MAN‐M30 – Mori Seiki Mill ‐ V09‐07‐2016
ChipBLASTER, Inc.
M30 Mori Seiki Mill Interface
CONSTANT VOLUME MODEL
HIGH PRESSURE / HIGH VOLUME COOLANT DELIVERY SYSTEM
INSTALLATION, OPERATION and SERVICE MANUAL ChipBLASTER, Inc. 13605 South Mosiertown Road Meadville, PA 16335 USA www.chipblaster.com Telephone: (814) 724 – 6278 Fax: (814) 724 – 6287 Serial Number:
Document Title: Operator/Installation Manual
Document ID: MAN‐M30 – Mori Seiki Mill ‐ V09‐07‐2016
Rev. Revision Description Date Issued Document Nomenclature
A Original 03/18/2016 MAN‐M30 – Mori Seiki Mill ‐ V03‐18‐2016
B Updated Cable Print 9514 and Piping Schematic
03/23/2016 MAN‐M30 – Mori Seiki Mill ‐ V03‐23‐2016
C Updated Cable Print 9484‐03 05/11/2016 MAN‐M30 – Mori Seiki Mill ‐ V05‐11‐2016
D Updated PLC Input Wiring Schematic drawing #M30‐70‐03
07/06/2016 MAN‐M30 – Mori Seiki Mill ‐ V07‐06‐2016
E Updated Power Wiring Supply Schematic drawing #JV40‐01A‐STD
07/11/2016 MAN‐M30 – Mori Seiki Mill ‐ V07‐11‐2016
F Updated Electrical Schematics drawings M30‐70‐03, JV40‐06C, and Cable Print 9360‐02
09/07/2016 MAN‐M30 – Mori Seiki Mill ‐ V09‐07‐2016
Table of Contents 4. DATA NAMEPLATE ..................................................................................................................................... 5 5. GENERAL WARNINGS ................................................................................................................................. 6
5.1 Introduction ................................................................................................................................................. 6
5.2 FCC Regulations ............................................................................................................................................ 9
6. UNIT SPECIFICATIONS ............................................................................................................................... 10 7. STORAGE .................................................................................................................................................. 11
7.1 Moving Machine ........................................................................................................................................ 11
7.2 Placing A ChipBLASTER ............................................................................................................................... 12
7.3 Prior to Installation of ChipBLASTER Unit .................................................................................................. 12
8. MECHANICAL INSTALLATION ..................................................................................................................... 14 8.1 Standpipe Installation ................................................................................................................................ 14
8.2 Suction Strainer Cleaning ........................................................................................................................... 19
8.3 Transfer Pump Hose Installation ................................................................................................................ 19
8.4 High Pressure Hose Installation ................................................................................................................. 22
9. ELECTRICAL INSTALLATION ........................................................................................................................ 23 9.1 Power Connections .................................................................................................................................... 23
9.2 Control Interface ........................................................................................................................................ 24
9.3 Standard Hardwire 6 Pin DIN Interface Connections ................................................................................. 26
9.4 Error Signal Interface (ES) .......................................................................................................................... 27
10. START UP .................................................................................................................................................. 28 10.1 Motor Rotations ......................................................................................................................................... 28
10.2 Pump Air Purge .......................................................................................................................................... 28
10.3 HP Pump Priming ....................................................................................................................................... 28
11. THEORY OF OPERATION ............................................................................................................................ 29 11.1 Fixed Volume High‐Pressure Units ............................................................................................................. 29
12. PREVENTATIVE MAINTENANCE ................................................................................................................. 30 12.1 Preventative Maintenance Schedule ......................................................................................................... 30
12.2 Tank Cleaning ............................................................................................................................................. 31
12.3 Float Cleaning ............................................................................................................................................. 31
12.4 Bolt Torque ................................................................................................................................................. 31
12.5 Transfer Pump ............................................................................................................................................ 31
12.6 Filter Pump ................................................................................................................................................. 32
12.7 Check High‐Pressure Pump Oil via Sight Glass ........................................................................................... 38
12.8 Changing High‐Pressure Pump Oil .............................................................................................................. 38
12.9 Check for Leaks .......................................................................................................................................... 39
12.10 High Pressure Pump Replacement ............................................................................................................. 39
12.11 Belt Tensioning and Force Guide ............................................................................................................... 44
13. FILTER CHANGING ..................................................................................................................................... 46 13.1 N/A ............................................................................................................................................................. 46
14. TROUBLESHOOTING .................................................................................................................................. 47 14.1 Troubleshooting Flow Chart ....................................................................................................................... 47
14.2 Troubleshooting Chart ............................................................................................................................... 48
14.3 Pressure Regulator ..................................................................................................................................... 51
14.4 Pressure Regulator Adjustment Procedure without Drive ......................................................................... 52
15. ELECTRICAL SCHEMATICS .......................................................................................................................... 53 15.1 Power Wiring Schematic ‐ US and CSA Certified ........................................................................................ 53
15.2 Power Wiring Schematic – CE Certified...................................................................................................... 54
15.3 Power Wiring Schematic – Power Supply .................................................................................................. 55
15.4 Control Wiring Schematic .......................................................................................................................... 56
15.5 PLC Input Wiring Schematic ‐ Base ............................................................................................................. 57
15.6 PLC Output Wiring Schematic – Base ......................................................................................................... 58
15.7 Interface Wiring Schematic‐ Mori Seiki Mill Series .................................................................................... 59
15.8 Mori Seiki Series Cable Drawings ............................................................................................................... 60
16. PIPING SCHEMATIC ................................................................................................................................... 68 17. MECHANICAL ASSEMBLY ........................................................................................................................... 69
17.1 Footprint .................................................................................................................................................... 69
18. ORIFICE REFERENCE CHARTS ..................................................................................................................... 70 18.1 20 bar/2000 kpa Chart ............................................................................................................................... 70
18.2 35 bar/3500 kpa Chart ............................................................................................................................... 72
18.3 70 bar/7000 kpa Chart ............................................................................................................................... 74
18.4 103 bar/10300 kpa Chart ........................................................................................................................... 76
18.5 140 bar/14000 kpa Chart ........................................................................................................................... 78
18.6 175 bar/17500 kpa Chart ........................................................................................................................... 80
18.7 207 bar/20700 kpa Chart ........................................................................................................................... 81
18.8 345 bar/34500 kpa Chart ........................................................................................................................... 82
19. WARRANTY .............................................................................................................................................. 83 19.1 New Equipment .......................................................................................................................................... 83
19.2 Used Equipment ......................................................................................................................................... 85
19.3 Retrofits ...................................................................................................................................................... 87
19.4 Warranty Claim Form ................................................................................................................................. 89
19.5 Warranty Registration Card ....................................................................................................................... 90
19.6 Warranty Validation Card ........................................................................................................................... 91
4. DATANAMEPLATE
Machine data nameplate is located on the front enclosure door of the ChipBLASTER unit. The data nameplate will provide information for the machines rated power (KVA/WATTS), and full
load amps.
4 Data Nameplate – All – V07‐25‐2012
5. GENERALWARNINGS
5.1 Introduction
Thank you for purchasing a ChipBLASTER high pressure coolant system! For reliable, safe and long term operation of your ChipBLASTER unit, please follow all guidelines and
warnings detailed within this manual. The ChipBLASTER unit must be installed and connected to electric service per the installation portion of
the manual.
ALL PERSONS WHO WILL BE OPERATING AND MAINTAINING THIS MACHINE MUST READ AND UNDERSTAND THIS ENTIRE MANUAL.
DO NOT AT ANY TIME USE FLAMMABLE OR EXPLOSIVE FLUIDS IN OR AROUND THE UNIT
DO NOT STAND ON MOTORS, SUPPORTS OR JUNCTION BOXES WHILE WORKING ON THE ChipBLASTER
DO NOT EXCEED THE MANUFACTURER’S MAXIMUM OPERATING PRESSURE FOR THE MACHINE TOOL
The items described in these instructions are very important so you are able to use the ChipBLASTER unit safely and prevent injury to yourself and others as well as prevent damage to the property in the
area near the ChipBLASTER unit. Thoroughly familiarize yourself with the symbols and indications shown within this section first before continuing to read the remainder of the manual. Make sure you observe any and all given warnings.
SYMBOLS MEANING
DANGER Indicates that error in operation may lead to serious injury or death.
WARNING Indicates that error in operation may lead to injury to people1 or that these
errors may cause damage to physical property2.
PROHIBITED Indicated prohibition and will be described in or near the symbol in either
text or picture form.
MANDATORY Indicated a mandatory action and will be described in or near the symbol in
either text or picture form.
PINCH POINT Any point where fingers may be pinched by lids or covers. Exercise caution
when closing lids or covers (i.e. oil skimmer lid).
CUTTING HAZARD Any point where exposed fan blades may cause a cutting hazard to fingers
when a guard or inlet hose is not in place. Do not operate without a guard or inlet hose in place (i.e. MistBLASTER inlet)
BELT MOTOR PINCH POINT Any point where fingers may be pinched by the motion of a belt. Do not
operate with guard or cover open.
LIFTING HAZARD Use caution when lifting filter bags from filter housing. For example, filter
bags may be heavy depending on the material being machined.
ELECTRICAL SHOCK HAZARD Shut off the main disconnect before opening any electrical enclosures or
junction boxes. Be aware that units with adjustable frequency drives will hold a lethal charge for a minimum of ten (10) minutes.
LOCK OUT ELECTRICAL POWER Lockout / tagout any and all disconnect switches before performing any
maintenance work on any equipment.
SAFETY GLASSES REQUIRED When removing filter bags or working on equipment, safety glasses must be
worn to prevent personal injury from hazards, such as splashing fluid.
!
!
MACHINE STARTS AUTOMATICALLY ChipBLASTER equipment will start without operator input. Do not remove any guards or covers until the disconnect switches are shut off, locked out
and tagged out.
UNPLUG ENERGY SOURCE Before performing any work on items such as the oil skimmer, unplug the
unit.
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 the equipment, forks of the truck must be located between the points indicated on the unit to prevent any mechanical damage to the unit.
SAFE OPERATING PRESSURE Safe operating pressure will be listed below this symbol in PSIG or BAR.
DO NOT STEP OR STAND ON Do not use surface as a step or platform when surfacing the unit. Motors and electrical boxes are not designed to be used as steps or platforms and injury
may result from a fall.
READ THE TECHNICAL MANUAL Before attempting to work on or repair this machine, you must read and
understand this manual. If certain procedures are not followed, mechanical damage and/or personal injury may result.
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 the 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 equipment.
BURN HAZARD / HOT SURFACE Surfaces, such as the transformer, may become hot after extended periods of operation. Do not set anything on or restrict airflow around these surfaces.
Do not touch.
INHALATION HAZARD Consult MSDS sheet for hazard listings. Possible coolant mist emission.
5.2 FCCRegulations This ChipBLASTER unit 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 my 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 the ChipBLASTER service department at (814) 724 – 6278.
5 General Warnings– D30C – V07‐25‐2012
6. UNITSPECIFICATIONS For specific model, please refer to data nameplate information.
M30‐70
Maximum Pressure
bar 70
psi 1000
Coolant Volume
Liters per minute 30
gpm 8
Filter Element – CHIPBLASTER CYCLONIC FILTER
Coolant Tank Volume
Liters 200
Gallons 52.6
General Recommended Area Required L × W × H
200L Tank
Millimeters 1840 × 1566 × 1532
Inches 72.4 × 61.7 × 60.3
7. STORAGE If the ChipBLASTER unit is to be stored for any period of time it must be kept in an area that is protected from freezing and temperatures exceeding 55°C (131°F). Keep the ChipBLASTER unit covered until ready to move to site. If a MistBLASTER unit was also supplied, keep this unit covered, also. It is recommended that if a ChipBLASTER is going to be stored for an extended period of time, to drain all fluids from tank, filters, hoses, etc.
7.1 MovingMachine When moving the ChipBLASTER to the final site, be certain to adhere to the following steps.
1. The ChipBLASTER unit should ONLY be lifted at specifically labeled lift points. Failure to do so will result in machine damage.
2. The fork truck lifting capacity must be sufficient to safely lift the ChipBLASTER unit without tipping.
Move slowly as to not drop the ChipBLASTER. Do not try to move the ChipBLASTER with fluid in the tank. Do not stand under the ChipBLASTER unit at any time.
7.1.1 IfMistBLASTERisSuppliedwithChipBLASTER
1. To lift or move a standalone MistBLASTER unit, use a fork tuck or hand truck. 2. Always lift from the panel side (front) of the MistBLASTER unit. 3. Place the forks under the bottom plate located between the legs and feet of the stand. 4. If lifting or moving a mounted MistBLASTER unit, lift the unit by eye bolts located on the top of
the unit. Move slowly as to not drop the MistBLASTER. Do not stand under the MistBLASTER unit at any time.
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!LIFT POINTS
!
LIFT HERE
DO NOT LIFT FROM SIDE
LIFT HERE
!
7.2 PlacingAChipBLASTER
1. After receiving a ChipBLASTER unit, prepare the site location for the ChipBLASTER. The installation site must be flat and level.
2. The ChipBLASTER unit needs to be kept within three (3) meters (10') of the machine tool sump. 3. Make sure the unit is placed so maintenance can easily get to the electrical cabinet,
SkimBLASTER (if equipped), and Suction/Discharge on the ChipBLASTER unit. Please refer to footprint drawings for recommended clearances.
4. When lifting the ChipBLASTER, make sure 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.
5. After removing the ChipBLASTER from the skid, place the unit in its final location. 6. Upon positioning the unit, make sure the machine is level. The ChipBLASTER must be level to
ensure proper operation. Power for the ChipBLASTER unit must be available before scheduling installation.
7.3 PriortoInstallationofChipBLASTERUnit
1. The following steps should be taken before proceeding with the installation of a ChipBLASTER unit:
a. Power up the machine tool to verify there are no alarms b. If any alarms are present, have the operator clear them. c. Shut down the machine tool control screen. d. Once the control screen is completely shut down, turn off the main disconnect for the
machine tool. e. Verify that the 3 phase power source voltage matches the voltage label on the
ChipBLASTER. f. Verify the 3 phase power source has a kVA rating capable of carrying the full load amp
rating of the unit. g. Verify the machine tool hose you will be coupling to is rated for at least 68.9 bar
(1000psi / 6894kpa). h. Locate the following components that were shipped with the unit:
i. Locate the following components of the machine tool:
Electrical circuit schematic
Helispring Suction Hose High Pressure hose
Hose clamps Hose fittings
Standpipe assembly Power receptacle and cable
Control interface receptacle and cable
Through‐tool‐coolant pump (if any)
Blank cover plate on machine tool sump
8. MECHANICALINSTALLATION INSTALLER MUST COMPLY WITH ALL LOCAL AND NATIONAL CODES AND SAFETY GUIDELINES
8.1 StandpipeInstallation8.1.1 1”StandpipeAssembly
1. At the machine tool/chip conveyor, locate the blank cover plate on the filtered side of the conveyor sump.
2. Remove the cover plate mounting fasteners. 3. Remove the cover plate to allow for working room
without contaminating the sump. 4. Measure depth of the sump from the cover plate to the
bottom of the sump tank. Refer to Figure 8.1.1 5. Subtract the “cut length” measurement (refer to Chart
8.1.1) from the above sump depth measurement and cut the supplied 1” (25mm) hose.
6. Attach one end of the hose to the standpipe sub assembly with hose clamp. Attach the other end to the suction strainer with hose clamp. Refer to Figure 8.1.2
7. Cut a 5.83” (148mm) diameter hole through the cover plate.
8. Place the standpipe assembly through the hole cut in the previous step. Use this as a template to mark four (4) M6×1 holes.
9. Drill and tap four (4) M6×1 holes through the cover plate. 10. Mount the standpipe bracket to the cover plate. 11. Place the mounted standpipe assembly and cover plate
into the original cover plate location. NOTE: If the suction strainer touches the bottom of the sump, you must trim the hose again to position the strainer approximately 0.5” (12.5mm) from the bottom of the sump. Refer to Figure 8.1.3
12. Once the standpipe assembly fits correctly, mount the entire assembly at the cover plate’s original position.
NOTE: Do not cut the hose short. Do not bend or kink hose. Refer to Figure 8.1.4 and 8.1.5
Chart 8.1.1 SUMP DEPTH CUT LENGTH
7” (177.8mm) 1.25” (31.75mm)
8” (203.2mm) 2.25” (57.15mm)
9” (228.6mm) 3.25” (82.55mm)
10” (254.0mm) 4.25” (107.95mm)
11” (279.4mm) 5.25” (133.35mm)
12” (304.8mm) 6.25” (158.75mm)
NOTE: For sumps less than 7” (177.8mm), refer to Section 8.1.2
Figure 8.1.2
Figure 8.1.1
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8.1.2 ForSumpDepthsMeasuringLessThan7”1. Trim no more than ¼” (6.4mm) from each plastic hose barb. This
will shorten the entire assembly by ½” (12.8mm) and will allow for a sump depth of 6.5” (165.1mm).
