ChipBLASTER, Inc.

Transcription

ChipBLASTER, Inc.

P/N: MAN-D3001
ChipBLASTER, Inc.
D30-80-1
FIXED VOLUME MODELS
HIGH PRESSURE / HIGH VOLUME COOLANT DELIVERY SYSTEM
STANDARD AND
CERTIFIED
STATEMENT NUMBER 00-10-005
INSTALLATION, OPERATION and SERVICE
MANUAL
ChipBLASTER, Inc.
13605 South Mosiertown Road
Meadville, PA 16335
USA
www.chipblaster.com
Telephone
Fax
814-724-6278
814-724-6287
For your records please list serial number from nameplate ______________
REV K
2
ChipBLASTER Inc
REVISION RECORD
REVISION
DATE
A
02 MAR 2006
B
17MAR06
C
31 MAR 2006
D
5 APR. 06
E
19 MAY 2006
PERSON
WPA
JRG
WPA
R.B.
R.B.
F
G
10 JULY 2006
8 JAN. 2007
RRW
R.B.
H
J
18JUN07
21JUN07
JRG
JRG
K
11JAN08
TD
DESCRIPTION OF CHANGE
NEW RELEASE
ADDED MORI CABLES
DWG REV SECT 21.0.
DWG. REV. PAGE 42
ADDED PAGE 25 (CHECKING
OIL USING SIGHT GAUGE)
ADDED DAEWOO INTERFACE
REVISED SHIP LOOSE ITEMS
PAGE 59.
ADDED KIWA CABLE
ADDED LOW PRESSURE
OPTION
ADDED AIR PURGE
PROCEDURE
3
ChipBLASTER Inc
GENERAL:
This manual covers the following ChipBLASTER model:
D30-80-1 - STANDARD UNIT (60Hz)
For the model number of your unit refer to the data nameplate located on
the enclosure door.
UNIT MODEL NUMBER
UNIT SERIAL NUMBER
DATA NAME PLATE
4
ChipBLASTER Inc
GENERAL:
This manual covers the following ChipBLASTER model:
D30-80-1 - CE CERTIFIED UNIT (50Hz)
For the model number of your unit refer to the data nameplate located on
the enclosure door.
DATA NAME PLATE
UNIT MODEL NUMBER
UNIT SERIAL NUMBER
ChipBLASTER Inc
1.0. GENERAL WARNINGS:
5
Thank you for purchasing a ChipBLASTER high-pressure coolant system.
For reliable, safe and long term operation of your ChipBLASTER:
Machine must be installed and connected to electric service per the installation
portion of this manual.
All persons who will be operating and maintaining this machine must read and
understand this manual.
DO NOT AT ANY TIME USE FLAMMABLE OR EXPLOSIVE FLUIDS IN OR
NEAR MACHINE.
DO NOT STAND ON MOTORS, SUPPORTS, or JUNCTION BOXES WHILE
WORKING ON THE ChipBLASTER.
REFER TO SECTION 4.1. FOR EXPLANATION OF MARKINGS
1.0
6
ChipBLASTER Inc
2.0. Table of Contents:
General (Standard Unit)
General (CE Certified Unit)
General warnings
Section 1.0
Table of contents
Section 2.0
Specifications
Section 3.0
Safety precautions
Section 4.0
Explanation of markings
Section 4.1
Storage
Section 5.0
Moving machine
Section 6.0
Placing a ChipBLASTER
Section 7.0
Mechanical installation
Section 8.0
Electrical installation
Section 9.0
Power Interface
Section 9.1
Control Interface
Section 9.2
Start up
Section 10.0
Air Purge Procedure
Section 11.0
Operation
Section 12.0
Electrical operation
Section 12.1
Coolant flow
Section 12.2
Coolant flow Diagram (Figure 1)
Section 12.2
Alarms
Section 13.0
Preventive maintenance
Section 14.0
Schedule (Figure 2)
Section 14.1
High pressure pump – Check oil - Dipstick Section 14.2
High pressure pump – Check oil – Sight gauge
Section 14.2
High-pressure pump –
Oil change procedure
Section 14.3
High pressure pump – Check belt
Section 14.4
High-pressure pump – Check for leaks
Section 14.5
High-pressure pump – Rebuild
Section 14.6
Return (Transfer) Pump – Check for leaks Section 14.9
Cartridge filter – Check pressure gauge
Section 14.12
Filter change procedure – General Warnings Section 14.13
Dual manual change filter (shutdown)
Section 14.14
Dual manual change filter (operating)
Section 14.15
Filter Replacement form
Section 14.16
Filter assemblies – Check for leaks
Section 14.17
Filter assemblies – Cleaning
Section 14.18
Pump mounting bolts – Check
Section 14.27
Return pump - Check flow rate
Section 14.29
Page 3
Page 4
Page 5
Page 6
Page 8
Page 9
Page 9
Page 14
Page 14
Page 15
Page 16
Page 17
Page 17
Page 17
Page 18
Page 19
Page 20
Page 20
Page 20
Page 21
Page 22
Page 22
Page 23
Page 24
Page 25
Page 26
Page 29
Page 29
Page 29
Page 29
Page 29
Page 30
Page 30
Page 31
Page 32
Page 33
Page 33
Page 33
Page 33
7
ChipBLASTER Inc
2.0. Table of Contents (Cont.):
Return pump - Check for leaks
Return pump - Check inlet and outlet
Troubleshooting
Troubleshooting flow chart (Figure 3)
Pressure adjustment procedure
High pressure pump replacement
Belt installation
Deflection force chart
System contamination purging procedure
Electrical drawings
Mori Seiki Power Interface
Mori Seiki Control Interface
Daewoo/Doosan Interface
Kiwa Interface
Schematic piping drawing
Mechanical assembly
Gauge Panel – Top
Control Panel – Front
Control Panel – Inside Enclosure
Sub Plate Elevation – Left Side
Sub Plate Elevation – Right Side
Manifold block assembly
Filter Assembly
Ship Loose Items
Spare Parts
Footprint drawing
Warranty
Warranty (limited) – New equipment
Warranty (limited) – Used equipment
Warranty (limited) – Retrofits
Warranty claim form
Warranty registration card
Warranty validation card
Optional Equipment
Machine Sump Standpipe Assembly
Supplement Data
1000 PSI orifice chart
Section 14.30
Section 14.31
Section 15.0
Section 15.1
Section 16.0
Section 17.0
Section 18.0
Section 18.5
Section 19.0
Section 20.0
Section 20.0
Section 20.0
Section 20.0
Section 20.0
Section 21.0
Section 22.0
Section 22.1
Section 22.2
Section 22.3
Section 22.4
Section 22.5
Section 22.6
Section 22.7
Section 22.8
Section 22.13
Section 23.0
Section 24.0
Section 24.1
Section 24.2
Section 24.3
Section 24.4
Section 24.5
Section 24.6
Section 27.0
Section 27.1
Section 28.0
Section 28.1
Page 33
Page 33
Page 34
Page 35
Page 36
Page 37
Page 38
Page 40
Page 41
Page 43
Page 51
Page 52
Page 53
Page 54
Page 59
Page 60
Page 60
Page 61
Page 62
Page 63
Page 64
Page 65
Page 66
Page 67
Page 68
Page 69
Page 70
Page 70
Page 72
Page 74
Page 76
Page 77
Page 78
Page 79
Page 79
Page 80
Page 80
2.0
ChipBLASTER Inc
3.0. SPECIFICATIONS:
8
FCC REGULATIONS:
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two
conditions: (1) This device may not cause harmful interference, and (2) this device must accept
any interference received, including interference that may cause undesired operation.
**All specifications, instruction, pictures, and illustrations in this manual are believed to be
accurate and may contain ChipBLASTER Inc. proprietary information, which is privileged,
confidential, or subject to copyright / patent belonging to ChipBLASTER Inc.. This manual is
intended for the operation and maintenance of your ChipBLASTER unit. You are hereby notified
that any dissemination, distribution, copying, or action taken in regard to the content of this
manual is strictly prohibited and may be unlawful. ChipBLASTER Inc. also reserves the right to
change the contents of this manual without notice. If you have any questions please contact
ChipBLASTER Inc. at (814) 724-6278.
3.0
9
ChipBLASTER Inc
4.0. SAFETY PRECAUTIONS:
The items described in these instructions are very important, so that you can use
the ChipBLASTER safely, prevent injury to yourself and other people around you as well
as prevent damage to property in the area. Thoroughly familiarize yourself with the
symbols and indications shown below and then continue to read the manual. Make sure
that you observe all warnings given.
4.1. EXPLANATION of MARKINGS:
Symbols
!
Meaning of Symbols
DANGER
Indicates that error in operation may lead to death or serious injury.
WARNING
Indicates that error in operation may lead to injury (*1) to people or that
these errors may cause damage to physical property. (*2)
*(1)
*(2)
Such things as injury, burns or shock that will require
hospitalization or long periods of outpatient treatment.
Physical property damage refers to wide-ranging damage to
assets and materials.
Prohibited
Indicates prohibition (Don’t do it).
What is prohibited will be described in or near the symbol in either text
or picture form.
4.0-4.1
ChipBLASTER Inc
4.1. EXPLANATION of MARKINGS (Cont.):
Symbols (Cont.)
10
Meaning of Symbols
Mandatory
!
Indicates something mandatory (must be done).
What is mandatory will be described in or near the symbol in either text or
picture form.
PINCH POINT
Any point where lids or covers may pinch fingers.
Exercise caution when closing lids or covers. (Oil skimmer cover).
CUTTING HAZARD
Any point where exposed fan blades may cause a cutting hazard to fingers
when guard or inlet hose is not in place. Do not operate without guard or
inlet hose in place. (Inlet to MistBLASTER).
PINCH POINT
Any point where fingers may be pinched by the motion of a belt.
Do not operate with guard or cover open. (Oil skimmer).
LIFTING HAZARD
Use caution when lifting filter bags from filter housing. Bags may be
heavy depending on the material being machined.
4.1
ChipBLASTER Inc
Symbols
11
Meaning of Symbols
ELECTRICAL SHOCK HAZARD
Shut off main disconnect before opening any electrical enclosures or
junction boxes. UNITS WITH ADJUSTABLE FREQUENCY
DRIVES: BEFORE PERFORMING ANY WORK, BE AWARE
THAT A DRIVE WILL HOLD A LETAL CHARGE FOR A
MINIMUN OF 10 MINUTES.
LOCK OUT ELECTRICAL POWER
Lock out and tag any and all disconnect switches before performing any
maintenance work on equipment.
SAFETY GLASSES REQUIRED
When removing filter bags or working on equipment, safety glasses must
be worn to prevent injury from splashing fluid or from other hazards.
MACHINE STARTS AUTOMATICALLY
ChipBLASTER equipment will start without operator input. Do not
remove any guards or covers until disconnect switches are shut off, locked
out and tagged.
UNPLUG SOURCE OF ENERGY
Before performing any work on items, such as the oil skimmer, unplug the
unit.
4.1
ChipBLASTER Inc
Symbols (Cont.)
12
Meaning of Symbols (Cont.)
NO ACCESS FOR UNAUTHORIZED PERSONS
Do not open electrical enclosures or remove any guards if you have not
been trained or do not have knowledge of the equipment.
FORK TRUCK LIFTING POINT
To transport equipment, forks of truck must be located between points
indicated so that mechanical damage to machine will not result.
SAFE OPERATING PRESSURE
Safe operating pressure will be listed below symbol in PSIG and Bar.
Do not operate above stated pressures as equipment damage or personal
injury will result.
DO NOT STEP OR STAND ON
Do not use surface as a step or platform when servicing equipment.
Motors and electrical boxes are not designed to be used as steps or
platforms and injury may result from falls.
READ THE TECHNICAL MANUAL
Before attempting to work on or repair this machine read and understand
this manual. If certain procedures are not followed, mechanical and or
personal injury will result.
4.1
ChipBLASTER Inc
13
Meaning of Symbols (Cont.)
Symbols (Cont.)
WEAR SAFETY GLOVES
When changing filter bags it is recommended to wear safety gloves to
protect hands from metal chips and the coolant that may be used in the
machine.
DO NOT OPERATE WITH GUARD REMOVED
Do not operate machine with guards removed as hazards to personnel will
be present and injury to personnel could result.
LIFTING POINT
Machine must only be lifted at points indicated in order to avoid
mechanical damage and personal injury. Lifting slings or chain slings
must be adequately sized to carry the weight of the MistBLASTER.
Refer to MistBLASTER footprint drawing for actual weight.
BURN HAZARD HOT SURFACE
Surface of transformer will become hot after extended periods of
operation. Do not set anything on transformer or restrict airflow around
transformer. DO NOT TOUCH.
4.1
14
ChipBLASTER Inc
5.0. STORAGE:
!
If the ChipBLASTER is to be stored for any period of time it must be keep in an area that is protected
from freezing. Freezing temperatures will damage the pumps and the valves. Keep ChipBLASTER
covered until ready to move to site. If MistBLASTER is also supplied keep covered.
6.0. MOVING MACHINE:
!
When moving the ChipBLASTER to the final site the following must be adhered to:
Lift ChipBLASTER only from the sides adjacent to the electrical enclosure.
Forks must extend the full distance under ChipBLASTER. The fork truck lifting capacity must be
sufficent to safely lift the ChipBLASTER without tiping. Refer to footprint drawing (Section 23) for
machine dry weight.
!
MOVE SLOWLY AS NOT TO DROP THE ChipBLASTER.
!
DO NOT TRY TO MOVE ChipBLASTER WITH FLUID IN FILTERS.
!
DO NOT STAND UNDER ChipBLASTER AT ANY TIME.
If MistBLASTER is supplied with ChipBLASTER:
When lifting or moving the MistBLASTER, lift only at the eyebolts provided on the top.
Sling must be of sufficent capacity to safely lift the MistBLASTER.
!
DO NOT STAND UNDER MistBLASTER AT ANY TIME.
5.0-6.0
ChipBLASTER Inc
7.0. PLACING A ChipBLASTER:
7.1.
!
15
After you receive your new ChipBLASTER unit the first thing you need
to do is prepare the site where you would like to place the unit.
INSTALLATION SITE MUST BE FLAT AND LEVEL.
7.1.1. You need to keep the unit within 3M (10’) of the machining center that you are
conncecting the ChipBLASTER to.
7.1.2. Locate the unit so the ChipBLASTER’s electrical cabinet is within 3M (10’) of
the machining center’s electrical cabinet.
7.1.3. Make sure you place the unit so maintenance can easily get to the filter housings
and electrical cabinet on the ChipBLASTER unit. Refer to footprint drawing
(Section 23) for recommended clearances.
