PowerStream SA High Pressre Coolant Service Manual
Contents
1. PUBLICATION 864510 0016 Page 4 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL HIGH PRESSURE COOLANT REQUIREMENTS CONSIDERATIONS 1 MACHINE CAPABILITY The machine tool coolant path spindle seals rotary unions hose fittings etc must be suitable for the pressure applied The machine components must have a working pressure rating equal to or greater than the maximum coolant pressure supplied 2 MACHINE ENCLOSURE Higher pressure at the tool along with faster metal removal rates may produce more splash and coolant atomization mist depending on the machining process 3 FILTRATION Most spindle OEM s recommend that coolant should be filtered to between 10 and 30 microns for proper operation of their systems This higher filtration also improves part finish and tool holder to spindle accuracy less contamination Most machine tool manufacturers provide a police filter in the coolant path near the machine tool spindle This filter functions as a back up filter downstream of the main filters to insure against stray contamination from the coolant hoses fitting sealant improper filter media in the main filters and etc Such a filter usually has a nominal filtration level significantly higher less filtration than the main coolant filters As such it should not require attention except during periodic system cleaning It is recommended to insure the machine is equipped with such a filter2. PUBLICATION 864510 0016 15 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL HIGH PRESSURE MAINTENANCE Gear Pump Maintenance The gear pumps used on PowerStream systems are maintenance free The pumps will provide reliable service as long as the system upstream is maintained to provide adequate filtered coolant Hydracell D12 DAILY Check the oil level and the condition of the oil When the pump is operating the oil in the pump housing gets warm and expands filling into the oil reservoir Depending on the type of oil and the operating temperature of the system the oil level will vary in the reservoir If there is no oil in the reservoir when the system has reached operating temperature add oil through the fill cap on the reservoir Fill the reservoir about 25 full If the pump is too full of oil it will overflow the reservoir and reach equilibrium This is no cause for concern When the unit is shut down and the oil has cooled the oil will drain out of the reservoir and back into the pump housing Use the appropriate motor oil for the application refer to the chart below Your unit was shipped from the factory with Hydra Oil Standard Grade 10W30 weight oil This oil is designed for lower temperatures and lighter loads It maintains consistent viscosity over a wide temperature range and repeated cold start ups If your high pressure pump is going to run for continuou
3. CAUTION The two bolts item 38 shown on page 33 exploded view that screw through the back of the pump housing 904 89 into the cylinder casting 90A 74 hold the casting to the pump housing Do not remove them except when repairing the hydraulic end NOTE The following service procedures refer several times to the Wanner Took Kit We strongly urge you not to try to repair the hydraulic end of the pump without using the tools in this kit Part No A03 200 1101 Remove Motor and Coupler from Pump 2 Disconnect all Electrical Connections or lock out power to the unit 3 Remove Pump Housing a Remove the head of the pump and the diaphragms as outlined in the Fluid End Service Section Drain the oil from the pump housing by removing the drain plug 90A 80 Stand the hydraulic end of the pump face down on the cylinder casting 90A 74 Check the shaft for sharp burrs Smooth any burrs to prevent scarring the housing seals 90A 104 when you disassemble the pump e Remove the bolts item 38 shown on page 33 exploded view that secure the housing to the cylinder casting The piston return springs 90A 90 will force the cylinder casting and housing apart f Lift off the housing 90A 89 g Inspect the cam and bearings 90A 102 and the bearing race in the rear of the housing If the bearings are pitted or binding or if the housing race is worn contact the factory 4 Disassemble Pistons a With the pump housing removed see
4. Cracked cylinder casting Replace damaged cylinder casting or pump AUGUST 2005 1 6 2 222 0 1 PUBLICATION 864510 0016 25 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION 3 Pump Runs a Worn pump valves HydraCell only Rough Oil level low HydraCell only Add oil as required d Wrong weight oil for cold operating See recommended oil for operating conditions as temperatures change to lighter weight shown in this manual HydraCell only e Cavitation See 1 of this chart f Air in suction line HydraCell only Seal suction line g Restriction in inlet suction line Clear restriction in inlet suction line h Hydraulic cells not primed after changing diaphragms HydraCell only i Foreign material in inlet or outlet valves Clean inlet and outlet valves HydraCell only j Damaged diaphragm HydraCell only Replace damaged diaphragm Fatigued or broken valve spring 13 Replace damaged valve spring HydraCell only I Broken piston return spring inside Replace damaged return spring hydraulic end HydraCell only a Frozen pump __ Failure of Pump b Puncture by a foreign object Replace diaphragm H Elastomer incompatible with fluid being Consult factory to determine if there i
5. ON ON ON LHVd 90119 WALI 901V1V9 Wall PUBLICATION 864510 0016 AUGUST 2005 1 nnrneenmnenennennnnnnnnnnnnnnnnnnennnnnns Page 34 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL RELIEF VALVE ASSEMBLY ITEM CATALOG DESCRIPTION ITEM CATALOG DESCRIPTION NO NO NO NO 1 91A 70 HOSE ASSY 7 91A 77 ELBOW 2 91A 71 PIPE 8 91A 78 PLUG 3 91A 73 BUSHING 9 91A 79 ELECTRICAL DIN PLUG 4 91A 74 VALVE COVER 10 91 A 80 ELBOW 5 91A 75 VALVE SUPPORT 11 91A 81 NIPPLE 6 91A 76 RELIEF VAVLE AUGUST 2005 LNS PUBLICATION NO 864510 0016 35 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL TRANSFER PUMP ASSEMBLY 9 CL cy O 3 S 8 es S gt cw Q p X Y ITEM CATALOG DESCRIPTION ITEM CATALOG DESCRIPTION NO NO NO NO 1 91A 90 REDUCER BUSHING 6 91A 95 TRANSFER PUMP 2 91A 91 HOSE BARB 7 91A 96 NIPPLE CLOSE 3 91A 92 HOSE CLAMP 8 91A 97 ELBOW STREET 4 91A 93 HOSE 9 91A 98 REDUCER BUSHING 5 91A 94 CHECK VALVE 10 91A 99 NIPPLE AUGUST 2005 LNS enennmnemnmmnennnnnnnnnnnnnnnnnnnnnnne PUBLICATION NO 864510 0016 36 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL OIL COOLER ASSEMBLY OPTIONAL AUGUST 2005
6. 4 HEAT Properly applied coolant absorbs much of the heat generated in the cutting zone High pressure coolant enables more effective cooling which allows a higher metal removal rate which in turn results in more heat transferred to the coolant A high pressure pump may also introduce heat to the coolant In some cases the process dictates the use of an external cooling mechanism LNS clean coolant reservoir provides an effective heat dissipation mechanism This eliminates the need for additional cooling equipment in many cases AUGUST 2005 LNS 4 esses eene 1 1 sna inn inna sensns PUBLICATION NO 864510 0016 Page 5 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL FEATURES OF POWERSTREAM HIGH PRESSURE COOLANT SYSTEMS SWISS TURN MULTI PORT POWERSTREAM SYSTEM The PowerStream ST coolant system uses a low pressure pump to transfer coolant from the main machine tank through a filter system to a holding tank A high pressure pump delivers filtered coolant from the holding tank to a bank of up to 8 individual solenoid valves Each valve is independently controlled to supply the filtered high pressure coolant to each machine coolant circuit The optional coolant transfer pump is mounted integrally to the PowerStream ST unit It draws coolant from the machine tank and pumps it through a canister filter As contamination collects in the filter element resistance to flow causes
7. ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL Thank you for choosing an LNS Chip Conveyor We are proud to have you among our LNS family of users LNS Chip Conveyors simply and reliably remove waste from machining operations Machine efficiency is increased and operator safety is improved since the conveyor work with little operator attention and without interrupting production time LNS Conveyors are available for many types of machine tools or other applications They can be arranged to deliver wet or dry waste to containers or to conveyor or chute type disposal systems For further information contact Inside Sales Department LNS TURBO 203 Turbo Drive Kings Mountains NC 28086 This Service Manual is intended to assist with the normal maintenance that will assure long service life of your LNS Chip Conveyor It is in two parts a Service Instruction Section followed by a Parts Section which includes drawings and parts lists for the basic elements of the conveyors AUGUST 2005 LNS PUBLICATION NO 864510 001 6T Page 1 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL NOTICE ALL INFORMATION CONTAINED IN THIS MANUAL IS INTENDED TO BE CORRECT HOWEVER INFORMATION AND DATA IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE LNS MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS INFORMATION OR DATA FURTHER LNS IS NOT RESPONSIBLE FOR ANY OMISSIONS OR ERRORS OR CONSEQUENTIAL DAMAGE CAUSED BY THE
8. LNS YQ i SRN lt 2 LE tc lt Lu 7 co C a E 5 OG 9 35 Y uu 35388888 arag o 365 99990009 lt 9 4 lt 444 lt lt 4 lt ea Pere LL 5 E lt lt e 5 lt 2985529 lt 5 lt o T CO f 10 10 dg 9990252090101 12 lt lt 4 lt lt lt lt lt lt OR PUBLICATION NO 864510 0016 Page 37 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL POWERSTREAM HIGH PRESSURE SYSTEM ELECTRICAL INFORMATION LNS high pressure systems are supplied with a variety of electrical controls and interfaces depending customer s application and machine tool high pressure system interface Only a qualified electrician or machine service technician should perform any maintenance repairs or adjustments on this equipment READ THIS SECTION BEFORE APPLING ELECTRICAL POWER TO THIS EQUIPMENT ONLY QUALIFIED ELECTRICIAN OR SERVICEMAN SHOULD PERFORM ELECTRICAL TROUBLESHOOTING OR MAINTENANCE TO THIS EQUIPMENT DO NOT PERFORM ANY MAINTENANCE REPAIRS OR ADJUSTMENTS ON THIS EQUIPMENT WITHOUT FIRST LOCKING OUT ALL ELECTRICAL CONTROLS PERSONNEL SHOULD BE TRAINED IN OSHA COMPLIANT
9. Remove the oil drain cap 904 80 and allow all oil and contaminant to drain out Dispose of it properly b Fill the reservoir with kerosene or solvent manually turn the pump shaft to circulate the kerosene and drain CAUTION If you have EPDM diaphragms or if food grade oil is in the reservoir do not use kerosene or solvents Instead flush with the same lubricant that is in the reservoir Pumps with EPDM diaphragms have an as the 7 digit of the Model No Repeat the flushing procedure step b d Fill the reservoir with fresh oil manually turn the pump shaft to circulate the oil and drain once again e Refill the reservoir If the oil appears milky there is still contaminant in the reservoir Repeat the flushing procedure until the oil appears clean T Prime the Hydraulic Cells a With the pump horizontal and the fluid end head removed fill the reservoir with the appropriate Hydra Oil brand motor oil for the application b Allair in the oil within the hydraulic cell behind the diaphragms must be forced out by turning the shaft and thus pumping oil into the piston If the motor is connected to the pump rotate the shaft by rotating the motor fan blade If the motor and coupler have been removed from the pump use the shaft rotator that is included in the Wanner Tool Kit Turn the shaft until a bubble free flow of oil comes from behind all the diaphragms Watch the oil level in the reservoir if it gets too low during pr
10. SYSTEM SCHEMATIC 055 HOIH JVW OL JILVWAHIS 15 4 3 IS WV3Y1SH3MOd 35155359 HOIH 438 3NIHO VM 3A0vA 313738 S3H21IMS TJ3A31 agi WNOILdO LINN 9NI1002 39v9 L HDLIMS 35155339 431113 EN amp gt gt p JNIHJYW OL SYNSS3Yd 3999 3HNSS34d 7 105 334 SdHNd 1 1002 2 01 4 03431113 3NIH2VW 01 02402 3305 389 98 1 105 8317114 321A83S 13431 ES 9015 M3JSNYMIL 253 LYVLS dW d YJJSNYYL 53 PUBLICATION 864510 0016 AUGUST 2005 1 6 0 4 2 2 2 2 4 1 ntn natns 11 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL SERVICE SECTION BEFORE INITIAL START UP HIGH PRESSURE PUMP Before you start the pump be sure that All shut off valves are open and the pump has an adequate supply of fluid All connections are tight The coupler that connects the pump and motor has been sized and installed correctly IMPORTANT PRECAUTIONS Adequate Fluid Supply To avoid cavitation and premature pump failure be sure that the pump will have an adequate fluid supply and that the inlet line will not be obstructed Shut Off Valves Never install shut off valves between the pump outlet and discharge pressu
11. above turn the unit over and set it on a flat surface piston side down b With the diaphragms removed see the Fluid End Service Section reinsert a follower screw 90A 67 into the hole in one of the valve plungers 90A 94 Tap the screw lightly with a hammer the plunger 90 71 should slip off the valve plunger 90A 94 The hydraulic piston assembly 90A 90 90A 99 can now be disassembled Inspect all parts and replace all O rings and any other parts which are worn or damaged c Repeat step b for the remaining pistons NOTE When you reassemble the hydraulic piston use new plungers 90A 71 They are press fit onto the valve plungers 90A 94 and are not reusable 5 Reassemble Pistons a Drop ball 90A 98 into each opening in the bottom of a piston assembly 90A 99 b Insert a retaining washer 90A 97 and O ring 90A 96 to hold the ball in place c Insert a valve plunger 90A 94 into a valve cylinder 90A 95 Slide a spring 90A 93 over the plunger inside the valve cylinder d Insert an O ring 90 92 into a spring retainer 90A 91 AUGUST 2005 1 6 2 22 PUBLICATION NO 864510 0016 Page 21 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL Slide the assembled valve cylinder plunger and spring 90 93 90A 95 into the spring retainer 90A 91 f Slide the complete cylinder and retainer assembly 90A 91 90A 95 into the piston
12. psig Furthermore incoming flow should never exceed 40 psig MAINTENANCE PROCEDURE To replace the filter element in the canister QV de N 10 11 12 13 Press the Filter Reset button on the PowerStream control panel if so equipped Open the bleed off valve to vent any residual pressure to tank NOTE 1 Inspect the canister pressure gauge to ensure pressure has reached zero Loosen the eye nut on each of the 3 canister lid swing bolts Swing the canister lid away from the canister body to expose the inside of the canister and filter element Take care not to damage the o ring situated in the canister flange Take care to prevent contamination from the used filter element coolant inlet area or external sources from entering the canister during the rest of this procedure Remove the used filter element from the filter basket in the canister and discard in an approved manner Place a new filter element in the filter basket Ensure that the filter element ring is seated against the filter basket flange and canister walls Inspect the canister lid and canister flange Ensure they are clean and undamaged Inspect the canister o ring and ensure it is clean undamaged and properly seated Lubricate with Viton compatible grease as needed Replace the canister lid Position canister lid swing bolts and tighten the eye nuts hand tight Close the bleed off valve NOTE 1 The canister is now ready for serv
