Stationary Oil Removing Unit

Transcription

1 Stationary Oil Removing Unit OPERATIONS MANUAL BETRIEBSANLEITUNG MANUEL D EMPLOI ET DE MAINTIEN ISTRUZONI PER L USO MANUAL DE INSTALACION Y OPERACIONES English MODEL A-400 LESTOPREX AG CH-8735 St. Gallenkappel

2 CONTENTS Page 1. General Notice for safe use Function Unpacking of the unit Installation Instruction Unpack Electrical connection Start of Operation Construction Operation Pump Unit setup EMERGENCY-STOP Operation Maintenance General fault finding guide Specifications Technical Data Spare list Exploded View Electrical Connection LESTOPREX AG Tel. Nr. +41 (0) Page 2

3 1. General This manual explains about safe and effective usage of this unit. Read this manual carefully and understand the use of the unit fully before you start with the installation, the use or the maintenance. 2. Notice for safe use 1. Install the unit properly according to the instructions in this manual. 2. Connect correct power voltage according to state and local instructions. 3. Do only use the unit when all safety elements are installed and ready to work. 4. Use the device in a device-compliant environment and operate it only stationary, and according to the function and purpose. 5. Disconnect power supply, before you open the unit for maintenance and service. 6. Follow the written recommendations of the cooling lubricants manufacturer and the actual regulations. 7. Protect the skin when handling with the coolant lubricant effectively and avoid skin contact. 8. Wear respiratory and eye protection when in open or semi-open coolant reservoir coolant vapour is created. 9. State and local specific safety and environmental standards are to be considered and kept. 3. Function The stationary oil separator LESTOL is a coolant care unit for tooling machines. The system pumps the emulsion gently by use of a progressive cavitiy pump (PCP) out of the tank to be maintained. The surface of the machine tank will be cleaned from oil by a special intake swimmer. An exclusion of air through the oil layer is prevented and this eliminates the cause of bad smells (anaerobic condition). In the coalescence separator the oil drops are removed in a second step from the emulsion. The fluid moves through a stainless steel lamella package. With just a few millimeters of distance these lamellas accumulates the oil drops to bigger drops (coalision). This large oil drops go through special holes towards the surface. Through an overflow the oil is held back in a disposal canister. The cleaned emulsion goes back again into the machining center. As the unit is operated on bypass, the production will not be affected. For safety reasons the fluid level of the separation tank is monitored. The oil disposal canister optionally also can be monitored by a float switch. Like the housing the lamella package also is made out of stainless steel. Therefore it can be cleaned with a high pressure cleaner or in a washing box. Together with a UVC flat-bed reactor, the cleaned emulsion can be sterilized optionally gently but effectively using UVC radiation. The stationary oil separator comes complete with suction hose, suction float, return hose and disposal can. LESTOPREX AG Tel. Nr. +41 (0) Page 3

4 Model: A Unpacking of the unit We have created a package which is protecting the unit as far as possible against damage during transport. However damages can not be completely excluded during transport. We recommend to proceed in the following manner just after receipt of the unit: 1. First and directly after receipt: check whether there are any damages. 2. In case of registered transportation damages: inform the responsible transportation agency immediately. The shipping of the unit should be done on pallets, secured with clamping bands, as well as with standard transport equipment (fork-lift truck etc.). Important! Please note! Do not stand under a suspended load. 5. Installation Instruction The unit is intended for the internal use of stationary use. It shall only be filled with coolant oil after a secure installation and fixation. The unit should be mounted above a fixed tank, so that in case of a failure the leaking coolant is captured. The stationary oil separator can optionally be equipped with an overflow protection. Important! Please note! Before the unit is switched on, the connections and installations has to be done as described. The threaded connections must be sealed Unpack The unit is delivered on a pallet. Cut the protective foil below the housing and pull upwards. Then lift the unit about 30 cm vertically and remove the transportation pallet. Important! Please note! Only handle the unit in an upright position because the pump housing is already filled with liquid at the factory place (different on overseas shipments) Electrical connection The unit is as standard equipped with a power cable and a 16A CE plug, and turned clockwise. If the unit is installed on an unchecked electrical power grid, the direction of the pump rotation can be checked by briefly starting (max. 5 seconds). There is an arrow on the pump housing. LESTOPREX AG Tel. Nr. +41 (0) Page 4

