OIL MIST COLLECTORS Series WS mod. 170 - 330 - 700 - 1020 ...€¦ · i) Centrifugal filtration (stage 2) A special impeller (vibration free) ensures the centrifugal effect that enables

OIL MIST COLLECTORS Series WS mod. 170 - 330 - 700 - 1020 - 1250 INSTRUCTION AND INSTALLATION MANUAL

© LNS FOX Instruction manual series WS (USA) pag. 2 of 28 - rev. 06-2014

Index

1. General information ............................ ............................................................................................ 3

1.1. Foreword .................................................................................................................................... 3

1.2. Safety operation ......................................................................................................................... 3

1.2.1 Description and positioning of information labels .................................................................................... 3

1.2.2. Main safety prescriptions: ....................................................................................................................... 4

1.3. Range of applications: ................................................................................................................ 4

1.3.1. Intended uses ......................................................................................................................................... 4

1.3.2. Not intended uses................................................................................................................................... 4

1.3.3. Operating conditions .............................................................................................................................. 4

1.4. Identification and specifications .................................................................................................. 5

1.5. Supply Content ........................................................................................................................... 5

1.6. Accessories ................................................................................................................................ 5

1.7. Warranty .................................................................................................................................... 6

2. Handling, transportation and storage ........... ................................................................................. 6

2.1. Movement and transportation of the packaged unit .................................................................... 6

2.2. Movement and transportation of the unit .................................................................................... 6

2.3. Storage ...................................................................................................................................... 6

3. Description and features of the unit ........... ................................................................................... 7

3.1. Description of the components ................................................................................................... 7

3.2. General characteristics ............................................................................................................... 8

3.3. Air Flow curves ........................................................................................................................... 8

3.4. Electrical characteristics ............................................................................................................. 8

3.5. Dimensions (inches) ................................................................................................................... 9

4. Installation ................................... .................................................................................................. 10

4.1. Minimum space for installation ................................................................................................. 10

4.2. Examples of possible installations ............................................................................................ 10

4.3. Ducting ..................................................................................................................................... 10

4.3.1 Trap with use of trap bracket (included in the supply) ........................................................................... 12

4.3.2 Trap without use of trap bracket ............................................................................................................ 12

4.3.3 Trap with immersion of the tube in a container of liquid ........................................................................ 13

4.4. Electrical connections ............................................................................................................... 14

4.4.1 electrical connection for electric motor with 9 wires .............................................................................. 15

4.4.2 electrical connection for electric motor with 6 wires .............................................................................. 15

4.4.3. Thermal switch settings ........................................................................................................................ 15

5. Unit’s operation ............................... .............................................................................................. 16

5.1. Starting and stopping the unit ................................................................................................... 16

5.2. Monitoring devices ................................................................................................................... 16

6. Maintenance .................................... .............................................................................................. 17

6.1. Maintenance schedule ............................................................................................................. 17

6.2. Ordinary maintenance .............................................................................................................. 17

6.2.1. Pre filter (stage 1) maintenance ........................................................................................................... 17

6.2.1.a Emulsion version prefilter ................................................................................................................... 18

6.2.1.b Oil version prefilter ............................................................................................................................. 18

6.2.2. Main filter (stage 3) maintenance for OIL and EMULSION versions ................................................... 20

6.3. Special maintenance ................................................................................................................ 20

6.3.1. Centrifugal filtration (stage 2) maintenance ......................................................................................... 20

6.3.2. Cleaning of the impeller ........................................................................................................................ 21

6.3.3. Seals Replacement .............................................................................................................................. 22

6.3.4. Electric motor - Installation and removal .............................................................................................. 22

6.4. Torque settings ........................................................................................................................ 23

6.5. Periodic checks ........................................................................................................................ 23

6.6. Troubleshooting ....................................................................................................................... 25

6.7. Disposal ................................................................................................................................... 26

6.7.1. Disposal of consumables ..................................................................................................................... 26

6.7.2 Disposal of the unit ................................................................................................................................ 26

7. Spare parts .................................... ................................................................................................ 27

7.1. Spare filters reorder codes ....................................................................................................... 27

7.2. Complete Spare List ................................................................................................................. 28


1. General information

1.1. Foreword Dear customer, this manual contains all the indications and necessary information for the installation, operation and maintenance of the WS oil mist filters. The indications included in this manual can be classified as:

A) Indications relative to Personal safety This warning symbol identifies special instructions or procedures which, if partially or totally ignored, could result in physical injuries.

B) This caution symbol identifies special instructions referring to the integrity of the unit and to procedures which, if not strictly followed, could result in damages to or destruction of the unit and/or of connected equipments.

C) This symbol refers to other important indications that are not already included in the 2 previous categories.

1.2. Safety operation Before operating the unit it is recommended to read this manual, paying particular attention to the prescriptions contained in the Personal safety and integrity of the unit sections. This unit has been designed and produced in compliance with the following safety norms of the European Community:

• Machine directive 2006/42/EC • Low tension guidance 2006/95/EC • Directive magnetic compatibility 2004/108/EC

In compliance to safety norms, every residual risk found during the risk analysis has been reported and highlighted on this manual. Additional safety indications are described on the labels placed on the unit.

