Bazell Microseparator User manual

Microseparator™ Systems
Transport, Installation and
Initial Startup
Manufactured by Bazell Technologies Corporation
5066 Commercial Circle
Concord, CA. 94520
Tel: [phone] Fax: (925) 603-
0901
Email: [e-mail] Web: www.bazell.com
Sold exclusively by SatisLoh
Confidential to Satisloh and purchasers of this equipment. © 2008 Bazell Technologies. All rights reserved.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 2/78
1Preface............................................................................................................. 8
2System Versions............................................................................................... 9
3Electrical Documentation................................................................................. 9
4Spare Parts and Service ................................................................................... 9
5Symbols ........................................................................................................... 9
6Operator Safety.............................................................................................. 10
7System Capacity Data .................................................................................... 11
7.1 Overview of System Component Combinations................................... 12
7.1.1 Surfacing Operations............................................................... 12
8Delivery.......................................................................................................... 12
8.1 General............................................................................................... 12
8.2 Dimensions of the Machines ............................................................... 13
9Transport....................................................................................................... 14
9.1 Overview ............................................................................................ 14
9.2General Instructions for Transport ..................................................... 14
9.3 Transport by Crane ............................................................................. 14
9.4 Transport with a Fork Lift or Lift Truck ............................................... 15
10 Transporting the Components........................................................................ 16
10.1 Microseparator™ CF65 G..................................................................... 16
10.2 Microseparator™ HC – CF105 G .......................................................... 17
10.2.1 Mounting the Centrifuge to the Stand ................................... 18
10.3 Pump Station/Pump Station Low Profile ............................................ 20
10.4 Overview ............................................................................................ 21
10.4.1 Floor Requirements............................................................... 21
10.4.2 Ambient Conditions ............................................................... 21
10.4.3 Electromagnetic Influence..................................................... 21
10.4.4 Utility Connections ................................................................ 21

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 3/78
10.4.5 Piping Installation Diagrams................................................. 21
10.4.6 Space Requirements.............................................................. 22
10.5 Plumbing connections - Microseparator™........................................... 23
10.6 Electrical Connections to Centrifuge and Main Tank........................... 24
10.7 Compressed Air Connection................................................................ 25
10.7.1 Microseparator™ Standard System – CF65 ............................ 25
10.7.2 Microseparator™ HC System – CF105.................................... 26
11 System General Arrangement Drawings & Utility Requirements.................... 27
11.1 Microseparator™ Coolant System - Standard...................................... 27
11.2 Microseparator™ Coolant System - HC................................................ 28
11.3 Chip Separator with Tank, Short – 6SIGD001..................................... 29
11.3.1 Chip Separator with Tank Setup Options............................... 30
11.4 Chip Separator with Tank – Tall Drawing 6SATD001 .......................... 31
11.5 Pump Station Drawing 6SATU001....................................................... 32
11.6 Pump Station Drawing 6SATF001....................................................... 33
11.7 Chip Separator - Single Assembly Drawing 6SATT001 ........................ 34
11.8 Chip Separator Dual Assembly Drawing 6SATK001............................. 35
11.9 Chip Separator Triple Assembly Drawing 6SATV001........................... 36
12 Microseparator™ Initial Start Up................................................................... 37
13 Control Panel Operation................................................................................. 39
14 Coolant Makeup System Operation ................................................................ 39
15 Cleaning Frequency Calculation ..................................................................... 39
16 Coolant Makeup System................................................................................. 40
17 Flow Rate Information................................................................................... 42
17.1 Checking Flow Rate ............................................................................ 42
18 Pump Station/Pump Station Low Profile........................................................ 44
18.1 Principles of Operation ....................................................................... 44