7.2.
After you have the site cleared for the ChipBLASTER unit you are
ready to prepare the ChipBLASTER.
7.2.1. Remove the lumber that is used to hold the unit in place during transporation
using a phillips screw driver or an electric screw gun.
7.2.2. Before you remove the ChipBLASTER from the skid take a moment to locate the
bags containing the casters.
7.2.3. When removing the ChipBLASTER from the skid, lift unit from the sides only!
Insure the forks extend completely under the ChipBLASTER unit.
!
DO NOT AT ANY TIME REACH UNDER THE ChipBLASTER UNIT
OR STAND UNDER THE ChipBLASTER UNIT WHILE IT IS
SUPPORTED BY A FORK TRUCK. IF YOU MUST REACH UNDER
THE MACHINE BLOCK IT UP FOR SAFETY.
7.2.5. After you remove the ChipBLASTER from the skid take the set of four casters
and mount them in the receptacles located at each corner of the ChipBLASTER
unit. As a safety precaution, block unit while installing casters. Note: Two
casters are rigid and two swivel. Locate both swiveling casters on same end of
unit.
7.2.6. After you have the casters in place, move the ChipBLASTER into desired
location.
7.0
ChipBLASTER Inc
7.0. PLACING A ChipBLASTER (Cont.):
!
16
After ChipBLASTER is in place and level, locate all ship loose items. Ship loose items
include: high pressure hose with adapter fitting, low pressure hose and low pressure hose
clamps. Place all hoses at the front of the unit (same end as enclosure).
7.2.7. After locating all ship loose items, you are now ready to either contact
ChipBLASTER, Inc. to schedule installation or proceed yourself depending on
your agreement.
!
POWER FOR ChipBLASTER MUST BE AVAILABLE BEFORE
SCHEDULING INSTALLATION.
8.0. MECHANICAL INSTALLATION:
8.1. PLUMBING INSTALLATION:
8.1.1. Locate the ½” high-pressure hose that ChipBLASTER Inc. has provided.
Connect one end to ChipBLASTER outlet located beneath the electrical
enclosure. Connect other hose end to the machining center (spindle, turret or
other designated tool/orifice).
8.1.2. Locate the 25mm (1”) clear hose and clamps that ChipBLASTER Inc. has
provided. This is the return line. Connect one end of the hose to the inlet hose
barb on the ChipBLASTER return pump located beneath the electrical enclosure.
Connect the other end to the coolant sump. Secure both ends with hose clamps
provided.
8.1.3. For best results, the inlet of the return hose in the machining center coolant sump
should be approximately 25mm (1”) from the bottom of the coolant sump.
ChipBLASTER recommends the use of Standpipe Assembly P/N 30011 for
connecting to the coolant sump. See optional equipment Section 27.1.
!
THE RETURN PUMP MUST BE WITHING 3.5 METERS (11.5 FEET) OF
THE MACHINING CENTER COOLANT SUMP.
8.0
ChipBLASTER Inc
9.0. ELECTRICAL INSTALLATION:
17
INSTALLER MUST COMPLY WITH ALL LOCAL AND NATIONAL ELECTRICAL
CODES AND SAFETY GUIDELINES WHEN MAKING ELECTRICAL
CONNECTIONS TO THE ChipBLASTER.
!
REFER TO THE ELECTRICAL DRAWINGS (SECTION 20) DURING ELECTRICAL
INSTALLATION. ALSO REFER TO THE FOOTPRINT DRAWING (SECTION 23) FOR
RECOMMENDED WORK CLEARANCE.
BEFORE OPENING THE MACHINING CENTER CABINET
DISCONNECT AND LOCKOUT / TAGOUT ALL ELECTRICAL ENERGY
SOURCES.
!
*NOTE-The ChipBLASTER is equipped to accept control interface voltages of 120vac or 24vdc. Please
make sure the appropriate control voltage relay is installed in CR1 & CR3 of the unit. The unit is
shipped from the factory with 120vac relays installed in CR1 & CR3. We also include 24vdc relays
loose in the electrical cabinet for interfacing convenience with 24vdc machines.
REFER TO ChipBLASTER NAMEPLATE FOR CORRECT SUPPLY
VOLTAGE. DO NOT EXCEED AMP RATING OF MACHINING
CENTER BREAKER IF CONNECTING TO LOAD SIDE. IF
CONNECTING TO A MAIN DROP, SIZE DISCONNECT AND WIRE
BASED ON INFORMATION SUPPLIED ON THE ChipBLASTER
NAMEPLATE.
!
9.1.
POWER INTERFACE
(REFER TO SECTION 20.0 DRAWING D30-003)
9.1.1. Connect 3 phase power to the line side of 1 CB or to pins 1, 2, 3 if power will be
supplied via the 12-pin power & control interface plug.
9.1.2. Connect the ground wire to a ground terminal located in the electric enclosure, or
to pin #4 if using the 12-pin power & control interface plug.
9.2.
CONTROL INTERFACE
(REFER TO SECTION 20.0 DRAWINGS D30-002 & D30-003)
* NOTE – THE COOLANT AND INDEX RELAY SIGNAL VOLTAGES MAY BE 24 VDC
OR 120 VAC DEPENDING ON VOLTAGE AVAILABLE. CHANGE CR1
AND/OR CR3 RELAY(S) AS NEEDED. RELAYS ARE SUPPLIED FOR 24 VDC
AND 120 VAC.
9.2.1. Locate the coolant relay signal in the machining/turning center. Connect this wire
to terminal #1 on the terminal block, located in the electrical control enclosure.
Or (if using the 12 pin power & control interface plug) connect this wire to pin #5
of the female plug. Connect the common wire of this signal, to COM1 located on
the terminal block or to pin #6 of the interface plug.
9.0-9.2
ChipBLASTER Inc
9.0. ELECTRICAL INSTALLATION (Cont.):
18
9.2.2. Locate the index relay signal in the machining/turning center. Connect this wire
to terminal #3 on the terminal block, located in the electrical control enclosure.
Or (if using the 12 pin power & control interface plug) connect this wire to pin #7
of the female plug. Connect the common wire of this signal, to COM3 located on
the terminal block or to pin #8 of the interface plug.
9.2.3. The dirty filter error signal is factory wired to an alarm horn located on the front
of the enclosure. For dirty filter error signal contact to machining/turning center,
remove jumper wires per drawing D30-002 (see Section 20.0.) and install jumper
wires per drawing D30-003 (see Section 20.0.). Connect signal wire to terminal
#9 on the terminal block, located in the electrical control enclosure. Or (if using
the 12 pin power & control interface plug) connect this wire to pin #9 of the
female plug. Connect the common wire for this signal, to terminal E located on
the terminal block or to pin #10 of the interface plug. Closed contact indicates a
dirty filter. NOTE: When utilizing this contact in the machine center control, be
aware that a time delay is required to allow system pressure to build and open the
contact.
9.2.4. Wire the ES, “Error Signal” relay to terminals E/E1 or E/E2 contacts into the
emergency stop or feed hold circuit of the machining/turning center. Or (if using
the 12 pin power & control interface plug) wire to pins 10/11 or 10/12. ES is the
ChipBLASTER error signal. NOTE: Machine tool damage could result if the
ES signal is not properly interfaced!
*NOTE - THE ES RELAY IS DE-ENERGIZED WHEN THE ChipBLASTER IS
OPERATING WITHOUT ERROR.
9.3.
9.4.
POWER INTERFACE TO MORI SEIKI
(REFER TO SECTION 20.0 DRAWING 9514-4)
CONTROL INTERFACE TO MORI SEIKI
(REFER TO SECTION 20.0 DRAWING 9516-4)
10.0. START – UP:
The ChipBLASTER return pump must be primed.
10.0.1.
Remove both filter lids and verify a filter cartridge has been installed in each
filter housing. Be careful not to damage filter hold-down plate, seal or spring.
Set lid aside.
10.0.2. Fill the housings with clean coolant.
10.0.3. Make sure the O-ring is in the proper groove before replacing the lid. Replace
the filter lid by setting straight down so that the filter hold-down plate will
contact filter cartridge.
10.0.4. Torque the filter lid bolts to 41 Nm (30 FT/LBS) in a star pattern.
10.0.5. Turn filter selector ball valve to filter “A” and open thumb valve on filter “A”
vent valve located on lid.
10.0.6. Prime Return Pump:
10.0.6.1. Remove return pump feed hose from sump end.
10.0.6.2. Elevate hose end and fill hose with clean coolant
ChipBLASTER Inc
10.0. START – UP (Cont.):
19
10.0.7. Reconnect hose to sump and tighten hose clamp.
10.0.8. Verify high-pressure hose is connected to machine center and is plumbed to an
appropriate nozzle.
!
CHECK MOTOR ROTATIONS. SEE BELOW.
!
CHECK MAIN PUMP ROTATION. ROTATION IS COUNTER
CLOCKWISE VIEWED FROM THE SHAFT END.
!
CHECK RETURN PUMP ROTATION. ROTATION IS
CLOCKWISE VIEWED FROM FAN END.
DO NOT RUN THE HIGH-PRESSURE PUMP DRY FOR ANY
PERIOD OF TIME. CAVITATION WILL RESULT IN
FAILURE OF THE PUMP. ALWAYS REMEMBER TO CHECK
THAT ALL PLUMBING VALVES ARE OPEN AND THAT
PUMPED COOLANT CAN FLOW FREELY TO THE INLET
OF THE HIGH- PRESSURE PUMP.
!
11.0. SYSTEM AIR PURGE:
11.1
SINGLE AND DUAL FILTER
11.1.1 Loosen the thumb screw on each automatic vent valve two turns so that trapped
air can escape both filters.
11.1.2 Press the AIR PURGE push button to remove the air from the filters. Continue
to hold the button until you no longer hear air escaping from the automatic vent
valve. Close the thumb screws.
11.1.3 Start the Chipblaster and check for any coolant leaks.
11.1.4 Insure that all electrical circuits are operating correctly.
11.1.5 The coolant outlet pressure is factory preset to run at 1000 PSIG (69 bar), or a
customer specified pressure. Refer to Pressure Adjustment Procedure.
ChipBLASTER Inc
12.0. OPERATION:
20
12.1. ELECTRICAL OPERATION:
12.1.1. Energizing CR1 will start the coolant system and provide pressurized coolant to
outlet #1. At this time the main motor and return pump motor will come on line.
12.2. COOLANT FLOW (Refer to figure 1)
12.2.1. Coolant flow is divided into two groups, High-pressure and Low-pressure. Lowpressure is the flow of coolant from the machine sump, through the
ChipBLASTER return pump to the high-pressure pump. High-pressure is the flow
of coolant from the high-pressure pump to the nozzle outlet or tool, at the
machining center.
12.2.2. LOW-PRESSURE – Low-pressure coolant enters the return pump, is pumped
through the filter and goes to the high-pressure pump inlet. Filter pressure gauges
are located at the inlet and outlet of the filters. They provide a visual indication of
dirty filter condition. When the outlet gauge reading drops to 1 bar (15 psig), the
alarm horn will sound to indicate the filter cartridge is dirty and should be
replaced. Two pressure switches are located between the filters and the highpressure pump inlet. 2PS closes at 1 bar (15 psi) falling, for dirty filter contact to
the alarm horn / machine center. When utilizing this contact in the machine
center control, be aware that a time delay is required to allow system pressure to
build and open the contact. 1PS closes at 0.7 bar (10 psi) falling, for dirty filter
contact to the fault (error signal) relay.
12.2.3. HIGH-PRESSURE - High-pressure coolant leaving the pump goes to the
manifold block, which contains a regulator and solenoid valve. The regulator is
adjustable to relieve coolant at the system operating pressure. The regulator
protects the high-pressure coolant system from over pressure condition. Relieved
coolant is returned to the inlet of the return pump. Upon activation of coolant on
relay, CR1, the normally open solenoid (dump) valve is activated and allows
coolant to pressurize the high-pressure hose leading to the machine center. The
normally open solenoid valve is also used to bypass coolant to the return pump
inlet when the index control relay, CR3, is energized. Thus relieving pressure in
the high-pressure hose leading to the machine center. A pressure gauge is
installed to read the overall pressure between the high-pressure pump and the
nozzle outlet at the machining center. High-pressure coolant leaves the manifold
block and flows through the high-pressure hose to the machining center and on to
the tool being used.
12.2.4. LOW PRESSURE FLOOD is a factory installed feature. It is designed to be
used to supply filtered coolant at 5 gpm (18.9 liters/minute) 35 psig (2.4bar)
maximum. The flow and pressure is dependent on orifice diameter. The low
pressure flood is controlled by a separate maintained “M” code from the machine
tool. The low pressure, as supplied from the factory, is available at coolant outlet
number 1 and/or 2, depending on ChipBLASTER model. The low pressure flood
is used to flush parts, tool plates and general chip clearing.
NOTE: If the low pressure flood coolant is in use; high pressure coolant is
not available.
21
ChipBLASTER Inc
12.0. OPERATION (Cont.):
12.3. COOLANT FLOW DIAGRAM (Figure 1):
Figure 1
12.3
ChipBLASTER Inc
13.0. ALARMS:
22
13.1. The following errors will stop the operation of the coolant system and
cause the ES relay to change states:
13.1.1. Main motor starter overload trip.
13.1.2. Return pump overload trip.
13.1.3. Dirty filter, pressure switch 1PS.
13.2. To reset a fault:
13.2.1. Determine the cause of the fault and correct. Reset motor overload(s), and/or
correct dirty filter (switch selector valve to clean filter or replace dirty filter
cartridge). Note: power to unit must be cycled off/on to reset the ES relay
circuit. Re-energize the required “M” code to start the ChipBLASTER.
14.0. PREVENTATIVE MAINTENANCE:
DO NOT ATTEMPT ANY SERVICE ON ChipBLASTER UNIT
!
WITH POWER ENERGIZED. REMOVE ALL ENERGY
SOURCES AND LOCK OUT / TAG OUT.
13.0–14.0
23
ChipBLASTER Inc
14.0. PREVENTATIVE MAINTENANCE (Cont.):
Figure 2
14.1. PREVENTATIVE MAINTENANCE SCHEDULE (Figure 2):
14.1
24
ChipBLASTER Inc
14.2. CHECKING HIGH PRESSURE PUMP OIL (USING DIPSTICK OR
SIGHT GLASS):
14.2.1. The high-pressure pump oil may be checked by observing the level on the
dipstick attached to the oil fill cap located on top of the pump.
OIL FILL CAP
DIPSTICK
HIGH-PRESSURE
PUMP
14.2.2. The oil level must be maintained between the full and add marks. If required add
oil (refer to Section 14.3.6.).
