profluid PF70-30DFS User manual
High Pressure Coolant System Packages
INSTALLATION & OPERATION MANUAL
HPC Model PF70-30DFS (SFS)
Rev.20170601 V1.0E
*CONTENTS OF THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE.
1156, Dudong-ro, Dudong-myeon, Ulju-gun, Ulsan, Korea.
TEL : 82-52-289-4035 FAX : 82-52-289-4037 www.kemtech.co.kr
TABLE OF CONTENTS
SECTION Ⅰ - HPC Model 70-00DFS(SFS) Contents and Specifications ............................................. 3
SECTION Ⅱ - Safety Precautions and System Considerations .................................................................. 4
SECTION Ⅲ - Installation Guidelines ............................................................................................................................ 5
SECTION Ⅳ - Electrical Installation ............................................................................................................................... 7
SECTION Ⅴ - Prior to Initial Start-up ....................................................................................................................... 8
SECTION Ⅵ - System Start-up ........................................................................................................................................ 9
SECTION Ⅶ - Setting Pressure / Pressure Regulating Valve .................................................................... 9
SECTION Ⅷ - High Pressure and Orifice Sizing ............................................................................................... 10
SECTION Ⅸ - Filter Replacement Instructions .................................................................................................... 11
SECTION Ⅹ - Preventative Maintenance ................................................................................................................. 12
SECTION Ⅺ - Troubleshooting ....................................................................................................................................... 13
Manufacturer's Warranty ....................................................................................................................................................... 14
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 3
Section Ⅰ - HPC Model 70-30DFS Contents and Specifications
Contents
Verify that you have received all of the components listed below. Contact HPC Systems in Korea
at +82- 2-289-4034
Qty. Description
1 HPC Model 70-00DFS Pump Assembly including: (2) Filter Assembly
1 Pressure Calibration Orifice (see page 8)
1 Warning Label for your machine (see page 4)
1 Installation & Operation Manual
Inlet Pressure Gauge
Air Purge Line
Coolant Inlet
Filter Select Valve
Differential pressure switch
Pressure Gauge
Inlet Pressure Gauge
Coolant Reservoir Return
Filter Drain Valve
Locking Level Bolt(s)
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 4
MODEL
PF 70-30 DFS (SFS)
Main Power
3Ph 220Vac 50/60Hz
Motor
3Ph 220/380Vac 50/60Hz
7.5KW 27.6/26.1A
RequiredInlet Pressure [Bar(PSI)]
1.2~4.1(17~59)
MaxiumDischarge
Pressure [Bar(PSI)]
70 (1015)
Volume 50/60Hz [LPM(GPM)]
24(6.3) / 30(7.9)
Discharge Fitting
1/2"(-12)JIS37
INLET Hose Fitting
1"
DRAIN Hose Fitting
3/4"
Orifice[mm]
2.46
Dimensions [mm]
835 x 736 x 1339H
Ship Weight [Kg]
295
Ship Weight [Kg]
표준
Table 1
Note : Dual rated motor may be operated at 60Hz or 0Hz
Motor RPM and Discharge volume will be different
Volume = Discharge volume + Bypass volume
SF - Filter 1 ea , DF - Filter 2 ea
Section - Safety Precautions and System Considerations
SAFETY PRECAUTIONS:
・
Read and follow all instructions and safety warnings in this manual prior to installing or operating this high
pressure system.
・
Always wear safety glasses when operating high pressure.
・
Have all machine guards in place before activating high pressure.
・
Never put any part of your body in front of the coolant stream.
・
Never adjust Pressure Regulating Valve in increase coolant pressure without a properly sized discharge orifice
installed(Table 1 Reference).
・
Adjust coolant nozzles only when the system is not in operation.
・
Never direct the coolant stream at any person.
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 5
SYSTEM PRECAUTIONS:
Safety Valve:
HPC Systems generate pressure by positive displacement. A Bypass Pressure Regulating Valve is
provided as a safety valve and to control the maximum system pressure and to prevent over pressurization.
Incorrectly adjusting the regulator setting may void warranty and could result in personal injury or damage to the
pump or your machine tool.
Do not remove Pressure Regulating Valve from system.
The Manufacturer does not assume any liability or responsibility for the misuse of a customer's high-pressure
system.
Pump Lubrication:
Change oil after first 0-100 hours of operation and every 00 hours thereafter. Fill crankcase
with approximately 2 liters (84 oz) with approved oil. Refer to the Preventative Maintenance section for a list of
approved oils.
