FOREDOM K.1050 Manual

Operation & Maintenance Manual for
K.1050 Brushless Micromotor Kit
with additional Port for connecting a
Brush Type Handpiece
FOREDOM®
For Your Safety:
Read this Manual before operating your
Foredom Micromotor Power Tool.
Always wear eye protection while operating
this Micromotor.
HP4-817
Control
HP4-933
Cradle
HP7-7060
Foot Control
H.MH-150 Brushless Handpiece
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
[phone], Fax: [phone], Email: [email protected]
Visit our website: www.foredom.net for video
descriptions of this product.
F-1228 n 7/12 Printed in USA
•NEVER cut or exert pressure, toward your hand
or any other part of your body.
•DO NOT wear loose fitting clothing or jewelry.
Loose clothing or jewelry can be come entangled
in the tool. Do not wear items such as neckties,
necklaces, or bracelets when operating power
tools. Secure or tie back long hair.
•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.
1
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. NEVER operate it 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 8 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 acces-
sory 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.
•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 wear open shoes or sandals. Use
footwear that is tough enough to protect your
feet from falling tools.
•ALWAYS keep both hands and fingers away
from the cutting edge.
Limited Warranty
Foredom warrants its product to be free of defects in
material or workmanship for a period of two years after
purchase. Blackstone Industries, Inc. d/b/a The Foredom
Electric Company warrants, to the original purchaser only,
that its products will be free from defects in material or
workmanship for the applicable period of time indicated
above following the purchase date. During the warranty
period, the defective product will be repaired or replaced
without charge or, at our sole 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, WITHOUT
LIMITATION, IMPLIED WARRANTIES OF FITNESS FOR A
PARTICULAR PURPOSE AND MERCHANTABILITY, ARE
LIMITED IN DURATION TO THE APPLICABLE WARRANTY
PERIOD. IN NO EVENT WILL WE BE LIABLE FOR ANY
INCIDENTAL OR CONSEQUENTIAL DAMAGES. Some
states do not allow limitations on how long an implied
warranty lasts or the exclusion or limitation of incidental
or consequential damages, so the above limitations or
exclusion may not apply to you.
At our sole option, repair, replacement or refund will be
made if the product is returned postage prepaid 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
imitation 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.

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.
2a. If the fuse needs to be replaced (Fig. 5), replace it
with identical type and rating only– For 115 V micro-
motor use a 5x20mm,SLO-BLOW, 3.15A, 250V.
2b. 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 (Fig. 6).
•Use the Control Unit in locations with a
temperature below 100ºF
.Avoid excessively dusty, hot
or humid locations.
Complete Kit (Fig. 3)
Control Unit, Power Cord
Brushless Handpiece
Handpiece Holder,
Phillips Screw, Washer
Foot Pedal
Handpiece Cradle
Collet Changing Wrench
A Brush Type Handpiece
may be used with Kit
K.1050 but is NOT
included with this kit
16
2
Please retain your proof of purchase for warranty repairs.
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,
email 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 and advised of the cost to repair and to
purchase a new replacement.
Set-up
1. Fix the Handpiece Holder 23 to the right side of the Control Unit
with screw and washer. (Fig.7).
2. An optional Brush Type Handpiece Motor Cord may be plugged into
the Port A Outlet 13 located in the front of the Control Unit. (Fig.8).
3. Plug the supplied Brushless Handpiece Motor Cord 21 into the Port
B Outlet 17 located in the rear of the Control Unit and then tighten
the plug nut. (Fig.9).
4. Plug the Foot Pedal Cord 25 into the Foot Pedal Outlet 14
located in the rear of the Control Unit. (Fig.9)
5. Plug the Power Cord 27 into the Power Connector 15 in the
rear of the Control Unit. (Fig.9).
CAUTION Make sure that all cords are connected safely
and properly and that the Power Switch 12 is off before plugging in
the Power Cord (Fig. 11).
Burs may be stored on the magnetic bur holder strips located on the
side of the controller. Burs without enough ferrous metal will not
attach to the strip. (Protect from ferrous metal dust.) (Fig. 10).
Operation
a. Make sure that a bur is inserted in the micromotor
handpiece and collet is fully closed. (See page 5)
b. Set Power Switch 12 to off (O)(Fig. 11).
c. Plug the Power Cord27 into a grounded electric outlet (Fig. 4).
d. Set the Speed Control Knob 7to the slowest position.
e. Turn the Power Switch 12 on ( l )(Fig. 11) – switch lights up.
f. Select Port A (front) Brush Type or Port B (back) Brushless
Handpiece by pressing Handpiece Selector Switch 5 (Fig. 11).
g. Select the rotation direction by pressing Forward/Reverse
Selector Switch 8.(Forward is green / Reverse is orange)
CAUTION Never switch rotation direction
while the handpiece is running.
Hand Mode Operation,follow steps a. through g. above, then:
1. Press the Hand/Foot Selector Switch 10 to “Hand”.
(Hand/Foot Selector indicator light 11 turns green.)
2. Press the Motor On/Off Switch 3to run the motor. (Motor On/Off indicator light 4turns green.)
3. Set the Speed Control Knob 7to desired speed.
4. Use the Motor On/Off Switch 3 to stop the motor.
Foot Mode Operation,follow steps a. through g. above, then:
1. Press the Hand/Foot Selector Switch 10 to “Foot”. (Hand/Foot Selector indicator light 11 turns orange,
Motor On/Off indicator light 4turns green.)
2. Set the Speed Control Knob 7to desired maximum speed. continued
3
3
4
7
8
9
6
5
11
10
25
14
13
21
27
15
17
12
23
Port A Brush Type Handpiece Indicator Light 6
FRONT (Optional) turns Green
Port B Brushless Handpiece Indicator Light 6
BACK (Supplied) turns Orange
Optional
Brush Type
Handpiece
cord

