JENFAB Lean Clean 360-1 Manual
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JENFAB Lean Clean 360-1 Manual

Lean clean 360-1 cleaning system
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JENFAB #11996
Lean Clean 360-1
Cleaning System
LC360-1-001 11/14/06

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  • Page 1 JENFAB #11996 Lean Clean 360-1 Cleaning System LC360-1-001 11/14/06...
  • Page 2 Turnover Package We ship the Lean Clean 360-1 system with a CD ROM that includes: (1) OEM user guides for major components, (2) engineering drawings of the system, and (3) the system control program.
  • Page 3 Important Information Read the safety instructions in this manual before use and keep these instructions accessible for future reference. JENFAB will provide replacement user guides upon request. Learning to Use the Lean Clean 360 Cleaning System...

  • Page 4: Table Of Contents

    Table of Contents Preface Welcome to the User Guide ................. 6 Safe Use of the Lean Clean ................6 Safety Warnings ....................7 Statement of Proper Use ................7 Product Overview What the Lean Clean 360 Does ..............8 Optional Features ..................10 Description of Components Overview .......................
  • Page 5 Troubleshooting Troubleshooting Chart ................44 Inspection and Maintenance Inspection and Cleaning Chart ..............45 Cleaning the Chip Baskets ................46 Replacing Filter Bags ................... 47 Cleaning the Optional Oil Coalescer ............49 Adjusting the Rotator Proximity Switch ..........51 Spare and Replacement Parts How to Order Parts ..................

  • Page 6: Preface

    Preface Welcome to the User Guide This user guide describes how to use the JENFAB Lean Clean 360-1 aqueous cleaning system. Written for manufacturing engineers, production supervisors, and operating personnel, the user guide describes how to install, operate, and maintain the Lean Clean 360.

  • Page 7: Safety Warnings

    Statement of Proper Use JENFAB designed the Lean Clean 360 to clean parts using aqueous solutions and controlled, programmed sequences of operations within the washing chamber. If you use the Lean Clean 360 in a manner not specified by JENFAB, you may impair the protection provided by the equipment.

  • Page 8: Product Overview

    Product Overview What the Lean Clean 360 Does The Lean Clean 360 is a fast, high-performance parts washer that removes oils, chips, and other contaminates from new or used parts. Operators place a basket of parts into the Lean Clean and press the start button.
  • Page 9 Typical Wash Cycle A typical wash cycle includes the following steps: Loading—operator slides basket into the machine, closes the door, and presses the Cycle Start button. Washing—wash pump rapidly fills the process chamber and volume turbulation begins. Draining—basket rotates and drains solution from parts as the process chamber empties into holding tank.

  • Page 10: Optional Features

    Optional Features The following sections describe optional equipment available for the Lean Clean 360-1. Check your Lean Clean 360 or your purchasing specifications to determine which options your machine includes. Ultrasonic Generator and Transducer The tubular ultrasonic transducer and generator can provide ultrasonic energy in the wash chamber during wash and rinse cycles.
  • Page 11 10 mg/l. The coalescer removes only oil, not chemistry. External PLC Programming Port or Modem The external PLC programming port enables programming from an external computer. By adding the optional modem, JENFAB engineers can make programming changes or diagnose problem remotely, lowering service and troubleshooting costs.

  • Page 12: Description Of Components

    Description of Components Overview The Lean Clean 360 includes these components (Figure 1): Basket—holds parts during washing. One basket is provided with the machine. Several basket designs are available as options. Loading door—provides access to the washing chamber and seals the chamber.
  • Page 13 Figure 1. Lean Clean 360 components Customer supplies electrical, compressed air and water service Optional ultrasonic generator unit Access door Door interlock. Main power Prevents operator from disconnect opening door while machine is running. Operator interface Controls Basket holds parts Emergency stop button Loading door...

  • Page 14: Controls

    Controls The controls for the Lean Clean 360 consist of a touch screen monitor, four control buttons, and a control knob (Figure 2). Touch screen monitor—the touch screen monitor enables operators to select a cleaning program to run, monitor process conditions, modify program parameters, and run the cleaning system manually if desired (Figure 3).
  • Page 15 Figure 2. Lean Clean 360 controls Touch screen monitor Rotation speed control knob Start button with green indicator light Stop button with red indicator light Power button Emergency with yellow stop button indicator light Figure 3. Close up of the touch screen monitor The touch screen monitor enables you to navigate the process monitoring and...