“Personal safety – integrity of the unit” LNS FOX is not liable for possible injuries to people and/or damages to objects caused by negligence of non observance of any safety direction.

1.2.1 Description and positioning of information la bels A

Warning/caution label to recall the importance of reading the instruction manual and main safety prescriptions

B

Serial number label

C

Main filter technical data label (stage 3)

Label with minimum dimension/ distance of p-trap

D

Impeller rotation direction

E

Original filters set up

Fig. 1a Main signal labels


Fig. 1 b Labels location

1.2.2. Main safety prescriptions: a) This instruction manual must be read entirely before installing, starting and operating on the unit b) Ensure that the power supply is isolated before working on the unit. c) During installation or maintenance make sure that the operator wears appropriate safety protection clothes.

1.3. Range of applications:

1.3.1. Intended uses The WS oil mist filter line is designed for:

• Filtration of mist, vapors smoke and odors created by oil and emulsion used on machine tools. The elimination of smoke and odors is also possible by adding an additional filtration module.

1.3.2. Not intended uses

• Filtration of potentially flammable vapors • Filtration of substances potentially explosive • Filtration of solvent, paint or other adhesive substances • Filtration of acids and or corrosive substances

“Personal safety– integrity of the unit” LNS FOX declines any responsibility for possible injuries to people and/or damages to objects due to incorrect utilization of the unit.

1.3.3. Operating conditions Operating conditions must be within the following ranges:

• Temperature: from 41 to 104 Fahrenheit • Relative humidity of the environment: from 30 to 85% • Relative humidity on the unit’s inlet: from 30 to 98%


• Maximum altitude: 3300 feet above sea level • Maximum concentration of the oil mist: 360 mg/m3

“integrity of the unit” LNS FOX declines any possible responsibility for damages to the unit due to use under conditions different than the ones above specified.

1.4. Identification and specifications Technical data and identification of the unit are listed on the serial number tag (located on the back of the unit by the power inlet).

(fig.2 serial number)

The following information can be found on the serial number tag:

Modello/Model

WS 330

Matricola/Serial

1005

Anno/Year

2003

I max [A]

1,00

Portata/Air Flow [cfm]

330

Power [hp]

0,5

Massa/Weight [lbs]

77

[V/Hz/ph]

230/60/3~

LNS ITALIA s.r.l. con socio unico Via Mons.Colombo,34-21053 CASTELLANZA (VA) Italy Tel.(+39) 0331 501901

Made in Italy

1.5. Supply Content • Instruction manual • Inspection sheet • CE declaration • Anti-vibration mounts kit

1.6. Accessories For a complete list of available accessories please contact our sales department.


1.7. Warranty LNS Italia, the supplier, guarantees its products for 365 days starting from the date of the installation which, unless specifically agreed must not be over 60 days from the delivery date. The warranty is ex works and, upon discretion of the supplier is limited to the repair or replacement of the product once proven to be defective or not appropriate for the use it was designed for. The buyer is responsible for officially reporting the supplier within 7 days the anomaly found. In addition, the buyer is also responsible for having the product at the supplier’s disposition. If necessary, in order to avoid further damages or following a specific request from the supplier, the buyer is responsible for stop using the unit from the time when the failure is found. Lack of communicating the problem within 7 days or additional damages done to the unit due to its continuous use, can result, upon discretion of the supplier, in a reduction or cancellation of the warranty. The warranty is ex works unless specified by the supplier. In the event of repair works done on the customer’s site the warranty does not cover travel related expenses. The warranty does not apply in case of damages caused by improper and/or not according to this manual use of the unit. Every attempt to repair the unit by personnel not authorized by LNS Italia will result in a reduction or cancellation of the warranty. Except in the case of intentional malpractice of the supplier, the monetary compensation for damages can not exceed the cost of the unit. LNS Italia is not liable for indirect damages.

2. Handling, transportation and storage

2.1. Movement and transportation of the packaged un it

“Personal safety – integrity of the unit” LNS FOX declines any possible responsibility for possible injuries to people and/or damages to objects due to movement procedures not conforming with safety standard.

Unit must be handled by qualified personnel properly trained for utilization of tools and machines dedicated for the movement of the goods. Weights of the units and indications on how to move it are indicated on the packages.

2.2. Movement and transportation of the unit Each unit is equipped with 4 eye bolts that must be used only for moving the unit.

“Personal safety – integrity of the unit” Lifting operations must be undertaken by trained personnel with adequate lifting devices.

The unit must be lifted with wire ropes having proper load capacity. The rope must be tied to the eye bolts.

