Related Manuals for HST WFS - 101545
Summary of Contents for HST WFS - 101545
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Page 1: Sheet
WFS 101545 Operations Manual ORIGINAL INSTRUCTIONS Installation and Operation Water Filtration System WFS – 101545 Serial Number: _________ HST Spindles, LLC. 1357 Route 3A Bow, NH 03304 USA www.highspeedtechnologies.com... -
Page 2: Table Of Contents
WFS 101545 Operations Manual TABLE OF CONTENTS SECTION I OVERVIEW 1. NOMENCLATURE Page 4 2. GENERAL DESCRIPTION Page 4 a. Process Loop Page 6 b. Spindle Loop Page 6 c. Internal Recirculating Loop Page 7 d. Lift Station Page 7 3. -
Page 3: Sheet
WFS 101545 Operations Manual SECTION II COMMISIONING Page 32 1. COMMISSIONING PREREQUISITES Page 32 2. FILLING THE RESERVOIR Page 33 3. FILLING THE RECIRCULATING FILTER HOUSINGS Page 34 4. FILLING THE PROCESS FILTER HOUSINGS Page 35 5. STARTING THE SPINDLE CIRCUIT Page 35 6. -
Page 4: Section I Overview
WFS 101545 Operations Manual SECTION I OVERVIEW NOMENCLATURE NOTE: This message highlights a feature, function or procedure that may be helpful. CAUTION: This message warns of a condition that may have unintended negative action or consequences. It indicates a need for heightened diligence. WARNING: This message warns of a condition or procedure that has potential for physical injury or death. -
Page 5: Sheet
WFS 101545 Operations Manual The WFS 101545 provides economies in two ways: Significantly reduces DI water consumption by reconditioning and reusing the water. Eliminates or reduces contaminated or hazardous liquid waste disposal by filtering out contaminates into a removable cartridge. The cartridge can be dried and the waste material can then be handled as solid waste. -
Page 6: Process Loop
WFS 101545 Operations Manual The system provides two (2) separate cooling circuits. One is specifically for cooling the dicing or sawing process. The other provides cooling water to the spindle or drive motors. Used process water is cooled by refrigeration, filtered and deionized. Used spindle cooling water is cooled by refrigeration in a separate circulating loop. -
Page 7: Internal Recirculating Loop
WFS 101545 Operations Manual SIMPLIFIED SCHEMATIC OF THE SPINDLE CHILLER SPINDLE MOTORS SPINDLE COOLANT CHAMBER The spindle coolant loop is rated at 10 GPM at 45 PSI c. Internal recirculating Loop This loop constantly recirculates process water returned from the lift station through filters and cooling. -
Page 8: Specifications
WFS 101545 Operations Manual SPECIFICATIONS a. Pump 1 Recirculating water Gould # 5HM04N11T6PBQE 25gpm 45psi RECIRCULATING WATER PRESSURE FLOW 0.31 b. Pump 2 Process Water USA ONLY EU ONLY Gould Gould 3HM07N11T6PBQE 3HM10N151T6PBQE 1.5hp 2.0 HP ... -
Page 9: Lift Station
WFS 101545 Operations Manual filtered water. The chiller uses a Copeland FFAP-03OZ condensing unit with a two custom made evaporator units. It requires 208 -220 VAC 50-60 hz three phase electrical power. The evaporators use custom made titanium evaporation coils enclosed in schedule 80 PVC housing. -
Page 10: Filtration
WFS 101545 Operations Manual Filtration The WFS uses proprietary stainless-steel housings that require three 20” disposable filter cartridges for filtration of the process water. The filters housings are arranged in two parallel sets of two. One set of two filters for the Internal Recirculating Loop and one set of two filters for the Process Loop. -
Page 11: Setup
WFS 101545 Operations Manual SETUP a. Floor Space Prior to installation consider the space required for proper servicing. Figure 4-1 provides recommended clearances for servicing the various components on the WFS 101545. 84” 2134m 39” AREA FOR SERVICING 1000m 39” FILTERS 1000m AREA... -
Page 12: Electrical Power Requirements
WFS 101545 Operations Manual Figure 4-2 shows the minimum door height clearance required to accommodate passage of the main WFS platform prior to assembly. FIGURE 4-2 c. Electrical Power Requirements WFS requires the following: 3 phase 40 amp circuit 230 VAC 50 hz or 220 VAC 60 hz The Lift Station requires the following: 115 VAC 50/60 hz 7.5 Amps... -
Page 13: Assembly
WFS 101545 Operations Manual Before verifying that the platform is level, insure all six of the leveling legs are firmly on the floor. If any leg is not touching the floor, adjust by loosening the [visible] copper plated leg lock nut and winding this ½... - Page 14 WFS 101545 Operations Manual Install the connector on cable CBL-PT2 on the pressure transducer. Tight the center screw. FIGURE 4-4 Preparing The Chiller for Installation Remove the chiller from its crate and inspect for damage. Remove the drip pan and the four carriage bolts from the Chiller Support Frame.
