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27.0. OPTIONAL EQUIPMENT (Cont.)

1. 23 1 ChipBLASTER Inc 89 24 0 WARRANTY 24 1 WARRANTY LIMITED NEW EQUIPMENT ChipBLASTER Inc Limited Warranty New Equipment Limited Warranty ChipBLASTER Inc warrants its ChipBLASTER high pressure coolant systems to be free from defects in materials and workmanship for the lesser of one year or 4160 hours of operation from the date of original installation subject to the conditions set forth below During this warranty period ChipBLASTER will repair or replace at its sole option defective products or parts without charge to the purchaser Limited Warranty Conditions 24 1 1 Limited warranty applies only to new ChipBLASTER equipment and is solely for the benefit of and applicable to the end user 24 1 2 This limited warranty does not apply to any damage failure defect or loss caused by any or all of the following circumstances or conditions failure to follow instructions or observe cautions and warnings relating to installation operation applications inspection and regular maintenance as specified in this warranty and or any ChipBLASTER manual quotation acknowledgment spec sheet or installation instructions all of which shall hereinafter be referred to as ap
2. PRESETS Code Label Value Default value Logical address Menu ACC Acceleration ramp time 4 MODELS 3 05 9001 ADC Automatic DC Injection Yes DC inj for adj time Yes DC inj for adj time 10401 ADCO Drive CANopen address 6051 Configuration Configuration reference 1 4821 Configuration of AI2 Suniminginput2 4822 regulator feedback AIBA Configuration of AI3 Not configured Not configured 4823 1 Configuration of AO1 Configuration 0 20 mA Configuration 0 20 mA 4601 ATR Automatic restart No No 7122 BDCO CANopen trans speed 125 kbitls 125 kbitls 6053 Std motor frequency LIAE 50 Hz 3015 Brake control assigned assigned 10001 BRA Decel ramp adaptation Yes Yes 9003 CHP Switching motor 2 Not assigned Not assigned 8011 CLI Internal current limit 41 2A 41 2A 9201 COL Stop for CANopen fit COF Freewheel Freewheel 7011 cas Motor power factor 0 85 0 85 9606 CRH3 Value for high speed AI3 20 0 mA 20 0 mA 4444 CRL3 Value for low speed AI3 4 0mA 4 0mA 4434 CTD Motor current detection 27 5A 27 5A 11001 DCI DC brake via logic input assigned Not assigned 11203 DEC Deceleration ramp time ae MODELS 3 0 s 9002 DO AAOC AOVassignment Not assigned assigned 5031 DRN Derating for undervoltage No 7007 EPL Stop mode at external fit
3. swos un azis Woo Jejse qdiuo vsn wsmoisno 8Z9 vZ v18 Xv4 36591 Vd 52975 OILVIN3HOS ONIdid 718 3NOHd NMO LH3ISOW 8 5096 EEr Sasi OO auva SINN Jes 40 das tL 138 OL S3ATVA 9 8 OL SONLLLIJ JO NV LON 30 OILVIN3HOS V SI 5310 1 LNVIOO9 SVH OLAF 15 3LON 8 105 S INV1009 108 zi 108 70 V 1 LNV1009 uo1vinwnoov H3lsviadiuo NOISSIINH3d N3 LLIHM ALNOHLIM ONIHOLLOVAONVIW 303 GASN HO SH3HLIO OL GSSOTOSIC 38 LON AVIA NOLLVINHOHNI HONS A amp V L3IHdO d SNIVLNOO LN3An2OQ SIHL JO 3HL SIHL dS 1001 HSIN 02 Em WalsVi8dHO MOTdH3AO WN
4. 433 298 owa 312 __ 48 owe 199 502 34 oos 828 359 199 591 883 468 0260 10 497 osm oos es 788 J8 1000 JV8 1000 28 2 ChipBLASTER Inc 120 28 0 SUPPLEMENT DATA CONT 28 3 Orifice Reference Chart for 1500 PSI Sq Inches GPM Required joutputs 0001 150 89 0 01 0015 00002 150 56 03 os 000 0 003 1500 59 0 025 0005 1500 59 09 09 owo 1500 ooo 199 59 18 ME NN 0050 00020 150 56 35 36 0055 0004 150 56 42 43 ee SEES ____ 54 ooo ooz 10 s sol s alu 55 0005 0005 100 56 59 9 0070 150 56 68 70 1 0075 0004 150 56 78 81 E DE Dis __ XX56 0080 00050 150 so 89 392 0085 00057 150 56 101
5. 1 MOVIE Giolvinwnoov ddl NOLLWSINd 6p 14 3onvo L sunssaud 1001 3NIHOVIN M3NIVHIS HSIN OZ IWNOILdO 434SNVYD NYNLIY lt 4 HSVM n 88 105 HSVM 10 xt NOWOIW S vv 108 NMOG HSVM 10 NOWOIN S 5 7 7 A a 9 lt W WN 8000 a e ova a SHOSSSHdHOIM 1900 c 131009 8705 105 542 1 T 1 11Nv1000 Sde 00 9000 000 onyo 93 D 3onv Benv AMO warn AJIN 13uno 30018 GQ O3INVIN Mara ova INVIOOO KZ 1504 4 IYNSSIYd gt 00 YILT L37INI 20 01 19 1 5 2 NI 200 3A31H9IH gt OVE e 21 T KE n 21 2 TT ChipBLASTER Inc iping 21 3 Autocross Schematic P OV L A3iEL dO 90 18485 CC SIN ad
6. SOLENOID A FITTING NOT P N 4002 SHOWN FOR CLARITY LENOID B m BM REGULATOR UNLOADER P N 4546 PLUG P N 4156 Figure 17 19 4 1 Install Hose Adapter Fitting and attach low pressure hose ATTACH DISCHARGE TO FLUID CONTAINER TO ELIMINATE FLUID SPILLING 19 5 For units with pressure switch Refer to Figure 18 SOLENOID A P N 4002 FITTING NOT SHOWN FOR CLARITY SOLENOID B P N 4001 REGULATOR UNLOADER P N 4546 PRESSURE SWITCH P N 9498 REDUCING PRESSURE BUSHING SWITCH CORD P N 4620 ASSEMBLY Kou is P N 19 5 1 Remove electrical din connection from pressure switch 19 5 2 Remove pressure switch 19 5 3 Remove 2 1 8 reducing bushing See Figure 18 19 4 ChipBLASTER Inc 66 19 0 SYSTEM CONTAMINATION PURGING PROCEDURE Cont 19 5 4 Install hose adapter fitting and attach low pressure hose NOTE ATTACH DISCHARGE TUBE TO FLUID CONTAINER TO ELIMINATE FLUID SPILLING 19 6 FLUSHING CYCLE 19 6 1 Press the AIR PURGE RESET pushbutton located on the front of ChipBLASTER s electrical enclosure 19 6 2 Continue pressing the AIR PURGE RESET pushbutton until 5 gallon container is full 19 6 3 Close the Air Bleeder Valves located on the upper portion of the filter 19 6 4 Press the AIR PURGE RESET pushbutton again to continue flushing cycle Fill the 5 gallon container an addition 3 times to
7. 48 33 4 Nozze 6 tooo 48 49 1000 46 5i 605 0057 1000 45 82 se oo __ 1000 465 309 0096 303 79 1999 5195 61 oos o 45 2000 oms omoa 19 559 61 ooms tooo 45 omas 1009 78 gt oos 199 gt Nozze Boxee 299 191 _ __ 5 340 oosa 10 465 164 oom 465 ooe 10 273 181 oom 10 291 198 515 gt oom 28 oom 465 348 io 48 368 gt oo 100 oosa 100 411 291
8. 5 4 6001 7000 3 8001 0 00 N yw C 190 bal 7 2000 o o8 Te 9001 23 T 9001 S 1000 4 yl RA P Qvi gt voo 5 a o 9 E o gt 2 40 5 200 0000 8 E E 95 0001 gt 4 gt 8 8 23 88 5 5 26 2 9 8 58 Sz 5 3 8 8 8 amp 38 5 al gt B 8 8 91 9 81 21 AQ 8 5 8 8 8 8 8 8 8 8 8 x 8 2 2 5 2 2 8 CR C8 3 8 8 5 8 R 9 92 8 192 18 92 182 192 wow SWS 5 yes 20 3 ChipBLASTER Inc 69 20 5 PLC Input Wiring 8 45 S a DC 5 8 24VDC COM 2 E 300 207 PLC INPUTS 207 9 PLC 24 VDC INPUT 5 3 m lt 301 M 5 22 55 LI is 10 0 0 302 BAG FILTER DIRTY DETECT s Z i i 10 0 1 z lt 303 SPARE INPUT 1 6 5 2FS 10 0 2 a 304 TANK LOW LEVEL Ue ME 2 g 9 5 m TANK HIGH LEVEL sack 3 oreen 03 ug 5 E 8 amp mp srown TFS pen 10 0 4 B TANK LOW LIMIT AAFD
9. LNVIOO9 TIE ED Z ON INY1002 5 lt ED L eNINVIOOD yo NMOQ HSVM A ER E i 391440 9NNOOL EET S 7 x 7 x 7 MOVE Giolvinwnoov w Tal uar 2 67 3unssaud ET CN w SON MALVINOTY 015 1804 ova wv310s BunssaHd 1090 J J 5242 HSVM 910 11177 8105 105 2108 1009 14 1005 1NV1OOO 111005 dina Sdz 2000 9000 5000 1000 eae wang 5 4241 3 0018 i YILT 1NVIOOO E 1504 9 8 wNOlLdO 1 001 57 iC 20101 MO 2 590 71341 MOVIE whit uva W 6000 88105 S NMOG HSVM d 1105 5 000 4 108 n 7 LINI YALTA 4 00 YILT LIINI 21 3 ChipBLASTER Inc 78 22 1 EV Gage Panel Side Mechanical Assembly MEC INN 3 L
10. SWVN 5 HORSEPOWER 72 20 13 Power and Mistblaster Interface ChipBLASTER Inc V IHL ASATC Z 9 1002NvrIE ELAS ONC um venossro 1829 9020 9NIHIM 9nd YIMOd 311815 002 JS SEI Qd AV 8072 24918 aTIAGVaW NMOJNISOW 5 8091 En xx 100 Xxx 900 5000 GAL OYNON swm ET dooznvrie CONTROL INTERFACE ETHERNET CABLE 5171 CABLE 1 METER MACHINING CENTER POWER INTERFACE P N 9484 PLUG 12 PIN ChipBLASTER am 9 1CB L1 3 PHASE SUPPLY 12 INPUT REFER TO POWER WIRING L3 FOR CURRENT DRAW GND OPTIONAL ChipBLASTER TO MISTBLASTER INTERFACE PLUG 6 PIN 315919849 NOUS LNOHLIM 0351 ANY SH3HLO 01 0350101038 LON NOLLVARIO NI HONS 1 SNIVINOO 193 120 ELS YIEdIuO 40 ALUAdORd SI NIB CHIPBLASTER MISTBLASTER INTERFACE PLUG START SIGNAL TERMINAL BLOCK TERMINAL BLOCK CR7 21 524 115VAC SUPPLY 100 101 4 25 6 100 101 COMMON COM OCB 9L1 912 L1 12 9L3 STD 1
11. BE CAREFUL NOT CRIMP GAUGE TUBING LINES DO NOT RUN HIGH PRESSURE RUN WITHOUT OIL AS DAMAGE WILL RESULT AND VOID YOUR WARRANTY DO NOT ATTEMPT ANY SERVICE ON ChipBLASTER UNIT WITH POWER ENERGIZED REMOVE ALL ENERGY Q SOURCES AND LOCK OUT TAG OUT ChipBLASTER Inc 33 14 0 PREVENTATIVE MAINTENANCE Cont 14 4 HIGH PRESSURE PUMP CHECK BELT s 14 5 14 6 14 4 1 To check the high pressure pump drive belt the panel to the left of the gauge panel will need to be removed using a 6 mm hex wrench 14 4 2 Check belt tension Refer to SECTION 18 0 14 4 3 To adjust motor to pump drive belt turn the adjustment bolt on the pump mounting base using a 9 16 socket To tighten belt turn the adjustment screw counter clockwise to loosen belt turn the adjustment screw clockwise 14 4 4 Replace panel before operating the ChipBLASTER HIGH PRESSURE PUMP CHECK FOR LEAKS 14 5 1 Remove the panel to the left of the gauge panel using a 6 mm hex wrench 14 5 2 Check for leaks around pump head and on sub plate 14 5 3 Verify the fluid is not coming from a fitting or hose If a hose is leaking shut down the ChipBLASTER unit and replace hose If a fitting is leaking check tightness of fitting 14 5 4 If fluid is noticed the high pressure pump will require replacement Contact ChipBLASTER service department 14 5 5 Replace gauge panel before operating the ChipBLASTER unit HIGH PRESURE PUMP REBUILD 14 6 1
12. 14 2 CHECKING HIGH PRESSURE PUMP OIL 14 2 1 The high pressure pump oil may be checked by observing the level in oil sight glass located on exterior of the ChipBLASTER Typical sight glass mounting EV13 EVHP 4 OIL SIGHT GLASS 14 2 2 The oil level must be maintained between the full and add mark If required add oil refer to Section 14 3 2 5 FAILURE TO USE MOBIL 1 FULLY SYNTHETIC 15 50 WILL VOID YOUR WARRANTY gt WITH POWER ENERGIZED REMOVE ALL ENERGY DO NOT ATTEMPT ANY SERVICE ON ChipBLASTER UNIT Q SOURCES AND LOCK OUT TAG OUT ChipBLASTER Inc 30 14 0 PREVENTATIVE MAINTENANCE Cont 14 3 OIL CHANGE PROCEDURE r ITIS EXTREMELY IMPORTANT TO DISCONNECT AND LOCKOUT ANY AND ALL POWER SOURCES BEFORE ANY WORK IS TO BE z PERFORMED ON the ChipBLASTER UNIT 14 3 1 ChipBLASTER High Pressure Pump Change the crankcase oil every 2000 hours USE For ChipBLASTER Inc pump 2106 Mobil 1 fully synthetic 15W 50 FAILURE TO USE MOBIL 1 FULLY SYNTHETIC 15W 50 WILL VOID YOUR WARRANTY Other Pumps and Motors All have sealed bearings no lubrication is necessary 14 3 2 Oil Change Procedure 14 3 2 1 ChipBlaster High Pressure pump Change the crankcase oil every 2000 hrs 14 3 2 2 Remove accesses panel use 6mm hex wrench Typical access panel 14 3 2 3 Locate OIL SIGHT GAUGE ASSEMBLY and remove plug use 8mm hex wrench Allow to drain into a container For a single pu
13. 404 405 DESCRIPTION 406 407 408 1100 409 410 411 412 413 ind 100 415 416 atr 418 lad 100 420 227 423 424 100 425 1100 427 428 100 430 ee 432 TOUT vor TOUT vie vi gt 2 gt 205A ICOM Q0 0 0 2058 00 0 1 00 0 2 00 03 Q0 0 4 Q0 0 5 00 0 6 00 0 7 Q0 0 8 Q0 0 9 Q0 0 10 Q0 0 11 00 0 12 Q0 0 13 Q0 0 14 Q0 0 15 CR6 D 14 PLUG AND HOOD 2 TO 24V 1AFD TO COM 1AFD LI 1AFD SPARE SPARE SPARE PLC RELAY OUTPUTS 1KSS AUTO OFF 110 Di 111 110 RECT AND PANEL MOUNT 1 CAP 8uF 250 VAC 6MTR OIL SKIMMER 1 40 HP 0 8 FLA SOL A C vat SOL B A tae T 2 SOL BROWN BLUE lt gt 1 SOL L A BROWN BLUE SNe 7MTR AIR PUMP 1 40 HP 0 8 FLA COM 240 COM 4 TB1 COM one OPTIONAL 1 2 4 OIL SKIMMER CONTROL MR2 amp 3 0 62 FILTER PUMP MOTOR 4 SPARE OUTPUT MR3 Ad 4 RETURN PUMP E OPTIONAL CENTRAL COOLANT SYSTEM SOL AA 4 SIDE COOLANT 1 CR7 AXE MISTBLASTER ENABLE DUMP SOLENOID SIDE B COOLANT 1 4 SPARE OUTPUT SPARE OUTPUT OPTIONAL AUTOCROSS SIDE A RUN FILTER A
14. maximum Sq Ft Sec GPM Required outputs Inches RE MR n oem ow wo 19 38 f oos 54 fowr 5 23 78 oos fowo 5 31 19 fow 41 28 UI LIAE sms me nr evs 28 6
15. 103 EV2000 Vega 2002 0090 00004 150 56 113 ne Cose 57 0095 00071 150 55 i26 129 0100 00079 150 569 139 O 0405 150 6 154 158 0410 0005 150 169 73 0415 omo 150 56 184 189 0120 oom 1580 56 201 206 0 125 00125 1500 569 218 224 00133 150 569 235 242 0 0133 69143 1 569 27 5 0 00154 150 56 273 291 00165 150 569 293 301 150 56 314 322 te el 28 3 ChipBLASTER Inc 28 0 SUPPLEMENT DATA CONT 28 4 Orifice SETE for 2000 PSI Outlet Area Velocity Volume Horsepower Machine maximum Sq Ft Sec GPM Required outputs Inches aoi 0 6 02 200 e 94 0 0003 2000 Eo OT ee eee EE a 7 0 015 0 020 0 025 0 045 0 050 0 055 0 2 0 5 2 0 2 7 3 5 Nozze 055 20 200 8 33 0 065 0 070 0038 200 108 EVZ000 Vega 2002 oos Nozze 6 0 004 20 oo 0 085 0 090 Lowe mu wr ms 585 ow 1 a
16. Due to the manufacturing tolerances required for the internal parts of the high pressure pump rebuilding the high pressure it is not recommended A new replacement pump can be purchased from ChipBLASTER When ordering a new pump from the ChipBLASTER service department advise the contact person that you wish to receive an RGA number for the pump to be replaced 14 6 2 When the old pump is received at ChipBLASTER the pump will be inspected for any damage If no damage is noted a core charge credit will be issued 14 9 FILTER PUMP CHECK FOR LEAKS 14 9 1 Remove the panel to the left of the gauge panel using a 6 mm hex wrench 14 9 2 Check for leaks around pump head and on sub plate 14 9 3 Verify the fluid is not coming from a fitting or hose If a hose is leaking shut down the ChipBLASTER unit and replace hose If a fitting is leaking check tightness of fitting 14 12 BAG FILTER UNIT s CHECK PRESSURE GAUGES 14 12 The inlet and outlet pressure gauges should read within 15 PSI 1 Bar of each other If the outlet filter gauge reads less than the inlet gauge this will be an indication of the bag filter becoming clogged The JV units will indicate a dirty or clogged filter with a flashing red light 14 4 14 12 ChipBLASTER Inc 34 14 0 PREVENTATIVE MAINTENANCE Cont 14 13 FILTER CHANGING PROCEDURE AO USE CARE WHEN CHANGING FILTER BAGS AS THEY MAY BE HEAVY DEPENDING ON MATERIAL BEING MACHINED THE USE OF
17. S000 XXXX S000 0 WH3TIIHO Id SZ 20 42 AALLVINWNDDYNON seoueJejo 431591994 S3l1ON LH Vd 5 ALO Ll S31OH ONILNNOW MNVL Af S3 OH ONILNNOW S3LON 000 096 5 5 NOISSIWe3d S3SOd fd SNIHOLOVAIONVIN GASN SYJHLO OL Q3SO I9SIG LON AVIA NOLLVINHOJNI HONS ANY NOLLVINHOJNI 5 LN3IWn2o0d SIHL 315 7991 0 JO ALYadOUd JHL SI LNIHd SIHL 096 000 00 281 THRU 6 PLACES alva SINVN 15 938 23 250 27 21 OPTIONAL DROP IN CHILLER Cont 27 0 OPTIONAL EQUIPMENT Cont 27 21 13 DIMENSIONAL PRINT ChipBLASTER Inc 27 21 266266 000 22 500 NOTE 1 008266 REF ChipBLASTER Inc 118 28 0 SUPPLEMENT DATA 28 1 PROGRAM REVISION USING EEPROM CHIP 28 1 1 The TWIDO PLC has the capabilities of changing programs and restoring programs via a replaceable EEPROM Electrically Erasable Programmable Read Only Memory chip The EEPROM can be inserted only when the PLC is powered down DO NOT INSTALL OR REMOVE AN EEPROM CARTRIDGE WHILE THE PLC IS POWERED 28 1 2 Power down the PLC by turning off 4CB 28 1 3 Lift the cover over the output terminal strip lower cover 28 1 4 Install the EEPROM cartridge The EEPROM cart
18. WARRANTY AND DAMAGE THE MACHINE 27 21 1 UNCRATING amp INSPECTION 27 21 11 2214 2 Rough handling during shipment may cause obvious and or concealed damage Upon arrival the cooler should be inspected carefully and claims for damage must be filed immediately with the trucker When uncrating the cooler inspect it thoroughly for signs of concealed damage Coolers that have been dropped or shipped on their side may not show external damage If damages are found a claim must be filed with the carrier within thirty days of delivery 27 21 2 COOLER PLACEMENT 27 21 2 1 The cooler is designed to be mounted on top of a tank with the stainless 21 21 22 2721 213 steel evaporator coils fully immersed Tank liquid level should be maintained within 8 of the top of the tank Lower liquid level will reduce the cooling capacity or damage the compressor The cooler should never be operated without the stainless steel evaporator coils completely immersed in liquid The cooler is provided with an air intake filter that must be kept clean The cooler will draw air in through the air filter on the front panel and exhale air through the top It is imperative that these vents remain open to permit the free movement of air Lack of adequate cool air will cause a reduction in cooling capacity and or completely shutdown the refrigeration compressor Two feet of open space on air intake and discharge The cooler is provided with two lifti
19. 0 Hz 0 0 Hz 11301 LAC Function access level Access to std functions Access to std functions 3006 IAF Limit forward direction assigned Not assigned 11601 LAR Limit reverse direction assigned assigned 11602 LC2 Enable current limit 2 assigned Not assigned 9202 LCC Remote terminal control No 64003 IFF Fall back speed 10 0 Hz 10 0 Hz 7080 LFL Stop mode at loss 4 20mA Fault ignored Fault ignored 7003 I Forward LITA Config logic input 1 ALL UNITS Forward 4801 Select 2 preset PI refs LIZA Config logic input 2 ALL UNITS Reverse 4802 2 Select 4 preset PI refs LISA Config logic input 3 ALL UNITS Select 2 preset speeds 4803 LI4A Config logic input 4 Not configured Select 4 preset speeds 4804 LIBA Config logic input 5 Not configured Not configured 4805 LIGA Config logic input 6 Not configured configured 4806 4 8 8 15 0 Hz LSP Low Speed EV GV CV 10 0 Hz 0 0 Hz 3105 JVA 12 6 A JV8 19 1 A EV 25 5 NCR Nominal motor current GV20 42 A 22 0A 9603 NRD Motor Noise Reduction Yes Yes 3107 1780 rpm NSP Nominal motor speed ALL MODELS 1780 rpm 9604 NST Freewheel stop assigned Not assigned 11202 OHI Stop mode at drive oheat Freewheel Freewheel 7008 all mode at motor oheat Freewheel Freewheel 7009 Output Phase loss fault fault 9611 PIC inversion No 11940 Analog input AI2 5 PIF PI regulator feedback ALL MODELS configured 11901 Yes PII Internal ref
20. 2 The coolant systems return pump will run automatically and independent of CRI This pump is controlled through the PLC via the tank level switch 12 2 COOLANT FLOW Refer to figures 6 through 6b 12 2 1 Coolant flow is divided into two groups High pressure and Low pressure Low pressure is the flow of coolant from the fourth compartment of the ChipBLASTER s tank to the high pressure pump High pressure is the flow of coolant from the high pressure pump to the nozzle outlet or tool at the machining center 12 2 2 LOW PRESSURE Low pressure leaves the fourth compartment of the ChipBLASTER s coolant tank and goes to the filter pump The filter pump pumps the coolant into a large filter where it will be filtered to 5 micron If a post filter is used it will be in series with the larger filter If the filters gets dirty a flashing red lamp will give an alarm After filtration the coolant is then sent through a post filter which is used to protect the high pressure pump in the event the bag filter was incorrectly changed A steady red light will indicate a dirty post filter The coolant is sent to the high pressure pump 12 2 3 HIGH PRESSURE High pressure coolant leaving the pressure pump goes to the manifold block which consists of an unloader 3000 psi 206 Bar pressure gauge solenoids transducer pulsation dampener and a pressure switch optional The unloader is adjustable to blow off coolant at 200 psi 13 7 Bar above the norm
21. 38 LON AV 8 Z9 vZ vL8 3NOHd VOY NMOLYSISOW S09 lt 0000 ed HONS ANY LNSWND00 SIHL JO ALH3dOSd JHL SI LNIHd SIHL ANINdLOOS 143 2 v d S s seswespo 4315918940 S310N ON Iud g 8 g g amp 5 E 8 5 m amp PEN 5 S mm d pu EN pu Jit 5 5 z 9 19 Fl o o 3 H LI Le Lr 29 L1 Li 1 g 8 3 ER ER 2 8 i 8 ks 8 8 1 99 5 8 EN 227 ef 66890 X ISd 5 a 1HOI3M GIN1d SINOLLdO LHOISM 3SV8 9NIQVO 40014 8 9768 9 LV AINT 3LON gv99 3 1113 AINT 81 85 3 114 3T9NIS Ll 81006 591961 81006 c1 001 dWnd u34SNvuL 55001 1022 3804 E 2 IWINSPELH X INWZOZLl X WWGLZLM HES X 19 3ZIS H3NIV INOO 810021 LH IIM 99969 9700p 1H5I3M 3sva 5 8 z 9012021 our S13Nvd 8 ET