  • Page 16: Installation And Setup

    Installation and Setup Introduction Complete these steps to prepare the Lean Clean 360 for use: Unpack the machine   Choose a location Connect optional equipment   Connect power and utilities Unpacking the Lean Clean 360 Your Lean Clean 360 should arrive shrink-wrapped and bolted to a pallet.

  • Page 17: Choosing A Location

    Choosing a Location Locate the Lean Clean on a smooth level floor capable of holding 2,350 pounds (wet weight) and the weight of any accessory equipment such as the optional oil separator or drain station. The Lean Clean footprint is 3 feet by 5 feet, but sufficient room should be left for operation and maintenance and optional equipment.

  • Page 18: Connecting Optional Equipment

    Connecting Optional Equipment JENFAB technicians and engineers install the following optional equipment at the factory before the Lean Clean is shipped: fresh water spray rinse, rocking drive, stack light, auto rust inhibitor, external PLC programming port, and modem. You must connect these options upon delivery: Ultrasonic generator—Factory technicians install the transducer at the...
  • Page 19 Connecting the Ultrasonic Generator JENFAB factory technicians install the ultrasonic transducer and all wiring for the transducer and generator. To install the ultrasonic generator, unpack it from its box and place it on top of the control panel facing the front of the machine. Connect the preinstalled power cable, transducer cable, and interface cable according to the generator OEM manual (Figure 4).
  • Page 20 Lean Clean 360-1, wash and rinse water disposal may require treatment to meet national, state, and local environmental regulations. Before connecting the Lean Clean 360-1 to a drain, ensure the drain is appropriate for the contaminates in the rinse and wash water.
  • Page 21 Figure 5. Schematic of typical drain station showing features and connections High and low level To waste floats and switches collection 5 gallon drain station tank High and low level Air-operated sensors send signal pump to the Lean Clean control system to Tank inlet control pump operation...
  • Page 22 Connecting the Oil Separator If your Lean Clean 360 includes the optional coalescing oil separator, follow these steps to install it: 1. Locate the following parts included with the oil separator: 10 feet of ½-inch flexible hose 12 feet of 1-inch flexible hose 15 feet of ¼-inch tubing for compressed air 2, ½-inch airplane clamps 2, 1-inch airplane clamps...
  • Page 23 Oil Separator Skimmed Air pressure Unit oil outlet regulator Water inlet Air driven pump 1-inch hose, water outlet 1/4-inch air line Tubing supports ½-inch hose, water inlet Compartment Compartment drain outlet drain outlet Learning to Use the Lean Clean 360 Cleaning System...

  • Page 24: Utility Requirements And Connections

    Utility Requirements and Connections Requirements You will need to supply the following utilities:  Electrical requirements—460VAC, 3-Phase, 60-Hz, 65-FLA, LM 6.2A, 100A-disc switch (Other voltage are optional. Check to ensure machine voltage matches supply voltage.)  Compressed air requirements—60 to 80 psig, regulated, instrument quality ...
  • Page 25 Figure 7. Main power connection to the Lean Clean See the electrical schematic supplied on the system’s CD ROM for correct termination of wires on main disconnect. Compressed Air Connect the compressed air source to the compressed air line at the top of the Lean Clean using a ¼-inch connector.

  • Page 26: Operating The Lean Clean 360

    To avoid bodily harm, always follow your company’s safety procedures and lockout/tagout procedures when changing the inline filters on the Lean Clean 360-1. Learning to Use the Lean Clean 360 Cleaning System...
  • Page 27 Expert Advice—During operation, you can press the button to stop the Stop cleaning program. The system holds its current position. When you press the Start button, the system resumes operation from point at which it was stopped. Unless there is an emergency, do not stop machine while solution is transferring. After operating the machine in manual mode, ensure individual fill and drain valves are in there proper position before returning the machine to automatic mode.

  • Page 28: Cold Startup

    Cold Startup Follow these steps to complete a cold startup: 1. Close the drain lines for the wash and rinse tanks. 2. Add the washing chemistry to the wash tank per the chemistry manufacturer’s recommendations. The wash tank holds 55 gallons. If you are using the oil separator, consider its 15-gallon volume in the chemistry calculation.
  • Page 29 10. Set the diverter to the rinse tank position. Open the bleed valve on the top of the rinse tank filter housing and start the rinse pump. When water flows from the rinse bleed line, close the bleed valve and stop the pump.