2.3. Storage Units must be kept in a dry environment and conditions must be within the following ranges:

• Temperature 32F – 104F • Relative Humidity: 30 – 80 %


3. Description and features of the unit

Fig. 4 Components of the unit

a) Control panel box b) Pressure gauge c) Inlet d) Drainage e) Draw latches f) Eye bolts g) Anti-vibration mounts h) Prefilter (stage 1) i) Centrifugal filtration (filterless, vibration free) (stage 2) j) Main cartridge filter (stage 3)

3.1. Description of the components a) Control panel box with thermal switch The control panel can also include additional optional controls such as:

• Timer • Signal lights • on/off switch (in place of the thermal switch) • Remote relay

for additional information please contact our technical department b) differential pressure gauge – The gauge indicates the clogging status of the main filter (stage 3). The cartridge must be replaced once it reaches the red area of the scale. It is possible to have, as an option, a pressure gauge to monitor the prefilter (stage 1). c) air inlet d) drain tube - to discharge recollected coolant e) Draw latches - equipped with a safety springs to prevent accidental opening of the unit. To open the unit press the spring and unlock the latches

“Personal safety – integrity of the unit” Before unlocking latches verify that the unit is securely installed on the 4 anti vibration mounts.

f) Eye bolt for lifting the unit


g) anti-vibration mounts to reduce the vibration level transmitted to the structure. h) Pre-filtration (stage 1) The cartridge, composed of 3 different stages with progressive filtration levels guarantees high capability of accumulating particles and the slow and efficient draining effect. The first element (metallic screen) is washable. i) Centrifugal filtration (stage 2) A special impeller (vibration free) ensures the centrifugal effect that enables the continuous discharge of condensed particles. j) Main filtration (stage 3) Made of fibreglass, provides an average filtration efficiency level > 99 %. (measured accordingly to AFNOR NFX 44-060 norm). Its clogging is monitored by a pressure gauge that, once it reaches the red area of the scale, indicates that the cartridge must be replaced. For special applications there is the possibility to install an additional filtration module that perfectly fits on the unit. The addition is simple and can be performed even later on with a special kit.

• Absolute: to eliminate dry smoke, filtration level HEPA up to H 13 - 99.95 MPPS according to EN 1822

• Activated carbon: to eliminate odors

3.2. General characteristics Model WS 170 WS 330 WS 700 WS 1020 WS 1250 Frequency [Hz] 60 60 60 60 60 Air flow (*) [cfm] 168 330 665 1012 1248 Pressure max [IN W.C.] 2,41 3,57 5,70 7,23 9,23

Noise level [dB(A)] 63 65 71 73 75

R.P.M. [min -1] 3290 3350 3420 3425 3425

Weight [lbs] 62 77 121 165 187 (*) with additional filtration stage (HEPA filter or activated carbon) air flow is reduced by about 15%

3.3. Air Flow curves

Fig. 5 Performance curve at 60Hz

3.4. Electrical characteristics Electric motor (three phases)

WS 170 WS 330 WS 700 WS 1020 WS 1250 Shaft height 63 71 80 90 90 Frame B5 B5 B5 B5 B5 N° poles 2 2 2 2 2 Protection index IP 55 55 55 55 55 Isolation class F F F F F Voltage/frequency V/Hz] 230-400-460/60 Power [hp] 0.4 0.6 1.2 2.4 3.5


3.5. Dimensions (inches)

Model A B C D E ΦF G H I L N1xN2xΦM

WS 170 14,88 18,74 22,20 16,46 8,86 3,86 0,98 1,26 3,15 3,94 13,07 x 15,04 x 23/64" WS 330 16,06 19,88 24,80 17,72 10,43 4,84 0,98 1,65 3,35 4,69 14,29 x 15,55 x 23/64" WS 700 20,67 23,31 30,75 20,98 13,90 5,83 0,98 1,65 3,54 5,35 18,82 x 18,82 x 23/64" WS 1020 23,62 26,26 35,12 23,90 15,24 7,80 0,98 1,65 3,74 6,61 21,73 x 21,73 x 23/64" WS 1250 26,10 28,74 38,62 26,38 17,20 7,80 0,98 1,65 3,94 6,81 24,21 x 24,21 x 23/64"

Fig. 6 Dimensions

Model A B C D E ΦF G H I L N1xN2xΦM

WS 170V 14,88 18,74 23,43 16,46 6,61 3,86 0,98 1,26 3,15 7,52 13,07 x 15,04 x 23/64" WS 330V 16,06 19,88 27,17 17,72 7,15 5,43 0,98 1,65 3,35 8,07 14,29 x 15,55 x 23/64" WS 700V 20,67 23,31 33,15 20,98 9,41 7,01 0,98 1,65 3,54 10,2 18,82 x 18,82 x 23/64" Fig. 6 a Dimensions


4. Installation

“Personal safety – integrity of the unit” In order to avoid possible damages to people or objects make sure that installation in undertaken by qualified personnel.

Before proceeding with the installation of the unit locate the best possible position for placing the unit and for locating the suction point. Consider the following hints:

4.1. Minimum space for installation Before installing the unit verify and make sure that enough space is available as described in the following drawing:

A B C D

WS 170 12 4 12 24 WS 330 12 4 14 24 WS 700 14 4 16 24

WS 1020 16 4 18 28 WS 1250 18 4 20 28

Fig. 7 minimum space for installation (inches)

4.2. Examples of possible installations

Fig. 8a) Direct installation on the machine tool enclosure

b) Installation on trolley c) Installation on a vertical stand

4.3. Ducting The suction hole (if not already present on the machine tool enclosure) must be done according to the following indications (whenever possible): - Opposite side of the machine opening door - Furthest away from working area. - Minimizing ducting length (in order to reduce pressure drop is it reccomended, use suction tube lenght max

of 15 feet.)


- In case of considerable distance between the unit and the machine tool is it recommended to have some portion of it rigid instead of flexible.