22. 4 HIGH PRESSURE GAUGE EV13 4025 gt 6 CONTROL 1 57801 7 BAGFILTER POSTFILTER DIRTY LIGHT 75389 8 X TANKFLOATSWTICH 15688 aa 107 1 EA 12 13 1 2 3 4 5 7 10 11 12 13 14 15 22 1 ChipBLASTER Inc 79 22 6 EV Single Filter Side Mechanical Assembly 1 2 3 4 5 7 10 11 12 13 14 15 ER El 22 6 ChipBLASTER Inc 80 22 11 EV Control Panel Side Mechanical Assembly 3 CONTROL TRANSFORMER CONTROL SIGNAL INTERFACE CABLE S 7 OPTIONAL RETURN PUMP 3510 i METERS TER POWER AND CONTROL INTERFACE 5731 2 POWER INTE POWER INTERFACE CABLE Pk OVER FLOW 11 DISCONNECT 12 TANK FLOAT SWITCH 13 13 __ 22 11 ChipBLASTER Inc 81 22 16 EV Filter Mechanical Assembly ITEM No DESCRIPTION PART No 1 FILTER LID WITH BAG HOLD DOWN 3201A O RING SEAL 8 NOT SHOWN 2571 FILTER BAG 8 x 30 5 Micron 3013 5 BASKET SCREEN 8 3024 R2 FILTER HOUSING JV and EV 3200 FLUID OUTLET N A ILTER DRAIN N A ILTER MOUNTING BRACKET 8700 17 FLUID INLET N A GAUGE PORT USED ON J UNITS ONLY N A 10 FILTER BLEED AIR PURGE USED ON JV EV GV CV N A 22 16 ChipBLASTER Inc 22 17 EV Manifold Block Assembly ITEM No DESCRIPTION SHEAVE EV13 PUMP SHEAVE EVHP wee BELT EV13 DRIVE BELT EVHP IDEE SHEAVE EV13 DRIVE SHEAVE EVH
23. 4525 ChipBLASTER Inc 4 1 0 GENERAL WARNINGS Thank you for purchasing a ChipBLASTER high pressure coolant system For reliable safe and long term operation of your ChipBLASTER Machine must be installed and connected to electric service per the installation portion of this manual All persons who will be operating and maintaining this machine must read and understand this manual DO NOT AT ANY TIME USE FLAMMABLE OR EXPLOSIVE FLUIDS IN OR NEAR MACHINE gt THE ADJUSTABLE FREQUENCY DRIVE HAS THE POTENTIAL TO HOLD A LETHAL CHARGE FOR APPROXIMATELY 10 MINUTES AFTER POWER IS REMOVED FROM THE DRIVE REFER TO THE DRIVE MANUAL FOR DETAILS DO NOT STAND ON MOTORS SUPPORTS or JUNCTION BOXES WHILE WORKING ON THE ChipBLASTER REFER TO SECTION 4 1 FOR EXPLANATION OF MARKINGS 1 0 ChipBLASTER Inc 2 0 TABLE OF CONTENTS General General warnings Table of contents Specifications Safety precautions Explanation of markings Storage Moving machine Placing a ChipBLASTER Mechanical installation Electrical installation Control interface Power connections Start up System air purge Single filter Dual filter Autocross Operation Electrical operation Coolant flow Theory of operation auto cross option Alarms Preventive maintenance Maintenance schedule chart High pressure pump check oil High pressure pump change oil High pressure pump check belt High pressure pump check for leaks High pressure pump rebuild Fil
24. 5 es kS RIC RIB 10 0 5 ii 9 307 1AFD FAULT 4 5 AN 40 5 a a a 2 u 10 0 6 55 308 SPARE INPUT 5 z2 8 MR2 201 z2 8 S es 10 0 7 ou c 309 FILTER PUMP OVERLOAD 06 95 7 i m 8 MR3 30L 5 ot Van 10 0 8 51 310 RETURN PUMP OVERLOAD gt 98 65 Bie o 10 0 9 5 5 311 SPARE INPUT d E z 5 10 0 10 83 312 SPARE INPUT Q g e Sb 2 APR 10 0 11 X oc 313 RESET AIR PURGE gu d a 10 0 12 221 5 z em SPARE INPUT E me 10 0 13 29 POST FILTER DIRTY DETECT 315 8 Q OQ Oct o 10 0 14 suood d 5 316 SPARE INPUT SES Du EP 4 10 0 15 gt at 317 SPARE INPUT 55 255 si 10 0 16 318 SPARE INPUT SZ RS x 5 10 0 17 p gt ER 0 319 SPARE INPUT 8 8 10 0 18 DZE 320 SPARE INPUT 5 90 10 0 19 19 a 321 SPARE INPUT 2678 10 0 20 were 322 SPARE INPUT 2 Evon 10 0 21 3 22 B 323 SPARE INPUT aya E To m 10 0 22 04998 324 SPARE INPUT 2 x2 10 0 23 325 SPARE INPUT cu Oo5oz 22216 z 095 45200 6295 EEBOR zZhu zatz 5290 5 ooorc TOLSE razas 20 5 ChipBLASTER Inc 20 7 PLC Output Wiring DATE m 400 401 NAME 4025 240 100 TB1 100 403
25. 55060600258 60000000000000000000000900000900900999 20 23 Sub Panel Layout ChipBLASTER Inc 20 23 75 ChipBLASTER Inc iping 21 1 Single Filter Schematic P AS 1 30 901d3S CC SIN Wu 1338 in Woo Jeise qdiuo vsn TUYN wawoisno 929 VZJ v19 Xv3 92291 Vd 3TIIAQV3N MAL 319NIS 8729 7299 3NOHd VOY 50961 OLLVW3HOS LA3 NOlLdhios3a Jes 40 das 138 OL S3A1VA YINIVYLS 8 3NIHOVIN OL SONILLIJ HAWN LON SJOA 9Nldid OIL VIN3HOS SI SIHL L SILON NOISSIWH3d N3 LLISM 1nOHLIM SASOduNd ONINNLOVANNVW Q3Sn ANY SYSHLO OL 036012510 38 LON AVI NOLLVIAHOJNI HONS NOLLVIAHOJNI A3V L3lidOHd 5 SIHL 31SV 18diu5 40 ALH3dOMd JHL 51 LNIHd SIHL dNNS 1001 M3NIVHIS 1 HSIN MBISVISdIHO 4 MOTHH3AO 2 5 EL Aa IVNOILdO ON LNVIO09 EZ 9 1 1002 xA a ort ANO HE LNY1009 e
26. 86 22 33 EV Ship Loose Items ITEM No DESCRIPTION PART No 1 J PREFILTER SOCK 3017 300 LEVELING FEET 8269A 22 33 ChipBLASTER Inc 87 22 38 EVHP Spare Parts Recommended Listing SPARE PARTS ES EV EVHP DESCRIPTION PART No KIT PART KIT PART No NO NO e l 30017 30017 QT Y KIT QT Y KIT SOLENOID VALVE 4005 N O SOLENOID VALVE AD N C UNLOADER REGULATOR 3000 PSIG TS UNLOADER REGULATOR 5000 PSIG TRANSDUCER 0 2000 PSIG 9662 1 __ 1 E TRANSDUCER 0 5000 PSIG 9670 1 72022 71 0 0 L 4d 0 n 0 11 ho cxx 0 4642 2412 2611 2621 2556 2938 9668 HIGH PRESSURE PUMP NOT INCLUDED IN SPARE PARTS KIT FOR REFERENCE ONLY O 8 22 38 88 23 1 EV Footprint Drawing ChipBLASTER Inc 8 9010021 81 our our E sao oum w e is aia Sy 1adud Wow 58 ioo xxx LnOHLIM N04 uwm 1829 5618 xwa 500 SH3HLO O1 035010510
27. COOLER MRE Lu A23 RECTEPTACLE MAGNETIC SKIMMER 7 0 17 HP 22 P 5T2 5 1725 RPM N 230 VAC 30 FLA 1 2 213 tery 5573 lt 460 VAC 32 FLA 0 6 42 2 FRAME 126 111 908 911 c 1 TO MISTBLASTER 12 TENE L UNIT 122 AF 2 IF USED 1L3 9L3 129 e a lt a 130 500 USE 2 2 1000VA USE 3 H1 131 5 e C x 5 gt 2 4 4 o 4 4 200 460 vac 23 230VAC 2 77 WIRING WIRING YS 1L3 H S ed 200 d gt 500 VA 6 5 133 m 1000 VA 10 AMPS Jo SEE CHART PRIMARY TRANSFORMER TAP CONNECTION 134 GND 230V INPUT CONNECT H1 H3 CONNECT H2 H4 11 2408 41 460V INPUT CONNECT H2 H3 OPTIONAL CHILLER 136 UNIT 230V19 1L3 P 413 8000 BTU 137 212 20 230VAC PN 7590 ONLY NOTE FOR A DROP IN CHILLER FOR 460 VAC A STEP DOWN TRANSFORMER WILL BE REQUIRED 2CB 60 HZ 60 HZ 16A 15A 60 HZ 40A 1 1CB WITH 6 OUTLET UNITS ONLY USE 1000 VA TRANSFORMER 230 460 VAC 230 VAC 460 VAC 230 460 VAC 63A 2 USE FOR 500 VA TRANSFORMER 1 SET IR COMP TO 0 8 3 USE FOR 1000 VA TRANSFORMER CHART MODEL 60 HZ NOTE EV 13 EVHP 20 1 68 ChipBLASTER Inc 1C Schemat iring 20 3 Control W V Z00 ONIHL ASAr 2 30 90 1485 81
28. FILTER ELEMENT WATER BASED COOLANT OIL BASED COOLANT 10 10 3 0 ChipBLASTER Inc 10 3 0 SPECIFICATIONS Cont FCC REGULATIONS THIS DEVICE COMPLIES WITH PART 15 OF THE FCC RULES OPERATION IS SUBJECT TO THE FOLLOWING TWO CONDITIONS 1 THIS DEVICE MAY NOT CAUSE HARMFUL INTERFERENCE AND 2 THIS DEVICE MUST ACCEPT ANY INTERFERENCE RECEIVED INCLUDING INTERFERENCE THAT MAY CAUSE UNDESIRED OPERATION ALL SPECIFICATIONS INSTRUCTION PICTURES AND ILLUSTRATIONS IN THIS MANUAL ARE BELIEVED TO BE ACCURATE AND MAY CONTAIN CHIPBLASTER INC PROPRIETARY INFORMATION WHICH IS PRIVILEGED CONFIDENTIAL OR SUBJECT TO COPYRIGHT PATENT BELONGING TO CHIPBLASTER INC THIS MANUAL IS INTENDED FOR THE OPERATION AND MAINTENANCE OF YOUR CHIPBLASTER UNIT YOU ARE HEREBY NOTIFIED THAT ANY DISSEMINATION DISTRIBUTION COPYING OR ACTION TAKEN IN REGARD TO THE CONTENT OF THIS MANUAL IS STRICTLY PROHIBITED AND MAY BE UNLAWFUL CHIPBLASTER INC ALSO RESERVES THE RIGHT TO CHANGE THE CONTENTS OF THIS MANUAL WITHOUT NOTICE IF YOU HAVE ANY QUESTIONS PLEASE CONTACT CHIPBLASTER INC AT 814 724 6278 3 0 ChipBLASTER Inc 4 0 SAFETY PRECAUTIONS The items described in these instructions are a very important so that you can use 11 the ChipBLASTER safely prevent injury to yourself and other people around you as well as prevent damage to property in the area Thoroughly familiarize yourself with the symbols and indications s
29. FROM FILTER BAGS INTO DO NOT REUSE DIRTY FILTER BAGS 14 13 14 14 Handle at RUN FILTER A Handle at RUN FILTER B ChipBLASTER Inc 36 14 0 PREVENTATIVE MAINTENANCE Cont C 14 15 DUAL MANUAL FILTER CHIPBLASTER OPERATING USE EXTREME CAUTION WHEN CHANGING THE FILTER BAG WHILE THE MACHINE IS IN OPERATION MAKE SURE TO LOCK OUT THE BALL VALVE TO PREVENT COOLANT FROM COMING THROUGH THE FILTER THAT IS BEING SERVICED IF THE BALL VALVE IS POSITIONED TO DIRECT FLOW WHILE THE LID IS OFF POTENTIAL PERSONAL INJURY COULD RESULT 14 15 1 14 15 2 14 15 3 14 15 4 T4 15 5 14 15 6 14 15 7 14 15 8 14 15 9 Check the handle of the filter ball valve If the handle is in the horizontal position running B filter than it is safe to change filter A If the filter ball valve is in the vertical position running A filter then it is safe to change filter B Make sure the air bleed petcocks are opened before changing the filter bag Remove lid and inspect for damage Be careful not to damage filter hold down plate seal or springs Set lid aside Remove optional hydrocyclonic filter 1f used from center of bag Pull the filter bag out of the housing Install the new filter bag in the housing Replace the optional hydrocyclonic filter 1f used Inspect the O ring for cracks or tears replace 1f damaged 14 15 10 Inspect filter hold down seal for cracks or tears replace 1f da
30. Freewheel Freewheel 7006 ERCO Error registry CANopen 6056 External fault assigned assigned 7131 FBS PI multiplication coef 1 0 1 0 11903 FLG Frequency loop gain 20 20 9620 FLO Forced local mode assigned assigned 8431 FLR Catch on fly No No 3110 FR1 Configuration reference 1 MEUS Analog input AI1 8413 FR2 Configuration reference 2 Not configured Not configured 8414 FRS Nominal motor frequency 60 0 Hz 60 0 Hz 0602 FRT Ramp 2 switch frequency 0 0 Hz 0 0 Hz 9011 FST Fast stop assigned Not assigned 11204 FTD Motor freq threshold 60 0 Hz 60 0 Hz 11003 HSP High Speed E ds 2 60 0 Hz 3104 15 9 ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 9 ALTIVAR 31 DRIVE AS SET PARAMETERS 460 VAC W and W O 54 PRESETS Cont Code Label Value Default value Logical address Menu INH Fault inhibit Not assigned Not assigned 7125 IPL loss of input phase Yes Yes 7002 JVA 12 6 A JV8 19 1 A EV 25 5 ITH Motor Thermal Current GV20 42 A 27 5A 9622 JF2 Skip frequency 2 0 0 Hz 0 0 Hz 11302 JOG Jog operation Not assigned Not assigned 11110 JPF Skip frequency 0 0 Hz 0 0 Hz 11301 LAC Function access level Access to std functions Access to std functions 3006 IAF Limit forward direction assigned Not assigned 11601 LAR Limit reverse direction assigned assigned 11
31. GLOVES AND SAFETY GLASSES IS STRONGLY RECOMMENDED DO TO THE CHIPS THAT MAY BE IN THE FILTERS Q DO NOT POKE HOLES IN FILTER BAG WHEN CHANGING DUMP COOLANT INTO MACHINE TOOL SUMP Q DO NOT DUMP COOLANT FROM FILTER BAGS INTO ChipBLASTER TANK Q DO NOT REUSE DIRTY FILTER BAGS 14 0 PREVENTATIVE MAINTENANCE Cont 14 13 1 SINGLE FILTER 14 13 1 1 A flashing red light will indicate when the bag filter is dirty OFF BEFORE CHANGING THE FILTER WHEN RUNNING A SINGLE FILTER THE SYSTEM MUST BE TURNED 14 13 1 2 Open the air bleed valve to remove any pressure from the filter housing Then remove the filter lid 14 13 1 3 Remove lid and inspect for damage Be careful not to damage filter hold down plate seal or springs Set lid aside 14 13 1 4 Remove optional hydrocyclonic filter if used from center of filter bag 14 13 1 5 Pull the filter bag out of the housing 14 13 1 6 Install the new filter bag in the housing insure it is all the way down 14 13 1 6 Install optional hydrocyclonic filter if used into the center of filter bag 14 13 1 7 Inspect the O ring for cracks or tears replace if damaged 14 13 1 8 Inspect filter hold down seal for cracks or tears replace if damaged 14 13 1 9 Make sure the O ring is in the proper groove before replacing the lid Replace the filter lid by setting straight down so that the filter hold down plate will contact filter bag 14 13 1 10 Torque filter lid cap screws to
32. MTR 3 MTR GND 3 L3 240V20A 240V 16A 480 V 16A 480 V 16A 20 13 73 ChipBLASTER Inc iring 20 15 Interface Cable W 200 9NIHL A3An 2 30 Z 0144581 SLN O 4334s awos aeda osdav inn 325 vsn uswoisno 7809 22 18 XV 95591 Vd 3OVJH3LNI 8229 72719 3NOHd 9092 3AIHO ANY B 3903 17 SYYN eel 7391519949 NOISSIWH3d 100 LNOHLIM 9 9 5 NO ISOdYNd 4 SHSHLO OL 095010514 38 LON AVIA NOLLVIAHOJNI S000 XXXX HONS SNIVLINOO IN3Anooa 50000 XXXXX SIHL 31571990 JO ALYSdOUd SI SIHL 3A Lv 1n Wn 29 VNON seouereo 31519909 SALON ON Lud ALO 5170 TWIDO PLC 24IN 16 OUT ATV 31 3SV3 8 PIN MINI DIN TO ETHERNET 5172 SERIAL LINK CABLE E E EI EI E EI EI E 5171 CAT5E TO ENCLOSURE DOOR
33. SIN SLAZOLAL 0 93903 ae weowosew mja NOISE Mea WSN ONIYN LOVANNVW sav uanoisno 829 2 8 Xv4 95591 Vd 3TAQVSW coo SH3HLO 01 035010510 38 LON AYN NOLLVINHOJNI 81 718 YOY NMOLYSISOW 90961 HONS NOLLVINSOINI SNIV LNOO 1IN3An20a suu 500070 SIHL JO JHL SIHL H31SxCTHO UO Au vinWnoovNON 531519949 S310N ON ALO nc 3 8 2 z 250 8 E E 9000 85 9 TP s 9 1001 Eu 7000 2 8 33 02001 23 COS gua 4 d 000 5 81001 4 ue 00 xl 8 m 54 pd 000 ake z n 0L 000 2 S 2 o8 28 No hee o 9 ve 6000 5 elt Lg 443 lt 8000 9 O 68 e 2 9000 2 2 O 8 woo 28 4 d 5000 t O Je
34. a belt Do not operate with guard or cover open Oil skimmer LIFTING HAZARD Use caution when lifting filter bags from filter housing Bags may be heavy depending on the material being machined 12 4 1 ChipBLASTER Inc 4 1 EXPLANATION of MARKINGS Cont Symbols Meaning of Symbols ELECTRICAL SHOCK HAZARD Shut off main disconnect before opening any electrical enclosures or junction boxes UNITS WITH ADJUSTABLE FREQUENCY DRIVES BEFORE PERFORMING ANY WORK BE AWARE THAT A DRIVE WILL HOLD A LETHAL CHARGE FOR A MINIMUM OF 10 MINUTES LOCK OUT ELECTRICAL POWER Lock out and tag any and all disconnect switches before performing any maintenance work on equipment SAFETY GLASSES REQUIRED When removing filter bags or working on equipment safety glasses must be worn to prevent injury from splashing fluid or from other hazards MACHINE STARTS AUTOMATICALLY ChipBLASTER equipment will start without operator input Do not remove any guards or covers until disconnect switches are shut off locked out and tagged UNPLUG SOURCE OF ENERGY Before performing any work on items such as the oil skimmer unplug the unit 13 4 1 ChipBLASTER Inc 4 1 EXPLANATION of MARKINGS Cont Symbols Cont Meaning of Symbols Cont NO ACCESS FOR UNAUTHORIZED PERSONS Do not open electrical enclosures or remove any guards if you have not
35. been trained or do not have knowledge of the equipment FORK TRUCK LIFTING POINT To transport equipment forks of truck must be located between points indicated so that mechanical damage to machine will not result SAFE OPERATING PRESSURE Safe operating pressure will be listed below symbol in PSIG and Bar Do not operate above stated pressures as equipment damage or personal injury will result DO NOT STEP OR STAND ON Do not use surface as a step or platform when servicing equipment Motors and electrical boxes are not designed to be used as steps or platforms and injury may result from falls READ THE TECHNICAL MANUAL Before attempting to work on or repair this machine read and understand this manual If certain procedures are not followed mechanical and or personal injury will result 14 4 1 ChipBLASTER Inc 4 1 EXPLANATION of MARKINGS Cont Symbols Cont Meaning of Symbols Cont WEAR SAFETY GLOVES When changing filter bags it is recommended to wear safety gloves to protect hands from metal chips and the coolant that may be used in the machine DO NOT OPERATE WITH GUARD REMOVED Do not operate machine with guards removed as hazards to personnel will be present and injury to personnel could result LIFTING POINT Machine must only be lifted at points indicated in order to avoid mechanical damage and personal injury Lifting slings or chain slings must be ad
36. complete the flushing cycle 19 7 REPLACE ALL PLUMBING FITTINGS AND PANELS TO THEIR ORIGINAL CONFIGURATION REPLACE ALL GUARDS BEFORE OPERATING ChipBLASTER Any questions on the Contamination Purging Procedures please contact the ChipBLASTER Service Department at 814 724 6278 Have the model and serial number of your ChipBLASTER unit ChipBLASTER Inc 20 1 Power Wiring Schematic 18A FLA 3 1A NOTES MATL DRAWING NUMBER TI31EV 1 STD 3MTR FRAME 230 VAC 460 VAC RETURN PUMP SIZE HP PART No OF 7 SHEET 1 EV POWER WIRNG SCHEMATIC FLA 18A CUSTOMER TITLE 15 AUG 07 DATE FLA DESCRIPTION SCALE NTS 2MTR FRAME 230 VAC 460 VAC FILTER PUMP FAX 814 724 6287 SIZE PHONE 814 724 6278 APPROVED BY HP 1 DRAWN BY WPA ary www chipblaster com FLA 128A Chip 13605 S MOSIERTOWN ROAD MEADVILLE PA 16335 USA FLA 255A EV13 SIZE UNT 1MTR FRAME 230 VAC 460 VAC MAIN PUMP SIZE 215T 0 0005 0 005 0 01 1 32 HP 10 NONACCUMULATIVE ChipBLASTER Tolerances REMOVE ALL BURRS amp BREAK ALL SHARP EDGES 460 VAC 15A 60 2 MISTBLASTER 20A 9CB 230 VAC 60 HZ 460 VAC 60 HZ 15A 1 HP MISTBLASTER 230 VAC 6A 60 HZ 60 HZ 2 2 4A 3 30 PURPOSE OR USED FOR MANUFACTURING PUR
37. coolant and power down the ChipBLASTER unit 16 0 8 Locate coolant outlet 1 SOL A and coolant outlet 2 SOL B re connect the solenoid din connector from each solenoid coil 16 0 9 Open the enclosure door and locate the adjustable frequency drive located in the lower left corner of the enclosure 16 0 ChipBLASTER Inc 57 16 0 PRESSURE ADJUSTMENT PROCEDURE ALTIVAR 31 DRIVES Cont 16 0 10 Turn the main disconnect on to repower the ChipBLASTER unit to alter the program pressure setting changes to the AFD Adjustable Frequency Drive USE EXTREME CAUTION WHEN WORKING ON LIVE EQUIPMENT 16 0 11 FOR ALTIVAR 31 DRIVES without setpoints Adjust the PID setpoint as follows 16 0 11 1 At the rdY promp on the display PRESS ENT SEt will be displayed 16 0 11 2 Press ENT rPI will be displayed 16 0 11 3 Press ENT 50 0 will be displayed 16 0 11 4 Press the up or down arrow keys as required to change hertz setting of the drive Decreasing the hertz setting will reduce the output pressure like wise increasing the hertz setting will increase the output pressure Do not exceed the maximum pressure rating of the machine tool 16 0 11 5 When the revised pressure setting is reached indicated on the high pressure gauge PRESS ENT 16 0 11 6 PRESS ESC three times to return to the rdy screen NOTE Lowering the setpoint will decrease the output pressure Raising the setpoint will increase the output pressure To view th
38. directions and instructions provided by ChipBLASTER applicable literature any damage or loss to products or parts which results from the alteration repair modification faulty installation or service other than regular maintenance by any one other than an authorized ChipBLASTER service technician and the use of any add ons parts accessories or components not obtained from ChipBLASTER or an authorized ChipBLASTER supplier approved in writing by ChipBLASTER damage to products or parts caused by accident abuse or misuse normal wear and tear damage which occurs in shipment or as a result of an act of God such as lightening or electrical failures such as line surges or brownouts 24 3 3 Any replacement equipment or parts provided to the purchaser in fulfilling this warranty are warranted for the un expired portion of the original warranty 24 3 4 If any ChipBLASTER products are found upon ChipBLASTER s examination in response to a warranty claim to have defects in material or workmanship ChipBLASTER will either replace or repair the product at its sole option 24 3 5 Warranty repairs will be completed at the purchaser s location 24 3 6 Other than the obligations imposed upon ChipBLASTER under this limited warranty ChipBLASTER shall not be liable for any other costs expenses or losses that the purchaser incurs to remedy any defect 24 3 7 Repairs of defects in material or workmanship during the limited warranty period shall be
39. filter lid Make sure the O ring is in the proper groove before replacing the lid Replace the filter lid by setting straight down so that the filter hold down plate will contact filter bag 14 16 13 Torque filter lid cap screws to 30 FT LB 41Nm in a star pattern 14 16 14 Refer to SECTION 11 START UP FOR FILTER PURGE DO NOT CHANGE THE B FILTER WHILE THE UNIT IS RUNNING Q THE B FILTER IS USED ONLY AS A BACKUP FILTER TANK TO CHANGE THE A FILTER WHILE THE UNIT IS RUNNING 14 16 11 Both filters can be changed while the unit is shut off 14 16 12 Refer to SECTION 11 START UP FOR FILTER PURGE after the filter s have been changed ChipBLASTER Inc 38 14 0 PREVENTATIVE MAINTENANCE Cont 14 16 13 FILTER REPLACEMENT FORM 14 15 14 16 PLEASE MAKE A COPY OF THE FILTER REPLACEMENT FORM BEFORE ORDER _ ChipBLASTER Inc No 13505 South Mosiertown Road Contact Name Meadville PA 16335 USA Phone No Telephone 814 724 5278 shipping Instructions Fax 814 724 5287 SHIP TO BILL TO Customer Customer Address Address Address Address City City State State Zip Zip Attention Attention PARTNo Description Micron Quantity 6 x 30 300 3835 8 x0 Single Fiter Bag 5 8 x 30 Single Filter Bag 10 8 x 30 Single Filter Bag 15 8 x 30 Single Filter Bag 25 3003300 8 30 Single Fitter Bag 100 8 x 30 Single Filte