13. remove any foreign material from shipping and insert the proper filter element s See Filter Maintenance Procedure Fill the tank with filtered coolant Never add coolant directly to the PowerStream tank All coolant must pass through the filter canister before introduction to the clean reservoir The unit is equipped with a number of level sensors that interface with the machine tool control the fluid level in the PowerStream tank during normal operation The recommentde method of coolant addition is to activate the Powerstream system and let the transfer pump pull coolant from the machnine tank and pump it throught he canister filter s into the clean reservoir Unfiltered coolant should be added to the machine tank as necessary until the transfer pump stops when the clean reservoir high level switch is reached Depending on the particular machine tool control the tank may have to be filled manually at installation Use the transfer pump or other means to pump coolant through a properly prepared canister filter until coolant starts to flow through the Powerstream discharge overflow line AUGUST 2005 1 86 2 2 2 2 4 02 29 1 41 4441 eaten sinn inn PUBLICATION NO 864510 0016 Page 9 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL 5 Machine tank coolant level It is very important not to overfill the mavhine coolant tank During normal operation the Powerstream unit will tra
14. so the threaded end of the stud can be put through one of the bolt holes in the cylinder casting and through the housing casting Start another nut on this end of the stud Now put the other stud through the hole on the other side of the cylinder casting and through the housing Start this nut Using both studs and the nuts tighten evenly to draw the cylinder casting tight to the housing Be sure the O ring 90A 105 stays in place when pulling the two parts together When tight install the bolts item 38 as shown on page 33 and washer into the cylinder casting to hold it to the housing Remove the two studs and nuts that were part of the Wanner Tool Kit g Turn the shaft again to check its alignment AUGUST 2005 1 6 4 2 42 2 2 4 2 entran PUBLICATION 864510 0016 22 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL r Replace Shaft Seals a Apply a thin film of grease on the seal protector tool part of the Wanner Tool Kit Slide both seals onto the tool with the spring side of the seals toward the open end of the tool Apply a heavier coat of grease between the seals and press them together b Apply a coating of Loctite amp 601 or equivalent locking compound to the outside surface of both seals and the inside surface of the opening in the pump housing where the seal will rest c Apply a light film of grease to th
15. 6 5 02 716 HV39 3905539 1 16 v 3NT1VA TIV8 61 16 LL AM ci VL6 81 916 OL AT8W3SSV ISOH LL WL6 L ON 9 ON ON LHVd 01V1V9 WALI 3INVN L4Vd WALI PUBLICATION NO 864510 0016 AUGUST 2005 1 6 2022222 2 1 4 1 4 4 intr ists atra 32 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL FILTER ASSEMBLY DETAIL A SCALE 0 30 1 ITEM CATALOG DESCRIPTION ITEM CATALOG DESCRIPTION NO NO NO NO 2 90A 17 ROD END 20 90A 19 FILTER BAG 3 90A 15 PRESSURE GAUGE 21 90A 27 ELBOW 4 90A 14 O RING 22 90A 24 PRESSURE SWITCH 6 90A 11 FILTER LID 23 90A 22 NIPPLE CLOSE 7 90 16 EYE NUT 24 90A 26 REDUCER BUSHING 18 90A 12 BASKET WELDMENT 25 90A 25 AUGUST 2005 1 6 2 PUBLICATION 864510 0016 33 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL HIGH PRESSURE SYSTEM VALVE ASSEMBLY amp COVERS 98 16 9 41109 H VI6 8L YOLOANNOO NIG 1VO9IH193 13 S V L6 S Q IO3INVIN Ot VI6 2 AATVA GION3 10S ve vi6 v ASSV 13H9VH9 LYOddNs 6 v L6 9 AQOS 31AVA 55 916 MO813 86 16 8 MO813 c V L6 aunssaud 46 6 2 1 7991919373 6 L
16. LOCK OUT TAG OUT AND ELECTRICAL SAFETY PROCEDURES MAKE CERTAIN THAT THE POWER SUPPLY IS DISCONNECTED BEFORE ATTEMPTING TO SERVICE OR REMOVE ANY COMPONENTS AT NO TIMES SHOULD CIRCUIT CONTINUITY BE CHECKED BY SHORTING TERMINALS WITH A SCREWDRIVER OR OTHER METAL DEVICE NEVER SHOULD ADJUSTMENTS MAINTENANCE OR CLEANING BE PREFORMED WITHOUT FOLLOWING PROPER SAFETY PROCEDURES IN ACCORDANCE WITH LOCAL STATE AND NATIONAL SAFETY CODES Before making any electrical connections be certain the voltage for which the conveyor drive and control are wired is the same as incoming voltage being delivered by the electric power supply Failure to do so may result in injury or damage to the equipment It may be necessary in the case of 220 440V 3 phase for example to change the motor wiring from one voltage to another Normally a wiring diagram is supplied with the equipment documentation package which indicates proper wiring for the incoming voltage supplied Refer to the machine tool s electrical schematics along with the electrical schematic provided with the high pressure coolant system to determine the proper electrical interface wiring instructions Some machines are equipped with internal electrical controls and a multi pin type accessory plug for connecting the high pressure coolant system these cases LNS high pressure system may be ordered with a electrical mating plug so that connecting the high pressure coolant system is as simple as pluggi
17. RESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL PERFORMANCE CHARACTERISTICS Standard System Filtration 10 standard 5 to 200 optional Transfer Filtration Flow 12 15 gpm Transfer Pressure lt 25 psi Maximum High Pressure Flow 10 gpm at 1000 psi with cutting oil Maximum Pressure 2000 psi Control Input Machine tool m codes to suit user Control Output 24 VDC Consult Factory For Other Pressures Flow Rates And Capacities OPTIONS 2000 psi 5gpm pump cutting oil 1000 psi 8 gpm pump suitable for oil or water based coolant Heat Exchanger Discharge Hose Assembly Transfer Hose Assembly Transfer Pump Alternative Pressure and Flow Consult Factory Filtration 5 um 98731130 10 um 98731127 Standard if not specified by customer 25 um 98731131 50 um 98731132 100 um 98731133 200 um 98731134 AUGUST 2005 PE PUBLICATION 864510 0016 Page 8 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL 1 2 POWERSTREAM INSTALLATION INSTRUCTIONS STANDARD UNITS Inspect for shipping damage Position the unit and connect to the machine tool and main coolant tank The proper location for the PowerStream unit must accommodate the following connections to the machine tool and its main coolant tank a High Pressure Outlet s e Plumb the machine s high pressure line s to the PowerStream s high pressure outlet manifold
18. Switch must be set to 15 2 PSIG for proper operation Duplex Filter Clean the floats if necessary to insure they move freely Change pump oil per the specified maintenance schedule 1000 PSI Systems Only Drain all coolant from the reservoir and clean sludge from the tank Recharge with clean coolant PUBLICATION NO 864510 0016 Page 29 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL POWERSTREAM ST HIGH PRESSURE SYSTEM STAND ALONE SYSTEM SEM 4 LI i ITEM CATALOG PART NAME NO NO 1 91A 1 ELECTRICAL CONTROL 2 91A 2 FILTER CANISTER ASSEMBLY 3 91A 3 VALVE MANIFOLD ASSEMBLY 4 91A 4 RADIATOR ASSEMBLY AUGUST 2005 LNS enennmnemnmmnennnnnnnnnnnnnnnnnnnnnnne PUBLICATION NO 864510 0016 Page 30 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL POWERSTREAM ST HIGH PRESSURE SYSTEM STAND ALONE SYSTEM ITEM CATALOG PART NAME NO NO 5 91A 5 HIGH PRESSURE PUMP ASSEMBLY 6 91A 6 TRANSFER PUMP ASSEMBLY AUGUST 2005 LNS enennmnemnmmnennnnnnnnnnnnnnnnnnnnnnne PUBLICATION NO 864510 0016 Page 31 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL 2000 PSI GEAR PUMP ASSEMBLY A18W3SSV ISOH 21 716 8 EZ V L6 91 9L VIS8 2 YOLOW 39v1 9 16 vl Moga 91 16 9 LZ V L6 L HOLOIN vL VL6
19. The PowerStream manifold terminates in female SAE 8 1 2 inch ports b Overflow Discharge Clean Coolant e Connect the overflow 1 5 inch NPT female to the machine tank optional Discharge Hose Assembly provides all hardware to accomplish this connection e During normal operation the PowerStream unit may filter more coolant than is used by the high pressure pump This excess will flow back to the machine tank Note that this is a gravity drain and the machine tank fluid level must be lower than the PowerStream fluid level for proper operation c Transfer Pump Dirty Coolant In e Connect the Filter inlet 1 inch NPT female to a suitable coolant supply optional Transfer Pump Assembly and Transfer Hose Assembly provide all hardware to accomplish the connection e Ifthe Transfer Pump Assembly is not used the customer must furnish a pump that supplies adequate flow for the selected high pressure pump at a head of 15 psi and develops a maximum pressure of no more than 35 psi e Ifthe Transfer Hose Assembly is not used it is recommended to install a check valve near the transfer pump to prevent drain back of fluid when the transfer pump is off d Electrical Control connections vary with control options Control schematics specific to each model are shipped inside the PowerStream s electrical control cabinet Make the necessary connections Prepare the canister filter s Open filter canister s check for and