Oil Fill Cap/Dipstick
“ADD” Mark
!
“FULL” Mark
FAILURE TO USE
MOBIL 1 FULLY-SYNTHETIC 15W-50 WILL
VOID YOUR WARRANTY
!
14.2
25
ChipBLASTER Inc
14.2. CHECKING HIGH PRESSURE PUMP OIL (USING DIPSTICK OR
SIGHTGLASS):
14.3.1. The oil level may also be checked by viewing the sight glass when the pump is
stopped.
OIL LEVEL
FULL MARK
OIL LEVEL
LOW MARK
14.3.2. The oil level must be maintained between the full and add marks. If required add
oil (refer to Section 14.3.6.).
!
FAILURE TO USE
MOBIL 1 FULLY-SYNTHETIC 15W-50 WILL
VOID YOUR WARRANTY
!
14.2
26
ChipBLASTER Inc
14.3. OIL CHANGE PROCEDURE:
IT IS EXTREMELY IMPORTANT TO DISCONNECT AND LOCKOUT
ANY AND ALL POWER SOURCES BEFORE ANY WORK IS TO BE
PERFORMED ON the ChipBLASTER UNIT.
14.3.1. ChipBLASTER High-Pressure Pump: Change the crankcase oil after every 2000 hours
of operation.
USE: Mobil 1 fully synthetic 15W-50 oil.
!
FAILURE TO USE
MOBIL 1 FULLY-SYNTHETIC 15W-50 OIL
WILL VOID YOUR WARRANTY
14.3.2. Remove accesses panel from right side, as viewed from enclosure end, (use 4mm
hex head wrench).
14.3.3. Locate and remove the oil fill cap/dipstick located on top of pump.
14.3.4. Locate and remove the drain plug (use 17mm wrench) located on back side of
pump (opposite the head end). Allow oil to drain into a container capable of
holding at least 1 liter (32 ounces).
FILL-CAP/
DIPSTICK
DRAIN PLUG
DRAIN OIL
CONTAINER
14.3
27
ChipBLASTER Inc
14.3. OIL CHANGE PROCEDURE (Cont.):
14.3.5. After oil is drained from pump reinstall the plug in back of pump. Torque to 20
Nm (180 In LB).
!
PROPERLY DISPOSE OF OIL PER LOCAL REGULATIONS.
DO NOT REUSE OIL.
14.3.6. Locate High Pressure Pump fill opening (ON TOP OF PUMP) Place a funnel,
with flexible spout, into opening.
FUNNEL W/
FLEX SPOUT
OIL FILL
OPENING
14.3
ChipBLASTER Inc
28
14.3. OIL CHANGE PROCEDURE (Cont.):
14.3.7. Add only MOBIL 1 FULLY-SYNTHETIC 15W-50 oil. Bring oil level to
“ADD” indicator mark on dipstick. (See Section 14.2.2.)
14.3.8. Allow oil to settle for 3 to 4 minutes.
14.3.9. Check level and if required add small amounts slowly until level is at “FULL”
indicator.
14.3.10. Reinstall dipstick plug. Do not over tighten.
14.3.11. Reinstall right side panel. Tighten BHCS to 12 Nm (106 In Lb).
!
DO NOT RUN HIGH PRESSURE PUMP WITHOUT OIL AS DAMAGE
WILL RESULT AND VOID YOUR WARRANTY.
!
14.3
ChipBLASTER Inc
29
14.4. HIGH PRESSURE PUMP – CHECK BELT(s):
14.4.1. To check the high-pressure pump drive belt, the panel on the right side of the
enclosure will need to be removed. Use a 4 mm hex head wrench.
14.4.2. Check belt tension. Refer to SECTION 18.0.
14.4.3. To adjust motor to pump drive belt turn the adjustment bolt on the pump
mounting base using a 9/16” socket. To tighten belt, turn the adjustment screw
counter clockwise. To loosen belt, turn the adjustment screw clockwise.
14.4.4. Replace side panel before operating the ChipBLASTER.
14.5. HIGH PRESSURE PUMP – CHECK FOR LEAKS:
14.5.1. Remove the panel on the right side of the enclosure using a 4 mm hex head wrench.
14.5.2. Check for leaks around pump head and on sub plate.
14.5.3. Verify the fluid is not coming from a fitting or hose. If a hose is leaking shut down the
ChipBLASTER unit and replace hose. If a fitting is leaking, check tightness of fitting.
14.5.4. If fluid is noticed the high-pressure pump will require replacement. Contact
ChipBLASTER service department.
14.5.5. Replace side panel before operating the ChipBLASTER unit.
14.6. HIGH PRESURE PUMP – REBUILD:
14.6.1. Due to the manufacturing tolerances required for the internal parts of the highpressure pump, rebuilding the high pressure it is NOT recommended. A new or
re-built replacement pump can be purchased from ChipBLASTER. When
ordering a replacement pump from the ChipBLASTER service department, advise
the contact person that you wish to receive an RGA number for the pump to be
replaced.
14.6.2. When the old pump is received at ChipBLASTER, the pump will be inspected for
any damage. If no damage is noted a core charge credit will be issued.
14.9. RETURN (TRANSFER) PUMP – CHECK FOR LEAKS:
14.9.1. Remove the panel on the left side of enclosure using a 4 mm hex head wrench.
14.9.2. Check for leaks around pump head and on sub plate.
14.9.3. Verify the fluid is not coming from a fitting or hose. If a hose is leaking shut
down the ChipBLASTER unit and replace hose. If a fitting is leaking, check
tightness of fitting.
14.12. CARTRIDGE FILTER - CHECK PRESSURE GAUGE:
14.12.1. The outlet pressure gauge should read more than 1 Bar (15 PSI). If the outlet
filter gauge reads less than 1 Bar (15 PSI), this will be an indication that the
filter cartridge has become clogged and should be replaced.
14.4-14.12
ChipBLASTER Inc
30
14.13. Filter Changing procedure General Warnings:
USE CARE WHEN CHANGING FILTER CARTRIDGES
AS THEY MAY BE HEAVY DEPENDING ON
MATERIAL BEING MACHINED. THE USE OF
GLOVES AND SAFETY GLASSES IS STRONGLY RECOMMENDED
DUE TO THE CHIPS THAT MAY BE IN THE FILTERS.
14.14. DUAL MANUAL FILTER: (CHIPBLASTER SHUT DOWN)
The preferred method is to shut down the ChipBLASTER.
14.14.1. A dirty filter error signal to alarm horn/machine center or a 1 bar (15 psi), or
less, pressure reading on the filter outlet pressure gauge will indicate when the
cartridge filter is dirty.
14.14.2. Check gauges to ensure that pressure is relieved from the housing. Then,
remove the filter lid hold-down screws using a 17mm wrench.
14.14.3. Remove lid and inspect for damage. Be careful not to damage filter hold down
plate, seal or spring. Set lid aside.
14.14.4. Pull the filter cartridge out of the housing.
14.14.5. Install the new filter cartridge in the housing. Ensure cartridge it is all the way
down and firmly seated.
14.14.6. Inspect the lid seal O-ring for cracks or tears, replace if damaged.
14.14.7. Inspect filter hold down plate, spring and seal. Replace any damaged parts.
14.14.9. Reinstall the filter lid. Make sure the O-ring is in the proper groove before
installing the lid. Set the filter lid straight down so that the filter hold down
plate will properly contact the seal on cartridge filter top.
14.14.10. Torque filter lid cap screws to 41Nm (30 FT LB) in a star pattern.
14.14.11. Turn the handle of the filter ball valve to the desired filter, “A” or “B”.
DO NOT REUSE DIRTY FILTER CARTRIDGES.
Handle Position
RUN FILTER “A”
Handle Position
RUN FILTER “B”
14.13–14.14
31
ChipBLASTER Inc
14.15. DUAL MANUAL FILTER: (CHIPBLASTER OPERATING)
!
EXERCISE EXTREME CAUTION WHEN CHANGING THE FILTER
CARTRIDGE WHILE THE MACHINE IS IN OPERATION.
!
ENSURE THAT THE SELECTOR BALL VALVE IS POSITIONED TO
DESIRED FILTER TO PREVENT COOLANT FROM FLOWING
THROUGH THE FILTER THAT IS BEING SERVICED. IF THE BALL
VALVE IS POSITIONED TO DIRECT FLOW WHILE THE LID IS OFF
POTENTIAL PERSONAL INJURY COULD RESULT.
14.15.1. Check the handle of the filter ball valve. If the handle is in the “B” position
(running "B" filter) then it is safe to change filter "A".
14.15.2. If the filter ball valve handle is in the “A” position (running "A" filter) then it is
safe to change filter "B".
14.15.3. Ensure that pressure is relieved from the housing. Then, remove the filter lid
hold-down screws using a 17mm wrench.
14.15.4. Remove lid and inspect for damage. Be careful not to damage filter hold down
plate, seal or spring. Set lid aside.
14.15.5. Pull the filter cartridge out of the housing.
14.15.6. Install the new filter cartridge in the housing. Ensure cartridge it is all the way
down and firmly seated.
14.15.7. Inspect the lid seal O-ring for cracks or tears, replace if damaged.
14.15.8. Inspect filter hold down plate, spring and seal. Replace any damaged parts.
14.15.9. Reinstall the filter lid. Make sure the O-ring is in the proper groove before
installing the lid. Set the filter lid straight down so that the filter hold down
plate will properly contact the seal on cartridge filter top.
14.15.10. Torque filter lid cap screws to 41Nm (30 FT LB) in a star pattern.
Vent Valve
Thumb Valve
14.15
ChipBLASTER Inc
32
14.16. FILTER REPLACEMENT FORM
PLEASE MAKE A COPY OF THE FILTER REPLACEMENT FORM BEFORE ORDERING.
14.16
33
ChipBLASTER Inc
14.0. PREVENTATIVE MAINTENANCE: (Cont.):
14.17. FILTER ASSEMBLIES – CHECK FOR LEAKS:
14.17.1. Check inlet and outlet hoses for leaks especially at hose clamps. If leaks are
detected, replace hoses. THE ChipBLASTER MUST BE SHUT DOWN.
14.18. FILTER ASSEMBLIES – CLEANING:
14.18.1. Remove filter lids and cartridges, see Filter Changing Procedure, Section 14.14.
Remove all coolant and debris from filter housing using a wet/dry vacuum or
other suitable device.
14.27. PUMP MOUNTING BOLTS – CHECK:
14.27.1. The return (transfer) pump mounting bolts should be checked for tightnes. The
recommended torque is 24 Newton-meters (210 IN LB).
14.27.2. The bolts for the main high pressure pump to mounting rails should be torqued
to 23 Newton-meters (200 IN LB).
14.29. RETURN (TRANSFER) PUMP – CHECK FLOW RATE:
14.29.1. This pump should be checked every six months to insure the correct flow rate.
If the flow rate has decreased, the pump should be rebuilt or replaced.
14.29.2. An indication the return pump may be clogged will be constant low pressure at
the filter inlet
14.29.3. The ChipBLASTER must be powered down and the disconnect placed in the
OFF position and locked out.
14.29.4. Remove the inlet and outlet hoses by loosening the hose clamps. Inspect the
inlet and outlet for chips that may have accumulated. Remove chips as
required.
14.29.5. Remove the four (4) bolts using a 7/16” wrench that hold the casting in place.
14.29.6. Clean all chips from the casting and impeller. Be careful not to damage the back
of the casting where it mates to the adapter, as this is a metal-to-metal seal.
14.29.7. Re-assemble the casting and replace the four (4) bolts. Insure the casting is
snugly in place. Check the shaft to insure it rotates freely. (Use the screwdriver
slot in the motor to turn the shaft).
14.29.8. Re-install the inlet and outlet hoses and tighten the hose clamps securely.
14.29.9. Re-power the ChipBLASTER unit and check for leaks.
14.30. RETURN (TRANSFER) PUMP – CHECK FOR LEAKS:
14.30.1. Check for leaks around the casting where it mates with the adapter.
14.30.2. If pump is leaking around casting, tighten the four (4) bolts. DO NOT OVER
TIGHTEN.
14.31. RETURN (TRANSFER) PUMP – CHECK INLET and OUTLET:
14.31.1. Check for leaks around the inlet and outlet connections.
14.31.2. If the hoses are cracked or cut replace hoses.
14.17-14.31
34
ChipBLASTER Inc
15.0. TROUBLESHOOTING:
Fault
Symptom
Cure
ChipBLASTER has no power
Disconnect switch is off
Turn on disconnect 1DS
Control Relay CR1 not energizing
No command voltage from
machining center
Faulty relay
Check command voltage
Replace relay
Main pump motor not operating
MR1 trip or not turned on
Circuit Breaker 1CB trip
Reset or turn on MR1
Reset Circuit breaker 1CB
Cannot achieve required
outlet pressure
Pump seals are bad
faulty solenoid valve
Faulty regulator
Incorrect nozzle size
Plugged or kinked Hose
Replace seals
Replace solenoid valve
Check or replace regulator
Replace nozzle with a recommended
standard size. See section 28 of this
manual.
Adjust regulator. See
Section 16.0 of this manual
Replace hose
No coolant flowing when high
pressure is operating
Solenoid valve is sticking
Solenoid coil is faulty
Regulator sticking
Replace solenoid valve
Replace coil
Replace regulator
Coolant is pulsating from high
pressure nozzle
High-pressure pump valve
is sticking.
Hose plugged
Clean or replace the valve
Replace Hose
Return pump not operating
MR3 trip or not turned on
Circuit Breaker 2CB trip
Reset or turn on MR3
Return pump coolant flow
rate slow
Plugged inlet
Chips stuck inside
pump vane
Motor wired in reverse
Clean inlet
regulator not set properly
Clean chips from inside pump
Change motor rotation
Coolant is foaming
Incorrect coolant
Use coolant with anti-foaming agents
for high pressure
ES relay ON (See Note below)
Main motor overload trip
Return Pump motor
overload trip
Pressure switch “1PS” trip
Reset motor overload MR1
System won’t operate
Reset motor overload MR3
Switch filter or change cartridge
Loss of 120VAC - Circuit
breaker 3CB trip
Loss of 3 ph power Breaker in machine tool trip Reset Breaker in Machine Tool
15.0
35
ChipBLASTER Inc
15.0. TROUBLESHOOTING (Cont.):
!
NOTE: BEFORE RESETTING A MOTOR STARTER OVERLOAD, FIRST
DETERMINE THE CAUSE AND CORRECT!
FOR ADDITIONAL INFORMATION PLEASE CONTACT ChipBLASTER
SERVICE DEPARTMENT AT (814) 724-6278.
