Foredom K1050 User Manual

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Page 1

FOREDOM

Operation and Maintenance Manual for K.1050 Brushless Micromotor Kit

HP4-717 HP7-7060 Foot Control

HP4-933 Cradle

Control

H.MH-150 Handpiece

For Your Safety:

Read this Manual before operating your Foredom Micromotor Power Tool.

Always wear eye protection while operating this Micromotor.

Page 2

Safety Instructions

A Micromotor Handpiece is a high speed rotary power tool which can be dangerous and cause serious injury if it is not used properly. without wearing eye protection.

• ALWAYS wear proper eye and face protection.

• ONLY use accessories rated for 50,000 rpm or higher speeds when

operating this micromotor. Follow the Allowable Rotation Speed chart on page 9 of this manual for safe operation when using accessories with head diameters of more than 3/32″ (2mm).

• ALWAYS observe the manufacturer's maximum speed rating when using any accessory.

NEVER use or continue to use any accessory which appears to be damaged, loose,

• vibrating, bent, or out of balance. Inspect each accessory for cracks or flaws before use.

• ALWAYS insert the shank or arbor of an accessory or mandrel into the collet or chuck of the handpiece as far as possible in order to provide proper support and close the collet or chuck securely.

• NEVER use excessive side pressures which may tend to bend or break the shank or arbor of an accessory. Let the speed of the accessory do the work.

• DO NOT stall the motor by jamming or using excessive pressure on the mounted point, buff, wheel or accessory. This can result in damage to the motor.

NEVER operate it

WEAR a dust protector, mask or respirator to prevent the inhalation of harmful dust or

• debris from grinding, carving or other operations performed with this power tool.

• NEVER operate with a damaged power cord. If the power cord or plug to the handpiece is damaged, repair or replace immediately.

• USE a dust collector (vacuum system) to pull sawdust, grinding dust, or other debris away from the work area and the micromotor intake vents.

• NEVER turn on or start the Handpiece while chuck is in open (unlocked) position. This can damage the handpiece. Make sure that a bur is installed and secured in the collet, that the spindle is NOT locked and that the bur can spin freely. Always operate and store it with a bur or other accessory in the chuck and with the chuck in the closed position.

DO NOT operate the handpiece in the presence of any flammable liquid or gas.

•

Page 3

Components

1 Control Unit (HP4-717) 2 Speed Display 3 Motor On/Off Switch 4 Motor On Indicator Light 5 Auto Cruise Switch 6 Auto Cruise On Indicator Light 7 Speed Control Knob 8 Forward/Reverse Selector Switch 9 Forward/Reverse Indicator Light

10 Hand/Foot Selector Switch 11 Hand/Foot Indicator Light 12 Power On/Off Switch & Light 13 Handpiece Plug Outlet 14 Foot Pedal Plug Outlet 15 Power Cord Plug Outlet 16 Fuse Holder with spare fuse 17 Test Bur 18 3/32″ Collet (1/8″ is optional)

Collet part numbers and sizes are listed on page 7.

19 Handpiece (Brushless DC

Micromotor H.MH-150)

20 Handpiece Motor Cord 21 Handpiece Cradle

(HP4-933)

Handpiece Holder

Chuck Wrench

Foot Pedal

Foot Pedal Cord

Power Cord

(HP7-7060)

25 24 26

21 22

Page 4

Complete Kit (Fig. 3)

Control Unit, Power Cord

Handpiece Handpiece Holder,

Phillips Screw, Washer

Foot Pedal

Handpiece Cradle

Chuck wrench

AC Power Input (Fig. 4)

1. Check the label on the rear of the Control Unit to

make sure that the electrical specifications match your AC power.

2. If the fuse needs to be replaced ( Fig. 6), replace it

with identical type and rating only– 5x20mm,SLOBLOW, 3.15A, 250V. For a 230V Micromotor use a 5x20mm,SLO-BLOW, 1.6A, 250V. The Fuse Holder 16 contains a spare fuse (Fig. 5).

CAUTION

• Never plug or unplug the Power Cord with wet

hands to avoid electric shock.