DO NOT RUN PUMP WITHOUT OIL IN THE CRANKCASE.
Inlet Pressure:
A positive head pressure must be maintained to avoid problems associated with cavitation. In so
doing, a dedicated supply pump is required to feed coolant to the HPC inlet. The supply pump's pressure capability
should be determined prior to its installation. The HPC filter vessels have a pressure rating of 4.1 Bars(60psi)
maximum. For supply pumps that provide excessive inlet pressure, regulating 4.1 Bar(60psi) maximum is required.
The accumulation of fine particulate in the active filter will create a pressure drop in the coolant supply through
the filter.
Filtration:
High capacity filter bag elements rated at 100, 0, 2 , 10 or -micron are available from our factory.
Coolant Viscosity:
The standard HPC may be used to pump coolants or oils of viscosity down to 12
SUS(cST:26).
Considerations before Installation
A. Before Installing the HPC Unit, verify that your entire coolant delivery system(hoses, valves fittings,
coolant couplings ) is capable of supporting your desired operating pressure.
B. For best results, replace contaminated coolant and clean out machine reservoir to remove accumulated chips
and debris.
C. Your HPC Unit uses both tapered pipe (PT/NPT) fittings and 37°JIC hydraulic fittings. The JIC fittings
are designed to seal against pressure and vacuum leaks without the use of any pipe sealant compound.
For threaded PT/NPT connections, use curing pipe thread sealant(such as Loctite # 6 ) or PTFE liquid/tape.
If tape is used, do not wrap beyond the last thread to avoid tape from being lodged within the system.
D.
If you have any questions or require factory assistance during installation, please contact HPC
Systems at Fax:(052)288-4036 Phone:(052)289-4034~5 in Korea
Section Ⅲ - Installation Guidelines
LOCATING THE PUMPING SYSTEM
・
The HPC Unit should be located to minimize the required hose lengths between the HPC and your
machine.
Verify HPC interface cable length is adequate to reach machine tool.
・
Position the pump assembly to provide adequate work space and allow room for checking the oil level,
changing oil, inspecting pressure gauges, and servicing filters.
・
If possible, install a completely submerged baffle plate in the coolant tank to separate the supply pump inlet
point from the coolant returning to the tank. This helps reduce aeration and turbulence in the coolant supply to
the HPC.
INLET PLUMBING
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 6
・
Do not use inlet hoses or components(valves, fittings, etc.)smaller than 1 .9mm( /8") I.D.
・
If elbows are required in the inlet plumbing, 4 °fittings are preferred to 90°fittings. Try to arrange sweeping
hose curves if 90°routings are required.
・
Use thread sealant on any PT/NPT fittings in the HPC inlet plumbing. Any leaking joints can allow air to
be drawn into the system and cause cavitation. Sealant is not required for JIC 37°fittings.
・
If a shutoff valve is used in the inlet plumbing, it should be a full opening type and the opening through the
valve should be no smaller than 19mm(3/4") I.D.
Do not
run the HPC with the shutoff valve closed.
・
Do not connect rigid piping directly to the HPC coolant inlet. A flexible hose should be used to reduce
vibrations in the plumbing. Hose kits are available from HPC.
・
Install hose or piping supports where necessary to relieve strain and to minimize vibration.
Connect
Inlet Hose
and
Bypass/Drain Hose
. Use pipe sealant on the fitting threads. Route the
Bypass Hose
to
the coolant tank, as far as possible from the
Supply Pump
inlet (to reduce the change of turbulence and
cavitation). The
Bypass Hose
should be secured at the coolant tank end to prevent the hose from being ejected
from the tank.
CAUTION: Never install shutoff valves in the bypass/drain line.
HIGH PRESSURE HOSE GUIDELINES
Use at least 0.9M(3 ft.) of flexible hose between the HPC high pressure
Discharge Fitting
and any fixed
connection or rigid piping at the machine. This is a protective measure to reduce vibration in the machine's coolant
plumbing. A Pulsation Dampening Assembly is available to further minimize any adverse effects caused by high
pressure pulsations.
If the machine's coolant hoses are not rated for a minimum working pressure of 100 Bar(1 00psi)prior to installing
a HPC Model 70-20, they should be replaced. Recommended discharge hose size is 12.7mm(1/2")I.D. Line size
should not be smaller than 9. mm(3/8")I.D. Consult the factory for use of smaller discharge line sizes.
The
Discharge Fitting
on the HPC is a 3/4" (-12)37°, JIC male hydraulic fitting.
