Unist UNI-MAX ST Operation Manual

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Operation Manual

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Page 1 Operation Manual...
Page 3 Quick Start Guide Mount system Systems with enclosure Direct mount Magnet mount 1/4-20 fasteners included for Shown with optional enclosure threaded inserts or keyholes magnet mounting kit (part number 305956) Systems without enclosure Rear magnet mount Bottom magnet Direct mount mount Factory-installed, Through holes for...
Page 4: Supply Air
Quick Start Guide Supply air Connect clean, dry, compressed air at 80–100 psi [5.5–7 bar] (See pg. 11 for more details). Systems with enclosure Systems with chip guard 1/4” NPT air inlet 1/4” or 1/8” NPT air inlet depending on system Systems with air pilot option 2 x 1/8”...
Page 5 Quick Start Guide Mount nozzle(s) Install nozzles with magnet (if included) or hard mount with appropriate fastener. Nozzle tips should be as close as possible to the cutting edge, ideally within 2” [50.8 mm]. Carefully route tubing to avoid cuts or kinks (See pg.14 for more details). Set initial atomizing airflow •...
Page 6: Important Operator Information
Consult this documentation in all cases where this caution symbol appears. This symbol is used to inform you of any potential HAZARD or actions that require your attention. Use of this equipment in a manner other than that specified by Unist, Incorporated may compromise design integrity and become unsafe. WARNING: This equipment is not intended for use in explosive environments.
Page 7: Table Of Contents
Table of Contents System Introduction ..............1–8 System identification & support ..........1 System function ................2 Common system layout ............3 System specifications ...............4 Pump specifications ..............5 Solenoid valve specifications ............8 System Installation ..............9–13 Position & mount system ............9 Mounting a system with enclosure ..........9 Mounting a system without enclosure .........9–10 Air supply &...
Page 8 Table of Contents Tapping ...................31 Punching .................32 Cut-off knives & shears ............32 Die lubrication .................33 Assembly operations ...............33 Lubricant injection prior to forming ..........34 Wear point and chain lubrication ..........34 Troubleshooting ..............35–38 Pump is not cycling ..............35 No fluid output from cycling pump ...........35 Fluid flows continuously without pumps cycling ......35 Air bubbling in the fluid reservoir when system is operating ...36 Pneumatic pulse generator not operating .......36...
Page 9: System Introduction
System Introduction Thank you for purchasing a Unist Uni-Max ST. This system was ® designed as an easy-to-use, maintenance-friendly Minimum Quantity Lubrication system that delivers consistent and reliable results. Figure 1: Uni-Max ST System ® The Uni-Max ST uses Unist 230 Micro Pumps to achieve ®...
Page 10: System Function
System Introduction System Function The Uni-Max ST delivers lubricant with one or two pneumatically- ® powered, positive-displacement, self-priming, 230 Micro Pumps ™ The lubricant is combined with air and delivered in the form of an atomized spray. The 230 Micro Pumps are actuated using either a Pulse R ™...
Page 11: Common System Layout
System Introduction Common System Layout Figure 3: Common layout of system with enclosure A. Air inlet F. Pump stroke adjustment knob 80–100 psi [5.5–7 bar] recommended Controls fluid volume delivered per stroke. B. Pump timer Not present on fixed output pumps Pneumatic pulse generator or G.
Page 12: System Specifications
System Introduction System Specifications Supply air Clean, dry, compressed air, 80–100 psi [5.5–7 bar] pressure Reservoir dependent, 16–64 oz [473–1893 mL]. Fluid supply For systems with a pressurized fluid supply: clean, filtered fluid, 15 psi [1.0 bar] max Pump Size 20µL 40µL 60µL...
Page 13: Pump Specifications
System Introduction Pump Specifications Pump components and identification Pump bodies are marked to indicate pump size and part number. Locate these markings and identify pump components using Figure 4 below. Adjustable Output Pumps Prime setting “P” indicator Pump size Part Number Piston Pump stroke adjustment knob Setting indicator mark...
Page 14 System Introduction...
Page 15 System Introduction...
Page 16: Solenoid Valve Specifications
System Introduction Solenoid Valve Specifications To determine the valve, refer to the drawing supplied with the system or the part number scheme in Appendix D (pg. 46). Din connector Unist Part # Voltage Power size 68-1040-18-110 120 VAC 5.4 W 9.4 mm...
Page 17: System Installation
System Installation Position and Mount System Mount the system on or near the machine in an accessible location without obstructions that may pinch or kink inlet or outlet lines. Ensure the system is level and the reservoir faces up. See Figure 7 on the previous page for details.
