Water filtering system for optician Instruction manual Version 3.7 02-05-2012
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Safety instructions Intended application This device has been developed for the filtration of the water used to edge ophthalmic lenses. Do not use it for any other reason. General Safety Before putting the device into operation please read the safety instructions and the operation manual carefully. That way all functions can be used safely and reliably. Keep this operation manual. In the case of handing over this device to someone else, this manual has to be passed on as well. Packaging materials are in no way toys. Prevent children from playing with the bags that are made out of plastics. There is risk of suffocation. Keep children away from the materials included in the active carbon cartrige and the Zinc Ricinoleate bottle. In case of inadvertent contact, wash skin and eyes with water. Do not try to open or repair the device yourself. Repairs should only be carried out by trained personnel. Installation Conditions The device must be placed on a solid and stable subsurface. Do not run the device in a surrounding where water or liquid might enter. In case of ingress of water there is a risk of electric shock. Make sure that all cables and tubes are arranged in a way that no one might stumble. The air in- and outlet of the anti-smell device must be kept entirely free. Precautions against electric and magnetic dangers Make sure that the device is connected with a bus bar that provides the same voltage and frequency as stated on the type plate and that it is grounded according to the local requirements. The device is only to be run with a voltage of 220-240 VAC. The device has a maximum electric consumption of 400 W. To pull the plug, always pull the plug, not the cable. For a better protection against the dangers of electric current a special safety switch should be used if an installation for that purpose is missing. Cleaning and maintenance Before any cleaning or maintenance, switch the device off and disconnect it from the bus bar by pulling the plug out of the socket. Never switch on the device during cleaning or maintenance. In case of interferences Pull the plug immediately if cable or device is damaged. Do not induct any objects into the device. Conductor rails might be touched. If liquids or foreign substances get into the device, pull the plug immediately. The device should then be checked before it is put into operation again. If a proper function is not possible even if the function is according to all articles of the operation manual, the device has to be disconnected. Besides these advices in the operation manual all local rules for accident prevention have to be considered and followed. V 3.7-3 -
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Operating Principle The operating principle of the system is simple. The edger cooling water is contained in the right tank of the Neptune filtration. These 50 litres of polluted water during the day by edging residues are pumped into the left tank of the system when starting the filtration cycle. The left tank includes a filter bag with a 70 litres capacity which will retain the grinding residues: the 50 litres of water and, as the filtration cycles accumulate, up to 20 litres of residues, which is on average equivalent to 1500 lenses. Day Night Returned water from edger Water to the edger It is imperative that one of the 2 tanks is always empty of water so that the system works by a principle of communicating vessels! Filtering bag When sending polluted water into the filtering tank, a portion of this water is used to clean the walls of the working tank and its bottom. When all the water is pumped into the filtering tank, the pump stops and Filtration tank Working tank Cleaning and filling of the tank with clean water approximately 1 liter of filtered clean water returns from the filtering tank to the working tank. This water is used again to clean the walls, the bottom and then returns to the filtering tank. This cycle will repeat 10 times and will last from 10 minutes to 1 hour depending on the quantity of residues in the bag. As the bag will fill up with residues, the cycle time will lengthen, but the maximum time will always be 1 hour or less. The number of cycles in the allocated time will therefore become shorter. It is this count that will determine the moment for changing the bag. Although the cycle varies from 10 minutes to 3 ~ 4 hours, the total powered time is about 10 minutes, which represents an average energy consumption of 0.11. Start the cycle every day to prevent the accumulation of residues which will eventually block the pumps. V 3.7-5 -
