Fervi P018/230V User manual

USE AND
MAINTENANCE MANUAL
Kit di refrigerazione per macchine utensili
Art. P018/230V e P018/400V
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
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PREFACE
Please ens
ure you have read this manual before operation
TRANSLATION OF THE ORIGINAL INSTRUCTIONS
It is compulsory to read this instruction manual before starting operation. The guarantee that
the machine will function and perform properly is strictly dependent upo
n the application of all
the instructions contained in this manual.
Operator Qualifications
The workers responsible for the use of this machine must have all the necessary
information and instruction and should be given adequate training in relation
to safety
regarding:
a)
Conditions of use for the equipment;
b)
Foreseeable abnormal situations, pursuant to Article 73 of Legislative Decree
81/08.
We guarantee the Machine complies with the specifications and technical instructions
described in the Manual
on the date of issuance and listed herein; On the other hand,
the machine may also be subject to important technical changes in the future, without
the manual being updated.
Therefore, contact FERVI for information about modifications that may have been
im
plemented.
REV. 1
Ottobre
2013
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CONTENTS
1
INTRODUCTION
................................
................................
........................
4
1.1
Preface
................................
................................
................................
..........................
5
2
SAFETY WARNINGS
................................
................................
..................
6
2.1
General safety rules for machine equipment
................................
................................
.
6
2.2
Special safety rules for cooling systems
................................
................................
........
7
2.3
Safety rules for electrical machine
-
tools
................................
................................
.......
8
2.4
Technical Support
Errore. Il segnalibro non è definito.
................................
..................
8
2.5
Other provisions
Errore. Il segnalibro non è definito.
................................
....................
8
3
DESCRIPTION AND INTE
NDED USE
................................
...........................
9
3.1
Technical specifications
................................
................................
..............................
10
3.2
Identification
................................
................................
................................
..............
10
3.3
Pictograms
................................
................................
................................
..................
11
4
IMPROPER USES AND PR
ECAUTIONS
................................
......................
12
5
INSTALLATION AND OPE
RATION
................................
............................
13
6
OPERATION
................................
................................
............................
17
7
MAINTENANCE AND CLEA
NING
................................
...............................
18
7.1
Replacing the coolant liquid
................................
................................
........................
18
7.2
Cleaning the electric pump
................................
................................
..........................
18
7.3
Disposal
................................
................................
................................
......................
19
8
REPLACEMENT PARTS
................................
................................
.............
20
9
ELECTRICAL SYSTEM
................................
................................
...............
22
9.1
Art. P018/230V
................................
................................
................................
...........
22
9.2
Art. P018/400V
................................
................................
................................
...........
22
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1
INTRODUCTION
This manual is considered an inte
gral part of the machine it was attached to at the time of
purchase.
The manufacturer holds all ownership to material and intellectual property of this manual;
any disclosure or copying, even partial, of this publication without prior written consent is
f
orbidden.
The purpose of this manual is to provide the knowledge necessary for the use and
maintenance of the machine
Kit di refrigerazione per macchine utensili
Art.
P018/230V e P018/400V
and create a sense of responsibility and an understanding of the
capabilities and limitations of the means entrusted to the operator.
As the machine is entrusted to experienced and skilled operators, the following machine must
be perfectly known by the
operator if you want it to be used safely and effectively.
Operators must be properly trained and prepared, so make sure that this manual is read and
consulted by the staff responsible for commissioning, operation and maintenance of the
Kit di
refrigerazione per macchi
ne utensili
.
This is to make all operations the safest and most
effective possible for those who carry out these tasks.
Therefore, it is imperative to strictly comply with the requirements in this manual, a
necessary c
ondition for safe and satisfactory operation of the machine.
Before starting operation, installation and use of the
Kit di refrigerazione per macchine
utensili
, authorized staff must therefore:

read this technical document carefull
y;