20. USER OF THE PRODUCT LNS RESERVES THE RIGHT MAKE MANUFACTURING CHANGES WHICH MAY NOT BE INCLUDED IN THIS MANUAL LNS supplies data necessary for the proper instruction test operation and maintenance of this product LNS retains all proprietary rights in and to the information so disclosed and such shall not be reproduced copied or used in whole or in part for purposes other than those for which it is furnished TABLE OF CONTENTS CONTENTS PAGE Introduction amp Table of Contents 1 Instructions for Ordering 2 Warranty RR 2 Benefits of High Pressure Coolant 3 High Pressure Coolant Requirements Considerations 3 Features of LNS PowerStream High Pressure Coolant System 4 Standard Features 5 Performance Characteristics Standard System 6 Optional Equipment 6 Size Information 6 Installation Instructions 7 System Sch matic aw re pru 9 Prestart Up 10 Maintenance Procedures 11 22 Filter Maintenance Procedure 11 Pressure Switch Installation amp Maintenance 12 Level Switch Installation amp Maintenance 13 H
21. assembly 90A 99 g Insert a return spring 90A 90 into the piston assembly wide end first This is a tight fit and can best be done by screwing the spring in counterclockwise h Repeat the above procedure for the other two pistons 6 Reassemble Housing and Casting NOTE Inspect the shaft seals 90A 104 before continuing If they look damaged in any way replace them remove by pounding them out from inside the pump housing Both seals should be replaced at the same time Be careful not to damage the seal bore a Place the cylinder casting 90A 74 face down on a flat surface Insert the assembled pistons 90A 90 90A 99 into the cylinder casting Note the location of the outer ring of holes in the cylinder casting and in the pump housing flange in particular the holes where bolts item 38 as shown on page 33 will be installed d Stand the camshaft assembly 90A 102 on the cylinder casting 90A 74 CAUTION The pilot bearing MUST be properly nested in the bearing race 90A 102 during assembly If misaligned the bearing will be damaged and the pump will fail within the first hours of operation e Install the O ring 90 105 and slide the housing 90A 89 down over the shaft and onto the threaded studs from step c Be sure the holes in the housing and the cylinder casting are properly aligned f Using the two threaded studs in the Wanner Tool Kit put a nut on the studs Thread the nut down on the stud
22. bottom center of the manifold Open any draincocks in the piping Start the pump and allow it to run until all fluid is removed from the pump head Stop the pump and reinstall the drain plug Fill the pump with antifreeze When you put the pump back into service thoroughly flush the antifreeze AUGUST 2005 1 6 4 2 42 2 2 4 2 PUBLICATION 864510 0016 Page 17 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL SERVICE FLUID END This section explains how to disassemble and inspect all easily serviceable parts of the high pressure pump Repair procedures for the hydraulic end oil reservoir of the pump are included in a later section of the manual CAUTION Always disconnect power from the motor before doing maintenance on the pump or motor CAUTION Do not disassemble the hydraulic end unless you are a skilled mechanic CAUTION The two bolts item 38 shown on page 33 exploded view that screw through the back of the housing into the cylinder casting hold the casting over the hydraulic end of the pump Do not remove them except when repairing the hydraulic end 1 Hinge Pump to Horizontal Position 2 Disconnect all Electrical Connections or lock out power to the unit 3 Remove Manifold 90A 56 Valve Plate 90A 66 a Remove all nuts 90A 81 bolts 90A 54 and washers 90A 55 around the manifold Do not remo
23. e drive shaft Slide the seal protector tool with the two seals over the end of the shaft d Slide the seal inserter tool from the Wanner Tool Kit over the seal protector tool and press the seals completely into place Tap the tool with a soft mallet to firmly seat the seals 8 Adjust Camshaft Endplay a If the three set screws 90 72 are in the cylinder casting 90A 74 remove and clean them b Insert the centerbolt 90A 51 into the hole in the center of the cylinder casting Turn it in to move the bearing adjusting plate 90A 101 and cup tight against the bearing cone c Back out the centerbolt two full turns then turn it back in again until it is tight against the adjusting plate 90A 101 d Backoutthe centerbolt or set screw exactly 1 4 of a turn With a plastic mallet or a regular mallet and wooden board to prevent damage to the shaft rap the end of the shaft 3 or 4 times This will provide about 006 in 0 15mm endplay in the shaft f Apply removable threadlocker to the threads of the three cleaned set screws 90A 72 Screw the three set screws 90A 72 into the cylinder casting until they contact the bearing adjusting plate 90A 101 g Remove the centerbolt 90A 51 9 Reinstall Plungers NOTE If the plungers 90A 71 have been removed from the valve plungers 90A 94 do not reuse them Install new ones instead a b Place a plunger on the screw end of the plunger guide tool from the Wanner Tool Ki
24. e introduction of high pressure coolant at the tool to part interface allows the cutting fluid to do its job more effectively With lower pressures the coolant does not effectively cool the shear zone rather most heat is dissipated via conduction to material around the shear zone Higher pressures allow the coolant to dissipate heat at the cut more directly enabling higher metal removal rates and therefore lower cycle times 2 TOOLLIFE Properly applied high pressure coolant helps to break chips and evacuate them from the cutting area This minimizes re cutting of chips Along with more effective cooling this not only reduces tool wear it also makes tool life more predictable Tooling wears it doesn t fail from chip damage and heat 3 PART FINISH Elimination of chip re cutting higher metal removal rates more effective cooling predictable tool wear along coolant filtration all contribute to a better surface finish 4 OTHER e Improved accuracy by the reduction of chips contaminating the tool holder to spindle taper interface e Improved chip evacuation from fixtures and the machining area e Improved machining capability range e g Larger L D ratios higher metal removal rates etc e Improved through put by combining operations on a single machine set up e g milling and deep drilling e Improved capabilities with exotic material and tooling AUGUST 2005 1 6 024 4 2 2 1 2 1 1 4
25. he original specified user Seller will repair or replace at its option free of charge except freight FOB shipping point any parts it finds nonconforming on these conditions a request user promptly allows seller to inspect and user returns all requested parts to seller s plant and b user has operated and maintained products in accordance with seller s maintenance and operational literature and good business practice and products have not been misused abused damaged by accident or altered without seller s written consent and d user employs trained maintenance and operating personnel and e buyer meets all payment obligations Seller warrants products manufactured by others to the extent warranted by their original manufacturers on these conditions Parts which have expected life shorter than one year under normal usage are excluded USED PRODUCTS ARE SOLD AS IS SELLER MAKES NO WARRANTY FOR USED PRODUCTS EXCEPT AS TO TITLE BUYER MAY INSPECT AND TEST BEFORE SHIPMENT AND ACCEPTS USED PRODUCTS ON THESE TERMS THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN ORAL OR IMPLIED INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE AUGUST 2005 LNS enmnnenemnemnennnnnnnnnnnnnnnnnnnnnnnne PUBLICATION NO 864510 0016 Page 3 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL BENEFITS OF HIGH PRESSURE COOLANT 1 CYCLE TIME Th