• Use only with a grounded AC power receptacle.

Installation

CAUTION

• The Control Unit should rest on a flat, steady

surface. Avoid blocking the ventilation openings in the bottom of the case.

• Use the Control Unit in locations that have a

temperature below 100ºF. Avoid excessively dusty, hot or humid locations.

Page 5

Set-up and Electric Connection

1. Fix the Handpiece Holder 22 to the right side of the Control Unit with screw and washer. (Fig.7).

2. Plug the Handpiece Motor Cord

13 located in the rear of the Control

26 into the Power Connector 15

Motor Connector Unit and then tighten the plug nut. (Fig.8).

3. Plug the Foot Pedal Cord 14 located in the rear of the Control Unit. (Fig.8)

4. Plug the Power Cord in the rear of the Control Unit. (Fig.8).

Make sure that all cords are connected safely and properly and that the Power Switch is off before plugging in the Power Cord.

It is convenient to store burs on the surface of the magnetic bur holder strips located on the side of the controller. Some burs do not contain enough ferrous metal to attach to the magnet. (Protect from ferrous metal dust.) (Fig. 9).

CAUTION

Operation

a. Make sure that a bur is inserted in the motor

handpiece and collet is fully closed.

12 to off.

3 4

8 9

11 10

b. Set Power Switch

c. Plug the Power Cord

electric outlet.

d. Set the Speed Control Knob

slowest position.

e. Turn on the Power Switch

f. Select the rotation direction by pressing

Forward/Reverse Selector Switch

CAUTION Never switch rotation direction

while the handpiece is running.

Hand Mode Operation, follow steps a. through f. above, then:

1. Press the Hand/Foot Selector Switch 10 to “Hand”.

(Hand/Foot Selector indicator light

2. Press the Motor On/Off Switch

3. Set the Speed Control Knob

4. Use the Motor On/Off Switch

oot Mode Oper

1. Press the Hand/Foot Selector Switch 10 to “Foot”. (Hand/Foot Selector indicator light 11 lights

up orange

2. Set the Speed Control Knob

ation

Motor On/Off indicator light

11 lights up green.)

3 to run the motor. (Motor On/Off indicator light 4 lights up green.)

7 to desired speed.

3 to stop the motor.

above, then:

ough f

, follow steps a.

7 to desired maximum speed. continued

thr

4 lights up green.)

20 into the Handpiece

25 into the Foot Pedal Outlet

26 into a grounded

7 to the

12.

Page 6

Foot Mode Operation c

3. Press the Foot Pedal 24 to run the motor from start to a maximum speed (set by the speed control knob).

4. To increase speed, release foot pedal and allow motor to stop. Dial in new maximum speed and proceed.

In Foot Pedal Mode the micromotor will not exceed the preset speed.

ontinued

Changing from Foot to Hand Mode

1. Press Hand/Foot selector switch, 10.

2. Press Motor On/Off switch,

3 and select a speed using the control knob 7.

Auto Cruise Mode

When the Foot Pedal is used, the Auto Cruise feature allows the speed to be maintained when the Foot Pedal is NOT pressed. Activate by pressing the Auto Cruise Switch Pedal depressed, for 2 seconds at the desired speed. Deactivate by pressing the Foot Pedal.

5 while keeping the Foot

Components

Collet part numbers and sizes are listed on page 7.

19 Handpiece (

micromotor H.MH-150)

Brushless DC

20 Handpiece Motor Cord 21 Handpiece Cradle

(No. HP4-933)

Handpiece Holder

Chuck Wrench

Foot Pedal

Foot Pedal Cord

Power Cord

(HP7-7060)

21 22

25 24 26

Page 7

CAUTION

• Do not exceed the maximum operating speed of the bur or accessory in the handpiece

to avoid personal injury.

• Before turning off the Power Switch, make sure that the motor has been stopped.

• When the unit is not in use, for maximum safety, unplug the Power Cord.