Page 18 System Installation Figure 9: Alternate mounting dimensions (bottom view) Loosen bolts Remove bolts with with a 7/16” wrench. a 3/16” hex key Remove guard by sliding it forward. Flip block. Remove magnet with a Phillips head screwdriver. Use alternative 3” Replace guard by long ¼-20 bolts, sliding it forward.
Page 19: Air Supply & Control
System Installation Air supply and control Air Supply Attach an air supply line to the 1/4” or 1/8” NPT air inlet. If your system includes an air pilot valve, there will be an 1/8” NPT air inlet and an 1/8” NPT air inlet for the control air signal. Systems with enclosures include an air filter with a water trap.
Page 20: Fluid Supply
Fluid Supply Adding fluid: systems with fluid reservoir Remove the cap, fill the reservoir with fluid, and replace the cap. Use Coolube for the best results! Go to unist.com/clb to learn ® more. Figure 13: Filling the fluid reservoir Adding fluid: systems with pressurized fluid supply...
Page 21: Fluid Monitoring
System Installation Fluid Monitoring Connect low-level switch (if applicable) A low-level switch indicates that fluid needs to be added to the reservoir. If your system has a low-level switch, it can be wired to an input on the machine, an external annunciator, or another device that indicates the fluid level is low or handles the condition.
Page 22: Nozzle Installation
Nozzle Installation Tubing routing and connections Install the nozzle(s) as close as possible to the point of application. Route the tubing back to the system and connect to the outlet port(s). Refer to the Nozzle Positioning section (pg. 16) or the Applications section (pg.
Page 23 Nozzle Installation Connecting coaxial outputs The Uni-Max ST uses a quick connect adapter for all nozzles with ® coaxial tubing. Simply push the tubing and quick connect adapter into the push-to-connect fitting until it is firmly seated. You should be able to feel a distinct click when the tubing is locked in place.
Page 24: Nozzle Positioning
For more detail, refer to your specific application (pg. 25). Single-line systems Refer to the mounting instructions sent with the system to mount the nozzles correctly or go to unist.com/tkb and find the appropriate document for your nozzle. Coaxial systems Keep the nozzle as close as possible to the cutting edge, ideally within 2”...
Page 25: System Operation
System Operation Starting the flow of lubricant The Uni-Max ST will deliver lubricant when the air control valve is ® opened. The air control valve can be a manual slide valve, a solenoid valve, or an air pilot valve depending on system configuration. Systems with a manual slide valve deliver lubricant when the valve is manually actuated.
Page 26: System Priming
System Operation Systems with an air pilot valve deliver lubricant when an air signal is received. 1/8” NPT inlet air 1/8” NPT air pilot signal Optional air 25–125 psi [1.7–8.6 Bar] pilot valve Figure 22: Pneumatic air pilot valve Attention: Ensure air pressure is not present when connecting the air pilot signal to the Uni-Max ST air pilot valve as this could cause personal injury ®...
Page 27: Lubricant Output Adjustment - Continuous Mode
System Operation Lubricant output adjustment – continuous mode Note: The Uni-Max ST is factory preconfigured to operate in either ® continuous or shot mode. The mode cannot be changed. When adjusting lubricant output, we recommend setting the pump at full stroke (“P” setting) and increasing or decreasing the pump cycle rate with either the Pulse R or the pneumatic pulse generator.
Page 28 System Operation Pump stroke Use the pump stroke adjustment knob to change the pump stroke. “P” indicates full stroke and self-priming functionality. “0” indicates no output. Refer to Figure 6 on page 7 for pump output details. Figure 25: Pump stroke adjustment knob in prime position (left) and in the off position (right)
Page 29: Lubricant Output Adjustment - Shot Mode
System Operation Lubricant output adjustment – shot mode Note: The Uni-Max ST is factory preconfigured to operate in either ® continuous or shot mode. The mode cannot be changed. When adjusting lubricant output, we recommend changing the stroke count. If more precision is needed, adjust the pump stroke (this cannot be done with a fixed output pump).
Page 30: Atomizing Airflow Adjustment
System Operation Atomizing airflow adjustment The air metering screw will adjust how fine of a spray is generated at the nozzle. Too little airflow will result in a pulsating and spitting spray. Too much airflow will create a fog of very fine mist! Figure 28: Adjusting atomizing airflow Rotate the air metering screw clockwise until it is fully seated, then: •...
Page 31 System Operation...