- Page 15 WFS 101545 Operations Manual FIGURE 4-5 iii. Installing The Chiller CAUTION: The Chiller is heavy and awkward. Use proper equipment and personnel for installation. CAUTION: Ther may be sharp edges on some of the metal parts use proper Personal Protective Equipment (PPE) CAUTION: Use care when connecting the chiller unions.
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Page 16: Facility Interface
WFS 101545 Operations Manual Ease the chiller into a position where all four unions line up with the mating parts. The union faces must be “flat” to one another. Verify that the O-rings are in place. Tighten the union. Install washers and nuts on the carriage bolts and tighten. Connect the Power Cord and the Solenoid Control Cord to the round receptacles on the bottom of the Control Panel. - Page 17 WFS 101545 Operations Manual Spindle Cooling Supply Spindle Cooling Return Process Cooling Supply Process Cooling Return Figure 4-7 shows the approximate location of the plumbing connections. The connection for the for the Spindle Coolant Make-Up Water is 1” NPT. The water source can be provided from clean ordinary tap water.
- Page 18 WFS 101545 Operations Manual The power wires attach to the three lugs provided on the top of the distribution bus bar. The ground wire must be attached to the grounding terminal to the left of the bus bar. See Figure 4-8. CAUTION: Installation wiring must comply with local and national electrical codes.
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Page 19: Operator Controls
WFS 101545 Operations Manual OPERATOR CONTROLS Other than the mechanical ON/OFF switch and the E-Stop push button all controls are through a touch screen HMI. See Figure 5-1 WARNING! The Control cabinet contains High Voltage electrical connections. Accidental contact with electrically live components can cause serious injury or death. -
Page 20: Audible Alarm
WFS 101545 Operations Manual This is illuminated when electrical power is on to the control system. d. Audible Alarm (Optional) An audible alarm is sounded if a fault condition is detected. See ALARMS section 5.e.vi e. Touch Screen HMI Display Panel All functions other than Power ON-OFF or E-Stop are controlled or displayed through the Touch Screen HMI. - Page 21 WFS 101545 Operations Manual FIGURE 5-3 START / STOP / ENABLE The pumps are started and stopped and the chiller is enabled by pressing the appropriately labeled push button. If conditions permit (no critical alarms) each pump will start or stop immediately when the associated button is touched. The chiller is only enabled.
- Page 22 WFS 101545 Operations Manual for 10 minutes. The ALARM indicating light will remain illuminated reminding the operator that there is an alarm condition. The Alarm indicator may illuminate along with an audible alarm tone for a brief moment during start-up until the process flow exceeds set point. To view the specific cause of the alarm, select the ALARMS page.
- Page 23 WFS 101545 Operations Manual The indicating light above TEMP SET POINT displays the status of the chiller and whether or not the system is calling for refrigeration. Actual cooling is only done when the Chiller compressor is running. TEMP DELTA (HYSTERISIS) This prevents the compressor motor from rapid cycling or “chattering”.
- Page 24 WFS 101545 Operations Manual This page does not permit any changes to the various set points. FIGURE 5-7 Set Points The SET-POINT page can be accessed from any other page simply by touching the SET POINTS button at the bottom of the current page. It also provides a digital display of the current process status.
- Page 25 WFS 101545 Operations Manual This page permits the operator to select the trip point for when an alarm notification will be triggered. It can be used to notify when the filter needs to be switched over. It can provide notification if a critical process parameter is exceeded. For instance, if a maximum temperature for the process water was 75 F the TEMP ALARM could be set for that temperature and would trigger an alarm if it was exceeded.