know which protections and safety devices are available on the machines, their location
and how they work.
The buyer is responsible for ensuring that users are properly trained, that they are aware of
all the information and instructions in this docume
nt and that they are aware of the potential
risks of operating the
Kit di refrigerazione per macchine utensili
.
The manufacturer waives any and all responsibility for damage to people and/or
things caused by non
-
observance of the
instructions in this manual.
The
Kit di refrigerazione per macchine utensili
was designed and built with mechanical
guards and safety devices designed to protect the operator/user from possible injury. It is
strictly forbidden to
modify or remove guards, safety devices and caution labels. If you do so
temporarily (for example, for the purposes of cleaning or repair), make sure that no one can
use the machine.
Modifications to the machines carried out by the user must be considere
d their sole
responsibility, therefore the manufacturer declines all responsibility for any damage
caused to persons and/or property resulting from maintenance performed by
unqualified personnel and in a manner different from the operating procedures
shown
below.
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G
RAPHIC REPRESENTATIO
N OF SAFETY
,
OPERATIONAL AND RISK
WARNINGS
The following boxes are designed to attract the attention of the reader / user for the
proper
and
safe
use of the machine:
Pay Attention
This highlights behavioural rules to prev
ent damage to the machine and/or the occurrence of
dangerous situations.
Residual Risks
This highlights the presence of dangers that cause residual risks to which the operator must
pay attention in order to avoid injury or damage to property.
1.1
Preface
For safe and easy operation of the
Kit di refrigerazione per macchine utensili
, this
manual must be read carefully in order to acquire the necessary knowledge. In other words,
durability and performance are strictly dependent on h
ow it is used.
Even if already familiar with the
Kit di refrigerazione per macchine utensili
, it is
necessary to follow the instructions contained herein, in addition to the general precautions to
be observed while working.

Acquire
full knowledge of the machine.
Read this manual carefully to understand: operation, safety devices and all necessary
precautions. All this is to allow safe use of the equipment.

Wear appropriate clothing for the job.
The operator must wear appropriate clo
thing to prevent the occurrence of unforeseen
accidents.

Maintain the machine with care.
Using the Machine
The machine must only be used by qualified personnel trained to use the machine by
authorized personnel.
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2
SAFETY WARNINGS
2.1
General safety rules
for machine equipment
Risks associated with using the machine
DO NOT underestimate the risks associated with using the machine and concentrate on the
work in progress.
Risks associated with using the machine
Despite the implementation of all the s
afety devices for safe use of the machine, it is
necessary to take note of all the requirements for the prevention of accidents reported in
various parts of this manual.
Risks related to Using the Machine
Every person who is responsible for the use a
nd maintenance of the machine should have first
read the instruction manual, particularly the chapter on safety information.
It is recommended that the plant safety manager get written confirmation of the above.
Risks associated with using the machine

During all work phases with the machine, you should proceed with great caution in
order to avoid damage to persons, to the property or to the machine itself.

Please only use the machine for its envisaged uses.

Don't tamper with the safety devices equippin
g the machine.
Risks associated with using the machine
Before starting any work on the machine, the operator must wear the appropriate personal
protective equipment (PPE) such as gloves and eye protection.
1.
Always check the efficiency and integrity o
f the machine.
2.
Before connecting the machine to the mains make sure that the switch is in the rest
position.
3.
Do not start the machine in an enclosed or poorly ventilated area, or in the presence of
a flammable and/or explosive atmosphere. Do not use the ma
chine in damp and/or wet
locations, or those exposed to rain or humidity.
4.
Avoid starting accidentally.
5.
Before starting the machine, get used to ensuring that no remaining maintenance and
service keys are inserted.
6.
Keep the workplace tidy and free from obst
ruction; disorder causes accidents.
7.
Make sure that your work environment is forbidden to children, strangers and animals.
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8.
Do not perform tasks on the machine other than those for which it was designed. Only
use the machine in the manner in which it was int
ended, as described in this instruction
manual.
9.
Work without disturbances.
10.
Work areas must be well lit.
11.
Always wear eye protection and protective gloves while working. Ù
12.
Wear appropriate clothing. Loose clothing, dangling jewellery, long hair, etc.., can g
et
caught in the moving parts, causing irreparable injury.
13.
Replace worn and/or damaged parts, check that the guards and protection devices work
properly before operating. If necessary, have the machine checked by the service
support personnel. Use only ori
ginal spare parts.
14.
Cut the mains voltage supply of the machine when:

the machine is not being operated;

it is left unattended;

performing maintenance or registration, because the machine does not work
properly;

the power cable is damaged;

the tool is repla
ced;

it is being moved or transported;

