S U D S A V E R

INSTRUCTIONMANUAL

SERIAL No. 100320

Installation, Operating & Maintenance Manual

INDEX

Section Page No.

1 Introduction 2

2 Plant Description 5

3 Tramp Oil Separator Fig.2 7

Start-Up Procedure 8

Operating Procedure 9

Maintenance Instructions 10-11

Precautions 12

Warranty Exclusions 13

4 Flatbed filter General Description 16

Operation 16

Changing Filter roll 17

Checking and adjustment 18

Maintenance 19

5 Recommended Spares 20

6 Drawings Electrical Circuit Diagram

7 Manufacturer’s Literature

Separator Feed Pump

Soluble Oil Mixer unit

Clean Fluid discharge pump

2

Section 1

Introduction

The ‘SUDSAVER’ offers an economic and effective solution to coolant management problems for individual types of soluble oil.

It removes free floating, dispersed and mechanically emulsified tramp oils, can remove suspended solids down to 10 microns and has an automatic soluble oil mixing unit for maintaining correct cooling mix.

Remember, neither the process through the separator to remove tramp oil, nor through the flatbed filter to remove the solids will change the true strength of the soluble oil mix.

3

Section 2

4

5

Plant Description

(See Flow Diagram and General Arrangement Drawing)

The layout of the ‘SUDSAVER’ is as follows:-

The main body of the ‘SUDSAVER’ is comprised of a two-section tank, the “Clean Tank” and the “Dirty Tank”. The dirty coolant to be treated is pumped from the swarf conveyor, or collected from the machine tool sumps, and deposited into the inlet of the Flatbed Filter. The Flatbed Filter is intended to remove solids from the coolant, the Flatbed Filter is positioned above the “Dirty Tank”.

The dirty tank is equipped with a floating suction device connected via a flexible hose to the system feed pump. There is also fitted a low-level switch to prevent this pump running dry.

Pipework from the system feed pump is connected to the tramp oil separator.

The normal treatment route of the dirty coolant would be through the Flatbed Clarifier for solids removal with the outflow gravity feeding into the Dirty Tank. From the Dirty Tank the coolant is drawn through the Floating Suction device by the system pump and passed to the Free Oil Separator. From the Free Oil Separator, with the free oil removed, it is gravity discharged into the second chamber of the two-section tank, namely the “Clean Tank”.

There is an overflow port between the clean and dirty tanks to allow clean coolant to overflow from the clean tank into the dirty tank. It should be noted here that there is an alarm level switch fitted in the dirty tank, this will cause the alarm beacon to flash and close the inlet valve to prevent flows coming in from the swarf conveyor. If the alarm beacon is flashing do not deposit more coolant into the flatbed filter.

There is a third level switch fitted in the system to switch on the automatic top up system allowing water to pass through the soluble oil mixer, drawing up soluble oil concentrate and, as it does so, produces an oil-water mix at the required strength. This ensures that there is always sufficient clean coolant to be taken to the machine tool sumps.

The clean tank is fitted with a diaphragm air operated clean fluid discharge pump.

6

Section 3

FREE OIL SEPARATOR

INSTRUCTION MANUAL

7

Fig 2

8

Free Oil Separator

a)Start-Up Procedure

Check for the correct rotation of the feed pump.Check that the flow to the separator is unrestricted.Check that all valves in the inlet piping, water and oil outlet are open.Check that all drain valves are closed.

Check that the media basket is correctly located.The media should be contained in a media basket with the media level below the water discharge weir level.

Set the oil weir height by establishing the height from the water discharge weir to the top of the separator. Using the same datum at the top of the separator, adjust the oil weir to the above established dimension less 13mm.

Prime the Pump with clean water – see Manufacturer’s Literature Section 9.

Fill the separator with clean water or coolant until the water is 25mm below the water discharge weir.

A 4-ball suction float has been supplied with the SUDSAVER’.Place the float in the liquid to be treated, ensure that the flexible hose between the float and the pump inlet is correctly secured. To set the suction pipe in the centre of the float at the correct height, release the lock screws and move ball framework up or down to position the top of the suction pipe just above liquid level.Re-lock with lock screws.

The equipment is now ready for operation.

9

b)Operating Procedure

Start the pump and recheck the height of the suction float.

