The following steps should be followed prior to operating your EDAC Machinery/Gros-Ite spindle.
A precision spindle must be handled carefully. The spindle should not be bumped or dropped. Each spindle is securely packaged in a custom fitted shipping/storage case at the factory. It is recommended that this case be retained for storage of the spindle when it is not in use. It is also recommended that the lubrication inlet ports and well as any drains or vents that were plugged or covered during shipment remain plugged or covered until the spindle is mounted to the machine or into a bracket. These features should remain covered or plugged until the Oil Mist line(s) are ready to be connected to the spindle.
If the spindle is idle, or will not be used for more than 30 days, it should be stored in low humidity, and at normal room temperature (60-90 °F). To avoid contamination, all inlets must be plugged and all drains or vents must be covered to prevent the ingress of foreign particulate or liquids. Coat any unprotected metal surfaces with a metal protectant to prevent rust or corrosion. (See Start Up) The spindle shaft should be rotated during storage several revolutions by hand every 30 days. This will keep the bearings lubricated, as oil tends to settle in the bottom of the raceways during periods of long-term storage. This action also prevents false brinelling of the bearing races due to the inherent low-level vibrations present in most buildings.
As with any precision assembly, the mounting surfaces are critical to the spindle performance. All mounting surfaces (spindle and machine) should be stoned and wiped clean. This will eliminate any small nicks or burrs that may have occurred on the mounting surfaces during shipping and handling. Never deliver any shock loads or hammer a spindle. This will permanently damage the spindle bearings and result in reduced life.
Use pullers and jack screws whenever possible. Mishandling the spindle will void the warranty. For cartridge style spindles it is only necessary to tighten the clamping screws sufficiently enough to prevent the rotation of the spindle housing in the bracket. Over tightening of the clamping screws may destroy the built-in clearances to provide ideal performance of the spindle bearings. This can cause overloading and overheating of the bearings and result in chatter and vibration as well as shortening the life of the spindle.
If the spindle is belt driven: The proper tensioning of the drive belt is essential to the performance and life of the spindle. The belt should be tensioned enough to prevent slippage and vibration, but loose enough to prevent excessive radial load being transmitted to the rear bearings.
If your spindle is motorized and requires liquid cooling use PH balanced water based coolant with a rust inhibitor. A good coolant is a 50-50 mix of water and antifreeze. Water with high salt or mineral content should be avoided, as it tends to leave deposits in the internal porting, which can become plugged. The coolant flow rate recommended is 6 gallons per horsepower per hour at a temperature of 70-80 °F. If oil is used as the cooling media, the flow must be increased to 15 gallons per horsepower per hour. The coolant pressure at the spindle should not exceed 35 psi.
Oil Mist Lubrication System
The majority of EDAC Machinery/Gros-Ite designed (and most other competitor’s) spindles using Oil-Mist Lubrication were designed to use a Norgren Oil Mist Lubrication System consisting of the following:
- #B12-221-A2LA Filter/Regulator
- #10-015-004 Lubricator
- #18-001-015 Mounting Bracket
- #18-014-001-013 Solenoid Valve
Please contact EDAC Machinery/Gros-Ite if this spindle will be operated with a lubrication system other than a Norgren Oil-Mist System.
It is highly recommended that an air pressure switch be installed on the output side of the lubricator to ensure that there is oil mist pressure to the spindle. The signal from the pressure switch should be interlocked with the Start/Stop circuit for the spindle drive motor, preventing the starting of the drive motor unless oil-mist pressure is present. It is also highly recommended that an oil level switch be installed in the oil mist reservoir. This switch can be interlocked in the same manner as the pressure switch. The Oil-Mist Lubrication System should be installed at a point higher than the spindle being lubricated and not more than 15 feet from the spindle. The connecting oil mist line(s) should be arranged to eliminate any loops or sharp bends that could create oil puddles or restrict oil flow.
Use plastic tubing with a minimum inside diameter of 3/8″ from the lubricator to the spindle. All fittings and connecting tubing are to be deburred and flushed with clean, filtered solvent or oil and blown out with clean dry air prior to connecting to the lubricator and the spindle. This greatly reduces the chance of contamination entering the spindle. DO NOT use Teflon tape on any of the connections between the lubricator and the spindle. Teflon tape may break or flake off and travel into the oil mist orifices in the spindle causing a blockage. It is recommended that Loctite Hydraulic Sealant #569 be used. Use only brass, stainless steel, or un-plated steel fittings on the connections between the spindle and the lubricator.