WHEN CONTACTING ChipBLASTER SERVICE DEPARTMENT PLEASE
HAVE MODEL AND SERIAL NUMBER OF YOUR ChipBLASTER UNIT.
15.1. TROUBLESHOOTING FLOW CHART (Figure 3):
DO YOU HAVE CORRECT
PRESSURE AT
THE MACHINE TOOL?
DO YOU HAVE PRESSURE
ON ChipBLASTER's HIGH
PRESSURE GAUGE?
YES
ChipBLASTER IS
OKAY
YES
NO
DO YOU HAVE ANY
PRESSURE ON
ChipBLASTER's HIGH
PRESSURE GAUGE?
YES
NO
HIGH PRESSURE
GAUGE NOT
WORKING
IS PRESSURE
HIGHER OR LOWER
THAN NORMAL?
HIGHER
NOZZLE PLUGGED
WITH CHIPS, NOZZLE
TOO SMALL
NO
FAULTY REGULATOR,
N.O. SOLENOID
NOT WORKING,
BROKEN BELT
LOWER
IS HIGH PRESSURE
PUMP RUNNING?
N.O. SOLENOID
DEFECTIVE
YES
NOZZLE OPENING TOO LARGE,
LEAKAGE BETWEEN
ChipBLASTER AND
MACHINE TOOL NOZZLE,
DEFECTIVE REGULATOR
NO
DEFECTIVE STARTER OR
OVERLOAD,
FAULTY MOTOR,
IS POWER ON?
Figure 3
15.1
ChipBLASTER Inc
16.0. PRESSURE ADJUSTMENT PROCEDURE:
36
This procedure is to be used to adjust the output pressure of the ChipBLASTER high-pressure unit.
Please be aware that you must have working knowledge of the complete ChipBLASTER system
before making any pressure adjustments. All ChipBLASTER units are shipped out of the factory
pre-set at a working pressure of 69 Bar (1000 psi), unless otherwise specified by the end user. This
pressure can be read from the high pressure gauge located on the top of the ChipBLASTER unit.
Check the machine tool specifications for a maximum operating pressure before proceeding with
this procedure.
DO NOT EXCEED THE MANUFACTURERS MAXIMUM OPERATING
PRESSURE.
Procedure:
16.0.1. Locate the regulator on the manifold assembly under the ChipBLASTER’s electrical
enclosure. The regulator will need to be accessible during this procedure for
achieving settings over 69 Bar (1000 psi).
16.0.2. Regulator adjustment: The regulator is used to regulate the pressure to the
machining center from over pressure.
16.0.3. Loosen locking nut using a ¾” wrench.
16.0.4. Turning the adjustment screw in using a 3/16” hex head wrench (clockwise)
increases the regulator setting.
16.0.4. Turning the adjustment screw out (counter clockwise) decreases the regulator
setting.
16.0.5. After setting the regulator, tighten the locking nut.
USE EXTREME CAUTION WHEN WORKING ON LIVE EQUIPMENT.
If you cannot achieve the desired output pressure, please check to be sure that the unloader has been
properly set. Also refer to the orifice reference chart (SECTION 28) included in this manual to verify
nozzle size to make sure you are within the machine’s capabilities.
69 Bar (1000 PSI) at 27.4 l/min (7.25GPM):
Factory setting is with a #55 (0.080” [2 mm] dia.) nozzle to achieve 69 Bar (1000 psi)
16.0
ChipBLASTER Inc
17.0. HIGH PRESSURE PUMP REPLACEMENT:
37
IT IS EXTREMELY IMPORTANT TO DISCONNECT AND
LOCKOUT ANY AND ALL POWER SOURCES BEFORE
ANY WORK IS TO BE PERFORMED ON THE
ChipBLASTER UNIT!
17.1. LUBRICATION
!
After pump replacement procedure, check to ensure that the replacement pump
crankcase contains oil, and is at the proper level. Use synthetic Mobil One 15w50 oil only.
17.2. DRIVE BELT REMOVAL
17.2.1. Loosen the four mounting bolts, located on the pump, to allow for pump
adjustment or drive belt removal. To remove the drive belt, release the belt
tension by advancing the pump forward. Turning the pump mount adjustment
idlers counter-clockwise will advance the pump forward, towards the driven
pulley until the belt can be easily removed.
DO NOT PRY OR FORCE THE DRIVE BELT OFF OF THE PULLEYS,
THIS MAY RESULT IN PERMANENT DAMAGE TO THE PULLEY OR
BELT.
!
ONCE THE DRIVE BELT HAS BEEN REMOVED, VISUALLY INSPECT
IT FOR ABNORMAL WEAR AND TOOTH SHEAR. REPLACE THE
BELT AS NECESSARY.
17.3. THE REPLACEMENT PUMP
17.3.1. Transfer the driven pulley, intake, discharge fittings and the high pressure pump
brackets (with fasteners) from the defective pump to the new pump.
17.3.2. Apply anti-seize compound to the high-pressure pump shaft before mounting the
driven pulley.
17.3.3. Install the plumbing fittings to the high-pressure manifold. The top ports on the
pump manifold are for high-pressure connections (output). The bottom ports are
for low-pressure connections (input).
17.3.4. Torque all hex and square plumbing fittings to 48.8 Nm. (36 ft-lbs).
17.3.5. Reinstall the pump brackets to the new high-pressure pump and mount the
pump/bracket assembly on the machine sub plate.
17.0
38
ChipBLASTER Inc
18.0. BELT INSTALLATION:
18.1. Align Sprockets:
18.1.1. Sprocket alignment and parallelism of the shafts is very important. Proper
alignment helps to equalize the load across the entire belt width, thereby reducing
wear and extending belt life. The sketches below show how to align a
Synchronous drive properly. PLACE A STRAIGHTEDGE against the outside
edge of the sprockets as shown in Figure 11; Figure 12 shows the four points
where the straightedge should touch the sprockets.
Figure 11
Figure12
18.1.2. The straightedge should cross the sprockets at the widest possible part. (See
Figure 13.) OR USE A STRING. Tie a string around either shaft (Figure 14) and
pull it around and across the outer edge of both sprockets. Figure 15 shows how
the string should touch four points when the drive is properly aligned. After
aligning the sprockets, check the rigidity of the supporting framework. Shafts
should be well supported to prevent distortion and a resulting change in the center
distance under load. Do not use spring-loaded or weighted idlers. Idler sprockets
or pulleys must be locked into position after adjusting belt tension. Please note:
At least one sprocket must have a flange.
Figure 13
Figure 14
Figure 15
18.2. Install Belt:
18.2.1. Do not pry or otherwise force the belt onto the sprockets, as this can result in
permanent damage to the belt. Either remove the sprocket's outside flange or
reduce the center distance between the sprockets so that the belt can be easily
installed.
18.3. Belt Tensioning - General Method
18.3.1. This method of tensioning Synchronous belts should satisfy most drive
requirements.
18.3.1.1. Reduce the center distance so that the belt can be placed onto the
sprockets without forcing or prying it over the flanges.
18.0
ChipBLASTER Inc
18.0. BELT INSTALLATION (Cont.):
39
18.3.1.2. Increase the belt tension until the belt feels snug or taut. Avoid over
tensioning the belt.
18.3.1.3. Start the drive and apply the most severe load condition. This may be
either the motor starting torque or during the work cycle. A belt that is
too loose will “jump teeth" under the most severe load condition. When
this occurs, gradually increase the belt tension until satisfactory
operation is achieved.
18.4. Belt Tensioning - Force Deflection Method:
18.4.1. An alternate numerical method can also be used to properly tension the belt on a
Synchronous drive. This procedure, commonly referred to as the Force Deflection
Method, consists of measuring the pounds of force required to deflect the belt a
given amount.
18.4.1.1. Install the belt as per Steps 1 and 2 of the General Method. Measure the
span length (in inches) as illustrated in Figure 11.
18.4.1.2. From Figure 11, determine the deflection height required for the drive.
The deflection height is always 1/64" per inch of span length. For
example, a 32" span length requires a deflection of 32/64" or 1/2". To
measure the deflection height place a straightedge from sprocket to
sprocket on top of the belt or wrap a string or steel tape around the
sprockets on top of the belt. This will serve as a reference line to
measure deflection inches.
18.4.1.3. Using the formula at below, calculate the minimum and maximum force
values (lbs.).
18.4.1.4. Using a spring scale, apply a perpendicular force to the belt at the midpoint of the span as illustrated in Figure 1. NOTE: For belts wider than 2
inches, it is suggested that a rigid piece of key stock or something
similar be placed across the belt between the point of force and the belt
to prevent belt distortion. Compare this defection force value to that
found in 18.4.1.4. Adjust belt tension accordingly.
Actual belt installation tension required depends on peak loads, system
rigidity, teeth in mesh. etc. In some instances it may be necessary to
gradually increase the belt tension to achieve proper operation of the drive.
18.0
ChipBLASTER Inc
18.0. BELT INSTALLATION (Cont.):
40
Figure 16
Maximum Force=
4000 x DHP
RPM x Pitch Diameter
Minimum Force =
5000 x BHP
RPM x Pitch Diameter
DHP = Belt Horsepower or Motor Horsepower x Recommended Service Factor
BHP = Brake Horsepower Or Motor Horsepower
RPM = Speed of Fastest Shaft
Pitch Diameter = Diameter of Smallest Sprocket
REFER TO CHART FOR DEFLECTION AND FORCE FOR THE MODEL IN USE.
REINSTALL ALL (GUARDS) PROTECTIVE PANELING ON THE
ChipBLASTER UNIT.
18.5. Deflection and force chart:
18.5
ChipBLASTER Inc
19.0. SYSTEM CONTAMINATION PURGING PROCEDURE:
41
19.1. Tools Required:
19.1.1.
19.1.2.
19.1.3.
19.1.4.
19.1.5.
4mm Hex Head Wrench
3/8” Hex Head Wrench
5 Gallon Fluid Container
Section of Low Pressure Hose
Adapter Fitting (½” NPT to Hose Connection)
19.2. Change Filter Cartridge: SEE SECTION 14.14
!
IF THERE IS PRESSURE PRESENT DO NOT OPEN FILTER HOUSING
SEEK ASSISTANCE FROM QUALIFIED MAINTENANCE
PERSONNEL TO RELIEVE PRESSURE.
19.3 Install Purge Hose:
19.3.1. Remove right side access panel from ChipBLASTER unit using 4mm hex head
wrench (Panel on right side as viewed from enclosure end).
19.3.2. Locate & remove ½” NPT plug from end of manifold block using 3/8” hex head
wrench.
REGULATOR
½” NPT
PLUG
MANIFOLD
BLOCK
19.3.3. Install ½” NPT to hose adapter fitting in the end port and attach low-pressure
hose.
19.0
42
ChipBLASTER Inc
19.0. SYSTEM CONTAMINATION PURGING PROCEDURE (Cont.):
!
NOTE: ATTACH DISCHARGE TUBE TO FLUID CONTAINER IN
ORDER TO ELIMINATE FLUID SPILLING.
19.4. FLUSHING CYCLE
19.4.1. Manually energize CR1 three (3) times for three (3) seconds.
19.5. REPLACE ALL PLUMBING FITTINGS AND PANELS TO THEIR
ORIGINAL CONFIGURATION.
REPLACE ALL GUARDS BEFORE OPERATING ChipBLASTER
Any questions on the Contamination Purging Procedures, please contact the
ChipBLASTER Service Department at (814) 724-6278. Have the model and serial
number of your ChipBLASTER unit.
19.0
2L1
460 VAC
WIRING
3 CB
2L3
129
SEE CHART
H2
H3
H1
H3
116
118
119
120
121
122
123
124
125
H2
X2
127
X1
COM
4 CB
200
SEE CHART
100
H4
1 TX
SEE CHART
PRIMARY TRANSFORMER
TAP CONNECTION
230V INPUT CONNECT H1,H3
CONNECT H2,H4
460V INPUT CONNECT H2,H3
200
H1
250VA
115
117
THIS PRINT IS THE PROPERTY OF ChipBLASTER. THIS
DOCUMENT CONTAINS PROPRIETARY INFORMATION AND SUCH
INFORMATION MAY NOT BE DISCLOSED TO OTHERS FOR ANY
PURPOSE OR USED FOR MANUFACTURING PURPOSES WITHOUT
WRITTEN PERMISSION FROM ChipBLASTER.
213T
0.0005
0.005
0.01
1/32
REMOVE ALL BURRS &
BREAK ALL SHARP EDGES
X.XXXX
X.XXX
X.XX
X.X
(NONACCUMULATIVE)
13 A
6.5 A
IT.
9.5 A
QTY.
1
1
2.7 A
2.7 A
DESCRIPTION
Chip BLASTER
19 A
C
SIZE:
UNIT:
JRG
DRAWN BY:
JRG
APPROVED BY:
NTS
SCALE:
CUSTOMER:
11JAN06
DATE:
PART No.
1 OF
SHEET:
3
D16, D30
POWER WIRING
TITLE:
1.4 A
1.4 A
230 VAC 460 VAC
FLA
FLA
PHONE: (814)724-6278
13605 S. MOSIERTOWN ROAD
FAX: (814)724-6287
MEADVILLE, PA 16335
www.chipblaster.com
USA
184T
5
113
7.5
FRAME
SIZE
MR 1
Chip BLASTER Tolerances
250VA
114
2A
112
2A
111
2A
110
2A
109
4A
108
4A
107
16 A
RETURN PUMP
SEE CHART
16 A
3T3
3 MTR
16 A
2L3
16 A
3T2
1L3
16 A
2L2
16 A
3T1
1L2
25 A
SEE CHART
HP
MR 3
FRAME 230 VAC 460 VAC
FLA
FLA
SIZE
SEE CHART
20 A
HP
1T3
MAIN PUMP
SEE CHART
VA
1L3
1 MTR
120 VAC
1Ø
60 HZ
1T2
1L3
RETURN PUMP
3MTR
1L2
L3
460 VAC 230 VAC 460 VAC 230 VAC 460 VAC
3Ø
3Ø
3Ø
3Ø
3Ø
60 HZ
60 HZ
60 HZ
60 HZ
60 HZ
2L1
2CB
1T1
D30
128
1L2
D16
126
L2
230 VAC
3Ø
60 HZ
106
1L1
1L1
MODEL
105
3
1CB
MAIN PUMP
1MTR
104
GND
3
2
1L1
1 TX
103
L3
2
1 DS
4 CB
102
L2
L1
3 CB
101
L1
1
2 CB
100
1
1 CB
DESCRIPTION
CHANGED 3CB @ 230VAC
JRG
NAME
MAT'L:
D-001
DRAWING NUMBER:
DATE
16MAY06
NOTES
230 VAC
OR
460 VAC
3Ø
60 HZ
CHART
B
REV
B
REV:
ChipBLASTER Inc
20.0. ELECTRICAL DRAWINGS (POWER SCHEMATIC USA):
43
H4
20.0
126
128
129
125
2L1
3 CB
127
SEE CHART
116
118
119
120
121
122
123
124
H1
H2
X4
H3
2L3
X3
H4
1 TX
X1
LINE CONNECTIONS:
380 VAC L1 TO H1, L3 TO H2
COM
200
X2
115 VAC
4 CB
SEE CHART
100
200
115
117
REMOVE ALL BURRS &
0.0005
0.005
0.01
1/32
(NONACCUMULATIVE)
X.XXXX
X.XXX
X.XX
X.X
6.5 A
IT.
