURE TO COMPLY WITH THE RECOMMENDED LUBRICATION SPECIFICATIONS MAY RESULT IN SPINDLE FAILURE SPINDLES SHOULD NOT BE STORED WITH THE GEAR OIL LUBRICATION IN THE RESERVOIR EMPTY ALL OIL FROM THE SPINDLE PRIOR TO STORAGE 16 Publication No R 0007 5 final 27 2008 SEALING SETCO precision spindles are designed with special sealing arrangements to protect the spindle and its bearings from contamination coolant ingress and condensation The most common of these sealing designs are Rubbing seal with air purge a positive contacting type seal Mini maze seal with air purge non contacting metallic type seal Bearing isolator a non contacting metallic labyrinth type seal Positive Internal Pressure PIP a low pressure air seal Air oil lubrication a medium pressure
8. DURING THE RUN IN PROCEDURE OR THE TEMPERATURE INCREASES MORE THAN 5 DEGREES FAHRENHEIT IN 1 MINUTE IMMEDIATELY SHUT THE SPINDLE OFF AND ALLOW IT TO COOL TO ROOM TEMPERATURE ONCE AT ROOM TEMPERATRE RE START THE RUN IN PROCEDURE AT THE STEP AT WHICH IT WAS SHUT DOWN Abbreviated Run in Procedure for a Spindle with 1 2 2 hours of Idle Time 1 Start the heat exchanger when required and run coolant throughout the motor coolant passages and bearing passages if required until the temperature stabilizes See pages 2 3 30 31 32 33 and SETCO s outline drawing for bearing and motor cooling operating cautions and parameters Verify that all required auxiliary systems are operating properly Run the spindle at 50 of the rated speed for approximately 3 5 minutes and monitor the front and rear bearing temperatures Start the machine for operation 11 Publication No R 0007 5 final 27 2008 STORAGE Attention must be given to the spindle assembly when it is not in production The following guidelines should be followed when the spindle assembly is not in service 1 spindle should be stored where it will not be subjected to the danger of bumping or excessive vibration due to jack hammers machines etc This phenomenon may cause severe bearing damage when the spindle is not rotating 2 spindle storage area should be clean dry with a stable temperature of 65 F to 120 F 18 C to 49 C a
9. PROCEDURE OR THE TEMPERATURE INCREASES MORE THAN 5 DEGREES FAHRENHEIT IN 1 MINUTE IMMEDIATELY SHUT THE SPINDLE OFF AND ALLOW IT TO COOL TO ROOM TEMPERATURE ONCE AT ROOM TEMPERATRE RE START THE RUN IN PROCEDURE AT THE STEP AT WHICH IT WAS SHUT DOWN 10 Publication No R 0007 5 final 27 2008 Increase the operating speed of the spindle to 50 of the rated speed for approximately 1 2 hour and repeat the temperature check Increase the operating speed of the spindle to 75 of the rated speed for approximately 1 2 hour and repeat the temperature check Increase the operating speed of the spindle to the full rated speed for approximately 1 2 hour and repeat the temperature check Start Up Procedure for an Idle Spindle 1 Week or More 1 Follow the initial start up procedure Daily Run In Procedure 1 Start the heat exchanger when required and run coolant throughout the motor coolant passages and bearing passages if required until the temperature stabilizes See pages 2 3 30 31 32 33 and SETCO s outline drawing for bearing and motor cooling operating cautions and parameters Verify that all required auxiliary systems are operating properly Run the spindle at 50 of the rated speed as shown on the nameplate for ten 10 minutes and check the front and rear bearing temperatures Start the machine for operation IF THE BEARING TEMPERATURE REACHES 140 DEGREES FAHRENHEIT OR HIGHER AT ANY TIME
10. Positive Internal Air Purge PIP System REFER TO AIR PURGE UNIT MANUFACTURER S INSTALLATION PROCEDURES FOR MORE COMPLETE INSTRUCTIONS 1 Mount manifold and gauge panel in a convenient location on the spindle assembly for accessible service 2 Run the required pneumatic connection but do not connect to the spindle 3 Purge the system 4 Connectair line to the spindle 5 Set pressure regulator 6 Start the air purge system AIR PURGE MUST BE STARTED PRIOR TO STARTUP AND OR EXPOSURE TO CONTAMINATING CONDITIONS COOLANT DUST HUMIDITY ETC FOR SHUT DOWN AIR PURGE MUST REMAIN ON FOR A MINIMUM OF 30 MINUTES AFTER THE SPINDLE HAS STOPPED AND THE COOLANT HAS STOPPED FLOWING 7 Check the air line to ensure that air has reached the air purge inlet 8 Start the spindle assembly 21 setco SETCO AirShield SAS and USAS The SETCO AirShield SAS is a patented spindle air purge seal system that uses regulated air pressure to back pressure a flexible lip seal to prevent contaminants and coolant ingress from entering the spindle SETCO also offers a compact version of the AirShield called the Universal SETCO AirShield See Fig 8 below The USAS design offers a smaller cross and can be used retrofit seal of spindle designs with cloe center distances The USAS provides the same sealing qualities as the original SAS design The USAS provides a precision machined steel housing that encases the flexible lip sea
11. REAR BEARING RETAINER CAPS WITH AIR PURGE INLET NAMEPLATES DO NOT MISTAKE AIR PURGE INLETS FOR PIP AIR OIL LUBRICATION OR SAS INLETS FAILURE TO COMPLY MAY CAUSE CONTAMINATION OF THE SPINDLE BEARINGS RESULTING IN SPINDLE FAILURE Air Quality Specification for Air Purge Sealing Inlet air temperature 70 to 90 F 21 to 32 C Inlet dew point temperature maximum 45 F 7 C Filter Size 5 micron absolute Filter efficiency 99 99 Inlet air pressure 10 to 15 psig at spindle inlet ports 69 to 103 kPa 17 Publication No R 0007 5 final 27 2008 In addition the recommended air purge system consists of 9 9 High pressure air supply system Regulator optional Regulator filter unit one per spindle assembly Pressure gauge one per spindle assembly Procedure to Connect the Air Purge System REFER TO AIR PURGE UNIT MANUFACTURER S INSTALLATION PROCEDURES FOR MORE COMPLETE INSTRUCTIONS Mount manifold and gauge panel in a convenient location on the spindle assembly for accessible service 2 Make all required pneumatic connections but do not connect to the spindle 3 Purge the system 4 Connect air lines to the spindle 5 Set pressure regulator 6 Start the air purge system AIR PURGE MUST BE STARTED PRIOR TO STARTUP AND OR EXPOSURE TO CONTAMINATING CONDITIONS COOLANT DUST HUMIDITY ETC FOR SHUT DOWN AIR PURGE MUST REMAIN ON FO
12. Suwanee GA 30024 Toll Free 1 800 830 4992 Western Service Center Huntington Beach California 92649 Toll Free 1 866 362 0699 England SIEMENS Cheshire England SK9 3PR Phone 011 44 1625 543 480 For additional information visit our website wwWW setcousa com 41 ER CNC Gear driven amp Motorized designs PRECISION SLIDES Dovetail Hardened Way amp Linear Bearing Designs EXPERT CNC SPINDLE REPAIR REBUILD amp RETROFIT SERVICES Most Any Make amp Model setco j RESET Senses s die Setco 000 543 0470 setcousacom Set for Life NES ns e mail sales setcousa com 2007 Setco Sales
13. block style housing provide vibration transducer mounting locations over the front and rear spindle bearings for vibration analysis These machined surfaces arranged with a tapped hole will accommodate either magnet mounted or stud mounted vibration transducers Data Collection Data Collection should be recorded using a spectrum analyzer and a magnet mounted transducer at horizontal vertical and axial directions in each bearing plane where possible Data should be taken at maximum spindle operating speed Data should be taken with the spindle at its steady state operating temperature For a motorized spindle amperage draw should be recorded using a clamp on current probe for all phases of the motor AVOID OPERATING THE SPINDLE AND OR DRIVE MOTOR AT OTHER SYSTEM COMPONENT TEST STAND MACHINE PLATEN V BLOCKS MOUNTING BRACKETS ETC RESONANT FREQUENCIES THAT WILL CAUSE THE VIBRATION DATA TO BE HEAVILY AMPLIFIED 27 ky Publication No R 0007 5 final 27 2008 Baseline Signature For comparative data initial base line vibration signatures should be taken to observe the following conditions While the spindle is on the test stand When spindle is mounted on the machine spindle only After tooling has been dynamically balanced and mounted to the spindle REFER TO THE SPINDLE START UP AND RUN IN SECTION OF THIS DOCUMENT These vibration signatures will allow for baseline readings to be established