40. from machine tool sump repeat the above steps CHECK MOTOR ROTATIONS PLEASE REFER BELOW 9 3 9 4 CHECK FILTER PUMP ROTATION ROTATION IS CLOCKWISE VIEWED FROM FAN END CHECK MAIN PUMP ROTATION ROTATION IS COUNTER CLOCKWISE VIEWED FROM THE SHAFT END CHECK RETURN PUMP ROTATION IF USED ROTATION IS CLOCKWISE VIEWED FROM FAN END ChipBLASTER Inc 21 11 0 SYSTEM AIR PURGE 11 1 SINGLE FILTER 11 1 1 Open the 1 4 petcock located on both the filter and post filter so that trapped air can escape both filters 11 1 2 Press the RESET AIR PURGE push button to remove the air from the filters When all of the air has escaped close the petcocks This will lower the tank level and start the return transfer pump and lower the sump level Depending on the capacity of the machine tool sump the lower level will allow the ChipBLASTER high pressure to fill the sump without overflowing the machine tool sump Unless the sump is completely emptied DO NOT REFILL MACHINE TOOL SUMP 11 1 3 Start the ChipBLASTER and check for any coolant leaks 11 1 4 Insure that all electrical circuits are operating correctly 11 1 5 The coolant outlet pressure is factory preset to run at 1000 PSIG 69 bar or a customer specified pressure Refer to Pressure Adjustment Procedure Section 16 0 11 0 SYSTEM AIR PURGE Cont 11 2 DUAL FILTER 11 2 1 Open the 1 4 petcock located on both the filters and post filter so that t
41. in an auto cross becomes dirty the system will change from filter A to filter B if A filter is operating If the system is running on B filter than the low pressure wash down coolant will shut off The filter dirty light will flash to indicate a dirty filter Refer to SECTION 14 5 for filter changing procedure WASH DOWN WASH DOWN HOSE START STOP PUSH BUTTON 27 20 ChipBLASTER Inc 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER TURMOIL WEST SWANZEY NH 03469 603 352 0053 INSTALLATION MAINTENANCE and OPERATION MANUAL MODEL OC 75 DI CTC ATC TABLE OF CONTENTS Description Page Uncrating amp Inspection Section 27 21 1 120 Cooler Placement Section 27 21 2 120 Electrical Hook up Section 27 21 3 120 Temperature Controller Section 27 21 4 121 Start up Section 27 21 5 121 Operation Section 27 21 6 121 Safety Interlocks Section 27 21 7 121 Maintenance Section 27 21 8 121 Trouble Shooting Section 27 21 9 122 Parts List Section 27 21 10 123 ATC CTC Temperature Controller Setup Section 27 21 11 124 Electrical Schematic Section 27 21 12 127 Dimensional Prints Section 27 21 13 128 107 27 21 ChipBLASTER Inc 108 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont WARNING DO NOT ATTEMPT TO START UP THIS COOLER UNTIL YOU HAVE READ THROUGH THE INSTRUCTIONS COMPLETELY IMPROPER START UP WILL VOID THE COOLER
42. in the case of lathes the filter should be changed more often The tell tail signs of a dirty filter cartridge are 14 37 Erratic density readings large fluctuations between readings A large difference between the percent of concentrate read on a refractometer and the percentage shown on the HMI If a large amount of way oil is present in the coolant a good refractometer reading may be difficult 14 34 1 Power down ChipBLASTER unit 14 34 2 Depress pressure release button to relieve pressure in filter housing 14 34 3 Unscrew housing using spanner wrench NOTE When opening filter housing to change cartridge it is common for o ring Gasket to lift out of housing and stick to cap Remove used cartridge and discard Rinse out housing and fill about 1 3 full with clean premixed coolant NOTE Make sure the o ring is seated level in the groove or gasket is on rim of sump CAUTION If a ring gasket appears damaged or crimped it should be replaced at this time Contact ChipBLASTER service for replacement parts 14 34 4 Insert a new cartridge into the sump making sure that it slips down over the sump standpipe 14 34 5 Screw the sump onto the cap and hand tighten DO NOT OVER TIGHTEN Make sure cartridge slips over the cap standpipe 14 34 6 Turn on power to the ChipBLASTER and energized a call for coolant Allow the ChipBLASTER to run until the DELAY BEFORE SAMPLE timer in the PLC times out and a coolant sample is diverted throug
43. signal i e 24 VDC or 110 27 19 3 Is acknowledgement ACK or finish FIN signal is required by machine tool 27 19 4 Will one M code turn on each of the call for coolant and or pressure requests and than use one code to shut all codes off 27 19 5 Also any special considerations that may be required DO NOT EXCEED THE MACHINE TOOL MANUFACTURERS MAXIMUM OPERATING PRESSURE ChipBLASTER Inc 106 27 0 OPTIONAL EQUIPMENT Cont 27 20 OPTIONAL WASH DOWN 27 20 1 The optional wash down feature is designed to allow the machine tool operator to utilize low pressure filtered coolant to wash off fixtures vises and parts as required for a timed period 27 20 2 In order to use this feature the M codes to call for a coolant must be off and the high pressure pump must be off 27 20 3 To use the wash down feature the operator must press the wash down start push button located on the ChipBLASTER electrical enclosure The filter pump will operate and low pressure coolant will be available at the nozzle of the wash down hose for two 2 minutes 27 20 4 The low pressure wash down may be stopped by pressing the wash down start push button energizing a call for coolant or allowing the timer to time out 27 20 5 During the low pressure wash down the bag filter s are still monitored If a bag filter in a single filter system becomes dirty the low pressure wash down coolant will shut off If the bag filter
44. standstill 19 2A 19 2A 10403 SDC2 DC current at standstill 2 9 5 ALL MODELS 9 5 10405 SDS Display scale factor 30 0 30 0 12001 SFR Drive switching frequency 4 0 kHz 4 0 kHz 3102 SLL Stop mode at Modbus SLF Freewheel Freewheel 7010 SLP Slip Compensation 10096 100 9625 SRF Disable speed loop filter No No 9101 STA Frequency loop stability 20 20 9621 SIP stop on power loss Lock drive freewheel stop Lock drive freewheel stop 7004 isn Normal stop mode ramp On ramp 11201 2 wire or 3 wire control 2 wire control 2 wire control 11101 TCT of 2 wire control Edge triggered Edge triggered 11102 TDC1 DC injection time 0 5 s O 5 s 10402 TDC2 2nd DC injection time 0 0 5 0 0 10404 Max output frequency 22 3103 TLS Low speed time out O Os 0 0 5 11701 TNL Auto tuning fault config Yes Yes 7012 nD Motor thermal threshold 100 100 11002 TUN Automatic tuning Not assigned Not assigned 9608 UFR Voltage boost 20 20 9623 UFT Select type of U F ratio Sensorless flux vector ctrl Sensorless flux vector ctrl 9607 UNS Nominal motor voltage EN 460V 9601 15 9 ChipBLASTER Inc 56 16 0 PRESSURE ADJUSTMENT PROCEDURE ALTIVAR 31 DRIVES This procedure is to be used to adjust the output pressure of the ChipBLASTER high pressure unit Please be aware that you must have working knowledge of the complete ChipBLASTER system before making any pressure adjustments All ChipBLASTER units are shipped ou
45. to ChipBLASTER for examination at ChipBLASTER s direction ChipBLASTER will reimburse the purchaser for the expense incurred in returning any product to ChipBLASTER if ChipBLASTER has provided prior written authorization to the purchaser and the problem is covered by this warranty In the event the problem is not covered by this limited warranty ChipBLASTER will not be responsible for payment of shipping expense 24 1 6 Other than the obligations imposed upon ChipBLASTER under this limited warranty ChipBLASTER shall not be liable for any other costs expenses or losses that the purchaser incurs to remedy any defect Regular maintenance includes the minor normal maintenance required to be performed by buyer at buyer s expense as set forth in the maintenance schedule included with this warranty as Exhibit A and posted on the outside panel of the ChipBLASTER Use of filters other than ChipBLASTER will void warranty coverage for any filtration related damage or failures 24 1 ChipBLASTER Inc 90 24 0 WARRANTY Cont 24 1 7 Repairs of defects in material or workmanship during the limited warranty period shall be performed only by ChipBLASTER approved service technicians the cost of repairs performed by others will not be reimbursed by ChipBLASTER unless prior approval is received in writing from ChipBLASTER 24 1 8 This limited warranty shall cover alleged defects in materials and workmanship about which ChipBLASTER receives notice
46. within thirty 30 days of either the discovery of the alleged defect or the expiration of the limited warranty period whichever is earlier Any claim not made within this time shall be conclusively deemed to having been waived by the purchaser 24 1 9 Failure of the purchaser to maintain the equipment by completing all of the scheduled maintenance tasks set forth in Exhibit A to this limited warranty entitled ChipBLASTER Maintenance Schedule will void this limited warranty and release ChipBLASTER from any liability hereunder ChipBLASTER may require purchaser to provide evidence of timely completion of the scheduled maintenance tasks set forth in Exhibit A 24 1 10 ChipBLASTER warranty card must be completed by purchaser and returned to ChipBLASTER within 30 days after installation of ChipBLASTER equipment to validate this limited warranty Procedures for Obtaining Technical Service or Warranty Service Repair or replacement under this limited warranty can only be obtained by registering a warranty claim directly with ChipBLASTER To enable ChipBLASTER to respond to a request for technical assistance or a request for warranty service the purchaser must provide at a minimum the following information during the initial telephone call model number serial number and information regarding any optional ChipBLASTER components the date of purchase the dealer or supplier from whom the equipment was purchased and the nature of the problem or dif
47. 0 WARRANTY Cont 24 3 WARRANTY LIMITED RETROFITS ChipBLASTER Inc Limited Warranty High Pressure Retrofits Limited Warranty ChipBLASTER Inc warrants its ChipBLASTER high pressure retrofits to be free from defects in materials and workmanship for the lesser of one year or 4160 operating hours from the date of delivery to the original user subject to the conditions set forth below During this warranty period ChipBLASTER will repair or replace at its sole option defective products or parts without charge to the purchaser ChipBLASTER Inc further warrants that its ChipBLASTER high pressure retrofit systems will not adversely affect or damage the cutting equipment on which ChipBLASTER installs such systems Limited Warranty Conditions 24 3 1 Warranty applies only to new ChipBLASTER retrofits 24 3 2 This limited warranty does not apply to any damage failure defect or loss caused by any or all the following circumstances or conditions failure to follow instructions or observe cautions and warnings relating to installation operation applications inspection and regular maintenance as specified in any ChipBLASTER manual quotation acknowledgment sales literature spec sheet or installation instructions all of which shall hereinafter be referred to as applicable literature use of ChipBLASTER retrofits outside the parameters of normal usage including but not limited to misapplication misuse failure to follow
48. 1 Page 61 Page 61 Page 62 Page 63 Page 64 Page 67 Page 67 Page 68 Page 69 Page 70 Page 71 Page 72 Page 73 2 0 ChipBLASTER Inc 2 0 TABLE OF CONTENTS Cont EV Sub panel layout Schematic piping drawings EV Piping schematic single filter EV Piping schematic dual filters EV Piping schematic autocross filters Mechanical assembly EV Gauge panel side EV Filter side EV Control panel side EV Filter assembly EV Manifold block EV Sub plate plan view EV Oil level site gauge EV Tank plan view w screens and baffles EV Ship loose items EV Spare parts Footprint drawings EV Footprint Warranty Warranty limited New equipment Warranty limited Used equipment Warranty limited Retrofits Warranty claim form Warranty registration card Warranty validation card Optional Equipment Magelis Human machine interface unit Oil skimmerfor model without MistBLASTER Magnetic separator Hydrocyclonic filter insert Multiple preset pressures Low pressure wash down option Optional drop in chiller Section 20 23 Section 21 0 Section 21 1 Section 21 2 Section 21 3 Section 22 0 Section 22 1 Section 22 6 Section 22 11 Section 22 16 Section 22 17 Section 22 22 Section 22 27 Section 22 28 Section 22 33 Section 22 38 Section 23 0 Section 23 1 Section 24 0 Section 24 1 Section 24 2 Section 24 3 Section 24 4 Section 24 5 Section 24 6 Section 27 0 Section 27 1 Section 27 15 Section 27 17 Sec
49. 20 15 74 als A3 ONIHL H38AnN do L 133HS Z0AVINOE ava vb vos ONIH L g zs Q31ON SV u102 Jejse qdiuo MMM 1 303 1 T3NVd ui 1829 2018 Xv 9 29 vc4 V18 3NOHd vsn 3943 dHVHS Sung TIv 3AOWJ3H S 9 Vd 3TIIAQV3W QvO3 NMOLYAISOW 8 SO9EL tE e Sara E 00 4000 X S000 0 SALLY INWNODOWNON seoueleo 1 SALON 1 401208 VdM aav LNAYYND 01 31vaan g 7 20B 1 Fir nar maru 1 Jalsv18diu NOISSIWH3d N3LLIHM ONINNLOVANNVA GASN 5 SSH3H LO OL 035012814 38 LON AVIA NOLLVINSHOHNI HONS NOLLVINHOHNI SNIVINOO 4 SIHL 40 JHL SI LNIHd SIHL g g e o 1 90995960 22222222 0 eol 256655666 888888888827 222222 6000009888
50. 2500 0 090 0 0064 2500 Nozzle XX57 0 0069 2500 005 20 ess 250 0 105 0 0087 2500 0 110 0 0095 2500 0 115 0 0104 2500 0 120 0 0113 2500 0 125 0 0123 2500 0 130 0 0133 2500 Nozzle XX58 0 0138 2500 0 135 0 0143 2500 0 140 0 0154 2500 0 145 0 0165 2500 0 150 0 0177 2500 0 155 0 0189 2500 0 160 0 0201 2500 0 165 0 0214 2500 0 170 0 0227 2500 0 175 0 0241 2500 0 180 0 0254 2500 0 185 0 0269 2500 0 190 0 0284 2500 0 195 0 0299 2500 0 200 0 0314 2500 28 5 ChipBLASTER Inc 123 28 0 SUPPLEMENT DATA CONT 28 6 Orifice SETE for 3000 PSI Orifice Dia Outlet Area Velocity Sq Ft Sec Inches ooi ooo 350 85 opis 00002 soo se omo ooms 3x9 8 amp 5 0025 oos 3 se ooor 350 8 amp 5 ooo 3000 86 3x0 85 opis 00046 3000 86 00020 soo 8 amp 5 oos ooo 8e Nozzle 0004 300 86 Nozze xx55 0 0028 30 85 0060 0008 300 8e 0003 39 ats 3 85 or 198 Bas WEN clue UNE 5 oco 122 z2 359 s 300 85 142 25 cv 5 6 obo gt 8 7 Orifice meleteace BALL for 5000 PSI Orifice Dia Outlet Area Velocity Volume
51. 30 FT LB 41Nm in a star pattern 14 13 1 11 Refer to SECTION 11 START UP FOR FILTER PURGE 14 13 ChipBLASTER Inc 35 14 0 PREVENTATIVE MAINTENANCE Cont 14 14 DUAL MANUAL FILTER CHIPBLASTER SHUT DOWN The preferred method is to shut down the ChipBLASTER 14 14 1 A flashing red light will indicate when the bag filter is dirty 14 14 2 Open the air bleed valve to remove any pressure from the housing Then remove the filter lid 14 14 3 Remove lid and inspect for damage Be careful not to damage filter hold down plate seal or springs Set lid aside 14 14 4 Remove optional hydrocyclonic filter if used from center of bag 14 14 5 Pull the filter bag out of the housing 14 14 6 Install the new filter bag in the housing insure it is all the way down 14 14 7 Replace the optional hydrocyclonic filter 1f used 14 14 8 Inspect the O ring for cracks or tears replace if damaged 14 14 9 Inspect filter hold down seal for cracks or tears replace if damaged 14 14 10 Replace the filter lid Make sure the O ring is in the proper groove before replacing the lid Replace the filter lid by setting straight down so that the filter hold down plate will contact filter bag 14 14 11 Torque filter lid cap screws to 30 FT LB 41Nm in a star pattern 14 14 12 Refer to SECTION 11 START UP FOR FILTER PURGE Q DO NOT POKE HOLES IN FILTER BAG WHEN CHANGING ChipBLASTER TANK DUMP COOLANT INTO MACHINE TOOL SUMP Q DO NOT DUMP COOLANT
52. 51 au 140 3903 5 SAOWSY WON NOISSIINS3d N3 LLIHM 255 LNOHLIM SNIein CASN 6070 X04 SHAHLO 01 035010910 LON X HONS SNIVLNOO LNINNOOG 9000 0 SIHL 31518949 JO ALY3dOud 3H SI SIHL 31318940 20 9 iring 20 9 Drive Control and Power W ChipBLASTER Inc S310N L8 Vd a o e lt alg E t x oS gt 95 9 N N ocu n V r a lt n su 28 7 9n lt 20 4 o Haarr sn inc 5 x 18 aly Ave S 0 0l 4 5 viu 5 a oov WOO 5 18 ev zv E 5 gu 558 3 5 8 g 9 299 55 52299 T 9906 woo 98822 z 7 8 9 5 55 5 a NO 8 Ee es 25500 6 o N gis 418 o a Wi AA EN NO as ze HM 55 a 5 a E 2 52 9 2e 9 a LOOZNVPLE V
53. 602 LC2 Enable current limit 2 assigned Not assigned 9202 LCC Remote terminal control No 64003 IFF Fall back speed 10 0 Hz 10 0 Hz 7080 LFL Stop mode at loss 4 20mA Fault ignored Fault ignored 7003 I Forward LITA Config logic input 1 ALL UNITS Forward 4801 Select 2 preset PI refs LIZA Config logic input 2 ALL UNITS Reverse 4802 2 Select 4 preset PI refs LISA Config logic input 3 ALL UNITS Select 2 preset speeds 4803 LI4A Config logic input 4 Not configured Select 4 preset speeds 4804 LIBA Config logic input 5 Not configured Not configured 4805 LIGA Config logic input 6 Not configured configured 4806 4 8 8 15 0 Hz LSP Low Speed EV GV CV 10 0 Hz 0 0 Hz 3105 JVA 12 6 A JV8 19 1 A EV 25 5 NCR Nominal motor current GV20 42 A 22 0A 9603 NRD Motor Noise Reduction Yes Yes 3107 1780 rpm NSP Nominal motor speed ALL MODELS 1780 rpm 9604 NST Freewheel stop assigned Not assigned 11202 OHI Stop mode at drive oheat Freewheel Freewheel 7008 all mode at motor oheat Freewheel Freewheel 7009 Output Phase loss fault fault 9611 PIC inversion No 11940 Analog input AI2 5 PIF PI regulator feedback ALL MODELS configured 11901 Yes PII Internal reference PI ALL MODELS No 11908 logic input LI2 5 PR2 Enable 2 preset PI refs MODELS assigned 11909 Logic input LI3 3 PRA Enable 4 preset PI refs ALL MODELS assigned 11910 PS16 Enable 16 preset speeds
54. A OPTIONAL AUTOCROSS SIDE A RUN FILTER AB 4 SPARE OUTPUT 4 SPARE OUTPUT OIL SKIMMER 6MTR 1 40 HP 0 8FLA COM AIR PUMP 7MTR 1 40 HP 0 8 FLA A REV NOTES MATL JVEV THINC 004 DRAWING NUMBER PART No 4 OF 7 SHEET PLC OUTPUT WIRING SCHEMATIC CUSTOMER 18 SEPT 06 DATE DESCRIPTION NTS SCALE PHONE 814 724 6278 FAX 814 724 6287 APPROVED BY R B DRAWN BY 13605 S MOSIERTOWN ROAD www chipblaster com MEADVILLE PA 16335 JV10 EV13 UNIT USA SIZE 0 0005 0 005 0 01 1 32 NONACCUMULATIVE XX REMOVE ALL BURRS amp Chip BLASTER Tolerances BREAK ALL SHARP EDGES PURPOSE OR USED FOR MANUFACTURING PURPOSES WITHOUT DOCUMENT CONTAINS PROPRIETARY INFORMATION AND SUCH WRITTEN PERMISSION FROM ChipBLASTER INFORMATION MAY NOT BE DISCLOSED TO OTHERS FOR ANY THIS PRINT IS THE PROPERTY OF ChipBLASTER THIS 20 7 71 V S00 ONIHL ASAr 4 dO S 13848 ZONVE LE aiva SLN aos LA3 0LAP O 325 18c9 vcJ v1 9 XY4 3AMGNalsvw 89 YAMOd 8 MMM 96591 Vd NMOLH3ISON 09
55. AL COOLANT SUPPLY the ChipBLASTER will be supplied with a fill solenoid valve and regulator in place of a return pump The fill solenoid will operate based on the float assembly in the ChipBLASTER s coolant tank and will maintain the tank coolant level The central supply system must be capable of supplying at least 1 5 times the flow rate of the ChipBLASTER model being used The supply pressure should be in the range of 20 to 30 PSIG 1 4 to 2 bar The maximum particle size should not exceed 100 micron LOW PRESSURE FLOOD is a factory installed feature It is designed to be used to supply filtered coolant at 5 gpm 18 9 liters minute 35 psig 2 4bar maximum The flow and pressure is dependent on orifice diameter The low pressure flood 1s controlled by a separate maintained M code from the machine tool The low pressure as supplied from the factory is available at coolant outlet number 1 and or 2 depending on ChipBLASTER model The low pressure flood is used to flush parts tool plates and general chip clearing NOTE If the low pressure flood coolant is in use high pressure coolant is not available HIGH LOW PRESSURE is available as a factory option if high pressure coolant is required from one coolant outlet and low pressure flood coolant is required from the other coolant outlet at the same time The low pressure coolant as supplied from the factory is available as standard on coolant outlet number 1 NOTE If HIGH LOW PRESSURE is requ