5 5.3. Start of Operation (1) Each time the unit first has to be installed and secured above the coolant tank. The installation site should have no inclination. (2) Then the suction pipe, together with the supplied inlet skimmer, have to be placed and sceurde into the cooling lubricant tank of the machine tool. It is important to adjust the height of the skimmer in a manner that the surface of the cooling lubricant is constantly skimmed and, at the same time, a dry run of the skimmer is prevented. Important! Please note! Running the pump dry will damage the pump after a few minutes and increased the wear of the stator and rotor. (3) The return hose is now also fixed in the cooling lubricant container in the machine tool, as far as possible from the skimmer position, hooked, and protected against inadvertent sliding out of the container, using magnetic clip or similar. This produces a cooling lubricant circuit. (4) Make sure that the return nozzle of the stationary oil separator unit is at least 100 mm higher than the running edge of the container to be maintained, to ensure free running off of the cooling lubricant. (5) Insert the float switch in the external cans. The float shuts off the unit when the canister is full. (6) Now plug the connector into the electrical power socket. (7) After switch on the circuit the pump starts to work. Control the media flow from the skimmer to the pump to avoid a dry run of the pump. If necessary adapt the skimmer to a better working position. LESTOPREX AG Tel. Nr. +41 (0) Page 5

6 5.4. Construction Complete housing (front panel with control box and back side view). 6. Operation 1 The unit is equipped with a motor circuit breaker with low voltage release and contactor control. After a power loss the unit cannot start automatically. It must be started manually. With the main switch (1) the power supply is switched on and off Pump Pump model: M 075 M6F Manufacturer: PCM Type of pump: Progressive cavity pump (PCP) Pump: - Drawing Annex A - Spare part list Annex B - Fault guide Annex C 6.2. Unit setup Set and adjust (single default setting) the built-in Oil skimmer ("rain gutter"). The skimming edge should be set approx. 3 mm above the clean coolant. The inlet skimmer for the extraction has to be placed in the cooling tank of the machine and adjusted to the required height. Floating skimmers have to be roughly adjusted at the liquid surface, the fine tuning goes automatically. LESTOPREX AG Tel. Nr. +41 (0) Page 6

7 6.3. EMERGENCY-STOP In case of an EMERGENCY-STOP the main switch (1) has to be turned off Operation Fill in the coolant (minimal filling is achieved by filling the pump casing and the suction hose) Connect the unit to the power supply according to the electrical specifications Place the skimmer with suction hose into the coolant tank of the machine Connect the return hose to the stationary oil separator and secure the the free end which goes into the machine by a magnetic bracket. Turn on the main switch Adjust the skimmer Important! Please note! A sufficient flow of Coolant is required to avoid a possible damage to the pump due to dry running! ATTENTION! Please empty the waste can regularly to avoid an overfilling. 7. Maintenance A periodic maintenance is recommended in order to keep proper function for a long time. Important! Please note! Maintenance only has to be done when the power is disconnected. When working with oil, grease and other chemical substances, the respective safety regulations have to be considered. Completely empty the unit into a suitable container by pressing the drain valve on the rear side of the device. Clean the housing surface. Remove the dirt in the coalescence separator. Clean and replace if necessary the hoses, nipples and skimmer. Check and replace if necessary the seals. 8. General fault finding guide Fault Possible cause Action Unit does not work, the pump does not start Unit can not be started; the pump does not start; Power is on - No electric power - Check power connection - Can overflow protection is triggered - Insert plug - Turn on main switch - Remove liquid; Empty, device restart canister The unit is running, the pump is on, it sucks but no liquid is taken out. - Pump overload relais is triggered - Direction of rotation of the pump is wrong - Make off the unit; switch on again - Check pump rotation direction (arrow) and, if necessary, correct let direction of rotation of the receptacle by a power LESTOPREX AG Tel. Nr. +41 (0) Page 7

8 Attention! Important! The pump will be damaged by dry running. Also aqueous phase (emulsion) emerges from the disposal procedures Skimmer of the machine tank is constantly empty Skimmer of the machine tank constantly gets full, as there is no skim effect - Skimmer in the tank of the machine is set incorrectly or misaligned engineer - Check skimmer and change - Oil spill is not adjusted - Adjust overflow in the unit during operation so that only the fat or oil over the whole width of the skimmer can expire - Skimmer is adjusted incorrectly - Adjust the skimmer in the tank of the machine downwards - Skimmer is adjusted incorrectly Adjust the skimmer upwards as far as a regular Skim effect is reached LESTOPREX AG Tel. Nr. +41 (0) Page 8