14. operation of coolant union at maximum rated pressure with maximum rated speed If operating conditions are marginal consult the SETCO Service Team or the coolant manufacturer Rotating coolant unions that are equipped with grease fittings or oil cups require periodic lubrication Contact the coolant union manufacturer for a lubrication guide Do not run dry OQ Publication No R 0007 5 final 27 2008 START UP AND RUN IN PROCEDURES Although each spindle is ran off at SETCO prior to shipment it must further be ran off by the customer prior to being placing in operation This will ensure proper channeling of the bearing lubrication to prevent excessive bearing temperatures which could result in immediate bearing failure Prior to spindle start up and run in a check of any auxiliary systems for proper flows pressures and temperatures must occur All of the information when required is defined by SETCO outline drawing and described in this section The run in procedures are broken down into four sections The first section should be followed when the spindle is being operated for the first time The second section should be followed when the spindle is being operated after it has sat idle for a week or more The third section should be followed when the spindle is being operated after it has sat idle for 24 hours The fourth section should be followed when the spindle is being operated after it is has sat for a short pe
15. reading which can be reasonably compared to SETCO s reading at the time of shipment If all the vibration readings are acceptable the spindle can be mounted in its operating environment REMEMBER TO TAKE ALL THE PRECAUTIONARY STEPS NOTED IN THIS MANUAL WHILE INSTALLING THE PRECISION SPINDLE TO ENSURE PROPER OPERATION Once the spindle is mounted on the machine a second vibration reading should be taken prior to installing any tooling if possible If all the vibration readings are acceptable the tooling can be mounted to the spindle After the tooling is mounted a third set of vibration readings should be taken This reading will serve as a baseline for all future readings Progressive vibration readings as detailed above will allow the analyst to isolate between external spindle vibration and vibration which may be internal to the spindle Vibration analysis can prove to be an extremely valuable PM Predictive Maintenance tool Vibration data will not exactly duplicate that from SETCO because of different accelerometers magnets mounting methods etc Instrumentation and Equipment Instrumentation and Equipment required for conducting vibration analysis on a precision spindle assembly is as follows Spectrum Analyzer FFT Fast Fourier Transform Vibration Transducer 0 10kHz range for most spindles Vibration Test Stand Spindle should be analyzed on a test stand with known resonance properties AVOID TAKING VIBRATION MEA
16. which could be used by a vibration analyst to determine the trend of and future spindle conditions Once the spindle is in production it is recommended that vibration signatures be taken Approximately once a month for the first three 3 months to provide trend information This will serve as a comparative tool to the previous baseline signatures After this three month period vibration readings be reduced to approximately once every two 2 or three 3 months Documentation of all vibration measurements taken on the precision spindle assembly is extremely important This data can be analyzed and compared to previous measurements to predict scheduled downtime and spindle servicing It also can be used to diagnosis the spindle condition and determine the possible cause of spindle failure 28 ky Publication No R 0007 5 final 27 2008 ELECTRICAL CONNECTIONS Supply Disconnecting Device TURN OFF ALL ELECTRICAL POWER BEFORE OPENING GUARDS OR PERFORMING MAINTENANCE OR SERVICING EQUIPMENT REFER TO THE SAFETY SECTION OF THIS MANUAL Spindle motors are not equipped with any electrical disconnect device from the factory A disconnect device must be installed in each power supply circuit The disconnecting device must be one of the following types A switch disconnector A disconnector which has an auxiliary contact which in all cases causes switching devices to break the load circuit before opening of the
17. 08 TROUBLESHOOTING CHART Problem Contamination Chatter Problem Cause Corrective Action Redirect coolant flow away from spindle nose Stop all coolant flow before stopping spindle Coolant ingress Start spindle before starting coolant flow or at the same time Avoid cleaning the machine with high pressure coolant pressure washers or steam cleaners Lack of or no air purge on spindle Utilize Positive Internal Pressure PIP Store spindle a clean dry stable temperature and Condensation condensing environment Turn off all coolant flow when spindle is stopped Open guarding doors between shifts Improper direction or pressure from coolant nozzles Redirect coolant flow away from spindle nose Reduce coolant flow and pressure Bearing isolator drain port not arranged for attitude of spindle mounting Clean chips away from spindle drain holes Orient bearing isolator and or bearing retainer cap so that drain ports are directed toward the ground Improper guarding which does not allow chip or coolant dispersion Clean chips away from spindle drain holes Arrange guarding so that coolant is not allowed to pool Loose or incorrect seal of cover plates and or electrical connectors Loss of preload Properly seal and secure all connections Replace seals and gaskets if necessary Seal all threaded connections with
18. N IN ALL FACETS OF SAFETY SHALL BE MAINTAINED ALL COMPANY SAFETY STANDARDS PRECAUTIONS AND REGULATIONS OF 5 SHALL BE MAINTAINED DURING TRAINING ASSEMBLY AND DISASSEMBLY OF PRECISION SPINDLES AWARNING AWARNING AWARNING AWARNING AWARNING 4 Publication No R 0007 5 final 27 2008 GENERAL SAFEGUARDS DO NOT OPERATE THE SPINDLE ASSEMBLY AND OR ITS COMPONENTS UNLESS YOU HAVE READ THIS DOCUMENT RETAIN FOR FUTURE REFERENCE FOLLOW ALL WARNINGS AND INSTRUCTIONS MARKED ON THE SPINDLE ASSEMBLY AND OR ITS COMPONENTS 1 Read Instructions Read all the safety and operating instructions prior to operating a precision spindle assembly and or its components 2 Retain Instructions The safety and operating instructions of the precision spindle assembly and or its components should be adhered to These documents should be retained for future reference 3 Heed Warnings warnings on the precision spindle assembly its components and operating instructions should be adhered to 4 Follow Instructions operating and user instructions of the precision spindle assembly and or its components should be followed 5 Attachments and Equipment Never add any attachments and or equipment to the precision spindle assembly without approval of the manufacturer as such additions may result in spindle failure personal injury and or voiding of the warranty 6 Ser
19. R A MINIMUM OF 30 MINUTES AFTER THE SPINDLE HAS STOPPED AND THE COOLANT HAS STOPPED FLOWING 7 Check the air lines to ensure that air has reached the air purge inlets 8 Start the spindle assembly For precision spindles arranged with air purge SETCO recommends Air purge must hooked up and operational for all spindles arranged with air purge Only clean dry shop air should be utilized Air pressure should be maintained between 10 to 15 psi 69 to 103 kPa at the spindle inlet port Air purge must be operating at all times while coolant is flowing Proper pneumatic fittings and line size must be used for proper air purge operation 18 Publication R 0007 5 final 27 2008 Bearing Isolators BEARING ISOLATORS are labyrinth type seals that function as a pump Should contamination and or coolant enter the bearing isolator it pumps it out through various drain ports arranged in the bearing retainer caps and or the spindle housing As a result the spindle drain ports must be kept clear Spindles arranged with bearing isolators are typically used in conjunction with the PIP sealing arrangement Recommendations for Spindles Arranged with Bearing Isolators Drain ports must be oriented toward the ground ONLY THE DRAIN PORTS ORIENTED TOWARD THE GROUND ARE OPEN ALL OTHER DRAIN PORTS MUST BE PLUGGED REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR EXACT DRAIN PORT LOCATIONS S