56. BY AFD MANIFOLD BLOCK lt HIGH PRESSURE SAMPLE LINE LOWPRESSURE ELECTRICAL CONNECTION 25 Figure 6 JV EV units Single filter Figure 6a JV EV units Dual filters Manual change over Figure 6b JV EV units Autocross filters Automatic change over 12 2 ChipBLASTER Inc 26 12 0 OPERATION Cont 12 3 THEORY OF OPERATION AUTO CROSS OPTION OOO 12 3 1 12 3 2 12 3 3 12 3 4 12 3 5 12 3 6 The ChipBLASTER is designed to operate with two 2 filters The ChipBLASTER will typically start on filter A and run until this filter becomes clogged dirty When the filter becomes clogged dirty the flow will be switched to filter B automatically The red tower light will begin to flash indicating a clogged dirty filter A The ChipBLASTER will continue to operate While the ChipBLASTER is running on filter B filter A can be changed refer to Section 14 9 for procedure When the ChipBLASTER is running on filter B and it becomes clogged dirty the ChipBLASTER will go to an emergency stop condition after the call for coolant is shut off This will prevent damage to the high pressure pump It should be noted the filter bag A or B is monitored when the ChipBLASTER is operating The post filter is also monitored when the ChipBLASTER is operating If the post filter becomes dirty the red tower light will turn on steady The reason the post filter can become dirty is do to improper changing of the f
57. CAUSE THE ES RELAY TO D 13 1 THE FOLLOWING ERRORS WILL STOP THE OPERATION ON 13 2 13 3 13 4 13 5 CHANGE STATES 13 1 1 Main drive fault 13 1 2 Filter pump overload 13 1 3 Return pump overload 13 1 4 Monitored circuit breaker trip 13 1 5 Dirty A filter at end of cycle De energize call for coolant Single filter unit 13 1 6 Dirty B filter at end of cycle De energize call for coolant Auto cross over option 13 1 7 Dirty post filter at end of cycle De energize call for coolant 13 1 8 Low coolant level in the ChipBLASTER coolant tank 13 1 9 High pressure to the machining center is below 300 PSI 20 6 Bar with no alarm This requires an optional pressure switch to be purchased with ChipBLASTER THE FOLLOWING ERRORS WILL CAUSE THE ALARM TO SOUND 13 1 1 Any motor overload constant blast 13 1 2 Monitored circuit breaker trip constant blast 13 1 3 Low coolant limit intermittent blast 13 1 4 Post filter for one 1 hour without de energizing call for coolant 13 1 5 Flow rate of coolant from the machining center s coolant tank sump to the ChipBLASTER tank is less than 8 GPM 30 2 l min intermittent blast warning only SLOW COOLANT RETURN THE FOLLOWING ERROR WILL CAUSE THE ERROR LIGHT TO FLASH 13 3 1 Dirty filter either a single dual or autocross filter system THE FOLLOWING WILL CAUSE THE ERROR LIGHT TO TURN ON STEADY 13 4 1 Post fi
58. HIS OPERATION MAY DAMAGE THE SYSTEM OR THE MOTOR IF REPEATED ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 8 ALTIVAR 31 DRIVE AS SET PARAMETERS 230 VAC W and W O 50 PRESETS Code Label Value Default value Logical address Menu ACC Acceleration ramp time 4 MODELS 3 05 9001 ADC Automatic DC Injection Yes DC inj for adj time DC inj for adj time 10401 ADCO Drive CANopen address 0 6051 Configuration of Configuration reference 1 4821 Configuration reference 1 PI Configuration of AI2 regulator feedback Summing input 2 4822 ALL MODELS AIBA Configuration of AI3 Not configured configured 4823 1 Configuration of AO1 Configuration 0 20 mA Configuration 0 20 mA 4601 ATR Automatic restart No No 7122 BDCO CANopen trans speed 125 kbitls 125 kbitls 6053 Std motor frequency 50 Hz 3015 Brake control assigned Not assigned 10001 BRA Decel ramp adaptation Yes Yes 9003 CHP Switching motor 2 Not assigned Not assigned 8011 CLI Internal current limit 41 2A 41 2A 9201 COL Stop for CANopen fit COF Freewheel Freewheel 7011 cas Motor power factor 0 85 0 85 9606 CRH3 Value for high speed AI3 20 0 mA 20 0 mA 4444 Value for low speed 4434 CTD Motor current detection 27 5A 27 5A 11001 DCI DC brake via logic input assigned Not ass
59. L INTERFACE For Control Interface instructions please refer to The Chipblaster with THINC Control Installation Procedure received with the Chipblaster 9 3 POWER SUPPLY CONNECTIONS REFER TO ChipBLASTER DATA NAMEPLATE FOR CORRECT SUPPLY VOLTAGE DO NOT EXCEED AMP RATING OF MACHINING CENTER BREAKER IF CONNECTING TO LOAD SIDE IF CONNECTING TO A MAIN DROP SIZE DISCONNECT AND WIRE BASED ON INFORMATION SUPPLIED ON THE ChipBLASTER NAMEPLATE 9 3 1 The EV is supplied from the factory with a 12 pin plug and receptacle If the receptacle is not used wire L1 L2 and L3 to the line top of the main circuit breaker 1CB Wire the PE from the machining center to the ground terminal in the ChipBLASTER control panel otherwise 1 to terminal 1 L2 to terminal 2 and L3 to terminal 3 Connect PE to the ground terminal of the receptacle 10 0 START UP 10 1 Fill the ChipBLASTER reservoir with clean coolant to within 3 76 mm of top DO NOT OVERFILL 10 1 If machine tool sump is not full top off as required DO NOT OVERFILL 10 2 If ChipBLASTER s optional return transfer pump is used the pump must be primed 10 3 1 Remove the fill line form the inlet of the ChipBLASTER tank 10 3 2 Fill line with clean coolant A 10 3 3 Manually energize return transfer pump motor starter MR3 9 7 9 8 10 3 4 The return transfer pump should now pull from machine tool sump 10 3 5 If pump does not pull fluid
60. LT TENSIONING FORCE DEFLECTION METHOD 18 4 1 An alternate numerical method can also be used to properly tension the belt on a Synchronous drive This procedure commonly referred to as the Force Deflection Method consists of measuring the pounds of force required to deflect the belt a given amount 18 4 1 1 18 4 12 18 4 13 18 4 1 4 Install the belt as per Steps 1 and 2 of the General Method Measure the span length in inches as illustrated in Figure 11 From Figure 11 determine the deflection height required for the drive The deflection height is always 1 64 per inch of span length For example a 32 span length requires a deflection of 32 64 or 1 2 To measure the deflection height place a straightedge from sprocket to sprocket on top of the belt or wrap a string or steel tape around the sprockets on top of the belt This will serve as a reference line to measure deflection inches Using the formula at below calculate the minimum and maximum force values 165 Using a spring scale apply a perpendicular force to the belt at the mid point of the span as illustrated in Figure 1 NOTE For belts wider than 2 inches it is suggested that a rigid piece of key stock or something similar be placed across the belt between the point of force and the belt to prevent belt distortion Compare this defection force value to that found in 18 4 1 4 Adjust belt tension accordingly Actual belt installation tension requ
61. NAL EQUIPMENT Cont 27 17 Magnetic separator The magnetic separator consists of a high strength collector that will remove 90 of all ferrous particles over 25 microns The filthy coolant associated with materials like cast iron is not a problem when a magnetic separator is utilized 27 17 1 Magnetic separator requires no maintenance other than to check roller periodically for any build up Tm TREZ MAGNETIC d 27 17 ChipBLASTER Inc 104 27 0 OPTIONAL EQUIPMENT Cont 27 18 HYDROCYLONIC FILTER INSERT This option mechanically separates the heavy particles out of the coolant and forces the particles to the bottom of the filter canister to increase the overall filter life SAFETY GLASSES AND GLOVES MUST BE WORN WHEN CHANGING FILTER USE EXTREME CARE WHEN REMOVING FILTER BAGS AS THEY WILL BE HEAVY REFER TO SECTION 14 5 FOR FILTER CHANGING PROCUDURE O gt 27 18 ChipBLASTER Inc 105 27 0 OPTIONAL EQUIPMENT Cont 27 19 PRESET PRESSURES 27 19 1 Preset pressures add the flexibility of four pre programmed drive speeds to give four separate operating pressures by the use of codes from the machine tool The machine tool control must be capable of a total of 4 sets of maintained on and off M codes total for a single outlet ChipBLASTER or 5 sets of maintained on and off for a two outlet ChipBLASTER The machine tool must also be capable of supplying tw
62. NS AND DRIVE BELT REMOVAL 17 2 1 Loosen the four mounting bolts located on the high pressure pump to allow for high pressure pump adjustment or drive belt removal To remove the drive belt release the belt tension by advancing the high pressure pump forward Turning the high pressure pump mount adjustment idler counter clockwise will advance the high pressure pump forward towards the driven pulley 17 2 2 Tools required for pump replacement 17 2 2 1 Pump mounting bolts 9 16 wrench 17 2 2 2 Pump mount adjustment idler 9 16 wrench 17 2 2 3 Motor drive pulley 7 16 wrench 17 2 2 4 JV10 JVHP GV20 GVHP high pressure fittings 7 8 wrench 17 2 2 5 EV13 EVHP high pressure fittings 1 1 8 wrench 17 2 2 6 JV10 JVHP EV13 EVHP GV20 GVHP low pressure fittings pipe wrench 17 2 2 7 Pump bracket bolts 5 16 hex key DO NOT PRY OR FORCE THE DRIVE BELT OFF OF THE PULLEYS THIS MAY RESULT IN PERMANENT DAMAGE TO THE PULLEY OR BELT ONCE THE DRIVE BELT HAS BEEN REMOVED VISUALLY INSPECT IT FOR ABNORMAL WEAR AND TOOTH SHEAR REPLACE THE BELT AS NECESSARY ChipBLASTER Inc 60 17 0 HIGH PRESSURE PUMP REPLACEMENT SINGLE PUMP Cont 17 3 THE REPLACEMENT PUMP 17 3 1 17 32 17 3 3 17 3 4 17 3 5 Remove the low pressure hose high pressure hose oil line hose black drain line lines and the pulley from the defective pump Remove the 4 bolts that secure the pump to the rails a
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64. P 4 PUMP MOTOR 5 SOLENOID VALVE 6 SOLENOID VALVE TRANSDUCER PRESSURE TRANSDUCER UNLOADER REGULATOR REGULATOR 9 MANIFOLD BLOCK 10 HIGH PRESSURE PUMP gt r 1 LL 211 19 EV13 EVHP EV13 EVHP 2260 2556 2595 4002 4001 9670 4546 82 22 17 22 17 ChipBLASTER Inc 83 22 22 EV Sub Plate Plain View Mechanical Assembly ITEM No DESCRIPTION PART No 1 J FILTER PUMP 4251A PUMP SHEAVE 2260 DRIVE BELT EVHP 2556 5 DRIVE SHEAVE EV13 2595 DRIVE SHEAVE EVHP 2944 6 SOLENOID VALVE N O 402 PRESSURE TRANSDUCER 9670 8 MANFOLDBLOK 1 896701 9 X SOLNOIDVALVENC 1 4001 114 HIGH PRESSURE PUMP 2119 12 HIGH PRESSURE SUPPLY HOSE N 5 22 22 ChipBLASTER Inc 84 22 27 EV Oil Level Sight Mechanical Assembly ITEM No DESCRIPTION PART No 1 OIL SIGHT GAUGE ASSEMBLY 8681 fe ___ OIL LEVEL LABEL D MEE ___ OIL DRAIN PLUG 9997 22 27 ChipBLASTER Inc 22 28 EV Tank Plan View With Screens and Baffles Mechanical Assembly ITEM No DESCRIPTION PART No 1 2 3 4 5 7 10 11 12 13 14 15 16 CONTROL ENCLOSURE DIRTY FILTER LIGHT 7538 7539 F S LOAT SWITCH ASSEMBLY EMI CLEAN COOLANT COMPARTMENT NA NA NA 5968 B 85 22 28 ChipBLASTER Inc
65. P N MAN EV001TC BEGSTER HIGH PRESSURE HIGH VOLUME COOLANT SYSTEMS EV13 EVHP with TWIDO PLC and OPTIONAL THINC INTERFACE VARIABLE VOLUME MODELS HIGH PRESSURE HIGH VOLUME COOLANT DELIVERY SYSTEM THESE MODELS ARE PROTECTED UNDER UNITED STATES PATENT NUMBER 5 951 216 THINC PARTNERS INSTALLATION OPERATION and SERVICE MANUAL ChipBLASTER Inc 13605 South Mosiertown Road Meadville PA 16335 USA www chipblaster com Telephone 814 724 6278 Fax 814 724 6287 For your records please list serial number from nameplate REV C ChipBLASTER Inc REVISION RECORD REVISION DATE PERSON DESCRIPTION OF CHANGE A 17MAR08 TD NEW RELEASE B 02APR 08 TD UPDATE PRINTS 16 08 TD UPDATE EXPLANATION OF MARKINGS ChipBLASTER Inc 3 GENERAL This manual covers the following ChipBLASTER models EV13 and EVHP with THINC Control For the model number of your unit refer to the data nameplate located on the enclosure door UNIT MODEL NUMBER UNIT SERIAL NUMBER DATA NAME PLATE wa MEADVILLE PA 16335 USA TELEPHONE 814 724 6278 FAX 814 724 6287 MODEL SERIAL No SUPPLY VOLTAGE PHASE FREQUENCY VAC PH HZ FULL LOAD CURRENT AMPS LARGEST LOAD AMPS AMP RATING OF DISCONNECT DEVICE AMPS DATEOFMFG HIGH PRESSURE PUMP LUBRICANT Mobil 15W 50 FOR THE NEAREST MOBIL LUBRICANT SUPPLIER OR FOR TECHNICAL INFORMATION CALL 1 800 662
66. POSES WITHOUT DOCUMENT CONTAINS PROPRIETARY INFORMATION AND SUCH INFORMATION MAY NOT BE DISCLOSED TO OTHERS FOR ANY WRITTEN PERMISSION FROM ChipBLASTER THIS PRINT IS THE PROPERTY OF ChipBLASTER THIS 3CB 39 60 HZ 2 3 POWER PLUG REFER TO DRAWING o T31 0006 OR 731 0006 n 230 VAC T31 0006A OR T31 0006A OR T31 0006B OR T31 0006C 5 460 AS REQUIRED al al 171 HERI TE 112 MAIN PUMP e XY 1 MTR SEE CHART 5 102 L3 3 o X X SEE CHART 230V 40A 58 i03 GND lt lt 460V 20A E 21 MR 4 E 104 e Ore o Lo EN 12 212 2 E 212 e FILTER PUMP amp 105 c gt 44 Le 3 92 a 2 SEE CHART S 13 213 y M o 106 5 107 5 21 3714 108 gia 22 21722 3 mtp RETURN PUMP E e CHART 5 213 3133 110 e gt a dt MR 3 AUX 112 5 RETURN PUMP E vg SIGNAL 74 113 STANDARD PUMP SIGNAL MR 3 AUX DKE 5 RETURN ici PUMP 115 15 SIGNAL OPTIONAL MORI PUMP SIGNAL 116 Gw OPTIONAL COOLER SEE BELOW 5 jm ATH Z i 3 COOLER MOTOR lt gt o TN B 22 ee 119 6 3 4 MTR 3 As 230 VAC 39 FLA 1 0 m 460 VAC 39 FLA 0 5 8 L 7 m 1 IEC 63 FRAME 74 121 Z KEYING 2 PIN OPTIONAL MAGNETIC SKIMMER
67. QUIRE MORE FREQUENT CLEANING IF LARGE AMOUNTS OF TRAMP OIL IS PRESENT IN COOLANT RESERVOIR OR CUTTING OILS ARE USED ChipBLASTER Inc 40 14 0 PREVENTATIVE MAINTENANCE Cont 14 25 14 27 14 29 14 30 14 31 TANK CLEANING 14 25 1 Coolant in the tank should be drained yearly so that the tank may be prope cleaned 14 25 2 Dispose of fluid per local regulations 14 25 3 Clean all baffles and replace 14 25 4 After tank has been cleaned all filters should be replaced 14 25 5 The ChipBLASTER should be stated as a new unit Refer to SECTION 10 0 14 17 14 23 PUMP MOUNTING BOLTS CHECK 14 27 1 The filter pump mounting bolts should be checked for tightnes The recommended torque is 210 IN LB 24 Newton meters 14 27 2 The bolts for the main high pressure prussure pump to mounting rails should be torqued to 200 IN LB 23 Newton meters RETURN PUMP ChipBLASTER supplied CHECK FLOW RATE 14 29 1 This pump should be checked every six months to insure the correct flow rate If the flow rate has decreased the pump should be rebuilt or replaced 14 29 2 An indication the return pump may be clogged will be constant SLOW COOLANT RETURN warnings 14 29 3 The ChipBLASTER must be powered down and the disconnect placed in the OFF position and locked out 14 29 4 Remove the inlet and outlet hoses by loosening the hose clamps Inspect the inlet and outlet for chips that may have accumulated remo
68. TER unit to the support DO NOT AT ANY TIME REACH UNDER THE ChipBLASTER UNIT OR STAND UNDER THE ChipBLASTER UNIT WHILE IT IS SUPPORTED BY A FORK TRUCK IF YOU MUST REACH UNDER THE MACHINE BLOCK IT UP FOR SAFETY 7 2 5 The EV units are shipped from the factory with leveling feet as shown in figure la The leveling feet must be installed when setting up the ChipBLASTER 7 2 8 After you remove the ChipBLASTER from the skid take the set of four feet and install the studs of the leveling feet through the holes in the legs Block unit while installing feet for safety Reference top of foot to the bottom of second nut 17 The feet have two functions the first being to level the ChipBLASTER unit and the second being to help eliminate the transfer of noise Refer to figure 1 7 2 9 After you have the feet in place proceed with moving the ChipBLASTER into place ChipBLASTER Inc 18 7 0 PLACING A ChipBLASTER Cont Mounting feet installation Figure 1 Recommended 1 inch 25 4 mm EV Upon positioning the unit go ahead and level the machine The ChipBLASTER must be level to insure proper operation Remember the ChipBLASTER unit has float switches and an overflow if the unit is not level these items may not work properly After ChipBLASTER is in place and level remove all items from inside of the tank Items located in the tank are hoses filter bag s and pre filters Place all hoses at the back of the unit same end as
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70. W PRESSURE ELECTRICAL CONNECTION DUAL FILTERS FILTER INLET FILTER OUTLET lt gt PRESSURE PRESSURE lt gt AN RETURN PUMP ChipBLASTER FILTER PUMP ex TANK 1 FILTER VESSEL N N V 1 1 FILTER VESSEL pif pe Aer et E ea rh dd E E PRESSURE MACHINE TOOL 1 DUMP SWITCH SUMP SOLENOID UNLOADER Y VALVE POST S FILTER So j PRESSURE 4 soLENOID A 4 SWITCH VALVE MACHINE TOOL MANIFOLD BLOCKWITH H HIGH PRESSURE ACCUMULATOR PUMP OPTIONAL COOLANT 2 SOLENOID 4 MECHANICAL COUPLING VALVE MOTOR FEEDBACK SIGNAL TRANSDUCER CONTROLLED BY AFD MANIFOLD BLOCK S EM XU Re 4 HIGH PRESSURE SAMPLE LINE LOW PRESSURE ELECTRICAL CONNECTION AUTO CROSS FI LTERS FILTER INLET FILTER OUTLET PRESSURE PRESSURE RUN FILTER A Y RETURN PUMP ChipBLASTER FILTER PUMP SOLENOID TANK VALVE E A 1 FILTER VESSEL AT RUN FILTER B SOLENOID L VALVE 1 1 DA FILTER VESSEL epe E re p PRESSURE MACHINE TOOL DUMP SWITCH SUMP SOLENOID C 4 UNLOADER T VALVE POST lt FILTER gt COOLANT 1 mE Y 4 SOLENOID A 4 SWITCH VALVE MACHINE TOOL MANIFOLD BLOCKWITH 4 HIGH PRESSURE ACCUMULATOR PUMP OPTIONAL 4 COOLANT 2 4 SOLENOID B MECHANICAL COUPLING VALVE v FEEDBACK SIGNAL MOTOR TRANSDUCER CONTROLLED
71. ace of the fluid in the ChipBLASTER tank The oil skimmer cycles on for 5 minutes and then is off for 10 minutes 2 BEFORE STARTING THIS OR ANY MAINTENANCE ON A ChipBLASTER UNIT MAKE SURE ALL POWER IS OFF TO THE UNIT VM 27 15 1 2 You will need a 9 16 wrench or socket and ratchet for this job 27 15 2 To replace worn belts is suggested the oil skimmer unit be removed from the tank 27 15 3 Remove the belts from the lower set of idler wheels that are normally inside the reservoir tank 27 15 4 Loosen the four 3 8 16 bolts that hold the shaft in place Remove belts from idlers first 27123 27 15 ChipBLASTER Inc 102 27 0 OPTIONAL EQUIPMENT Cont 27 15 OIL SKIMMER Cont 27 15 6 Inspect the wheels and make sure they are clean and still have grooves to grip the belt Note If the wheels on the shaft are smooth they will not grip the belts 27 15 7 After you inspect the wheels replace the new belts on the shaft 27 15 8 Put the bolts back in place and tighten the bolts 27 15 9 Place the belts back on the wheels in the reservoir tank 27 15 10 Re install the oil skimmer unit back on tank 27 15 11 Plug oil skimmer in and turn power on and inspect when the oil skimmer turns on 27 15 12 Close lid and install locking fastener DO NOT OPERATE OIL SKIMMER OUTSIDE TANK REPLACE ALL PANELS GUARDS BEFORE RETURNING THE ChipBLASTER TO PRODUCTION STATUS 27 15 ChipBLASTER Inc 103 27 0 OPTIO
72. al running pressure to prevent any over pressure in the high pressure coolant system The blow off coolant is then returned to the first compartment in the ChipBLASTER s tank through a check valve The dampener unit is installed to dampen the fast changes in coolant pressure A pressure gauge is installed to read the overall pressure between the high pressure pump and the nozzle s outlet at the machining center The transducer reads the overall pressure and produces an error voltage that is fed back to control the speed of the variable drive 1 AFD The optional pressure which is only used to produce an error signal if there is a reduction of pressure below 300 psi 20 6 Bar The solenoids are used for diverting the coolant for different machine operations The high pressure coolant leaves the manifold block and flows through the machining center to the tool being used 12 1 12 2 ChipBLASTER Inc 24 12 0 OPERATION Cont 12 2 4 12 2 5 12 2 6 12 2 7 12 2 8 The RETURN TRANSFER PUMP is a separate system but is very important It must maintain the levels of the coolant in the ChipBLASTER s coolant tank and the machining center s coolant tank The return pump returns coolant from the machining center s sump to the ChipBLASTER s coolant tank The float assembly in the ChipBLASTER s coolant tank will maintain all coolant levels including the machining center s sump If the ChipBLASTER is to operated from a CENTR