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Page 26: Resitivity Sensors
WFS 101545 Operations Manual ALARM DISMISS To dismiss or ignore a particular alarm move the associated slide switch to “ON” position by touching the “ON” side of the image. This will permanently silence the alarm and ignore the fault. CAUTION: The alarm condition still exists. - Page 27 WFS 101545 Operations Manual FIGURE 5-11 Each filter housing holds three 2.5” diameter x 20” long filter replaceable filter cartridges. These cartridges come in a wide variety of composition and micron size. The first two units # 1 & 2 filter the recirculating water. Units #3 & 4 are the final filters for the process water. They catch any loose particles that may come from the resin beds.
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Page 28: Filter Element Installation
WFS 101545 Operations Manual a. Filter Element Installation The filter elements or cartridges are provided by the customer. The specific filtration / particulate size and element medium is determined by individual customer requirements. i. Remove the cover. The six wing nuts should be loosened in a “Star”... -
Page 29: Configuration
WFS 101545 Operations Manual vi. Verify the position and condition of the O-Ring. If the O-ring exhibits any signs of wear or cracks replace with new. It may be necessary to stretch a replacement O-ring to permit it to lay flat completely in the grove. -
Page 30: Air Bleed Valves
WFS 101545 Operations Manual Each filter housing has a “In- Flow” ball valve and an “Out- Flow”. During normal operation only the valves on one housing should be open while the other housing valves are closed. When the pressure reading indicates that filter elements require change-out both the In- Flow and the Out-Flow valves... -
Page 31: Nuisance Tripping
WFS 101545 Operations Manual The pumps will not re-start until the strip is dried off. e. Nuisance Tripping WARNING! The following procedure can only be performed by qualified personnel. WARNING! Disconnect all power before opening the control cabinet WARNING! The control cabinet contains high voltage wiring that can cause injury or death. -
Page 32: Resin Tank Gages
WFS 101545 Operations Manual It is anticipated that the customer will utilize two (2) ionic exchange resin beds and one activated carbon vessel. (Collectively these are all referred to as resin beds or resin tanks unless specifically speaking about the activated carbon filter) g. -
Page 33: Filling The Reservoir
WFS 101545 Operations Manual Lift Station is installed and proper facility power is on. NOTE: The lift station will not run until a certain water level in the holding tank is reached. It will cycle on and off when a constant flow of water is supplied. ... -
Page 34: Filling The Recirculating Filter Housings
WFS 101545 Operations Manual 3. FILLING THE RECIRCULATING FILTER HOUSINGS Fill all three chambers of the reservoir to the top of the spindle chamber. Verify all four associated valves with the recirculating Spindle water filter housings are open. Dirty Side o 2 In-Flow valves o 2 Out-Flow Valves... -
Page 35: Filling The Process Filter Housings
WFS 101545 Operations Manual This procedure assumes it is performed immediately after Section 3 and all other conditions remain the same. Fill all three chambers of the reservoir to the top of the spindle chamber. Verify all four associated valves with the process filter housings (#3 &... -
Page 36: Reservoir Process Flow
WFS 101545 Operations Manual NOTE: The chiller has a “Bump Start” design feature. This may cause the chiller to perform three rapid Start-Stop sequences before commencing with normal operation. The chiller also has built in delays that regulate how quickly the unit can recycle. 7. - Page 37 WFS 101545 Operations Manual FIGURE C8-1...
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Page 38: Appendix
WFS 101545 Operations Manual APPENDIX... -
Page 39: Electrical Schematics
WFS 101545 Operations Manual ELECTRICAL SCHEMATIC SHEET 1 OF 7 230 VAC 50 Hz L 1 L 2 CB-1 L3-1 T3-1 BLUE L2-1 T2-1 PUMP L1-1 T1-1 BLACK CB-2 L3-2 T3-2 BLUE L2-2 T2-2 PUMP L1-2 T1-2 BLACK CB-3 L3-3 T3-2 BLUE L2-3... - Page 40 WFS 101545 Operations Manual ELECTRICAL SCHEMATIC SHEET 2 OF 7 FROM SHEET 1 FROM SHEET 1 PROGRAMABLE LOGIC CONTROLLER PLC INPUTS E-STOP PB-10 Leak Sensor OPTIONAL FLOW SWITCH RECIRC OPTIONAL FLOW SWITCH SPINDLE OPTIONAL GRAPHIC INTERFACE CABLE TO PLC SHEET 1 DROK DC-DC 5003MC 5VDC...