The following components are necessary for installing the unit:

• Anti-vibration kit (included in the supply) • Flexible ducting • Flange adaptor • Flexible drainage tube • Duct clamps • Optional drained oil container • Optional drain trap

Additional accessories are available. Please contac t LNS Italia for complete list and prices - In case of installation of type a: drill 4 holes ø 23/64” on the machine tool enclosure according to dimensions

described on the technical sheet. - Secure the flange adaptor on the machine tool enclosure - Secure the unit on the selected area according to the indications described in the paragraph Movement and

transportation of the unit . - Mount the 4 anti vibrations according to the following drawing.

(fig.9a installation of anti-vibration support)

(fig. 9b anti-vibration)

- Connect the extraction duct with the flange adapter fitted on the machine using a piece of flexible tubing of

proper diameter and length. Secure both ends of the duct with metal clamps.


Fig.10a Unit overview

Fig.10b Extraction duct assembly

Fig 10c Extraction duct assembly on the flange adapter

create a trap on the drainage tube according to the instructions below

Warning: Do NOT use the purifier without a trap on the drainage tube!! The absence of a trap on the drainage and relative preloading operation prevents re-condensed liquids from being discharged while the purifier operates. The normal product life of filters could be seriously jeopardised by continuous use of the purifier without a drainage trap.

4.3.1 Trap with use of trap bracket (included in th e supply) - Insert a piece of flexible hose in the discharge duct and secure it with a metal clamp - Attach the bracket to siphon drainage (10e) in a fixed position using two or more screws - Pass the drain hose into the bracket so that it assumes the shape of "S" as shown in Figure (10 f) - Insert the other end of the drainage hose inside the tank for collecting the refrigerant or alternatively within a

container as shown schematically in the figure. - After having create the trap, release the two front latches and lift the top part of the purifier. - Use a suitable container to remove about 200-300 cc of coolant liquid (oil or emulsion) from the coolant tank. - Pour the coolant inside the lower part of the purifier in the drainage hole area, in order to preload the

drainage trap and allow the re-condensed liquids to be discharged from the first phases the purifier is used. - Lower the top part and secure the latches. - After a few seconds, the oil coming out of the drainage tube indicates that the drainage trap has been

properly preloaded.

4.3.2 Trap without use of trap bracket In case it is not possible to use the trap bracket, in order to discharge the re-condensed liquid, build a drainage trap on the flexible discharge hose as indicated in figure 10 g-h-i-l. - Preloading the trap by following the above procedure in 4.3.1

Fig.10d Secure the drainage hose

Fig.10e Bracket for siphon trap

Fig.10f Trap with use of dedicated bracket

Fig.10g Fig.10h - Secure the ring with Fig.10i


Make a ring as shown in the picture two plastic clamps Drainage trap diameter > 150 mm

10 l) Siphon trap made on a discharge hose 10 m) Siphon trap made with immersion of the hose in a container

Fig.10n Release the latches and lift the top part of the extractor fan

Fig.10o Pour 200-300 cc oil in the drainage hole area

Fig.10p Make sure that oil comes out of the drainage tube after a few seconds

4.3.3 Trap with immersion of the tube in a containe r of liquid In the event that it was not possible to realize the siphon trap according to the previous procedures, it is possible to directly enter the drainage tube into the tank of cooling liquid or in a container partially filled with liquid (oil or emulsion) . In this case make sure that the tube is permanently immersed in the liquid in order to ensure the perfect drainage of the liquid re-condensed Fig. 10 m)


4.4. Electrical connections

“Personal safety – integrity of the unit” Conduit electrical connections should be made by a qualified electrician and must comply with electrical codes and safety norms Be sure that power is cut off before wiring the unit

The unit is equipped with a protective bonding circ uit (in accordance with EN 60204-1 1998 norm). In order to obtain proper protection from in direct co ntacts, the power line must include an automatic circuit breaker. This will ensure an automatic cut off in case of line failure (in accordance with prescription 413.1 norm IEC 364-4-41) Main electrical connection, unless otherwise specified, must be done with a 3P + PE wire (3 poles + ground) according to regulating norms. As standard equipment, purifiers are supplied with an electrical cable 4Gx1.5 mm2 5 m long As an alternative, they can be supplied with a 5Gx1.5 mm2 cable It the cable must be replaced with one with different characteristics: - Loosen the cable gland located on the rear near the identification plate as shown in fig. 11. - Loosen the 4 front screws on the control panel and remove the front cover - Loosen the screws on the cable on the motor protector and on the earth terminal. - Pull the original electrical cable from the sheath. - Insert the new cable inside the protective sheath. - Fit a pin fork terminal on the three phase terminals of the new power supply cable and a spade terminal on

the protection terminal. - Insert the protection cable in the yellow/green terminal and tighten the screw - Insert three phase wires on the connecting terminals of the motor protector switch L1 – L2 – L3 and tighten

them with max. torque of 2 Nm. - Make sure the setting of the motor protector switch is congruent with the electrical power data on the plate

(unless subsequent changes have been made, the motor protector switch is normally set during factory tests).

- Reassemble the front cover and loosen the screws - Tighten the rear cable gland check that the cable is sealed securely - Connect the power supply cable to the mains supply using proper components that comply with the

applicable standards.