73. ansion valve to absorb heat as it evaporates in the evaporator heat exchanger When the controller calls for heating the compressor and fan shut down The cooler should now be ready for continuous operation 27 21 7 SAFETY INTERLOCKS 23 217120 27 HIGH TEMPERATURE INTERLOCK 21 7 1 1 This cooler has a HIGH TEMPERATURE interlock warning built into the temperature controller See ATC CTC controller instructions attached If the coolant temperature exceeds the high temperature setting the cooler will continue to run but contacts across terminals 10 and 11 will open 27 21 8 MAINTENANCE 2121 8 Every Turmoil cooler is carefully assembled from the finest components by skilled craftsmen Each cooler is thoroughly tested and inspected before it leaves the factory However in order to obtain efficient service and long life from this cooler it must be given proper care as with any other piece of mechanical equipment 27 21 ChipBLASTER Inc 110 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont 27 21 8 2 AIR FILTER Keep Clean 27 21 8 3 CONDENSER Condenser fins should be cleaned of dust and dirt regularly 27 21 8 4 PUMP See attached pump instructions 27 21 9 TROUBLE SHOOTING PROBLEM CAUSE SOLUTION Cooler operative A Low Coolant Level Add Coolant but not cooling B Dirty Air Filter Clean C Blocked Air Flow Remove Blockage D Condenser Clogged Clean E Faulty Controller Repair Replac
74. arlier Any claim not made within this time shall be conclusively deemed to have been waived by the purchaser 24 2 9 Failure of the purchaser to maintain the equipment by completing all of the scheduled maintenance tasks set forth in Exhibit A to this limited warranty entitled ChipBLASTER Maintenance Schedule will void this limited warranty and release ChipBLASTER from any liability hereunder ChipBLASTER may require purchaser to provide evidence of timely completion of the scheduled maintenance tasks set forth in Exhibit A 24 2 10 ChipBLASTER warranty card must be completed by purchaser and returned to ChipBLASTER within 30 days after installation of ChipBLASTER equipment to validate this limited warranty Procedures for Obtaining Technical Service or Warranty Service Repair or replacement under this limited warranty can only be obtained by registering a warranty claim directly with ChipBLASTER To enable ChipBLASTER to respond to a request for technical assistance or a request for warranty service the purchaser must provide at a minimum the following information during the initial telephone call model number serial number and information regarding any optional ChipBLASTER components the date of purchase the dealer or supplier from whom the equipment was purchased the nature of the problem or difficulty A warranty claim form can be obtained by contacting ChipBLASTER at 800 241 3163 Limitation of Liability ChipBLASTER s liability u
75. assigned Not assigned 11404 Not assigned A PS2 Enable 2 preset speeds ALL MODELS Logic input LI3 11401 assigned ae PS4 Enable 4 preset speeds ALL MODELS Logic input 4 11402 PS8 Enable 8 preset speeds Not assigned assigned 11403 PST STOP Key Priority Yes Yes 64002 15 9 ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 9 ALTIVAR 31 DRIVE AS SET PARAMETERS 460 VAC W and W O 55 PRESETS Cont Code Label Value Default value logical address Menu R1 Relay R1 Drive fault Drive fault 5001 R2 Relay R2 Not assigned Not assigned 5002 RFC Enable switching refs Configuration reference 1 Configuration reference 1 8411 RIG Integral gain PI regulator V MODELS 1 00 11942 RP2 preset reference 30 0 11921 RP3 3rd PI preset reference 60 0 11922 RP4 preset reference M 90 0 11923 Proportional 1 50 1 00 11941 RPI Internal PI reference 45 0 0 096 11920 RPS Ramp switching Not assigned Not assigned 9010 RPT of Ramp Linear ramp 9004 RRS Reverse ere Logic input 112 11105 RSC Cold stator resistance Inactiv Inactiv 9643 RSF Fault reset Not assigned Not assigned 7124 SA2 Summing input 2 Analog input AI2 11801 Summing input configured Not configured 11802 SDC1 DC current at
76. ation misuse failure to follow directions and instructions provided by ChipBLASTER applicable literature any damage or loss to products or parts which results from the alteration repair modification faulty installation or service other than regular maintenance by any one other than an authorized ChipBLASTER service technician and the use of any add ons parts accessories or components not obtained from ChipBLASTER an authorized ChipBLASTER supplier or approved in writing by ChipBLASTER damage to products or parts caused by accident abuse or misuse replacement of filters normal wear and tear damage which occurs in shipment or as a result of an act of God such as lightening or electrical failures such as line surges or brownouts 24 2 3 Any replacement equipment or parts provided to the purchaser in fulfilling this warranty are warranted for the un expired portion of the original warranty 24 2 4 If any ChipBLASTER products are found upon ChipBLASTER s examination in response to a warranty claim to have defects in material or workmanship ChipBLASTER will either replace or repair the product at its sole option 24 2 5 ChipBLASTER expects that warranty repairs will be completed at the purchaser s location however if requested by ChipBLASTER purchaser shall return the alleged defective product to ChipBLASTER for examination at ChipBLASTER s direction ChipBLASTER will reimburse the purchaser for the expense incurred in retur
77. ce being careful not to cross thread the filter If the post filter is equipped with a petcock open the petcock and press the air purge button on the electrical panel to remove air from the filter When all of the air is purged from the filter close the petcock 14 19 SOCK FILTER CHANGING 14 19 1 This can only be replaced when the ChipBLASTER is shut down 14 19 2 To remove cut or untie the cord holding sock filter in place 14 19 3 Slide the replacement sock filter in place over the fitting and tie securely 14 19 4 To reorder sock pre filters refer to form in SCTION 14 16 13 14 23 FLOAT SWITCH CLEANING 14 23 1 Check float switch rod for build up of particulate material BE CAREFUL NOT TO BEND THE ROD 14 23 2 If float switch barrel has dirt build up inside it will be necessary to disassemble the switch assembly 14 23 2 1 Remove the plug from the top using a 3 16 hex key 14 23 2 2 Unscrew the float bulb from the brass rod 14 23 2 3 Push the brass rod and magnetic carrier up until the magnetic carrier can be pulled out of the housing 14 23 2 4 Clean the barrel of the housing with a round soft bristle brush DO NOT LUBRICATE THE FLOAT ASSEMBLY AS THIS WILL CAUSE IMPROPER OPERATION 14 23 3 Re assemble float switch BE CAREFUL NOT TO BEND THE ROD 14 23 4 Clean the float bulb also 14 23 5 After cleaning insure the rod moves up and down freely without any binding NOTE FLOAT STEM CLEANING MAY RE
78. ck the Transducer s feedback voltage use your meter in the DC mode Remove the drive control cover Start the machine and place your Neg lead on The COM terminal Place your Pos lead on the AD terminal and record the reading NOTE Electrical troubleshooting can be done over the phone if you have a qualified person USE EXTREME CAUTION WHEN WORKING INSIDE THE ELECTRICAL ENCLOSURE ChipBLASTER Inc 45 15 0 TROUBLESHOOTING Cont 15 3 Troubleshooting Flow Chart TROUBLE SHOOTING FLOW CHART DO YOU HAVE CORRECT PRESSURE AT THE MACHINE TOOL DO YOU HAVE ANY DO YOU HAVE PRESSURE PRESSURE ON ON ChipBLASTER s Ed ChipBLASTER s HIGH PRESSURE GAUGE PRESSURE GAUGE IS PRESSURE FAULTY UNLOADER ChipBLASTER IS 2 HIGHER BYPASS SOLENOID OKAY LOWER NOT WORKING WORKING THAN NORMAL BROKEN BELT HIGHER N C SOLENOID NOT WORKING NOZZLE IS HIGH PRESSURE PLUGGED WITH CHIPS PUMP RUNNING NOZZLE TOO SMALL NOZZLE OPENING TOO LARGE AFD DRIVE TRIPPED LEAKAGE BETWEEN CR7 NOT ENERGIZED ChipBLASTER AND FAULTY AFD DRIVE MACHINE TOOL NOZZLE FAULTY MOTOR Figure 7 15 3 ChipBLASTER Inc 46 15 0 TROUBLESHOOTING Cont 15 4 ALTIVAR 31 DRIVE 1 AFD ERROR CODES FOR DETAILED INFORMATION ON DRIVE AND OR FAULTS REFER TO THE SQUARE D ALTIVAR 31 MANUAL 15 4 1 The drive controller can be unlocked after a fault by the following methods 15 4 1 1 Removing power from the drive controller until the display cl
79. e Invoice Date I on hereby declare the ChipBlaster Signature date high pressure coolant system has been installed on according machine model to ChipBlaster procedures Note ChipBlaster Standard Warranty will commence with the above signed date if all conditions of the procedures are met SEND TO ChipBLASTER Office Use Only 13605 South Mosiertown Road Date Warranty Registration Received Meadville PA 16335 Attn Warranty Dept 24 6 ChipBLASTER Inc 98 27 0 OPTIONAL EQUIPMENT 271 Magelis Human machine interface Unit HMI 27 1 1 24 12 27 1 3 27 1 4 27 1 5 Used to display in plain English operating status and faults During normal operation the status of the of the coolant system will be displayed on the operator interface unit The following information will be displayed 27 1 2 1 Coolant No 1 ON Will show filter being used A or B when autocross option is being used 27 1 2 2 Coolant No 2 ON Will show filter being used A or B when autocross option is being used 27 1 2 3 Coolant No 1 and 2 Will show filter being used A or B when autocross option is being used 27 1 2 4 Index No 1 ON Will show filter being used A or B when autocross option is being used 27 1 2 5 Index No 2 ON Will show filter being used A or B when autocross option is being used 27 1 2 6 Index No 1 and 2 ON Will show filter being used A or B when autocross optio
80. e F Low Refrigerant Charge Repair G Faulty Compressor Repair Replace H Faulty Solenoid Valve Replace Coil I Incorrect Expansion Adjust Expansion Valve to proper setting Valve setting Cooler inoperative A Faulty Power Source Check amp Correct or does not start B Cooler OFF on Low Check for Pressure Low Coolant Level No Coolant Flow across the coils Low Ambient Wrong Setting on Pressure Switch Low or Lost Refrigerant Charge Incorrect Expansion Valve Setting e Actions designated with should only be done by a Qualified Refrigeration Service Person check with factory for proper settings 2121 ChipBLASTER Inc 111 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont 27 21 10 PARTS LIST SYMBOL DESCRIPTION MANUFACTURE MODEL PART NUMBERS FLTR AIR FILTER SMITH _______ __ gue ee ee CT SCRI 2222 2225 22454222222 EXPANSION VALVE ALCO ACP 3 14011 27 21 ChipBLASTER Inc 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont 27 21 11 ATC CTC TEMPERATURE CONTROLLER SETUP TURMOIL 112 27 21 ChipBLASTER Inc 113 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont 27 21 11 ATC CTC TEMPERATURE CONTROLLER SETUP Cont on terminal gized and the display will r
81. e load on the motor With display showing rdY Press ENT display will show Set Press the DOWN arrow three times until SUP is displayed Display will show FrH Press the DOWN arrow key four times until LCr is displayed This will display the motor current in amps To return to the rdY display press ESC Q DO NOT PRESS ENT 16 0 11 7 Test run the machine and check the output pressure on the high pressure gauge and make the necessary adjustments to achieve the desired working pressure 16 0 ChipBLASTER Inc 58 16 0 PRESSURE ADJUSTMENT PROCEDURE ALTIVAR 31 DRIVES Cont If you cannot achieve the desired output pressure please check to be sure that the unloader has been properly set Also refer to the orifice reference charts SECTION 28 included to verify nozzle size to make sure you are within the machine s capabilities MODEL ORIFICE SIZE FLOW PRESSURE EV13 EVHP 0 110 2 9 mm 13 8 GPM 52 2 m 1000 PSIG 68 9 bar 16 0 ChipBLASTER Inc 59 17 0 HIGH PRESSURE PUMP REPLACEMENT SINGLE PUMP IT IS EXTREMELY IMPORTANT TO DISCONNECT AND LOCKOUT ANY AND ALL POWER SOURCES BEFORE ANY WORK IS TO BE PERFORMED ON THE ChipBLASTER UNIT 17 1 LUBRICATION 17 1 2 After pump replacement procedure check to insure that the replacement pump crankcase contains oil and is at the proper level Use synthetic Mobil One 15w 50 oil only Refer to SECTION 14 3 2 for oil filling instructions 17 2 HYDRAULIC CONNECTIO
82. ead EEE if sensor 1 is open or short circuited RACKING ATC MODE Ambient illuminated when re rigntme de vhen the jrammed at emperature Del ta T value and 1 will read EEE if Sensor 1 or Sensor 2 is open or SET once LIMIT DELTA between the limits of 1 will enter will light vill adj pushing SET agai Pushing SET again will return to the display and control mode both the UP ad AST adjust the SET POINT DELTA T between 20 degrees F 11 and 11 degrees C gain will return to the display and control button i approximately return to disp programming the new values are automatically saved in non volatile 27 21 114 ChipBLASTER Inc 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont 27 21 11 ATC CTC TEMPERATURE CONTROLLER SETUP Cont TURMOIL 27 21 ChipBLASTER Inc 115 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont 27 21 12 ELECTRICAL SCHEMATIC TURMOIL 27 21 116 S3903 V soinrzo our our T Vau 28 8 133HS va 3799 A8 Ag 2
83. ears 15 4 1 2 Automatically if the automatic restart function is enabled PARAMETER Atr IS SET TO YES SEE PAGE 75 OF THE Altivar3 1 PROGRAMMING MANUAL 15 4 1 2 By a logic input if a logic input is assigned to the fault reset Function PARAMETER rSF ASSIGNED TO LI SEE PAGE 75 OF THE Altivar3 1 PROGRAMMING MANUAL DO NOT RESET THE INVERTER WHEN TRIPPED BECAUSE OF A FAULT OR ERROR BEFORE ELIMINATING THE PROBLEM THAT CAUSED THE FAULT OR TRIP 15 4 2 Faults which cannot be automatically reset 15 4 2 1 Faults which cannot be automatically reset are listed in the table on next page to clear these faults 15 4 2 2 Remove power from the drive controller 15 4 2 3 Wait for the display to go off completely 15 4 2 4 Determine the cause of the fault and correct it 15 4 2 5 Reapply power bLF CrF OCF SOF AND tnF CAN ALSO BE RESET REMOTELY VIA A LOGIC INPUT REFER TO THE RSF PARAMETER ON PAGE 75 OF THE PROGRAMMING MANUAL 15 4 ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 5 ALTIVAR 31 DRIVE 1 AFD ERROR CODES Cont 47 FAULTS WHICH CANNOT BE AUTOMATICALLY RESET Probable Cause Remedy Fault bLF Brake sequence Brake release current not reached Check the drive controller and motor connections Check the motor windings Check the Ibr setting in the FUn menu Refer to page 68 Precharge circuit fault InF Internal fault OCF Overcurrent SEF Motor short circuit SOF Overs
84. equately sized to carry the weight of the MistBLASTER Refer to MistBLASTER footprint drawing for actual weight BURN HAZARD HOT SURFACE Surface of transformer will become hot after extended periods of operation Do not set anything on transformer or restrict airflow around transformer DO NOT TOUCH INHALATION HAZARD Consult MSDS Sheet for Hazard Listings Possible Coolant Mist Emission 15 ChipBLASTER Inc 16 Q T 5 1 If the ChipBLASTER is to be stored for any period of time it must be keep in an area that is protected from freezing Freezing temperatures will damage the pumps and the valves Keep ChipBLASTER covered until ready to move to site If MistBLASTER is also supplied keep covered 6 1 When moving the ChipBLASTER to the final site the following must be adhered to 6 1 1 Lift ChipBLASTER only from the opposite end of the electrical enclosure Forks must extend the full distance under ChipBLASTER 6 1 2 The fork truck lifting capacity must be sufficent to safely lift the ChipBLASTER without tipping Refer to footprint drawing Section 23 for machine dry weight 5 0 STORAGE 6 0 MOVING MACHINE MOVE SLOWLY AS NOT TO DROP THE ChipBLASTER DO NOT TRY TO MOVE ChipBLASTER WITH FLUID IN TANK DO NOT STAND UNDER ChipBLASTER AT ANY TIME If MistBLASTER is supplied with ChipBLASTER 6 2 When lifting or moving the MistBLASTER lift only at the eye bolts provided on the top 6 3 S
85. erence PI ALL MODELS No 11908 logic input LI2 5 PR2 Enable 2 preset PI refs MODELS assigned 11909 Logic input LI3 3 PRA Enable 4 preset PI refs ALL MODELS assigned 11910 PS16 Enable 16 preset speeds assigned Not assigned 11404 Not assigned A PS2 Enable 2 preset speeds ALL MODELS Logic input LI3 11401 assigned ae PS4 Enable 4 preset speeds ALL MODELS Logic input 4 11402 PS8 Enable 8 preset speeds Not assigned assigned 11403 PST STOP Key Priority Yes Yes 64002 15 8 ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 8 ALTIVAR 31 DRIVE AS SET PARAMETERS 230 VAC W and W O 52 PRESETS Cont Code Label Malue Default value logical address Menu R1 Relay R1 Drive fault Drive fault 5001 R2 Relay R2 Not assigned Not assigned 5002 RFC Enable switching refs Configuration reference 1 Configuration reference 1 8411 RIG Integral gain PI regulator E MODELS 1 00 11942 RP2 bnd preset reference pc bee 30 0 11921 3rd PI preset reference al MOBEUS 60 0 11922 RP4 preset reference ieee 90 0 11923 Proportional 1 50 1 00 11941 RPI Internal reference 45 096 0 096 11920 RPS Ramp switching Not assigned Not assigned 9010 RPT of Ramp I Linear ramp 9004 RRS Reverse Logic input LI2 11105 RSC Cold stat
86. ficulty A warranty claim form can be obtained by contacting ChipBLASTER at 800 241 3163 Limitation of Liability ChipBLASTER s liability under this warranty is limited as set forth herein This limited warranty and the remedies set forth herein constitute the sole and exclusive remedy available to the purchaser of ChipBLASTER equipment covered by this limited warranty and are lieu of any all other remedies whether based on statements or promises which are oral written express or implied and whether in contract tort equity or otherwise ChipBLASTER neither extends nor provides any warranty expressed or implied on any products not manufactured by or sold by ChipBLASTER Problems caused to ChipBLASTER equipment or other equipment by products used in conjunction with ChipBLASTER equipment which are not either manufactured by ChipBLASTER or manufactured to design specifications provided by ChipBLASTER and specifically approved by ChipBLASTER in writing are not the responsibility of ChipBLASTER either under this warranty or otherwise This warranty excludes all implied warranties of merchantability or fitness for particular purpose or any purpose This warranty specifically excludes reimbursement or liability for downtime loss of income and or consequential damages In no event will ChipBLASTER s liability to the purchaser resulting from any claim loss arising out of a purchaser s purchase of ChipBLASTER equi
87. filters 7 2 10 After you remove everything from inside the tank you are now ready to either contact ChipBLASTER Inc to schedule installation or proceed yourself depending on your agreement POWER FOR ChipBLASTER MUST BE AVAILABLE BEFORE SCHEDULING INSTALLATION 7 0 ChipBLASTER Inc 19 8 0 MECHANICAL INSTALLATION 8 1 PLUMBING INSTALLATION 8 1 1 When you are ready to start the installation of the ChipBLASTER unit you first must locate the high pressure hoses that ChipBLASTER Inc has provided Connect the female end to the ChipBLASTER outlet 1 and 2 hoses located on the filter side lower right then connect the other ends to the machining center spindle turret or other designated tool orifice 8 1 2 Next you will want to find the 1 clear hose this will be for the return line For units that do not have a ChipBLASTER supplied return transfer pump connect the 1 clear hose to the 1 inlet on the ChipBLASTER reservoir tank The other end will connect either to the existing machining center coolant pump For units that are supplied with a return transfer pump connect the 1 clear hose to the inlet of the return transfer pump and connect the other end to the 1 hose barb of the standpipe assembly after installation on the machine tool sump 8 1 3 For best use the inlet of the 1 clear hose in the machining center coolant sump should be approximately 1 from the bottom of the coolant Sump If using the standpi