9 9. Specifications 9.1. Technical Data deutsch français english Model A 400 Förderleistung Capacité de traitement Effect ca. 400l/h Motor Moteur Motor kw/h 0.5 kw V/Hz 400 V/ 50 Hz Pumpe Pompe Pump Progressive cavity pump (PCP) Förderdruck Pression Pressure bis / jusqu à /up to 3 bar Behälterinhalt Contenance Tank capacity 75 l Entsorgungsbehälterinhalt Bidon d évacuation Disposal tank capacity 9 l Gerätebeständigkeit Resistance ph ph range bis / jusqu à /up to ph 10 Betriebstemperatur Resistance thermiques Temperature range bis / jusqu à /up to 5-60 C Schlauchanschluss Vorlauf Raccord du tuyau d entrée Inlet hose ¾ Schlauchanschluss Rücklauf Raccord du tuyau de sortie Outlet hose 1 ¼ Abmessungen Dimensions Dimensions LxBxH/mm 700x535x750 Ausführung Exécution Execution Standard Gehäuse Boîtier Casing Inox Farbe Couleur Color Standard RAL 7035 / 7016 grau, gris, grey Gewicht, leer Poids à vide Weight empty ca. 60 kg LESTOPREX AG Tel. Nr. +41 (0) Page 9

10 9.2. Spare list Detail Lestoprex deutsch français english No. No Behälter Bac Tank Behälterdeckel Couvercle Lid Bügelgriff Poignée Handle Lamellenpacket Paquet de lamelles Lamella package Excenterschneckenpumpe Pompe de limace d excentrique Progressive cavity pump (PCP) Pumpenstator Stator Stator Schalteinheit Partie commutation Switch panel Raumsparkanister (Entsorgungsgehälter) Bidon d évacuation Can Ansaugskimmer (Ballonskimmer) komplett) Dispositif d aspiration en surface Exhausting skimmer Schwimmerschalter vertikal (im Kanister), Ueberlaufschutz Commutateur de flotteur (Bidon d évacuation) M8, 30 mm Gummifuss Pied en caoutchouc Overfill protection Rubber Base Rücklauf Schlauch PVC 32 mm (1 ¼ ) Tuyau d évacuation 32 mm (1 ¼ ) Outlet hose 32 mm (1 ¼ ) Zulauf Schlauch PVC 20 mm (3/4 ) Tuyau d entrée 20 mm (3/4 ) Inlet hose 20 mm (3/4 ) Kantenschutzprofil Protection de bord Edge protection Hydraulikschlauch Tuyau hydrolique Hydraulic hose R 1 Schlauchtülle Bride Hose clip R 3/4 Schlauchtülle Bride Hose clip R 1 1/4 Schlauchtülle Bride Hose clip Winkel 90 I/A MS R 1" # 3092 Angle 90 Angle 90 LESTOPREX AG Tel. Nr. +41 (0) Page 10

11 Winkel 90 I/A MS R 3/4" # 3090 Angle 90 Angle Winkel 90 I/A MS R 3/4" # 3092 Angle 90 Angle Reduzierstück A/I R ½ Kugel KFE Hahn MS Kappe mit Sechskant Réduction Robinet Bouchon hexagone Reduction Ball valve Hexagon ¾ Langnippel MS (Fremdölabscheider) Raccord (séparateur d huile) Fitting (Oil separator) Schlauchschelle für ¾ Bride Hose clip Schlauchschelle für 1 ¼ Bride Hose clip PTFE Dichtband Joint Leak proof band Haltewinkel für Schwimmerschalter Fixation pour interrupteur à flotteur Hanger for floating gauge U-Scheibe für M6 Rondelle M6 Washer M Sechskantmutter M 6 Bouchon hexagone Hexagon nut M Zylinderschrauben M6 Vis M6 Screw M6 32 LESTOPREX AG Tel. Nr. +41 (0) Page 11

12 9.3. Exploded View 9.4. Electrical Connection LESTOPREX AG Tel. Nr. +41 (0) Page 12