Foot Mode Operation continued
In Foot Pedal Mode the micromotor will not exceed the preset dial speed.
3. Press the Foot Pedal 26 to run the motor from start to a maximum speed (set by the speed control knob).
4. To increase the maximum speed setting, release foot pedal and allow motor to stop. Dial in new
maximum speed and proceed.
Changing from Foot to Hand Mode
1. Press Hand/Foot selector switch, 10
(Hand/Foot Selector indicator light 11 turns green)
2. Press Motor On/Off switch, 3 and select a speed
using the control knob 7.
Auto Cruise Mode
In Foot Mode operation, the Auto Cruise feature allows a preset speed to be maintained when the Foot
Pedal is released. To enable Cruise Mode, press motor run switch 3, the indicator light 4 will turn
orange. To activate, hold the pedal at the desired speed position and after 2 seconds there will be a
double beep. The foot pedal can then be released, and the selected speed will be maintained. Pressing
the foot pedal again will release the preset speed. A new preset speed can then be selected by holding
the foot pedal at the desired speed for 2 seconds until a double beep is heard. To return to normal Foot
Control operation, press the Motor On/Off & Auto Cruise switch 3. The Indicator light 4will turn green.
3
4
8
9
5
6
7
10
11
12
15
14
16
17
1
2
18 19
21
20
24 25 26 27
22 23
4
Components
1 Control Unit (HP4-817)
2 Digital Speed Display (x 1,000 rpm)
3 Motor On/Off & Auto Cruise
Switch
4 Motor On/Off & Auto Cruise
Indicator Light
5 Handpiece Port Selector Switch
6 Handpiece Port Indicator Light
7 Speed Control Knob
8 Forward/Reverse Selector Switch
9 Forward/Reverse Indicator Light
19 3/32″ Collet (1/8″ is optional)
Collet part numbers and sizes
are listed on page 5.
20 Brushless Micromotor
Handpiece H.MH-150)
21 Handpiece Motor Cord
22 Handpiece Cradle (HP4-933)
23 Handpiece Holder
24 Chuck Wrench (HP4-993)
25 Foot Pedal Cord
26 Foot Pedal (HP7-7060)
27 Power Cord
10 Hand/Foot Selector Switch
11 Hand/Foot Indicator Light
12 Power On/Off Switch & Light
13 Port A Brush Type Handpiece
Plug Outlet
14 Foot Pedal Plug Outlet
15 Power Cord Plug Outlet
16 Fuse Holder with spare fuse
17 Port B Brushless Handpiece
Plug Outlet
18 Test Bur
13
Using the Brushless Motor Handpiece
(H.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 Switch 3
and the Power Switch 12.
2. Twist the Front of Handpiece 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).
3. Remove the accessory and replace with another
accessory. Insert accessory shank fully (about 11⁄8
″) into
the collet for maximum support. You should feel it
touch the back of the collet.
4. Twist the knurled Front of Handpiece toward the “S”
or secure position by turning counterclockwise 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 (<
8) mark in the silver
center ring.
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.
CAUTION Never run the handpiece
when the collet is open or in the
intermediate position. The spindle is in the
locked position and will not turn. This will
damage the motor.
Removing and Installing Collets
1. With knurled Front of Handpiece in “R” release posi-
tion and bur or accessory in collet, place triangular hole
in Chuck Wrench 24 over triangular flats of Collet head
and unscrew the collet counterclockwise (Fig. 12)
Remove collet.
2. With bur or accessory in new collet, thread into
handpiece. Place triangular hole in Chuck Wrench 24
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.
[Fig.12]
Front of handpiece
Back of
handpiece
Front of
handpiece
Bur
Collet
bur triangular hole
24
Collet Collet
Part No. Size
HP4-117 2.35mm (3/32″)
HP4-117B 3.18mm (1/8″)
HP4-117C 3.00mm
HP7-5008 2.35mm (3/32″)
HP7-5007 3.18mm (1/8″)
HP7-5006 3.00mm
Handpiece
Serial Nos.
808xxxx
and above
807xxxx
and below
To order the correct Replacement
or Additional Collet for the H.MH-150
check the Handpiece Serial Number
See video on
Changing Collets
&Accessories at:
www.foredom.net
5