“Personal safety – integrity of the unit” Install a protection device that ensures automatic power cut off in case of failure to the unit or to the power supply.

-

(Fig.11) Power supply inlet (Fig. b) Removal of control panel box (Fig. c) electrical connection

(Fig. d) Setting of thermal switch (Fig. e) Tight gland (Fig. f) Impeller rotating direction


- Once installation is completed unlock the 2 latches, lift the upper part of the unit and, in accordance to safety norms, press (in order) the start and stop buttons verifying the rotating direction of the impeller. (rotation is clockwise side from air intake side.

- If the arrow does not match the rotating direction of the impeller interchange two of the power connection wires (ensure that power is cut off first)

- Re-start the unit and verify the rotating direction.

Note If the electrical connections is not the one of the standard version refer to an additional electrical diagram supplied as attachment.

4.4.1 electrical connection for electric motor with 9 wires

Connection 230V 60 Hz Connection 460 V 60 Hz (Fig. 12 Wiring diagram 3 ph ∼∼∼∼ [V/Hz] 230-60 - 460-60)

4.4.2 electrical connection for electric motor with 6 wires

Fig. 12a Connection star 400-460V- 60 Hz Fig.12b Connection Delta 230V-60 Hz

1- termal switch; 2 - ground; 3 – terminals inside electric motor box

4.4.3. Thermal switch settings The following data consumption may be subject to change. Please check the comsumption data, shown on the motor's nameplate or serial.

Model Voltage Motor Power hp (kW ) Absorbed current (A) Ampere Setting (A)

WS 170 460 0.4 (0,3) < 0,78 0,78 230 0.4 (0,3) < 1,42 1,42 400 0.4 (0,3) <0,82 0,82

WS 330 460 0.6 (0,44) < 1,09 1,09 230 0.6(0,44) < 2,04 2,04 400 0.6(0,44 <1,18 1,18

WS 700 460 1.2 (0,9) < 1,7 1,7 230 1.2 (0,9) < 3,53 3,53 400 1.2 (0,9) <2,04 2,04

WS 1020 460 2.4 (1,80) < 3,31 3,31 230 2.4(1,80) < 6,76 6,76 400 2.4(1,80) <3,91 3,91

WS 1250 460 3.5 (2,6) < 4,29 4,29 230 3.5 (2,6) < 9,1 9,1 400 3.5 (2,6) <5,26 5,26


5. Unit’s operation

5.1. Starting and stopping the unit • The unit can be started by pressing the start button located inside the control panel box. • Press the stop button to stop the unit.

5.2. Monitoring devices The unit is equipped with a pressure gauge to monitor the clogging of the main filter (stage 3). Maintenance of the prefilter (stage 1) is normally required less often and as a consequence is not monitorized by the pressure gauge. Verify conditions of the prefilter when doing maintenance on the main filter. From the gauge shown in Figure 13 you can have the following information: a) Figure 13a the gauge needle near to zero indicates that there is no passage of air and this may be due to two different causes: - the oil mist collector is not in operation - the pre-filter is clogged -

b) the position b (with needle normally between .1 and .2) is with clean filters and oil mist collector in function c) the position c (with a needle on the orange or red) indicates that the final cartridge is clogged

13 a) collector OFF or prefilter clogged

13 b) with clean filter at first start 13 c) final cartridge clogged

Note In some extreme cases the prefilter can require shorter maintenance intervals than the main filter. One example is an application with presence of large amounts of metallic dust. In these cases make sure that verify conditions of the prefilter more often than indicated on the maintenance section table

Upon request the mist collector can be equipped with additional monitoring devices. Please contact LNS Italia sales department for additional information.


6. Maintenance

“Personal safety – integrity of the unit” • Before inspecting the unit:

- Press the stop button on the thermal switch, lock the control panel and take key away.

- Isolate the unit from electrical power source ensuring that nobody can it. - Signal with proper signs that maintenance operations are undergoing. - During maintenance operations wear appropriate safety protective gears such as:

gloves, goggles, shoes and so on. • In order to avoid possible damages to people or objects be sure that maintenance

is undertaken by qualified personnel and in respect of safety procedures. • Before reusing nuts and bolts make sure that they are in perfect conditions

otherwise replace them with new ones. Self locking nuts must always be replaced.

Note Maintenance intervals displayed on the following table refer to an average situation and they can change depending on the type and quantity of the pollutant to be eliminated.

6.1. Maintenance schedule Clean Replace Check

PRE-FILTRATION (Stage 1)

Pre filtration case 1000 hrs Prefilter 1000 hrs

CENTRIFUGAL FILTRATION Filterless vibration free (Stage 2)

Impeller case 2000 hrs Drainage ring 2000 hrs Impeller 2000 hrs

MAIN FILTRATION (Stage 3)

Cartridge When signalled by pressure gauge

6.2. Ordinary maintenance

6.2.1. Pre filter (stage 1) maintenance - Unlock and open draw latches (a) - Hold the handle and lift the upper part of the unit - Unscrew wing nut securing the prefilter(b) - Remove the prefilter cartridge (c)

“integrity of the unit” Cleaning must NOT be undertaken with tools such as metallic brushes in order to avoid possible damages to the surfaces and to the internal sealing of the case

- unscrews prefilter wind nut - remove upper cover and the outer metallic filtration stage (emulsion version only). If clogged, it must be

cleaned with a brush - remove the filter media - carefully remove possible residuals from the bottom of the unit - verify that the drain slotes are not clogged - verify the seal placed between the prefilter (stage 1) and the impeller case is intact and without leaks - Wrap new filter set on the filter’s structure ensuring proper closing and positioning - Reinstall outer metal screen (Emulsion version only), put the top back and secure it.