88. h the filter Check for any leaks The ChipBLASTER may require several samples before the filter housing and sample line is purged of air EQUIPMENT COOLAING FANS CLEANING 14 37 1 To clean the equipment cooling fans first power down the ChipBLASTER unit by turning off the main disconnect and locking it out 14 37 2 Use a soft bristle brush to clean the fan blades If dirt is caked on it may be necessary to remove the fan guard to clean use a mild soap and water with stiff bristle brush to clean the fan blades Be careful not to damage the fan blades Replace the fan guards before returning the ChipBLASTER to service DO NOT USE COMPRESSED AIR TO CLEAN EQUIPMENT COOLING FANS 14 34 14 37 ChipBLASTER Inc 15 0 TROUBLESHOOTING 15 1 TROUBLESHOOTING CHART FAULT Chipblaster Has No Power CRI Or CR3 Not Energized High Pressure Motor Not Operating With CALL FOR COOLANT And Or CR3 Energized High Pressure Motor Running Slow High Pressure Motor Running Fast Cannot Achieve Required Outlet Pressure SYMPTOMS Disconnect Switch Is Off Machine Tool Off Overload Tripped No Command Voltage From Machining Center Faulty Relay Faulty Transducer Faulty Solenoid Or CR7 Not Working ES Relay De Energized CR8 Not Working Faulty Transducer Faulty Solenoid Sol A Or B Nozzle To Large Leak In Pressure Line Faulty Transducer Faulty Solenoid Faulty Unloader Faulty AFD Pu
89. hown below and then continue to read the manual Make sure that you observe all warnings given 4 1 EXPLANATION of MARKINGS Symbols Meaning of Symbols DANGER Indicates that error in operation may lead to death or serious injury WARNING Indicates that error in operation may lead to injury 1 to people or that these errors may cause damage to physical property 2 1 Such things as injury burns or shock that will require hospitalization or long periods of outpatient treatment 2 Physical property damage refers to wide ranging damage to assets and materials PROHIBITED Indicates prohibition Don t do it What is prohibited will be described in or near the symbol in either text or picture form 4 0 4 1 ChipBLASTER Inc 4 1 EXPLANATION of MARKINGS Cont Symbols Cont Meaning of Symbols MANDATORY Indicates something mandatory must be done What is mandatory will be described in or near the symbol in either text or picture form PINCH POINT Any point where fingers may be pinched by lids or covers Exercise caution when closing lids or covers Oil skimmer cover CUTTING HAZARD Any point where exposed fan blades may cause a cutting hazard to fingers when guard or inlet hose is not in place Do not operate without guard or inlet hose in place Inlet to MistBLASTER PINCH POINT Any point where fingers may be pinched by the motion of
90. igned 11203 DEC Deceleration ramp time MODELS 3 0 9002 DO assigned Not assigned 5031 DRN Derating for undervoltage No No 7007 EPL Stop mode at external fit Freewheel Freewheel 7006 ERCO Error registry CANopen 6056 External fault Not assigned assigned 7131 FBS PI multiplication coef 1 0 1 0 11903 FLG Frequency loop gain 20 20 9620 FLO Forced local mode Not assigned assigned 8431 FLR Catch on fly No No 3110 FR1 Configuration reference 1 Analog input 12 Analog input AI1 8413 ALL MODELS FR2 Configuration reference 2 configured Not configured 8414 FRS Nominal motor frequency 60 0 Hz 60 0 Hz 0602 FRT Ramp 2 switch frequency 0 0 Hz 0 0 Hz 9011 FST Fast stop assigned Not assigned 11204 FTD Motor freq threshold 60 0 Hz 60 0 Hz 11003 HSP High Speed a RC 3104 15 8 ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 8 ALTIVAR 31 DRIVE AS SET PARAMETERS 230 VAC W and W O 51 PRESETS Cont Code Label Value Default value Logical address Menu INH Fault inhibit Not assigned Not assigned 7125 IPL loss of input phase Yes Yes 7002 JVA 12 6 A JV8 19 1 A EV 25 5 ITH Motor Thermal Current GV20 42 A 27 5A 9622 JF2 Skip frequency 2 0 0 Hz 0 0 Hz 11302 JOG Jog operation Not assigned Not assigned 11110 JPF Skip frequency 0
91. ilter bags Improper changing will allow chips or contaminates into the bottom of the filter housing which than pass to the post filter The post filter is designed to prevent chips or contaminates from going through the high pressure pump and damaging the seals The post filter also prevents chips or contaminates from damaging solenoid vales and pressure switches 12 2 Refer to figure 6b section 12 2 for flow diagram The autocross units are also equipped to change from filter A to B after a timed period This prevents coolant in filter B from becoming stagnate and allowing algae to grow The ChipBLASTER will start out on filter A and after one 1 hour of accumulated run time the flow will be diverted through filter Filter B will be used for twenty 20 minutes and than change back to filter A This cycle will repeat until a filter becomes dirty at which time the timed change over will be stopped until the filters are changed During the timed change over the filters will still be monitored DO NOT ALLOW CHIPS OR CONTAMINATES TO FALL OUT OF FILTER BAGS INTO FILTER HOUSING WHEN CHANGING BAGS DO NOT POUR COOLANT FROM BAG INTO FILTER HOUSING POUR INTO MACHINE TOOL SUMP DO NOT POKE HOLES IN BAG WHEN LIFTING OUT OF FILTER HOUSING DO REFER TO SECTION 14 9 FOR CORRECT PROCEDURE FOR CHANGING FILTER BAGS DO NOT REUSE DIRTY FILTER BAG 12 3 ChipBLASTER Inc 27 13 0 ALARMS THE COOLANT SYSTEM AND
92. ired depends on peak loads system rigidity teeth in mesh etc In some instances it may be necessary to gradually increase the belt tension to achieve proper operation of the drive 18 4 ChipBLASTER Inc 63 18 0 BELT INSTALLATION Cont Figure 16 Maximum Force 4000 x DHP RPM x Pitch Diameter Minimum Force 5000 x BHP RPM x Pitch Diameter DHP Belt Horsepower or Motor Horsepower x Recommended Service Factor BHP Brake Horsepower Or Motor Horsepower RPM Speed of Fastest Shaft Pitch Diameter Diameter of Smallest Sprocket REINSTALL ALL GUARDS PROTECTIVE PANELING ON THE ChipBLASTER UNIT 18 5 EV EVHP BELT TIGHTENING CHART DEFLECTION oe INCHES DEFLECTION PouNDs or KILOGRAMS NEAREST MILLIMETERS FRACTION DECMIAL 0 084 ChipBLASTER Inc 64 19 0 SYSTEM CONTAMINATION PURGING PROCEDURE 19 1 Tools Required 19 1 1 6mm Hex Head Wrench 19 1 2 7 8 Wrench For Unit Without Pressure Switch Option 19 1 3 1 1 4 Wrench For Unit With Pressure Switch Option 19 1 4 5 Gallon Fluid Container 19 1 5 Section of Low Pressure Hose 19 1 6 Adapter Fitting 2 SAE to Hose Connection 19 1 7 Small Phillips Screw Driver For Unit With Pressure Switch Option 19 2 Change Filter Bag 19 2 1 Shut off all power to machine 19 2 2 Open the Air Bleeder Valves located on the upper portion of the filter and on post filter to release any pressure on filter housing 19 2 3 Vi
93. ired for both coolant outlets a second HIGH LOW PRESSURE option must be purchased The low pressure is designed to be used to supply filtered coolant at 5 18 9 liters minute 35 psig 2 4bar maximum The flow and pressure is dependent on orifice diameter The low pressure flood 1s controlled by a separate maintained M code from the machine tool LOW PRESSURE HOSE WASH DOWN is also available as an option to provide low pressure filtered coolant through a 20 0 6 meter garden hose Refer to SECTION 27 19 for a complete description of this option 12 2 ChipBLASTER Inc 12 0 OPERATION Cont SINGLE FILTER FILTERINLET FILTER OUTLET PRESSURE PRESSURE gt f ON RETURN PUMP ChipBLASTER FILTER PUMP lt gt i 1 FILTER VESSEL PRESSURE SWITCH MACHINE TOOL DUMP SUMP SOLENOID C 4 UNLOADER Aos VALVE lt FILTER A PRESSURE COOLANT 1 SWITCH SOLENOID A 4 VALVE MACHINE TOOL MANIFOLD 4 BLOCKWITH 4 HIGH PRESSURE ACCUMULATOR PUMP OPTIONAL COOLANT a MECHANICAL COUPLING VALVE MOTOR FEEDBACK SIGNAL TRANSDUCER CONTROLLED BY MANIFOLD BLOCK UR UNE PECORE J 4 HIGH PRESSURE SAMPLE LINE LO
94. ling must be of sufficent capacity to safely lift the MistBLASTER DO NOT STAND UNDER MistBLASTER AT ANY TIME DO NOT MOVE A ChipBLASTER WITH A MistBLASTER MOUNTED ON TOP OO OOO 5 0 6 0 ChipBLASTER Inc 17 7 0 PLACING A ChipBLASTER 7 1 After you receive your new ChipBLASTER unit the first thing you need to do is prepare the site where you would like to place the unit INSTALLATION SITE MUST BE FLAT AND LEVEL 7 1 1 You need to keep the unit within 10 of the machining center that you are connecting the ChipBLASTER to 7 1 2 Locate the unit so the ChipBLASTER s electrical cabinet is within 15 of the machining center s electrical cabinet 7 1 3 Make sure you place the unit so maintenance can easily get to the filter housing and electrical cabinet on the ChipBLASTER unit Refer to footprint drawing Section 23 for recommended clearances 7 2 After you have the site cleared for the ChipBLASTER unit you are ready to prepare the ChipBLASTER 7 2 1 Remove the lumber that is used to hold the unit in place during transporation using a phillips screw driver or an electric screw gun 7 2 2 Before you remove the ChipBLASTER from the skid take a moment and remove the lid from the top of the ChipBLASTER unit Remove the bag containing the leveling feet 7 2 3 When removing the ChipBLASTER only from the opposite end of the electrical enclosure 7 2 4 Insure the forks extend completely under the ChipBLAS
95. lter dirty TO RESET A FAULT 13 5 1 Determine the cause of the fault and correct Press RESET AIR PURGE push button on enclosure door Re energize the required M code to start the ChipBLASTER 28 ChipBLASTER Inc 14 0 PREVENTATIVE MAINTENANCE 14 1 PREVENTATIVE MAINTENANCE SCHEDULE 14 1 NO NANO LN3A 38d OL 3940 NI 38 LSNA ASYL JHL JHL AN 1 NWHL SHOW SI LAHS 8 A3 T9NIS 903 09391590 SI FINGSHIS TATION SIHL SNY4 IN3HdInb3 999084899 3991994 39v 19018 1574109 ONY LIINI 2493H9 903 ALATI NY319 92113 54997 4315919949 Ag 40 YSISNVHL 4005 0 3991934 4905 92114 1504 92113 1504 Sotv31dod o3H2 HO G3WHvTv 5598 53173 3OvTd3H 998 539019 3Hn8S3Hd 23H9 8044242 SUVSA HO 00001 G TIng3s S v311NY 1002 804 23H9 5 HY3A 303 1139 MOSH HO 0002 10 30v 1d3H OS AASL 1 TIGOW 0802 SHHCZL JONVN3LNIVH A ChipBLASTER Inc 29 14 0 PREVENTATIVE MAINTENANCE Cont
96. maged 14 15 11 Replace the filter lid Make sure the O ring is in the proper groove before 14 15 replacing the lid Replace the filter lid by setting straight down so that filte hold down plate will contact filter bag 14 15 12 Torque filter lid cap screws to 30 FT LB 41Nm in a star pattern 14 15 13 Refer to SECTION 11 START UP FOR FILTER PURGE ChipBLASTER Inc 37 14 0 PREVENTATIVE MAINTENANCE Cont 14 16 AUTO CROSS OVER A filter change while unit is in operation 14 16 1 Change the filter only when the CHANGE FILTER LIGHT is flashing 14 16 2 Place the CHANGE FILTER key switch in the change filter position Remove the key 14 16 3 Open the A filter petcock to make sure there is no pressure coming out of the filter housing 14 16 4 If air or coolant is coming out of this valve DO NOT PROCEED PLEASE CALL THE FACTORY FOR ASSISTANCE 14 16 5 Remove lid and inspect for damage Be careful not to damage filter hold down plate seal or springs Set lid aside 14 16 6 Remove optional hydrocyclonic filter 1f used from center of bag 14 16 7 Pull the filter bag out of the housing Close the filter air purge petcock 14 16 8 Install the new filter bag in the housing 14 16 9 Replace the optional hydrocyclonic filter 1f used 14 16 10 Inspect the O ring for cracks or tears replace if damaged 14 16 11 Inspect filter hold down seal for cracks or tears replace if damaged 14 16 12 Replace the
97. ment cooling fans cleaning Troubleshooting Troubleshooting chart Transducer voltage Troubleshooting flow chart Drive error codes ALTIVAR 31 Drive Drive as set parameters 230 VAC Drive as set parameters 460 VAC Pressure adjustment procedure High pressure pump replacement single pump Belt installation Align sprockets Install belt Belt tensioning General method Belt tensioning Force deflection method Deflection and force chart System contamination purging procedure Electrical drawings Power wiring schematic Control wiring schematic PLC input wiring PLC output wiring Drive control and power wiring Power and Mistblaster Interface Interface Cable Wiring Section 14 15 Section 14 16 Section 14 16 13 Section 14 17 Section 14 18 Section 14 19 Section 14 23 Section 14 25 Section 14 27 Section 14 29 Section 14 30 Section 14 31 Section 14 34 Section 14 37 Section 15 0 Section 15 1 Section 15 2 Section 15 3 Section 15 4 Section 15 8 Section 15 9 Section 16 0 Section 17 0 Section 18 0 Section 18 1 Section 18 2 Section 18 3 Section 18 4 Section 18 5 Section 19 0 Section 20 0 Section 20 1 Section 20 3 Section 20 5 Section 20 7 Section 20 9 Section 20 13 Section 20 15 Page 36 Page 37 Page 38 Page 39 Page 39 Page 39 Page 39 Page 40 Page 40 Page 40 Page 40 Page 40 Page 41 Page 41 Page 42 Page 42 Page 44 Page 45 Page 46 Page 50 Page 53 Page 56 Page 59 Page 61 Page 6
98. mp Seals Are Bad Faulty Solenoid Faulty Unloader Incorrect Nozzle Size Unloader Not Set Properly Faulty AFD Plugged Or Kinked Hose 42 Turn On Main Power Turn On Disconnect Turn On Machine Tool Correct Problem Reset Overload Check Command Voltage Replace Relay Changes Transducer Change Solenoid Check Circuits Correct Problem And Press Reset Air Purge Pushbutton Check CR8 Circuit Replace Transducer Replace Solenoid Replace Nozzle Repair Leak Replace Transducer Replace Solenoid Check Unloader Repair AFD Replace Seals Replace Solenoid Check Unloader Replace Nozzle With A Recommended Standard Size Adjust Unloader Repair AFD Replace Coil ChipBLASTER Inc No Coolant Flowing When High Pressure Is Operating Coolant Is Pulsating From High Pressure Nozzle Coolant Continues To Flow During Tool Changes Lathes Only Return Pump Not Operating Return Pump Coolant Flow Rate Is Slow Coolant Is Foaming High Pressure Pump Shuts Down After 5 Seconds ES Relay Not Energized System Won t Operate Systems Solenoid Valve Is Sticking Solenoid Coil Is Faulty High Pressure Pump Valve Is Sticking Hose Plugged CR3 Or CR4 Not Working Solenoid SOL A Or B Sticking MR3 Motor Protector Tripped Or Not Turned On Center Float Sticking Plugged Inlet Low On Coolant Chips Stuck Inside Pump Vane Motor Wired In Reverse Incorrect Coolant Faulty Optio
99. mp unit there will be 32 ounces 0 9 liters for a two pump unit there will be 64 ounces 1 9 liters NOTE In a two pump unit both pumps will be drained at the same time DRAIN PLUG LOCATION 14 3 ChipBLASTER Inc 14 0 PREVENTATIVE MAINTENANCE Cont 14 3 2 OIL CHANGE PROCEDURE Cont 14 3 2 4 After oil is drained from pump reinstall the plug in oil sight gauge assembly Torque to 180 In LB 20 Nm BE SURE TO INSPECT NYLON WASHER TO INSURE IT IS NOT DAMAGED 31 PROPERLY DISPOSE OF OIL PER LOCAL REGULATIONS DO NOT REUSE OIL 14 3 2 5 Locate High Pressure Pump p n 2106 and remove dip stick LOCATED AT TOP OF PUMP Place a small funnel in OIL FILL CAP dipstick opening 4 7 d Qag a a go Refilling pump with MOBIL 1 TRI SYNTHETIC 15W 50 NOTE IN A TWO PUMP UNIT ONLY ONE PUMP WILL NEED FILLING AS FLUID WILL SELF LEVEL ChipBLASTER Inc 32 14 0 PREVENTATIVE MAINTENANCE Cont 14 3 2 OIL CHANGE PROCEDURE Cont 14 3 2 6 Add only MOBIL 1 FULLY SYNTHETIC 15W 50 Bring oil level to ADD indicator mark on sight glass FULL ADD INDICATOR LABEL 14 3 2 7 Allow oil to settle for 3 to 4 minutes 14 3 2 8 Check level and if required add small amounts slowly until level is at FULL indicator 14 3 2 9 Reinstall dipstick plug Do not over tighten 14 3 2 10 Reinstall gauge panel Tighten BHCS to 200 In Lb 22 Nm
100. n is being used Faults that will be displayed are 27 1 3 1 Filter dirty single filter system 27 1 3 2 Filter A dirty autocross system 27 1 3 3 Filter dirty autocross system 27 1 3 4 Post filter dirty 27 1 3 5 Drive Fault 27 1 3 6 Slow coolant return 27 1 3 7 Low pressure lockout Optional Pressure Switch Required 27 1 3 8 Low coolant limit 27 1 3 9 Circuit breaker or Overload trip Available as part of the operator interface is a provision to view the last eight 8 faults To view the past eight 8 faults press the DOWN ARROW key while the coolant system is stopped and not in a fault condition The display uses a last in last out sequence that is the last fault that occurred will be the first fault displayed Each press of the DOWN ARROW key will display a fault until the pass eight have been stepped through at which time the display will revert to the start up screen If there is no fault stored in any of the past eight 8 storage locations a message will indicate NO FAULT STORED IN LOCATION No x At any time the main screen may be recalled by pressing the ESC key stepping through all eight 8 fault storage areas or when a Call for coolant is requested Included also are screens to display the total number of faults and the total time in minutes that the coolant system was in a fault condition To step through these screens press the RIGHT ARROW key Each press will step to the next sc
101. nal Low Pressure Detect Switch Seals Bad In High Pressure Pump Motor Overload Trip AFD Trip Low Limit Coolant Circuit Breaker Trip Loss Of 120VAC 43 Replace Solenoid Replace Coil Clean Or Replace The Valve Replace Hose Check Circuit Change Solenoid Reset Breaker Turn On MR3 Free Up Float Clean Inlet Add Coolant Clean Chips From Inside Pump Change Motor Rotation Use Coolant With Anti Foaming Agents For High Pressure Replace Low Pressure Detect Switch Change High Pressure Pump Check For Leaks And Repair Reset Motor Overload Reset Power To AFD Add Coolant Reset Circuit Breaker Check Transformer Reset 3CB And Or 4CB ChipBLASTER Inc 44 STARTER OVERLOAD DETERMINE THE CAUSE AND CORRECT BEFORE RESETTING AN AFD CIRCUIT BREAKER OR MOTOR Q FIRST AFTER THE ERROR IS CLEARED PRESS THE RESET PURGE IF THE ES RELAY TURNS OFF THE SYSTEM MUST BE RESET PUSHBUTTON ON THE ENCLOSURE DOOR FOR ADDITIONAL INFORMATION PLEASE CONTACT ChipBLASTER SERVICE DEPARTMENT AT 814 724 6278 WHEN CONTACTING ChipBLASTER SERVICE DEPARTMENT PLEASE HAVE MODEL AND SERIAL NUMBER OF YOUR ChipBLASTER UNIT 15 2 TRANSDUCER VOLTAGE 15 2 1 If calling we would like to know the transducer s feedback voltage The 15 1 information displayed on the digital read out of the AFD Motor Drive and what the high pressure gauge reading is on the ChipBLASTER s panel 15 2 2 ALTIVAR 31 DRIVE To che
102. nd remove the defective pump Install the replacement pump on the rails using the hardware removed in step 17 3 1 above Install the pulley DO NOT TIGHTEN low pressure hose high pressure hose oil line hose black drain line on the replacement pump NOTE The upper port is the high pressure port and the lower port is the low pressure port Torque all of the hex and square plumbing fittings to 36ft Ibs 48 8 Nm Using a straightedge to line up the pulleys on the pump and motor Tighten pulley set screws Torque bushing bolts to 108 in Ib 12 2 Nm 17 0 ChipBLASTER Inc el 18 0 BELT INSTALLATION 18 1 ALIGN SPROCKETS 18 1 1 Sprocket alignment and parallelism of the shafts is very important Proper alignment helps to equalize the load across the entire belt width there by reducing wear and extending belt life The sketches below show how to align a Synchronous drive properly PLACE A STRAIGHTEDGE against the outside edge of the sprockets as shown in Figure 11 Figure 12 shows the four points where the straightedge should touch the sprockets C EU ONE 4 41 eni vigai iii Figure 11 Figurel2 18 1 2 The straightedge should cross the sprockets at the widest possible part See Figure 13 OR USE A STRING Tie a string around either shaft Figure 14 and pull it around and across the outer edge of both sprockets Figure 15 shows how the string should touch four points when the drive is prope
103. nder this warranty is limited as set forth herein This limited warranty and the remedies set forth herein constitute the sole and exclusive remedy available to the purchaser of ChipBLASTER equipment covered by this limited warranty and are in lieu of any or all other remedies whether based on statements or promises which are oral written express or implied and whether in contract tort equity or otherwise ChipBLASTER neither extends nor provides any warranty expressed or implied on any products not manufactured by or sold by ChipBLASTER Problems caused to ChipBLASTER equipment or other equipment by products used in conjunction with ChipBLASTER equipment which are not either manufactured by ChipBLASTER or manufactured to design specifications provided by ChipBLASTER and specifically approved by ChipBLASTER in writing are not the responsibility of ChipBLASTER either under this warranty or otherwise This warranty excludes all implied warranties of merchantability or fitness for particular purpose or any purpose This warranty specifically excludes reimbursement or liability for downtime loss of income and or consequential damages In no event will ChipBLASTER s liability to the purchaser resulting from any claim or loss arising out of a purchaser s purchase of ChipBLASTER equipment or the operation thereof exceed the purchase price of the product manufactured or sold by ChipBLASTER 24 2 ChipBLASTER Inc 93 24