26. ice NOTE 1 This step applies only on units equipped with optional bleed off valves AUGUST 2005 1 6 0 242 42 2 PUBLICATION 864510 0016 13 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL PRESSURE SWITCH INSTALLATION amp ADJUSTMENT To install the switches use a suitable wrench on the port and plumb into place with the proper sealant For electrical wiring refer to wiring codes below and to the specification sheet for the switch ratings For low DC loads 50 mA TTL logic use switches with gold contacts The switch installed on the high pressure unit is adjustable but has been preset at the factory to 15 2 PSIG prior to shipping the unit In case a replacement is orderrd follow the following procedures All switches are maintenance free DIN Connector Micro Switch Positioning P N Adjuster Snap Action Micro Switch Electrical Housing SO SOA TNS fr AN Gland Actuator Nose Ad EN Cushion SN UN N S Wear Disc SS Ss 02471 Secs LA RS Diaphragm Port Adjusting the Set point For DIN Connector Style Switches A Remove DIN connector then remove the top cover B Remove center screw with female internal thread Then follow the steps below 1 All non DIN models have an outer 1 8 Allen head cap that must be removed to allow access to the 1 8 Allen adjustmen
27. igh Pressure Pump Maintenance 14 22 Trouble Mele eek IR e er ses 23 26 Maintenance Schedule 27 PowerStream Service 28 35 PowerStreamElectrical Information 36 37 AUGUST 2005 1 6 4 2 42 2 2 4 2 entran PUBLICATION 864510 0016 2 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL INSTRUCTIONS FOR ORDERING PARTS Furnish the following information on your order Furnish exact shipping instructions e Model and serial no of machine e Complete shipping address Catalog number and name of part e Mode of delivery Quantity wanted e Parcel post truck line etc e Purchase order number e Bill to address How to find the model and serial number of your machine The machine model number and serial number is stamped on the machine nameplate located on the motor cover INS Turbo Inc 203 Turbo Drive Kings Mountain NC 28086 MODELS 5 5 0 S SERIAL 5 5 7 1 1 An ISO 9001 Certified Company Phone 704 739 7111 Fax 704 739 6039 www LNSAmerica com DIRECT YOUR ORDER TO LNS Turbo 203 Turbo Drive Kings Mountains NC 28086 U S A Telephone 704 739 7111 Fax 704 739 6039 WARRANTY Seller warrants that within 12 months from original shipment if its products are operated by t
28. iming air will be drawn into the pistons inside the hydraulic end and will cause the pump to run rough c Wipe excess oil from the cylinder casting and diaphragms 8 Reinstall Valve Plate 90A 66 Manifold 90A 56 a Reinstall the valve plate 90A 66 with the valve assemblies installed as outlined above onto the cylinder casting Using a 5 mm hex Allen wrench install the two socket head cap screws 90A 73 and secure the valve plate to the cylinder housing b Reinstall the O rings 90A 57 90A 58 90A 59 on the rear side of the manifold Use petroleum jelly or lubricating gel to hold them in place c Reinstall the manifold onto the valve plate Be sure the drain plug 904 53 is at the bottom of the manifold d Insert all six bolts 904 54 around the edge of the manifold Reinstall the pump centerbolt 90A 51 with its washer 90A 52 e Alternately tighten the perimeter bolts until all are secure Torque to 45 ft lbs 54 N m f Tighten the pump centerbolt Torque to 45 ft Ibs 54 N m 9 Recheck all bolts for tightness 9 Reconnect Electrical Power to Motor or remove lock out from power source AUGUST 2005 1 6 4 2 42 42 2 2 PUBLICATION 864510 0016 Page 20 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL SERVICE HYDRAULIC END CAUTION Do not disassemble the hydraulic end of the pump unless you are ea skilled mechanic
29. ing Valve for proper operation and leaks Inspect High Pressure pump for proper operation noise and leaks Check the pressure switch to insure it is set properly Check float level switches to insure they are working correctly Change pump oil after first 100 hours of operation and every 1000 hours or six months thereafter whichever comes first HydraCell Punp Systems Only Clean High Pressure tank reservoir If transfer pump is not operating correctly the high pressure coolant system will not have an adequate coolant supply Pump may run hot or noisy if oil level is too low An improperly functioning pressure regulating valve leads to unstable system pressure Noisy pumps normally indicate a pump problem Leaks can lead to premature pump wear and or performance problems Improperly set pressure switch may not provide adequate alarm that filters are clogged Inspect float level switches to insure the floats move up and down freely and the switches work correctly If oil is not changed regularly it can lead to excessive wear on pumps parts and possible failure Depending upon the level of filtration sludge may accumulate in the bottom of the tank reservoir Bag filter is clogged Clean or change bag filter Repair as required Add oil or change oil as needed 1000 PSI Systems Only Repair valve and seal leaks as required Repair pump and seal leaks as required Pressure
30. ith O ring through the diaphragm follower 90A 69 and diaphragm 90A 70 and screw it into the valve plunger 90A 94 h Hold the diaphragm Allen wrench tighten the follower screw to 18 in Ibs 2 0 N m of torque i Repeat the above procedure for the plungers and diaphragms of the other two cylinders j Fill the reservoir with fresh oil and prime the pump as outlined in the Fluid End Service Section 11 Reassemble Pump Head Reassemble the pump head as outlined in the Fluid End Service Section 12 Reconnect Electrical Power to Motor or remove lock out from power source AUGUST 2005 1 6 024 4 2 2 PUBLICATION 864510 0016 Page 24 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL POWERSTREAM HIGH PRESSURE COOLANT SYSTEM TROUBLESHOOTING GUIDE The following chart will show some problems their probable causes and possible solutions PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION 1 High Pressure a Inadequate fluid supply because inlet Open the valve Pump Cavitation supply line vavle is closed b Inadequate fluid supply because of inlet Replace inlet line line collapsed or clogged c Inadequate fluid supply because of Replace clogged filter element clogged filter element d Inadequate fluid supply because of Inspect and repair transfer pump and or hose malfunction in transfer pump or hose Fluid is too hot for the i
31. ng flexibility Usually caused by pumping a fluid that is incompatible with the diaphragm material e Slice in ridge of diaphragm Occurs when a Viton diaphragm is operated at cold temperatures e Diaphragm edge chewed away Usually caused by over pressurizing the system e Inspect the plunger 90A 71 for any rough surfaces or edges Do not remove the plunger from the plunger shaft Smooth the surfaces and edges as necessary with emery cloth or a fine file CAUTION If a diaphragm has ruptured and foreign material or water has entered the oil reservoir do not operate the pump Check all diaphragms then flush the reservoir completely as outlined below and refill it with fresh oil Never let the pump stand with foreign material or water in the reservoir or with the reservoir empty f Install a new diaphragm ridge side out AUGUST 2005 1 65 2 2 tnn nanaisin ainai aaan naaa PUBLICATION 864510 0016 Page 19 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL 9 Clean the screw 90 67 and remove any oil from it medium strength threadlocker to the screw Reinstall the screw follower 90A 69 and a new O ring 90 68 Tighten to 18 in Ibs 2 0 N m h Repeat the above inspection procedure and replacement if necessary with the other two diaphragms 6 Flush Contaminant from Hydraulic End only if a diaphragm has ruptured a