“Note” If the drainage slotes are obstructed, remove and clean impeller case as described in “Centrifugal stage Maintenance”. If seal is damaged or broken it must be replaced as described in “Seals maintenance”


13a) unlock latches b) unscrew main central knob c) remove Prefilter cartridge

6.2.1.a Emulsion version prefilter

d) unscrew two knobs e) lift top f) remove metal screen

g) Remove dirty filter set h) Place clean internal filter around

the structure (only for WS 250-1500-2000)

i) wrap clean filter around the structure

l) Reposition metal screen m) close down top n) tight 2 external knobs

6.2.1.b Oil version prefilter


o) unscrew two knobs p) lift top q) remove dirty filtering media

r) place upper seal ring s) place lower seal ring t) insert new filtering media

u) close down top v) tight two external knobs

w) clean bottom of the unit x) check drain slotes y) check seal

“integrity of the unit” Make sure that the prefilter cartridge is correctly assembled once the filtering media is replaced. An incorrect assembly of it can result in shorter lifetime of the filter and/or problems when closing the unit.

- Verify that the surface where the prefilter will be placed is completely clean. - Insert prefilter and tight main knob. - Verify that the top pf the prefilter and the seal of the impeller case are both clean - Close the unit

14 a) Insert prefilter b) Tight main knob c) Close the unit

“Note” Excessive resistance while closing down the unit can be a signal of an imperfect positioning of the prefilter or of presence of residual materials underneath. If that is the case verify the cause, take care of the problem and close the unit.


- Secure the draw latches to the upper part of the unit and rotate them until safety springs snap.

“integrity of the unit” The length of the latch is adjustable and it is preset from factory in order to have correct load and sealing. Do not change their setting in order to avoid possible problems.

6.2.2. Main filter (stage 3) maintenance for OIL an d EMULSION versions

“Personal safety” Never remove the main filter (stage 3) while the unit is on. Removal of main filter while the unit is functioning can result in mechanical damages due to the rotation of the impeller.

The clogging status of the main filter is monitored by the pressure gauge located to the left of the control panel box. Replacement of the main filter is suggested when the pressure gauge indicates the following values:

Model WS 170 WS 330 WS 700 WS 1020 WS 1250 Max Pressure at 60 Hz 380 Pa 450 Pa 800 Pa 850 Pa 900 Pa

“Safety of the people” Do not remove the main filter cartridge (stage 3) while the unit is on. In order to avoid accidental removal of this filter by unauthorized personnel secure the nut with a tool. Removal of this filter, while the unit is on, can cause dangerous mechanical problems due to rotation of the impeller

Replacement of the main filter :

2a check pressure gauge 2b remove upper cover (WS170-300-1700 with magnetic catches)

2c remove upper cover (WS1020, WS1250 with Quarter Turn Fasteners)

2d unscrew nut 2e remove main filter cartridge 2f Replace the filter cartridge with a

new one and securing it with the nut

“Note” The main cartridge (stage 3) is made of fibreglass and can not be regenerated.

6.3. Special maintenance

6.3.1. Centrifugal filtration (stage 2) maintenance Normally the centrifugal stage does not require any maintenance. On some applications it may be necessary to periodically clean the drainage ring and the relative holes according to the following procedure:

• Unlock the 2 draw latches hinges and lift the upper part of the unit • Unscrew knob and remove filter • Unscrew nuts securing impeller case/drainage ring • Only if necessary proceed with the removal of the impeller (see cleaning of the impeller)


• Clean and remove residuals from the inside of the impeller case and of the drainage ring • Clean with accuracy drainage ring and impeller case • Reinstall impeller case, drainage ring and tight relative nuts

17a) open the unit b) unscrew nuts c) remove impeller case

d) remove drainage ring e) cleaning of drainage ring f) re-assembly

6.3.2. Cleaning of the impeller

“Personal safety – integrity of the unit” Nuts and bolts can only be reused if in perfect conditions. Otherwise replace them with new ones identical to the originals. Verify torque specifications indicated and apply thread seal as indicated.

Procedure for cleaning the impeller case: • Remove impeller case • Unscrew main screw and using a special extractor remove the impeller. Do not use the impeller for

leverage. • In order to avoid unbalancing of the impeller make sure that residuals are removed completely using a

brush and degreaser. Do not use acids or solvent. • Once cleaning has completed reinstall impeller on the motor shaft. • Apply thread seal LOCTITE (medium type) on the thread of the screw. Tight it according to the torque

value listed on the relative sheet. • Reinstall impeller case and drainage ring making sure that nuts are properly tight.