Starting to use the Neptune filtering system 1. Unpack Neptune and remove all the polystyrene packaging. 2. Lift the filtration cover using the two handles (left side) and verify that the metal bracket at the bottom is in place, that the power cord from the return pump does not disturb the movement of the float switch. Reposition the cover. 3. Connect the control box Run the cable through a hole in the work bench Connect the cable to the box Place the box next to the edger 4. Connect Neptune to the mains. 5. Switch on the power switch on the bottom left side of the filtration system Neptune (diodes of the control box will flash and initialize). 6. Install the pump of the edger in the back of the working tank. 7. Fill the tank of the working tank (right side) with 50 liters of water. The green diode of the series of three diodes 5MIN, OK, MAX) located on the the box should be lit. If there is not enough water, the lower red light is on, add water. If you put too much water, the upper red light lit up. It is imperative to pull water out from the tank to return to the OK position. With Anti-Smell option The Anti- smell device is composed of three parts The collector / diffuser of zinc soap Remove the Zinc bottle cap and clip it into position on top of the tank Position the module with the orange ring in the hole on the upper tray Note: the bottle of zinc is to be changed when empty, approximately every three months. Fix the activ carbon filter on the Zinc soap diffuser module Note: this module is to be changed every six months. The fan module Put the stick fragrance into the tube (if desired) Fix the fan module on the active carbon filter Connect jack socket 8. Set up the return drain (100mm diameter) between the edger and Neptune 9. Neptune is ready to be used V 3.7-6 -
Description Control Unit 1. DAY mode switch and LED indicator 2. NIGHT mode switch and LED indicator 3. Inverter switch DAY/NIGHT 4. Filtering tank water presence LED indicator (T2) 5. Water level LED indicator in working tank (T1) 6. RUN switch 7. STOP switch 8. Cycle counter 9. ERROR LED Use Operation The master switch is located on the lower left side of the machine. When pressed, all LED from the control panel will lit for initialisation. When finished, only the DAY LED and the Water Level Indicator will remain lighted. Water level control Independantly from the selected mode, i.e. DAY or NIGHT, the T1 LED indicator indicate the water level in the working tank There are 3 positions: 1. Red upper LED: Too much water in the tank 2. Green middle LED: Water level is OK 3. Red lower LED: Not enough water in the tank Position N#1, red upper LED lit generates a system malfunction. Excess water has to be removed from the tank to return to the middle green position OK V 3.7-7 -
Filtration Cycle start Press the MODE switch every evening when closing the lab. The NIGHT mode LED lights. Press the RUN mode switch until the corresponding LED lights up. It confirms the starting of the filtering cycle (the pump should start at this same moment). The cycle will last from 1 hour to several hours depending of the quantity of waste in the filter, hence the reason for starting the cycle at the end of each the working day. The cycle counter will indicate the number of filtering cycles that have been performed within 60 minutes. This number is limited to 9 and the cycle can be shorter than 60 minutes if the bag is new. When the filtering cycle is finished, a letter/number will be shown: o If the counter indicates 3 or below, it is time to change the filtering bag. o If the counter indicates P, it is an error message. The return pump in the filtering tank has been working continuously for 8 hours. See maintenance section o If the counter indicates G, it is an error message. The main pump in the working tank has been working continuously for 15 minutes. See maintenance section. The T2 LED indicates water in the filtering tank. During the filtering cycle it will turn on and off. This is normal; it indicates that the water is filtered. This LED should never be lit during the DAY use. If it is lit, it indicates that water remains in the filtering tank. This situation is abnormal: 1. Too much water in the tanks: as the tanks communicate trough a communicating hole in their top, the filtering tank can never be emptied. 2. Edging residues have penetrated the filtering tank through the communication hole and have potentially blocked the small pump located at the bottom of the filtering tank. In both cases, remove the excess water, remove the filter assembly, clean the filtering tank and check the small pump operation: 1. Press MODE switch to DAY 2. Press RUN and wait for the cycle start. 3. Press STOP V 3.7-8 -
4. Press STOP again and maintain pressed. The small pump should start. If not, open it, check the rotor, clean it and re-assemble. Important: Empty and clean the filtering drawer every day, particularly if edging polycarbonate or milling (Essilor M. Blue, etc ). In case of important operation, empty and clean as much as needed. Installation Anti-Smell device 1. Position the bottle of Zinc ricinoleate soap. This bottle has to be changed when empty (roughly every 3 months). 2. Encase the diffusion box. 3. Position the active carbon filter. This filter has to be changed every 6 months. V 3.7-9 -