OPERATOR WARNING LABE
L
Affix the MACHINE WARNING LABEL to your machine,
preferably at eye level on the door of the machine, provid-
ing maximum visibility to operators.
After completing the installation instructions, you will be
ready to start up your HPC System.
Before continu-
ing, be sure you have read the Precautions Section.
Section Ⅳ - Electrical Installation
Caution:
This procedure should be performed by a qualified electrical technician.
WARNING!
BE SURE THE POWER SUPPLY IS SWITCHED OFF
BEFORE WORKING UNIT
Important note:
Before installing the HPC system, consideration should be given to the Start/Stop control method
for the pump motor. Rapid on/off cycling of the motor can cause premature damage and failure of the motor or
contactor due to excess heat generation.
If short high pressure cycles are required(i.e., several starts and stops within a few minute time span), then it may
be preferred to start the 70-00DF(SF) pump motor with one control signal and use another signal to a high
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 7
pressure bypass valve for controlling high pressure to your machine.
POWER CONNECTION
The HPC 70-00DF(SF) is shipped from the factory wired for Low Voltage operation(60HZ 220V).
Motor rotational direction is optional.
The unit must be properly grounded.
Alarm Control Circuit
The HPC is equipped with a Pressure Switch and a Differential Pressure Switch to monitor coolant supply
conditions at the inlet of the pump.
Pressure Sensing Connection
The 70-00DF(SF) Pressure Switch is plumbed to the HPC inlet fitting to monitor coolant supply, and will provide
a signal at 0.2 Bar(2. psi) inlet pressure, indicating a coolant supply problem. Normally open and closed contacts
are available.
Please set up 10 seconds of DELEY TIME for time filled filter vessel with coolant when HPC is runing at the
beginning. It may cause Inlet pressure alarm to make trouble.
Differential Pressure Sensing Connection
The 70-00DF(SF) Differential Pressure Switch is plumbed to the filter inlet and outlet fittings to monitor
differential pressure across the filter. As the filter element collects particulate, differential pressure across the filter
will develop. At approximately 8-10 psi/d the HPC Pressure Differential Switch will activate, indicating the need
for filter maintenance. Normally open and closed contacts are available.
Please set up 10 seconds of DELEY TIME for time filled filter vessel with coolant when HPC is runing at the
beginning. It may cause differential pressure alarm to make trouble.
Refer to the following schematics for optional electrical configuration.
Contact HPC technical support at Fax (0 2)288-4036 in Korea with any questions.
Section Ⅴ - Prior to Initial Start-Up
Differential
p r e s s u r e
switch
P r e s s u r e
Gauge
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 8
PRIOR TO INITIAL START-UP, be sure that:
・
Coolant level in the machine reservoir is sufficient to supply the HPC.
・
Any shut-off valves in the inlet lines are open, and the high pressure lines are not blocked.
・
All fittings are tight.
・
The oil level in the HPC pump reservoir is within the acceptable range.
・
The Pressure Regulating Valve adjusting bolt on the outlet of the pump is backed out to the full counter-
clockwise position to relieve spring tension. This assures that the pump starts under minimum pressure.
・
Either a bag filter or pleated cartridge element has been installed, the o-rings and wire filter hold downs have
seated properly, and the filter lids have been tightened securely.
・
All air has been purged from both 70-00DF(SF) filter canister.
Air Purge Line
Discharge Fitting
Discharge Pressure Regulator
Coolant Reservoir Return
Filter Drain Valve(s)
PROCEDURE FOR PURGING AIR FROM FILTER CANISTER
1. F
ilter Drain Valves
should be closed - valve handle horizontal.
2. Command
HPC System OFF
. Command coolant system
"ON".
Only the supply pump should be running
at this time.
3. Watch the clear
Air Purge/Drain Hoses
until only coolant is being discharged. Any air in the canister should
have command machine coolant system "OFF". Check the entire system for signs of leakage .
Command machine coolant system
"OFF"
.
NOTE:
Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an excessive
amount of air is entrained in the coolant supply to the HPC.
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 9
Section Ⅵ - System Startup
START-UP PROCEDURE
1. Verify coolant level in machine reservoir is at least 3/4 full.
2. Turn on power to both the supply pump and the HPC pump.
3. A fully primed system will run smoothly and deliver steady flow. Check the inlet pressure.
Inlet pressure 1.2Bar(14psi)~4.1Bar(60psi).
4. Listen for any erratic noise; look for unsteady flow.
. If the system has an air lock in the high pressure lines, the pump may fail to prime. Follow the instructions
for Setting Pressure below to remove air that may be trapped in the pump manifold and high pressure lines.