2. For sumps less than 6.5” (165.1mm), the plastic hose barbs and 1” clear hose must be removed and replaced with standard 1” pipe nipples. Refer to Figure 8.1.6
a. A 6” (152.4mm) sump will require a 5” (127mm) NPT pipe nipple.
b. A 5” (127mm) sump will require a 4” (101.6mm) NPT pipe nipple.
8.1.3 1.5”StandpipeAssembly1. At the machine tool/chip conveyor, locate the blank cover plate
on the filtered side of the conveyor sump. 2. Remove the cover plate mounting fasteners. 3. Remove the cover plate to allow for working room without contaminating the sump. 4. Measure depth of the sump from the cover plate to the bottom of the sump tank. Refer to
Figure 8.1.1 5. Subtract the “cut length” measurement (refer to Chart 8.1.2) from the above sump depth
measurement and cut the supplied 1.5” (38.1mm) hose. 6. Attach one end of the hose to the standpipe sub assembly with hose clamp. Attach the other
end to the suction strainer with hose clamp. Refer to Figure 8.1.6 7. Position the standpipe in the center of the blank cover plate. 8. Cut a 5.83” (148mm) diameter hole through the cover plate. 9. Place the standpipe assembly through the hole cut in the previous step. Use this as a template
to mark four (4) M6×1 holes. 10. Drill and tap four (4) M6×1 holes through the cover plate. 11. Mount the standpipe bracket to the cover plate. 12. Place the mounted standpipe assembly and cover plate into the original cover plate location.
NOTE: If the suction strainer touches the bottom of the sump, you must trim the hose again to position the strainer approximately 0.5” (12.5mm) from the bottom of the sump. Refer to Figure 8.1.3
Figure 8.1.5Figure 8.1.4Figure 8.1.3
Figure 8.1.6
13. Once the standpipe assembly fits correctly, mount the entire assembly at the cover plate’s original position.
NOTE: Do not cut the hose short. Do not bend or kink hose. Refer to Figure 8.1.4 and 8.1.5
Chart 8.1.2
SUMP DEPTH CUT LENGTH
10” (254mm) 3.25” (82.6mm)
11” (279.4mm) 4.25” (108mm)
12” (304.8mm) 5.25” (133mm)
13” (330mm) 6.25” (158.5mm
14” (355.6mm) 7.25” (184mm)
NOTE: For sumps less than 10” (254mm), refer to Section 8.1.4
8.1.4 ForSumpDepthsMeasuringLessThan10
1. Trim no more that ½” (12.7mm) per barb. This will reduce the entire standpipe assembly by 1” (25.4mm).
2. For sumps less than 10” (254mm), remove plastic hose barbs from standpipe bracket and suction strainer and replace with 1 ½” NPT double ended pipe nipple. Refer to Chart 8.1.3 and Figure 8.1.6
Chart 8.1.3
SUMP DEPTH PIPE LENGTH
9” (228.6mm) 7” (177.8mm)
8” (203.2mm) 6” (152.5mm)
7” (177.8mm) 5” (127.0mm)
6” (152.4mm) 4” (101.6mm)
8.1.5 CycloneFilterDischargeStandpipeInstallation
1. At the machine tool/chip conveyor, locate a blank cover plate on the dirty side of the conveyor sump.
2. Remove the cover plate mounting fasteners. 3. Remove the cover plate to allow for working room without contaminating the sump. 4. Using the Template shown in Figure 8.1.7, Drill Cut a 2.50” (65.3mm) diameter hole through the cover plate. 5. Using the Template shown in Figure 8.1.7, mark two (2) M6×1 holes. 6. Drill and tap two (2) M6×1 holes through the cover plate. 7. Mount the standpipe bracket to the cover plate. 8. Attach .50" (12.7mm) hose end to the standpipe sub assembly with hose clamp. 9. Use a 7/8” box wrench to tighten the nut on the end of hose connected to the discharge standpipe. Refer to Figure 8.6.1
CHIPBLASTER CYCLONIC FILTER DUMP STANDPIPE MOUNTING BRACKET TEMPLATE NOTE: USE THIS PAGE AS A TEMPLATE FOR MARKING HOLES FOR SUMP FLOAT MOUNTING BRACKET DRILL HOLE IN TOP OF THE SUMP TANK FROM 2.50” (63.50 mm) – 3.50” (88.90 mm) FOR INSTALLATION OF THE SUMP FLOAT ASSEMBLY.
Figure 8.1.7
8.1.6 LabelApplication1. The label provided in the standpipe assembly kit will need to be placed to the right of the sight
glass with bottom edge aligned with the bottom of the sump. 2. Thoroughly clean the area where the label will be affixed. 3. Remove paper backing from the label to expose the adhesive. 4. Place the label in proper position and press firmly to attach the label. Refer to Figure 8.1.7
Figure 8.1.7
8.2 SuctionStrainerCleaning1. Locate and remove the four (4) M6×1 bolts that hold standpipe assembly to sump tank. 2. Remove assembly from sump tank. 3. Remove suction strainer from hose barb with an adjustable wrench using flats provided on
fittings. 4. Wash strainer with a heavy duty degreaser to remove any chips or debris on or inside the screen
element. Rinse well with water. NOTE: For extremely dirty or clogged strainers, soak in degreaser and scrub with a stiff nylon bristle brush.
5. Inspect for cracks, tears or other damage to suction strainer. If there is visible damage, contact the ChipBLASTER service department for a replacement.
6. Wrap threads with Teflon tape. 7. Reconnect suction strainer to hose barb with adjustable wrench.
NOTE: Do not over tighten. 8. Place standpipe assembly in sump tank and reattach with the four (4) M6×1 bolts.
THE TRANSFER PUMP MUST BE WITHIN 3.7 METERS (12') OF THE MACHING CENTER COOLANT TANK
8.3 TransferPumpHoseInstallation
8.3.1 StandpipeHoseConnection
1. Using the proper sized supplied 4.5 meter (15’) black hose,
connect the hose to the suction pipe on the ChipBLASTER standpipe assembly. Refer to Figure 8.6.1
2. Install the worm drive clamp to the hose and tighten nut with 5/16" socket.
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8.3.2 TransferPumpPrimeandHoseConnection
1. Fill the 4.5 meter (15’) black hose connected to the standpipe with clean coolant. 2. Connect the coolant filled hose to the transfer pump suction inlet located on the ChipBLASTER
unit. Figure 8.3.2A 3. Install the worm drive clamp and tighten nut with 5/16" socket. 4. Attempt to Air Purge the system, if the pump does not take prime proceed with the following. 5. Remove the bolts and panel indicated in Figure 8.3.2 6. Locate the ½” fitting on the top of the head of the transfer pump, remove the fitting. 7. Using a funnel, fill the transfer pump head cavity with clean coolant. Re‐install the ½” fitting and
tighten. 8. Re‐install the panel and bolts shown in Figure 8.3.2B
FILL THE HOSE OVER A CONTAINER OR SUMP TO ELIMINATE FLUID SPILLING THE TRANSFER PUMP MUST BE WITHIN 3.7 METERS (12') OF THE MACHING CENTER COOLANT TANK
REMOVE BOLTS
Figure 8.3.2B
!
Figure 8.3.2A
SUCTION INLET
Figure 8.7.1
8.4 HighPressureHoseInstallation
1. Locate the high pressure hoses that ChipBLASTER has provided with unit. 2. Connect the female end of the 4.5 meter (15’) hose to ChipBLASTER male end high pressure.
Refer to Figure 8.8.1 3. Connect the other end to the machining center high pressure hose to the spindle, turret or
other designated tool/orifice. Refer to Chart 8.8.1 below for replacement high pressure hoses.
Chart 8.8.1: High Pressure Hose Replacement
Machine Type Hose Assembly Length Part Number
Standard ½" HP (2500psi) 15’ 4736
CE ½" HP (2500psi) 15' total (1 ‐ 9', 1 ‐ 6') 4736CE
HP ‐ CE ½" HP (3500psi) 15' total (1 ‐ 9', 1 ‐ 6') 4736HPCE
HP ½" HP (3500psi) 15' 4736HP
Standard ¾" HP (2500psi) 15' 4738‐1525PSI
CE ¾" HP (2500psi) 15' total (1 ‐ 9', 1 ‐ 6') 4738CE‐1525PSI
Figure 8.8.1
CONNECT HIGH PRESSURE HOSE
HERE
9. ELECTRICALINSTALLATION INSTALLER MUST COMPLY WITH ALL LOCAL AND NATIONAL ELECTRICAL CODES AND SAFETY GUIDELINES WHEN MAKING ELECTRICAL CONNECTIONS TO THE ChipBLASTER. REFER TO THE ELECTRICAL SCHEMATICS (Section 15) DURING ELECTRICAL INSTALLATION. REFER TO THE FOOTPRINT DRAWING (Section 17) FOR RECOMMENDED WORK CLEARANCE.
BEFORE OPENING THE MACHINE TOOL ELECTRICAL CABINET, DISCONNECT AND LOCKOUT /
TAGOUT ALL ELECTRICAL ENERGY SOURCES
9.1 PowerConnections9.1.1 DINInterface
1. Connect 3 ∅ phase power wires (L1,L2, and L3) to pins 1, 2, and 3 via
the supplied 6 pin female power and control DIN interface. 2. Connect the ground wire to PE (ground) tab of the 6 pin female power. 3. Connect control interface.
Pin # Description Wire Color 1 L1 Orange
2 L2 Orange
3 L3 Orange
4
5 Coolant On – Outlet #1 (CR1) BLACK
6 Machine Tool Common ‐ COM 1 WHITE
PE ground GREEN/Yellow
6
3
4
5
1
2
! 3 ∅ Phase Power
Connections
L1 L2 L3 1 COM 1
9.2 ControlInterfaceWARNING!!! MACHINE TOOL VOLTAGE FOR THE ChipBLASTER INTERFACE MAY BE 24VDC OR
120VAC. VERIFY MACHINE TOOL INTERFACING VOLTAGE BEFORE MAKING ANY ELECTRICAL CONNECTIONS. FALUIRE TO INSTALL THE CORRECT INTERFACE RELAYS WILL RESULT IN RELAY DAMAGE. NOTE: The ChipBLASTER is equipped to accept the control interface voltage of 24VDC. The unit is shipped from the factory with 24VDC interface relays included in the electrical enclosure. Please make sure the appropriate control voltage relay (‘s) are installed in CR1, CR3 and CR31 on the unit. *NOTE: 120VAC INTERFACE RELAYS WILL NOT BE PROVIDED IN THE ChipBLASTER UNIT. CONTACT THE ChipBLASTER SERVICE DEPARTMENT (PHONE: 814‐724‐6278) FOR 120VAC MACHINE INTERFACE RELAY KIT.
ChipBLASTER Relay Table
9.2.1 24VDCControlInterfaceRelayConfiguration
24VDC control interface relay configuration will use 24VDC relays provided in the ChipBLASTER electrical enclosure. 24VDC interface relays are factory installed in the specific machine relay bases. Refer to example Figure 9.1.1.1 below for 24VDC control interface relay configuration.
Interface Relays Control Relays (DO NOT REMOVE)
CR1(Coolant On) ‐ Outlet 1 CR6(Oil Skimmer)*Option
CR3(Index) ‐ Outlet 1 ES(Error Signal)
CRH(Alarm Horn)
Control Relays (DO NOT REMOVE)
Interface Relays
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!
!
Figure 9.2.1.1
9.2.2 *OPTIONAL*120VACControlInterfaceRelayConfiguration
*NOTE: 120VAC INTERFACE RELAYS WILL NOT BE PROVIDED IN THE ChipBLASTER UNIT. CONTACT THE ChipBLASTER SERVICE DEPARTMENT (PHONE: 814‐724‐6278) FOR 120VAC MACHINE INTERFACE RELAY KIT. 120VAC control interface relay configuration ‐ Install relays for interface only. Refer to example Figure 9.1.2.1 below for 120VAC control interface relay configuration.
9.2.3 24VDCand120VACControlInterfaceRelayConfiguration*NOTE: 120VAC INTERFACE RELAYS WILL NOT BE PROVIDED IN THE ChipBLASTER UNIT. CONTACT THE ChipBLASTER SERVICE DEPARTMENT (PHONE: 814‐724‐6278) FOR 120VAC MACHINE INTERFACE RELAY KIT. 24VDC and 120VAC configuration will use 24VDC and 120VAC interface relays only. In certain applications machine tools will require different voltages for interface signals. THE FOLLOWING IS ONLY AN EXAMPLE OF USING INTERFACE RELAYS WITH MIXED VOLTAGE SIGNALS For example CR1 (Coolant On) relay may be connected to 120VAC, which will require the installation of the 120VAC relay (RJ1S‐C‐A120). The CR3 and CR31 (Index and Low Pressure Flood) relays may be connected to 24VDC, which will require the installation of the 24VDC (RJ1S‐C‐D24/RJ1S‐C‐D24). Determine the specific voltages before installing the interface relays.
Interface Relays Control Relays (DO NOT REMOVE)
!
Figure 9.1.2.1
9.3 StandardHardwire6PinDINInterfaceConnectionsPin # Description Wire Color 1 Error Signal – E2 Orange
2 Sp1 yellow
3 5 black
4 6 green
5 Index #1 – Outlet #1 (CR3) brown
6 Index #1 – Outlet #1 (CR3) blue
Refer to Figure 9.2.1 for 6pin control DIN interface plug reference. Refer to Section15 (Electrical Diagrams) for interface print (15.1.13).
Figure 9.2.1
6 Pin Control DIN interface
9.4 ErrorSignalInterface(ES) “ES” refers to the ChipBLASTER error signal circuit and relay. The ChipBLASTER is supplied with a 6 pin power and 6 pin control DIN interface base (9360C & 9514PC). *The DIN interface base comes pre‐wired from the factory per the wiring diagram. Determine connection points inside machine tool electrical cabinet for error signal interface. Pin #5 on DIN interface is used for the error signal common, which will power the (ES) contacts on the ChipBLASTER (ES) relay. Pin #1 on the DIN interface is used for the “Normally Closed” contact via the (ES) relay. Refer to Diagram 9.3.1 for specific (ES) relay contact operation. Refer to Figure and Chart 9.3.1. *Drawing 9484M – 01 is attached to the interface cable. NOTE: MACHINE TOOL DAMAGE COULD RESULT IF THE (ES) SIGNAL IS NOT PROPERLY INTERFACED. NOTE: THE ES RELAY IS ENERGIZED WHEN THE ChipBLASTER IS OPERATING WITHOUT ERROR.
9 Electrical Installation –M30 ‐ Mori Mill ‐ V03‐18‐2016
ERROR SIGNAL (E)PIN 10 (RED)
ChipBLASTER ERROR SIGNAL (ES) CONTACTS
NORMALLY CLOSED(N.C.)
NORMALLY OPEN (N.O.)
ERROR SIGNAL (E2)PIN 12 (ORANGE)
ERROR SIGNAL (E1)PIN 11 (YELLOW)
ERROR SIGNAL COMMONVOLTAGE FEED FOR (ES)CONTACTS
(E2) CONNECTIONPOINT FORNORMALLY CLOSEDCONTACT
(E1) CONNECTIONPOINT FORNORMALLY OPENCONTACT
Figure 9.4.1
ChipBLASTER ERROR SIGNAL (ES) WIRING DIAGRAM Diagram 9.4.1
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10. STARTUP
10.1 MotorRotations
1. Check transfer pump rotation (if used) – Rotation is clockwise when viewed from the fan end. 2. Check main pump rotation – Rotation is clockwise when viewed from the fan end.
10.2 PumpAirPurge
10.2.1 TankFilterAirPurge(chipblastercyclonicfilter) For units with a coolant tank, momentarily press the RESET/AIR PURGE button on the enclosure door, noted by the RESET/AIR PURGE label. The Return pump will begin running and purging/filling the system. It may take some time for the Return pump to draw coolant into the hose during the initial installation/operation of the pump. If no coolant enters the hose after 1 minutes, stop the tank fill process by momentarily pressing the RESET/AIR PURGE button. Remove the plug located in the head of the pump. Fill the cavity using a funnel until the pump head is full. Replace the plug and resume the process by momentarily pressing the RESET/AIR PURGE button again. NOTE: The system will automatically fill until the coolant holding tank has reached high level and then automatically shut off. At any time to stop the fill procedure, momentarily press the RESET/AIR PURGE button.