4. Insert the air vacuum box. A perfume stick (identical to those used in vacuum cleaners) can be positioned in the pierced tube. 5. Connect the box to the power supply cable Operation 1. Press the MODE switch to make sure that the system is in Day mode. It is not necessary if the Day LED is already lit. 2. Press the RUN mode switch until the corresponding LED lights up. It will start the anti-smell cycle (the fan will start). The cycle will last for 30 minutes and stops automatically. The cycle can be started as much as needed. 3. The STOP switch can be pressed for immediate stop. In this case, both DAY LED and NIGHT LED will flash. Press MODE to resume normal operation. 4. The STOP switch can be pressed for immediate stop. In this case, both DAY LED and NIGHT LED will flash. Press MODE to resume normal operation. Nb: When starting the cleaning/filtering cycle, the fan will run for 1/2 hour to remove the odour of brewing water charged with grinding particles. V 3.7-10 -
Maintenance Changing the filtering bag The bag has to be changed every 1500 lenses on average. Do not clean it! When the cycle counter indicates 3 or less, the filtering bag has to be changed within a few days, i.e. next week end. In order to operate this operation as much comfortable as possible, it is better to plan it in advance: Do not start the filtering status the previous day so that the bag is as dry as possible (less heavy ) Prepare a garbage bag of 100 litres (22 Gal) Lift the filtering assembly and place it directly in the garbage bag Remove the upper screws Remove the metallic frame Remove the filter, close the garbage bag and place it in the domestic garbage. Install the new filter, make sure that the metallic frame clips the bag Tighten the screws back Before re-inserting the filtering assembly, clean if necessary the tank, check that the pump is OK and that the water presence switch is free to move. Check the position of the grid support. It must "protect" the sensor N 1. Take advantage of this operation to verify that the nozzles of the hydraulic system are not blocked Check water level after one complete cycle Cycle counter should indicate 9 Zinc soap Every 3 months, check level and eventually replace. Active carbon filter To be changed every 6 months. V 3.7-11 -
Reminder : The filtering bag is a consumable, it should be changed approximately every 1500 lenses. Reusing a bag after cleaning it will cause a failure in the system. Changing the water In order to maintain the best performance of the filtering system, it is recommended to drain the water at least once a year. Depending of the nature of the water and the amount of edged lenses, it might be necessary to perform this operation more often. Draining the water is simple and has to be done when changing the filtering bag: o Remove the filtering bac with its cover. o Introduce a bucket under the hydraulic tube connecting the filtering bag. o In DAY mode, hold down RUN to start a cycle. o As soon as the RUN LED is lit, press STOP. Neptune is in test mode and the 2 LEDs NIGHT and DAY blink. o Press RUN to start the main pump and start to transfer the water into the bucket. o When finished, press MODE to return to the DAY mode. o Fill up the tank with fresh water. Pour a bottle of SIDEROPTIC in the fresh water to decrease foam, the "greasy film" adhering to the walls and prevent bacterial growth. The product is active as the water is not changed. Hydraulic circuit cleaning The hydraulic circuit can become clogged with edging particles, especially those of polycarbonate. At each change of bag, check with the hand that the nozzles of the circuit are not blocked. Otherwise, clean nozzles as follows: o Remove the cover located on top of the tray. o Unscrew the porpoise nut indicated with the yellow arrow o Remove the hydraulic circuit. V 3.7-12 -
o Check the nozzles o o if necessary, dislocate the pipes (each pipe is glued at one end to an elbow to facilitate reassembly of the circuit). Clean the pipes with a stiff wire. Relocate the circuit, tighten the porpoise nut and reset the cover. Cleaning return pump The return pump can be blocked by the intrusion of a broken lens in its impeller or a solidification of edging residues if the filtering cycle is not performed every day To clean the pump : o Carefully open the cover to avoid breaking the plastic stand. o Remove the impeller from the pump body, clean it if necessary and reassemble. It should rotate freely. o Check the presence of the white nylon bearing and reassemble the cover. o Test the operation of the pump as indicated in the next section. V 3.7-13 -