104. ng eyebolts Use these two eyebolts to lift the cooler and place it in position on the sump tank The cooler cabinet should be securely fastened to the sump top 27 21 3 ELECTRICAL HOOK UP 27 21 3 1 2721532 See Electrical diagram attached cooler is wired for 230 Volt 60 Hertz 1 Phase Check name plate to verify the proper voltage hertz and phase The supply voltage must be within 10 of the rated voltage on the tag Make ground connection to the grounding screw provided Check for loose wires The power connection should be made to the terminals tagged L1 and L2 on the terminal strip in the junction box on the right side panel Terminals 10 and 11 are wired to a HIGH TEMPERATURE interlock switch This switch opens when coolant temperature exceeds a high temperature setting See attached temperature controller instructions on adjusting this setting 27 21 ChipBLASTER Inc 109 27 0 OPTIONAL EQUIPMENT Cont 27 21 OPTIONAL DROP IN CHILLER Cont 27 21 4 TEMPERATURE CONTROLLER 27 21 4 1 27 21 42 27 21 43 27 21 5 START 2121234 This unit is supplied with a digital temperature controller mounted on the front panel See the attached instruction sheet for operating this controller A selector switch on the front panel tagged ATC CTC sets the controller to respond as an Ambient Tracking Controller ATC or as Set point Temperature Controller CTC The ATC setting works to maintain the coolan
105. ning any product to ChipBLASTER if ChipBLASTER has provided prior written authorization to the purchaser and the problem is covered by this warranty In the event the problem is not covered by this limited warranty ChipBLASTER will not be responsible for payment of shipping expense Regular maintenance includes the minor normal maintenance required to be performed by buyer at buyer s expense as set forth in the maintenance schedule included with this warranty as Exhibit A and posted on the outside panel of the ChipBLASTER Use of filters other than ChipBLASTER will void warranty coverage for any filtration related damage or failures 24 2 ChipBLASTER Inc 92 24 0 WARRANTY Cont 24 2 6 Other than the obligations imposed upon ChipBLASTER under this limited warranty ChipBLASTER shall not be liable for any other costs expenses or losses that the purchaser incurs to remedy any defect 24 2 7 Repairs of defects in material or workmanship during the limited warranty period shall be performed only by ChipBLASTER approved service technicians the cost of repairs performed by others will not be reimbursed by ChipBLASTER unless prior approval is received in writing from ChipBLASTER 24 2 8 This limited warranty shall cover alleged defects in materials and workmanship about which ChipBLASTER receives notice within thirty 30 days of either the discovery of the alleged defect or the expiration of the limited warranty period whichever is e
106. o maintained M codes at the same time for pressures of 750 500 and 250 to 300 psig The call for coolant M code used to energize CR1 and or CR2 if used alone will be used for pressure number 1 typically 1000 PSIG 68 9 Bar The call for coolant code used to energize and or CR2 if used and CR21 will be used for pressure number 2 typically 750 PSIG 51 7 Bar The call for coolant code used to energize and or CR2 if used and CR22 will be used for pressure number 3 typically 500 PSIG 34 4 Bar The call for coolant code used to energize CR1 and or CR2 if used and CR23 will be used for pressure number 4 typically between 250 and 300 PSIG 17 2 and 20 6 Bar Refer to figure 21 for chart NOTE OTHER PRESSURE SETTINGS ARE AVAILABLE BETWEEN THE MINIMUM AND MAXIMUM RANGE OF THE ChipBLASTER UNIT FOR OTHER SETTING PLEASE ADVISE ChipBLASTER Inc AT THE TIME OF ORDER IT IS RECOMMENDED THAT PRESET PRESSURES BE PURCHASED AT THE SAME TIME THE ChipBLASTER UNIT IS PURCHASED Figure 21 CR 1 M RAT R23 FRESDURS SPEED 1 1 1000 FASTEST SPEED 2 1 1 0 0 750 SPEED 3 1 1 500 SPEED 4 1 0 0 1 250 300 SLOWEST 1 INDICATES WHICH RELAY IS ENERGIZED IF MAINTAINED M CODES ARE NOT AVAILABLE PLEASE CONTACT ChipBLASTER SALES FOR AN INTERFACE TO CONVERT PULSED OR MONENTARY CODES TO MAINTAINED PLEASE PROVIDE THE FOLLOWING INFORMATION 27 19 2 Voltage of
107. of the motor during auto tuning If a downstream contactor is being used close it during auto tuning 15 5 1 2 With the automatic restart function Refer to parameter in the FLT menu on page 75 of the programming manual 15 5 1 3 Via a logic input Refer to the rSF parameter in menu on page 75 of the programming manual 15 5 1 4 By cycling power to the drive controller 15 5 ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 6 ALTIVAR 31 DRIVE 1 AFD ERROR CODES Cont 48 FAULTS WHICH CAN BE AUTOMATICALLY RESET COF Serial link failure CANopen EPF External fault LFF Overvoltage during deceleration Drive overload OLF Motor overload Motor phase failure 5 Overvoltage during steady state operation or during acceleration PHF Input phase failure SLF Serial link failure Modbus Probable Cause Loss of communication between the drive controller and communication device or remote keypad User defined Check the communication bus e Refer to the product specific documentation User defined Lose m 1 2a 4 20 mA reference on follower RS Check the connection on input AI3 Braking too rapidly e Overhauling load Increase the deceleration time install a braking resistor if necessary Activate the brA function if it is com
108. ontroller nameplate rating Reset the drive controller Check the connections and the fuses Disable the fault by setting IPL to nO Refer to page 76 Verify that the input power is correct Supply three phase power if needed Loss of connection between the drive controller and the communication device or the remote keypad display e Check the communication connection e Refer to the product specific documentation 15 6 ChipBLASTER Inc 49 15 0 TROUBLESHOOTING Cont 15 7 ALTIVAR 31 DRIVE 1 AFD ERROR CODES Cont FAULTS THAT RESET WHEN THE FAULT IS CLEARED Fault Probable Cause Remedy Restore the factory settings or load the backup configuration if it is valid See parameter FCS in the drC menu page 31 EFF Configuration fault The parameter configurations are not suited to the application The parameter configurations loaded in the drive controller via the serial link are not suited to the application Configuration fault via serial link e Check the configuration loaded previously Load a compatible configuration e Check the line voltage Dnesuppiy e Check the setting of the UNS Transient voltage dip Damaged precharge resistor USF Undervoltage parameter See page 26 Replace the drive controller TURNING THE INVERTER POWER OFF AND THEN ON AGAIN RESETS THE INVERTER IMMEDIATELY T
109. or any purpose This warranty specifically excludes liability of ChipBLASTER for downtime loss of income and or consequential damages In no event will ChipBLASTER s liability to the purchaser resulting from any claim or loss arising out of a purchaser s purchase of ChipBLASTER retrofits or the operation thereof exceed the purchase price of the product manufactured or sold by ChipBLASTER 24 3 ChipBLASTER Inc 95 24 0 WARRANTY Cont 24 4 WARRANTY CLAIM FORM WARRANTY CLAIM FORM Unit Serial Unit Description Purchased From Invoice Invoice Date Installation Date Nature of Problem including date of occurrence 24 4 ChipBLASTER Inc 96 24 0 WARRANTY Cont 24 5 WARRANTY REGISTRATION CARD Detach this part of the sheet and mail to ChipBLASTER to activate your warranty This form MUST be filled out completely to be a valid warranty registration WARRANTY REGISTRATION CARD Unit Serial Company Name Unit Description Address Purchased From City Invoice State Zip Code Invoice Date Contact Person Installation Date E mail Address Please mail to Phone ChipBLASTER 13605 South Mosiertown Road Fax Meadville Pennsylvania 16335 Or fax to 814 724 6287 Attention Service Department 24 5 ChipBLASTER Inc 97 24 0 WARRANTY Cont 24 6 WARRANTY VALIDATION CARD WARRANTY VALIDATION CARD UNIT SERIAL Unit Description Installation Date Purchased From Invoic
110. or resistance Inactiv Inactiv 9643 RSF Fault reset Not assigned Not assigned 7124 SA2 Summing input 2 MODELS Analog input AI2 11801 Summing input 3 Not configured Not configured 11802 SDC1 DC current at standstill 19 2A 19 2A 10403 SDC2 DC current at standstill 2 9 5A 10405 SDS Display scale factor 30 0 30 0 12001 SFR Drive switching frequency 4 0 kHz 4 0 kHz 3102 SLL Stop mode at Modbus SLF Freewheel Freewheel 7010 SLP Slip Compensation 100 100 9625 SRF Disable speed loop filter No No 9101 STA Frequency loop stability 20 20 9621 SIP stop on power loss Lock drive freewheel stop Lock drive freewheel stop 7004 isn Normal stop mode On ramp On ramp 11201 2 wire or 3 wire control 2 wire control 2 wire control 11101 TCT of 2 wire control Edge triggered Edge triggered 11102 TDC1 DC injection time 0 5 5 5 10402 TDC2 2nd DC injection time 0 0 s 0 0 10404 TFR Max output frequency 3103 TLS Low speed time out O Os 0 0 s 11701 TNL Auto tuning fault config Yes Yes 7012 nD Motor thermal threshold 100 100 11002 TUN Automatic tuning Not assigned Not assigned 9608 UFR Voltage boost 20 20 9623 Select type of U F ratio Sensorless flux vector ctrl Sensorless flux vector ctrl 9607 NS Nominal motor voltage 240 V All MODELS 230V 9601 15 8 ChipBLASTER Inc 15 0 TROUBLESHOOTING Cont 15 9 ALTIVAR 31 DRIVE AS SET PARAMETERS 460 VAC W and W O 53
111. patible with the application Refer to page 48 Drive controller or ambient temperature are too high e Continuous motor current load is too high Thermal trip due to prolonged motor overload Motor power rating too low for the application Loss of phase at drive controller output Downstream contactor open Motor not connected Instability in the motor current Drive controller oversized for motor e Line voltage too high Line supply transients Input phase loss blown fuse drive controller used on a single phase line supply Input phase imbalance Transient phase fault NOTE This protection only operates with the drive controller running under load Check the motor load the drive controller ventilation and the environment Wait for the drive controller to cool before restarting Check the ItH setting motor thermal protection page 22 check the motor load Allow the drive controller to cool before restarting e Check the connections from the drive controller to the motor If a downstream contactor is being used set OPL to OAC Refer to page 76 e Test the drive controller on a low power motor or without a motor set OPL to nO Refer to page 76 Check and optimize the UFr page 23 UnS page 26 and nCr page 26 parameters and perform auto tuning page 27 Check the line voltage Compare with the drive c
112. pe assembly position the suction pipe pipe with 45 degree taper 1 from bottom of machine tool sump this should be connected to the inlet of the return transfer pump 8 1 4 Connect the 1 1 2 hose to the overflow outlet barb on the side of the ChipBLASTER tank The other end of this hose should go to the machining center coolant tank If using the standpipe assembly connect the 1 1 2 to the hose barb THE RETURN PUMP MUST BE WITHING 12 FEET OF THE MACHINING CENTER COOLANT TANK 9 0 ELECTRICAL INSTALLATION INSTALLER MUST COMPLY WITH ALL LOCAL AND NATIONAL ELECTRICAL CODES AND SAFETY GUIDELINES WHEN MAKING ELECTRICAL CONNECTIONS TO THE ChipBLASTER REFER TO THE ELECTRICAL DRAWING S SECTION 20 DURING ELECTRICAL INSTALLATION ALSO REFER TO THE FOOTPRINT DRAWING SECTION 23 FOR RECOMMENDED WORK CLEARANCE BEFORE OPENING THE MACHINING CENTER CABINET DISCONNECT AND LOCKOUT TAGOUT ALL ELECTRICAL ENERGY SOURCES NOTE The ChipBLASTER is equipped to accept control interface voltages of 115vac or 24vdc Please make sure the appropriate control voltage relays are installed in through CR4 Before applying control power to the unit The unit is shipped from the factory with 115vac relays installed in CR1 CR2 CR3 CR4 We also include the 24vdc relays loose in the electrical cabinet for interfacing convenience to 24vdc machines 8 0 9 0 ChipBLASTER Inc 20 9 0 ELECTRICAL INSTALLATION Cont 9 1 CONTRO
113. peed EnF Auto tuning fault Precharge circuit damaged Reset the drive controller Replace the drive controller e Internal fault Internal connection fault Incorrect parameter settings in the SEt and drC menus e Acceleration too rapid Drive controller and or motor undersized for load Mechanical blockage Remove sources of electromagnetic interference Replace the drive controller Check the SEt and drC parameters Ensure that the size of the motor and drive controller is sufficient for the load Clear the mechanical blockage Short circuit or grounding at the drive controller output Significant ground leakage current at the drive controller output if several motors are connected in parallel Instability Overhauling load Check the cables connecting the drive controller to the motor and check the motor insulation Reduce the switching frequency Connect output filters in series with the motor Check the motor gain and stability parameters Add a braking resistor Check the size of the motor drive controller and load Motor or motor power not suitable for the drive controller Motor not connected to the drive controller 15 5 1 Faults which can be automatically reset 15 5 1 1 After the cause of the fault has been removed the faults in the table listed on the next page can be reset Use the L or the P ratio see UFt on page 27 Check the presence
114. performed only by ChipBLASTER approved service technicians the cost of repairs performed by others will not be reimbursed by ChipBLASTER unless prior approval is received in writing from ChipBLASTER Regular maintenance includes the minor normal maintenance required to be performed by buyer at buyer s expense as set forth in the maintenance schedule included with this warranty as Exhibit A and posted on the outside panel of the ChipBLASTER Use of filters other than ChipBLASTER will void warranty coverage for any filtration related damage or failures 24 3 ChipBLASTER Inc 94 24 0 WARRANTY Cont 24 3 8 This limited warranty shall cover alleged defects in materials and workmanship about which ChipBLASTER receives notice within thirty 30 days of either the discovery of the alleged defect or the expiration of the limited warranty period whichever is earlier Any claim not made within this time shall be conclusively deemed to have been waived by the purchaser 24 3 9 ChipBLASTER warranty card must be completed by purchaser and returned to ChipBLASTER within 30 days after installation of ChipBLASTER retrofits Procedures for Obtaining Technical Service or Warranty Service Repair or replacement under this limited warranty can only be obtained by registering a warranty claim directly with ChipBLASTER To enable ChipBLASTER to respond to a request for technical assistance or a request for warranty service the purchaser must provide a
115. plicable literature use of ChipBLASTER equipment outside the parameters of normal usage including but not limited to misapplication misuse failure to follow directions and instructions provided by ChipBLASTER applicable literature any damage or loss to products or parts which results from the alteration repair modification faulty installation or service other than regular maintenance by any one other than an authorized ChipBLASTER service technician the use of any add ons parts accessories or components not obtained from ChipBLASTER or an authorized ChipBLASTER supplier or approved in writing by ChipBLASTER damage to products or parts caused by accident abuse or misuse replacement of filters normal wear and tear damage which occurs in shipment or as a result of an act of God such as lightening or electrical failures such as line surges or brownouts 24 1 3 Any replacement equipment or parts provided to the purchaser in fulfilling this warranty are warranted for the un expired portion of the original warranty 24 1 4 If ChipBLASTER products are found upon ChipBLASTER s examination response to a warranty claim to have defects in material or workmanship ChipBLASTER will either replace or repair the product at its sole option 24 1 5 ChipBLASTER expects that warranty repairs will be completed at the purchaser s location however if requested by ChipBLASTER purchaser shall return the alleged defective product
116. pment or the operation thereof exceed the purchase price of the product manufactured or sold by ChipBLASTER 24 1 ChipBLASTER Inc 91 24 0 WARRANTY Cont 24 2 WARRANTY LIMITED USED EQUIPMENT ChipBLASTER Inc Limited Warranty Used Equipment Limited Warranty ChipBLASTER Inc warrants the used ChipBLASTER high pressure coolant systems to be free from defects in materials and workmanship for the lesser of 90 days or 1040 hours from the date of installation subject to the conditions set forth below During this warranty period ChipBLASTER will repair or replace at its sole option defective products or parts without charge to the purchaser Limited Warranty Conditions 24 2 1 Limited warranty applies only to used ChipBLASTER equipment and is solely for the benefit of and applicable to initial purchaser 24 2 2 This limited warranty does not apply to any damage failure defect or loss caused by any or all the following circumstances or conditions failure to follow instructions or observe cautions and warnings relating to installation operation applications inspection and regular maintenance as specified in this manual and or any ChipBLASTER manual quotation acknowledgment sales literature spec sheet or installation instructions all of which shall hereinafter be referred to as applicable literature use of ChipBLASTER equipment outside the parameters of normal usage including but not limited to misapplic
117. pped air can escape both filters 11 3 2 Press the RESET AIR PURGE push button to remove air from the filters and post filter When all the air has escaped from the filters close the 1 4 petcocks This will lower the tank level and start the return transfer pump and lower the sump level Depending on the capacity of the machine tool sump the lower level will allow the ChipBLASTER high pressure to fill the sump without over flowing the machine tool sump Unless the sump is completely emptied DO NOT REFILL MACHINE TOOL SUMP 11 3 3 Start the ChipBLASTER and check for any coolant leaks 11 3 4 Insure that all electrical circuits are operating correctly DO NOT RUN THE HIGH PRESSURE PUMP DRY FOR ANY N PERIOD OF TIME CAVITATION WILL RESULT IN FAILURE OF THE PUMP ALWAYS REMEMBER TO CHECK THAT ALL PLUMBING VALVES ARE OPEN AND THAT PUMPED COOLANT CAN FLOW FREELY TO THE INLET OF THE HIGH PRESSURE PUMP ChipBLASTER Inc 23 12 0 OPERATION 12 1 ELECTRICAL OPERATION A 12 1 1 Energizing CR1 will start the automatic operation on the coolant system and provide coolant out of solenoid 1 At this time the filter pump and the main drive will come on line 12 1 2 Energizing CR3 index 1 will stop coolant flow out of solenoid 1 and place the unit into an idle condition This state is primarily used for tool changes on turning center applications 12 1 3 De energizing CR3 will return the unit to normal operation 12 1