20. SERVICE MANUAL Instructions for the Use and Care of Precision SETCO Spindles Publication 0007 5 Date of Issue May 27 2008 Issued By SETCO Sales Company 5880 Hillside Avenue Cincinnati Ohio 45233 513 941 5110 Repair amp Rebuild Services Setco Set for Life Publication No R 0007 5 final 27 2008 SETCO spindles super precision components that require the highest level of care and handling SETCO precision spindles are manufactured to the highest quality having passed inspection testing and run off procedures prior to shipment Compliance with the recommended care and handling procedures will ensure long spindle life reliability and the highest quality of performance when placed into service The purpose of this precision spindle care and handling manual is to assist in the proper handling installation operation and maintenance of the precision spindle assembly Some precision spindles are complex systems which require auxiliary support equipment for complete operation of the spindle A thorough background of the precision spindle assembly functionality and the operating parameters of its auxiliary support equipment is strongly recommended prior to putting the spindle into service Therefore SETCO recommends that the precision spindle assembly be maintained and operated by well trained and qualified personnel FAILURE TO COMPLY WITH THE PROCEDURES AND SPECIFICATIONS
21. SUREMENTS ON A SPINDLE MOUNTED TO A TEST STAND THAT HAS A RESONANCE NEAR EITHER THE SPINDLE OR MOTOR SPEED Clamp on current probe for recording amperage draw in the spectrum analyzer for motorized spindles 25 ky Publication No R 0007 5 final CO May 27 2008 Testing Procedure Testing Procedure should consist of vibration measurements taken in the directions and locations as stated below where possible Horizontal direction for block spindles perpendicular to the axis of rotation and parallel to the mounting surface Vertical direction for block spindles perpendicular to the axis of rotation and perpendicular to the mounting surface Axial direction parallel to the axis of rotation and parallel to the mounting surface TO MINIMIZE VIBRATION AND IMPROVE PERFORMANCE ALL TOOL ASSEMBLIES SHOULD BE BALANCED Vibration Transducers Vibration Transducers affixed to the precision spindle assembly can be magnet mounted or stud type mount If it is suspected that magnet resonance is affecting the measurements try using the stud mounted transducer Magnet Mounted Transducer Should have the appropriate geometric magnet to assure proper contact with the mounting surface of the spindle A flat rare earth magnet should be used when the transducer mounting location is on a flat surface two rail magnet must be used when the transducer mounting location is a round surface Do use a flat rare earth
22. T THE SPINDLE ASSEMBLY USING ONLY THE MOTOR FRAME EYEBOLT THE LIFTING ARRANGEMENT MUST PROVIDE A BALANCED LOAD AND STABLE CONDITION Transporting Spindles Transporting of the precision spindle assembly for service or to another facility requires that attention be paid to the packaging and crating Guidelines for Transporting a Spindle 1 When a precision spindle assembly is transported it must be bolted or banded to the container in which it is to be shipped so Fig 6 Lifting that damage does not occur Arrangement for Spindle and Motor 2 The spindle assembly must be completely enclosed within the Drive Assembly container 3 The container must properly support the weight of the spindle assembly 4 Allservice ports must be plugged when disconnected to prevent contamination from entering the spindle assembly 5 SETCO recommends shipping of the spindle in its original shipping container 6 To prevent excessive shear loading on the eyebolt threads apply lifting load in line with the eyebolt threads In other words the chains or lifting straps should be kept in line with eyebolt threads and perpendicular to the floor as much as possible Publication No R 0007 5 final 27 2008 MOUNTING THE SPINDLE Installation of the precision spindle assembly onto the machine must be handled with extreme care The spindle assembly must not be bumped or dropped to avoid damage The precision spindle assembly is t
23. URGE MUST REMAIN ON FOR A MINIMUM OF 30 MINUTES AFTER THE SPINDLE HAS STOPPED AND THE COOLANT HAS STOPPED FLOWING 7 Checkthe air lines to ensure that air has reached the air purge inlets 8 Startthe spindle assembly Note SPECIAL GUARDING AND OR ENCLOSURES SPINDLES EQUIPPED WITH THE SETCO AIRSHIELD REQUIRE NON OBSTRUCTED AREA SURROUNDING THE FRONT AND REAR SHAFT SPINDLE SEAL DO NOT ENCAPSULATE THE SPINDLE IN A STRUCTURE THAT INHIBITS FREE AIR MOVEMENT FROM THE SPINDLE ENCAPULATING MAY CAUSE SPINDLE COMPONENT FAILURE AND VOID WARRANTY SAS is an abbreviation for the standard Setco AirShield USAS is an abbreviation for the Universal Setco AirShield 24 ky Publication No R 0007 5 final 27 2008 VIBRATION MEASUREMENT Vibration analysis is one of the most valuable tools for qualifying a spindle and for predictive maintenance when done correctly Each spindle manufactured by SETCO is qualified through a vibration certification test which is electronically archived at SETCO Similar vibration testing should be conducted at the installation site for predictive maintenance information If proper care and time are taken to attain good reliable vibration data the spindle user can save tremendous amounts of time and money in minimizing their downtime due to catastrophic and unpredicted spindle failures While the spindle is on the test stand a vibration signature should be taken This will establish a baseline
24. air seal SETCO AirShield SAS a SETCO patented air purge seal design Ceramic Face Seals hydrostatic spindles 9 9 Although spindle assemblies are usually arranged with the same sealing arrangement at the front nose end of the spindle and the rear drive end of the spindle there are some applications that require a combination of the above sealing arrangements between the nose end and the drive end REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR THE TYPE OF SEALING ARRANGEMENT PROVIDED IN THE SPINDLE ASSEMBLY Air Purge AIR PURGE is positive low pressure applied to spindles providing an air barrier that protects against coolant ingress and contaminants Air purge is used in conjunction with a rubbing seal and or mini maze seal to provide additional protection to the spindle This design does NOT allow air to flow directly through the spindle bearings Air purge is introduced into the spindle through inlet ports in the spindle housing Some spindle designs such as cartridge housing configurations prohibit the air purge inlets from being in the housing therefore the air purge inlets are located in the front and or rear bearing retainer caps Also when equipped most spindles are arranged with air purge inlets at each end of the spindle REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR THE NUMBER LOCATION AND SIZE OF THE AIR PURGE INLETS AIR PURGE INLETS ARE TAGGED ON THE SPINDLE HOUSING AND OR THE FRONT AND