Pumps and sensors tests All components of Neptune can be individually tested to diagnose a possible breakdown Filtration tank bottom sensor Sensor N 1 to the moving of the sensor. This sensor indicates the presence of water in the filtering tank. Its signal triggers the start of the return pump. Its correct operation is verified by moving it manually and checking the lighting and the extinction of the corresponding T2 diode of the control box. Warning: this signal is delayed and reacts slowly Working tank water sensor Sensor N 2 This sensor indicates the water level in the working tank. It is located on the front side of the tank, under the tray. When it indicates MAX, the water cannot be returned from the filtration tank to the working tank in order to avoid the overflowing of the working tank. Its correct operation is verified by moving it manually up and down and checking the lighting and extinction of the three diodes (MIN, MAX and OK) on the control box. Warning: this signal is delayed and reacts slowly to the moving of the sensor Filtering tank water presence sensor Sensor N 3 This sensor is located at the bottom of the working tank and indicates the presence of water in it Its correct operation is verified by moving it manually in upper position and simultaneously starting a filtration cycle (NIGHT + RUN mode). The main pump should start. Warning: this signal is delayed and reacts slowly to the moving of the sensor V 3.7-14 -
Main pump and return pump Their correct operation can be checked: o Press the MODE button to switch to night mode o Start the cycle by pressing the RUN button (min3 sec.) o Stop the cycle immediately by pressing the STOP button. NIGHT and DAY diodes blink. o Press the STOP button to test the return pump If the pump does not start, then proceed with its cleaning. o Press the RUN button to test the main pump. If the pump does not start, this is likely due to a locked rotor. Clean pieces of lenses or other materials that may be the cause. V 3.7-15 -
Answers to frequently asked questions (FAQ) Filtration (night) cycle does not start The starting of the night cycle is controlled by the RUN button and the signal "presence of water" in the work tank emitted by the water level sensor N 3 located at the bottom of the tank. With water, it must be set in the high position. Check that the floating sensor N 3 is not affected in its movement by edging residues or the power cable from the pump. The night cycle started normally and this morning the red light is on and the counter shows the letter "P". The return pump from the filtering tank worked continuously for 8 hours. The water level is set to OK o Turn off power on the left side of the tank, wait several seconds and turn on again the tank. Monitor the LED test on the control unit (they light up one after the other). After this test, the control box must be in DAY mode, T2 LED off and water level OK. The cycle counter will indicate a point, no number (no cycle has been achieved since power on). If this is the case, the control software bugged during the cycle. T2 LED is on and the water level is on MIN o Check the filter tank pump as previously said o Check the hydraulic connection between the pump and working tank o Ensure free movement of the water sensor in the filtering tank The night cycle started normally and this morning the red light is on and the counter shows the letter "G". The working tank pump worked continuously for 15 minutes. Check that the floating sensorn 3 is not affected in its movement by edging residues or the power cable from the pump The hydraulic system which is fed by the working tank pump is clogged. Unscrew the tube coming out of the pump (big porpoise nut) remove out all the tubes and clean them with a stiff wire or a knitting needle The green tray T2 is turned on while the filter cycle is finished There is too much water in the entire system. Remove water from the working tank before restarting the cycle at the end of the day. If necessary complete with water in the morning. Beware; the filtering tank has probably been polluted by contaminated water from the working tank. As soon as possible, while the filtering tank is empty after a filtration cycle (T2 LED off), remove the filtering bag and clean the tank. V 3.7-16 -
Accessing to the electrical box and fuses o Unplug the electrical plug from the socket. Unscrew the 2 upper screws holding the working tank cover and remove it. o Unscrew the 2 side screws holding the front upper cover and remove it. o Unscrew the screw holding the stainless steel part. o Remove the part. o o Lift the front panel and gain access to the electrical box in which the fuse (2A/250V or 5A/110V) is located. Reassemble in the inverse sequence. V 3.7-17 -
Main Board Version 3 Control panel V3 (Filtering cycle counter) Anti-smell electric board V 3.7-18 -