10.3 HPPumpPriming After the tank is full, press and hold the RESET / AIR PURGE pushbutton on the enclosure door of the ChipBLASTER unit for 1‐2 minute. It may take some time for the high pressure pump to draw coolant into the hose during the initial installation/operation of the pump.
11. THEORYOFOPERATION
11.1 FixedVolumeHigh‐PressureUnits The coolant leaving the high‐pressure pump goes to the manifold block which consists of a regulator, 206 bar (3,000 psi / 20,684 kPa) pressure gauge and solenoids. The regulator is adjustable to bypass coolant at 10 bar (1000 psi / 6894 kPa) to prevent any over‐pressure in the high‐pressure coolant system. The bypass coolant is then returned to the machine tool. A pressure gauge is installed to read the overall pressure between the high‐pressure pump and the nozzle’s outlet at the machining tool. The solenoids are used for diverting the coolant to the desired ChipBLASTER outlet in the manifold block. The high‐pressure coolant leaves the manifold block through the machining center to the tool being used.
12. PREVENTATIVEMAINTENANCE12.1 PreventativeMaintenanceSchedule
MAINTENANCE CHARTHOURS 40
WEEKLY 172 MONTHLY 500 688
QUARTERLY 1376
SEMIANNUAL 8000 UNIT TASK
High Pressure Pump (10W30 standard duty)
Check oil level X Replace oil every 4000 hr. or * X
Check belt for wear & adjustment X Check seals for coolant leaks X
Filter Pump Check for leaks X
Filter Unit
Check pressure gauges X Replace bag filter when alarmed X
Check for leaks X Float Unit Clean the float rod X
Tank Clean the tank X Lamps Check all lamp bulbs X
Pump Motor Check mounting bolts X
Transfer Pump (If supplied by ChipBLASTER)
Clean pump cavity X Check for leaks X
Check all inlet & outlet plumbing for blockage
X
Oil Skimmer (If supplied by ChipBLASTER)
Clean troughs X
Check belts X
Equipment Fan Clean fan X
*This normal maintenance schedule is designed for a single 8‐hour shift. If you are running more than one shift a day, the hours must be used in order to prevent downtime.
12.2 TankCleaning The coolant in the tank should be drained yearly so the tank may be properly cleaned.
Dispose of fluid according to all local regulations.
After the tank has been emptied and cleaned, all filters should be replaced.
The ChipBLASTER unit should be restarted as if it were a newly purchased unit.
12.3 FloatCleaningCheck the float switch rod for build‐up of particle material and/or sludge. Be careful not to bend the
float switch rod.
Clean the float bulb and rod.
After cleaning, ensure the rod moves up and down freely without any binding. NOTE: Float rod cleaning may be required more frequently if large amounts of tramp oil are present in coolant reservoir or if cutting oils are used.
12.4 BoltTorquePlease refer to the table below for all recommended bolt torques for each of the following components.
12.5 TransferPump12.5.1 FlowRate
This pump should be checked every six (6) months to ensure correct flow rate.
An indication the transfer pump may be clogged will be constant “SLOW COOLANT RETURN” warnings. Refer to Section 17 (Troubleshooting) for warnings
The ChipBLASTER unit must be powered down and the electrical disconnect placed in the off position and locked out.
Remove the inlet and outlet hoses by loosening the hose clamps.
Inspect the inlet and outlet hoses for chips that may have accumulated. Remove any chips/debris as required.
Remove the four (4) bolts that hold the casting in place using an adjustable wrench.
Clean any and 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.
Component Recommended Torque
Filter pump mounting 17 Nm (12 lbf‐ft)
HP motor mounting 17 Nm (12 lbf‐ft)
Hp pump to slide base 22 Nm (16 lbf‐ft)
Slide base mounting 17 Nm (12 lbf‐ft)
Bag filter lid 17 Nm (12 lbf‐ft)
Transfer pump mounting 20 Nm (15 lbf‐ft)
Manifold block mounting 17 Nm (12 lbf‐ft)
Reassemble the casting and replace the four (4) bolts. Ensure the casting is snugly in place. Check the shaft to ensure it rotates freely. Use the screwdriver slot in the motor to turn the shaft.
Reinstall the inlet and outlet hoses and tighten the hose clamps securely.
Power up the ChipBLASTER unit and check for any leaks. 12.5.2 CheckforLeaks
Check for leaks around the pump head and the sub plate.
Verify the fluid is not coming from a fitting or a hose. If a fitting is leaking, check the tightness of the fitting. If a hose is leaking, shut down the ChipBLASTER unit and replace the hose.
If fluid is leaking from around the motor shaft, the filter pump will require replacement. Please contact the ChipBLASTER service department.
ALL GUARDS MUST BE IN PLACE BEFORE OPERATING THE ChipBLASTER UNIT.
12.6 FilterPumpRemove the panel to the left of the electrical enclosure using a hex
wrench. Refer to Figure 12.6.1
Check for leaks around the pump head and on the sub plate.
Verify there is no fluid leaking from a fitting or a hose. If a fitting is leaking, check the tightness of the fitting. If a hose is leaking, shut down the ChipBLASTER unit and replace the leaking hose.
If any fluid is noticed leaking from the motor shaft, the filter pump will require replacement. Please contact the ChipBLASTER service department.
Reinstall the side cover panel. ALL GUARDS MUST BE IN PLACE BEFORE OPERATING THE ChipBLASTER UNIT.
12.6.1 ReplacingFilterPump‐MechanicalToolsRequired 6mmAllenWrench 5/16”NutDriver 7/8”Wrench 10mmWrench 5/8”Wrench 13mmWrench 13/8”Wrench 13/16”Wrench Largeadjustablewrench(Optional) #2PhillipsHeadScrewDriver 3/8”DriveInch‐PoundTorqueWrenchwith
10”Extension 13mmSocket(3/8”Drive) 10mmSocket(3/8”Drive) 5/16”Socket(3/8”Drive) TeflonTape
PipeSealant WireTies PipeWrench(Optional) Flashlight
Filter Pump Access Panel
Figure 12.6.1
WARNING!!! DO NOT ATTEMPT ANY SERVICE ON A CHIPBLASTER UNIT WITH POWER ENERGIZED. REMOVE ALL ENERGY SOURCES AND LOCK OUT / TAG OUT.
1. Disconnect ALL power sources from the ChipBlaster unit and utilize the lock out/tag out system to prevent accidental injury during pump replacement. FAILURE TO DO SO WILL RESULT IN PERSONAL INJURY OR DEATH!!
2. Remove the panel to the left of the electrical enclosure to gain access to the filter pump. Use a 6mm Allen wrench to remove the bolts. Once the bolts are removed, set the panel aside.
3. Locate and unplug the Orange power cable running from the filter pump to the bottom of the electrical enclosure, generally labeled MR2.
4. Remove the hose clamp and hose from the inlet side of the filter pump using a 5/16” nut driver. For location of the inlet side on Self‐Primer pump, Refer to Figure 12.6.1.1A. For location of the inlet side on Centrifugal pumps, Refer to Figure 12.6.1.1B. When removing the inlet hose, be sure to secure it with a wire tie so that it cannot drop into the tank.
5. Remove the hose clamp and hose from the outlet side of the filter pump using a 5/16” nut driver. For the outlet location on a Self‐Primer pump, Refer to Figure 12.6.1.1A. For the outlet location on a Centrifugal pump, Refer to Figure 12.6.1.1B.
For units equipped with an Auto‐priming system proceed with steps 6‐9. If an Auto‐priming system is not equipped, skip to step 10.
6. If Auto‐priming is equipped, remove the ¼” priming tube from the push‐lock fitting located on the impeller housing. To remove the ¼” priming tube, simply push on the tabs of the push‐lock fitting and pull the tubing. For the push‐lock fitting location on Self‐primer or Centrifugal pumps, Refer to Figures 12.6.1.2A and 12.6.1.2B.
Figure 12.6.1.1A Figure 12.6.1.1B
InletInlet
Outlet
Outlet
7. Remove the push‐lock fitting along with any adapter fittings from the impeller housing using
a 5/8” wrench. Do not remove the push‐lock fitting from the adapter. 8. On the replacement pump, remove the adapter fitting located where the push‐lock fitting
assembly will be located using a 5/8” wrench. 9. Install the push‐lock fitting assembly to the impeller housing on the new pump using a 5/8”
wrench. 10. Locate and remove the two (2) mounting bolts. For Self‐priming pumps, use a 10mm
wrench to remove the mounting bolts which are on opposite corners of the pump base. On Centrifugal pumps use a 13mm wrench to remove the mounting bolts. When removing the mounting bolts, take a moment to mark the proper mounting holes for use when installing the replacement filter pump.
11. Remove the old filter pump from the unit and place it on a flat, level surface. If possible, bolt or clamp the old pump to a working surface to facilitate removal of plumbing fittings in steps 12 and 13.
For some models, a large adjustable wrench and/or pipe wrench may be required for steps 12‐16. 12. Remove the inlet side plumbing assembly from the filter pump. Use a 1 3/8” wrench for
Self‐priming pumps, or a 1 3/16” wrench for Centrifugal pumps. Take note of the plumbing orientation as it will be necessary to reproduce the orientation on the replacement filter pump.
13. Remove the outlet side plumbing assembly from the filter pump using a 1 3/8” wrench. Take note of the plumbing orientation as it will be necessary to reproduce the orientation on the replacement filter pump.
14. Prior to installing the inlet and outlet plumbing assemblies into the replacement filter pump, use Teflon tape and pipe sealant to seal any threaded joints that were dislodged during assembly removal. If possible, bolt or clamp the replacement filter pump to a working surface to facilitate installation of plumbing fittings in steps 15 and 16.
15. Install the inlet side plumbing assembly into the replacement filter pump. Use a 1 3/8” wrench for Self‐priming pumps, or a 1 3/16” wrench for Centrifugal pumps. Make sure that the final orientation replicates the original configuration.
16. Install the outlet side plumbing assembly into the replacement filter pump using a 1 3/8” wrench. Make sure that the final orientation replicates the original configuration.
17. Remove the cover plate of the electrical box on the filter pump. To do this, remove the four (4) Phillips head screws attaching the cover with a #2 Phillips head screw driver. Also remove the cover plate on the replacement filter pump.
Figure 12.6.1.2A Figure 12.6.1.2B
Port for Auto‐priming system push‐lock fitting
18. Verify the voltage and frequency of your ChipBLASTER unit. The “DELTA” wiring scheme should be used for 200V and 230V machines, the “STAR” should be used for 400V and 460V machines. NOTE: The numerical labels on the wires in the orange cable do not correspond to R, Y, or B on the wiring schematic, any of the numbers can be used with any of the letters, this will only affect the motor phasing which will be checked at a later time. Depending on the replacement order, the power cable may already be attached to the replacement pump. If this is the case, verify that the wiring is configured for the proper wiring scheme and skip to step 28. However, if the power cable is not attached, follow steps 19‐27 to transfer the old power cable, or attach a new power cable to the replacement pump.
19. Remove the Wagos from the old filter pump. To remove each wire from the Wago, simply flip the orange lever up to unlock the wires, to lock the wires into place flip the orange lever down.
20. Remove the screw affixing the grounding wire to the interior of the electrical box. 21. Using a 7/8” wrench, loosen the compression nut on the power cable, Refer to Figure
12.6.1.3 22. Using a 7/8” wrench, remove the compression fitting from the electrical box. Refer to Figure
12.6.1.3
23. Remove the power cable from the electrical box. 24. If using the old power cable, thread the power cable into the electrical box then install the
compression fitting using a 7/8” wrench. If using a new power cable, thread the power cable through the compression nut and compression fitting then into the electrical box. Install the compression fitting with a 7/8” wrench.
25. Pull approximately 3” (75mm) of wire into the electrical box, then tighten the compression nut to hold the cable in place. Strip approximately 3/8” (10mm) of the wire jacket from the end of each of the wires; trim the orange jacket as necessary.
Compression Fitting
Compression Nut
Power Cable (Orange)
Electrical Box
Figure 12.6.1.3
26. Attach the ground wire to the grounding screw in the electrical box using a #2 Phillips head screw driver. If using a new power cable, it may be necessary to crimp a ring terminal onto the end of the ground wire.
27. Wire the replacement pump per the wiring schematic on the inside of the cover plate using the Wagos from the old filter pump, Figure 12.6.1.4A shows the “DELTA” 200V/230V wiring and Figure 12.6.1.4B shows the “STAR” 400V/460V wiring. NOTE: The numerical labels on the wires in the orange cable do not correspond to R, Y, or B on the wiring schematic, any of the numbers can be used with any of the letters, this will only affect the motor phasing which will be checked at a later time.
28. Verify that all of the wires are affixed firmly by holding the Wago and gently tugging each of the wires (including the ground wire).
29. Gently press all of the wires into the electrical box and reinstall the cover plate with the four (4) Phillips head screws making sure to maintain the integrity of the gasket seal. If using a new cable, remove the label on the plug of the old cable and affix it to the plug of the new cable using a cable tie.
30. Place the replacement filter pump into the ChipBLASTER unit and align with mounting holes marked during the removal of the old pump. Install two (2) mounting bolts in the marked holes. For Self‐priming pumps use a 10mm socket and for Centrifugal pumps use a 13mm socket. Torque the bolts per Table 12.6.1.
31. Rout the Power cable through the panel behind the electrical enclosure, and plug the cable into the proper port on the bottom of the electrical enclosure, generally MR2. If a new cable was used, it is recommended to re‐label the new plug.
32. For units equipped with the Auto‐priming system, re‐install the ¼” priming tube into the push‐lock fitting on the impeller housing.
To help facilitate restart, it is recommended to prime the pump at this point using steps 33 and 34. 33. Remove the wire tie securing the inlet hose. Fill the inlet hose with clean coolant, then
install the inlet hose and hose clamp onto the inlet side of the filter pump using a 5/16” socket, torque per Table 12.6.1. For inlet location, Refer to Figure 12.6.1.1A and 12.6.1.1B
34. Install the hose clamp and outlet hose onto the outlet side of the filter pump using a 5/16” socket, torque per Table 12.6.1. For outlet location, Refer to Figure 12.6.1.1A and 12.6.1.1B
35. Remove Lock out/tag out and reconnect power to the ChipBLASTER. Check the rotation of the filter pump by pressing and holding the “RESET/AIR PURGE” button, and looking at the fan end of the pump. The rotation should be in the clockwise direction as indicated by the arrow on the fan housing of the pump, it may be necessary to use a flashlight to see the fan
Figure 12.6.1.4A Figure 12.6.1.4B
“DELTA“ 200V/230V Wiring “STAR” 400V/460V Wiring
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blades. Take extreme care as moving parts are exposed and are capable of causing severe bodily harm; stay clear of all moving parts. If the motor rotation is correct, skip to step 40, if the motor rotation is incorrect, follow steps 36‐39.
36. Disconnect ALL power sources from the ChipBLASTER unit and utilize the lock out/tag out system to prevent accidental injury during pump replacement. FAILURE TO DO SO WILL RESULT IN PERSONAL INJURY OR DEATH!!
37. Open the electrical enclosure and locate the Motor Starter that has a label which matches the pump that has been replaced (typically MR2)
38. Using a #2 Phillips head screwdriver, swap the wire attached to either 2T1 with the wire on 4T2 at the bottom of the Motor Overload corresponding to the filter pump being replaced (typically MR2 OL). Torque the terminal screws per Table 12.6.1. Make sure to check the wires are firmly attached by gently pulling each wire.
39. Close the electrical enclosure, remove Lock out/tag out and reconnect power to the ChipBLASTER. Recheck the rotation of the filter pump by pressing and holding the “RESET/AIR PURGE” button, and looking at the fan end of the pump. The rotation should be in the clockwise direction as indicated by the arrow on the fan housing of the pump. Take extreme care as moving parts are exposed and are capable of causing severe bodily harm; stay clear of all moving parts.
40. Visually verify correct operation and all connections to be leak free. 41. Re‐install panel and bolts on the left of the electrical panel using a 6mm Allen wrench.