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 4/78
18.2 Limits of Operation............................................................................. 44
18.3 Technical Data.................................................................................... 45
Machine Components..................................................................................... 47
18.3.1 Work Space Requirements .................................................... 49
18.3.2 Floor Requirements............................................................... 49
18.3.3 Electromagnetic Influence..................................................... 49
18.3.4 Dimensions of the Machine.................................................... 50
18.4Connecting the Pump Station ............................................................. 52
18.4.1 Connection Safety Instructions ............................................. 52
18.4.2 Note about connection dimensions........................................ 52
18.5 Description of Connections................................................................. 53
18.6 Electrical Power.................................................................................. 54
18.6.1 Connection Point at the Machine........................................... 54
18.7 Compressed Air................................................................................... 54
18.7.1 Connection Point at the Machine........................................... 54
18.8 Coolant Supply to the Machine ........................................................... 54
18.8.1 Connection Point at the Machine........................................... 54
18.9 Clean Coolant Supply to Generator..................................................... 54
18.9.1 Connection Point at the Machine........................................... 55
18.10 Dirty Coolant Drain from Generator ................................................ 55
18.10.1 Connection Point at the Machine......................................... 55
18.11 Dirty Coolant Return to Coolant System.......................................... 55
18.12 Connection Procedure..................................................................... 55
18.12.1 Connecting the Compressed Air Supply............................... 55
18.12.2 Connecting the Overhead Coolant Pipelines........................ 55
18.12.3 Connecting the Coolant Supply Line.................................... 56
18.12.4 Connecting the Coolant Drain Line ...................................... 56

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 5/78
18.13 Electrical Connection ...................................................................... 56
18.13.1 Connecting Electrical Power............................................... 57
18.13.2 Pump Station Operation...................................................... 57
19 Chip Separator with Transfer Tank – Tall (6SATD001)................................... 58
19.1 Principles of Operation ....................................................................... 58
19.2 Limits of Operation............................................................................. 58
19.3 Machine Components.......................................................................... 59
19.4 Installation Requirements.................................................................. 59
19.4.1 Work Space Requirements .................................................... 59
19.4.2 Floor Requirements............................................................... 59
19.4.3 Electromagnetic Influence..................................................... 60
19.5 Dimensions of the Machine................................................................. 60
19.6 Connecting the Chip Separator with Tank – Tall................................. 61
19.6.1 Connection Safety Instructions ............................................. 61
19.6.2 Description of Connections.................................................... 61
19.7 Electrical Power.................................................................................. 62
19.7.1 Connection Point at the Machine........................................... 62
19.8 Compressed Air................................................................................... 62
19.8.1 Connection Point at the Machine........................................... 62
19.9 Coolant Pipeline Connections.............................................................. 62
19.9.1 Dirty Coolant Drain from the Generator................................. 62
19.10 Retrieval of Deblocked Lenses ........................................................ 62
20 Chip Separator with Tank – Short 6SIGD001 ................................................. 63
20.1 Principles of Operation ....................................................................... 63
20.2 Limits of Operation............................................................................. 63
20.3 Machine Components.......................................................................... 64
20.4 Installation Requirements.................................................................. 64

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 6/78
20.4.1 Work Space Requirements .................................................... 64
20.5 Dimensions of the Machine................................................................. 65
20.6 Connecting the Chip Separator with Tank – Short .............................. 66
20.6.1 Connection Safety Instructions ............................................. 66
20.7 Description of Connections................................................................. 66
20.8 Electrical Power.................................................................................. 67
20.8.1 Connection Point at the Machine........................................... 67
20.9 Compressed Air................................................................................... 67
20.9.1 Connection Point at the Machine........................................... 67
20.10 Coolant Pipeline Connections.......................................................... 67
20.10.1 Dirty Coolant Drain from the Generator............................... 67
20.11 Retrieval of Deblocked Lenses ........................................................ 67
21 Chip Separator Assemblies (Without Pumping Tank)..................................... 68
21.1 Principles of Operation ....................................................................... 68
21.2 Limits of Operation............................................................................. 68
21.3 Machine Components.......................................................................... 69
21.4 Installation Requirements.................................................................. 70
21.4.1 Work Space Requirements .................................................... 70
21.4.2 Floor Requirements............................................................... 70
21.4.3 Electromagnetic Influence..................................................... 70
21.4.4 Dimensions of the Machine(s)............................................... 71
21.5 Connecting the Chip Separator Assemblies......................................... 72
21.5.1 Connection Safety Instructions ............................................. 72
21.6 Description of Connections................................................................. 72
21.7 Electrical Power.................................................................................. 73
21.7.1 Connection Point at the Machines ......................................... 73
21.8 Compressed Air................................................................................... 73