25. control of the spindle housing to maintain the centerline to centerline relationship of the spindle pattern These spindles are arranged with internal recirculating cooling by either a cooling jacket and or a continuous serpentine cooling groove machined in the spindle housing Coolant Requirements General Conditions Inlet temperature 80 to 85 F 27 to 29 C Coolant mixture 80 water and 20 Glycol Filter size 25 microns absolute Filter efficiency 99 99 Inlet pressure 425 psi maximum 2940 kPa MOTOR COOLING of a precision liquid cooled motorized spindle assembly is employed to dissipate motor heat from the motor stator providing better spindle performance This arrangement consists of recirculating coolant throughout the spindle housing and around the motor stator REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR RECOMMENDED COOLING REQUIREMENTS AND SPECIFICATIONS Cooling ports are machined into the spindle housing and are tagged with MOTOR COOLANT INLET and MOTOR COOLANT OUTLET nameplates REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR LOCATION AND SIZE OF COOLING PORTS 31 ky Publication No R 0007 5 final CO May 27 2008 Setup Recommendations For a liquid cooled motorized spindle that requires cooling of the motor Use a quality closed loop refrigeration unit for best performance gt Use the recommended installation and operating procedures provided by the manufacturer of
26. equires recirculating cooling Use a quality closed loop refrigeration unit for best performance gt Use the recommended installation and operating procedures provided by the manufacturer of the refrigeration unit To avoid thermal shock to the spindle assembly coolant flow cannot be completely stopped and then restarted while the spindle is rotating coolant return lines must be free flowing back to the refrigeration unit with no line restrictions or blockages Coolant temperatures must be within stated limits to avoid condensation and thermal shock to the spindle assembly All threaded connections and fittings must be sealed with pipe sealant 34 Publication No R 0007 5 final 27 2008 TRANSPORTING AND OPERATING CONDITIONS Ambient Conditions Transporting Ambient transporting conditions refer to the conditions the precision spindle assembly is subjected to during transportation Air Temperature 40 to 158 F 40 to 70 C Relative Humidity 95 maximum non condensing Atmospheric Pressure 9 to 15 psi 0 6 to 1 bar Vibration 3 5 mm maximum 2 to 9 Hz 15 m s maximum 9 to 200 Hz Shock 100 m s maximum 11 ms Bump 300 m s maximum 6 ms Free Fall Dropping a spindle in its shipping container packed or unpacked may result in damage that will effect performance and warranty If dropped a full inspection is required Consult factory Ambient Conditions Operatio
27. erious damage to the spindle assembly and or its components A SPINDLE ASSEMBLY AND CART COMBINATION SHOULD BE USED WITH CARE QUICK STOPS EXCESSIVE FORCE AND UNEVEN SURFACES MAY CAUSE THE SPINDLE ASSEMBLY AND CART COMBINATION TO OVERTURN Overloading Do not overload the precision spindle assembly and or its components The spindle assembly and or its components should be operated within their rated capacity Damage Requiring Service Disconnect all power to the precision spindle assembly and or its components and refer servicing to qualified service personnel under the following conditions a If the spindle assembly and or its components do not operate normally by following the operating instructions b If the spindle assembly and or its components have been dropped or the shipping crate has been damaged c When the spindle assembly and or its components exhibit a distinct change in performance d Ifthe spindle assembly and or its components have been wrecked e Ifthe spindle assembly exhibits a rapid change in operating temperature f Ifthe spindle assembly exhibits a rapid change in vibration level g Ifthe spindle assembly locks up and cannot rotate Publication No R 0007 5 final 27 2008 UNCRATING THE SPINDLE SETCO ships each precision spindle assembly in a highly stable shipping container to prevent damage to the spindle assembly during shipment The spindle assembly and its components are rigidly fi
28. ew point temperature maximum DP F Ambient Temp F 20 F Not to Exceed 50 F DP C Ambient Temp C 11 C Not to Exceed 10 C Filter Size 5 micron absolute Filter efficiency 99 99 Inlet air pressure 10 to 15 psig at spindle inlet ports 69 to 103 kPa AIR INLET PRESSURES MUST BE MAINTAINED AT EACH END OF THE SPINDLE INLET PORTS SUFFICIENT AIR VOLUME CFM MUST BE ESTABLISHED TO MAINTAIN AIR PRESSURE REFER TO THE SPINDLE OUTLINE DRAWING FOR SPECIFIC PORT LOCATIONS AND ESTIMATED FLOW REQUIREMENTS AIR QUALITY SPECIFICATIONS MUST BE MAINTAINED FAILURE TO COMPLY MAY CAUSE COOLANT INGRESS AND CONTAMINATION RESULTING IN SPINDLE FAILURE THE AIRSHIELD IS AN AIR PURGE TYPE SEAL SYSTEM DO NOT ENCAPSULATE THE SPINDLE IN A STRUCTURE THAT CHOKES AIR FLOW FROM THE SEAL S ENCAPSULATION MAY CAUSE SPINDLE COMPONENT FAILURE AND VOID THE WARRANTY 23 Publication R 0007 5 final 27 2008 Procedure Connect the SETCO AirShield SAS and USAS System 1 Mount manifold and gauge panel in a convenient location on the spindle assembly for accessible service 2 Make all required pneumatic connections but do not connect to the spindle 3 Purge the system 4 Connectair lines to the spindle 5 Set pressure regulator 6 Startthe air purge system AIR PURGE MUST BE STARTED PRIOR TO STARTUP AND OR EXPOSURE TO CONTAMINATING CONDITIONS COOLANT DUST HUMIDITY ETC FOR SHUT DOWN AIR P
29. factured to be lifted from the top are arranged with tapped holes in the top of the spindle housing for accepting eyebolts those that are to be lifted from the side have tapped holes for mounting swivel type hoist rings Securely fasten the eyebolts or swivel type hoist rings to the spindle Lift and transport the spindle using either a lifting strap or chains see fig 4 connected to a crane with adequate lifting capacity Fig 4 Use of a Lifting Strap or Lifting Chains Publication No R 0007 5 final 27 2008 Cartridge amp Flanged Cartridge Spindle Housings CARTRIDGE AND FLANGED CARTRIDGE SPINDLE HOUSINGS do not have provisions for lifting and transporting using eyebolts or swivel type hoist rings The proper method for lifting and transporting these types of spindle housing styles is by use of a lifting strap and crane Wrap the lifting strap around the spindle housing ensuring that the strap does not slip Ensure that the spindle is securely supported and balanced Use a crane with adequate lifting capacity to lift and transport the spindle see fig 5 SPINDLE ASSEMBLIES WITH MOTOR DRIVE PACKAGES employ the same procedures for lifting and transporting as described for the block style Fig 5 Lifting spindle housings In addition use a lifting sling or if provided the lifting Sling on a eyebolt secured to the motor frame to provide additional support and balance Cartridge Spindle see fig 6 DO NOT LIF
30. hipping container perform the following 1 Visually inspect the spindle assembly for any damage that may have occurred during shipment If damage to the spindle is evident immediately notify the trucking company and SETCO s service team 2 Locate the weight of the spindle assembly which may be found on the outline drawing the shipping container and or the spindle nameplate 3 Ensure the rated lifting capacity of the hoisting equipment crane straps chains etc is greater than the weight of the spindle and is in good condition 4 Refer to the spindle outline assembly drawing for the proper method of lifting the spindle assembly and for the locations and size of the lifting holes 5 Make sure the spindle assemblies eyebolts swivel type hoist rings or lifting bars are fastened securely and match the outline assembly drawing Note not applicable to cartridge spindles and flange type cartridge spindles 6 Pad all sharp edges of the spindle assembly that might come into contact with the lifting straps to ensure that lifting straps are not damaged NEVER LIFT OR TRANSPORT SPINDLE ASSEMBLY BY ANY OF ITS ROTATING COMPONENTS DO NOT CARRY LOADS OVERHEAD UNLESS ABSOLUTELY NECESSARY Publication R 0007 5 final 27 2008 Block Style Spindle Housings BLOCK STYLE SPINDLE HOUSINGS are designed to be lifted and transported using either eyebolts or swivel type hoist rings see fig 3 Spindles that are manu