118. r Bag 200 x 30 Double Filter Bag 155 8 x 30 Double Filter Bag 255 35385 PeostFiter SpnOn 100 DENS Sample Line Fiter 5 2571 Lid seal O ring 3201A Llidassembly N A 3523 Electrostatic Filter 3522 Grease Filter NA 9660 NA 351 Expanded Aluminum ___ NOTE Minimum order is 25 00 USD Consult factory for current pricing Unless your ChipBLASTER was ordered with a special micron level at your request your unit was shipped from the factory with a 300 micron prefilter and a 5 micron 8 x 30 filter bag for a water based system or a 10 micron 8 x 30 filter for an oil based system 14 16 13 ChipBLASTER Inc 39 14 0 PREVENTATIVE MAINTENANCE Cont 14 17 FILTER BAG ASSEMBLIES CHECK FOR LEAKS 14 17 1 Check inlet and outlet hoses for leaks especially at hose clamps If leaks are found replace hoses THE ChipBLASTER MUST BE SHUT DOWN 14 18 POST FILTER CHANGING THIS CAN ONLY BE REPLACED WHEN THE ChipBLASTER IS SHUT DOWN 14 18 1 Change post filter when the filter light is on steady 14 18 2 Unscrew and remove the post filter when dirty 14 18 3 Remove gasket if it does not come off with filter 14 18 4 Fill the new filter with clean coolant before replacing This will speed up the purge time USE THE SUPPLIED GASKET install in groove in the post filter mounting base Screw the filter into pla
119. rapped air can escape both filters 11 2 2 Rotate the ball valve handle to the RUN FILTER A position See Figure 4 Figure 4 Run filter A 11 2 3 Press the RESET AIR PURGE push button to remove air from the filter and post filter When all the air has escaped from the filters close the 1 4 petcock on filter A 11 2 4 Rotate the ball valve handle to the RUN FILTER position See figure 5 Figure 5 Run filter B ChipBLASTER Inc 22 11 0 SYSTEM AIR PURGE Con t 11 2 5 Press the RESET AIR PURGE push button to remove air from the filter and post filter When all the air has escaped from the filters close the 1 4 petcock on filter B and on the post filter This will lower the tank level and start the return transfer pump and lower the sump level Depending on the capacity of the machine tool sump the lower level will allow the ChipBLASTER high pressure to fill the sump without over flowing the machine tool sump Unless the sump is completely emptied DO NOT REFILL MACHINE TOOL SUMP 11 2 6 Start the ChipBLASTER and check for any coolant leaks 11 2 7 Insure that all electrical circuits are operating correctly 11 2 8 The coolant outlet pressure is factory preset to run at 1000 PSIG 69 bar or a customer specified pressure Refer to Pressure Adjustment Procedure Section 16 0 11 3 AUTOCROSS 11 3 1 Open the 1 4 petcock located on both the filters and post filter so that tra
120. reen until each has been displayed at which time the display will revert to start up screen At any time the main screen may be recalled by pressing the ESC key stepping through all eight 8 screens or when a Call for coolant is requested The first screen that will be displayed will be the coolant system total run time The total run time is displayed in years hours and minutes NOTE the years displayed is based on shift of operation 2080 hours 27 1 ChipBLASTER Inc 99 27 0 OPTIONAL EQUIPMENT Cont 27 1 Magelis Human Interface Unit HMI Cont 27 1 6 27 1 7 The order of screens 27 1 6 1 Machine run time 27 1 6 2 Circuit breaker or overload trip 27 1 5 3 Pressure below 300 PSIG requires optional pressure switch 27 1 5 4 Tank low limit 27 1 5 5 Drive fault 27 1 5 6 Filter A dirty 27 1 5 7 Filter dirty 27 1 5 8 Post filter dirty Also included as part of the HMI programming is the Super Users Group In this screens it possible to modify certain control parameters The parameters are 27 1 7 1 Coolant 1 off delay set point adjustable from 0 to 2 5 seconds default is 2 5 seconds 27 1 7 2 Coolant 2 off delay set point adjustable from 0 to 2 5 seconds default is 2 5 seconds 27 1 7 3 Skimmer off set point adjustable from 5 to 30 minutes default is 10 minutes 27 1 7 4 Skimmer on set point adjustable from 1 to 20 minutes default is 5 minutes 27 1 7 5 Slow coolant
121. return delay before warning set point adjustable from 2 to 4 minutes default is 2 minutes 27 1 7 6 Low pressure switch enable This will enable the use of an optional pressure switch to monitor outlet number 1 An alarm will be sounded if the pressure falls below 300 PSIG 20 6 bar 27 1 7 7 Autocross enable This will enable automatic change over from filter A to filter B when filter A becomes dirty This requires factory installed filters solenoid valves and additional inputs outputs from the PLC THIS NOT A RECOMMENDED FIELD MODIFICATION 27 1 7 8 Run relay enable This option sets the ChipBLASTER to run continuous with high pressure controlled by the Call for coolants only This option would be used for machine tools that have multiple fast tool changes with short cycle times 27 1 7 9 Pulsed M code enable This option sets the ChipBLASTER to operate using a pulsed M code in lieu of a maintained M code When this option is enabled a FIN ACH signal is available as an output to machine tool Also available is a input to the ChipBLASTER for a machine tool door open switch 27 1 7 10 Low pressure hose wash down enable This option allows the use of a garden style hose to be used to with low pressure filtered coolant to wash off the mill table or tomb stone during a part change THIS NOT A RECOMMENDED FIELD MODIFICATION 27 1 7 11 Low pressure flood coolant enable This will enable the ChipBLASTER to supply low pres
122. ridge will came only be installed one way Push cartridge into place until it is firmly seated 28 1 5 Power up the PLC by turning on 4CB 28 1 6 The RUN and START green LED along with the ERR red LED will flash 28 1 7 When only the RUN LED is flashing cycle power to the PLC again 28 1 8 The RUN LED will flash and than change to solid on 28 1 9 The EEPROM cartridge may be left plugged into the PLC or if it is to be removed power down the PLC by turning off 4CB and than removing the EEPROM cartridge and then re power the PLC by turning on 4CB 28 1 10 Close the cover over the output terminal strip 28 1 11 After the revised program is loaded check all circuits for proper operation EEPROM socket location 91234557555 91234569725 EEPROM socket located under this cover EEPROM cartridge in place 28 1 ChipBLASTER Inc 119 28 0 SUPPLEMENT DATA 28 2 Orifice Serene Chart for 1000 PSI Orifice Dia Outlet Area Velocity Ft Sec Volume Horsepower Machine maximum 59 Inches SPM Required ao 000 456 91 005 0002 45 03 0020 0025 0 0005 1000 0040 0 050 0 055 00024 1000 34 24 1000 se 24 ooo 0008 1000 41 28 Nozzle x55 0 0028 1000 455 41 34 1000 oos
123. rly aligned After aligning the sprockets check the rigidity of the supporting framework Shafts should be well supported to prevent distortion and a resulting change in the center distance under load Do not use spring loaded or weighted idlers Idler sprockets or pulleys must be locked into position after adjusting belt tension Please note At least one sprocket must have a flange Figure 13 Figure 14 Figure 15 18 2 INSTALL BELT 18 2 1 Do not pry or otherwise force the belt onto the sprockets as this can result in permanent damage to the belt Either remove the sprocket s outside flange or reduce the center distance between the sprockets so that the belt can be easily installed 18 3 BELT TENSIONING GENERAL METHOD 18 3 1 This method of tensioning Synchronous belts should satisfy most drive requirements 18 3 1 1 Reduce the center distance so that the belt can be placed onto the sprockets without forcing or prying it over the flanges 18 1 ChipBLASTER Inc 62 18 0 BELT INSTALLATION Cont 18 312 18 3 1 3 Increase the belt tension until the belt feels snug or taut Avoid over tensing the belt Start the drive and apply the most severe load condition This may be either the motor starting torque or during the work cycle A belt that is too loose will jump teeth under the most severe load condition When this occurs gradually increase the belt tension until satisfactory operation is achieved 18 4 BE
124. s SVH OLAF 3LON zi PONINVIOO y aune d _ 6000 FNS 108 391340 NAT 2 LNV1009 1 4 7001 3NIHO VIN 108 T f 105 1 INVIO09 E 29108 nssaud _ 7 4105 HSVM uo1v1nWnoov NOILVS1Nd 1 ON Y aunssaud 116 c idt 910 LNV1009 1000 igno 4 INVIOOO WNOlLdO 3onvo 17 3YNSS3Yd 6p Hana of gt aala 1604 MLN 8000 i S BYNSSAYd 1900 1 8105 105 9 108 41009 HSVM 111009 anna NOME 54 9000 9000 000 goo 3078 voo amp SG ning A TENETUR ED 1804 ova d LINN HOIH 00 001 LINK MOT 27 20701 T3A31MO1 5 NI 500 1 1 gt OOS LIINI 4 2 1 76 ChipBLASTER Inc iping 21 2 Dual Filter Schematic
125. sually check filter inlet and outlet pressure gauges for zero pressure IF THERE IS PRESSURE PRESENT DO NOT OPEN FILTER HOUSING SEEK ASSISTANCE FROM QUALIFIED MAINTENANCE PERSONNEL TO RELIEVE PRESSURE 19 2 4 Remove Filter Housing Lid 19 2 5 Remove and inspect the O ring 19 2 6 Remove Filter Displacement Device or Optional Hydrocyclonic Filter 19 2 7 Remove and discard old filter DO NOT POUR REMAINING COOLANT FROM FILTER BAG BACK IN THE VESSEL OR CONTAMINATES WILL ENTER THE SYSTEM 19 2 8 Replace with a new filter bag making sure that it is seated firmly against the top of the Filter Basket 19 2 9 Replace Filter Displacement Device or Optional Hydrocyclonic Filter 19 2 10 Fill filter housing with coolant 19 2 11 Replace the O ring making sure it is properly seated in the rim of the Filter Body 19 2 10 Replace the lid being careful not to displace O ring 19 2 11 Torque all Filter Lid fasteners to 360 480 in Ibs 40 6 54 2 Nm 19 3 Remove access panel 19 3 1 Remove rear access panel from ChipBLASTER unit Panel opposite to the Gauge Panel 19 4 For units without pressure switch 19 4 1 Remove SAE pipe plug fitting from the high pressure manifold This fitting is located on the lower right side of the high pressure manifold See Figure 8 19 0 ChipBLASTER Inc 65 19 0 SYSTEM CONTAMINATION PURGING PROCEDURE Cont 19 4 For units without pressure switch Refer to Figure 17
126. sure filtered coolant through coolant number 1 outlet to the machine tool THIS NOT A RECOMMENDED FIELD MODIFICATION 27 1 ChipBLASTER Inc 100 27 0 OPTIONAL EQUIPMENT Cont 27 1 Magelis Human Interface Unit HMI Cont 27 1 7 12 To access the Super Users Group press the RIGHT ARROW key and the FAULT RESET PURGE pushbutton at the same time 27 1 8 Pass fault memory clear and pass fault counter timer clear 27 1 8 1 The past fault data may be cleared by pressing the DOWN ARROW key and the FAULT RESET PURGE pushbutton at the same time NOTE this will only clear the fault memory not the machine run timer data 27 1 9 The Magelis HMI may be field installed by cutting the mounting hole in the door of the control enclosure mounting the HMI plugging in the communication adapter module to the PLC plugging in the communications cable into the PLC and the HMI PLEASE CONTACT ChipBLASTER to order the preprogrammed HMI and associated components NOTE IF THE COOLANT SYSTEM IS STARTED WHILE IN EITHER OF THE PASS FAULT SCREEN OR TOTAL FAULTS SCREEN THE SCREEN BEING DISPLAYED WILL CHANGE TO ONE OF THE RUN STATUS SCREENS DEPENDING ON THE ACTUAL OPERATING CONDITION At this time the LEFT ARROW and UP ARROW keys are not used 27 1 ChipBLASTER Inc 101 27 0 OPTIONAL EQUIPMENT Cont 27 15 OIL SKIMMER 27 15 1 Oil Skimmer operation 27 15 1 1 The oil skimmer is designed to remove floating tramp oil from surf
127. t 394 745 193 ooo 20 220 9 e 23 97 95 297 Los 0 120 0 125 0 130 0 0104 CV26 Les esr 31 90148 20 e 387 ons mm er ms 4 0 140 0 145 0 150 0 315 482 57 65 015 0 37 50 foon mm 0 165 0 170 0 175 0 180 98 T4 ors 009 mea omo Dom mm sr ms 0 195 121 28 4 ChipBLASTER Inc 122 28 0 SUPPLEMENT DATA CONT 28 5 Orifice Reference Chart for 2500 PSI Orifice Dia Outlet Area PSI Velocity Volume Horsepower Machine maximum Sq Ft Sec Inches 0 010 0 0001 2500 0 015 0 0002 2500 0 020 0 0003 2500 0 025 0 0005 2500 0 030 0 0007 2500 0 035 0 0010 2500 0 040 0 0013 2500 0 045 0 0016 2500 0 050 0 0020 2500 0 055 0 0024 2500 Nozzle XX54 0 0024 2500 0 060 0 0028 2500 Nozzle XX55 0 0028 2500 0 065 0 0033 2500 0 070 0 0038 2500 0 075 0 0044 2500 Nozzle XX56 0 0049 2500 0 080 0 0050 2500 0 085 0 0057
128. t a minimum the following information during the initial telephone call model and serial number of the equipment on which the ChipBLASTER retrofit was installed information regarding the installed ChipBLASTER retrofit the date of purchase the dealer or supplier from whom the equipment was purchased the nature of the problem or difficulty A warranty claim form can be obtained by contacting ChipBLASTER at 800 241 3163 Limitation of Liability ChipBLASTER s liability under this warranty is limited as set forth herein This limited warranty and the remedies set forth herein constitute the sole and exclusive remedy available to the purchaser of ChipBLASTER retrofits covered by this limited warranty and are in lieu of any or all other remedies whether based on statements or promises which are oral written express or implied and whether in contract tort equity or otherwise ChipBLASTER neither extends nor provides any warranty expressed or implied on any products not manufactured by or sold by ChipBLASTER Problems caused to ChipBLASTER retrofits used in conjunction with ChipBLASTER equipment which are not either manufactured by ChipBLASTER or manufactured to design specifications provided by ChipBLASTER and specifically approved by ChipBLASTER in writing are not the responsibility of ChipBLASTER either under this warranty or otherwise This warranty excludes all implied warranties of merchantability or fitness for particular purpose
129. t at a adjustable temperature differential relative to a fluctuating ambient temperature The AIR ambient sensor is mounted under the temperature controller on the front panel The coolant sensor is mounted in a dry well close to the evaporator coils The controller will alternate flashing the ambient temperature and the coolant temperature The CTC setting works to maintain the coolant temperature within 0 5 F of the adjustable set point The controller will alternate flashing the set point temperature S and the actual temperature F UP Once the cooler has been installed and the proper electrical connections have been made it can be started by pressing the ON OFF switch on the front panel to the ON position When the switch is pressed to the ON position an internal green light will energize and the compressor and fan will start if the controller is calling for cooling after a one minute delay Do not operate the cooler if the evaporator coils are not completely submersed in coolant 27 21 6 OPERATION 27 21 6 1 27 21 0 2 When ON OFF switch is pressed to the ON position an internal green light will energize and the compressor and fan will start 1f the controller is calling for cooling after a one minute delay Set the controller to the desired temperature When the controller calls for cooling the compressor and condenser fan come on after a one minute delay Refrigerant is pumped by the compressor through the exp
130. t of the factory pre set at a working pressure of 1000 psi 68 9 Bar unless otherwise specified by the end user This pressure can be read from the high pressure gauge located on the side of the ChipBLASTER unit Check the machine tool specifications for a maximum operating pressure before proceeding with this procedure DO NOT EXCEED THE MANUFACTURERS MAXIMUM OPERATING 9 PRESSURE Procedure 16 0 1 Shut off power to the ChipBLASTER unit 16 0 2 Locate the Coolant Manifold Assembly under the ChipBLASTER s coolant tank This Manifold Assembly will need to be accessible during this procedure for achieving settings over 1000 psi 68 9 Bar 16 0 3 Locate coolant outlet 1 SOL A and coolant outlet 2 SOL B disconnect the solenoid din connector from each solenoid coil 16 0 4 Repower the ChipBLASTER unit USE EXTREME CAUTION WHEN WORKING ON LIVE EQUIPMENT 16 0 5 Energize call for coolant on the machining center 16 0 6 Locate and adjust the high pressure unloader using the high pressure gauge to view the pressure setting Set the high pressure unloader 200 psi 13 7 Bar over the desired working pressure After the correct adjustment has been made tighten the lock nut to secure the setting TURNING THE UNLOADER ADJUSTMENT ROD CLOCKWISE INCREASES THE PRESSURE SETTING OF THE UNLOADER TURNING THE UNLOADER ADJUSTMENT ROD COUNTER CLOCKWISE DECREASES THE PRESSURE SETTING OF THE UNLOADER 16 0 7 Turn off high pressure
131. ter pump check for leaks Bag filter unit check pressure gauges Bag filter unit change filter single filter unit Bag filter unit change filter dual filter unit shut down Section 1 0 Section 2 0 Section 3 0 Section 4 0 Section 4 1 Section 5 0 Section 6 0 Section 7 0 Section 8 0 Section 9 0 Section 9 1 Section 9 3 Section 10 0 Section 11 0 Section 11 1 Section 11 2 Section 11 3 Section 12 0 Section 12 1 Section 12 2 Section 12 3 Section 13 0 Section 14 0 Section 14 1 Section 14 2 Section 14 3 Section 14 4 Section 14 5 Section 14 6 Section 14 9 Section 14 12 Section 14 13 1 Section 14 14 Page 3 Page 4 Page 5 Page 9 Page 11 Page 11 Page 16 Page 16 Page 17 Page 19 Page 19 Page 20 Page 20 Page 20 Page 21 Page 21 Page 21 Page 22 Page 23 Page 23 Page 23 Page 26 Page 27 Page 28 Page 28 Page 29 Page 30 Page 33 Page 33 Page 33 Page 33 Page 33 Page 34 Page 35 2 0 ChipBLASTER Inc 2 0 TABLE OF CONTENTS Cont Bag filter unit dual filter unit operating Bag filter unit autocross unit operating Filter replacement form Bag filter unit change filter check for leaks Post filter changing Sock filter changing Float switch cleaning Tank cleaning Pump mounting bolts checking Return transfer pump check flow rate Return transfer pump check for leaks Return transfer pump check inlet outlet LDENS sample line filter changing Equip
132. tion 27 18 Section 27 19 Section 27 20 Section 27 21 Page 74 Page 75 Page 75 Page 76 Page 77 Page 78 Page 78 Page 79 Page 80 Page 81 Page 82 Page 83 Page 84 Page 85 Page 86 Page 87 Page 88 Page 88 Page 89 Page 89 Page 91 Page 93 Page 95 Page 96 Page 97 Page 98 Page 98 Page 101 Page 103 Page 104 Page 105 Page 106 Page 107 2 0 ChipBLASTER Inc 2 0 TABLE OF CONTENTS Cont Supplement Data Program revision using EEPROM chip 1000 PSI orifice chart 1500 PSI orifice chart 2000 PSI orifice chart 2500 PSI orifice chart 3000 PSI orifice chart 5000 PSI orifice chart Section 28 0 Section 28 1 Section 28 2 Section 28 3 Section 28 4 Section 28 5 Section 28 6 Section 28 7 Page 118 Page 118 Page 119 Page 120 Page 121 Page 122 Page 123 Page 123 2 0 ChipBLASTER Inc 9 3 0 EV13 EVHP SPECIFICATIONS EVHP EV13 230 VAC 460 VAC 230 VAC 460 VAC MAXIMUM PRESSURE PSsIGG 1 190 1900 3000 3000 206 8 206 8 MAX COOLANT VOLUME GALLONS MIN LITERS MIN COOLANT TANK VOLUME GALLONS LITERS 181 6 181 6 181 6 181 6 DIMENSIONS DxLxH INCHES 35 55 48 35 55 48 35x55x48 35x55x48 MILLIMETERS 889139731219 88913971219 89 1397 x1219 889 1397 1219 AREA REQUIRED DxWxH FEET 70 9 5 70 7 0x9 6x7 0 7 0x96x7 0 7 0x9 6x7 0 METERS 210901 202921 202921 212921 LARGEST LOAD LHP 9 9 59 91 J 91 91 9
133. ve chips as required 14 29 5 Remove the four 4 bolts using a 7 16 wrench that hold the casting in place 14 29 6 Clean all chips from the casting and impeller Be careful not to damage the back of the casting where it mates to the adapter as this is a metal to metal seal 14 29 7 Re assemble the casting and replace the four 4 bolts Insure the casting is snugly in place Check the shaft to insure it rotates freely Use the screwdriver slot in the motor to turn the shaft 14 29 8 Re install the inlet and outlet hoses and tighten the hose clamps securely 14 29 9 Re power the ChipBLASTER unit and check for leaks RETURN PUMP ChipBLASTER supplied CHECK FOR LEAKS 14 30 1 Check for leaks around the casting where it mates with the adapter 14 30 2 If pump is leaking around casting tighten the four 4 bolts DO NOT OVER TIGHTEN RETURN PUMP ChipBLASTER supplied INLET and OUTLET 14 31 1 Check for leaks around the inlet and outlet connections 14 31 2 If the hoses are cracked or cut replace hoses ChipBLASTER Inc 4l 14 0 PREVENTATIVE MAINTENANCE Cont 14 34 LDENS SAMPLE LINE FILTER Used with optional Auto Concentrate Monitor and Adjust CHANGING THIS CAN ONLY BE REPLACED WHEN THE CHIPBLASTER IS SHUT DOWN The LDENS filter is not monitored because of the very low flow rate The cartridge filter should be changed every 30 days under normal conditions If there is a high volume of way oil

27.0. OPTIONAL EQUIPMENT (Cont.)

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