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 7/78
21.8.1 Connection Point at the Machines ......................................... 73
21.9 Coolant Pipeline Connections.............................................................. 73
21.9.1 Dirty Coolant Drain from the Chip Separators ....................... 73
22 Microseparator™ Daily Operation................................................................... 74
22.1 Preliminary Checks ............................................................................. 74
22.2 Startup................................................................................................ 74
22.3 Shut Down.......................................................................................... 75
22.4 Screen Box Operation and Service...................................................... 75
22.5 Benefits .............................................................................................. 76
22.6 Defoamer............................................................................................ 76
23 Table of Figures ............................................................................................. 77

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 8/78
1Preface
Dear Customer
This Transport and Installation manual describes all steps you must take
to transport, install, and perform initial startup on your Microseparator™
coolant system components.
Please read this manual carefully and also observe the instructions on the
following page.
With the aid of this manual, you can perform the following steps:
Prepare for the installation of the equipment
.
Transport the machinery safely
Install the machine safely and easily.
Connect the machines correctly
Perform an initial startup
Always keep this manual in the immediate vicinity of the
machine so that it is available when needed.
In addition to this manual, the complete documentation package also
consists of the following:
Project specific “Piping Installation” drawings.
Project specific Electrical Prints
Service and Maintenance Manual.
Operators Manual.
We are confident of your success with our products and we ask that you
contact us whenever we may be of service.
Bazell Technologies Corporation
Microseparator™ Product Design Team

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 9/78
2System Versions
The Microseparator™ coolant systems for ophthalmic fluid processing is
manufactured in variants for both CE and non-CE markets. Consult your
purchase documentation regarding the specification of your system.
Where variations in specification exist, they are specified within the body
of this document.
3Electrical Documentation
Electrical wiring diagrams are provided separately from this document. If
you require additional copies, please contact Bazell Technologies by
telephone at [phone] or [phone], or by email
[e-mail] . Please provide the system serial number when
requesting electrical documentation.1
4Spare Parts and Service
Please direct to either your local Satisloh contact or to Bazell
Technologies directly.
5Symbols
The following signs indicate safety or general instructions throughout the
text.
Imminent danger which can cause loss of life,
serious injuries or extensive damage.
Potentially dangerous situation which may cause
loss of life, serious injuries, or damage.
Potentially dangerous situation which may cause
injuries, or damage.
Attention!
Caution!
Warning!