- Page 41 WFS 101545 Operations Manual ELECTRICAL SCHEMATIC SHEET 3 OF 7 FROM SHEET 2 FROM SHEET 2 PLC OUTPUTS E-STOP PB-10 PUMP 1 CONTACTOR RECIRCULATING PUMP 2 CONTACTOR PROCESS PUMP 3 CONTACTOR SPINDLE CHILLER CONTACTOR CHILLER CR-2 ZONE 1 SOLENOID SONALERT SL-1 AUDIBLE ALARM TO SHEET...
- Page 42 WFS 101545 Operations Manual ELECTRICAL SCHEMATIC SHEET 4 OF 7 FROM SHEET FROM SHEET DIN-C Connector Pressure Transmitter 4-20ma CBL PT2 SPT25-20-0150D Blue DIN-C Connector Pressure Transmitter 4-20ma Blue CBL PT1 SPT25-20-0150D Brown M12 Connector Flow Transmitter 4-20ma CBL FLOW FTS100-1001 Blue M12 Connector...
- Page 43 WFS 101545 Operations Manual ELECTRICAL SCHEMATIC SHEET 5 OF 7 FROM SHEET FROM SHEET M12 Connector Flow Transmitter 4-20ma CBL FLOW FTS100-1001 Blue M12 Connector Black Temperature Transmitter 4-20ma CBL TEMP XTP25N-050-0100C C0-04AD-1 ANALOG INPUT Blue CH-1 SPINDLE WATER TEMP CH-2 SPINDLE WATER FLOW...
- Page 44 WFS 101545 Operations Manual ELECTRICAL SCHEMATIC SHEET 6 OF 7 FROM SHEET FROM SHEET PLC OUTPUTS Y301 CHILLER CR-3 ZONE 2 SOLENOID Y301 Y302 Y303 Y304...
- Page 45 WFS 101545 Operations Manual ELECTRICAL SCHEMATIC SHEET 7 OF 7 TOUCH SCREEN EA9-T7CL-R USB TYPE A EA-2CBL TO USB TYPE B GRAPHIC INTERFACE CABLE INTERFACE CABLE EA-MG-PGM-CBL PROGRAMMING INTERFACE CABLE PROGRAMMING ONLY SERIAL SERIAL USB PORT USB PORT PORT 1 PORT 2 WINDOWS C0-00DR-D...
- Page 46 WFS 101545 Operations Manual PLUMBING SCHEMATIC...
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Page 47: Troubleshooting
WFS 101545 Operations Manual TROUBLESHOOTING PROBLEM POTENTIAL CAUSE Pumps and Chiller will not operate E-Stop Button in depressed detent Tripped Circuit Breaker Leak Sensing Strip is wet Facility Power is off Chiller will not start Chiller Circuit Breaker is off Chiller Freon is low Chiller cycles rapidly Hysteresis setting on controller too small. -
Page 48: Design Data Links
WFS 101545 Operations Manual DESIGN DATA PRODUCT LINK https://s3.amazonaws.com/pumpproducts/pdf/547800_5_Goulds+e- Gould HM Pumps HM+Multistage+Pump+Technical+Brochure.pdf FSI X 1000 Filter http://www.fsifilters.com/assets/files/literature/x100-convertible-filter- Housings housing.pdf Copeland Air-Cooled https://climate.emerson.com/documents/copeland-scroll-air-cooled-refrigeration- Condensing Unit condensing-units-en-2884068.pdf IFM SA4110 Flow https://www.ifm.com/us/en/product/SA4110 Sensors Resilite RES 7130 https://www.servapure.com/assets/images/PDF/Resilite%20Red- Resistivity Sensor Green%20Purity%20Lights.pdf http://www.sharkpw.com/Upload/CPDCategoryDocuments/Shark%20Hudson%20 Hudson Float Valve Float%20Valve_1407.pdf http://hudsonvalve.com/products/ Omron 61F-GPN-...
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