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WFS 1545 Operations Manual

b.

INTERNAL RECIRCULATING LOOP

This loop constantly recirculates process water returned from the lift station through filters and
cooling

c.

LIFT STATION

The lift station returns contaminated water from the dicing process to the WFS.

2.

SPECIFICATIONS
a.

PROCESS WATER

b.

CHILLER

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Summary of Contents for WFS-1545

Page 1: ...Operations Manual ORIGINAL INSTRUCTIONS Installation and Operation Water Filtration System WFS 1545 WFS 1545 6F Serial Number _________ HST Spindles LLC 1357 Route 3A Bow NH 03304 USA www highspeedtechnologies com ...

Page 2: ...entation and Alarms Page 18 SECTION II COMMISIONING 1 Commissioning Prerequisites Page 23 2 Filling the Reservoir Page 23 3 Recirculating Circuit Page 24 4 Process Supply Circuit Page 25 5 Starting the Chiller Page 26 6 Relief Valve Pressure Setting Page 26 7 Pressure Regulating Valve Page 27 SECTION III NORMAL OPERATION 1 Start Up Check List Page 27 2 Power Up Page 27 3 Pump and Chiller Start Up ...

Page 3: ...nnel This symbol warns of a potential shock hazard that may cause injury or death Images and Illustrations Each unit is hand built to order and may have slight variations from the images depicted in this manual Additionally some images used are of a generic assembly and may not depict certain optional equipment that is included on any particular unit Application This manual is for use with WFS 154...

Page 4: ...4 WFS 1545 Operations Manual SECTION I OVERVIEW ...

Page 5: ... a removable cartridge The cartridge can be dried and the waste material can then be handled as solid waste The WFS1545 system consists of an Internal Circulating Loop and a Process Loop all on a self contained skid The Process Loop includes an off skid Lift Station typically installed near the process machinery for collecting used water and returning it back to the WFS1545 skid The WFS1545 system...

Page 6: ...ING LOOP This loop constantly recirculates process water returned from the lift station through filters and cooling c LIFT STATION The lift station returns contaminated water from the dicing process to the WFS 2 SPECIFICATIONS a PROCESS WATER b CHILLER ...

Page 7: ...cade of three filters and a chiller unit and then back to the Clean Side of the reservoir The clean water cascades over a weir and back into the dirty side This is a continuous process and maintains clean refrigerated water ready for process use 3 SETUP AND REQUIREMENTS a FLOOR SPACE Prior to installation consider the space required for proper servicing Figure 2 provides recommended clearances for...

Page 8: ...d ships with the base skid A smaller crate contains the chiller unit The outside of the crates should be inspected for damage prior to uncrating Additionally Tip and Tell and shock indicators are attached to the exterior They should be inspected prior to uncrating If these indicators are missing or indicate that the crate has been subjected to damaging shock loads or tipped you should notify your ...

Page 9: ...he Lift Station requires the following 115 VAC 50 60 hz 7 5 Amps See manufactures design data in appendix d LEVELING THE BASE Once the unit is properly situated the base must be leveled and supported at four 4 points Figure 4 shows the leveler location A standard spirit or bubble level will provide sufficient accuracy for leveling the unit FIGURE 3 ...

Page 10: ...djustment is necessary However if more than adjust the respective legs accordingly Ensure all leg locknuts are tight e CHILLER ASSEMBLY WARNING Avoid personal injury Installing the chiller and attaching the control panel requires lifting and maneuvering heavy and bulky items Use proper equipment and have adequate unobstructed room for safe installation After uncrating move the WFS base to an area ...

Page 11: ...sioning of the system See Figure 6 Units provided in seismically active areas2 have provisions for bolting the chiller to the frame Install the four 4 tie down bolts with spacers through the corner tabs of the chiller and bolt the chiller to the frame f CONTROL CABINET INSTALLATION Once the chiller is properly mounted the control panel can be attached to the chiller frame The chiller frame comes w...

Page 12: ...ghten all four bolts Connect the yellow power cord to the round receptacle on the bottom of the Control Panel Note Connect any sensor cables that may have been unplugged g ELECTRICAL CONNECTION WARNING Accidental contact with electrically live components can cause serious injury or death Always disconnect electrical power from source and lock out tag out when working inside the Control Panel Only ...

Page 13: ...ion pump The connection for the Process Cooling Return is 1 1 4 NPT This connection directs return water from the Lift Station back to the reservoir The connection for the Make Up Water is 1 NPT The water source can be provided from clean ordinary tap water i LIFT STATION INSTALLATION The inlet to the Lift Station LS is gravity fed from used process water and therefore must be mounted at a lower e...

Page 14: ...nted on the main base A third pump is built into the remote lift station The system is designed to provide a nominal 15 GPM 57 LPM at 45 PSI 0 31 MPa The Internal Circulating pump pulls water from the Dirty Side of the reservoir and pumps it through a cascade of three 3 filters a chiller and returns the water back to the clean side of the reservoir The Process Loop pump pulls clean refrigerated wa...

Page 15: ...re and 110o F degrees maximum temperature ii Filter Elements Each filter housing is designed to hold three cartridge type filter elements The housings accept filter cartridges of various composition and filtration rating The customer must determine the type of filter element to best satisfy their requirements iii Gauges Each filter housing has a pressure gauge mounted directly on top WFS These gau...