Page 32: Mql Best Practices
MQL Best Practices • Use only a quality lubricant formulated for Minimum Quantity Lubrication such as Unist Coolube . Non-MQL metalworking ® fluids do not offer the proper lubricity or flash point for use in MQL and any biocides they contain can become airborne causing a safety issue.
Page 33: Applications
Coolube ® lubricant directly to the critical areas of the saw blade and guides. Unist recommends the following settings as a starting point for band saw applications. Pump cycles Stroke length...
Page 34 Applications Band Saw Guide Nozzle - mounted to the blade guide (horizontal band saw applications) When blade guide lubrication is required, the Band Saw Guide (BSG) Nozzle will lubricate both sides of the blade to help minimize friction. The BSG Nozzle can be mounted directly to a guide block, to the BSB Nozzle, or installed with the provided mounting kit.
Page 35: Circular Saws
The Uni-Max ST precisely delivers the optimal amount of Coolube ® ® directly to critical areas of the saw blade. Unist recommends the following settings as a starting point for circular saw applications. Pump cycles Stroke length Air metering screw...
Page 36: Drilling
Drilling The Uni-Max ST reduces drill wear and improves hole quality. ® Unist recommends the following settings as a starting point for drilling applications. Pump cycles Stroke length Air metering screw Output mode...
Page 37: Milling
Applications Milling The Uni-Max ST increases tool life and improves surface finishes. ® Unist recommends the following settings as a starting point for milling applications. Pump cycles Stroke length Air metering screw Output mode per minute settings 10–25 Full to 1/2 1/4–3/4 Turns open...
Page 38: Broaching
Applications Broaching The Uni-Max ST improves tool life when combined with compressed ® air blow-off to clear chips. Unist recommends the following settings as a starting point for broaching applications. Pump cycles Stroke length Air metering screw Output mode per minute settings 10–25...
Page 39: Tapping
Applications Through the turret - directed at cutting tool (external spray or through-the-tool CNC turning center) The Uni-Max ST can deliver metered lubricant through a CNC ® turning center’s coolant ports. The ability to apply MQL in this fashion depends on the design of the machine turret. Tapping The Uni-Max ST reduces tap wear and improves thread quality.
Page 40: Punching
Cut-off knives & shears Apply a small amount of Coolube to knives and shears to produce ® cleaner cuts and increase tool life. Unist recommends the following settings as a starting point for cut-off knives & shear applications. Pump cycles per Stroke length...
Page 41: Die Lubrication
ST is ideal when only a small amount of in-die lubrication ® is needed. This system lubricates punches, forming dies, or in-die taps. Unist recommends the following settings as a starting point for die lubrication. Pump cycles per Stroke length Air metering screw...
Page 42: Lubricant Injection Prior To Forming
Wear point and chain lubrication Uni-Max ST makes lubricating cams, bearings, chains, or other ® wear points a simple process. Unist recommends the following settings as a starting point for wear point and chain lubrication. Pump cycles per Stroke Air metering...
Page 43: Troubleshooting
Troubleshooting Attention: While troubleshooting, it may be necessary to access the electrical solenoid on the Uni-Max ST. Only qualified individuals should ® perform such work and control power to the Uni-Max ST should be turned ® off when accessing this enclosure. Pump is not cycling •...
Page 44: Air Bubbling In The Fluid Reservoir When System Is Operating
Troubleshooting Air bubbling in the fluid reservoir when system is operating • Replace or rebuild the pump. Internal components may have failed or become contaminated with debris. Pneumatic pulse generator not operating • Remove the pneumatic pulse generator and check the air inlet screen for debris.
Page 45: The Pump Is Cycling, But The Output Is Inconsistent
Troubleshooting The pump is cycling, but the output is inconsistent • Check for a kink or break in nozzle tubing. • Confirm the reservoir contains adequate fluid and the filter screen is clean. • For coaxial nozzles, confirm the internal fluid tubing is properly seated on both the quick connect adapter and the nozzle splicer.
Page 46 Troubleshooting • Mounting the nozzle coupler block at an angle so fluid flows down into, and eventually out of, the nozzle. See Figure 32 below for an example of proper nozzle coupler block mounting. Figure 32: Proper nozzle positioning...
Page 47: Maintenance
Maintenance Refer to the following instructions for common maintenance tasks: Routine pump inspection Routine inspection and maintenance of the system’s 230 Micro Pumps is critical to ensure smooth operation. Check for proper ™ operation and output of the pump(s) every 6 months or 2.5 million cycles.