Table 12.6.1: Torque Table
Component Location Torque (Nm) Torque (Ft‐lbs) Torque (In‐lbs)
1” Hose Clamp Inlet and Outlet Plumbing Assemblies
4 3 35
M6x1.00 Mounting Bolt Self‐Priming Pump Base 11 8 96
M8x1.25 Mounting Bolt Centrifugal Pump Base 26 19 228
Overload Terminal Screws
Motor Overload 1.7 1.25 15
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12.7 CheckHigh‐PressurePumpOilviaSightGlass1. The high‐pressure pump oil may be checked by observing the level in the oil sight glass located
on the opposite side from the electrical enclosure. 2. The oil level must be maintained between the “ADD” and “FULL” indicator marks. If required,
add oil. Refer to Figure 12.7.1 for oil fill ADD ONLY Hydra‐Oil 10W30 STANDARD DUTY FAILURE TO USE Hydra‐Oil 10W30 STANDARD DUTY OIL WILL VOID YOU WARRANTY
3. Bring oil level to the “ADD” indicator mark on the sight glass. 4. Allow oil to settle for three (3) to four (4) minutes. Check
oil level and, if required, add small amounts of oil slowly until level is at “FULL” indicator mark. Refer to Figure 12.7.1
5. Reinstall the dipstick plug. Do not over tighten. Be careful not to crimp gauge tubing lines.
12.8 ChangingHigh‐PressurePumpOil
1. Remove Panel to the left of the electrical enclosure to gain access to high‐pressure pump. 2. Locate the oil sight gauge assembly and remove the two (2) mounting screws. 3. Pull assembly out of the unit and allow the oil to drain into a container capable of holding 1.05
liters (35.5 ounces) for a single pump. PROPERLY DISPOSE OF OIL ACCORDING TO LOCAL REGULATIONS. DO NOT REUSE OIL.
ADD ONLY Hydra‐Oil 10W30 STANDARD DUTY FAILURE TO USE Hydra‐Oil 10W30 STANDARD DUTY OIL WILL VOID YOU WARRANTY
4. Locate the high‐pressure pump and remove the oil cap. 5. Place a small funnel into the opening. Refer to Figure 12.10.1 6. Refill the pump with Hydra‐Oil 10W30 standard duty oil. 7. Add oil to bring the oil level to the “ADD” indicator mark on the sight glass. Refer to Figure
12.7.1 8. Allow the oil to settle for three (3) to four (4) minutes. 9. Check the oil level and, if required, add small amounts of oil until the level is at the “FULL”
indicator mark. See Figure 12.7.1 10. Reinstall the oil cap. Do not over tighten.
BE CAREFUL NOT TO CRIMP THE GAUGE TUBING LINES!
Verify oil level
Figure 12.7.1
12.9 CheckforLeaks1. Remove the panel to the left of the gauge panel using a hex wrench. 2. Check for leaks around the pump head and on the sub plate. 3. If fluid is noticed, verify the fluid is not coming from a fitting or a hose. If a fitting is leaking,
check the tightness of the fitting. If a hose is leaking, shut down the ChipBLASTER unit and replace the hose.
4. If fluid is still apparent, the high‐pressure will need to be replaced. Please contact the ChipBLASTER service department for a replacement pump.
5. Replace the gauge panel before operation the ChipBLASTER.
12.10 HighPressurePumpReplacement
12.10.1 RemovingOldHighPressurePumpToolsRequired
2.5mmAllenwrench 6mmAllenwrench 8mmAllenwrench 1/8”Allenwrench 8mmwrench 13mmwrench 17mmwrench Belttensiongauge–PartNumber:CB2939
(Notprovidedwithmachine,mustbepurchasedthroughtheChipBLASTERservicedepartment)
½”Drivefoot‐poundtorquewrench Straightedge 3/8”Drivew/10”extension
¼”Driveinch‐poundtorquewrenchwith8mmCrowfoot
9/16”Wrench 7/8”Wrench 5/16”Nutdriver 7/16”Socket 1¼”Wrench 13mmSocket 3/8”Driveratchet NeedleNosePliers 3/8”Driveinch‐poundtorquewrench OilFunnel TeflonTape
9/7/2016 2:15 PM
WARNING!!! DO NOT ATTEMPT ANY SERVICE ON ChipBLASTER UNIT WITH POWER ENERGIZED. REMOVE ALL ENERGY SOURCES AND LOCK OUT / TAG OUT.
1. Disconnect ALL power sources from ChipBLASTER unit and utilize the lock out/tag out system to prevent accidental injury during pump replacement. FAILURE TO DO SO MAY RESULT IN PERSONAL INJURY OR DEATH!!
2. Remove Panel to the left of the electrical enclosure to gain access to the high pressure pump. Use a 6mm Allen wrench to remove the bolts. Once the bolts are removed, set the panel aside.
3. Locate the oil sight gauge assembly and remove the two (2) mounting screws using a 2.5mm Allen wrench. You may need to use needle nose pliers to hold the nut on the interior side of the panel while removing the screws.
4. Pull assembly out of the unit and allow the oil to drain into a container capable of holding 1.05 liters (35.5 oz) for a single pump.
PROPERLY DISPOSE OF OIL ACCORDING TO LOCAL REGULATIONS. DO NOT REUSE OIL. ADD ONLY Hydra‐Oil 10W30 STANDARD DUTY OIL. FAILURE TO USE Hydra‐Oil 10W30 STANDARD DUTY OIL WILL VOID YOUR WARRANTY.
5. Remove high pressure outlet line from high pressure outlet fitting. Refer to Figure 12.10.1 6. Remove hose clamp and hose line from high pressure pump feed port using a 5/16” nut
driver. Refer to Figure 12.10.1
7. Locate the four (4) bolts holding the pump slide base to the machine sub plate.
Figure 12.10.1
High Pressure Pump
Feed Port
High Pressure
Outlet Fitting
Hex Plug
Oil Fill Cap
P a g e | 41
8. Loosen but do not remove the four (4) bolts holding the slide base to the subplate. On the right side of the pump use a 13mm wrench. On the left side use a 3/8” drive rachet with a 3/8” drive 10” extension and a 13mm socket due to the tight space. Refer to Figure 12.10.2
9. Locate and loosen the nut on the right side of the adjustment rail using 9/16” wrench. This will relieve the tension on the belt. NOTE: Pay attention to the number of turns required to loosen the belt. Tightening will take approximately the same number of turns.
10. Locate and tighten the bolt on the left side of the adjustment rail using a 13mm wrench.
This will guide the slide base back so that the belt can be removed. NOTE: Pay attention to the number of turns required to loosen the belt. Tightening will take approximately the same number of turns.
11. Remove the belt and inspect for wear or damage. NOTE: If the belt shows signs of wear or damage, do not reuse.
Note: It is recommended to loosen the fittings prior to removing the pump from the unit. See steps 15‐19 for tools required to loosen each fitting.
12. Remove the four (4) slide base bolts then remove pump and base from ChipBLASTER unit and place on a flat, stable surface. Refer to Figure 12.10.2
Figure 12.10.2
Slide Base Bolts (2) NOT SEEN IN VIEW
Slide Base Bolts (2)
DO NOT REMOVE
Adjustment Rail Bolt
Adjustment Rail Nut
P a g e | 42
13. Remove high pressure pump feed port fitting and install into replacement pump hand tight. 14. Remove high pressure outlet fitting and install into replacement pump hand tight. 15. Loosen the set screw on the pulley bushing using a 1/8” Allen wrench. 16. Remove three (3) bushing bolts from the old pump using a 7/16” socket, Refer to Figure
12.10.3. Use the bushing bolts in the threaded holes of the bushing to jack the bushing out of the pulley.
17. Remove the bushing and pulley from the pump shaft. 18. Turn the old pump over and remove the four (4) cap screws holding pump to the slide base
using an 8mm Allen wrench. 19. On the replacement pump locate and remove the hex plug on the bottom of the pump. 20. Remove the oil sight gage fitting and install and tighten into replacement pump where the
hex plug was located. 21. Attach the slide base to the new high pressure pump using the four (4) cap screws and an
8mm Allen wrench, torque per Table 12.10.1. 22. Turn the replacement pump upright and place the pulley onto the pump shaft and remove
the bushing bolts from the threaded jack holes of the bushing. 23. Install the bushing onto the
pump shaft; make sure the key hole is flush with the end of the shaft. Now place the three bushing bolts into the thru holes on the bushing into the threaded holes of the pulley and tighten them down by hand.
24. Tighten the set screw on the bushing using a 1/8” Allen wrench. With a 7/16” socket wrench, tighten the bushing bolts down evenly to prevent bushing and pulley becoming crooked. Torque bushing bolts per Table 12.10.1.
25. Position the newly
assembled high pressure pump assembly back into the ChipBLASTER unit and loosely install the four (4) slide base bolts using a 13mm wrench.
26. With the pump loosely secured in the unit, torque the fittings on the pump head to the values specified in Table 12.10.1.
27. Install the adjustment nut and bolt into the slide rail, then install the belt onto the pulleys. Do not pry or force the belt onto the pulleys as this can result in permanent damage to the belt. Reduce the distance between the pulleys using the adjustment nut and bolt so the belt can be easily installed. NOTE: If the belt shows signs of wear or damage, do not reuse.
28. With the belt in place, slightly tighten the four (4) slide base bolts, leaving the bolts loose enough that the base will still move.
29. Slowly tighten the nut on the right side of the adjustment rail with a 9/16” wrench. As the slide base starts to tighten the belt, slowly adjust (in/out) the left side bolt on the adjustment rail to maintain alignment. NOTE: Make sure to keep the pulleys aligned
Bushing
Bushing Bolts (3)
Pulley
Figure 12.10.3
P a g e | 43
correctly when tightening the belt!! Center lines on the pulleys must align in a straight line.
30. Tighten belt until there is a small amount of tension. NOTE: Do not over tighten the belt. 31. Tighten four (4) slide base bolts with 13mm wrench, torque per Table 12.10.1.
Using a straight edge and the belt tension gauge (not provided) verify belt tension is correct. Refer to Section 12.11 for belt tensioning and force guide. NOTE: Slide base bolts must be tightened before taking any belt tension readings!!!
32. If tension is incorrect, loosen four (4) slide base bolts so the base can move. Adjust the tension using the nut on the right side of the adjustment rail and the alignment using the bolt on the left side of the adjustment rail. Re‐torque four (4) slide base bolts and check alignment and belt tension. Repeat as necessary until alignment and belt tension are correct.
33. Install high pressure outlet line to high pressure outlet fitting, torque per Table 12.6.2. Refer to Figure 12.10.2
34. Re‐Install two (2) mounting screws to hold the oil sight in position using 2.5mm Allen wrench. Refer to Figure 12.10.1
35. Remove high pressure pump oil fill cap located on the top of the pump. Using a funnel, fill using only Hydra‐Oil 10W30 standard duty oil until the sight level indicates full approximately 1.05 liters (35.5 oz), replace fill cap. NOTE: ADD ONLY Hydra‐Oil 10W30 STANDARD DUTY OIL. FAILURE TO USE Hydra‐Oil 10W30 STANDARD DUTY OIL WILL VOID YOUR WARRANTY.
36. Install feed hose and hose clamp using 5/16” nut driver, torque per Table 12.10.1. 37. Remove Lock out/tag out and reconnect power to ChipBLASTER and proceed with Start‐Up
instructions per the standard ChipBLASTER manual. Take extreme care as moving parts are exposed and are capable of causing severe bodily harm; stay clear of all moving parts. Visually verify correct operation and all connections to be leak free.
38. Re‐install panel and bolts on the left of the electrical panel using 6mm Allen wrench.
P a g e | 44
Table 12.10.1: Torque Table
Component Location Torque (Nm) Torque (Ft‐lbs) Torque (In‐lbs)
M8‐1.25 Hex Head Bolt Mount Pump Base to Sub‐Plate
16 12 144
M10‐1.5 Socket Head Cap Screw
Mount Pump to Pump Base
24 18 216
¼‐20 Cap Screw SDS Pump Bushing 12 9 108
High Pressure Outlet Fitting
Pump Head 45 33 402
High Pressure Pump Feed Port
Pump Head 117 86 1035
High Pressure Line Swivel (1/2”)
HP Outlet Line 54 40 480
Hose Clamp High Pressure Feed Line 4 3 35
Recommended Torque Values – Actual torque may vary depending on component conditions
12.11 BeltTensioningandForceGuideNOTE: Actual belt 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.
1. Set large O‐ring to required deflection as specified in Table 12.11.1. Slide small O‐Ring to base for measurement. Refer to Figure 12.11.1
2. Align straight edge on the side of the belt leaving space in the center of the belt for the belt
tension gauge.
3. Using the belt tension gauge, press on the center of the belt span until the large O‐ring on the gauge is flush with the edge of the straight edge. When reading the scale it is extremely important to use the correct scale labeled POUNDS. Refer to Figures 12.11.2, and 12.11.3
Figure 12.11.1
Small O‐Ring in Position
Large O‐Ring Set Per Table 14.11.1
To Measure Press on End
P a g e | 45
4. Determine the pounds of force on the gauge by reading the small O‐ring. Refer to Figure
12.11.1 5. The belt tension gauge must read the force value show in Table 12.11.1 for the specific
machine model, otherwise the belt will be too loose or too tight. Refer to Table 12.11.1 6. Before operating the ChipBLASTER unit, check all bolts for tightness once belt tensioning is
complete.
Table 12.11.1: Belt Tension Table
Model Deflection (mm) Deflection (in) Force (kg) Force (lb)
HV 2.7 0.105 3.2 7
FORCE
DEFLECTION
BELT SPAN
Figure 12.11.3
Figure 12.11.2
Large O‐Ring Flush with
Straight Edge
12 Preventative Maintenance – Hydracell – V02‐29‐2016
P a g e | 46
13. FILTERCHANGING13.1 N/A
13 Filter Changing – M30 – V03‐18‐2016
P a g e | 47
14. TROUBLESHOOTING
14.1 TroubleshootingFlowChart
Do you have the correct pressure at the machine
tool?
Do you have any pressure on
ChipBLASTER's high pressure gauge?
Do you have pressure on ChipBLASTER's
high pressure gauge?
ChipBLASTER is okay!
High pressure gauge is not
working
Is pressure HIGHER or LOWER than
normal?
Faulty pressure regulator;Dump solenoid "C" not
working;Broken belt
NONO
NONOYESYES
YESYESNONOYESYES
N.C solenoid not working;
Nozzle plugged with small chips;
Nozzle too small
Is high pressure pump running?
AFD drive tripped;CR7 not energized;Faulty AFD drive;
Faulty motor
Nozzle opening too large;
Leakage between ChipBLASTER and machine tool nozzle
HIGHERHIGHER LOWERLOWER
NONOYES - OPTION 1YES - OPTION 1
Pressure regulator is out of calibration. Reset by using the "Dead Head"
procedure.
YES - OPTION 2YES - OPTION 2
P a g e | 48
14.2 TroubleshootingChartFault Symptom Remedy
ChipBLASTER has no power
Disconnect switch is off
Machine tool is off
Turn on main power. Turn on main disconnect
Turn on machine tool
Power source fuse blown
Continuous horn
Overload tripped
Tank at low limit
Media free filter: loss of pressure
Correct problem, reset overload.
Check machine tool sump coolant level
Intermittent horn Low coolant / Slow
return
Add coolant to the machining center
coolant tank or clear chips from the inlet hose
Dirty filter: Flashing Red Light
Dirty filter bag
Pressure switch (2PS) malfunction
Change filter bag
If filter inlet bag gauge is reading below 15psi and the alarms still occurs,
replace 2PS
CR1 or CR3 not energizing No command voltage
from machining center
Faulty relay
Check command voltage and wiring connections
Replace relay
High‐pressure motor not operating with “Call for Coolant”
(CR1 and/or CR3) energized
Faulty transducer
Faulty solenoid
CR1 or CR7 not working
ES relay de‐energized
Change transducer
Change solenoid
Check circuits
Correct problem and press RESET/AIR PURGE
pushbutton
High‐pressure motor running slow
CR8 not working
Faulty solenoid “A”
Check CR8 circuit
Replace solenoid
High‐pressure motor running fast but low pressure
Nozzle too large
Leak in pressure line
Faulty transducer
Faulty solenoid “C”
Faulty regulator
Replace nozzle
Repair leak
Replace transducer
Replace solenoid
Check regulator
P a g e | 49
Fault Symptom Remedy
Cannot achieve required outlet pressure
Pump seals are bad
Faulty solenoid
Faulty regulator
Incorrect nozzle size
Regulator not set properly
Plugged or kinked hose
Replace seals
Replace solenoid
Check regulator
Replace nozzle with a recommended standard
size
Adjust regulator
Replace hose
No coolant flowing when high‐pressure is operating
Solenoid valve is sticking
Solenoid coil is faulty
Replace solenoid
Replace coil
Coolant is pulsating from high‐pressure nozzle
High‐pressure pump valve is sticking
Hose plugged
Clean or replace valve
Replace hose
Coolant continues to flow during tool changes (lathes only)
CR3 or CR 4 not working
Solenoid (Sol. A or B) is sticking
Check circuit
Change solenoid
Fault Symptom Remedy
Return pump not operating
MR3 motor overload tripped
MR3 circuit breaker tripped
Reset motor overload
Reset circuit breaker
Return pump coolant flow rate slow
ChipBLASTER float sticking
Plugged inlet
Machine sump low on coolant
Chips stuck inside pump vane
Motor wired in reverse
Free up float
Clean inlet
Add coolant
Clean chips from inside pump
Change motor rotation
Coolant is foaming Incorrect coolant Use a coolant with anti‐
foaming agents for high‐pressure
High‐pressure pump shuts down after five (5) seconds
Faulty optional low pressure detect switch
Seals bad in high‐pressure pump
Coolant pressure loss
Replace low‐pressure detect switch
Change high‐pressure pump
Check for leak and repair
ES relay not on (See note below)
Motor overload trip
Low coolant limit
Circuit breaker trip
Reset motor overload
Add coolant
Reset circuit breaker
System will not operate Loss of 120VAC Check transformer circuit, reset 3CB and/or
4CB
P a g e | 50
!