18a) remove impeller case and drainage ring

b) removal of impeller c) impeller cleaning


d) reinstallation of the impeller e) tight main screw f) reinstallation of impeller case and

drainage ring

6.3.3. Seals Replacement Main seal

• Remove the seal • Remove completely possible residual of the old seal using a sharp blade • Degrease the surfaces with accuracy using alcohol or specific products. • Dry surfaces • Apply on the surface a light layer of cyanocrylate (Loctite or equivalent) and position the seal

along the perimeter.

19a) Remove the seal b) Clean the surfaces c) Apply seal

d) Remove safety protection screen e) Remove seal f) Reinstallation of safety protection

screen

“Safety of people” Do not start the unit without having safety protection screen in place. It could otherwise result in possible damages due to the rotation of the impeller.

• Unscrew screws securing the safety protection screen • Remove seal of the safety protection screen • Apply the new seal on the safety protection screen • Mount the protection safety screen (along with the seal) onto the impeller case. Secure it with

screws.

6.3.4. Electric motor - Installation and removal Removal • Remove the impeller as described in the general cleaning section • Unscrew the 4 screws securing the cover of the control panel box


• Loosen screws securing motor’s wires located on the on/off switch or on the thermal switch • Loosen motor’s cable gland (positioned on the control panel) • Pull out power supply cable from the control panel box and from the hole of the main filter support flange • Unscrew 4 nuts and remove the motor

Reassembly

• Reinsert power supply cable through hole on the main filter up to the control panel box • Secure with the bolts the motor to the structure. • Tight the cable gland on the box and verify correct positioning of the gland on the filter support flange • Slide in terminals and tight (at 2 Nm) fixing screws on the thermal switch or on the switch • Reposition the cover and tight the 4 screws

“Personal safety – integrity of the unit” Before restarting the unit verify that all screws are properly tight and that inside the impeller case there are no objects (tools, nuts and rugs) Nuts and bolts can only be reused if in perfect conditions. Otherwise replace them with new ones identical to the originals.

20 a) Remove control panel box b) disconnect wires from thermal

switch junction c) remove electric cable from the box

d) remove cable from filter’s flange e) unscrew nuts and bolts f) replacement of the motor

6.4. Torque settings WS 170 WS 330 WS 700 WS 1020 WS 1250 Impeller screw 4 Nm 5 Nm 10 Nm 22 Nm 22 Nm Nuts securing the motor 22 Nm 22 Nm 22 Nm 35 Nm 35Nm Nuts securing impeller case 20 Nm 20 Nm 20 Nm 20 Nm 20 Nm Screws securing electrical terminals 2 Nm 2 Nm 2 Nm 2 Nm 2 Nm

6.5. Periodic checks

“Personal safety – integrity of the unit” Period checks must be performed in accordance to the following maintenance table in order to avoid potential damages to people or to the unit

Every 5000 hrs the following checks must be performed:

• Integrity of electrical boxes • Verify continuity of protective bonding circuit • Integrity of structural parts relative to the motor support plate • Tighten of nuts securing the motor • Tighten screw securing impeller • Integrity and efficiency of gas charged springs


• Integrity of anti vibrations mounts and securing of relative bolts

In case of failure service the unit immediately and do necessary repairs. For additional information do not hesitate to contact our technical department.

21 a) check power supply cable b) verify control panel c) verify cables

d) check electric boxes e) check motor support f) verify nuts securing motor

g) verify screw securing impeller h) check conditions of the gas

charged spring i) check anti-vibration


6.6. Troubleshooting The following is a list of possible problems with relative solutions. For additional clarifications or support please contact our technical department.

“Personal safety – integrity of the unit” Before inspecting the unit: - Press the stop button on the thermal switch, lock the control panel and take key

away. - Isolate the unit from electrical power source ensuring that nobody can restore power. - Signal with proper signs that maintenance operations are undergoing. - During maintenance operations wear appropriate safety protective gears such as:

gloves, goggles, shoes and so on. • In order to avoid possible damages to objects or people censure that

maintenance is undertaken by qualified personnel in accordance to safety procedures..

• Nuts and bolts can only be reused if in perfect conditions. Otherwise replace them with new ones identical to the originals. Self locking nuts must always be replaced with new ones.

Problem Possible cause Remedy Insufficient air flow

Clogged filter

• Check reading on the pressure gauge and if necessary replace the main filter (stage 3)

• Check conditions of the prefilter (stage 1) and replace it if necessary

Clogged inlet ducting Remove objects obstructing inlet

Exhaust air on the Upper lid clogged

Remove objects obstructing cleaned air exhaust

Incorrect selection of Ws size (unit too small for the application)

Contact our technical department

Machine tool enclosure sealed

If by slightly opening the machine’s door the problem s solved remove minor covers or drill ventilation holes in order to let fresh air inside the unit

Insufficient air filtration level

Main filter (stage 3) deteriorated or incorrectly installed

Verify correct filter positioning. If necessary replace it or replace seal.

Dry smoke due to coolant burning

Install absolute Hepa filter

Excessive vibrations

Unbalanced impeller and/or worn bearings

Turn the unit off and contact our technical department.

Securing of the unit approximate and/or anti vibration mounts broken, worn or incorrectly positioned

Check positioning and conditions of the anti vibrations and replace them if necessary.

Abnormal noise

Worn bearings Replace motor bearings Interference between the impeller and its case and or other part of the unit.