  • Page 30: Starting The Oil Separator

    Starting the Oil Separator If your systems include the optional oil separator, start it following these steps. 1. Fill the inlet-coalescing tube compartments to the overflow weir with water. The weir overflows into the outlet compartment with the vertical standpipe. 2.

  • Page 31: Operating The Lean Clean

    Operating the Lean Clean Once the machine and oil separator (if installed) are ready to operate, follow these steps to clean parts: 1. Press the button on the main operating screen and select the Program program you want to run. Press then Enter Done...

  • Page 32: Running The Lean Clean Manually

    Running the Lean Clean Manually JENFAB does not recommend you complete whole cleaning cycles manually. The proper method to create custom cleaning cycles is to create a program and then run the program. You should use the manual mode for troubleshooting, diagnostics, and to recover from a power failure or other condition that disables the machine.

  • Page 33: Using The Operator Interface

    Using the Operator Interface This section of the user guide describes how to startup, operate, and shutdown the Lean Clean and optional equipment: General Considerations Automatic Mode In automatic mode, the Lean Clean operates automatically and in accordance with the preset parameters in the program you have selected to run. Normally you run the Lean Clean in automatic mode.
  • Page 34 Expert Advice—The windows presented on the following pages are typical. Depending upon the options you ordered, window appearance and functionality can vary slightly. See the appendix for images of the actual windows included with your system. Main Message Window Use the main message window to monitor key process parameters, select the program you want to run, select auto or manual modes of operation, and open other windows.
  • Page 35 Program Change Screen Pressing the button in the main message window opens the Program # Program # window where you can select the cleaning program you want run. When selecting the cleaning program, use the numeric keypad to enter the program number.
  • Page 36 Process Monitoring Screen The process monitoring screen enables you to monitor the cycle time of each cleaning step. In this window, display boxes indicates the preset cycle time and real time accumative cycle time in seconds for each of the keys Returns you to the Main Message Brings you to page 2 for...
  • Page 37 Numeric Windows There are two numeric windows utilized by the operator program: you can enter your password using one and change process parameter set points using the other. You can use these windows in automatic and manual mode. If you have a password and authority to change process parameter, enter your password by pressing the...
  • Page 38 Options Window The Options window lets you manually control the wash and rinse tank heaters and the dryer heater. It also directs you to windows where you can program process cycle times ( window) and view the Program Cycle Data Entry window.
  • Page 39 Motors, Pumps, Drains Window window is inactive in automatic mode except for the Motors, Pumps, Drains button which opens the window that enables you to set- Heat/Sonics/Rotator Set-up up heat, sonics, and drains. The button returns you to the Main/Message Center window.
  • Page 40 Program Cycle Data Entry Window When you want to change a program’s presets, use the Program Cycle Data Entry window. You can setup the program to use sonics or the rotator, set the process temperatures, and set the cycle times for each step in the cleaning cycle.
  • Page 41 7Day Time Clock Data Entry Window When you want to change the clock’s presets, use the window. 7Day Time Clock You can change the time of day that the tank heat will turn on or off. To change a cycle time or temperature set point, press the button of the parameter you want to change and use the numeric window to change the set point value as described on page 37.

  • Page 42: Modifying A Program

    Modifying a Program Process Variables that You Can Modify You can set the following program parameters and then save the changes as a new program for future use: Wash cycle time Rinse cycle time Fresh water rinse cycle time (if equipped) Fresh water rinse on or off (if equipped) Dryer cycle time Dryer temperature set point...
  • Page 43 5. You are now in the programming window for Program 1 by default. (Note the program number at the top of the screen.) 6. If you want to modify Program 2, press the Next Part Program Screen button. If your want to modify Program 3, press the Next Part Program button again.

  • Page 44: Troubleshooting

    Troubleshooting Troubleshooting Chart Symptom Possible Cause Corrective Action Machine does not start when Emergency stop condition Ensure there is no emergency or Cycle Start button is (Emergency stop button pushed in) equipment problem and pull Emergency pressed. Stop button out. Process chamber door not closed Close process chamber door Low level in wash or rinse tank...

  • Page 45: Inspection And Maintenance

    Inspection and Maintenance Inspection and Cleaning Chart Performing the proper maintenance on your Lean Clean 360-1 will extend its service life: Component What to Inspect Frequency Door seal Seal Daily Chip baskets Empty, inspect, and clean Daily Temperature probes Inspect and clean...