31. ing screws are secured OVER TIGHTENING A DRIVE BELT CAN CAUSE BEARING OVER LOAD AND EXCESSIVE HEAT OVER TIGHTENING A DRIVE BELT MAY LEAD TO PREMATURE SPINDLE BEARNG FAILURE A MODERATE BELT DEFLECTION IS NORMAL SHORT CENTERLINE DISTANCES HAVE LESS DEFLECTION THAN LONGER SPANS 37 Publication No R 0007 5 final 27 2008 Lubrication Many machine components require lubrication to function properly It is important to ensure that all lubrication reservoirs are properly filled and maintained for oil cleanliness Refer to SETCO s outline drawing and the Oil Lubrication section for proper specifications and maintenance instructions Note that oil analysis is an excellent tool for trending lubrication condition For spindles with oil reservoirs check oil level after installation before running the spindle weekly change every 1000 hours of operation Drawbar Maintenance Visually inspect for dirt build up daily Clean as required Do not lubricate tool holding surfaces Dry Floor and Tunnel Guarding Dry Floor Guarding and Tunnel Guarding are used quite often in the machine tool industry on transfer lines These types of guarding create an environment with extremely high temperatures and humidity To reduce the possibility of spindle failure caused by condensation the following recommendations should be considered Utilize a mist collection system to remove excessive moisture from the inside of the machine gua
32. l in the stator stationary section A rotor or rotating cap provides the sealing surface for the lip seal Different from a PIP system which utilizes a labyrinth type seal the SAS and USAS systems use a stationary lip seal secured to the bearing end cap With the spindle stopped and with air purge off no air flow the lip seal forms a positive seal between the spindle arbor and the end cap When air pressure is applied escaping air lifts the seal face creating minimal backpressure and forming a near frictionless seal as the spindle rotates Two beveled surfaces outside of the seal lip see figure 7 form a uniform air purge generator as the spindle rotates As the flood coolant pressures increase additional pressure is applied to the sealing face further increasing the effectiveness of the SAS and USAS systems The air pressure maintains minimal clearance to prevent the lip seal from wearing 22 Bearing Publication No R 0007 5 final May 27 2008 aM PRESSURIZED AIR FLOW CROSS SECTION AIRSHIELD SYSTEM Fig 7 Diagram of the Patented SETCO AirShield Equalized and Dispersed Air Stator with Viton Seal Fig 8 View of the Patented Universal SETCO AirSheld Design USAS Publication No R 0007 5 final 27 2008 Air Quality Specification for SAS USAS Sealing Inlet air temperature 70 to 90 F 21 to 32 C Inlet d
33. le assembly to provide coolant through the spindle shaft Use the following procedures for installation of the rotating coolant union as a guide Superseded by rotating coolant union manufacturer s installation instructions Refer to manufacturer s literature for proper installation instructions Improper use may result premature leakage or failure of the coolant union Periodically inspect the coolant union for wear and tear as the seal wears out the coolant union must be replaced or repaired to avoid the consequence of leakage Keep vent holes clear and non restricted Should a drain line be required to redirect leakage contact the SETCO Service Team or the manufacturer of the coolant union Secure the rotating coolant union to the spindle shaft by o Connect both supply and drain hoses to the union before mounting the union on the spindle Thoroughly clean all mounting surfaces before installing the union Verify all drain holes run downward continuously Insert the male threads of the coolant union into the rear of the spindle shaft Using the proper tools on the rotor hex tighten the rotor threads until the male pilot on the rotor seats on the diameter and the face of the spindle shaft Verify thread form using outline drawing as reference No exterior bracing should be used to prevent the housing of the rotating coolant union from rotating Use only flexible connections DO NOT PIPE SOLID Do not install hose taut Avoid
34. magnet The two rail magnet must be firmly attached to the spindle to eliminate rocking Stud Mounted Transducer Should be mounted on a smooth flat surface at least the size of the transducer base A tapped hole should be used to secure the transducer to the spindle housing with enough threads to allow the transducer conducting surfaces to be tighten down without the threads bottoming out Transducer Mounting Surface Preparation is extremely important to assure repeatable vibration measurements The transducer mounting surface should be flat with a smooth surface finish for best results The transducer mounting surface should be clean and free of metal burrs or any other foreign particles that may interfere with the contacting surfaces Do not mount the transducer to a painted surface Do not mount the transducer to a rough surface 26 ky Publication No R 0007 5 final 27 2008 Transducer Mounting Preparation Apply a thin layer of silicone grease between the accelerometer and the magnet and between the magnet and the mounting surface This will help fill the microscopic voids between surfaces allowing better transmission of the vibration signal Unless otherwise specified by the transducer manufacturer use a torque specification of 40 in Ib 4 5 Nm when attaching the accelerometer to the magnet or when stud mounting it to the spindle surface Most SETCO spindles manufactured with the
35. main contacts of the disconnector A circuit breaker suitable for isolation The supply cable must be according to state and local safety regulations and capable of carrying the total RMS input current Power cables should be installed away from and separate from signal processing cables Use shielded cable for all control and signal processing equipment Prior to making any electrical connections verify that the motor power connector is compatible with the connection on the rear of the spindle REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR LOCATION AND SIZE AND OR DESIGNATION OF THE CONNECTOR REFER TO THE SPINDLE ELECTRICAL CONNECTION AREA FOR THE PROPER WIRING DIAGRAM ALL ELECTRICAL CONNECTIONS MUST BE WATERTIGHT CONNECTIONS After verifying that all mating connectors are correct carefully insert the plug into its proper location and tighten down on the receptacle to insure a good electrical connection is established LOOSE CONNECTIONS MAY RESULT IN IMPROPER SPINDLE OPERATION AND POSSIBLE MOTOR DAMAGE SETCO recommends that all threaded electrical fittings be sealed with pipe thread sealant and that all gasketing material be made of VITON Improperly sealed connections may result in motor shortouts and spindle bearing failure due to coolant ingress 29 ky Publication No R 0007 5 final 27 2008 HYDRAULIC AND PNEUMATIC ACCESSORIES If the spindle is equipped with a power drawbar connection
36. mperature 70 to 90 F 21 to 32 C Inlet dew point temperature max 45 F 7 C Filter Size 5 0 micron maximum Filter efficiency 99 99 The recommended air oil lubrication system consists of A quality air oil lubrication package that includes Pump manifold reservoir combination to include outlet check valve system fill check valve high pressure blowout assembly and pressure gauge Controller Pneumatic solenoid valve Low level switch Panel optional Pre oil filter Final oil filter Divider valve Cycle switch Air flow switch Low pressure check valve one per bearing lubrication point Air oil mixing block one per bearing lubrication point Nozzle adapter assembly one per bearing lubrication point Relief valve GENERALLY NOZZLE TUBES ARE REQUIRED THAT THE OIL RESTRICTION TO THE BEARING IS MACHINED INTO THE BEARING SPACERS Setup Recommendations Spindle drain holes must be oriented toward the ground Properly seal all hydraulic pneumatic and electrical connections Seals and gaskets can be susceptible to coolant ingress if not properly secured or if the sealing deteriorates over time All threads of hydraulic pneumatic and electrical fittings are to be sealed with pipe sealant when connected Do not use pipe tape 14 Publication R 0007 5 final May 27 2008 Procedure to connect the air oil lubrication system 10 11