9.5 A
QTY.
1
1
2.7 A
2.7 A
DESCRIPTION
Chip BLASTER
13 A
13 A
C
SIZE:
UNIT:
R.B.
DRAWN BY:
APPROVED BY:
NTS
SCALE:
NAME
PART No.
CUSTOMER:
1A OF
SHEET:
3
NOTES
D-001-CE
DRAWING NUMBER:
MAT'L:
D16, D30 CE APPROVED
POWER WIRING
TITLE:
1.4 A
1.4 A
16 MAY 06
DATE:
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
www.chipblaster.com
USA
213T
184T
114
7.5
113
5
200 VAC 380 VAC
3Ø
FLA
50 HZ
MR 1
112
250VA (CE)
111
250VA (CE)
110
4A
109
4A
108
4A
SEE CHART
4A
107
5A
RETURN PUMP
SEE CHART
5A
3 MTR
16 A
3T3
16 A
2L3
16 A
1L3
16 A
3T2
16 A
2L2
16 A
1L2
25 A
3T1
20 A
MR 3
FRAME
SIZE
SEE CHART
D30
2L1
2CB
HP
1T3
MAIN PUMP
SEE CHART
FRAME 200 VAC 380 VAC
FLA
SIZE 3 Ø
50 HZ
1L3
1 MTR
D16
HP
1T2
1L3
VA
1L2
L3
120 VAC
1Ø
50 HZ
1L1
1T1
380 VAC 200 VAC 380 VAC 200 VAC 380 VAC
3Ø
3Ø
3Ø
3Ø
3Ø
50 HZ
50 HZ
50 HZ
50 HZ
50 HZ
1L2
RETURN PUMP
3MTR
L2
200 VAC
3Ø
50 HZ
106
PE
1L1
MODEL
105
3
1CB
MAIN PUMP
1MTR
104
PE
3
2
1L1
1 TX
103
L3
2
1 DS
4 CB
102
L2
L1
3 CB
101
L1
1
2 CB
100
1
1 CB
DESCRIPTION
380 VAC
3Ø
50 HZ
CHART
REV
DATE
A
REV:
ChipBLASTER Inc
20.0. ELECTRICAL DRAWINGS (POWER SCHEMATIC CE):
44
20.0
11
212
214
216
218
220
221
100
95
207
100A
209
100A
211
100A
213
100A
215
100A
217
96
11
21
11
13
21
CR1
14
CR1
24
MR1
14
95
104
96
11
CR3
12
DIRTY FILTER DETECT
(SET @ 15PSI)
PS1
TM1
100A
107
5
9
A1
205
14
ES
103
A1
MR1
105
CR31
14
106
108
13
TM1
1
BLACK
A1
24
100A
A2
READY SIGNAL
ON = OKAY
A2
MAIN PUMP
14
ON DELAY TIMER
(SET @ 6 SEC.)
SOL "C"
WHITE
N.O.
2
A2
DUMP SOLENOID
MR3
RETURN PUMP
CR31
LOW PRESSURE
COOLANT
PB1
PURGE PUSH BUTTON
219
AL1
DIRTY FILTER ALARM
222
223
224
225
226
227
JRG
DRAWN BY:
JRG
APPROVED BY:
NTS
SCALE:
PART No.
2 OF
SHEET:
3
D30-80-1
CONTROL WIRING
CUSTOMER:
21JUN07
DATE:
ES
C
102
Chip BLASTER
MR3 OL
POWER ON LIGHT
UNIT:
101
TITLE:
G
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
www.chipblaster.com
USA
MR1 OL
TB1-COM
SIZE:
100
LT1
REMOVE ALL BURRS &
210
TB1-100
0.0005
0.005
0.01
1/32
208
100
COM
X.XXXX
X.XXX
X.XX
X.X
204
127
206
100
DESCRIPTION
203
QTY.
201
IT.
202
129
(NONACCUMULATIVE)
DESCRIPTION
200
REV
MAT'L:
NOTES
D30L-002
DRAWING NUMBER:
NAME
DATE
A
REV:
ChipBLASTER Inc
20.0. ELECTRICAL DRAWINGS (Cont.):
45
228
COM
20.0
213
214
217
218
219
220
221
222
223
224
225
226
227
228
100
212
MR1 OL
MR3 OL
104
100
95
14
96
21
95
24
206
208
96
207
102
210
DIRTY FILTER DETECT
(SET @ 15PSI)
PS1
TM1
100
106
5
9
A1
205
102
A1
MR3
11
CR3
12
103
A1
TM1
209
1
BLACK
105
A1
107
A2
MAIN PUMP
A2
RETURN PUMP
A2
ON DELAY TIMER
(SET @ 6 SEC.)
SOL "C"
WHITE
N.O.
2
A2
DUMP SOLENOID
ES
READY SIGNAL
ON = OKAY
AL1
DIRTY FILTER ALARM
215
216
COM
APPROVED BY:
JRG
JRG
NTS
SCALE:
PART No.
2 OF
SHEET:
3
D30-80-1
CONTROL WIRING
CUSTOMER:
11JAN06
DATE:
MR1
C
102
DRAWN BY:
ES
UNIT:
101
Chip BLASTER
CR1
POWER ON LIGHT
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
www.chipblaster.com
USA
G
REMOVE ALL BURRS &
211
11
LT1
COM
SIZE:
100
TITLE:
100
TB1-COM
0.0005
0.005
0.01
1/32
203
127
DESCRIPTION
100
X.XXXX
X.XXX
X.XX
X.X
204
TB1-100
QTY.
202
129
IT.
E
201
(NONACCUMULATIVE)
D
200
ADDED HORN
REVISED PER CUSTOMER SPEC.
C
DESCRIPTION
ADDED TIMER
CHANGED ES TO 4 POLE
B
REV
27FEB06
27FEB06
15 MAY 05
JRG
JRG
JRG
R.B.
D30-002
DRAWING NUMBER:
MAT'L:
NOTES
DATE
16FEB06
NAME
E
REV:
ChipBLASTER Inc
46
47
ChipBLASTER Inc
9
LOW PRESSURE
COOLANT
CR31
COMMON
ERROR SIGNAL
(READY SIGNAL)
COMMON
11 N.O. ERROR SIGNAL
(READY SIGNAL)
CLOSED = OKAY
12 N.C. ERROR SIGNAL
10
ES
ES
(READY SIGNAL)
OPEN = OKAY
CONTROL PLUG (9PIN)
OPTIONAL USE WITH MACHINE TOOL SPECIFIC INTERFACE
1
2
3
4
COMMON
6
ERROR SIGNAL
(READY SIGNAL)
COMMON
N.O. ERROR SIGNAL
(READY SIGNAL)
CLOSED = OKAY
9
DRAWING NUMBER:
A
D30L-003
3 OF
21JUN07
DATE:
SCALE:
NTS
JRG
APPROVED BY:
DRAWN BY:
JRG
SHEET:
3
MAT'L:
D30-80-1 STANDARD CONTROL
AND POWER INTERFACE
COMMON
LOW PRESSURE
OPTION
8
CUSTOMER:
INDEX
5
7
GND (PE)
COOLANT #1 ON
UNIT:
8
C
INDEX
CR3
SIZE:
7
COMMON
REMOVE ALL BURRS &
REV
6
Chip BLASTER
COOLANT #1 ON
CR1
NOTE:
1. CR1 & CR3 COIL VOLTAGE IS DEPENDENT
ON THE MACHINE TOOL OUTPUT
VOLTAGE.
2. SPARE CABLE WIRES: GRAY, BROWN,
PINK,
ORANGE, YELLOW, WHITE, WHITE/GREEN.
3. 12 PIN COMPONENTS
P/N 5810 (1) INSERT
P/N 5808 (1) HOUSING
4. 9 PIN COMPONENTS
P/N 5146 (1) RECEPTACLE
P/N 5149 (1) CAP
P/N 5150 (9) CRIMP PINS
P/N 0560 (1) O-RING
5. TO USE THE LOW PRESSURE OPTION
CONNECT CONTROL VOLTAGE AS
REQUIRED TO PIN9 ON 12 PIN PLUG
OR PIN 5 ON 9 PIN PLUG. THEN CONNECT
COM 31 TO COM1 OR COM3 DEPENDING
ON VOLTAGE USED.
0.0005
0.005
0.01
1/32
GND (PE)
(NONACCUMULATIVE)
5
L3
X.XXXX
X.XXX
X.XX
X.X
4
3 PHASE SUPPLY
TITLE:
GND (PE)
L2
DESCRIPTION
3
L1
QTY.
DESCRIPTION
2
IT.
1
3 PHASE SUPPLY INPUT
REFER TO POWER
WIRING FOR
CURRENT DRAW.
PART No.
1DS
NAME
STANDARD POWER INTERFACE PLUG (12 PIN)
ChipBLASTER
MACHINING CENTER
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
USA
www.chipblaster.com
NOTES
DATE
REV:
N.C. ERROR SIGNAL
(READY SIGNAL)
OPEN = OKAY
GND (PE)
20.0
ES
ES
GND (PE)
6
7
8
2PS
NOTE 5
CR1
COOLANT #1 ON
COMMON
INDEX
COMMON
9
NOTE 5
RUN RELAY SIGNAL
SEE NOTE 5
FILTER DIRTY SIGNAL
(SET @ 15PSI)
10
ERROR SIGNAL
(READY SIGNAL)
COMMON
11 N.O. ERROR SIGNAL
(READY SIGNAL)
CLOSED = OKAY
12 N.C. ERROR SIGNAL
(READY SIGNAL)
OPEN = OKAY
CONTROL PLUG (9PIN)
1
2
3
4
5
6
7
8
9
COOLANT #1 ON
COMMON
INDEX
COMMON
FILTER DIRTY SIGNAL
ERROR SIGNAL
(READY SIGNAL)
COMMON
N.O. ERROR SIGNAL
(READY SIGNAL)
CLOSED = OKAY
N.C. ERROR SIGNAL
(READY SIGNAL)
OPEN = OKAY
GND (PE)
CR1
C
SIZE:
UNIT:
JRG
DRAWN BY:
JRG
APPROVED BY:
NTS
SCALE:
CUSTOMER:
11JAN06
DATE:
PART No.
3 OF
SHEET:
3
MAT'L:
D30-003
D
REV:
16 MAY 06
NOTES
DRAWING NUMBER:
DATE
27FEB06
27FEB06
D30-80-1 STANDARD CONTROL
AND POWER INTERFACE
TITLE:
GND (PE)
REMOVE ALL BURRS &
5
L3
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
www.chipblaster.com
USA
4
3 PHASE SUPPLY
0.0005
0.005
0.01
1/32
GND (PE)
L2
DESCRIPTION
3
L1
QTY.
2
X.XXXX
X.XXX
X.XX
X.X
INSTALL JUMPERS
ON BOTTOM OF
THEMINAL STRIP
1
CR3
IT.
REFER TO POWER
WIRING FOR
CURRENT DRAW.
Chip BLASTER
R.B.
JRG
JRG
NAME
1DS
(NONACCUMULATIVE)
DESCRIPTION
CHANGED ES TO 4 POLE
ADDED HORN
ADDED DIRTY FITER OR
RUN RELAY SIGNAL OPTION
ChipBLASTER
MACHINING CENTER
B
C
D
REV
ChipBLASTER Inc
48
PIN
1
2
3
4
5
6
7
8
9
10
11
12
5
6
7
8
2
1
9
10
11
12
7, 8
7
CRT. #
WIRE COLOR
ITEM No.
L1
BLACK
1
L2
BLACK
1
BLACK
L3
1
GND
GREEN W/YELLOW
2
BLACK
1
3
WHITE/BLACK
COM1
3
3
PURPLE
3
COM3
GREEN
3
9
3
BLUE
E
3
RED
WHITE/RED
E1
3
E2
3
TAN
4
3
8
10
5
6m (20'-0")
NOTE 1
14
13
12
11
10
9
8
7
6
5
4
3
2
1
ITEM
4
6
LEAVE SLACK (2" MIN)
3
REV
B D16, D30
UNIT:
JRG
DRAWN BY:
JRG
APPROVED BY:
NTS
SCALE:
CUSTOMER:
20NOV06
DATE:
NAME
DATE
5045
4098
5810
5807
5484
5590
5506
5110
5095
7410
CB PART No.
1 OF
SHEET:
1
9513-6
DRAWING NUMBER:
AS NOTED
MAT'L:
D16 AND 30 12 PIN 6M POWER AND
CONTROL INTERFACE CABLE ASS'Y
TITLE:
DESCRIPTION
FORK TYPE TERMINAL, PN10-10F
WIRE MARKERS, TYTON TAG 26L-105
INSERT 12 PIN FEMALE, HARTING 09 38 012 2701
SIDE ENTRY HOOD, HARTING 09 30 024 0540
CONDUIT ADAPTER, HARTING 73 00 000 5314
NON-METALIC FLEXIBLE CONDUIT, 3/4", GRAY, CARLON
NON-METALIC FITTING, 3/4" STRAIGHT, T&B LT502
CABLE, SHIELDED #20-15
# 10 AWG THHN GREEN WITH YELLOW STRIPE WIRE, 90° C
# 10 AWG THHN BLACK WIRE, 90° C
DESCRIPTION AND MFG. PART NUMBER
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
USA
www.chipblaster.com
SIZE:
2
1
NOTES:
1. MARK BOTH ENDS OF WIRES WITH WIRE MARKERS - ITEM 9.
Chip BLASTER
1
38
1
1
1
20 FT.
2
27 FT.
27 FT.
81 FT.
QT'Y.
4
2 m (6'-6")
3/8"
TYP. WIRE
MARKER LOCATION
FOR BOTH ENDS
9
1/4"
A
REV:
ChipBLASTER Inc
49
3 2 1
6 5 4
9 8 7
CRT. #
1
COM1
3
COM3
9
E
E1
E2
PE
PIN
1
2
3
4
5
6
7
8
9
3,4,5,6
COLOR
GREEN
RED/GREEN
RED/YELLOW
RED
BLUE
WHITE
PURPLE
RED/BLACK
BLACK
1
1
25 FT.
QT'Y.