Check periodically that the inlet flow rate does not exceed the rated capacity of the separator by sampling at the inlet to the separator.

The oil discharge weir should be regularly checked to ensure that the treated liquid is not being discharged with the oil. It is, an indication of one of the following:-

1. The oil weir is set too low – raise the oil weir until only oil is flowing.2. A build up of dirt or biological growth in the separator which has increased

the pressure drop through the media – clean out the separator – see Maintenance Instructions Section 4.

3. The discharge piping is obstructed – rectify.4. Differential of specific gravity of separated liquids is not sufficient to allow

gravity separation.

The separated oil will automatically flow through into the oil storage container.

Note: This may take some time if the feed contains low oil content.

10

c)Maintenance Instructions

(Read in conjunction with fig. 2 and G.A. Drawing).

Since there are no moving parts or filters in the Free Oil Separator (except for pump sets and level controls), maintenance consists of periodic flushing of the sediment, which may accumulate. Frequency of flushing of the sediment is determined by the amount of solids/sludge in the liquid being treated.

Flushing is carried out in three stages:-

Divert the oil discharge pipe to an alternative waste tank as water willBe discharged with oil during this cleaning operation.

1. Removing the Surface Oil

Close the clarified water outlet valve with pumps still feeding theSeparator. Allow liquid level to rise causing the surface oil to discharge through the oil weirs.Stop the pump.

2. Flushing the Inlet Chamber

Shut off supply to the separator.Open the Inlet Chamber sludge valve at the bottom of the tank and drain out the sludge.Flush tank with fresh water.Close the sludge drain valve.

3. Flushing the Media Bed Chamber

Close clarified outlet valve.Refill the Inlet Chamber with Clean water until all separated oil above the media basket has discharged over the oil weir.Open the separator drain valve and drain out the sludge.Close separator drain valve.Inject water into the top of the discharge chamber by using a hose and allow this water to reverse flow up through the media bed and pass out through the oil weir.(Take care not to overflow the oil discharge tank).Continue until the sediment is flushed from the media and acceptable water quality has been obtained (determined by visual observation). If media contamination is excessive – see instructions below.Open the clarified outlet valve, turn off the water injection supply.Re-introduce the supply to the separator – checking flow rate is not exceeded.

Separator is back in service.

11

Contaminated Media

If the media becomes fouled with tarry materials etc., it can be cleaned in one of two methods:-

1. Lift out the media basket and, with the media retained in the basket, totally immerse in a detergent wash.

Or

2. By using a lance, introduce steam into the media bed. The steam will Dissolve any tarry materials, washing them from the media bed.

Check quality of media basket seal on the media basket support angle and replace as necessary.

Refit media basket.

Feed Pump

If a reduction in the feed rate of the liquid to the separator is experienced then this is likely to be due to one of the following:-

1. Suction pipe on float set too high – rectify as necessary.2. Wear in pump – see pump manufacturer’s instructions.3. Partially blocked or split feed pipe, either float to pump or pump to separator –

rectify as necessary.

12

d)Precautions

Always fill the separator with CLEAN, OIL FREE water prior to introducing the untreated mixture.

Never drain the separator without having first removed all the oil at the top portion of the media bed.

Never exceed the rated low of the separator.

100% oil can be processed, but only for short duration runs.

Never operate the separator with the oil weir in the highest position or when the oil flow out of the separator is restricted.

Pumps must always be filled with liquid and must NEVER be run dry.

Changes in process conditions should be discussed with A-D Hyde Ltd. to establish suitability of supplied unit.

13

e)Warranty Exclusions

The following are NOT covered by the HYDEAWAY Ltd. warranty:-

Adjustment to the oil weir for optimum setting

Incorrect adjustment to pump gland packing or mechanical seals

Incorrect adjustment of floating suction device

Incorrect rotation of pump

Adjustment to hose clips

Adjustment to unit level feet

Routine cleaning and maintenance

Changes in process conditions

Use of spare parts and service items not approved by Hydeaway Ltd. will invalidate all warranties.

Warranty of some parts may be foreshortened by process conditions and changes thereof.

Call out for any of the above will be charged for at Hydeaway Ltd. current service charges.

Regular routine servicing is essential for the continued good operation of the equipment.