37. n Ambient operating conditions refer to the conditions the precision spindle assembly is subjected to when installed and running Air Temperature 50 to 120 F 10 to 49 C Consult factory for temperatures exceeding this range Relative Humidity 5 to 95 non condensing No condensation allowed Vibration 0 3 mm maximum 2 to 9 Hz 1 m s maximum 9 to 200 Hz 35 ky Publication No R 0007 5 final CO May 27 2008 PERIODIC MAINTENANCE Coolant Management Coolant management is an extremely important subject that is often overlooked in the operation of a precision spindle assembly Coolant ingress to the spindle assembly may cause the bearing lubrication to break down be washed out or become contaminated with chips resulting in bearing failure long before its full life expectancy Although SETCO uses the best sealing methods available to protect the spindle assembly other factors can considerably reduce the life of a spindle assembly The following are recommendations by SETCO to improve the spindle environment by coolant management Check Cooling Inlet Ports For Leakage And Clean Once A Year Coolant nozzles must be directed at the tool and or workpiece and not at the spindle nose gt High pressure coolant spray directed at the spindle can overcome the spindle sealing arrangement Refer to the SEALING section of this manual AIR PURGE PIP MUST REMAIN ON ANYTIME THE SPINDLE IS RUNNING OR WHEN COOLANT IS FLOWING
38. nd non condensing humidity level This will help prevent harmful effects of condensation within the spindle 3 All service ports must be plugged when disconnected to prevent contamination from entering the spindle assembly 4 SETCO recommends that a log be maintained to ensure proper maintenance of the spindle 5 Rotate spindles by hand several revolutions each month REFER TO THE SPINDLE LUBRICATION SECTION FOR ADDITIONAL INFORMATION Ambient Conditions Storage Ambient storage conditions refer to the conditions the precision spindle assembly is subjected to during storage Air Temperature 40 to 158 F 40 to 70 C Relative Humidity 95 maximum No condensation allowed Atmospheric Pressure 9 to 15 psi absolute 0 6 to 1 bar Vibration 1 5 mm maximum 2 to 9 Hz 5 m s maximum 9 to 200 Hz Shock 100 m s maximum 11 ms 12 Publication No R 0007 5 final 27 2008 Because of the various applications encountered by a precision spindle assembly several methods of lubrication are employed To ensure the successful operation of a precision spindle assembly the importance of the correct type and method of lubrication cannot be over emphasized Grease Lubrication GREASE LUBRICATION is widely used in a precision spindle assembly since it provides the simplest and most economical method of lubricating bearings while providing some degree of protection against the ingre
39. o be carefully mounted onto the machine using chains or lifting straps and hoisting equipment having adequate lifting capacity NEVER FORCE A SPINDLE INTO POSITION A RUNNING OR SLIDING FIT IS RECOMMENDED NEVER FORCE A CARTRIDGE SPINDLE INTO A HOUSING WHEN USING POWER LIFTING DEVICES CARE SHOULD BE TAKEN NOT TO BIND THE SPINDLE For optimum spindle performance the mounting surface to which the spindle assembly is to mount must be to the highest quality including Cleanliness Strength Flatness Surface finish Vibration damping 9 9 Secure the precision spindle assembly to the mounting surface using the appropriate mounting hole locations bolt sizes bolts are not supplied by SETCO and standard torque values REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR THE MOUNTING HOLE LOCATIONS SIZE AND APPLICATION SPECIFICATIONS DO NOT OVER TIGHTEN THE MOUNTING BOLTS OVER TIGHTENING OF THE MOUNTING BOLTS WILL DISTORT THE SPINDLE HOUSING RESULTING IN IMMEDIATE SPINDLE FAILURE AND VOIDING OF THE SPINDLE WARRANTY After mounting is complete any pneumatic hydraulic coolant or electrical connections to the spindle should be completed if required Refer to the spindle outline assembly drawing for the required spindle services and the related specifications Publication No R 0007 5 final 27 2008 Mounting Accessories ROTATING COOLANT UNIONS are typically mounted on the rear of the precision spind
40. oop refrigeration unit for best performance gt Use the recommended installation and operating procedures provided by the manufacturer of the refrigeration unit To avoid thermal shock to the spindle assembly coolant flow cannot be completely stopped and then restarted while the spindle is rotating Bearing cooling ports must be connected separately from motor cooling ports unless specifically stated on the spindle outline assembly drawing All coolant return lines must be free flowing back to the refrigeration unit with no line restrictions or blockages Coolant temperatures must be within stated limits to avoid condensation and thermal shock to the spindle assembly All threaded connections and fittings must be sealed with pipe sealant 33 ky Publication No R 0007 5 final CO May 27 2008 Clustered Spindle Cooling CLUSTERED SPINDLE COOLING is employed for temperature control of the spindle assembly to maintain the centerline to centerline relationship of the spindle pattern This arrangement consists of recirculating coolant throughout the spindle housing REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR RECOMMENDED COOLING REQUIREMENTS AND SPECIFICATIONS Cooling ports are machined into the spindle housing and are tagged with COOLANT INLET and COOLANT OUTLET nameplates REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR LOCATION AND SIZE OF COOLING PORTS For a precision clustered spindle assembly that r
41. ough the bearings REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR THE PIP INLET LOCATION AND SIZE TYPICAL PIP INLETS ARE SAE 4 7 16 20 THREAD PIP INLETS ARE TAGGED WITH PIP ON THE SPINDLE HOUSING Since the air must flow through the spindle bearings special air quality requirements must be maintained Air Quality Requirements Air inlet pressure between 1 and 3 psi 0 07 to 0 21 bar at the spindle inlet port Air pressure settings are determined for each spindle during run in at SETCO Refer to the spindle nameplate for the recommended air pressure setting Air pressure must be monitored directly at the spindle inlet and not at the regulator Dew point level no greater than 32 F 0 C at the spindle Filter rating at 5 0 micron absolute Inlet air temperature of 70 to 80 F 21 to 27 C Estimated air flow of 4 scfm per spindle Filter Efficiency 99 99 9 AIR QUALITY SPECIFICATIONS MUST MAINTAINED FAILURE COMPLY MAY CAUSE COOLANT INGRESS AND CONTAMINATION RESULTING IN SPINDLE FAILURE AIR PURGE TYPE SEAL SYSTEMS SHOULD NOT BE OPERATED IN AN ENCAPSULATE STRUCTURE THAT CHOKES AIR FLOW FROM THE SEAL S THIS TYPE OF ENVIRONMENT STOPS AIR FLOW AND THE SPINDLE SEAL SYSTEMS WILL NOT OPERATE AS DESIGNS FAILURE TO FOLLOW THIS CAUTION MAY CAUSE SPINDLE COMPONENT FAILURE AND VOID THE WARRANTY 20 Publication No R 0007 5 final 27 2008 Procedure to Connect