6
CAUTION Keep a bur 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 open the collet while the motor is running. It will damage the handpiece.
•Always put the Handpiece on the Handpiece Cradle 22 or in Handpiece Holder 23 while not in
use. (Fig.7). Take special care not to drop it on the floor.
•Thoroughly clean the Collet with brush or compressed air 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 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, handpiece, or operator.
•Be sure to insert the Bur shank all the way, until it touches the back of the Collet Chuck. Then
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.
21
Replacing the Handpiece Cord Set
Unplug Handpiece Motor Cord Assembly 21 from
Handpiece Plug Outlet 17 on the back of the control.
The Motor Cord Assembly 21 can be replaced by
unthreading the Rear Cover from the
Motor Housing (Fig.13).
See videos
of Product
Features at:
www.foredom.net
Rear
Cover
Front of
handpiece
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.
Using an Optional Brush Type Motor Handpiece in Port A:
Foredom currently has 3 brush type handpieces for use in Port A on Control Box (HP4-817). These brush
type micromotor handpieces all have different speed ranges, as detailed below. However, since the
handpiece speed ranges do not match the factory maximum preset of 35,000 RPM on the digital
display, you can approximate the digital display speed with the actual speed of your specific
handpiece as follows:
Digital Display:
35 35,000 = full speed
26 26,000 = 3/4 speed
17 17,000 = 1/2 speed
99,000 = 1/4 speed
Dial position (shown below) is also an indicator of speed for these handpieces.
HPMH-011 Hammer Micromotor
Handpiece
Strokes Per Minute: 1- 2,500
H.MH-120 Chuck Style
Micromotor Handpiece
Maximum Speed- 20,000 RPM
H.MH-170 High Speed Rotary
Micromotor Handpiece
Maximum Speed- 38,000 RPM.
full speed 3/4 speed 1/2 speed 1/4 speed

8
Accessory more than 11⁄2 ″ 1″3/4″1/4″1/8″3/32″less than 3/32″
Diameter (40mm) (28– 40mm) (18 –28mm) (8– 18mm) (4 –8mm) (2 –4mm) (less than 2mm)
Rotation Speed – RPMs
Recommended Approximate Bur Speeds
See Maximum Speed Rating by Bur Manufacturer
50,000
45,000
40,000
35,000
30,000
25,000
20,000
15,000
10,000
5,000
0
Allowable Rotation Speed
The chart is a general guide for the maximum rotation speed of conventional burs. The allowable
rotation speed can be slightly different, depending on bur materials or types.
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 100ºF.)
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
Trouble Check Points Corrective Actions
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
the fuse blows again, repair or replace the unit.
Make sure Power Switch is working properly. Replace the Power Switch.
Make sure Motor Cord is plugged in properly. Correctly plug in the Motor Cord. If error code
continues, replace the Motor Cord.
Check if the Collet Chuck is open. If open, close the Collet Chuck. If error code
continues, repair or replace the handpiece.
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
continues repair or replace the control unit.
Check for high workplace temperature. If too warm, move the Control Unit to a loca-
tion with an indoor temperature of 32~100ºF.
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
continues,repair or replace Control Unit.
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-
tive. Repair or replace it.
The circuit of the Control Unit is defective. Turn off the Power Switch for about 10 mins.,
then restart the Control Unit. If error code
continues repair or replace the control unit.
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
Allowable Rotation Speed chart.
Check if the bur shaft is bent, or bur is out Replace with a new bur.
of round or unbalanced.
Make sure that the ball bearings are in Repair or replace the Motor Handpiece.
good condition.
Caution: Repairs should be performed only by qualified personnel.
Motor
Does
Not
Run
Power
Lamp
Does Not
Light
Foot Pedal
Does Not
Work
Motor
Vibrates
Excessively
and is
Unusually
Noisy
Handpiece over-
heats or is noisy
while operating
at no load
“1E”
displayed
“2E”
displayed
“4E”
displayed
“5E”
displayed
“6E”
displayed
“7E”
displayed
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.
9