Rotation Speed Display Set Mode

NOTE: Use this set mode only when you wish to operate the micromotor handpiece with

a lower maximum RPM rating. This function is for setting a safe maximum rotation speed of the handpiece. a.Turn on the Power Switch 12 while pressing the Motor On/Off Switch 3 and wait for a

beep. Release the Motor On/Off Switch. b. Set the maximum speed of the motor handpiece which you want to use by repeatedly

pressing the Hand/Foot Selector Switch 10.

c. Return to the main mode by pressing the Motor On/Off Switch.

Motor On/Off Switch Hand/Foot Selector Switch

“bc” displayed (Motor Handpiece) 25, 30, 35, 40, 45, 50 (x 1,000 rpm)

Maximum Torque Set Mode

This setting is used to match the maximum output of the control unit to the maximum torque capability of the handpiece, or to prevent damage to the bur. The maximum torque setting is preset at the factory to the recommended value. Use this procedure only if you are using another motor handpiece with a lower torque rating, or if you are using a bur which may be damaged by the full torque capability of the handpiece.

a. Turn on the Power Switch 12 while simultaneously pressing Forward/Reverse Selector Switch 8 when you hear a beep, release the Forward/Reverse Selector Switch.

b. Set the electric current (ampere) value for maximum torque of the motor handpiece by pressing Hand/Foot Selector Switch displayed. The higher the current value, the more powerful the torque.

10 repeatedly until the desired amperage value is

Fwd/Rev Switch Hand/Foot Selector Switch Recommended

“c1” displayed 1a, 2a, 3a, 4a, 5a, 6a, 7a Up to 6a

CAUTION

• Do not select a current value which exceeds the rating of the motor handpiece. Too high

a rating may shorten the motor life or damage the control unit. (Consult a qualified technician if possible.)

o check the values of maximum rotation speed and maximum torque which are

Note – already set, Switch

turn on the P

ower Switch

12 while simultaneously pressing the

5. The Set values are shown on the Speed Display LED 2 consecutively.

Auto Cruise

Page 8

[Fig.12]

chuck handle

triangular hole

bur

To order the correct Replacement or Additional Collet check the Handpiece Serial Number

Handpiece Serial Nos.

808xxxx and above

807xxxx and below

Collet Collet Part No. Size

HP4-117 2.35mm (3/32″)

HP4-117B

HP4-117C 3.00mm

HP7-5008

HP7-5007 3.18mm (1/8

HP7-5006

3.18mm (1/8

2.35mm (3/32

3.00mm

″)

Using the Motor Handpiece (MH-150)

Changing Accessories

Burs and other accessories can be inserted or removed from the handpiece collet when the collet is open. To open the collet:

1. Turn off the motor using the Motor On/Off

3 and the Power Switch 12.

Switch

2. Twist the Chuck Handle in the “R” or release direction (clockwise) until the raised indicator bar clicks into the far left mark ( 8>) on the silver center ring (Fig.11).

2. Remove the accessory and replace with another accessory. Insert the ‘new’ accessory shank fully

(about 1 You should feel it touch the back of the collet.

4.Twist the knurled Chuck Handle toward the “S” or secure position by turning counter-clockwise until it snaps to lock the collet. The accessory and the collet will be able to spin freely.The raised collet indicator bar will be above the far right (

Note: The intermediate position between “S” and

“R” holds both the spindle and the accessory in a locked position. This is useful to unscrew an over-tightened mandrel screw.

Never turn the power on when the collet is open or in the intermediate position. The spindle is in the locked position and will not turn.

motor.

How to Remove and Install the Collet

1. With knurled Chuck Handle in “R” release position

and bur or accessory in collet, place triangular hole in Chuck Wrench head and unscrew the collet counter-clockwise (Fig.

12) Remove collet.

2. With bur or accessory in new collet, thread into handpiece. Place triangular hole in Chuck Wrench over triangular flats of Collet head and tighten the collet clockwise. Be careful not to over-tighten. Test to insure that new collet releases accessory smoothly in the “R” released position. Test to insure that new collet holds firmly in the “S” secure position and spindle rotates freely.

⁄8″) into the collet for maximum support.

8) mark in the silver center ring.