!
NOTE: Before resetting a circuit breaker or motor starter overload determine the cause and correct first. FOR ADDITIONAL INFORMATION, PLEASE CONTACT THE ChipBLASTER SERVICE DEPARTMENT AT (814) 724 – 6278. WHEN CONTACTING THE ChipBLASTER SERVICE DEPARTMENT, PLEASE HAVE YOUR MODEL AND SERIAL NUMBER OF YOUR ChipBLASTER UNIT WITH YOU. NOTE: Electrical troubleshooting can be done over the phone with a ChipBLASTER service technician. USE EXTREME CAUTION WHEN WORKING INSIDE THE ELECTRICAL ENCLOSURE.
P a g e | 51
!
14.3 PressureRegulatorThe ChipBLASTER pressure regulator is installed for the safety of the operator, as well as the safety of the machine tool. The pressure regulator is pre‐set from the factory to the specific pressures listed in Chart 14.3.1. The specific color indicator markings on the pressure regulator determine the factory set pressure. Refer to Chart 14.3.2 & Figure 14.3.1. Adjustments to the pressure regulator can be made to accommodate operating pressure for the machine tool. Refer to manual section 14: Troubleshooting – 14.4 “Pressure Adjustment Procedure”. Failure to correctly follow the “Pressure Adjustment Procedure” will result in damage to the ChipBLASTER unit and the machine tool!
ChipBLASTER Pressure Regulator
CB Part No. Pressure Setting Color Indicator
4546G ‐ 500 500 PSI Green
4546Y ‐ 1000 1000 PSI Yellow
Factory Pre‐set Pressure Regulator Settings
CB Unit Pressure Regulator settings
J20,J30 69.4 bar (1000 psi/6984 kpa)
Chart 14.3.1
Color Indicators
Pressure Regulator
Figure 14.3.1
Chart 14.3.2
P a g e | 52
14.4 PressureRegulatorAdjustmentProcedurewithoutDrive
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 listed in Chart 14.3.1, unless otherwise specified by the end user. This pressure can be read from the high‐pressure gauge located on the side of the ChipBLASTER unit. Check the machine tool specifications for a maximum operating pressure before proceeding with this procedure. DO NOT EXCEED THE MACHINE TOOL MANUFACTURES MAXIMUM OPERATING PRESSURE NOTE: SOL A = COOLANT THROUGH TOOL SOL B = COOLANT THROUGH ATTACHMENT TOOL OPTION
Shut off power to the ChipBLASTER unit.
Locate the coolant manifold assembly at the back of the ChipBLASTER unit. This manifold assembly will need to be accessible during this procedure for achieving correct pressure settings.
Locate coolant outlet #1 (SOL A) and coolant outlet #2 (SOL B)*Optional. Disconnect the solenoid din connector from each solenoid coil. Refer to Figure 14.4.1
Power up the ChipBLASTER unit. USE EXTREME CAUTION WHEN WORKING ON LIVE EQUIPMENT!
Loosen the locking nut on the pressure regulator using a ¾” wrench.
Energize “Call‐for‐Coolant” (CR1) on the machining center.
NOTE: Use the high‐pressure gauge located on the side of the ChipBLASTER unit when adjusting the pressure regulator.
Adjust regulator pressure by turning the adjustment screw IN using a 3/16” hex head wrench. Turning the adjustment screw clockwise will increase the regulator setting. Turing the adjustment screw OUT using a 3/16” hex head wrench counter‐clockwise will decrease the regulator setting.
Set the pressure regulator to desired working pressure. NOTE: DO NOT EXCEED 83BAR (1200psi/8273kpa). Once the correct adjustment has been made, tighten the locking nut to secure the setting. Refer to Figure 14.4.2
TURNING THE REGULATOR ADJUSTMENT ROD CLOCKWISE INCREASES THE PRESSURE SETTING OF THE REGULATOR. TURNING THE REGULATOR ADJUSTMENT ROD COUNTER CLOCKWISE DECREASES THE PRESSURE SETTING OF THE REGULATOR.
Pressure Regulator
SOL B*Optional
SOL A
Figure 14.4.1
Figure 14.4.2
P a g e | 53
15. ELECTRICALSCHEMATICS15.1 PowerWiringSchematic‐USandCSACertified
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A B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
D30
M3
0-70
PO
WE
R W
IRIN
G S
CH
EM
AT
IC
RR
W07
-06
-201
5M
30-
70-
01
16
AN
TS
L3
PE
L2
L1
PE
3
2
PE
L2
L33
2
1 L11 M30-70HP PUMPFRAME 182/4TCKW 3.75(HP 5.0)RPM 1755FLA 230V - 12.9FLA 460V - 6.45
AMTSELF PRIMEKW .75 (HP 1)RPM 3450FLA 230V- 3.4FLA 460V- 1.7
2T1111
3
5
PE PE
3 3
2 2
2T3
2T2 3MTR3
PE
1MCPGV2ME20 230VGV2ME14 460V
5
3
1
MR 3
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1DS2
4
6
3
5
1
4
6
2
#14 GREEN & YELLOW4 4
6
4
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2T2
2T3
3x #14 BLACK
MR 1
3
5
1
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1T3I> 6
1T1I> 2
230V #12 AWG GREEN/YELLOW460V #14 AWG GREEN/YELLOW
230V 3X #12 AWG BLACK460V 3X #12 AWG BLACK
#12 AWG GREEN/YELLOW
1L3
1L2
1L1
AIN
ITIA
L R
ELE
AS
ER
RW
1-2
1-2
016
#6 GREEN/YELLOW
3MCPGV2ME08 230VGV2ME07 460V
BU
SB
AR
BU
SB
AR
1L1
1L2
1L3
FROM 1DS
GV1G09
230V 3X #8 AWG ORANGE460V 3X #10 AWG ORANGE
3X #10 AWG BLACK
P a g e | 54
15.2 PowerWiringSchematic–CECertified
#12 AWG GREEN/YELLOW
1L3
1L2
1L1
AIN
ITIA
L R
ELE
AS
ER
LC
2-23
-201
6
#6 GREEN/YELLOW
3MCPGV2ME10 200VGV2ME08 400V
BU
SB
AR
BU
SB
AR
1L1
1L2
1L3
FROM 1DS
GV1G09
200V 3X #8 AWG ORANGE400V 3X #10 AWG ORANGE
3X #10 AWG BLACK
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6335
US
A
NA
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A B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
M30
M30
-70
CE
PO
WE
R W
IRIN
G S
CH
EM
AT
IC
RLC
02-
23-2
016
M30
-70-
01-C
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6A
NT
S
L3
PE
L2
L1
PE
3
2
PE
L2
L33
2
1 L11 M30-70HP PUMPFRAME 182/4TCKW 3.75(HP 5.0)RPM 1755FLA 200V - 15.1FLA 400V - 7.74
TRANSFER PUMPGOULDSCENTRIFUGALKW 1.125 (HP 1.5)RPM 2850FLA 200V- 5.0FLA 400V- 2.5
2T1111
3
5
PE PE
3 3
2 2
2T3
2T2 3MTR3
PE
1MCPGV2ME20 200VGV2ME14 400V
5
3
1
MR 3
1MTR3
1DS2
4
6
3
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1
4
6
2
#14 GREEN & YELLOW4 4
6
4
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I>
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2T2
2T3
3x #14 BLACK
MR 1
3
5
1
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1T3I> 6
1T1I> 2
200V #12 AWG GREEN/YELLOW400V #14 AWG GREEN/YELLOW
200V 3X #12 AWG BLACK400V 3X #12 AWG BLACK
P a g e | 55
15.3 PowerWiringSchematic–PowerSupply
B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
REV DESCRIPTION DATENAME
ST
D
PO
WE
R S
UP
PLY
JV40
, JV
40
HP
PO
WE
R W
IRIN
G
ZM
A05
-20
-201
5JV
40-
01A
-ST
D1A
6A
NT
S
*SEE ROUTER FOR POWER SUPPLY PN PE
INPUT200VAC230VAC +
+
3 PWR SUP
OUTPUT24VDC1.7A
---N
L
#14 GREEN & YELLOW
INPUT400VAC460VAC +
+
OUTPUT24VDC5A
---L2
L1
24COM#18 WHITE/BLUE
3 PWR SUP
24COM
#14 GREEN & YELLOW
#18 WHITE/BLUE
1 OUTLET
H2
H4
H3120 VAC
X2
X1
H1
230VACWIRING
100
COM
#18 RED
#18 LIGHT BLUE
#14 GREEN/YELLOW
1TX50VA
4FU1.0A 230V0.5A 460V
2x #14 BLACK
4FUH1
4FUH4
2x #14 BLACK
CUSTOMER OUTLET
11 14 100A
1L1
1L2
FROM1CB
100#18 RED TO REMOTE HMI PWR SUP
1.7A OUTPUT
3FU 2.0A 2x #14 BLACK
1L1
1L2
3FUL1
3FUL2
INPUT200VAC230VAC400VAC460VAC
++
OUTPUT24VDC10A
---
3 PWR SUP
24COM
E-STOP
+24A
+24
+24A
#18 WHITE/BLUE
#18 BLUE
L2
L1
3FU3.0A 200, 230VAC2.0A 400, 460VAC 2x #14 BLACK
1L1
1L2
3FUL1
3FUL2
COM#18 LIGHT BLUE
FROM 1CB OR 1DS
3FU 2.0A 2x #14 BLACK
1L1
1L2
3FUL1
3FUL2
#14 GREEN & YELLOW
10A OUTPUT
INPUT200VAC230VAC +
+
3 PWR SUP
OUTPUT24VDC5A
---N
L
#14 GREEN & YELLOW
24COM#18 WHITE/BLUE
5A OUTPUT
230 VAC
115 VAC
3FU 3.0A 2x #14 BLACK
1L1
1L2
3FUL1
3FUL2
CR STP
11 14
CRESMT+24B 1 2
E-STOP
+24A
+24
+24A
#18 BLUE
11 14
CRESMT+24B 1 2
E-STOP
+24A
+24
+24A
#18 BLUE
11 14
CRESMT+24B 1 2
E-STOP
+24A
+24
+24A
#18 BLUE
11 14
CRESMT+24B 1 2
+24
+24
+24
+24
FROM 1CB OR 1DS
FROM 1CB OR 1DS
FROM 1CB OR 1DS
H2
H4
H3
H1
1TX50VA
460VACWIRING
INITIAL RELEASEA ZMA 05-20-2015
CHANGED RED WIRE SIZE (K-17)B MTS 07-06-2016
P a g e | 56
15.4 ControlWiringSchematic
PLC OUTPUT
Ry OUT
+24
+24A
24 VDC+ - COM 0
PLC OUTPUTS
+24A
3
PLC OUTPUTS
0 1 2Ry OUTCOM 1 4 5
+24A
Ry OUTCOM 26 7
PLC OUTPUT
Ry OUTCOM 38 9
PLC WIRING
0DC INCOM
+24
431 2 765
PLC INPUTS
9 108 12 1311
PLC POWER SUPPLY
24 COM
B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
CO
NT
RO
L W
IRIN
G S
CH
EM
AT
IC
RR
W1
-26
-201
6M
30
-70-
02
26
AN
TS
REFERENCE DESIGNATION
[01A00]
COLUMN
SHEET NO. ROW
+24
24 COM
24 COM#18 BLUE
#18 BLUE
A1 A2
1LTPOWER LAMP (GREEN)
#18 WHITE/BLUE
+24
+24A
AIN
ITIA
L R
ELE
AS
ER
RW
1-2
6-2
016
#18 WHITE/BLUE
PLCFU1.6A 250V
24
PL
C
+24A
~
CR STP
A2 A1+24A
P a g e | 57
15.5 PLCInputWiringSchematic‐Base
+24 24 COM#18 BLUE
#18 WHITE/BLUE
11
13
I0.0.11
CR11411
B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
BA
SE
PL
C IN
PU
T W
IRIN
G
NJK
07/
05/2
016
M30
-70
-03
36
BN
TS
I0.0.13
I0.0.1212
RED
BLACK
6I0.0.6
I0.0.10
I0.0.9
10
9
I0.0.88
I0.0.5
I0.0.4
I0.0.3
5
4
3
I0.0.2
I0.0.1
I0.0.0
1
2
0
PLC 24 VDC INPUT
PLC INPUTS
LOW INLET PRESSURE
TANK LOW LEVEL
RESET / AIR PURGE
MOTOR OVERLOAD
TANK LOW LIMIT
TANK HIGH LEVEL
SIDE "A"
MAIN MOTOR FAULT
SIDE "A"
SIDE "A"
SIDE "A"
2PS
1PB
3 4
COM NC
NO
CALL FOR COOLANT#1
3MCP AUX
13 14
1411
CR3
CALL FOR COOLANT#1INDEX
DC INCOM
AIN
ITIA
L R
ELE
AS
ER
RW
1-2
6-20
16
GREEN
BLACK
RED
1FS WHITE
3FS
2FS
*+24VDC MUST BE FROMCHIPBLASTER SUPPLY*
1MCP AUX13 14 77
I0.0.7
SPARE
SPARE
SPARE
SPARE
SPARE
GREEN
BLACK
RED
1FS WHITE
3FS
2FS
+24
CUSTOMER SUMP FLOAT
BC
HA
NG
ED
CU
ST
OM
ER
FL
OA
T C
ON
TA
CT
SN
JK8-
8-2
016
P a g e | 58
15.6 PLCOutputWiringSchematic–Base
+24 VDC
PLC RELAY OUTPUT
B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
BA
SE
PLC
OU
TP
UT
WIR
ING
RR
W1
-26
-20
16M
30
-70
-04
46
AN
TS
AIN
ITIA
L R
ELE
AS
ER
RW
1-2
6-2
016
Q0.0.6
COM3
9Q0.0.9
COM2
8Q0.0.8
7
6
Q0.0.7
RETURN PUMP
DUMP SOLENOIDSIDE A (N.O.)