42. pindles designed with the bearing isolator exposed must have the isolator expulsion port oriented toward ground All drain ports must be kept clear and open at all times to allow proper drainage Clear away all accumulating chips and or other contamination from the spindle assembly on a regular periodic basis so that the spindle drain ports are not restricted SPINDLES ARRANGED WITH BEARING ISOLATORS MUST BE ROTATING AT ALL TIMES WHEN COOLANT IS FLOWING FAILURE TO COMPLY MAY CAUSE COOLANT INGRESS AND CONTAMINATION RESULTING IN SPINDLE FAILURE All SPARE spindles arranged with the bearing isolator sealing arrangement should be checked and mounted for the proper drain port locations 19 Publication R 0007 5 final 27 2008 Positive Internal Pressure PIP System A Positive Internal Air Pressure system referred to as PIP is a low pressure air seal typically used in conjunction with spindles arranged with bearing isolators Spindles arranged with air purge or for air oil lubrication are not arranged with PIP DO NOT MISTAKE PIP INLETS FOR AIR PURGE INLETS By applying PIP a positive low pressure is created inside the spindle protecting it against condensation and coolant ingress PIP is highly effective in those environments which contain high humidity and or excessive coolant The low pressure air is directed into the spindle housing between the front and rear bearing arrangements requiring the air to flow thr
43. pipe sealant Verify lock up gap between front bearing retainer cap and housing is 0 005 to 0 010 minimum Verify bearing lock up and preload on bearings through front bearing assembly static compliance test If excess clearance is found adjust bearing preload Improper tool geometry Check tooling for balance and or excessive wear Reduce tool overhang 40 ky Publication No R 0007 5 final 27 2008 PRODUCT SUPPORT In the event that the spindle assembly is deteriorating should fail or general customer service is needed the following information should be provided to SETCO s service team Spindle serial number be found on the spindle nameplate or etched on the spindle housing Order number that the spindle was manufactured on can be found on the spindle nameplate or on the spindle outline assembly drawing the order number is the last five digits suffix of the type model number SETCO s spindle type as with the order number the spindle type is the prefix of the type model number Description of the current problem History of any predictive maintenance related to that spindle such as vibration analysis maintenance log etc SETCO Service Locations United States Great Lakes Service Center Novi Michigan 48375 Toll Free 1 877 773 5349 Midwest Service Center Cincinnati Ohio 45233 Toll Free 1 800 543 0470 SouthEast SETCO Service Center
44. pply No part of this document may be reproduced or transmitted in any form or by means electronic or mechanical for any purpose without the express written permission of the SETCO Corporate Office Do to continual improvement specifications are subject to change without notice For most current specifications visit our website setcousa com 2007 SETCO Sales Company SETCO AIRSHIELD and GOLD LINE are trademarks of the SETCO Sales Company ug Publication No R 0007 5 final 27 2008 Table of Contents SAFTEY PHEGAUTION eine e ette ete Dn ace 1 GENERAL SAFEGUARDS 2 UNGRATING THE SPINDLE 4 LIFTING AND TRANSPORTING 5 Block Style Spindle 05 2 2 44024 6 Cartridge amp Flanged Cartridge Spindle 7 Transporting rc Sed aes Ra Pat bua cee oe 7 MOUNTING THE SPINDLE noie Sto reatus 8 MOUNTING ACCESSOMN ECS oeste ber rne 9 START UP AND RUN IN 10 Initial Start up and Break in Procedure sssssseeseeeenen nenne 10 Start Up Procedure for an Idle Spindle 1 Week or More
45. rding Turn off all coolant sprays chip wash coolant through the shaft etc when the spindle is idle or stopped Open the guarding door between shifts This will reduce the internal humidity and prevent moisture from building up inside the enclosed environment Where possible reduce the volume of coolant flow 38 ky Publication No R 0007 5 final 27 2008 General Considerations Each spindle assembly is unique in its design and operation Spindle assemblies are arranged to accept various types of tool holders and accessories Therefore the following recommendations should be considered Always use proper tools when working on or with the spindle assembly so as not to cause damage to the spindle housing spindle internal components and spindle accessories Always use wheel guard which meets or exceeds the appropriate A N S I and 5 standards when using a grinding wheel with a spindle assembly tooling tool holders pulleys drawbars coolant unions and couplings must be dynamically balanced to the same specifications as the spindle assembly Mechanical runouts may result in high vibration levels and must be checked and corrected if necessary RUNOUTS MUST BE MORE CLOSELY CONTROLLED AT HIGHER SPINDLE SPEEDS Do not tighten cold quills in a hot spindle nose taper Spindle assembly must be cooled to the same temperature as the quill or the quill must be heated to the same tempera
46. riod of time 1 2 2 hours The following guidelines must be adhered to in order to ensure proper channeling of the bearing grease lubrication Improper spindle start up could result in spindle failure FEDERAL LAW PROHIBITS SHIPMENT OF AN OIL LUBRICATED SPINDLE WITH OIL IN THE RESERVOIR THEREFORE ALL SPINDLES MUST BE PROPERLY FILLED BY THE SPINDLE USER PRIOR TO INSTALLATION Initial Start up and Break in Procedure 1 Start the heat exchanger when required and run coolant throughout the motor coolant passages and bearing passages if required until the temperature stabilizes See pages 2 3 30 31 32 33 and SETCO s outline drawing for bearing and motor cooling operating cautions and parameters 2 Verify that all required auxiliary systems are operating properly AIR OIL LUBRICATION MUST BE STARTED A MINIMUM OF 15 MINUTES PRIOR TO STARTING THE SPINDLE ASSEMBLY AND MUST REMAIN ON FOR A MINIMUM OF 5 MINUTES AFTER THE SPINDLE HAS STOPPED AND THE COOLANT HAS STOPPED FLOWING 3 Run the spindle at 25 of the rated speed as shown on the nameplate for approximately 1 2 hour 4 Monitor the temperature of the front and rear bearings This can be done by taking temperature readings with a pyrometer at various locations around the front and rear housing If the temperature does not reach 140 degrees Fahrenheit move to the next step IF THE BEARING TEMPERATURE REACHES 140 DEGREES FAHRENHEIT OR HIGHER AT ANY TIME DURING THE RUN IN
47. rrangement is provided If the no specifications are available refer to the drive belt manufacturer for recommended belt tension specifications General Recommendations Check belt tension periodically during routine maintenance Adjust as necessary The illustration below shows how to measure arbor deflection as the result of belt tensioning The examples are provided to show how belt tension should vary with spindle size A drive belt should only be as tight as necessary to establish positive transmission of power without slippage Do not Publication No R 0007 5 final May 27 2008 Warning Loose drive belts will slip and not transmit enough power Over tightened drive belts can result in damage to the bearings and void warranty Refer to the drive belt manufacture for dedicated specifications Deflection 1 64 per inch of span deflection at force EXAMPLE STATIC LOAD TENSION Maximum Shaft Deflection Spindle Size STATIC INDICATOR READING SHAFT DEFLECTION UNDER STATIC LOAD 8050 0408 0005 over tighten the drive APO 8090 0808 0005 120 1008 0005 Ifthe pulleys are not aligned premature belt wear loss of power transmission and poor vibration reading will occur Check for drive pulley alignment After certain motor risers are adjusted belt tensioning will change as the locking screws are secured Check the belt tension after lock