cleaning.
15.
Do not use the machine in areas with a risk of fire and/or explosion.
16.
It is recommended that users of this publication, for maintenance and repair, have a
basic knowledge of the mechanical principles and pro
cedures inherent in repair
technique.
17.
The company safety officer is required to make sure that machine operators
have read and understood this manual in its entirety.
18.
The company safety manager is responsible for monitoring the company's risk
status accord
ing to Legislative Decree no. 81/08.
2.2
Special safety rules for cooling systems
1.
Attach the coolant outlet nozzle and the control panel in a stable manner, using the
appropriate fastening holes and the bolts and screws provided.
2.
Always place the tank on a fl
at surface, in a stable position.
3.
The electrical connection should be carried out by qualified experienced personnel.
4.
Connect the yellow
-
green protective conductor to the equipotential circuit of the
machine
-
tool on which the coolant pump is to be installe
d.
5.
Check the correct operation of the emergency button and all the coolant pump controls
6.
Check the correct assembly of the pump before starting operation
7.
Check the integrity of the wires before installing the accessory.
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2.3
Safety rules for electrical machine
-
tools
Risks associated with using the machine
1.
Do not modify the electrical system in any way. Any attempt in this regard may
jeopardize the operation of electrical devices, thus causing malfunction or accident.
2.
Work carried out in the electrical syste
m of the machine must, therefore, be carried out
only by qualified and authorized personnel.
3.
If one hears unusual noises, or feels something strange, immediately stop the machine.
Then carry out an inspection and, if necessary, perform any repairs as requi
red.
1.
The supply voltage must correspond to that stated on the label and in the technical
specifications.
2.
It is necessary to use a device for the automatic interruption of the power supply in
case of failure, which is to be coordinated with the machine's
electrical system. For
more detailed information, contact a trusted electrician.
3.
The mains power outlet should be bipolar grounded (10/16 A, 250 V), extension cables
must have sections that are the same or greater than the sections of the power cable
of th
e machine.
4.
Make sure that the power cord does not come into contact with hot objects, wet or
oiled surfaces, and/or sharp edges.
5.
The power cord should be checked regularly and before each use to check for signs of
damage or wear. If these are not in good c
ondition, replace the cable.
6.
Do not use the power cord to lift the machine or to remove the plug from the socket.
2.4
Technical Support
For any problems or concerns, please contact, without hesitation the Technical Support
Department of your dealer, who has co
mpetent and specialised staff, specific equipment and
spare parts.
2.5
Other provisions
I
T IS FORBIDDEN TO TA
MPER WITH SAFETY DEV
ICES
Check the presence and integrity of protections and the proper functioning of safety devices
before starting operation.
If a
ny defect is encountered do not use the machine!
It is absolutely forbidden, therefore, to modify or remove the guards, safety
devices, labels and information plates.
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3
DESCRIPTION AND INTE
NDED USE
The
coolant pump Art. P018/230V and Art. P018/400V
is an a
ccessory that can be
installed on certain types of machine
-
tools, provided with metal cutting elements (drills,
lathes, band saws for metal etc.), to discharge a jet of coolant liquid onto the cutting tool, in
order to reduce the operating temperature and
the friction with the material being processed,
reducing the cutting time and improving the final quality of the machining.
1
Coolant tank
4
Coolant outlet nozzle
2
Electric pump
5
Coolant tank lid
3
Control switch
6
Bolt
s and screws
1
2
3
4
5
6
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3.1
Technical specifications
Model
Art. P018/230V
Art. P018/400V
Nominal voltage
230 V / 50 Hz
400 V / 50 Hz
Nominal current
0.24 A
0.23 A
Power
40 W
40 W
Rotation speed
2800 (r/min)
2800 (r/min)
Isolation class
E
E
Protection class
IP 4
4
IP 44
Capacity
22 l/min.
22 l/min.
Head
3 m
3 m
3.2
Identification
The following identification plate is attached to the coolant pump tank.
Figure
1
–
Plates
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3.3
Pictograms
Figure
2
-
Pictograms
PLATE IN ITALIAN
PLATE IN ENGLISH
ATTENZIONE
È VIETATO ESEGUIRE LAVORI SU
APPARECCHIATURE ELETTRICHE SOTTO
TENSIONE