32. ng it in The best and most common source of power for the chip conveyor is the machine electrical cabinet It is the customer s responsibilities at the time of order to determine what if any electrical components are present and or order the appropriate high pressure coolant system electrical control Before starting the high pressure coolant system check to be sure no tools packing or other material have been left on the on or in the high pressure coolant system Before starting the high pressure coolant system read the start up procedures and insure the system is properly set up with all holes connected and the tank filled with the proper level of coolant After start up procedures have been reviewed start the conveyor and verify proper rotation of the coolant pumps Reverse polarity if the pumps are rotating in the wrong direction If the pumps are running in the wrong direction damage can be caused to the pump and due to inadequate operating effectively of the system tooling and or the work piece may be damaged AUGUST 2005 1 6 2 2 2 1 4 1 4 PUBLICATION 864510 0016 Page 38 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL AC SUPPLY CIRCUIT AMP LOAD FOR MICROFINE S CONVEYORS Your Powerstream High Pressure System is equipped with an AC motor to drive the high pressure pump The full load amp draw is based on the horse
33. nlet suction piping Determine cause of heat and correct the problem system f Air entrained in fluid piping system Purge air from piping 2 Drop in Volume f Aeration and turbulence in supply tank Determine cause of turbulence and correct problem or Pressure a Air leak in suction piping Seal air leak b Clogged suction line suction strainer or Clean clogged line strainer or filters tank filters c Suction line inlet above fluid level in Fill tank to proper level or extend suction line if it is tank too high h Foreign material in inlet or outlet valves Clean inlet and or outlet valves HydraCell only Loss of oil prime in cells because of low Add oil to proper level oil level HydraCell only j Ruptured diaphragm HydraCell only Replace diaghragm K Cavitation See 1 above 1 Warped manifold from overpressurized Replace manifold and review system operation System Repair system as required m Cracked suction hole Replace section casting or pump n O rings forced out of their grooves from Replace o rings and review system operation Repair overpressurization HydraCell only system as required 0 Empty supply tank Fill with clean coolant to proper level p Excessive aeration and turbulence in Review coolant flow from machine tool to the coolant supply tank tank Reduce or eliminate excessive turbulence q Worn regulator seat or plunger Replace regulator seat or plunger 2221
34. nsfer a volume of coolant via the HP circuits to the machine tool before the transfer pump is activated to move that volume of coolant back to the Powerstream system Then the transfer pump will move an amount ov coolant back to the clean holding tank During operation some coolant will be captive in the machine system This coolant amount varies with each machine type and pumbing arrangement Upon machine or HPC system shut down this captive coolant will drain back to the machine tank 6 Prepare the high pressure pump as necessary Gear Pumps it is imperative that the gear pump operate in the correct rotational direction and have an adequate supply of fluid See the detailed instructions in the Start Up section of this manual Balanced diaphragm piston pumps Hydra Cell Refer to the pump operation manual 7 Relief Valve not included on 200 psi units The relief valve is set at the factory for the maximum recommended system pressure The valve is adjustable for cases that require less than the maximum pressure UNDER NO CIRCUMSTANCES SHOULD THE RELIEF VALVE BE ADJUSTED TO PRODUCE A PRESSURE HIGHER THAN THE SYSTEM DESIGN PRESSURE SUCH ACTION MAY VOID THE SYSTEM WARRANTY CAUSE PREMATURE FAILURE AND OR PERSONNEL HAZARDS AUGUST 2005 1 6 024 4 2 2 PUBLICATION 864510 0016 Page 10 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL HIGH PRESSURE
35. ove contaminated oil as soon as discovered and replace it with clean oil This will help prevent corrosion of internal pump components PERIODICALLY Change the oil after the first 100 hours of operation and every 1000 operating hours thereafter To change the oil Disconnect or lock out the electrical power to the pump motor 2 Remove the access plate on the tank so there is room to hinge the pump motor to the horizontal position 3 Remove the four bolts that hold the pump base to the tank Hinge the pump motor to the horizontal position and support it in that position Place a pan under the pump oil drain Remove the drain plug 904 80 and fill plug 90A 78 from the pump housing The drain plug is magnetic clean any metal from the magnet on the plug CAUTION Do not turn the drive shaft while the oil reservoir is empty 6 When the oil has drained reinstall the drain plug 90A 80 Refill with the appropriate oil and install the fill plug 904 78 Tighten to 25 165 30 N m T Hinge the pump motor back to the vertical position Reinstall the four bolts that held the pump base to the tank and reinstall the access plate Restore the electrical power Follow the Initial Startup Procedures CAUTION Protect the pump from freezing Refer also the Shutdown Procedure SHUTDOWN PROCEDURE During Freezing Temperatures Disconnect the inlet and outlet piping from the pump Remove the drain plug 90A 53 at the
36. power of the AC motor as well as the input AC voltage The Powerstream High Pressure System may be supplied with an optional transfer pump equipped with an AC motor These motors will place an additional load on the AC power supply circuit The Powerstream High Pressure System motor control circuit is not separately fused The customer must provide a circuit breaker or a fused disconnect switch on the power supply to the conveyor may be necessary to change a circuit protection device on the incoming power supply line to accommodate the higher full load amp draw Refer to the following tables to determine the full load amp draw on the AC supply circuit AC CURRENT REQUIREMENTS FOR POWERSTREAM HIGH PRESSURE SYSTEM VOLTAGE PUMP TYPE MOTOR CURRENT AT RATED 3 PHASE HORSEPOWER FULL AMP LOAD 208 230 VAC High Pressure Pump 7 5 22 0 19 4 460 VAC High Pressure Pump 7 5 9 7 OPTIONAL MOTORS CURRENT REQUIREMENTS FOR POWERSTREAM HIGH PRESSURE SYSTEM VOLTAGE PUMP TYPE MOTOR CURRENT AT RATED 3 PHASE HORSEPOWER FULL AMP LOAD 208 230 VAC Chiller Fan 25 1 3 460 VAC Chiller Fan 25 65 208 230 VAC Chiller Pump 43 1 460 VAC Chiller Pump 43 6 208 230 Transfer Pump 15 3 460 VAC Transfer Pump 75 2 AUGUST 2005 LNS PUBLICATION NO 864510 0016
37. ragm by one edge and turn the pump shaft until the diaphragm pulls up This will expose machined cross holes in the plunger shaft behind the diaphragm To turn the pump over turn the motor shaft over by turning the motor fan The fan guard on the motor may have to be removed to allow you to turn the shaft Reattach the fan guard to the motor when done with maintenance NOTE Alternatively remove the coupler access plate and rotate the coupler by hand b Insert an Allen wrench through one of the cross holes in the plunger shaft to hold the diaphragm up The proper size tool is included in the Wanner A03 200 1101 Tool Kit Remove the screw 90 67 O ring 90A 68 and follower 904 69 in the center of the diaphragm Remove the diaphragm and inspect it carefully A ruptured diaphragm generally indicates a pumping system problem and replacing only the diaphragm will not solve the larger problem Inspect the diaphragm for the following e Half moon marks Usually caused by cavitation of the pump refer to Troubleshooting e Concentric circular marks Usually caused by cavitation of the pump refer to Troubleshooting Small puncture Usually caused by a sharp foreign object in the fluid or by an ice particle e Diaphragm pulled away from the center screw or from the cylinder casting or casting sides Usually caused by fluid being frozen in the pump or by over pressurization of the pump e Diaphragm becoming stiff and losi