2
ITEM
1
4
CABLE, 20AWG 15 CONDUCTOR
CONNECTOR 2 SQUEEZE STR
1
PLUG, FREE HANGING, 9 PIN, SIZE 13
BOOT, HEAT SHRINK, SIZE 13
SOCKET, CRIMP, 24-20 AWG
MARK BOTH ENDS OF WIRES WITH WIRE MARKERS - ITEM 6
3
9
1
18
5
15 FT
6
1
JRG
4098
1:2
12OCT06
1
1
AS NOTED
9513-5
CABLE, CONTROL 9 PIN
D16 & D30
6
10FT
JRG
CB PART No.
5140
5141
5147
5148
5151
2
A
ChipBLASTER Inc
50
5
6
7
8
2
4
3
9
10
11
12
L2
L3
2
3
COM1
6
12
11
10
9
8
7
1
5
4
CRT. #
L1
PIN
1
6
5810
5807
1
1
2
7
6
5
JRG
----
51 FT.
1
QT'Y.
17 FT.
2
ITEM
----
2
JRG
CB PART No.
5506
15 FT.
4
5590
5484
5483
3
TOP ENTRY HOOD, HARTING 09 30 016 0440
5482
1
INSERT 6 PIN MALE, HARTING 09 31 006 2601
1
8
5111
----
9
SHIELDED CABLE, 18-3 AWG
17FT
10
10
11
1,2,4,10,11
15 FT
1
7
5
3
IF REQUIRED.
ADDITIONAL CONDUCTORS MAY BE ADDED
CAN BE OPENED IN ORDER THAT
LEAVE SLACK (2" MIN) SO THAT CONNECTOR
1:2
3
8
5
L2
L3
2
3
COM1
6
6
5
3
1
16MAR06
1
2
9514-4
AS NOTED
POWER ADAPTER CORD FOR
D16 & D30 TO MORI SEIKI PLUG
1
5
4
CRT. #
L1
PIN
1
4
2
9
A
ChipBLASTER Inc
51
20.0
3 2 1
6 5 4
9 8 7
PIN
1
2
3
4
5
6
7
8
9
RED
TAN
E2
COLOR
E
CRT. #
6,8
17 FT.
QT'Y.
1
ITEM
1
4
1
1
5
1
1
6
2
1
7
CONNECTOR 2 SQUEEZE STR
1
CONDUIT ADAPTER , HARTING 73 00 000 5310
TOP ENTRY HOOD, HARTING 09 20 003 1440
6 PIN MALE INSERT, HARTING 09 70 006 2813
3
4
2
8
1 5 FT
9
1,9
JRG
3
2
1:2
PIN
1
2
3
4
5
6
4
RED
E
2
3
5
6
5
JRG
18MAY06
2
2
9516-4
AS NOTED
CONTROL ADAPTER CORD FOR
D16 & D30 TO MORI SEIKI PLUG
1
4
16MAR06
COLOR
TAN
CRT. #
E2
ADDED COLOR CODE
JRG
CB PART No.
5140
5141
5487
5486
7532
5147
5148
5151
4098
B
B
ChipBLASTER Inc
52
20.0
53
9
FILTER CHANGE TO PIN C
CR1
2PS
FILTER DIRTY SIGNAL
(SET @ 15PSI)
NOTE 5
INSTALL JUMPERS
ON BOTTOM OF
THEMINAL STRIP
10
ES
ES
11
12
ERROR SIGNAL (READY SIGNAL)
COMMON TO PIN A
NOT USED
N.C. ERROR SIGNAL (READY SIGNAL)
OPEN = OKAY TO PIN B
CONTROL PLUG (9PIN)
1
2
3
4
5
6
7
8
GND (PE)
9
NOT USED
NOT USED
A
30524
JRG
NTS
30JUN06
3 OF
3
MAT'L:
DRAWING NUMBER:
SHEET:
CUSTOMER:
DATE:
SCALE:
APPROVED BY:
DRAWN BY:
JRG
C
INSTALL JUMPERS
ON BOTTOM OF
THEMINAL STRIP
NOT USED
REMOVE ALL BURRS &
8
UNIT:
NOT USED
CR3
NOTE:
1. CR1 & CR3 COIL VOLTAGE IS 110VAC.
2. SPARE CABLE WIRES: GRAY, BROWN,PINK,
ORANGE, YELLOW, WHITE, WHITE/GREEN.
3. 12 PIN COMPONENTS
P/N 5810 (1) INSERT
P/N 5808 (1) HOUSING
4. 9 PIN COMPONENTS
P/N 5146 (1) RECEPTACLE
P/N 5149 (1) CAP
P/N 5150 (9) CRIMP PINS
P/N 0560 (1) O-RING
5. TO USE THE FILTER DIRTY SIGNAL
CONNECT TERMINAL 109 TO TERMINAL 9
6. 3 PHASE VOLTAGE IS SUPPLIED BY MACHINE
TOOL COOLANT PUMP MOTOR CONTACTOR.
7. TO USE CUSTOMERS MOTOR CONTACTOR
CONNECT TERMINAL 1 TO 100 AND COM 1
TO COM.
0.0005
0.005
0.01
1/32
7
NOT USED
X.XXXX
X.XXX
X.XX
X.X
REV
6
NOT USED
CR1
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
www.chipblaster.com
USA
PART No.
TITLE:
GND (PE) TO PIN H
DESCRIPTION
5
L3 TO PIN F
QTY.
GND (PE)
4
NOTE 6
3 PHASE SUPPLY
IT.
3
L1 TO PIN D
L2 TO PIN E
Chip BLASTER
DESCRIPTION
INSTALL JUMPERS
ON BOTTOM OF
THEMINAL STRIP
NOTE 7
2
1
D30 D16 INTERFACE TO
DAEWOO PUMA MX2000
1DS
REFER TO POWER
WIRING FOR
CURRENT DRAW.
(NONACCUMULATIVE)
NAME
ChipBLASTER
MACHINING CENTER
SIZE:
NOTES
DATE
REV:
ChipBLASTER Inc
Daewoo/Doosan Interface – Lathe
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
NOT USED
GND (PE)
20.0
H
PE
L2
L3
I
COM1
E
B
E2
F
C
8
L1
D
G
COM3
A
9
7
6
YELLOW
YELLOW
YELLOW
20
20
20
COM3
9
E2
5092
5092
5092
5092
-
16'
16'
16'
20
16'
YELLOW
20
COM1
-
-
-
20
-
-
7406
20
-
-
10
L3
-
BLACK
7406
7406
16'
16'
BLACK
BLACK
5095
16'
LENGTH PART NO
GRN W/YLW
COLOR
4
16'
10
10
L1
L2
10
AWG
PE
CRT.NO.
5
1) FEMALE CONNECTOR, VIEWED FORM TERMINATION SIDE
2) MALE CONNECTOR, VIEWED FROM TERMINATION SIDE
NOTE
NOTE#2
4
15'
12
9
8
6
-
-
-
3
2
1
PIN #
B
A
G
I
-
-
-
F
E
D
H
PIN #
HARTING CIRCULAR
3
NOTE#1
1
D30-80-1
2
JRG
2
1
2
4
1
15'
5
2
1
3
1
6
1
1
8
7
COM3
8
7
COM1
6
5
JRG
1:16
5810
5807
5484
5506
5590
5160
5164
5161
25 JUN 07
1
1
AS NOTED
30520-1
C
23MAY07
JRG
RB
D16 D30 DV30 INTERFACE CABLE
DAEWOO LATHE
DOOSAN
30JUN06
INSERT, 12 PIN FEMALE
HOOD, SIDE ENTRY
ADAPTER, PG21x3/4" NPT
CONNECTOR, 3/4" CONDUIT
CONDUIT, 3/4" NON-METALLC
FTG, COUPLING 3/4" NPT GRAY PVC
CIRCULAR MILL TO NPT ADAPTER
CONNECTOR, CIRCULAR 9 CONT
E2
12
11
10
9
9
4
1T1/L3
2
1S1/L2
PE
3
1R1/L1
1
B ADDED DV30
C REVISED E2 TO PIN B
WAS E1 FROM PIN 11
3 2 1
6 5 4
9 8 7
GREEN
8
1
1
1
1
1
1
17 FT.
QT'Y.
8
7
6
5
4
3
2
1
ITEM
1
2
SQUEEZE STR
CONNECTOR
CONDUIT ADAPTER
SIDE ENTRY HOOD
16 PIN MALE INSERT
JRG
5151
JRG
CB PART No.
5140
5141
7671
5068
5037
5147
5148
16
RED
RED/YELLOW
RED/GREEN
E
E1
E2
12
13
14
1:2
16
04JUN07
1
1
CONTROL CABLE
D16 & D30 TO KIWA
WHITE
COM2
11
15
RED/BLACK
COM1
10
9
15
GND
9
13
14
12
5
8
11
4
8
E2
10
3
9
2
1
7
8
RED/YELLOW
RED/GREEN
PURPLE
BLACK
COLOR
7
E1
3
CRT. #
1
5
6
7
RED
6
4
3
2
PIN
1
4
E
2
3
6
COM3
4
1,9
5
WHITE
3
3
7
15 FT
5
RED/BLACK
PURPLE
BLACK
COLOR
COM1
CRT. #
1
2
PIN
1
6,8
7421
AS NOTED
A
ChipBLASTER Inc
Kiwa Interface
55
20.0
5
6
7
8
2
4
3
9
10
11
12
GND
4
5
6
7
8
9
10
11
12
CRT. #
L1
L2
L3
PIN
1
2
3
6
1
9
2
15 FT.
2
17 FT.
51 FT.
QT'Y.
4
3
2
1
ITEM
JRG
JRG
CB PART No.
5099
5095
5506
5590
5484
5807
2
5
5810
1
5809
INSERT 12 PIN MALE, HARTING 09 38 012 2601
6
5129
----
SHIELDED CABLE, #20-4 (WEST PENN #3011)
1,2,4,10,11
7
8
17FT
10
10
11
15 FT
1
7
5
3
LEAVE SLACK (2" MIN) SO THAT CONNECTOR
CAN BE OPENED IN ORDER THAT
ADDITIONAL CONDUCTORS MAY BE ADDED
IF REQUIRED.
3
5
1:2
6
GND
4
5
6
7
8
9
5
6
7
8
1
2
4
3
9
10
11
12
1
2
POWER CABLE
D16 & D30 TO KIWA
10
11
12
CRT. #
L1
L2
L3
PIN
1
2
3
04JUN07
9
7420
AS NOTED
A
ChipBLASTER Inc
Kiwa Interface
56
20.0
57
5931 D30 STD
1
1
1 MAR 07
1:2
PANEL LAYOUT FOR D30-80-1
C
ChipBLASTER Inc
1CB
2CB
1DS
D30
RB
1TX
M R1
OL
M R3
OL
1TM
ES
M R3
CR3
M R1
4CB
CR1
3CB
MR1
MR1
OL
MR3
MR3
OL
CR31
D30
RB
1CB
1TM
1TX
ES
3CB
CR3
2CB
CR1
C
1:2
RB
4CB
1 MAR 07
1
1
1 MAR 07
5931 D30 STD
PANEL LAYOUT FOR D30-80-1
REVISED TO NEW LAYOUT
C
ChipBLASTER Inc
58
1DS
1"
1/4"
RED
FILTER INLET
GAUGE
1"
1"
1"
1"
M
3 MTR
1"
TRANSFER PUMP
3 MTR
1/4"
PS1
1/2"
FILTER DIRTY
SET @ 15PSI
1"
M
1/2"
0.0005
0.005
0.01
1/32
REMOVE ALL BURRS &
X.XXXX
X.XXX
X.XX
X.X
(NONACCUMULATIVE)
IT.
QTY.
1/2"
1/2"
DESCRIPTION
Chip BLASTER
1/2"
N.O.
DUMP
SOL "C"
DESCRIPTION
C
SIZE:
UNIT:
JRG
DRAWN BY:
JRG
APPROVED BY:
NTS
SCALE:
PART No.
NOTES
CUSTOMER:
1 OF
SHEET:
1
D30 SCH
DRAWING NUMBER:
MAT'L:
D30-80-1 PIPING SCHEMATIC
WITH DUAL FILTER
TITLE:
24FEB06
DATE:
C
REV:
12 MAY 06
R.B.
DATE
30 MAR. 06
NAME
R.B.
SHOP NOTES:
1. THIS DRAWING IS A SCHEMATIC ONLY OF
PIPING AND DOES REPRESENT AN ACTUAL
NUMBER OF FITTINGS REQUIRED TO PLUMB
MACHINE.
B ADDED HP CHECK VALVE
C CHANGED S.P. OF 1 PS TO 15
PSIG WAS 10 PSIG
PHONE: (814)724-6278
FAX: (814)724-6287
MEADVILLE, PA 16335
www.chipblaster.com
USA
HIGH PRESSURE
TOOLING ORFICE
HIGH PRESSURE
GAUGE
1/2"
MANIFOLD BLOCK
BLOWOFF
REGULATER
MACHINE TOOL SUMP
MACHINE TOOL
1/2"
HIGH PRESSURE 1/4"
PUMP
1 MTR
PS2
FILTER DIRTY
SET @ 15PSI
1"
10 MICRON
FILTER
10 MICRON
FILTER
FILTER OUTLET
GAUGE
BLUE
REV
ChipBLASTER Inc
21.0. SCHEMATIC PIPING DRAWING:
59
21.0
60
ChipBLASTER Inc
22.0. MECHANICAL ASSEMBLY:
22.1. GAUGE PANEL - TOP
ITEM No.
1
2
3
4
5
6
DESCRIPTION
FILTER OUTLET GAUGE
FILTER INLET GAUGE
FILTER SELECTOR BALL VALVE
HIGH PRESSURE GAUGE
FILTER LID “B”
FILTER LID “A”
PART No.
4077
4077
9526
4025
3208A
3208A
6
5
1
4
2
3
22.1
61
ChipBLASTER Inc
22.0. MECHANICAL ASSEMBLY (Cont.):
22.2. CONTROL PANEL - FRONT
ITEM No.