2
Q0.0.4
5
4
Q0.0.5
COM 1
3Q0.0.3
1
Q0.0.2
Q0.0.1
COM
0Q0.0.0
SKIMMER CONTROL
LOW INLET PRESSURE/MOTOR OVERLOAD
SOL "C"
A1 A2
+24A
+24A 24 COM
#18 BLUE#18 WHITE/BLUE
A2 A1
ES
MAIN PUMP
~~
BROWN
1 2BLUE
(RED)
~
C1
2LT
MR3
FAULT RELAY
IN ALARM STATE
RELAY ENERGIZEDW HEN SYSTEM IS NOT
MR1
A2A1 ~
+24A
+24A
+24A
ALARM
ALARM
2 c
SKMFU0.25A 250V
2421
OIL SKIMMER0.018 KW (1/40 HP)0.8 FLA11.6 RPM
VOLTAGE REGULATOR
....6MTR
243NOTE:ADD ONLY IF SKIMMERWAS ORDERED
SPARE
SPARE
SPARE
P a g e | 59
15.7 InterfaceWiringSchematic‐MoriSeikiMillSeries
TOTERMINALSTRIP
AIN
ITIA
L R
ELE
AS
EZ
MA
08-
27-2
015
1 2
E-STOP
1 2
FOR CEWIRE 2 SEPARATEE-STOP CONTACTSTO TERMINAL STRIP
#18 ORANGE
#18 ORANGE
CR1
BLACK
WHITE
COOLANT #1
COOLANT #1 COMMON
FOR CE WIRE CR1 TO 12 PIN AS SHOWN
CR4MASTER/SLAVE
USE CR2 FOR GV2MASTER/SLAVE
A1
A2
A1
A2
A1
A2
A1
MACHINE TOOL GROUND
5
6
GND
INDEX SIGNAL
INDEX SIGNAL COM
CHIPBLASTER UNIT
MR3
COMMON CONNECTION (+24 VDC)
RETURN PUMP SIGNAL4
3
N.C. ERROR SIGNAL#18 ORANGE 1
2SPARE - WIRE TO TERMINAL STRIP
INTERFACE PLUG P/N 9460
USE FOR MORI-SEIKI MILLS ONLYCHIPBLASTER UNIT
SHIELDED CABLE
3 PHASE SUPPLYINPUT REFER TOPOWER WIRINGFOR CURRENTDRAW.
CR1COOLANT #1
COOLANT #1 COMMON
MACHINE TOOL GROUND
RED
GND
4
WHITE
BLACK
1CB
L3
5
6
1
2
3
L1
L2
MACHINE TOOL
INTERFACE PLUG P/N 9459
CR3
CR23
PRESET PRESSURE300PSI (OPTIONAL)
NOTE:ADD CR23 ONLY WHEN PN E-1648-PPCALLED FOR ON ROUTERELSE PIN 4 IS SPARE, DO NOT ADD RELAY
#18 ORANGE
#18 ORANGE
#18 ORANGE
#18 ORANGE
#18 ORANGE
#18 ORANGE
#18 ORANGE
#6 GREEN
#18 GREEN
A2
A1
A2
22
21
ES
A1
A2
BU
PD
AT
ED
TE
RM
INA
LS, C
OM
MO
NS
NJK
8-1
8-20
16
Ch
ipT
HIS
PR
INT
IS T
HE
PR
OP
ER
TY
OF
Chi
pBLA
ST
ER
. T
HIS
DO
CU
ME
NT
CO
NT
AIN
S P
RO
PR
IET
AR
Y IN
FO
RM
AT
ION
AN
D S
UC
HIN
FO
RM
AT
ION
MA
Y N
OT
BE
DIS
CLO
SE
D T
O O
TH
ER
S F
OR
AN
YP
UR
PO
SE
OR
US
ED
FO
R M
AN
UF
AC
TU
RIN
G P
UR
PO
SE
S W
ITH
OU
TW
RIT
TE
N P
ER
MIS
SIO
N F
RO
M C
hipB
LAS
TE
R.
UN
IT:
SIZ
E:
4A
CU
ST
OM
ER
:
AP
PR
OV
ED
BY
:
FA
X: (
814
)724
-628
7P
HO
NE
: (8
14)7
24-6
278
BLA
ST
ER
ww
w.c
hipb
last
er.c
omD
RA
WN
BY
:D
AT
E:
TIT
LE
:
DR
AW
ING
NU
MB
ER
:
OF
S
HE
ET
:R
EV
:
MA
T'L
:
RE
VD
ES
CR
IPT
ION
DA
TE
SC
ALE
:
136
05 S
. MO
SIE
RT
OW
N R
OA
DM
EA
DV
ILLE
, PA
16
335
US
A
NA
ME
A B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
MO
RI
SE
IKI
PLU
G W
IRIN
G D
IAG
RA
MS
ZM
A0
8-2
7-2
015
JV4
0-0
6C6C
6B
NT
S
MACHINE TOOL
66
L11L1
PE
PE PE
5 5 PE
L2
L3
31L2 4
1 2
51L3 6
2 2
1 1
33
3 PHASE SUPPLY
1CB
ChipBLASTER MACHINING CENTER
POWER INTERFACE PLUG (12 PIN)
NOTE:ADD CR23 ONLY WHEN PN E-1648-PPCALLED FOR ON ROUTERELSE PIN 4 IS SPARE, DO NOT ADD RELAY
USE FOR MORI-SEIKI MILLS ONLY
RED 4 PRESET PRESSURE300PSI (OPTIONAL)
SHIELDED CABLE
CR23#18 ORANGE
MACHINE TOOL GROUNDG ND
#18 ORANGE
COOLANT #1
COOLANT #1 COMMON
BLACK 5
6WHITE
2
3
CHIPBLASTER UNIT
INTERFACE PLUGP/N: MORI-PWR12P-CNTL24P
MACHINE TOOL
1
USE FOR:ALL STANDARD UNITS WITH CHIPCHILLERALL STANDARD EV60 UNITS
P a g e | 60
15.8 MoriSeikiSeriesCableDrawings15.8.1 PowerandControlCable
# 8
AW
G T
HH
N G
RE
EN
84
FT
.
28
FT
.
12
# 8
AW
G T
HH
N O
RA
NG
E W
IRE
, 90°
C7
44
9
70
45
1)
INS
TA
LL
10
AW
G O
R 8
AW
G W
IRE
BE
LOW
WH
EN
SP
EC
IFIE
D IN
BO
M
# 1
0 A
WG
TH
HN
GR
EE
N
84
FT
.
28
FT
.
12
# 10
AW
G T
HH
N O
RA
NG
E W
IRE
, 90°
C74
51
70
46
1)
ON
LY
IN
ST
ALL
PO
WE
R W
IRE
S L
1, L
2, L
3,
WH
EN
SP
EC
IFIE
D I
N B
OM
Chi
pT
HIS
PR
INT
IS
TH
E P
RO
PE
RT
Y O
F C
hipB
LAS
TE
R.
TH
ISD
OC
UM
EN
T C
ON
TA
INS
PR
OP
RIE
TA
RY
INF
OR
MA
TIO
N A
ND
SU
CH
INF
OR
MA
TIO
N M
AY
NO
T B
E D
ISC
LOS
ED
TO
OT
HE
RS
FO
R A
NY
PU
RP
OS
E O
R U
SE
D F
OR
MA
NU
FA
CT
UR
ING
PU
RP
OS
ES
WIT
HO
UT
WR
ITT
EN
PE
RM
ISS
ION
FR
OM
Chi
pBLA
ST
ER
.U
NIT
:S
IZE
:
4A
CU
ST
OM
ER
:
AP
PR
OV
ED
BY
:
FA
X:
(81
4)7
24-6
287
PH
ON
E:
(81
4)72
4-62
78
BLA
ST
ER
ww
w.c
hipb
last
er.c
omD
RA
WN
BY
:D
AT
E:
TIT
LE:
DR
AW
ING
NU
MB
ER
:
OF
SH
EE
T:
RE
V:
MA
T'L
:
RE
VD
ES
CR
IPT
ION
DA
TE
SC
ALE
:
13
60
5 S
. M
OS
IER
TO
WN
RO
AD
ME
AD
VIL
LE
, P
A 1
6335
US
A
NA
ME
A B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
6 P
IN P
OW
ER
CA
BL
EM
OR
I S
EIK
I N
T10
00 &
NT
X10
00
JRG
JRG
27A
PR
019
359
12
AS
NO
TE
D
AN
TS
NO
N-M
ET
AL
LIC
FIT
TIN
G,
3/4
" C
ON
DU
IT S
WV
L P
S07
59N
BK
15
13
5
12
3' 0
"
TY
P.
WIR
EM
AR
KE
R L
OC
AT
ION
FO
R B
OT
H E
ND
S
10
1/4
"
3/8
"
51
11
CO
LOR
ITE
M #
1O
RA
NG
E
1 1
BLA
CK
12
WH
ITE
12
CB
EN
CL
CR
23R
ED
12
OR
AN
GE
OR
AN
GE
642
4 6531 2
CO
M1
1L3L1 L2
PIN
CR
T. #
51 3
6 7
9 5
3 C
ON
D.
SH
IEL
DE
D C
AB
LE
, W
ES
T P
EN
N #
18-
3 A
WG
MA
RK
BO
TH
EN
DS
OF
WIR
ES
WIT
H W
IRE
MA
RK
ER
S -
ITE
M 1
0
DE
SC
RIP
TIO
N A
ND
MF
G.
PA
RT
NU
MB
ER
WIR
E M
AR
KE
RS
, T
YT
ON
TA
G26
L-10
5
INS
ER
T 6
PIN
MA
LE
, H
AR
TIN
G 0
9 31
006
260
1
HO
OD
, C
AB
LE
-TO
-CA
BL
E,
#09
30 0
16 1
750
AD
AP
TE
R 3
/4",
HA
RT
ING
73
00 0
00 5
314
NO
N-M
ET
AL
LIC
FL
EX
IBL
E C
ON
DU
IT, 3
/4",
GR
AY
, CA
RLO
N
NO
N-M
ET
AL
LIC
FIT
TIN
G,
3/4
" S
TR
AIG
HT
, T
&B
LT
502
ITE
MQ
T'Y
.
RIN
G T
YP
E T
ER
MIN
AL,
TY
TO
N N
Y22
-10R
C2
9 6 4 3578
1 25
FT
.
111
12
10
11
28F
T.
61
CB
PA
RT
No.
54
84
51
52
54
82
55
06
55
90
52
31
1
55
25
LEA
VE
SLA
CK
(2"
MIN
) S
O T
HA
T C
ON
NE
CT
OR
CA
N B
E O
PE
NE
D I
N O
RD
ER
TH
AT
AD
DIT
ION
AL
CO
ND
UC
TO
RS
MA
Y B
E A
DD
ED
IF R
EQ
UIR
ED
.
4
25
' 0"
2
3
5' 0
"
11
P a g e | 61
15.8.2 MoriSeikiMillControlCable
MA
RK
BO
TH
EN
DS
OF
WIR
ES
WIT
H W
IRE
MA
RK
ER
S -
ITE
M 1
0
WIR
E M
AR
KE
RS
, TY
TO
N T
AG
26L
-105
DE
SC
RIP
TIO
N A
ND
MF
G. P
AR
T N
UM
BE
R
CA
BLE
, SH
IELD
ED
#22
-8
NO
N-M
ET
ALL
IC F
ITT
ING
, 1
/2"
ST
RA
IGH
T, T
&B
LT
501
NO
N-M
ET
AL
LIC
FLE
XIB
LE C
ON
DU
IT, 1
/2",
GR
AY
, CA
RLO
N
CO
ND
UIT
AD
AP
TE
R ,
HA
RT
ING
73
00 0
00 5
310
64 65PIN
CR
T. #
2 31
5IT
EM
12
28
FT
.
QT
'Y.
9 4 357810
25
FT
.
1112
59
425
' 0"
5487
1
CB
PA
RT
No.
5507
5033
NO
TE
2.
3
3' 0
"
10
1/4
"
E2
3/3
2"
SP
1
CO
M3
3
OR
AN
GE
CO
LOR
409
8
70
42
8
7
16
PIN
MA
LE
IN
SE
RT
, H
AR
TIN
G 0
9 70
006
281
37
532
NO
TE
S:
2. T
YP
. WIR
E M
AR
KE
R L
OC
AT
ION
FO
R B
OT
H
EN
DS
CB
EN
CL
B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
6 P
IN C
ON
TR
OL
CA
BLE
MO
RI
SE
IKI M
ILL
JRG
JRG
07M
AY
12
93
60-0
11
1
AS
NO
TE
D
AN
TS
YE
LLO
W
BLA
CK
GR
EE
N
BR
OW
N
BLU
E
ST
AN
DA
RD
UN
ITW
IRE
LA
BE
L
1N
ON
-ME
TA
LLIC
FIT
TIN
G,
1/2
" C
ON
DU
IT S
WV
L, #
PS
0509
NG
Y50
48
AU
PD
AT
E L
EN
GT
HR
RW
9-7
-20
12
BU
PD
AT
E C
AB
LE
PL
UG
TO
FE
MA
LEM
M1
0-3
-201
2
HO
OD
, TO
P E
NT
RY
, #09
20
003
1440
5486
1
CA
DD
NT
SE
RIE
S H
OO
DR
RW
10
-16
-201
2
SP
24 65PIN
CR
T. #
2 31
EE2
SP
1
CO
M3
3
OR
AN
GE
CO
LOR
YE
LLO
W
RE
D
WH
ITE
BR
OW
N
BLU
E
D C
UB
E U
NIT
WIR
E L
AB
EL
DA
DD
D-C
UB
E W
IRE
BLO
CK
RR
W1
2-1
0-2
012
EC
HA
NG
ED
TO
MU
LTI-
CO
ND
UC
TO
RG
AR
07-
11
-201
3
FC
HA
NG
ED
TO
MA
LE IN
SE
RT
DS
T0
3-1
4-2
014
P a g e | 62
15.8.3 ControlCable
8
66
16
PIN
FE
MA
LE IN
SE
RT
, H
AR
TIN
G 0
9 70
006
261
654
85
NO
TE
S:
2. T
YP
. W
IRE
MA
RK
ER
LO
CA
TIO
N F
OR
BO
TH
E
ND
S
CB
EN
CL
B C D E F G H I J K L M N O
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
COLUMN
[01A00]
REFERENCE DESIGNATION
SHEET NO. ROW
6 P
IN C
ON
TR
OL
CA
BLE
MO
RI
SE
IKI N
T1
000
& N
TX
1000
JRG
JRG
07M
AY
129
360-
021
1
AS
NO
TE
D
FN
TS
YE
LLO
W
BL
AC
K
GR
EE
N
BR
OW
N
BL
UE
ST
AN
DA
RD
UN
ITW
IRE
LA
BE
L
1N
ON
-ME
TA
LLIC
FIT
TIN
G, 1
/2"
CO
ND
UIT
SW
VL,
#P
S05
09N
GY
504
8
AU
PD
AT
E L
EN
GT
HR
RW
9-7-
2012
BU
PD
AT
E C
AB
LE P
LUG
TO
FE
MA
LEM
M10
-3-2
012
NT
SE
RIE
S O
NLY
NT
SE
RIE
S O
NLY
NT
SE
RIE
S O
NLY
NT
SE
RIE
S O
NLY
CA
DD
NT
SE
RIE
S H
OO
DR
RW
10-1
6-2
012
SP
24 65PIN
C
RT
. #
2 31
EE2
SP
1
CO
M3
3
OR
AN
GE
CO
LOR
YE
LLO
W
RE
D
WH
ITE
BR
OW
N
BLU
E
D C
UB
E U
NIT
WIR
E L
AB
EL
DA
DD
D-C
UB
E W
IRIN
G B
LOC
KR
RW
12-1
0-2
012
EC
HA
NG
ED
TO
MU
LTI-
CO
ND
UC
TO
RG
AR
07-1
1-20
13
FU
PD
AT
ED
WIR
E L
EN
GT
HN
JK8-
22-2
016
MA
RK
BO
TH
EN
DS
OF
WIR
ES
WIT
H W
IRE
MA
RK
ER
S -
ITE
M 1
0
WIR
E M
AR
KE
RS
, TY
TO
N T
AG
26L
-105
DE
SC
RIP
TIO
N A
ND
MF
G. P
AR
T N
UM
BE
R
CA
BLE
, SH
IEL
DE
D #
22-8
NO
N-M
ET
ALL
IC F
ITT
ING
, 1/2
" S
TR
AIG
HT
, T&
B L
T50
1
NO
N-M
ET
ALL
IC F
LEX
IBLE
CO
ND
UIT
, 1/2
", G
RA
Y, C
AR
LON
CO
ND
UIT
AD
AP
TE
R ,
HA
RT
ING
73
00 0
00 5
310
HO
OD
, TO
P E
NT
RY
, #09
20
003
1750
64 65PIN
C
RT
. #
2 31
5IT
EM
12
28 F
T.
QT
'Y.
9 6 4 35810
1 25 F
T.
1112
59
425'
0"
548
7
764
4
1
CB
PA
RT
No.
550
7
503
3
NO
TE
2.