Section Ⅶ - Setting Pressure / Pressure Regulating Valve
The Pressure Regulating Valve is the system safety valve to prevent over-pressurization.
Under no
circumstances
should the setting be higher than 70 Bar(1000 psi) for HPC Model 70-00DF(SF).
To Check the Regulator Set Point:
1. Verify that power to the HPC and machine High Pressure Discharge Fitting
"M" code activation signal are
"OFF"
Calibration Orifice
2. Remove the
Discharge Hose Fitting
from the Discharge Hose Fitting
High Pressure Discharge Fitting
. Install the
Calibrating Orifice
supplied with your system
(see illustration).
3. Loosen the lockdown nut on the Discharge
Pressure Regulator Adjusting Nut.
4. Turn the
Discharge Pressure Regulator
Adjusting Nut
to the full counterclockwise
position (3-4 turns) to decrease the spring
tension. Do not remove the bolt.
. Activate the HPC System. Slowly turn
the
Discharge Pressure Regulator Adjusting
Nut
clockwise to increase the setting until
the desired pressure is reached.
When operating
HPC Model 70-20DF do not exceed
70 Bar(1000 psi) under any circumstance!
If the
system does not run smoothly, prime by turning Discharge Pressure Regulator
the
Dis
c
harge Pressure Regulator Adjusting Nut
Adjusting Nut
in and out a few times as it smooths out. Locking Nut
6. After adjusting the
Discharge Pressure Regulator
Adjusting Nut,
tighten the Lockdown Nut to secure
setting.
7. De-activate the system and remove the
Calibrating Orifice.
Store for later use.
Caution: The HPC unit should not be run in production with the Calibrating
Orifice installed; flow will be over-restricted, and bypass to the coolant reservoir.
In the event you wish to run a pressure lower than 70 Bar(1000 psi), follow the above steps to set the desired
pressure level.
It is important to understand that the optimum orifice size will increase for a lower system pressure.
If system pressure or flow seems inadequate, verify HPC performance by installation of calibrating orifice.
Note:
The discharge Pressure Gauge needle should steadily increase. If the gauge needle stops moving while the
Adjustment Bolt is being turned, this indicates a problem. Typically, this occurs when the minimum discharge
orifice or nozzle in the system is larger than (Table 1 Reference)
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 10
Section Ⅷ - Pressure and Orifice Sizing
The HPC Model 70-20DF increases your machine tool's coolant pressure capability through the use
of a positive displacement pump. The pump does not create pressure, it simply pumps a constant volume.
Coolant pressure is controlled by restricting the discharge line. This restriction can be the orifice in your
tool or coolant nozzle. As the restricting orifice becomes smaller in size, the system pressure increases
up to the safety limit of 70 bar (1000psi) as set by the Pressure Regulating Valve.
The performance benefits from high
pressure assisted machining are
achieved by maximizing coolant delivery
into the cutting zone. The maximum
coolant velocity, pressure, and flow
rate of the pump is achieved with a
single orifice diameter of approximately
Φ
2.0mm(70-20),
Φ
2.0mm(70-30).
For restrictions smaller than
Φ
2.0mm(70-20),
Φ
2.0mm(70-30),
excess volume is proportionally by passed to
the coolant reservoir which reduces coolant
flow through the tool or coolant nozzle.
The operating curve for the 70-30DF is illustrated in the graph above:
The orifice data is based on water flowing
through sharp round orifices.
In actual practice, longer orifices
common to coolant fed tooling, or
higher viscosity fluids such as cutting
oil will result in reduced nozzle
efficiency, thus decreasing
the flow through the nozzle or tool.
The orifice area is calculated as follows: Area
= (π)x(Diameter)² = 0.7854 x (Diameter)²
4
For multi-orifice coolant delivery, single orifice diameter should be converted to area and the total area allocated
to the multiple orifices. Refer to the chart above for multiple orifice equivalents.
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 11
Section Ⅸ - Filter Replacement Instructions
System Notes:
Filter replacement is required when the differential pressure across
the filter element reaches (0.8Bar(8-10psi).
⓵
Filter Inlet Gauge
⓶
Filter Select Valve
⓷
Coolant Inlet
⓸
Outlet Filter Gauge
⓹
Outlet Filter Select Valve
⓺
Filter Drain Valve(s)
⓻
Filter basket
⓼
Filter presser plate
⓽
Filter
(
(stainless steel mesh)
To replace the filter, the procedure is as follows:
Verify HPC System and coolant system is "OFF",
1. Open
Drain Valve
.