DESCRIPTION
1
CONTROL ENCLOSURE
2
POWER ON INDICATOR LIGHT
3
4
DIRTY FILTER ALARM HORN
12 PIN P & C INTERFACE RECEPTACLE
5
ChipBLASTER DATA NAMEPLATE – STD
ChipBLASTER DATA NAMEPLATE – CE
OPTIONAL 9 PIN CONTROL INTERFACE
RECEPTACLE
6
7
8
9
10
11
DISCONNECT SWITCH
RETURN (TRANSFER) PUMP INLET (HOSE BARB)
CASTER – RIGID
CASTER - SWIVELING
RELIEF VALVE (REGULATOR)
HIGH PRESSURE OUTLET
PART No.
6075
5753
+ 5997
2650
5808
+ 5809
661
762
5146
+ 5149
+ 5150
6077
6022
9069
9070
4546
4214
1
7
2
3
4
8
9
6
5
11
10
22.2
62
ChipBLASTER Inc
22.3. CONTROL PANEL – INSIDE ENCLOSURE
ITEM No.
DESCRIPTION
1
TRANSFORMER 250VA (STD)
TRANSFORMER 250VA (CE)
2
ES RELAY
3
CONTROL RELAY CR1 & CR3 (120VAC)
CONTROL RELAY CR1 & CR3 (24VDC)
4
TIMER 1TM
5
TERMINAL BLOCK
6
7
8
9
10
11
12
13
14
PART No.
6076
5911
5706-CSA
5909
5910
5545
5205
+ 5206
5402
5466
5020
5017
4991
4992
4990
5015
6077
6084
5492
5492
CIRCUIT BREAKER 4CB
CIRCUIT BREAKER 3CB
OVERLOAD MR1 230V
OVERLOAD MR1 460V
OVERLOAD MR3 230V
OVERLOAD MR3 460V
CONTACTOR MR3
CONTACTOR MR1
DISCONNECT 1DC
CIRCUIT BREAKER 1CB 230V
CIRCUIT BREAKER 1CB 460V
CIRCUIT BREAKER 2CB
14
1
13
2
12
11
3
10
3
9
4
8
5
6
7
22.3
63
ChipBLASTER Inc
22.4. SUB PLATE ELEVATION – LEFT SIDE
ITEM No.
1
2
3
4
5
6
7
8
9
10
11
DESCRIPTION
PART No.
FILTER HOUSING
3207
FILTER INLET
N/A
FILTER OUTLET
N/A
CHECK VALVE
9527
MAIN PUMP MOTOR
2007
TRANSFER PUMP 60Hz – WATER
2072A
TRANSFER PUMP 60Hz – OIL
4251A
2073A
4250A
RETURN (TRANSFER) PUMP INLET
N/A
RETURN (TRANSFER) PUMP OUTLET
N/A
HP PUMP FEED LINE
N/A
PRESSURE SWITCH 2PS (FACTORY SET @ 15 PSI)
9682
PRESSURE SWITCH 1PS (*RESET TO 10 PSI)
*9682
}
11
10
1
2
3
9
8
4
7
5
6
22.4
64
ChipBLASTER Inc
22.5. SUB PLATE ELEVATION – RIGHT SIDE
ITEM No.
DESCRIPTION
1
FILTER HOUSING
2
HIGH PRESSURE GAUGE FEED HOSE
3
4
MANIFOLD DUMP LINE
5
HP PUMP OUTLET/MANIFOLD FEED HOSE
6
MANIFOLD BLOCK
7
HP PUMP INLET
8
PUMP PULLEY (56T)
9
HP PUMP MOUNTING RAIL
10
HP PUMP SLIDE BASE
11
TIMING (DRIVE) BELT
12
DRIVE PULLEY - STD [60HZ] (28T)
DRIVE PULLEY - CE CERTIFIED [50HZ] (32T)
13
MAIN PUMP MOTOR
14
HIGH PRESSURE PUMP
15
FILTER OUTLET
16
CHECK VALVE
17
FILTER INLET
PART No.
3207
N/A
2072A
4251A
2073A
4250A
N/A
N/A
8308
N/A
2544
8286
2618
2556
2944
2595
2007
2119
N/A
9527
N/A
17
1
16
15
2
14
3
13
4
5
6
7
8
10
11
12
65
ChipBLASTER Inc
22.6. MANIFOLD BLOCK ASSEMBLY (PLAN VIEW)
ITEM No.
1
2
3
4
5
6
7
8
DESCRIPTION
RETURN (TRANSFER) PUMP
RETURN (TRANSFER) PUMP INLET (HOSE BARB)
MANIFOLD BLOCK
HIGH PRESSURE COOLANT OUTLET
RELIEF VALVE (REGULATOR)
DUMP LINE
HIGH PRESSURE COOLANT MANIFOLD INLET
SOLENOID (DUMP) VALVE “C” N.O.
PART No.
3510
6022
8308
N/A
4546
N/A
N/A
4002
8
7
1
6
2
3
4
5
22.6
66
ChipBLASTER Inc
22.0 MECHANICAL ASSEMBLY (Cont.):
22.7. FILTER ASSEMBLY:
ITEM No.
1
2
3
4
5
6
7
DESCRIPTION
FILTER LID WITH HOLD DOWN ASSEMBLY
FILTER CARTRIDGE (10 µM)
O-RING SEAL (DISPLACED FROM GROOVE)
O-RING GROOVE
FILTER HOUSING
FILTER INLET
VENT VALVE (INCL W/ LID ASSY)
PART No.
3208A
3015-10
572
N/A
3207
N/A
5543
1
7
2
3
4
5
6
22.7
67
ChipBLASTER Inc
22.8. SHIP LOOSE ITEMS
ITEM No.
1
2
3
4
5
6
7
8
DESCRIPTION
CASTERS - RIGID
LOW PRESSURE 25mm (1”) SUCTION HOSE
HOSE CLAMPS (LOW PRESSURE)
HIGH PRESSURE HOSE ASSEMBLY
FITTING, ½ JIS MALE x ½” BSPT MALE STRAIGHT
CASTERS - SWIVELING
FITTING, #8 JIC (37°) FEMALE SWIVEL x ½” NPT
STRAIGHT (CONNECT TO ChipBLASTER)
VALVE, CHECK ½” NPT FEMALE IN-LINE HP
PART No.
9069
9543
6080
4801
4214
9070
4004
4171
4214
6
1
4
2
5
3
7
8
5
22.8
68
ChipBLASTER Inc
22.13. SPARE PARTS:
REFER TO DATA NAMEPLATE ON ENCLOSURE FOR CORRECT MODEL OF YOUR UNIT
ITEM
No.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
DESCRIPTION
SOLENOID VALVE
N.O.
SOLENOID VALVE
N.C.
UNLOADER(REGULATOR)
3000 PSIG
UNLOADER(REGULATOR)
5000 PSIG
TRANSDUCER 0 - 2000 PSIG
TRANSDUCER 0 - 3000 PSIG
HIGH PRESSURE PUMP
NOT INCLUDED IN
SPARE PARTS KIT
FOR REFERENCE ONLY
HIGH PRESSURE PUMP
NOT INCLUDED IN
SPARE PARTS KIT
FOR REFERENCE ONLY
MAIN DRIVE BELT
MAIN DRIVE BELT
MAIN DRIVE BELT
MAIN DRIVE BELT
MAIN DRIVE BELT
MAIN DRIVE BELT
PRESSURE SWITCH
SPARE PARTS
D16
PART No.
KIT PART
NO.
36807
QT'Y. / KIT
D20
KIT PART
NO.
36867
QT'Y. / KIT
D30
KIT PART
NO.
36837
QT'Y. / KIT
4002
0
1
1
4001
0
1
0
4546
1
1
1
4642
0
0
0
9662
9670
0
0
0
0
0
0
2106
1 (60 HZ UNITS)
1 (60 HZ UNITS)
0
2119
1 (50 HZ UNITS)
1 (50 HZ UNITS)
1 (50/60 HZ UNITS)
2264
2412
2611
2621
2556
2938
9682
1
0
0
0
0
0
1
1
0
0
0
0
0
1
0
0
0
0
1
0
1
MINIMUM SUGGESTED WORKING AREA
36.00 [914.4]
JRG
32.57 [827.4]
JRG
1:10
23NOV05
1
1
D16 D20 D30 FP
AS NOTED
D16-70, D20-140-5, D30-80
FOOTPRINT
FLOOR LOADING: BASE WEIGHT + OPTION(S) +FLUID WEIGHT = PSI
28.2744
PSI X .06895 = BAR
BASE WEIGHT: 550LB (249KG)
SHIPPING WEIGHT: 750LB (340KG)
SHIPPING CONTAINER SIZE (QT'Y 2): 48"W X 67"L X 53"H
W1219MM X L1702MM X H1346MM
ADD FOR:
FLUID (SINGLE FILTER): 22LB (10KG)
FLUID (DUAL FILTER): 44LB (20KG)
NOTE: FLUID WEGHT CALCULATED USING WATER AT 68° 8.3LB (3.8KG)
A
ChipBLASTER Inc
23.0. FOOTPRINT DRAWING:
69
19.69 [500.0]
76.53 [1943.9]
42.43 [1077.6]
12.00 [304.8]
31.69 [804.8]
14.96 [379.9]
41.87 [1063.5]
23.0
ChipBLASTER Inc
24.0. WARRANTY:
70
24.1. WARRANTY (LIMITED) – NEW EQUIPMENT
ChipBLASTER, Inc. Limited Warranty New Equipment
Limited Warranty. ChipBLASTER, Inc. warrants its ChipBLASTER™ high-pressure coolant systems
to be free from defects in materials and workmanship for the lesser of one year or 4160 hours of
operation from the date of original installation, subject to the conditions set forth below. During this
warranty period, ChipBLASTER will repair or replace, at its sole option, defective products or parts
without charge to the purchaser.
Limited Warranty Conditions:
24.1.1 Limited warranty applies only to new ChipBLASTER equipment, and is solely for
the benefit of and applicable to the end user.
24.1.2 This limited warranty does not apply to any damage, failure, defect or loss
caused by any or all of the following circumstances or conditions: failure to follow
instructions or observe cautions and warnings relating to installation, operation,
1
applications, inspection and “regular maintenance” , as specified in this warranty
and/or any ChipBLASTER manual, quotation, acknowledgment, spec. sheet or
installation instructions (all of which shall hereinafter be referred to as “applicable
literature”); use of ChipBLASTER equipment outside the parameters of “normal
usage” including, but not limited to, misapplication, misuse, failure to follow
directions and instructions provided by ChipBLASTER applicable literature; any
damage or loss to products or parts which results from the alteration, repair,
modification, faulty installation, or service (other than regular maintenance) by
any one other than an authorized ChipBLASTER service technician; the use of
any add-ons, parts, accessories or components not obtained from ChipBLASTER
or an authorized ChipBLASTER supplier or approved in writing by
ChipBLASTER; damage to products or parts caused by accident, abuse or
1
misuse; replacement of filters ; normal wear and tear; damage which occurs in
shipment or as a result of an act of God, such as lightening, or electrical failures
such as line surges or brownouts.
24.1.3. Any replacement equipment or parts provided to the purchaser in fulfilling this
warranty are warranted for the un-expired portion of the original warranty.
24.1.4. If any ChipBLASTER products are found upon ChipBLASTER’s examination in
response to a warranty claim to have defects in material or workmanship,
ChipBLASTER will either replace or repair the product, at its sole option.
24.1.5. ChipBLASTER expects that warranty repairs will be completed at the purchaser’s
location; however, if requested by ChipBLASTER, purchaser shall return the
alleged defective product to ChipBLASTER for examination, at ChipBLASTER’s
direction. ChipBLASTER will reimburse the purchaser for the expense incurred
in returning any product to ChipBLASTER if ChipBLASTER has provided prior
written authorization to the purchaser and the problem is covered by this
warranty. In the event the problem is not covered by this limited warranty,
ChipBLASTER will not be responsible for payment of shipping expense.
24.1.6. Other than the obligations imposed upon ChipBLASTER under this limited
warranty, ChipBLASTER shall not be liable for any other costs, expenses or
losses that the purchaser incurs to remedy any defect.
1
Regular maintenance includes the minor normal maintenance required to be performed by buyer, at buyer’s expense as set
forth in the maintenance schedule included with this warranty as Exhibit A and posted on the outside panel of the
ChipBLASTER. Use of filters other than ChipBLASTER will void warranty coverage for any filtration related
damage or failures.
24.1
ChipBLASTER Inc
24.0. WARRANTY (Cont.):
71
24.1.7. Repairs of defects in material or workmanship during the limited warranty period
shall be performed only by ChipBLASTER approved service technicians; the cost
of repairs performed by others will not be reimbursed by ChipBLASTER unless
prior approval is received in writing from ChipBLASTER.
24.1.8. This limited warranty shall cover alleged defects in materials and workmanship
about which ChipBLASTER receives notice within thirty (30) days of either the
discovery of the alleged defect or the expiration of the limited warranty period,
whichever is earlier. Any claim not made within this time shall be conclusively
deemed to having been waived by the purchaser.
24.1.9. Failure of the purchaser to maintain the equipment by completing all of the
scheduled maintenance tasks set forth in Exhibit A to this limited warranty
entitled “ChipBLASTER Maintenance Schedule” will void this limited warranty,
and release ChipBLASTER from any liability hereunder. ChipBLASTER may
require purchaser to provide evidence of timely completion of the
scheduled maintenance tasks set forth in Exhibit A.
24.1.10. ChipBLASTER warranty card must be completed by purchaser and returned to
ChipBLASTER within 30 days after installation of ChipBLASTER equipment to
validate this limited warranty.
Procedures for Obtaining Technical Service or Warranty Service. Repair or replacement under
this limited warranty can only be obtained by registering a warranty claim directly with ChipBLASTER.
To enable ChipBLASTER to respond to a request for technical assistance or a request for warranty
service, the purchaser must provide, at a minimum, the following information during the initial telephone
call: model number, serial number and information regarding any optional ChipBLASTER™
components; the date of purchase; the dealer or supplier from whom the equipment was purchased
and the nature of the problem or difficulty. A warranty claim form can be obtained by contacting
ChipBLASTER at 800-241-3163.
Limitation of Liability. ChipBLASTER’s liability under this warranty is limited as set forth herein. This
limited warranty and the remedies set forth herein constitute the sole and exclusive remedy available to
the purchaser of ChipBLASTER™ equipment covered by this limited warranty, and are in lieu of any or
all other remedies, whether based on statements or promises which are oral, written, express or
implied, and whether in contract, tort, equity or otherwise.
ChipBLASTER neither extends nor provides any warranty, expressed or implied, on any products not
manufactured by or sold by ChipBLASTER. Problems caused to ChipBLASTER™ equipment or other
equipment by products used in conjunction with ChipBLASTER™ equipment which are not either
manufactured by ChipBLASTER or manufactured to design specifications provided by ChipBLASTER
and specifically approved by ChipBLASTER in writing are not the responsibility of ChipBLASTER,
either under this warranty, or otherwise.