3
3' 0
"
10
1/4
"
E2
3/32
"
SP
1
CO
M3
3
OR
AN
GE
CO
LOR
4098
704
2
P a g e | 63
15.8.4 12pinPowerCable
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2013
15 Electrical Drawings – J30– Mori Seiki Mill‐ V02‐09‐201515 Electrical Drawings – M30 – Mori Seiki Mill – V09‐07‐2016
P a g e | 68
16. PIPINGSCHEMATIC
RE
SE
VO
IR
MA
CH
INE
TO
OL
1.5
"
3 M
TR
TR
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SF
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PU
MP
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1"
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16 Piping Schematic – M30 – V03‐23‐2016
P a g e | 69
17. MECHANICALASSEMBLY17.1 Footprint
17 Mechanical Assembly– M30 – Mori Seiki Mill – V03‐18‐2016
P a g e | 70
18. ORIFICEREFERENCECHARTS
18.1 20bar/2000kpaChart
Orifice Reference Chart for 20 bar/2000 kpa
Orifice Dia. (mm)
Outlet Area (mm2)
bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 20/2000 53 0.1 0.0
0.30 0.07 20/2000 53 0.2 0.0
0.40 0.13 20/2000 53 0.4 0.0
0.50 0.20 20/2000 53 0.6 0.0
0.60 0.28 20/2000 53 0.9 0.0
0.70 0.38 20/2000 53 1.2 0.1
0.80 0.50 20/2000 53 1.6 0.1
0.90 0.64 20/2000 53 2.0 0.1
1.00 0.79 20/2000 53 2.5 0.1
1.10 0.95 20/2000 53 3.0 0.1
1.20 1.13 20/2000 53 3.6 0.2
1.30 1.33 20/2000 53 4.2 0.2
1.40 1.54 20/2000 53 4.9 0.2
Nozzle #XX54 1.57 20/2000 53 5.0 0.2
1.50 1.77 20/2000 53 5.6 0.3
Nozzle #XX55 1.82 20/2000 53 5.8 0.3
1.60 2.01 20/2000 53 6.4 0.3
1.70 2.27 20/2000 53 7.2 0.3
1.80 2.54 20/2000 53 8.1 0.4
1.90 2.84 20/2000 53 9.0 0.4
2.00 3.14 20/2000 53 10.0 0.5
Nozzle #XX56 3.15 20/2000 53 10.0 0.5
2.10 3.46 20/2000 53 11.0 0.5
2.20 3.80 20/2000 53 12.1 0.6
2.30 4.15 20/2000 53 13.2 0.6
Nozzle #XX57 4.45 20/2000 53 14.1 0.7
2.40 4.52 20/2000 53 14.4 0.7
2.50 4.91 20/2000 53 15.6 0.7
2.60 5.31 20/2000 53 16.9 0.8
2.70 5.73 20/2000 53 18.2 0.9
2.80 6.16 20/2000 53 19.6 0.9
2.90 6.61 20/2000 53 21.0 1.0
3.00 7.07 20/2000 53 22.5 1.1
3.10 7.55 20/2000 53 24.0 1.1
3.20 8.04 20/2000 53 25.6 1.2
3.30 8.55 20/2000 53 27.2 1.3
P a g e | 71
Nozzle #XX58 8.90 20/2000 53 28.3 1.3
3.40 9.08 20/2000 53 28.8 1.4
3.50 9.62 20/2000 53 30.6 1.4
3.60 10.18 20/2000 53 32.3 1.5
3.70 10.75 20/2000 53 34.2 1.6
3.80 11.34 20/2000 53 36.0 1.7
3.90 11.95 20/2000 53 38.0 1.8
4.00 12.57 20/2000 53 39.9 1.9
4.10 13.20 20/2000 53 41.9 2.0
4.20 13.85 20/2000 53 44.0 2.1
4.30 14.52 20/2000 53 46.1 2.2
4.40 15.20 20/2000 53 48.3 2.3
4.50 15.90 20/2000 53 50.5 2.4
4.60 16.62 20/2000 53 52.8 2.5
4.70 17.35 20/2000 53 55.1 2.6
4.80 18.10 20/2000 53 57.5 2.7
4.90 18.86 20/2000 53 59.9 2.8
5.00 19.63 20/2000 53 62.4 2.9
5.10 20.43 20/2000 53 64.9 3.0
5.20 21.24 20/2000 53 67.5 3.2
5.30 22.06 20/2000 53 70.1 3.3
5.40 22.90 20/2000 53 72.8 3.4
5.50 23.76 20/2000 53 75.5 3.5
5.60 24.63 20/2000 53 78.3 3.7
5.70 25.52 20/2000 53 81.1 3.8
5.80 26.42 20/2000 53 83.9 3.9
5.90 27.34 20/2000 53 86.9 4.1
6.00 28.27 20/2000 53 89.8 4.2
6.10 29.22 20/2000 53 92.9 4.3
6.20 30.19 20/2000 53 95.9 4.5
6.30 31.17 20/2000 53 99.0 4.6
6.40 32.17 20/2000 53 102.2 4.8
6.50 33.18 20/2000 53 105.4 4.9
6.55 33.69 20/2000 53 107.1 5.0
6.60 34.21 20/2000 53 108.7 5.1
P a g e | 72
18.2 35bar/3500kpaChart
Orifice Reference Chart for 35 bar/3500 kpa
Orifice Dia. (mm)
Outlet Area (mm2)
bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 35/3500 68 0.1 0.0
0.30 0.07 35/3500 68 0.3 0.0
0.40 0.13 35/3500 68 0.5 0.0
0.50 0.20 35/3500 68 0.8 0.1
0.60 0.28 35/3500 68 1.2 0.1
0.70 0.38 35/3500 68 1.6 0.1
0.80 0.50 35/3500 68 2.1 0.2
0.90 0.64 35/3500 68 2.6 0.2
1.00 0.79 35/3500 68 3.2 0.3
1.10 0.95 35/3500 68 3.9 0.3
1.20 1.13 35/3500 68 4.6 0.4
1.30 1.33 35/3500 68 5.4 0.4
1.40 1.54 35/3500 68 6.3 0.5
Nozzle #XX54 1.57 35/3500 68 6.4 0.5
1.50 1.77 35/3500 68 7.2 0.6
Nozzle #XX55 1.82 35/3500 68 7.5 0.6
1.60 2.01 35/3500 68 8.2 0.7
1.70 2.27 35/3500 68 9.3 0.7
1.80 2.54 35/3500 68 10.4 0.8
1.90 2.84 35/3500 68 11.6 0.9
2.00 3.14 35/3500 68 12.9 1.0
Nozzle #XX56 3.15 35/3500 68 12.9 1.0
2.10 3.46 35/3500 68 14.2 1.1
2.20 3.80 35/3500 68 15.6 1.2
2.30 4.15 35/3500 68 17.0 1.4
Nozzle #XX57 4.45 35/3500 68 18.3 1.4
2.40 4.52 35/3500 68 18.6 1.5
2.50 4.91 35/3500 68 20.1 1.6
2.60 5.31 35/3500 68 21.8 1.7
2.70 5.73 35/3500 68 23.5 1.9
2.80 6.16 35/3500 68 25.3 2.0
2.90 6.61 35/3500 68 27.1 2.1
3.00 7.07 35/3500 68 29.0 2.3
3.10 7.55 35/3500 68 31.0 2.5
3.20 8.04 35/3500 68 33.0 2.6
3.30 8.55 35/3500 68 35.1 2.8
Nozzle #XX58 8.90 35/3500 68 36.5 2.9
3.40 9.08 35/3500 68 37.2 3.0
3.50 9.62 35/3500 68 39.5 3.1
P a g e | 73
3.60 10.18 35/3500 68 41.8 3.3
3.70 10.75 35/3500 68 44.1 3.5
3.80 11.34 35/3500 68 46.5 3.7
3.90 11.95 35/3500 68 49.0 3.9
4.00 12.57 35/3500 68 51.5 4.1
4.10 13.20 35/3500 68 54.2 4.3
4.20 13.85 35/3500 68 56.8 4.5
4.30 14.52 35/3500 68 59.6 4.7
4.40 15.20 35/3500 68 62.4 4.9
4.50 15.90 35/3500 68 65.2 5.2
4.60 16.62 35/3500 68 68.2 5.4
4.70 17.35 35/3500 68 71.2 5.6
4.80 18.10 35/3500 68 74.2 5.9
4.90 18.86 35/3500 68 77.3 6.1
5.00 19.63 35/3500 68 80.5 6.4
5.10 20.43 35/3500 68 83.8 6.6
5.20 21.24 35/3500 68 87.1 6.9
5.30 22.06 35/3500 68 90.5 7.2
5.40 22.90 35/3500 68 93.9 7.4
5.50 23.76 35/3500 68 97.5 7.7
5.60 24.63 35/3500 68 101.0 8.0
5.70 25.52 35/3500 68 104.7 8.3
5.80 26.42 35/3500 68 108.4 8.6
5.90 27.34 35/3500 68 112.1 8.9
6.00 28.27 35/3500 68 116.0 9.2
6.10 29.22 35/3500 68 119.9 9.5
6.20 30.19 35/3500 68 123.8 9.8
6.30 31.17 35/3500 68 127.9 10.1
6.40 32.17 35/3500 68 132.0 10.5
6.50 33.18 35/3500 68 136.1 10.8
6.55 33.69 35/3500 68 138.2 11.0
6.60 34.21 35/3500 68 140.3 11.1
P a g e | 74
18.3 70bar/7000kpaChart
Orifice Reference Chart for 70 bar/7000 kpa
Orifice Dia. (mm)
Outlet Area (mm2)
bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 70/7000 142 0.2 0.0
0.30 0.07 70/7000 142 0.4 0.1
0.40 0.13 70/7000 142 0.7 0.1
0.50 0.20 70/7000 142 1.2 0.2
0.60 0.28 70/7000 142 1.7 0.2
0.70 0.38 70/7000 142 2.3 0.3
0.80 0.50 70/7000 142 3.0 0.4
0.90 0.64 70/7000 142 3.8 0.5
1.00 0.79 70/7000 142 4.6 0.6
1.10 0.95 70/7000 142 5.6 0.8
1.20 1.13 70/7000 142 6.7 0.9
1.30 1.33 70/7000 142 7.8 1.1
1.40 1.54 70/7000 142 9.1 1.2
Nozzle #XX54 1.57 70/7000 142 9.3 1.3
1.50 1.77 70/7000 142 10.4 1.4
Nozzle #XX55 1.82 70/7000 142 10.8 1.4
1.60 2.01 70/7000 142 11.9 1.6
1.70 2.27 70/7000 142 13.4 1.8
1.80 2.54 70/7000 142 15.0 2.0
1.90 2.84 70/7000 142 16.8 2.3
2.00 3.14 70/7000 142 18.6 2.5
Nozzle #XX56 3.15 70/7000 142 18.6 2.5
2.10 3.46 70/7000 142 20.5 2.8
2.20 3.80 70/7000 142 22.5 3.0
2.30 4.15 70/7000 142 24.6 3.3
Nozzle #XX57 4.45 70/7000 142 26.3 3.5
2.40 4.52 70/7000 142 26.7 3.6
2.50 4.91 70/7000 142 29.0 3.9
2.60 5.31 70/7000 142 31.4 4.2
2.70 5.73 70/7000 142 33.8 4.6
2.80 6.16 70/7000 142 36.4 4.9
2.90 6.61 70/7000 142 39.0 5.3
3.00 7.07 70/7000 142 41.8 5.6
3.10 7.55 70/7000 142 44.6 6.0
3.20 8.04 70/7000 142 47.5 6.4
3.30 8.55 70/7000 142 50.6 6.8
Nozzle #XX58 8.90 70/7000 142 52.6 7.1
3.40 9.08 70/7000 142 53.7 7.2
3.50 9.62 70/7000 142 56.9 7.7
P a g e | 75
3.60 10.18 70/7000 142 60.2 8.1
3.70 10.75 70/7000 142 63.6 8.6
3.80 11.34 70/7000 142 67.0 9.0
3.90 11.95 70/7000 142 70.6 9.5
4.00 12.57 70/7000 142 74.3 10.0
4.10 13.20 70/7000 142 78.1 10.5
4.20 13.85 70/7000 142 81.9 11.0
4.30 14.52 70/7000 142 85.9 11.5
4.40 15.20 70/7000 142 89.9 12.1
4.50 15.90 70/7000 142 94.0 12.6
4.60 16.62 70/7000 142 98.2 13.2
4.70 17.35 70/7000 142 102.6 13.8
4.80 18.10 70/7000 142 107.0 14.4
4.90 18.86 70/7000 142 111.5 15.0
5.00 19.63 70/7000 142 116.1 15.6
5.10 20.43 70/7000 142 120.8 16.2
5.20 21.24 70/7000 142 125.6 16.9
5.30 22.06 70/7000 142 130.4 17.5
5.40 22.90 70/7000 142 135.4 18.2
5.50 23.76 70/7000 142 140.5 18.9
5.60 24.63 70/7000 142 145.6 19.6
5.70 25.52 70/7000 142 150.9 20.3
5.80 26.42 70/7000 142 156.2 21.0
5.90 27.34 70/7000 142 161.6 21.7
6.00 28.27 70/7000 142 167.2 22.5
6.10 29.22 70/7000 142 172.8 23.2
6.20 30.19 70/7000 142 178.5 24.0
6.30 31.17 70/7000 142 184.3 24.8
6.40 32.17 70/7000 142 190.2 25.6
6.50 33.18 70/7000 142 196.2 26.4
6.55 33.69 70/7000 142 199.2 26.8
6.60 34.21 70/7000 142 202.3 27.2
P a g e | 76
18.4 103bar/10300kpaChartOrifice Reference Chart for 103 bar/10300 kpa
Orifice Dia. (mm)
Outlet Area (mm2)
Bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 103/10,300 173 0.2 0.0
0.30 0.07 103/10,300 173 0.5 0.1
0.40 0.13 103/10,300 173 0.9 0.2
0.50 0.20 103/10,300 173 1.4 0.3
0.60 0.28 103/10300 173 2.0 0.4
0.70 0.38 103/10300 173 2.8 0.5
0.80 0.50 103/10300 173 3.6 0.7
0.90 0.64 103/10300 173 4.6 0.9
1.00 0.79 103/10300 173 5.6 1.1
1.10 0.95 103/10300 173 6.8 1.3
1.20 1.13 103/10300 173 8.1 1.6
1.30 1.33 103/10300 173 9.5 1.9
1.40 1.54 103/10300 173 11.0 2.2
Nozzle #XX54 1.57 103/10300 173 11.3 2.2
1.50 1.77 103/10300 173 12.7 2.5
Nozzle #XX55 1.82 103/10300 173 13.0 2.6
1.60 2.01 103/10300 173 14.4 2.9
1.70 2.27 103/10300 173 16.3 3.2
1.80 2.54 103/10300 173 18.2 3.6
1.90 2.84 103/10300 173 20.3 4.0
2.00 3.14 103/10300 173 22.5 4.5
Nozzle #XX56 3.15 103/10300 173 22.6 4.5
2.10 3.46 103/10300 173 24.8 4.9
2.20 3.80 103/10300 173 27.3 5.4
2.30 4.15 103/10300 173 29.8 5.9
Nozzle #XX57 4.45 103/10300 173 31.9 6.3
2.40 4.52 103/10300 173 32.4 6.4
2.50 4.91 103/10300 173 35.2 7.0
2.60 5.31 103/10300 173 38.1 7.5
2.70 5.73 103/10300 173 41.1 8.1
2.80 6.16 103/10300 173 44.2 8.7
2.90 6.61 103/10300 173 47.4 9.4
3.00 7.07 103/10300 173 50.7 10.0
3.10 7.55 103/10300 173 54.1 10.7
3.20 8.04 103/10300 173 57.7 11.4
3.30 8.55 103/10300 173 61.3 12.1
Nozzle #XX58 8.90 103/10300 173 63.8 12.6
3.40 9.08 103/10300 173 65.1 12.9
3.50 9.62 103/10300 173 69.0 13.7
P a g e | 77
3.60 10.18 103/10300 173 73.0 14.4
3.70 10.75 103/10300 173 77.1 15.3
3.80 11.34 103/10300 173 81.3 16.1
3.90 11.95 103/10300 173 85.7 17.0
4.00 12.57 103/10300 173 90.1 17.8
4.10 13.20 103/10300 173 94.7 18.7
4.20 13.85 103/10300 173 99.4 19.7
4.30 14.52 103/10300 173 104.1 20.6
4.40 15.20 103/10300 173 109.0 21.6
4.50 15.90 103/10300 173 114.1 22.6
4.60 16.62 103/10300 173 119.2 23.6
4.70 17.35 103/10300 173 124.4 24.6
4.80 18.10 103/10300 173 129.8 25.7
4.90 18.86 103/10300 173 135.2 26.8
5.00 19.63 103/10300 173 140.8 27.9
5.10 20.43 103/10300 173 146.5 29.0
5.20 21.24 103/10300 173 152.3 30.1
P a g e | 78
18.5 140bar/14000kpaChartOrifice Reference Chart for 140 bar/14000 kpa
Orifice Dia. (mm)
Outlet Area (mm2)
bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 140/14000 200 0.3 0.1
0.30 0.07 140/14000 200 0.6 0.2
0.40 0.13 140/14000 200 1.1 0.3
0.50 0.20 140/14000 200 1.6 0.4
0.60 0.28 140/14000 200 2.4 0.6
0.70 0.38 140/14000 200 3.2 0.9
0.80 0.50 140/14000 200 4.2 1.1
0.90 0.64 140/14000 200 5.3 1.4
1.00 0.79 140/14000 200 6.6 1.8
1.10 0.95 140/14000 200 7.9 2.1
1.20 1.13 140/14000 200 9.5 2.5
1.30 1.33 140/14000 200 11.1 3.0
1.40 1.54 140/14000 200 12.9 3.5
Nozzle #XX54 1.57 140/14000 200 13.2 3.5
1.50 1.77 140/14000 200 14.8 4.0
Nozzle #XX55 1.82 140/14000 200 15.2 4.1
1.60 2.01 140/14000 200 16.8 4.5
1.70 2.27 140/14000 200 19.0 5.1
1.80 2.54 140/14000 200 21.3 5.7
1.90 2.84 140/14000 200 23.7 6.4
2.00 3.14 140/14000 200 26.3 7.1
Nozzle #XX56 3.15 140/14000 200 26.3 7.1
2.10 3.46 140/14000 200 29.0 7.8
2.20 3.80 140/14000 200 31.8 8.6
2.30 4.15 140/14000 200 34.7 9.3
Nozzle #XX57 4.45 140/14000 200 37.2 10.0
2.40 4.52 140/14000 200 37.8 10.2
2.50 4.91 140/14000 200 41.0 11.0
2.60 5.31 140/14000 200 44.4 11.9
2.70 5.73 140/14000 200 47.9 12.9
2.80 6.16 140/14000 200 51.5 13.9
2.90 6.61 140/14000 200 55.2 14.9
3.00 7.07 140/14000 200 59.1 15.9
3.10 7.55 140/14000 200 63.1 17.0
3.20 8.04 140/14000 200 67.2 18.1
3.30 8.55 140/14000 200 71.5 19.2
Nozzle #XX58 8.90 140/14000 200 74.4 20.0
3.40 9.08 140/14000 200 75.9 20.4
3.50 9.62 140/14000 200 80.4 21.6
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3.60 10.18 140/14000 200 85.1 22.9
3.70 10.75 140/14000 200 89.9 24.2
3.80 11.34 140/14000 200 94.8 25.5
3.90 11.95 140/14000 200 99.9 26.9
4.00 12.57 140/14000 200 105.1 28.3
4.10 13.20 140/14000 200 110.4 29.7
4.20 13.85 140/14000 200 115.8 31.2
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18.6 175bar/17500kpaChartOrifice Reference Chart for 175 bar/17500 kpa
Orifice Dia. (mm)
Outlet Area (mm2)
bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 175/17500 224 0.3 0.1
0.30 0.07 175/17500 224 0.7 0.2
0.40 0.13 175/17500 224 1.2 0.4
0.50 0.20 175/17500 224 1.8 0.6
0.60 0.28 175/17500 224 2.6 0.9
0.70 0.38 175/17500 224 3.6 1.2
0.80 0.50 175/17500 224 4.7 1.6
0.90 0.64 175/17500 224 5.9 2.0
1.00 0.79 175/17500 224 7.3 2.5
1.10 0.95 175/17500 224 8.9 3.0
1.20 1.13 175/17500 224 10.6 3.6
1.30 1.33 175/17500 224 12.4 4.2
1.40 1.54 175/17500 224 14.4 4.8
Nozzle #XX54 1.57 175/17500 224 14.7 4.9
1.50 1.77 175/17500 224 16.5 5.6
Nozzle #XX55 1.82 175/17500 224 17.0 5.7
1.60 2.01 175/17500 224 18.8 6.3
1.70 2.27 175/17500 224 21.2 7.1
1.80 2.54 175/17500 224 23.8 8.0
1.90 2.84 175/17500 224 26.5 8.9
2.00 3.14 175/17500 224 29.4 9.9
Nozzle #XX56 3.15 175/17500 224 29.4 9.9
2.10 3.46 175/17500 224 32.4 10.9
2.20 3.80 175/17500 224 35.5 12.0
2.30 4.15 175/17500 224 38.8 13.1
Nozzle #XX57 4.45 175/17500 224 41.6 14.0
2.40 4.52 175/17500 224 42.3 14.2
2.50 4.91 175/17500 224 45.9 15.4
2.60 5.31 175/17500 224 49.6 16.7
2.70 5.73 175/17500 224 53.5 18.0
2.80 6.16 175/17500 224 57.6 19.4
2.90 6.61 175/17500 224 61.7 20.8
3.00 7.07 175/17500 224 66.1 22.2
3.10 7.55 175/17500 224 70.6 23.7
3.20 8.04 175/17500 224 75.2 25.3
3.30 8.55 175/17500 224 79.9 26.9
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18.7 207bar/20700kpaChartOrifice Reference Chart for 207 bar/20700 kpa
Orifice Dia. (mm)
Outlet Area (mm2)
bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 207/20700 245 0.3 0.1
0.30 0.07 207/20700 245 0.7 0.3
0.40 0.13 207/20700 245 1.3 0.5
0.50 0.20 207/20700 245 2.0 0.8
0.60 0.28 207/20700 245 2.9 1.1
0.70 0.38 207/20700 245 3.9 1.6
0.80 0.50 207/20700 245 5.1 2.0
0.90 0.64 207/20700 245 6.5 2.6
1.00 0.79 207/20700 245 8.0 3.2