38. re regulator or in the regulator bypass line Freezing Conditions Protect the pump from freezing See also the Maintenance Section All guards and safety covers have been installed All electrical wiring has been done correctly to electrical codes INITIAL START UP PROCEDURE HIGH PRESSURE PUMP Ensure an adequate unobstructed fluid supply to the pump as described above Jog power to the high pressure and transfer pump motors Observe that both motors turn in the direction of the arrows on the motor housings or fan guards Turn on power to the pump motor Listen for any erratic noise and look for unsteady flow AUGUST 2005 1 6 4 2 42 2 2 4 2 entran PUBLICATION 864510 0016 12 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL FILTER MAINTENANCE PROCEDURE SYSTEM DESCRIPTION The filter canister is integral to a holding tank no downstream plumbing and open to atmospheric pressure at its outlet As contamination collects in the filter element resistance to flow causes the pressure drop across the filter to increase The system incorporates a pressure switch to indicate when the filter requires service The pressure switch is set at the factory to approximately 15 psig This setting may be adjusted in the field to tailor operation to a specific procedure but the switch should always be set to activate at or below 20
39. s a more suitable HydraCell only pumped diaphragm material for the coolant being used d Cavitation See 1 on this chart e Pump running too fast Review motor specifications and changes if necessary f Broken piston return spring 50 Replace piston return spring g Excess pressure Inspect bypass relieving valve waterin or a Condensation Poo Reservoir HydraCell only b Ruptured diaphragm Replace diaghragm c Hydraulic cells not properly primed See priming procedures in this manual after diaphragm replacement Green pump a Diaphragm screw O ring 18 missing Replace damaged or missing o ring cracked f Cracked cylinder casting Replace damaged oylinder casting or pump AUGUST 2005 1 6 0 242 42 2 PUBLICATION 864510 0016 26 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION 6 Pump Flow Pulsations HydraCell only 7 Valve Wear HydraCell only 8 Loss of Oil HydraCell only 9 Premature Failure of Pump Valve Spring or Retainer HydraCell only a Foreign object lodged in pump valve Clean pump valve and repair if necessary b Loss of prime in hydraulic cells because of low oil level c Abrasives in the fluid Inspect filter elements to insure they are not damaged and are properly ins
40. s use at higher loads and temperatures 40W oil is recommended since it provides exceptional wear resistance and film thickness in extended high temperature applications However most machining operations do not require continuous high pressure coolant requirements OIL RECOMMENDATION PUMP MODEL D 10 OIL RESERVOIR CAPACITY 1 10 U S QUARTS 1 05 LITERS STANDARD DUTY APPLICATIONS 10W30 OIL CONTINUOUS DUTY APPLICATIONS 40W OIL COLD TEMPERATURE SEVERE DUTY 5W 30 SYNTHETIC OIL HIGH TEMPERATURE SEVERE DUTY 15W 50 SYNTHETIC OIL Standard Grade Synthetic Grade OIL CHARACTERISTICS 10W30 40W 5 30 15W50 Gravity API 60 F 31 1 28 7 30 4 30 2 Flash Point F 400 430 445 470 Fire Point F 440 470 N A N A Pour Point F 30 10 65 55 Viscosity SUS 100 F 360 811 265 556 SUS 210 F 63 85 60 90 Viscosity Index 148 107 165 170 AUGUST 2005 1 6 4 024242 4 2 2 2 2 1 ainan PUBLICATION 864510 0016 16 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL CAUTION If you are losing oil but don t see any external leakage or if the oil becomes discolored and contaminated one of the diaphragms 90A 70 may be damaged Refer to the Service Section Do no operate the pump with a damaged diaphragm CAUTION Do no leave contaminated oil in the pump housing or leave the housing empty Rem
41. sfer pump is working correctly Check to insure transfer pump is Insure that the filter bag s are not clogged If so operating and that filter bags are not troubleshoot pump or change bag filters clogged DAR es Check pressure switch to insure 2226 pressure switch if necessary or replace if it has proper setting and operation d The pump is mechanically blocked Remove the mechanical blockage of the pump Motor winding is defective Replace the motor Cable connection is loose or faulty Fasten or replace the cable connection 11 The high a The pump is running backwards Reverse the motor leads so that the belt is running in pressure pump will the correct direction not reach full pressure upon b Wrong voltage or phase is being Inspect pump motor nameplate to insure proper start up provided to the pump voltage and phase 12 Excess a Regulator pressure is not properly Reset regulator to proper operating pressure Pressure adjusted Required to Bynes Fluid at b Not enough fluid is being continuously Disassemble regulator inspect parts clean and Pressure bypassed replace any damaged parts or regulator Regulating Valve c Nozzles are worn Replace regulator nozzles 13 Fluid is a Regulator seals are worn Replace regulator seals Leaking from the Hole in the Regulator HydraC ell only 14 Pressure a Minimum bypass of 10 is not being Disassemble regulator inspect parts clean and Spikes main
42. specific applications The PowerStream ST system is a straight forward stand alone design which provides a high level of functionality with a low level of complexity AUGUST 2005 1 6 4 2 42 2 2 4 2 entran PUBLICATION 864510 0016 Page 6 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL Can STANDARD FEATURES Pressure up to 2000 psi at 5 gpm Flow up to 10 gpm at 1000 psi Other flow and pressure combinations available by request Simple control interface Accommodates from 1 to 8 independently controlled solenoid valves ister bag filter Open to built into tank No external plumbing downstream of filters Less agitation No timing issues with transfer pump starving HP pump Eliminates churning at transfer pump Readily available standard sized filter elements System built and serviced by LNS Simple installation Highly mobile Quick disconnect couplings JIC fittings and locking castors Easily retro fit to virtually any coolant system SIZE STAND ALONE UNIT Overall Size L 41 in 1040 mm W 26 in 660 61 1550 Nominal Volume 45 gal 170 AUGUST 2005 1 6 4 2 42 2 2 4 2 PUBLICATION 864510 0016 Page 7 POWERSTREAM ST HIGH P
43. t The flat side of the plunger should face the tool Screw the guide with the plunger into the valve plunger 90A 94 until tight Hold the stud with a wrench and tighten the nut against the plunger guide This will press fit the plunger onto the valve plunger Never reinstall used plungers 90A 71 NOTE Do not remove the plunger guide until the diaphragm is installed see below Install the diaphragm as outlined below then repeat the procedure steps 9a 9c for the other two plungers and diaphragms 10 Reinstall Diaphragms a b With the plunger guide tool still screwed into the valve plunger 90A 94 pull the valve plunger up until the cross holes in the valve plunger are exposed Insert a diaphragm Allen wrench from the Wanner Tool Kit or similar dowel type object through the holes to hold the plunger 90A 71 away from the cylinder casting and to keep the valve plunger from turning when the diaphragm is being installed AUGUST 2005 1 6 4 42 4 4 2 4 1 PUBLICATION 864510 0016 23 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL Place the diaphragm 90A 70 onto the plunger 90A 71 ridge side out Center the diaphragm follower 90A 69 on the diaphragm Place the O ring 90A 68 onto the follower screw 90A 67 Apply a small amount of Loctite 242 threadlocker to the threads of the follower screw Insert the follower screw w