EVENTUALI DEROGHE DEVONO ESSERE
AUTORIZZATE DAL CAPO RESPONSABILE

IN CONDIZIONI DI PARTICOLARE PERICOLO DEVE
ESSERE P
RESENTE UN’ALTRA PERSONA OLTRE A CHI
ESEGUE IL LAVORO
INIZIARE I LAVORI SOLO AD AVVENUTA
ATTAZIONE DELLE MISURE DI SICUREZZA
In ottemperanza al Dgs.81/08 relativo alla prevenzioni
infortuni
ATTENTION
IT IS PROHIBITED
TO WORK ON LIVE ELECTRICAL
EQUIPMENT

ANY EXCEPTIONS MUST BE APPROVED BY THE HEAD
MANAGER

UNDER PARTICULARLY DANGEROUS CONDITIONS,
ANOTHER PERSON MUST BE PRESENT WHO IS NOT
PERFORMING THE WORK
ONLY BEGIN WORKING WHEN SAFETY MEASURES
HAVE BEEN IMPLEMENTED
I
n accordance with Legislative Decree 81/08 on accident
prevention
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4
IMPROPER USES AND PR
ECAUTIONS
THE FOLLOWING IS STRICTLY PROHIBITED!

Using the coolant pump without having positioned the tank properly.

Using the coolant pump without having properl
y secured the coolant outlet nozzle and
the control box.

Using the coolant pump without connecting the protective conductor to the
equipotential circuit of the machine
-
tool.

Using the coolant pump without having fitted the tank lid.

Using the coolant pump
without having properly fixed the electric pump to the coolant
tank.

Using the coolant pump with liquids other than coolants for industrial use.

Directing the coolant jet at people and/or animals.

Running the coolant pump when "empty".

Using the coolant pu
mp with a damaged power cord.

Tampering with the operating controls of the coolant pump.
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5
INSTALLATION AND OPE
RATION
The coolant pump is found disassembled in the packaging, as such it is necessary to carry out
assembly before it can be installed on th
e designated machine. Proceed as follows.
Check that all the components listed below are included in the package before throwing away
the packaging:

Instruction manual

Declaration of conformity

Coolant tank (1)

Electric pump (2)

Electric cable and control
box (3)

Coolant passage pipe

Nozzle coolant outlet with shut off valve (4)

Coolant tank lid (5)

Bolts and screws (6)
To recognize the components and to carry out the correct assembly of the
equipment, refer to the picture on page 2 of this manual.
To car
ry out the assembly of the coolant pump proceed as described below:
1.
Insert the electric pump inside the hole present in the
coolant tank, orienting the electric cable towards the right
side of the tank, so that it will not be an obstruction.
Fi
gure
3
-
Pump insertion.
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2.
After inserting the electric pump inside the tank, align
the four fastening holes on the edge of the electric
pump with the holes on the coolant tank, then insert
the fastening bolts (the biggest in the pa
ckage),
interposing between the bolt and the pump a flat
washer and a split washer.
Figure
4
–
Fixing the pump
3.
Once all the bolts have been inserted, fasten them
using the special nuts included in the package, using a
hexago
nal wrench and an Allen wrench.
Figure
5
-
Pump insertion.
4.
After attaching the electric pump, fit the coolant tank
lid and align the two fastening holes.
Figure
6
–
Lid fitting
5.
Secure the l
id using the appropriate bolts supplied (the
smallest in the package), interposing between the bolt
and the lid the special flat washer, then tighten the
bolts using an Allen wrench.
Figure
7
–
Fixing the lid
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6.
At this point, t
he coolant pump is completely assembled, fill the tank with a suitable
coolant liquid, using the hole on the lid of the tank.
Coolant quantity
Fill the coolant tank by a little over half of its capacity, as this amount is sufficient for the
correct ope
ration of the equipment and avoids unnecessary waste of coolant liquid.
7.
After filling the tank with the coolant liquid, place it in the
vicinity of the machine on which the pump must be
installed, and then proceed to install the coolant outlet
nozzle on
to the machine, securing it using the special bolts,
supplied in the package, as shown in the next figure.
Figure
8
–
Fixing the nozzle
Installation of the coolant outlet nozzle
During the installation of the coolant outle
t nozzle, pay the utmost attention to not install the
accessory in a position that creates an obstruction during operation, also if possible, pass the
water tube behind the machine tool, so that will not be damaged accidentally.
8.
Install the coolant pump
control panel next to the control
panel of the machine
-
tool on which the equipment is
installed, fixing it by means of special bolts (not supplied)
Figure
9
–
Control Panel
Control panel installation
Install the contr
ol panel in a position that is convenient and easily accessible for the operator
during operation.
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9.
If the machine
-
tool, on which the coolant pump is
installed, is fitted with a used liquid recovery tray,
insert the coolant recovery tubing inside the hole
in
the lid of the coolant tank, so that the liquid used
during processing, can be recycled and reused.
Figure
10
–
Coolant recovery hole.
10.
Connect the yellow
-
green sheathed cable to the grounding terminal of the machine,
and
then connect the electric wires, respecting the supply voltage shown on the
machine's identification plate.
Electrocution
The electrical circuit connections can only be carried out by personnel that are experienced in
this area and specifically trained
for this purpose.
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6
OPERATION
The operation of the coolant pump is controlled by switches on the control panel of the
accessory, in particular:

To activate the operation of the electric pump, lift the red cap on the control panel and
press the green swit
ch “I”.

To stop the operation of the electric pump, lift the red cap on the control panel and
press the red switch “O”.

If a dangerous situation arises during operation of the coolant pump, immediately
press the emergency stop button, in order to immediate
ly stop the functioning of the
accessory.
Figure
11
–
Control panel buttons
After starting the coolant pump, it is possible to adjust the amount of coolant liquid
discharged through the nozzle, using a valve located on
the device.

To decrease the coolant discharge flow, rotate the valve clockwise (ref. A).

To increase the coolant discharge flow, rotate the valve anticlockwise (ref. B).
Figure
12
-
Valve
A
B
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7
MAINTENANCE AND CLEA
NING
Mai
ntenance
Always the machine from the power supply before performing any maintenance and/or
cleaning.
7.1
Replacing the coolant liquid
Periodically it is necessary to replace the coolant liquid present inside the tank, as during
processing it incorporates pro
cessing residues and dirt, which over time could clog the pump
and cause the malfunctioning of the accessory.
To replace the coolant liquid, proceed as follows:
1.
Disconnect the machine from the power supply;
2.
Remove the coolant tank lid;
3.
Empty the used coola
nt from the tank;
4.
Thoroughly clean the inside of the tank using a clean cloth that does not leave residue;
5.
Fill the tank with new coolant, up to 3/4 of the total capacity;
6.
Refit the lid of the tank;
7.
Carry out an operation test.
7.2
Cleaning the electric pump
P
eriodically it is necessary to perform thorough cleaning of the electric pump, which could
become clogged with the process residues and dirt accumulated in the coolant liquid.
To the pump, proceed as follows:
1.
Disconnect the machine from the power supply;
2.
R
emove the coolant tank lid;
3.
Empty the used coolant from the tank;
4.
Remove the pump from the tank by unscrewing the fastening bolts;
5.
Thoroughly clean the immersed tube of the pump using a special washing liquid;
6.
Dry the pump using a compressed air gun and re
peat the cleaning process several
times if necessary;
7.
Thoroughly clean the inside of the tank using a clean cloth that does not leave residue;
8.
Mount the pump and secure it using the appropriate bolts;
9.
Fill the tank with new coolant, up to 3/4 of the total
capacity;
10.
Refit the lid of the tank;
11.
Carry out an operation test.
In case of doubt or difficulty performing maintenance work, contact the dealer from
whom you purchased the coolant pump, who has competent and specialised staff,
able to suggest the correct
procedure to perform the desired operation.
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7.3
Disposal
The
Coolant pump Art. P018/230V and Art. P018/400V
is composed
o
f
metal (tank, pump etc.), plastic (coolant tubing, coolant outlet nozzle, sheaths
for electric cables etc.), electrical parts (cont
rol panel). These materials should
be separated for recycling.
Respect the environment!
The used coolant liquid must be disposed of at a suitable collection site and
under no circumstances should it be discharged into the sewer system, as it is highly t
oxic
and harmful to the environment.
Disposal of materials
Dispose of the materials that compose the machine and which are used by it, respecting the
laws in force and allocating waste to designated collection centres and disposal RESPECT THE
ENVIRONME
NT!!
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8
REPLACEMENT PARTS
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