This warranty excludes all implied warranties of merchantability or fitness for particular purpose or any
purpose.
This warranty specifically excludes reimbursement or liability for “downtime,” loss of income and/or
consequential damages.
In no event will ChipBLASTER’s liability to the purchaser resulting from any claim or loss arising out of
a purchaser’s purchase of ChipBLASTER™ equipment or the operation thereof exceed the purchase
price of the product manufactured or sold by ChipBLASTER.
24.1
ChipBLASTER Inc
72
24.2 WARRANTY (LIMITED) – USED EQUIPMENT
ChipBLASTER, Inc. Limited Warranty Used Equipment
Limited Warranty. ChipBLASTER, Inc. warrants the used ChipBLASTER™ high-pressure coolant
systems to be free from defects in materials and workmanship for the lesser of 90 days or 1040 hours
from the date of installation, subject to the conditions set forth below. During this warranty period,
ChipBLASTER will repair or replace, at its sole option, defective products or parts without charge to the
purchaser.
24.2.1 Limited warranty applies only to used ChipBLASTER equipment, and is solely for
the benefit of and applicable to initial purchaser.
24.2.2 This limited warranty does not apply to any damage, failure, defect or loss
caused by any or all the following circumstances or conditions: failure to follow
2
applications, inspection and regular maintenance , as specified in this manual
and/or any ChipBLASTER manual, quotation, acknowledgment, sales literature,
spec sheet or installation instructions (all of which shall hereinafter be referred to
as “applicable literature”); use of ChipBLASTER equipment outside the
parameters of “normal usage” including, but not limited to misapplication, misuse,
failure to follow directions and instructions provided by ChipBLASTER applicable
literature; any damage or loss to products or parts which results from the
alteration, repair, modification, faulty installation, or service (other than regular
maintenance) by any one other than an authorized ChipBLASTER service
technician and the use of any add-ons, parts, accessories or components not
obtained from ChipBLASTER or an authorized ChipBLASTER supplier or
approved in writing by ChipBLASTER; damage to products or parts caused by
1
accident, abuse or misuse; replacement of filters ; normal wear and tear;
damage which occurs in shipment or as a result of an act of God, such as
lightening, or electrical failures such as line surges or brownouts.
24.2.5. ChipBLASTER expects that warranty repairs will be completed at the purchaser’s
location; however, if requested by ChipBLASTER, purchaser shall return the
alleged defective product to ChipBLASTER for examination, at ChipBLASTER’s
direction. ChipBLASTER will reimburse the purchaser for the expense incurred
in returning any product to ChipBLASTER if ChipBLASTER has provided prior
written authorization to the purchaser and the problem is covered by this
warranty. In the event the problem is not covered by this limited warranty,
ChipBLASTER will not be responsible for payment of shipping expense.
2
damage or failures.
24.2
ChipBLASTER Inc
73
of repairs performed
by others will not be reimbursed by ChipBLASTER unless prior approval is
received in writing from ChipBLASTER.
deemed to have been waived by the purchaser.
24.2.9. Failure of the purchaser to maintain the equipment by completing all of the
scheduled maintenance tasks set forth in Exhibit A to this limited warranty
entitled “ChipBLASTER Maintenance Schedule” will void this limited warranty,
and release ChipBLASTER from any liability hereunder. ChipBLASTER may
require purchaser to provide evidence of timely completion of the
scheduled maintenance tasks set forth in Exhibit A.
ChipBLASTER within 30 days after installation of ChipBLASTER equipment to
validate this limited warranty.
call: model number, serial number and information regarding any optional ChipBLASTER™
components; the date of purchase; the dealer or supplier from whom the equipment was purchased;
the nature of the problem or difficulty. A warranty claim form can be obtained by contacting
ChipBLASTER at 800-241-3163.
the purchaser of ChipBLASTER™ equipment covered by this limited warranty, and are in lieu of any or
all other remedies, whether based on statements or promises which are oral, written, express or
implied, and whether in contract, tort, equity or otherwise.
manufactured by or sold by ChipBLASTER. Problems caused to ChipBLASTER™ equipment or other
equipment by products used in conjunction with ChipBLASTER™ equipment which are not either
manufactured by ChipBLASTER or manufactured to design specifications provided by ChipBLASTER
and specifically approved by ChipBLASTER in writing are not the responsibility of ChipBLASTER,
either under this warranty, or otherwise.
purpose.
This warranty specifically excludes reimbursement or liability for “downtime,” loss of income and/or
a purchaser’s purchase of ChipBLASTER™ equipment or the operation thereof exceed the purchase
price of the product manufactured or sold by ChipBLASTER.
24.2
ChipBLASTER Inc
74
24.3. WARRANTY (LIMITED) – RETROFITS
ChipBLASTER, Inc. Limited Warranty High Pressure Retrofits
Limited Warranty. ChipBLASTER, Inc. warrants its ChipBLASTER™ high-pressure retrofits to be free
from defects in materials and workmanship for the lesser of one year or 4160 operating hours from the
date of delivery to the original user, subject to the conditions set forth below. During this warranty
period, ChipBLASTER will repair or replace, at its sole option, defective products or parts without
charge to the purchaser. ChipBLASTER, Inc. further warrants that its ChipBLASTER™ high-pressure
retrofit systems will not adversely affect or damage the cutting equipment on which ChipBLASTER
installs such systems.
24.3.1. Warranty applies only to new ChipBLASTER retrofits.
24.3.2. This limited warranty does not apply to any damage, failure, defect or loss
caused by any or all the following circumstances or conditions: failure to follow
3
applications, inspection and regular maintenance, as specified in any
ChipBLASTER manual, quotation, acknowledgment, sales literature, spec sheet
or installation instructions (all of which shall hereinafter be referred to as
“applicable literature”); use of ChipBLASTER retrofits outside the parameters of
“normal usage” including, but not limited to misapplication, misuse, failure to
follow directions and instructions provided by ChipBLASTER applicable
literature; any damage or loss to products or parts which results from the
alteration, repair, modification, faulty installation, or service (other than regular
maintenance) by any one other than an authorized ChipBLASTER service
technician and the use of any add-ons, parts, accessories or components not
obtained from ChipBLASTER or an authorized ChipBLASTER supplier or
approved in writing by ChipBLASTER; damage to products or parts caused by
accident, abuse or misuse; normal wear and tear; damage which occurs in
shipment or as a result of an act of God, such as lightening, or electrical failures
such as line surges or brownouts.
24.3.5. Warranty repairs will be completed at the purchaser’s location.
of repairs performed by others will not be reimbursed by ChipBLASTER unless
prior approval is received in writing from ChipBLASTER.
3
damage or failures.
24.3
ChipBLASTER Inc
75
deemed to have been waived by the purchaser.
ChipBLASTER within 30 days after installation of ChipBLASTER retrofits.
call: model and serial number of the equipment on which the ChipBLASTER retrofit was installed;
information regarding the installed ChipBLASTER retrofit; the date of purchase; the dealer or supplier
from whom the equipment was purchased; the nature of the problem or difficulty. A warranty claim
form can be obtained by contacting ChipBLASTER at 800-241-3163.
the purchaser of ChipBLASTER™ retrofits covered by this limited warranty, and are in lieu of any or all
other remedies, whether based on statements or promises which are oral, written, express or implied,
and whether in contract, tort, equity or otherwise.
manufactured by or sold by ChipBLASTER. Problems caused to ChipBLASTER™ retrofits used in
conjunction with ChipBLASTER™ equipment which are not either manufactured by ChipBLASTER or
manufactured to design specifications provided by ChipBLASTER and specifically approved by
ChipBLASTER in writing are not the responsibility of ChipBLASTER, either under this warranty, or
otherwise.
purpose.
This warranty specifically excludes liability of ChipBLASTER for, “downtime,” loss of income and/or
a purchaser’s purchase of ChipBLASTER™ retrofits or the operation thereof exceed the purchase price
of the product manufactured or sold by ChipBLASTER.
24.3
ChipBLASTER Inc
76
24.4.WARRANTY CLAIM FORM:
WARRANTY CLAIM FORM
Unit Serial # ___________________
Unit Description _________________________________
Purchased From ________________________________
Invoice # ___________________
Invoice Date ____________________
Installation Date ______________________
Nature of Problem (including date of occurrence)
________________________________________________________________________
________________________________________________________________________
________________________________________________________________________
____________________________
24.4
77
ChipBLASTER Inc
24.5. WARRANTY REGISTRATION CARD:
----------------------------------------------------------------------------------------------------------------
Detach this part of the sheet and mail to ChipBLASTER to activate your
warranty. This form MUST be filled out completely to be a valid
warranty registration.
WARRANTY REGISTRATION CARD
Unit Serial # ____________________
Company Name: ____________________
Unit Description _________________
Address: ___________________________
Purchased From _________________
City: ______________________________
Invoice # _______________________
State, Zip Code: _____________________
Invoice Date ____________________
Contact Person: _____________________
Installation Date _________________
E-mail Address: _____________________
Please mail to:
ChipBLASTER
Meadville, Pennsylvania 16335
Phone: _____________________________
Fax: _______________________________
Or fax to (814) 724-6287 Attention Service Department
24.5
78
ChipBLASTER Inc
24.6. WARRANTY VALIDATION CARD:
WARRANTY VALIDATION CARD
UNIT SERIAL # ___________
Unit Description ___________________________
Installation Date_________________ Purchased From____________________________
Invoice # ___________________ Invoice Date ________________
I _____________________________ on _____________ hereby declare the ChipBlaster
Signature
date
high pressure coolant system has been installed on ______________________ according
machine model
to ChipBlaster procedures (Note: ChipBlaster Standard Warranty will commence with
the above signed date if all conditions of the procedures are met).
SEND TO: ChipBLASTER
(Office Use Only)
Date Warranty Registration Received __________
Meadville, PA 16335
Attn: Warranty Dept.
24.6
7
Ø6.3 (160MM) B.C.
(4) Ø0.28 (7MM)
HOLES EQ SP
1
8
9
6
MACHINE SUMP
BOTTOM
45°
1.0 (25MM)
RECOMMENDED
PLACEMENT
0.0005
0.005
0.01
1/32
REMOVE ALL BURRS &
X.XXXX
X.XXX
X.XX
X.X
(NONACCUMULATIVE)
Chip BLASTER
3
B
SIZE:
UNIT:
RA
DRAWN BY:
R.B.
ITEM 1 WAS P/N 8830
NOTE 1.
WPA
B
APPROVED BY:
NTS
SCALE:
0071
6107
6022
5524
7
6
5
4
8838
PART NO.
1
DETAIL
CUSTOMER:
11/01/00
DATE:
QTY.
1
1
1
2
1
1
1
1
1
DESCRIPTION
STANDPIPE BRACKET
1 1/2" STREET ELL
1 1/2" HOSE BARB
1 1/2" NPT LOCKNUT
1" HOSE BARB
1" ELBOW
5/16-24 X 1 1/2" HH BOLT
5/16-24 NUT
1" X 12" NIPPLE
1 OF
SHEET:
1
30011
DRAWING NUMBER:
MAT'L:
C
REV:
19 JUL 05
25 FEB. 03
DATE
UNIVERSAL STANDPIPE ASSEMBLY
TITLE:
6213
2
6059
0335
8
3
6249
9
NOTE:
1. TAPE FITTINGS 3, 5 AND 9 - TIGHTEN ALL FITTINGS.
C
PHONE: (814)724-6278
PO BOX 1057
FAX: (814)724-6287
MEADVILLE, PA 16335
USA
www.chipblaster.com
4
2
1
Ø7.1 (180MM)
5
DESCRIPTION
B ITEM 6 WAS 1" COUPLING AND ADDED
REV
ChipBLASTER Inc
27.0. OPTIONAL EQUIPMENT:
79
27.1. MACHINE SUMP STANDPIPE ASSEMBLY (P/N 30011):
27.1
80
ChipBLASTER Inc
28.0. SUPPLEMENT DATA:
28.1. Orifice Reference Chart for 1000 PSI
Orifice Dia.
Outlet Area
(Sq. Inches)
PSI
Velocity (Ft./Sec.)
Volume
(GPM)
Horsepower Machine maximum
Required
outputs
0.010
0.015
0.020
0.025
0.030
0.0001
0.0002
0.0003
0.0005
0.0007
1000
1000
1000
1000
1000
465
465
465
465
465
0.1
0.3
0.5
0.7
1.0
0.1
0.2
0.3
0.5
0.7
0.035
0.0010
1000
465
1.4
1.0
0.040
0.045
0.050
0.055
Nozzle #XX54
0.060
Nozzle #XX55
0.065
0.070
0.075
Nozzle #XX56
0.080
0.085
0.090
Nozzle #XX57
0.095
0.100
0.105
0.110
0.115
0.120
0.125
0.130
Nozzle #XX58
0.135
0.140
0.145
0.150
0.155
0.160
0.165
0.170
0.175
0.180
0.185
0.190
0.195
0.200
0.205
0.210
0.215
0.220
0.245
0.250
0.255
0.265
0.0013
0.0016
0.0020
0.0024
0.0024
0.0028
0.0028
0.0033
0.0038
0.0044
0.0049
0.0050
0.0057
0.0064
0.0069
0.0071
0.0079
0.0087
0.0095
0.0104
0.0113
0.0123
0.0133
0.0138
0.0143
0.0154
0.0165
0.0177
0.0189
0.0201
0.0214
0.0227
0.0241
0.0254
0.0269
0.0284
0.0299
0.0314
0.0330
0.0346
0.0363
0.0380
0.0471
0.0491
0.0511
0.0552
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
465
1.8
2.3
2.8
3.4
3.6
4.1
4.1
4.8
5.6
6.4
7.1
7.8
8.2
9.2
10.0
10.3
11.4
12.5
13.8
15.0
16.4
17.8
19.2
20.0
20.7
22.3
23.9
25.6
27.3
29.1
31.0
32.9
34.8
36.9
38.9
41.1
43.3
45.5
47.8
50.2
52.6
55.1
68.3
71.1
74.0
79.9
1.2
1.6
1.9
2.4
2.4
2.8
2.8
3.3
3.8
4.4
4.9
5.1
5.6
6.3
6.8
7.0
7.8
8.6
9.4
10.3
11.2
12.2
13.2
13.7
14.2
15.3
16.4
17.5
18.7
19.9
21.2
22.5
23.9
25.2
26.7
28.1
29.6
31.2
32.7
34.4
36.0
37.7
46.8
48.7
50.7
54.7
28.1

ChipBLASTER, Inc.

Transcription

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