44. t screw Using 1 8 inch Allen Hex wrench adjust clockwise to increase the set point and counterclockwise to lower the set point which is 15 PSIG 2 PSIG while applying this pressure and monitoring the switch s state 2 After verifying the set point re assemble the switch Wiring Code Leads DIN Black Common Green Normally closed Normally open AUGUST 2005 LNS esee nn entrent na tnna sena sinn sinn sme rnnt PUBLICATION NO 864510 0016 Page 14 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL LIQUID LEVEL SWITCHES INSTALLATION AND MAINTENANCE INSTALLATION Operation is stated in the tank dry position NC OPERATION Stainless Steel Floats Witness mark round circle down NO OPERATION Stainless Steel Floats Witness mark round circle up MAINTENANCE Maintenance should consist of inspection to see that the float is free to move and not coated with any substance which would change its weight or volume significantly If this occurs the float should be removed for cleaning This is easily accomplished without disturbing the installation In addition the stem may be wiped down to remove any build up Make sure float is replaced in the same orientation The only repair possible in the field is replacement of either the float or stem Dents or nicks on the float are usually of no consequence to operation AUGUST 2005 1 6 024 4 2 2
45. tained at pressure regulating replace damaged parts or regulator valve b Pressure regulating valve nozzles are Replace regulator nozzles worn c Pressure regulator pressure is not Reset regulator to proper operating pressure properly adjusted 15 The motor a Supply failure Connect the electricity supply does not run when started b Fuses are blown Replace fuses c Motor starter overload has tripped out Reactivate the motor protection d Main contacts in motor starter are not Replace contacts or magnetic coil making contact or the coil is faulty e Control circuit is defective Repair the control circuit f Motor is defective Replace the motor AUGUST 2005 1 6 4 2 42 2 eene PUBLICATION NO 864510 0016 Page 28 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL POWERSTREAM HIGH PRESSURE COOLANT SYSTEM MAINTENANCE SCHEDULE The following chart shows a suggested maintenance schedule for the conveyor to insure proper operation and longevity Daily Monthly Every 3 months Every 3 months Every 6 months Annually AUGUST 2005 LNS Check the filter housing to determine if bag filters are clogged Check transfer pump for proper operation excessive noise and coolant leaks Check the oil level and condition of the oil in the oil reservoir of the high pressure pump HydraCell Pump Systems Only Inspect Pressure Regulat
46. talled and seated in the filter housing d Valve incompatible with corrosives in the Change fluid if possible or replace valve with fluid compatible seals e Pump running too fast Review motor specifications and changes if necessary a External seepage Determine cause and correct b Rupture of diaphragm Replace diaphragm c Frozen pump d Diaphragm screw O ring 18 missing or Replace damaged diaphragm screw o ring cracked d Spring retainer material incompatible Change fluid if possible or replace spring retainer with with fluid being pumped compatible material e Excessive inlet pressure Check pressure relieving valve AUGUST 2005 1 86 2 2 2 2 4 02 29 1 41 4441 eaten sinn inn PUBLICATION NO 864510 0016 Page 27 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION 10 The high a The overload relay or fuse is tripped Reset the overload relay or replace the fuse Check to pressure insure the relay or fuse is properly sized Check to system will insure the system is wired correctly not start b Contacts in the motor starter overload Replace motor starter contacts are faulty c Check to insure no alarms are present If so trouble shoot cause of the alarm Check reservoir coolant level to Pre fill reservoir to the correct coolant level and insure insure the low level alarm is not on the tran
47. the valve seat for wear and replace it if necessary AUGUST 2005 CNS 4 esses 2 22 4 41 2 senes PUBLICATION NO 864510 0016 Page 18 POWERSTREAM ST HIGH PRESSURE COOLANT SYSTEM PARTS AND SERVICE MANUAL e Reinstall the valve assemblies e Clean the valve ports and shoulders with emery cloth and lubricate them with lubricating gel or petroleum jelly e Install the O ring 90 60 on the valve seat 90A 61 e Inlet 3 center valves Insert the spring retainer 15 into the valve plate then insert the spring valve and valve seat 90 61 90 62 90A 63 If the pump has plastic spring retainers install a flat O ring 90A 64 between the retainer and seat On abrasive duty pumps install a dampening washer 904 88 on top of the seat e Outlet 3 outer valves Insert the valve seat valve and spring then the retainer If the pump has metal spring retainers in the outlet valves position them so a leg does not point toward the center of the pump refer to the illustration On abrasive duty pumps install a dampening washer 90A 88 into the valve plate before installing the other parts 5 Inspect and Replace Diaphragms 90A 70 If it is necessary to service the diaphragms use a 5 mm Allen wrench to remove the two Allen head bolts 90 73 that secure the valve plate 90A 66 to the cylinder housing 90A 74 Inspect the valve plate as you did the manifold a Lift the diaph
48. the pressure differential across the filter to increase The system incorporates a pressure switch to indicate that the filter requires service The filter canister is integral to a holding tank no downstream plumbing The large holding tank aids in heat dissipation A high pressure pump draws filtered coolant from the holding tank and delivers it to the machine via a bank of independently controlled solenoid valves The coolant supply to the high pressure pump is supplied by an open system i e it is not pressurized or fixed flow rate The transfer pump is controlled by a hi lo level switch to maintain the proper volume of filtered coolant in the holding tank Consequently the transfer pump flow rate is somewhat independent of the high pressure pump flow rate That means the transfer pump does not have to be synchronized with the high pressure pump This provides significant advantage over in line filters or closed systems in which one is forced to choose between lag time and transfer pump churning dead heading The combination of a substantial holding tank and the elimination of transfer pump dead heading reduces heat build up and power consumption The holding tank also incorporates a level switch to provide an alarm signal if the volume of filtered coolant in the tank drops to an unacceptable level This could indicate a failure of the transfer pump or blockage of the canister filter system Additional sensors may be integrated for
49. ve the two bolts item 38 shown on page 33 exploded view that are installed through the back of the pump housing b Use a 10 mm hex Allen wrench to remove the pump centerbolt 90A 51 and its washer 90 52 in the center of the manifold CAUTION Do not turn the pump drive shaft while the manifold and valve plate are off the pump except when removing diaphragms or repriming the hydraulic cells c Remove the manifold 90A 56 The valve plate 90A 66 will remain on the cylinder housing 90A 74 d Inspect the manifold for warping or wear around the inlet and outlet ports If wear is excessive replace the manifold or return it to Wanner Engineering for resurfacing To check if the manifold is warped remove the O rings and place a straightedge across it A warped manifold should be replaced 4 Inspect Valves 90A 60 90A 65 The three inlet and three outlet valve assemblies are identical but face in opposite directions Inspect each valve as follows Check the spring retainer 90A 65 and replace if worn Check the valve spring 90A 63 If it is shorter than a new spring replace it don t just stretch the old spring Check the valve poppet 90A 62 If worn excessively replace it NOTE If your pump has plastic spring retainers there is a tetra seal flat O ring 90 64 between the retainer 90A 65 and valve seat 90A 61 Remove the valve seat 90A 61 A seat remover is included in the Wanner Tool Kit Inspect
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