This will damage the

23 over triangular flats of Collet

Page 9

Disassembling the Chuck Handle and the Motor

The Chuck Handle and the Motor are disassembled by continuously turning the Chuck Handle counterclockwise (Fig.13A).

Detaching the Motor and the Motor Cord

Unplug Handpiece Motor Cord Assembly 20

from Handpiece Plug Outlet 13 on the back of the control. The Motor Cord Assembly

20 can be replaced by unthreading the Rear Cover from the Motor Housing (Fig.13B).

CAUTION

It is recommended that a bur be kept in the chuck at all times. Do not operate the handpiece without a bur in the chuck.

• Use only recommended burs.

• Always be sure chuck is free of dirt or debris before replacing a bur.

• After replacing a bur, make sure that the Collet Chuck is fully closed before running the Motor.

• DO NOT to open the collet while the motor is running. It will damage the handpiece.

• Always put the Handpiece on the Handpiece Cradle 21 or in Handpiece Holder 22 while not in

use. (Fig.7). Take special care not to drop it on the floor.

• Thoroughly clean the Collet before reassembling. Clean at least once a week for

longer life.

• Keep the Handpiece clean and free of dirt and debris during disassembly.

• The spindle and the motor should be disassembled only by a qualified repair facility.

CAUTION

• Never exceed the maximum rotation speed specified by the manufacturer or for the bur

being used.

• Large burs, even when operated below maximum rated speed, may begin to vibrate. Speed

should be reduced immediately to prevent damage to the bur

until it touches the back of the Collet Chuck.

• Be sure to insert the Bur shank all the w

handpiece

, or operator.

T tighten the Collet Chuck. If the Bur is used while not inserted completely, it is very dangerous because vibration may cause it to come out, bend, or break.

hen

Page 10

Error codes

Error Code Status Cause

1. One or more hall sensors defective

“1E” Motor sensor error 2. The Motor Cord is unplugged or defective.

3. The Motor Cord is broken.

1. The Collet Chuck is opened.

“2E” Motor lock error 2. The Motor Handpiece is mechanically defective.

3. The Motor Handpiece is electrically defective.

“4E” Motor overvoltage 1. The circuit of the Control Unit is defective.

detection error

1. The Control Unit has been operated under a high load condition for too long a time.

“5E” Overheat error 2. The Control Unit has been exposed to an excessively

warm environment (more than 100

3. Air openings are blocked.

4. Temperature sensor is defective.

“6E” Overload error 1. The motor Handpiece was operated under an overload condition,

or was stalled by jamming the bur into the work.

“7E” Control Circuit 1. The circuit of the Control Unit is defective.

Board error

ºF.)

50,000

45,000

40,000

35,000

30,000

25,000

20,000

15,000

10,000

5,000

Accessory more than 1

⁄2″ 1″ 3/4″ 1/4″ 1/8″ 3/32″ less than 3/32″

Rotation Speed – RPMs

Diameter (40mm) (28– 40mm) (18 –28mm) (8–18mm) (4 –8mm) (2 – 4mm) (less than 2mm)

Allowable Rotation Speed

he chart is a general guide for the maximum rotation speed of conventional burs. The allowable

T rotation speed can be slightly different,

depending on bur materials or types

Page 11

Troubleshooting

NOTE: When an error reading is displayed, turn off the power switch for a few seconds and then turn it on again. If

“

5E” is displayed wait for about ten minutes. If the error reading re-appears, follow the Troubleshooting Chart below.

Trouble Check Points Corrective Actions

Power Lamp Does Not Light

displayed

Motor Does Not Run

displayed

Foot Pedal Does Not Work

Handpiece overheats or is noisy while operating at no load

Motor Vibrates Excessively and is Unusually Noisy

Make sure that the Power Cord is correctly Correctly plug in the Power Cord. plugged into the outlet and the control unit.

Check if the fuse is blown. Replace only with the recommended fuse. If

Make sure Power Switch is working properly. Replace the Power Switch.

“1E”

Make sure Motor Cord is plugged in properly. Correctly plug in the Motor Cord. If error code

isplayed

“2E”

Check if the Collet Chuck is open. If open, close the Collet Chuck. If error code

“4E”

The circuit of the Control Unit is defective. Repair or replace.