1.10 0.95 207/20700 245 9.7 3.8
1.20 1.13 207/20700 245 11.5 4.6
1.30 1.33 207/20700 245 13.5 5.4
1.40 1.54 207/20700 245 15.6 6.2
Nozzle #XX54 1.57 207/20700 245 16.0 6.4
1.50 1.77 207/20700 245 18.0 7.1
Nozzle #XX55 1.82 207/20700 245 18.5 7.4
1.60 2.01 207/20700 245 20.4 8.1
1.70 2.27 207/20700 245 23.1 9.2
1.80 2.54 207/20700 245 25.9 10.3
1.90 2.84 207/20700 245 28.8 11.5
2.00 3.14 207/20700 245 31.9 12.7
Nozzle #XX56 3.15 207/20700 245 32.0 12.7
2.10 3.46 207/20700 245 35.2 14.0
2.20 3.80 207/20700 245 38.6 15.4
2.30 4.15 207/20700 245 42.2 16.8
Nozzle #XX57 4.45 207/20700 245 45.2 18.0
2.40 4.52 207/20700 245 46.0 18.3
2.50 4.91 207/20700 245 49.9 19.9
2.60 5.31 207/20700 245 54.0 21.5
2.70 5.73 207/20700 245 58.2 23.2
2.80 6.16 207/20700 245 62.6 24.9
2.90 6.61 207/20700 245 67.1 26.7
3.00 7.07 207/20700 245 71.9 28.6
3.10 7.55 207/20700 245 76.7 30.5
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18.8 345bar/34500kpaChartOrifice Reference Chart for 345 bar/34500 kpa Orifice Dia. (mm)
Outlet Area (mm2)
bar/kpa Velocity (Meter/Sec.)
Volume (LPM)
Kilowatt Required
0.20 0.03 345/34500 317 0.4 0.3
0.30 0.07 345/34500 317 0.9 0.6
0.40 0.13 345/34500 317 1.6 1.1
0.50 0.20 345/34500 317 2.6 1.7
0.60 0.28 345/34500 317 3.7 2.5
0.70 0.38 345/34500 317 5.1 3.3
0.80 0.50 345/34500 317 6.6 4.4
0.90 0.64 345/34500 317 8.3 5.5
1.00 0.79 345/34500 317 10.3 6.8
1.10 0.95 345/34500 317 12.5 8.3
1.20 1.13 345/34500 317 14.8 9.8
1.30 1.33 345/34500 317 17.4 11.6
1.40 1.54 345/34500 317 20.2 13.4
Nozzle #XX54 1.57 345/34500 317 20.7 13.7
1.50 1.77 345/34500 317 23.2 15.4
Nozzle #XX55 1.82 345/34500 317 23.9 15.8
1.60 2.01 345/34500 317 26.4 17.5
1.70 2.27 345/34500 317 29.8 19.8
1.80 2.54 345/34500 317 33.4 22.1
1.90 2.84 345/34500 317 37.2 24.7
2.00 3.14 345/34500 317 41.2 27.3
Nozzle #XX56 3.15 345/34500 317 41.3 27.4
2.10 3.46 345/34500 317 45.5 30.1
18 Orifice Charts– All – V01‐22‐2015
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19. WARRANTY
19.1 NewEquipment
19.1.1 ChipBLASTER,Inc.LimitedWarranty–NewEquipment Limited Warranty: ChipBLASTER, Inc. warrants its ChipBLASTER™ coolant systems, MistBLASTER™ and ChipCHILLER™ (“ChipBLASTER equipment”) to be free from defects in materials and workmanship for the time period set forth above, starting on 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 ChipBLASTER equipment or parts without charge to the purchaser. Limited Warranty Conditions: This Limited Warranty applies only to new ChipBLASTER equipment, and is solely for the benefit of and applicable to the end user. 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, 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 ChipBLASTER equipment or parts or any other products which result from the alteration, repair, modification, faulty installation, or service (other than regular maintenance) by anyone other than an authorized ChipBLASTER service technician; the use of any add‐ons, parts, accessories or components not obtained from ChipBLASTER or any authorized ChipBLASTER supplier or approved in writing by ChipBLASTER; damage to ChipBLASTER equipment or parts or any other products caused by 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. 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 manual section 12.1 and posted on the outside panel of the ChipBLASTER. Refer to manual section 12.1 “Preventative Maintenance Schedule” Use of filters other than ChipBLASTER will void warranty coverage for any filtration related damage or failures. Any replacement equipment or parts provided to the purchaser in fulfilling this warranty are warranted for the un‐expired portion of the original warranty. If any ChipBLASTER equipment is found upon ChipBLASTER’s examination in response to a timely warranty claim to have defects in material or workmanship, ChipBLASTER will either replace or repair the product, at its sole option. 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
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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 expenses. 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. 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. 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. Failure of the purchaser to maintain the equipment by completing all of the scheduled maintenance tasks set forth in manual section 12.1 to this limited warranty entitled “Preventative 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 manual section 12.1 “Preventative Maintenance Schedule”. ChipBLASTER warranty card must be completed by purchaser and returned to ChipBLASTER within thirty (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 purchase and the nature of the problem or difficulty. A warranty claim can be obtained by contacting ChipBLASTER at: 1‐ (814) 724 ‐ 6278. 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 the 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 specification 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 other purpose.
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This warranty specifically excludes reimbursement or liability for “downtime,” loss of income and/or consequential damages, or any other direct or indirect 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.
19.2 UsedEquipment
19.2.1 ChipBLASTER,Inc.LimitedWarranty–UsedEquipment Limited Warranty: ChipBLASTER, Inc. warrants the used ChipBLASTER™ coolant systems, MistBLASTER and ChipCHILLER™ (“ChipBLASTER equipment”) to be free of defects in materials and workmanship for the lesser of ninety (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 ChipBLASTER equipment or parts without charge to the purchaser. Limited Warranty Conditions: Limited warranty applies only to used ChipBLASTER equipment, and is solely for the benefit of and applicable to initial purchaser. 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, applications, inspection and regular maintenance, as specified in this manual and/or any ChipBLASTER manual, quotation, acknowledgement, 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 ChipBLASTER equipment or parts or any other products which results from the alteration, repair, modification, faulty installation, or service (other than regular maintenance) by anyone 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 ChipBLASTER equipment or parts or any other products caused by 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 failure such as surges or brownouts. Regular maintenance includes minor normal maintenance required to be performed by buyer, at buyer’s expense as set forth in the maintenance schedule included with this warranty in manual section 12.1 and posted on the outside panel of the ChipBLASTER. Refer to manual section 12.1 “Preventative Maintenance Schedule”. Use of filters other than ChipBLASTER will void warranty coverage for any filtration related damage or failures. Any replacement equipment or parts provided to the purchaser in fulfilling this warranty are warranted for the un‐expired portion of the original warranty. If any ChipBLASTER equipment is 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 ChipBLASTER equipment, at its sole option.
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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 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. 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. 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 written approval is received in writing from ChipBLASTER. This limited warranty shall cover alleged defects in materials or 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 have been waived by the purchaser. Failure of the purchaser to maintain the equipment by completing all of the scheduled maintenance tasks set forth in manual section 12.1 to this limited warranty entitled “Preventative 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 manual section 12.1 “Preventative Maintenance Schedule”. ChipBLASTER warranty card must be completed by purchaser and returned to ChipBLASTER within thirty (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 provided, 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 sealer 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: 1‐ (814) 724 ‐ 6278. 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, expressed 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 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.
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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, or any other direct or indirect 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.
19.3 Retrofits
19.3.1 ChipBLASTER,Inc.LimitedWarranty–High‐PressureRetrofits. Limited Warranty: ChipBLASTER, Inc. warrants its ChipBLASTER™ high‐pressure retrofits to be free from defects in materials and workmanship for the lesser of one (1) year or 4160 operating hours from the date of delivery to the original user, subject to the conditions set forth below. During the warranty period, ChipBLASTER will repair or replace, at its sole option, defective ChipBLASTER equipment 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. Limited Warranty Conditions: Warranty applies only to new ChipBLASTER retrofits. 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, applications, inspection and regular maintenance, as specified in any ChipBLASTER manual, quotation, acknowledgement, 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 instruction provided by ChipBLASTER applicable literature; any damage or loss to ChipBLASTER equipment or parts or any other products which results from the alteration, repair, modification, faulty installation, or service (other than regular maintenance) by anyone 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 ChipBLASTER equipment or parts or any other products 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. 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 in manual section 12.1 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. Any replacement equipment or parts provided to the purchaser in fulfilling this warranty are warranted for the un‐expired portion of the original warranty. If any ChipBLASTER equipment is found upon ChipBLASTER’s examination in response to a timely warranty claim to have defects in material or workmanship, ChipBLASTER will either replace or repair the ChipBLASTER equipment, at its sole option. Warranty repairs will be completed at the purchaser’s location.
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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. Repairs of defects in material 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. 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 have been waived by the purchaser. ChipBLASTER warranty card must be completed by purchaser and returned to ChipBLASTER within thirty (30) days after installation of ChipBLASTER retrofits. 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 technical assistance or a request for warranty service, the purchaser must provide, at a minimum, the following information during the initial telephone 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 purchase; the nature of the problem or difficulty. A warranty claim form can be obtained by contacting ChipBLASTER at: 1‐ (814) 724 ‐ 6278. 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™ 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. ChipBLASTER neither extends nor provides any warranty, express or implied, on any products not manufactured 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. This warranty excludes all implied warranties of merchantability or fitness for particular purpose or any purpose. This warranty specifically excludes liability of ChipBLASTER for “downtime,” loss of income and/or consequential damage or any other direct or indirect damages. In no event will ChipBLASTER’s liability to the purchaser’s purchase of ChipBLASTER™ retrofits or the operation thereof exceed the purchase price of the product manufactured or sold by ChipBLASTER.
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19.4 WarrantyClaimForm
● Warranty Claim Form ●
Unit Serial Number:
Description of Unit:
Purchased From:
Invoice Number:
Invoice Date:
Date of Installation:
Nature of Problem: (including date of occurrence)
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19.5 WarrantyRegistrationCard Detach the bottom portion of this page 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 No.: Company Name:
Model: Address:
Purchased From: City:
Invoice No.: State, Zip Code:
Invoice Date: Contact Person:
Date of Installation: E‐mail Address:
Phone:
Fax:
Please return to: ChipBLASTER
Attention: Service Department
13605 South Mosiertown Road
Meadville, PA 16335
Phone: (814) 724 ‐ 6278
Fax: (814) 724 ‐ 6287
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19.6 WarrantyValidationCard Please remove this document from your manual and return the completed form to ChipBLASTER, Inc. in order for your warranty
to become valid and effective. Thank you!
● WARRANTY VALIDATION CARD ●
ChipBLASTER S/N and Model:
Purchased from:
Installation Date:
I do hereby declare the ChipBLASTER High Pressure Coolant System, MistBLASTER and/or ChipCHILLER have been installed on _________________________________ (machine model)
according to ChipBLASTER procedures.
(Note: ChipBLASTER standard warranty will commence with the above signed installation date if all conditions of the procedures are met)
Signature:
Date: Please return completed form to the following address:
ChipBLASTER, Inc. 13605 South Mosiertown Road Meadville, PA 16335
Date Warranty Registration received: _____________________________ (Office use only)
19 Warranty– All – V03‐10‐2015