Page 48: Rebuilding A Pump
Maintenance Rebuilding a pump Pumps are easily rebuilt, but to minimize downtime, Unist recommends keeping a spare pump on hand so the system can continue operation while the pump is rebuilt. Pump rebuild kits include all wear parts, seals, and instructions. Refer to Appendix A (pg.
Page 49: Appendix A: System Spare Parts
Appendix A: System Spare Parts Adjustable Output Pump Fixed Output Pump Size Pump # Rebuild Kit Size Pump # Rebuild Kit 20 µL 230-000-201 230-000-201R 20 µL 230-000-211 230-000-211R 40 µL 230-000-401 230-000-401R 40 µL 230-000-411 230-000-411R 60 µL 230-000-601 230-000-601R 60 µL 230-000-611 230-000-611R...
Page 50 Appendix A: System Spare Parts Air Filter 1/4” NPT 69-459 Quick Connect Adapter 304902-V (includes O-ring) Slide Valve Slide Valve Pump Mounting O-rings Standard 1/4” NPT 1/8” NPT 2-007-V884-75 69-5506 305856 Replacement Door with Latch Replacement Door with Key 306009-A Lock 306009-B Chip Guard...
Page 51: Appendix B: Accessories
Appendix B: Accessories Articulating Arm for Nozzle Mounting 306005 Enclosure Magnet Mounting Kit 305956 Enclosure Key Lock 306008 Metering Screw with Jam Nut 94-6202-J Full Flow Metering Screw 305193...
Page 52: Appendix C: Nozzle Spare Parts
Appendix C: Nozzle Spare Parts COAX HOSE ASSEMBLY, QUICK CONNECT, 305374-Q1-YY VITON SEAL, YY’ LONG NOZZLE ASSEMBLY, XX” PLASTIC, EXT. MIX W/ 6121-P-XXP-SS STAINLESS STEEL TIP NOZZLE ASSEMBLY, XX” COPPER EXTERNAL 6121-P-XXSR MAGNET, NOZZLE BLOCK 60-6340-22 NOZZLE COUPLER BLOCK, 1/8 NPT, 1/8 NPT 6110-3 NOZZLE COUPLER BLOCK, 1/8 NPT, 7/16-20 6110...
Page 53 Appendix C: Nozzle Spare Parts TUBING, 1/8” OD NYLON, PER FOOT 71-2050 TUBING EXTENSION KIT, SAW NOZZLE 302637 MAGNET, NOZZLE BLOCK 60-6340-22 NUT, COUPLING, HEX, 1/4-20 UNC X 7/8” LG 305482 THUMB SCREW, 1/4-20 X 1” LG 1420-1THS LOCKWASHER 1/4” 14-SPLOCK SPLITTER NOZZLE, 1/8”...
Page 54: Appendix D: Part Number Scheme
Appendix D: Part Number Scheme...
Page 55 Appendix D: Part Number Scheme...
Page 56: Appendix E: Pulse R And Faults
™ factory and should only be changed if directed to do so by a Unist representative. To change modes, simultaneously press and hold both the UP and DOWN buttons while turning on power to the Pulse .
Page 57 Appendix E: Pulse R Operating Modes ™ and Faults MODE 1 POWER PUMP STROKE TIME Figure 40: Mode 1 timing diagram Mode 3 – Deliver shots on power up When powered on, the Pulse R rapidly cycles output to deliver the ™...
Page 58: Locking The Display
Appendix E: Pulse R Operating Modes ™ and Faults Locking the Display To prevent accidental changes, the display can be locked by pressing and holding the UP and DOWN buttons simultaneously for 3 seconds. The display will show LOC for 1 second, and then show the setpoint for the current mode.
Page 59 UP or DOWN button on the control panel. If the F02 error code persists, there may be an issue with the memory or processor that cannot be resolved. Contact Unist for a replacement system.
Page 60: Appendix F: Trimming Coaxial Tubing
Appendix F: Trimming Coaxial Tubing Using tubing cutters, cut nozzle output tubing to the desired length. Carefully trim outer and inner tubing from quick connect adapter, ensuring the brass barb is not scratched or damaged. Pull out approximately 1” of inner tubing, trim and reinstall quick connect adapter to the tubing.
Page 61: Appendix G: Enclosure Mounting Template
Appendix G: Enclosure Mounting Template...
Page 62 Appendix G: Enclosure Mounting Template This page was intentionally left blank...
Page 63 Notes...
Page 64 Unist, Inc. 4134 36th Street SE Grand Rapids, MI 49512 USA U.S. & Canada: 800.253.5462 International: 616.949.0853 unist.com Email: salessupport@unist.com MANUMST...

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