  • Page 46: Cleaning The Chip Baskets

    Cleaning the Chip Baskets Periodically check and empty chips from the chip baskets by following these steps: 1. Shut of the machine by pressing the front panel button. Emergency Stop 2. Open the side panel door. 3. Remove chip baskets from the wash and rinse tanks by lifting the baskets out.

  • Page 47: Replacing Filter Bags

    Replacing Filter Bags Replace the wash and rinse water filter bags before the differential pressure reaches 15 psig (Figure 10). Follow these steps to replace the filter bags: 1. Shut of the machine by pressing the front panel Emergency Stop button.
  • Page 48 One recommended filter type is 1–1725, P–50–PK–01 made by Filtration Group Fluid Systems, Chicago, IL. Figure 11. Wash water filter housing Vent valve Cover bolts Filter housing Wash water inlet Drain line Drain line valve Learning to Use the Lean Clean 360 Cleaning System...

  • Page 49: Cleaning The Optional Oil Coalescer

    Cleaning the Optional Oil Coalescer Follow these steps to clean the optional oil coalescer: 1. Turn of the air to the oil coalescer pump using the manual pressure regulator on the side of the coalescer (Figure 12). 2. Open the bottom drain valves to drain all compartments of the coalescer.
  • Page 50 Figure 12. Oil separator (coalescing type) Tube bundle Air pressure regulator and valve Solution inlet Solution air-driven pump Figure 13. Top view of oil separator with cover removed Skimmed oil outlet Wash water inlet Outlet drains back to the Lean Clean wash tank Air-driven pump pumps wash water from wash...

  • Page 51: Adjusting The Rotator Proximity Switch

    Adjusting the Rotator Proximity Switch The rotator proximity switch consists of metal plate located on the back of the rotator gear and a detector mounted on the back wall of the washing chamber. During tilting, the system uses the proximity switch to time and control rotation in each direction.

  • Page 52: Spare And Replacement Parts

    How to Order Parts The tables on the following pages list spare and replacement parts. If you need spare or replacement parts for your Lean Clean 360, JENFAB recommends checking the OEM manuals on the supplied CD ROM and contacting the OEM manufacturer.

  • Page 53: Mechanical Parts List

    1 ½” bore, 3” stroke with bumpers *Cylinder Diverter .75DPSRBX4 Stainless steel smooth body air cylinder, double-acting, Parker rear-pivot mount, ¾"-bore, 4"-stroke, w/bumper *Hose Overflow 3’ 2” dia. JENFAB *Hose Diverter 1’ 3 ½” dia. JENFAB *Proximity Switch IGT202/E18014 Diverter position Efector...
  • Page 54 *Motor 06-6-0019-10 5hp, 185T-frame, 3450 rpm, 208/230/460/3/60 Weg/Chicago Blower Hose 6-SS 6"-stainless steel flexible hose JENFAB *Heaters KXS-2162-01 “U”-bent, finned elements, 3350-watt, stainless steel. JENFAB Note: 230-volt machine has four heaters *Temp Control PLC temp. setpoint - OIT *Temp. Probe G912-RTD-AL 12"-SS probe, 100Ω, ½"-NPT connection...

  • Page 55: Electrical Parts List

    Electrical Parts List Parts listed below are recommended spare parts. A complete parts list is included on the electrical drawing supplied with your Lean Clean 360-1 system. Item Qty. Part No. Description Supplier Fuse Misc TR-R 250V Time delay Shawmut...

  • Page 56: Specifications

    Specifications Technical Specifications Attribute Description Footprint 3’ x 5’ Average cycle time 7 minutes 12” x 18” x 6” or two 12” x 9” x 6” Basket size Basket output per hour 8.5 based on a 7 minute cycle Individual pump size 60 gpm, 40 PSI, 304-stainless steel Individual tank size 55 gallons...

  • Page 57: Appendix A-Operator Interface Windows

    Appendix A—Operator Interface Windows Learning to Use the Lean Clean 360 Cleaning System...
  • Page 58 JENFAB Aqueous Cleaning Systems Jensen Fabricating Engineers, Inc. 555 Wethersfield Road Berlin, Connecticut 06037 Telephone—860–828–6516 Fax—860–828–0473 salesinfo@jenfab.com www.jenfab.com © Jensen Fabricating Engineers, Inc. 2006 Learning to Use the Lean Clean 360 Cleaning System...

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11996

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