Plated fittings should not be used as the plating can shear off and either block a mist orifice or damage the bearings. It is highly recommended that the oil mist be started, either manually or automatically, approximately 10 minutes prior to the start of the spindle. This allows sufficient wetting of the balls and raceways. Spent oil should be present at all of the vents and around the end caps. Additionally, it is highly recommended that the oil mist be allowed to operate for a period of 10-15 minutes after the spindle is shut down. This serves to act as a purging action to prevent the ingress of contaminants as the spindle cools down.
The air supply to the Oil-Mist Lubricator should be clean and dry. The use of a combination filter/dryer prior to the Oil-Mist Lubrication unit is highly recommended. A coalescent type dryer is preferred to the desiccant type dryer. EDAC Machinery/Gros-Ite recommends the use of a P/N 79895115 filter/dryer with a .01-micron filtration rating available from MSC Industrial Supply.
The oil used in the oil mist lubricator should be highly refined mineral based oil. Depending on the type and style of the spindle, the oil will have a viscosity of 54-66 SUS @ 100 °F or 150-165 SUS @ 100 °F. The specific type of oil used to lubricate the spindle is specified in the instruction manual included with the spindle.
A listing of approved oils is included in this on line manual.
Setting the Lubricator
The Norgren Lubricator has several adjustments that need to be made prior to operating the spindle. They are:
- Air Pressure at the regulator.
- Air Pressure at the spindle.
- Oil Drops per minute.
Included in this manual is a listing of the proper settings for your new EDAC Machinery/Gros-Ite spindle.
A temporary pressure gage should be installed in a tee at the spindle oil mist inlet to ensure proper setting of the pressure at the spindle. With the temporary gage in place and the oil mist line connected to both the lubricator and the spindle, adjust the pressure regulator to the setting supplied. This pressure is read on the gage mounted to the regulator body. Adjust the air bypass screw on the lubricator to the setting supplied. This pressure is read on the temporary gage installed at the spindle Oil-Mist inlet.
Once the pressures are set, adjust the drops per minute to the specified value.
Remove the temporary gage from the Oil-Mist line and connect this line directly to the spindle.
When the above adjustments and gage removal have been complete, allow the lubricator to run for 10-15 minutes and observe the vents and end caps on the spindle. There should be air and oil present at these points. Once the presence of air and oil have been verified, begin running the spindle. The temperature of the spindle should be monitored closely for the first hour of operation as a safety precaution.
Oil Mist Data
Type of Lubricator: SEE DATA IN MANUAL SUPPLIED WITH SPINDLE
Type of Oil: SEE DATA IN MANUAL SUPPLIED WITH SPINDLE
Air Pressure at Regulator: SEE DATA IN MANUAL SUPPLIED WITH SPINDLE
Air Pressure at spindle: SEE DATA IN MANUAL SUPPLIED WITH SPINDLE
Oil Drops per Minute: SEE DATA IN MANUAL SUPPLIED WITH SPINDLE
Spindle Test Data including test speed and stabilized operating temperatures are included in this manual on the EDAC Machinery/Gros-Ite Final Inspection Form included in the installation manual supplied with the specific spindle.
Although your EDAC Machinery/Gros-Ite spindle has been thoroughly tested to the full operating speed at the factory, we suggest that when you receive it, or after it has been sitting idle or in storage for thirty (30) days or more, the spindle should be run up gradually prior to full time operation.
We also suggest the following:
- First rotate the spindle by hand to insure that it spins unobstructed or without any noticeable noise.
- Then begin running the spindle at 10% of the max operating speed for a period of 15 minutes.
- If the temperature does not exceed 100 °F or if you have no temperature sensor, hot to the touch. Increase the spindle speed an additional 25% and run for 15 minutes.
- Continue this process increasing the speed each time by 20% until the full operating speed is reached. If at any time during the run up the spindle exceeds 120 °F the spindle should shut down and be allowed to cool to ambient temperature before restarting at the previous speed. If after a run of 15-30 minutes the spindle does not stabilize or show signs of stabilization contact EDAC Machinery/Gros-Ite for further information.
- Once stabilized at the full operating speed the spindle should run no hotter than 120 °F. After this initial startup is completed the spindle may be now run at the full operating speed immediately upon start-up. However, please note that if the spindle has been in storage for thirty (30) days or more, this process should be repeated.
If the machine the spindle is mounted to has an automatic speed ramp up, it is recommended to give the spindle a 15-30 second ramp up to full operating speed after the initial startup procedure has been completed.
Avoid installing a cold tool in a warm spindle. This is of particular importance with the shallow tapers in an internal grinding spindle. By installing a cold quill in a warm spindle, the quill will be positioned too deep in the spindle shaft taper due to thermal expansion from the heat. When the spindle assembly is subsequently cooled down you will create a shrink fit of the quill in the taper, and most probably, the quill cannot be removed without machining and doing potential damage to the bearings.