48. s must be made prior to spindle operation Hydraulic and air connections are made through a rotary union located at the rear of the spindle Continuous hydraulic or air pressure is supplied to the union during spindle rotation SPINDLES EQUIPPED WITH A DRAWBAR MUST NEVER OPERATE UNDER POWER WITHOUT A TOOL HOLDER OR TOOL PLUG CLAMPED BY THE DRAWBAR HYDRAULIC UN CLAMPING PRESSURE SHOULD ONLY BE APPLIED AT SPINDLE STANDSTILL NEVER UN CLAMP THE DRAWBAR WHILE THE SPINDLE IS ROTATING RESIDUAL LINE PRESSURE SHOULD NEVER EXCEED 5 PSI 0 5 BAR HIGHER PRESSURE MAY RESULT IN HYDRAULIC OIL LEAKAGE AND MAY CAUSE DAMAGE TO THE ROTARY UNION FAILURE TO FOLLOW THE INSTRUCTIONS ABOVE MAY RESULT OF PERSONAL INJURY OR DAMAGE TO EQUIPMENT Hydraulic lines must be flexible and must not load the rotary union The hydraulic pressure must be within recommended operating range The spindle must never be rotated without the tool clamped to avoid spindle system damage and severe personal injury The recommended filtration for all hydraulic fluids is 10 microns IF POWER DRAWBAR IS EQUIPPED WITH A COOLANT UNION COOLANT MUST BE FLOWING WHEN ARBOR IS ROTATING 30 ky Publication No R 0007 5 final 27 2008 COOLING Various precision spindle assemblies such as liquid cooled motorized spindles require additional cooling to dissipate heat In addition various clustered spindle assemblies require recirculating cooling for temperature
49. ss of coolant and contaminants Grease lubrication provides Maintenance free operation Does not require re lubrication Spindles are permanently grease lubricated Lubricated for life 9 9 Air Oil Lubrication AIR OIL LUBRICATION is an extremely efficient and reliable method for lubricating bearings in a precision spindle assembly while providing some degree of protection against the ingress of coolant and contaminants It provides a medium pressure air sealing arrangement to the spindle assembly The oil lubrication to the spindle bearings is carried by air pressure at approximately 30 psi 2 1 bar Air oil lubrication is introduced into the spindle through inlet ports machined into the spindle housing Typically there is one port for each bearing in the spindle assembly REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING AND OR THE SPINDLE NAMEPLATE FOR THE EXACT AIR AND OIL LUBRICATION SPECIFICATIONS USED IN THE PRECISION SPINDLE ASSEMBLY REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR THE NUMBER LOCATION AND SIZE OF THE AIR OIL LUBRICATION INLET PORTS DO NOT MISTAKE AIR OIL LUBRICATION INLETS FOR AIR PURGE PIP OR SAS SETCO AIRSHIELD INLETS FAILURE TO COMPLY MAY CAUSE CONTAMINATION AND OR LACK OF PROPER LIBRICATION OF THE SPINDLE BEARINGS RESULTING IN SPINDLE FAILURE 13 Publication No R 0007 5 final May 27 2008 Air Quality Specification for Air Oil Lubrication Inlet air te
50. the refrigeration unit To avoid thermal shock to the spindle assembly coolant flow cannot be completely stopped and then restarted while the spindle is rotating Motor cooling ports must be connected separately from bearing cooling ports unless specifically stated on the spindle outline assembly drawing All coolant return lines must be free flowing back to the refrigeration unit with no line restrictions or blockages Coolant temperatures must be within stated limits to avoid condensation and thermal shock to the spindle assembly All threaded connections and fittings must be sealed with pipe sealant Bearing Cooling BEARING COOLING of a precision spindle assembly is employed to maintain a constant spindle temperature by recirculating coolant around the front spindle bearings This arrangement consists of recirculating coolant through the spindle housing and or front end bell and around the front bearing arrangement REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR RECOMMENDED COOLING REQUIREMENTS AND SPECIFICATIONS Cooling ports are machined into the spindle housing and are tagged with BEARING COOLANT INLET BEARING COOLANT OUTLET nameplates REFER TO THE SPINDLE OUTLINE ASSEMBLY DRAWING FOR LOCATION AND SIZE OF COOLING PORTS 32 Publication No R 0007 5 final 27 2008 For precision spindle which requires cooling of the spindle bearings Use a quality closed l
51. ture as the spindle assembly Failure to comply may result in over tightening of the quill which may make it difficult to remove and may result in damage to the spindle nose taper Do not operate the spindle assembly at speeds higher than its nameplate rating If over speeding occurs the spindle may fail due to excessive temperatures Do not operate the spindle assembly at speeds lower that its nameplate rating If under speeding occurs the spindle may not perform properly CONTACT SETCO S SERVICE TEAM FOR RECOMMENDATIONS TO OPERATING SPINDLE ASSEMBLY OUTSIDE ITS NAMEPLATE RATING Do not operate the spindle assembly with loose screws nuts keys any fasteners Failure to comply may result in damage to the spindle assembly or personal injury Do not bump or hammer on the spindle shaft as this may cause severe damage to the spindle bearings and or spindle shaft Never stand the spindle assembly on the end of the spindle shaft Do not lift or transport spindle assembly by its rotating shaft or any component attached to it Permanently grease lubricated spindles do not require additional lubrication Follow recommended belt tensioning installation procedures WHEN MOTOR RISERS ARE ADJUSTED SOME HEIGHT CHANGE MAY OCCUR WHEN LOCKING SCREWS ON THE RISER ARE TIGHTENED BELT TENSIONING SHOULD BE RECHECKED PRIOR TO INSTALLING THE BELT GUARD 39 setco TROUBLESHOOTING Publication No R 0007 5 final May 27 20
52. vicing Do not attempt to service the precision spindle assembly and or its components yourself as opening or removing covers and or guards may expose you to dangerous hazards Refer all servicing to qualified service personnel 7 Power Disconnect all power to the precision spindle assembly and or its components before any maintenance 8 Interlocks Do not by pass any protective interlocks built into the spindle assembly and or its components Disabling of interlocks may result in spindle failure personal injury and or voiding of the warranty Publication No R 0007 5 final 27 2008 10 11 12 13 14 Protection Always wear proper eye foot and head protection when lifting transporting and or operating any machinery Water and Moisture Unless approved by the manufacturer do not use the precision spindle assembly and or its components where they become immersed in water The spindle assembly and or its components are designed to function in moderate coolant applications Accessories Any mounting of the spindle assembly and or its components should follow the manufacturer s instructions and should use a mounting accessory recommended by the manufacturer if applicable Handling the Spindle Do not place the spindle assembly and or its components on an unstable cart stand tripod bracket or table The spindle assembly and or its components may fall causing serious personal injury and s
53. xed to the container using fasteners and or metal straps Prior to uncrating do the following 1 Inspect the shipping container for damage SERVICE MANUAL 2 Report any damage to the trucking company and to SETCO s Service Team Use and Care of Precision SETCO Spindles 3 Document any damage with photographs Issued SETCO Sales Company 5880 Hillside Avenue Cincinnati Ohio 45233 As you uncrate your spindle assembly please 513 041 5910 check to be sure that along with the spindle assembly and its components the following items are included 1 ASETCO Service Manual this document provides instructions for the Use and Care of Precision Spindles See Fig 1 2 ASETCO Gold Line TCT Certificate verifying tested performance see fig 2 3 A print of the precision spindle outline assembly drawing Lege Uncrating the spindle 1 Remove the fasteners and or metal straps that secure the spindle assembly to the container during shipment 2 Retain the lifting devices for lifting and transporting PRODUCT PASSED ALL SETCO TESTING REQUIREMENTS RESULTS ARE NEEDED CONTACT SETCO AT 513 941 5110 Fig 2 SETCO Goldline Certificate Publication No R 0007 5 final 27 2008 LIFTING AND TRANSPORTING IMPROPER LIFTING OF A SPINDLE ASSEMBLY CAN RESULT IN DAMAGE TO THE EQUIPMENT AND BODILY HARM TO PERSONNEL Prior to removing the spindle assembly from the s
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