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 10/78
Danger, high voltage. Only qualified personnel
should service or access this portion of the
equipment.
Application instructions and other useful or
important information.
6Operator Safety
All personnel responsible for operating the Microseparator™ should be
required to read these safety and cleaning procedures prior to operation.
Remember that centrifuges incorporate rotating components that should
be treated with the same caution as other rotating devices. Important
safety devices are built into each Microseparator™. Please carefully
observe the following safety notices.
1. Only qualified electricians or duly trained personnel under the
instruction and supervision of a qualified electrician may do any work
on electrical equipment and systems.
2. Always disconnect and lock out the power source before working on
or near the Microseparator™ rotor or drive motor.
3. Motor controls should conform to instructions given in the installation
manual provided with the Microseparator™. Motor controllers must
be securely and adequately grounded according to NEC and local
codes of the specific area.
4. Do not operate the Microseparator™ if severe vibration is observed.
Generally, incomplete rotor cleaning causes vibration. Do not operate
the Microseparator™ without a properly operating vibration switch.
5. The Chip Separator must be operated with the cover on and a
properly working pneumatic limit switch.
6. Do not place hands or feet in the Chip Separator, to avoid being
caught by the pneumatic arm.
7. Practice good housekeeping and maintain a Safety Training and
Safety Equipment Operation/Maintenance Program for all employees.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 11/78
7System Capacity Data
Microseparator™ Coolant System
Maximum connected generators: 2
Lens production capacity/hr. (total) ¹240 lenses/hr ¹
CR39 capacity ¹115 lenses/hr ¹
Coolant tank operating volume 150 gallons (568 litres)
Maximum coolant pressure 30 psi (2 bar)
Maximum coolant flow 45 GPM (170 lpm)
Centrifuge capacity 1.0 gal (3.7 litres)/ cycle
Microseparator™ HC Coolant System
Maximum connected generators 3
Lens production capacity/hr.(total) ²360 lenses/hr ²
CR39 capacity ²190 lenses/hr ²
Coolant tank operating volume 150 gallons (568 litres)
Maximum coolant pressure 37 psi (2.5 bar)
Maximum coolant flow 45 GPM (170 lpm)
Centrifuge capacity 2.1 gal (7.9 litres)/ cycle
All Chip Separators With Pump Tank
Maximum connected generators 1 ea.
Maximum coolant flow 25 GPM (95 lpm)
Chip Separators Without Pump Tank
Maximum connected generators 1 ea.
Note: This product requires one Pump Station or Pump Station Low
Profile per Chip Separator.
Pump Station/ Pump Station Low Profile
Maximum connected generators 1 ea.
Maximum coolant flow 25 GPM (95 lpm)
Note: This product requires one Chip Separator per Pump Station
Notes:
¹ 240 lenses per hour assumes a mixture of lens materials with CR39
production not exceeding 115 lenses per hour total for the system. For
two generator installations with values higher than above, the
Microseparator™ HC system should be utilized for optimum performance.
² 360 lenses per hour assumes a mixture of lens materials with CR39
production not exceeding 190 lenses/hr. total for the system.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 12/78
7.1 Overview of System Component Combinations
7.1.1 Surfacing Operations
Two primary options are available for system component selection and
integration:
•Separation of milling and turning debris at the generator and
small fines and coolant pumped overhead directly into the main
coolant system tank. This method requires Chip Separators with
Transfer Tank connected directly to the generator outlet. The
version (short or tall) should be selected as a function of the
generator coolant discharge pipe elevation. One Chip Separator
with Transfer Tank is required per generator.
•Separation of milling and turning debris remotely near the main
coolant tank. This method requires use of the Pump Station to
move all lens debris and coolant through overhead pipelines into
the mating Chip Separator. One Pump Station is required per
generator. One Chip Separator per Pump Station is required.
Chip Separators are available in configurations of one, two, or
three units.
8Delivery
8.1 General
Please note the dimensions of the components below and plan
accordingly regarding transport to the site of installation.
General
1. If you are responsible for loading or unloading,
please observe all instructions for transporting
the machinery (see section 9: Transport).
2. Immediately notify the carrier and Satisloh in
writing of any damage and other shortcomings,
e.g. missing items.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 13/78
8.2 Dimensions of the Machines
Width
[mm]
Height
[mm]
Depth
[mm]
Gross Wt.
[kg]
Centrifuge
On Pallet
1200
2108
1200
430
In Crate
1200
2260
1200
475
Centrifuge HC
On Pallet
915
1625
1829
600
In Crate
915
1778
1829
650
Coolant Tank
On Pallet
1219
1219
1930
390
In Crate
1219
1320
1930
434
Control Panel
On Pallet
1219
609
2260
210
In Crate
1219
813
2260
244
Chip Separators
With Tank Short
On Pallet
1067
864
1372
225
In Crate
1067
1016
1372
255
With Tank Tall
On Pallet
609
1250
1422
160
In Crate
609
1498
1422
189
Without Tank
Single
On Pallet
762
1250
762
In Crate
762
1524
762
156
Double
On Pallet
1524
1250
1524
In Crate
1524
1524
1524
281
Triple
On Pallet
2286
1250
1524
315
In Crate
2286
1524
1524
364
Figure 1 - Weights and Dimensions