14

Section 4

FLATBED FILTER(CLARIFIER)

INSTRUCTION MANUAL

15

16

GENERAL DESCRIPTION

The clarifier chassis A carries an endless chain mesh conveyor B which is driven by a geared motor unit C. The motor is controlled by the microswitch F, the float FT operates the micro switch F via the lever arm E. A roll of filter fabric K is housed in the container L, and a removable bin M receives the collected solids and used filter fabric.

OPERATION

The contaminated liquid is fed to the inlet N and falls on to the filter fabric resting upon the chain conveyor, which is shaped to allow a pool of liquid to form. the liquid passes through the filter fabric, which retains the solid material, and falls into the storage tank below.

When the accumulated solids prevent the liquid from passing through the filter fabric at the desired rate, the liquid level rises.

The rise in level lifts the float which moves the lever, arm to the micro switch, energising the motor control. The motor then drives the conveyor forward, automatically discharging the solids into the sludge bin, and bringing forward a new area of filter fabric. As soon as the liquid is flowing through the filter fabric at the normal rate, the level of the liquid pool falls, and the motor is switched off.

17

6. Fitting the Filter Fabric

a. Remove the fabric container cover.

b. Take out the fabric roll spindle and remove oneroll retaining bush (secured by a socket screw Allenkey 4mm).

c. Slide the spindle through the roll of fabric and replacebush. Adjust the roll centrally on the spindle and tightenthe socket screws. (See Fabric Selection page 9.1).

d. Lift the roll into the container. See that the roll turnsfreely, and that the fabric unwinds downwards at the frontof the container.

e. Feed the fabric behind the roller bar (Fig. 3) and forward towards the discharge end of the clarifier, and rest it onthe conveyor.

Note: If the fabric is not fed through correctly or is not evenand central on the conveyor, difficulty may be experienced in achieving proper operation.

f. Replace the container cover.

g. Operate the level control and allow the conveyor to carrythe fabric forward until it overhangs the bin. When dryit may be necessary to put a hand or weight on thefabric to give enough adhesion to the conveyor for thefabric to be carried along.

18

7. Liquid Connections

a. Arrange cover plates to give the most convenient inletposition. this should not be too near the discharge endor the sludge may be washed back. Also, where a floatis fitted, the inlet flow must not interfere with the operationof the float.

8. Checking and Adjusting

a. Put the machine and the clarifier into full operation. Whenthe clarifier was despatched, the switch was set to give anaverage operating level.

b. As the sludge collects, a pool will form and the liquid levelmust not be allowed to rise to the point where liquid overflows the edge of the filter fabric. the switch shouldoperate when the liquid level is approximately 25mm (1 inch)below the top edge of the filter fabric at the sides of the bed. Adjust the float position as required.

19

MAINTENANCE

Daily

Always ensure that the fabric is correctly and centrally spreadacross the conveyor chain.

Check that there is approximately 25mm (1 inch) of clear filterfabric along each side of the filter bed. If necessary adjust theswitch (See Checking and Adjusting para. 7).

Monthly Service

Check the mesh of the chain filter bed. If it appears slack adjustby loosening the two screws on each side of the clarifier at thedischarge end, and draw the conveyor roller forward until the slackin the mesh is taken up. Take care to keep the roller square with the sides and re-tighten the screws.

If the amount of filter fabric used becomes excessive, check:

a. The contamination in the liquid for a change in character.

b. That the grade of fabric is correct.

c. That the operating level of the liquid is not too low.

20

Re-ordering non-woven filter fabrics

Filter fabrics, developed especially for liquid filtration, areavailable in widths to suit each clarifier.

When ordering specify the correct Filter grade:

CoarseNormalFineExtra Fine

and state the width of the roll required:

NOTE:PLEASE STATE THE SERIAL NO. OF THE UNIT WHEN ORDERING SPARES TO ENSURE THE CORRECT PART IS SUPPLIED.

Section 5

Recommended Spares

Description Quantity

1” Pall rings (Media) 1 bag

15mm X 5mm S/A Neoprene (Basket Seal) 2m

1” Vineflex Hose (suction float) 2m

19796 stator kit (Separator feed pump) 1 off

19798 Rotor kit (Separator feed pump) 1 off

19734 Mechanical seal (Separator feed pump) 1 off

Geared Drive unit (clarifier) 1 off

637119-62-C Diaphragm kit (discharge pump) 1 off

Paper roll bushes (clarifier) 2 off

21