2. After pressure is relieved from filter housing
(Inlet Filter Gauge should read zero)
, remove lid.
3. Allow coolant to drain through filter element and back to machine sump. A filter canister holds 2 liters(6.
gallons).
Avoid spillage; check sump level prior draining canister(s).
4. Remove filter canister o-ring and filter hold down spring. Remove and discard dirty filter element. Verify metal
strainer basket is seated properly. Insert new element into basket. Be sure element seal ring is properly seated
evenly and firmly. A snug, light press fit prevents dirty coolant from leaking around the filter element seal ring.
Install filter canister o-ring, filter hold down and secure filter lid.
. Close the
Filter Drain Valve
- handle vertical.
Note:
Pressure gauge pointers should be steady. A bouncing or fluctuating pointer may indicate an excessive
amount of air is entrained in the coolant supply to the HPC Pump.
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 12
Section Ⅹ - Preventative Maintenance
DAILY CHECKS
Check the active filter's inlet pressure gauge. The 70-00DF(SF) has a system inlet pressure rating of 4.1Bar
(60psi) maximum.
A higher inlet coolant supply pressure must be regulated to ensure the safe operation of the 70-00DF(SF).
PERIODIC CHECKS
Check the oil level and the condition of the oil. An acceptable oil level is 1/2 to 2/3 full as viewed on the oil level
sightglass.
CAUTION
: If you are losing oil from the pump reservoir, but don't see any external leakage, or if the oil
becomes discolored and contaminated, one of the seals may be damaged. Do not operate the pump with a damaged
seal.
CAUTION:
Do not leave contaminated oil in the pump housing or leave the housing empty. Remove contaminated
oil as soon as discovered, and replace it with clean oil.
Visually check the condition of the components in the high pressure coolant circuit. Any worn or damaged hoses
should be replaced. Any leaking fittings should be tightened or replaced. Worn or damaged coolant nozzles can
result reduced system pressure.
Periodically inspect the discharge pressure gauge to verify that the HPC 70-20DF is operating at the desired
pressure.
Do not adjust th Discharge Pressure Regulator Adjusting Nut without a proper orifice restriction (
Φ
2.0mm max)
(0.079") at the coolant outlet in your system. If required, use the 70-20DF Calibrating Orifice and follow the
pressure setting instructions in Section Ⅶ.
CAUTION: Never tighten down the pressure adjusting bolt on the Discharge Pressure Regulator
Adjusting Nut without a proper line restriction.
This can result in an excessive pressure setting and damage
your pumping system or machine. System warranty may also be voided.
PROBLEM
PROBABLE CAUSE
SOLUTION
•
Low pressure or surging.
•
Inlet filter element clogged.
•
Fouled or dirty inlet or discharge
valves
•
Pressure Unloader stuck or
plugged
•
check and replace filter element.
•
Clean inlet and discharge valve
assemblies. Replace it pitted or
gouged.
•
Clean and adjust Unloader per
calibration instruction
•
Pump runs extremely rough,
pressure low
•
Air entering inlet plumbing.
•
Filter element dirty.
•
Leaking high pressure seals.
•
Check for airtight seal.
•
Check and replace filter.
•
Replace with Seal Kit.
•
Coolant leakage from under
the manifold, slight leakage.
•
Worn seals.
•
Repair with Seal Kit.
•
Coolant in crankcase
•
Worn crankcase oil seals or oil
seal installed backwards.
•
Prolonged operations with worn
Low Pressure Seals, High Pressure
Seals, or worn plunger retainer
o-ring
•
Replace oil seals.
•
Repair with Seal Kit.
•
Frequent or premature
failure of the packing
•
Scored or cracked ceramic plungers
•
Over pressure to inlet manifold.
•
Abrasive material in the fluid
being pimped.
•
Excessive discharge pressure.
•
Running pump only.
•
Replace plungers. Check compati-
bility of fluid being pumped.
•
Reduce inlet pressure using an
inlet pressure regulator.
•
Do not run system without a
filter.
•
Verify setting of unloader valve.
•
Do not run pump without coolant.
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 13
Section Ⅺ - Troubleshooting the 70-00DFS(SFS) Pump
In the event your pump runs bus performance is limited, refer to the chart flow:
< Model PF 70-30 DFS >
Rev.20170601 V1.0E HPC INSTALLATION & OPERATION MANUAL 14
High Pressure Coolant System Packages
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