Turn off the unit immediately, verify the reason for the interference and solve the problem. For further information contact our technical support

Short lifetime of the filter

Prefilter (stage 1) is missing or misplaced

Check whether the prefilter cartridge is placed correctly

Seals positioned incorrectly, worn or broken

Verify and in case replace seals (pay special attention to the one between the prefilter and the impeller case.

Unit is not perfectly closed Close the upper part and secure the latches. missing or incorrect implementation of the siphon

Do the siphon trap according to what is described in 4.3.1.

Thermal switch intervenes

Incorrect Ampere setting Verify absorbed current value and adjust thermal switch accordingly

Motor is causing a short or absorbed current is above nominal value

Verify possible causes and solve the problem. In case of the motor causing a short proceede with the replacement of the motor.


6.7. Disposal

“Note” To respect the environment and possible sanctions refer to the following guidelines

6.7.1. Disposal of consumables Materials such as filters and seals once dirty must be disposed in accordance to local rules and regulations.

6.7.2 Disposal of the unit In order to obtain the maximum reuse of the raw materials we strongly suggest to delegate this dismissal of the unit to a waste disposal specialized company


7. Spare parts

7.1. Spare filters reorder codes This is a summary of available filters. Check the label placed on the electrical box (as described in the section 1.2.1 “Description and positioning of information labels” ) to reorder the filters.

WS 170 WS 330 WS 700 WS 1020 WS 1250

Prefilter (1° stage)

Emulsion 350140000

Emulsion 350081000

Emulsion 350082000

Emulsion 350083000

Emulsion 350084000

Oil 350375000

Oil 350376000

Oil 350377000

Oil 350378000

Oil 350379000

Main filter (3° stage)

Emulsion 350121000

Emulsion 350005000

Emulsion 350006000

Emulsion 350007000

Emulsion 350008000

Oil 350146000

Oil 350147000

Oil 350148000

Oil 350149000

Oil 350150000

Absolute filter (optional)

N.A

350105000

350106000

350107000

350108000

Activated Carbon refill

(optional)

N.A

350109000

350110000

N.A

N.A


7.2. Complete Spare List

Pos. Description WS 170 WS 330 WS 700 WS 1020 WS 1250 Pz COD Pz COD Pz COD Pz COD Pz COD

1 LID 1 350125000 1 350001000 1 350002000 1 350003000 1 350004000

2 MAIN FILTER (stage 3) REFER TO SECTION 7.1

3 MOTOR (230V-60 Hz) 1 350222000 1 350223000 1 350399000 1 350400000 1 350401000

(400-460V-60 Hz) 1 350339000 1 350340000 1 350341000 1 350342000 1 350343000

4 UPPER CASE 1 350130000 1 350021000 1 350022000 1 350023000 1 350024000

5 CONTROL PANEL 230V 400-460V

1

1

350416000

350421000

1

1

350417000

350422000

1

1

350418000

350423000

1

1

350419000

350424000

1

1

350420000

350425000

Control panel box 1 350029000 1 350029000 1 350029000 1 350029000 1 350029000

Thermal switch 230 V 1 350032000 1 350034000 1 350035000 1 350031000 1 350031000

Thermal switch400- 460V 1 350033000 1 350032000 1 350034000 1 350035000 1 350036000

Ground terminal 1 350037000 1 350037000 1 350037000 1 350037000 1 350037000

6 PRESSURE GAUGE 1 350040000 1 350041000 1 350042000 1 350043000 1 350044000

7 HANDLE 1 350045000 1 350046000 1 350046000 1 350046000 1 350046000

8 IMPELLER 1 350132000 1 350049000 1 350050000 1 350051000 1 350052000

9 GAS CHARGED SPRING 2 350133000 2 350053000 2 350054000 2 350055000 2 350056000

10 IMPELLER CASE 1 350134000 1 350057000 1 350058000 1 350059000 1 350060000

11 SAFETY SCREEN 1 350135000 1 350061000 1 350062000 1 350063000 1 350064000

12 SEAL 1 350136000 1 350065000 1 350066000 1 350067000 1 350068000

13 PRE FILTER (stage 1)

Metallic mesh (Emuls.Only) 1 350211000 1 350073000 1 350074000 1 350075000 1 350076000

Support 1 350139000 1 350077000 1 350078000 1 350079000 1 35008000

Filter media REFER TO SECTION 7.1

14 HINGES 2 350085000 2 350085000 2 350086000 3 350086000 3 350086000

15 DRAW LATCHES 2 350089000 2 350089000 2 350089000 2 350089000 2 350089000

16 ANTIVIBRATION MOUNTS 4 350093000 4 350093000 4 350093000 4 350095000 4 350095000

17 LOWER CASE 1 350141000 1 350097000 1 350098000 1 350099000 1 350100000

18 SEAL 1 350143000 1 350113000 1 350114000 1 350115000 1 350116000

19 DRAINAGE RING 1 350142000 1 350101000 1 350102000 1 350103000 1 350104000

Documents

OIL MIST COLLECTORS Series WS mod. 170 - 330 - 700 - 1020 ...€¦ · i) Centrifugal filtration (stage 2) A special impeller (vibration free) ensures the centrifugal effect that enables