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 14/78
9Transport
9.1 Overview
9.2 General Instructions for Transport
•Neither Satisloh nor Bazell Technologies accept
any liability whatsoever for any damage caused
by improper transport.
•The Control Panel contains sensitive
components. Avoid shock and vibrations during
transport.
Safety Instructions for Transport of the Machines
•Caution, the centrifuge is relatively top-heavy.
Risk of Tipping Over! Use caution. Attach
safety straps to the upper eyebolts on the
centrifuge and secure on the forklift mast before
lifting.
9.3 Transport by Crane
•If unavoidable, the machine can also be
transported by crane.
•Lift using appropriate straps attached to the
machine eye bolts as shown in the photo above.
•Use only suitable technically satisfactory lifting
equipment with an adequate load bearing
capacity.
•Stay away from the danger area below
suspended loads.
•Only allow experienced personnel to secure the
loads and direct the crane driver. This person
must stay in the visual range of and in verbal
communication with the driver.
•Make sure that nobody is within range of the
fork lift or the load.
Attention!
Warning!
Warning!

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 15/78
9.4 Transport with a Fork Lift or Lift Truck
•The forklift truck driver must be licensed.
•Take suitable measures to prevent the machines
from slipping on the forks (e.g. place the
machines on rubber mats).
•The screws with which the machine is fastened
to the pallet must not be loosened during
transport. Remove the packaging materials from
the machines (foil or wood).
•Position the forklift tangs between the skids on
the pallets.
•Slowly lift the pallet and carefully transport the
machine to the installation site.
Warning!

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 16/78
10 Transporting the Components
10.1 Microseparator™ CF65 G
Figure 2 - Lifting CF65G
Position forks beneath the pallet for transport to the installation site.
Remove nuts and washers securing the centrifuge to the pallet and lift
the centrifuge by placing the tangs beneath the supporting frame as
shown.
Figure 3 - Lifting CF65G
Note: The mounting
stand must be lagged
to the floor in the
final installed
position using
appropriate concrete
anchor bolts.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 17/78
10.2 Microseparator™ HC – CF105 G
Figure 4 - Lifting CF105 G
Position forks beneath the pallet for transport to the installation site or to
the point where it will be mounted to the support stand.
Figure 5 - Lifting CF105 G
Alternatively, place forks inside the pockets of the transport frame as
shown at the red arrows above.
Note: The transport frame is not used when mounting the centrifuge to
the supporting framework. If a tall, custom stand is utilized, this
transport frame can be used and allows easy lifting of the centrifuge from
a higher elevation.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 18/78
10.2.1 Mounting the Centrifuge to the Stand
Note: Before mounting the centrifuge to the stand, decide which
direction the sludge cart beneath will be removed in the final installed
position. The mounting stand can be rotated 180º with respect to the
centrifuge.
Figure 6 - Mounting CF105 G to Stand
Using suitable lifting straps attached as shown in the photo above, lift the
centrifuge from the shipping frame after removal of the bolts and
washers. Align the vibration isolating bolts to the mounting stand paying
attention to the direction of removal of the sludge cart beneath. Once
securely bolted to the stand, the entire assembly can be lifted by placing
fork tangs beneath the horizontal framework of the stand.
NOTE: Centrifuge fluid outlet connections MUST face the tank.
Figure 7 - Mounting CF105 G to Stand
Note: The mounting
stand must be lagged to
the floor in the final
installed position using
appropriate concrete
anchor bolts.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 19/78
Lifting the Main Tank Assembly
Figure 8 - Lifting Main Tank Assy
After removing the surrounding crating material and packaging, lift the
tank assembly as shown. Block with wood to allow the forklift tangs to
pass fully under the tank assembly.
Figure 9 - Lifting Main Tank Assy
Lift the entire assembly and transport to the installation point.

Microseparator™ Coolant Systems Transport, Installation, & Initial Startup
M000005_A - V Twin Ultra Transport & Installation 5.2-EN TM 20/78
10.3 Pump Station/Pump Station Low Profile
When removing the Pump Station or Pump Station Low Profile from the
pallet, ensure that the fork tangs pass fully beneath the assembly as
shown in the photo below. Lift only from the side of the assembly.
Damage can result to the interior section of the Pump Station if forklift
tangs are not positioned as shown.
Pump Station Low Profiles are often shipped with 2 on a pallet. If this is
the case, be sure to remove any wood pieces running through both units
before attempting to lift the Pump Station Low Profile.
Figure 10 - Lifting Pump Station