Check if the Control Unit has been used at a Turn off the Power Switch for about 10 mins., high load and for a long time. then restart the Control Unit. If error code

“5E”

Check for high workplace temperature. If too warm, move the Control Unit to a loca-

Check control air openings for blockage. Unblock air opening.

Temperature sensor is defective. Replace the sensor.

Check if the Control Unit has been excessively Press the Auto Cruise Switch or turn off, then used under a high load condition. press the Motor On/Off Switch. If error code

“6E”

Check if the Collet Chuck is open. If open, close it by turning the Chuck Handle.

Make sure the shaft of the Motor Handpiece If it cannot be rotated with the chuck closed, can rotate freely. the spindle of the Motor Handpiece is defec-

“7E”

The circuit of the Control Unit is defective. Turn off the Power Switch for about 10 mins.,

Check if Foot Pedal Cord is properly plugged in. Plug in the Foot Pedal Cord correctly.

The Hand/Foot Selector Switch is set to “Hand”. Set the Hand/Foot Selector Switch to “Foot”.

Foot Pedal still does not work. Repair or replace it.

The ball bearings are defective. Repair the Motor Handpiece.

Make sure that the Collet Chuck is free of dirt. Thoroughly clean the Collet Chuck.

The rotation speed is too high. Reduce the rotation speed. Refer to

Check if the bur shaft is bent, of round or unbalanced.

Make sure that the ball bearings are in Repair or replace the Motor Handpiece. good condition.

or bur is out

the fuse blows again, repair or replace the unit.

continues, replace the Motor Cord.

continues, repair or replace the handpiece.

continues repair or replace the control unit.

tion with an indoor temperature of 32~100ºF.

continues, repair or replace Control Unit.

tive. Repair or replace it.

then restart the Control Unit. If error code continues repair or replace the control unit.

Allowable Rotation Speed chart.

Replace with a new bur

Caution:

s should be performed only by qualified per

Repair

sonnel.

Page 12

Repair Services

Authorized repair service is available at the Foredom factory in Bethel, CT. Send items for repair to the factory marked “Attention: Repair Department”. Enclose the item(s), a packing list, daytime phone number, return address, and information regarding the problem or repairs required. Estimates of repair cost will be made upon request. It is our policy not to proceed with a repair without your approval if the cost (labor plus parts) is more than fifty percent of the cost for a new replacement. You will be notified by mail and advised of the cost to repair and to purchase a new replacement. Please allow three business days for an estimate to be done and five to seven business days for repair work to be completed after we receive your approval to proceed.

Please retain your proof of purchase for warranty repairs.

Warranty

Foredom warrants its product to be free of defects in material or workmanship for a period of two years after purchase.

During the warranty period, the defective product will be repaired or replaced without charge or, at our option, the purchase price will be refunded.This warranty does not cover damage caused in transit or by accident, misuse, or ordinary wear.

ALL IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO WARRANTIES OF FITNESS AND MERCHANTABILITY, ARE HEREBY LIMITED IN DURATION TO A PERIOD ENDING ONE YEAR FROM DATE OF PURCHASE,AND WE WILL NOT BE LIABLE OR RESPONSIBLE FOR ANY SPECIAL OR CONSEQUENTIAL DAMAGES.

Repair or replacement will be made at our option if the product is returned postpaid to:

The Foredom Electric Company, 16 Stony Hill Road, Bethel, CT 06801

All warranty repairs must be done at the factory at the address above.We will not pay any shipping or transportation charges.

This warranty only covers the original purchaser of the product. Proof of purchase may be requested.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you. This warranty gives you specific legal rights, and you may also have other rights which vary from state to state.

For More Information

For more information on Foredom machines, handpieces or accessories, contact your local dealer. When no local dealer is available, write, call or fax:

The Foredom Electric Company, 16 Stony Hill Road, Bethel, CT 06801

(203)792-8622, Fax: 203-796-7861 or Email: [email protected]

Visit our website: www.foredom.com

F-1228 n 1/09

Printed in U.S.A.