Page 16: ...g the Tecumseh condensing unit see the design data page in the appendix d TEMPERATURE CONTROLLER The water temperature for the Process Circuit is controlled by a RANCO ETC111000020 Electronic Temperature Controllers This is mounted on the side of the main control cabinet Water temperature can be increased or decreased by use of the up or down arrows on the face of the RANCO unit NOTE For additiona...

Page 17: ...nal This lights up and may sound an audible alarm if a fault condition is detected See ALARMS section 4 h ii E Stop Push Button The E Stop push button stops all pumps and the chiller It is detented After it has been depressed it must be physically pulled out to permit resetting the controls iii Power Selector Switch This switch activates the control power When it is first turned to the on position...

Page 18: ...ponding pump or chiller is running ix Beacon Optional This illuminates when there is an alarm fault As a reminder it will also flash for 3 seconds once every minute if Alarm Override is active See Section XXX ALARMS g OPTIONAL INSTRUMENTATION AND ALARMS A variety of sensors and displays can be added to monitor process conditions and provide additional protection for pumps and equipment This equipm...

Page 19: ...etecting strip is installed around the base of the WFS unit A leak detecting relay LD 1 is mounted inside the control cabinet that monitors the condition of the sensing strip If it detects wetness it triggers an alarm The trip point is adjustable with a small knob on the relay vi HMI Touch Screen Display Panel The HMI is set up with three different pages and these are accessed by selecting one of ...

Page 20: ...ure at the recirculating pump exceeds 70 PSI This may indicate the need to change out the filter cartridges in one or more filters High Process Pressure Total head pressure at the process pump exceeds 70 PSI This may indicate the need to change out the filter cartridges in one or more of the filters It may also indicate an obstruction to flow someplace in the line such as a partially closed valve ...

Page 21: ...e blank We recommend that this is the normal display mode The fault will continue to display until the Reset Button is pushed This is true even if the fault has cleared itself E g the reservoir runs low and the Low Water Class 1 alarm is triggered The pumps will stop and the alarm will sound Before someone can come to inspect the unit the auto fill valve restores the reservoir to the proper level ...

Page 22: ... flow equilibrium The override mode also allows operation should the leak sensor strip become wet during a filter element change out The Alarm Override is canceled when the Cancel Alarm Override button is touched Additionally it will clear itself after 10 minutes if not manually canceled While operating in the Alarm Override mode the alarm tone will sound and the beacon will pulse for 3 seconds on...

Page 23: ...in water level in the holding tank is reached Process cooling water is gravity drained and collected into the lift station The lift station discharge is connected to the Process Water Return connection Facility water supply is open to the Water Make Up line Verify that the proper three 3 phase electrical power with ground is connected WARNING To be performed by qualified personnel only 2 FILLING T...

Page 24: ...While someone observes the pump rotation jog Pump 1 for two seconds i e depress the Pump 1 Start Push Button then the Pump 1 Stop Push Button Verify that the rotation of the pump is in the direction indicated on the pump housing If the pump rotation is not correct have a qualified electrician correct the wiring on the incoming line as indicated in the note below WARNING Pump Rotation To be perform...

Page 25: ...Lift Station is properly installed and powered NOTE The Lift Station has a small internal reservoir with a float switch and will not cycle on until the water level in the internal reservoir reaches a certain level The Lift Station will tend to cycle on and off NOTE The filling process will require many pump starts and stops to reach equilibrium CAUTION Use caution to avoid allowing water level to ...

Page 26: ...nnel from their opening If sensitive equipment is in the vicinity attach appropriate fittings and hose to direct water to safe container 5 STARTING THE CHILLER The chiller provides cooling by refrigeration for the process water The temperature is controlled by a RANCO Electronic Temperature Controller mounted on the front of the WFS to the side of the control cabinet To avoid icing up internal com...

Page 27: ... at or above fill lines b All facility interface ball valves are open c Lift Station has power d All appropriate valves on the process equipment are open e E Stop push button is pulled out 2 POWER UP Turn Power Selector Switch to On Red Alarm indicating light should illuminate Press black Reset Push Button Blue Power indicating light should illuminate 3 PUMP AND CHILLER START UP When properly powe...

Page 28: ...he Lift Station is controlled by an automated float sensor and can continue to return water to the Dirty Side reservoir for a period of time This may cause the Dirty Side to overflow The Lift Station will stop automaticity shortly after Pump 2 is stopped c Stop Pump 1 d Close Make Up Water ball valve We recommend closing the make up water ball valve when the system is not in use This is to prevent...

Page 29: ...m This provides a more accurate reading of the increase caused by the filter pressure Close the bypass valve to bring the process cooling loop back on line Filter change out is recommended when the pressure increase through the filter housing exceeds 50 PSI CAUTION There is no water flow to the process with the Bypass Valve open to reservoir BYPASS VALVE ...

Page 30: ...ircuit Breaker is off Chiller Freon is low Chiller cycles rapidly Hysteresis setting on RANCO controller too small Water Temperature varies significantly Hysteresis setting on RANCO controller is too large A particular pump will not start Pump circuit breaker is off Lift Station does not return water No power to Lift Station Internal Float switch failed Water overflows reservoir Float Valves jamme...

Page 31: ... pdf Hudson Float Valve http hudsonvalve com products Ashcroft Pressure Gauge http ashcroft com drawingsandmodels_pdf upload drawing industrial gauge 10 100s 02l pdf RANCO ETC 111000 http www rancoetc com ranco etc 111000 000 digital temperature controller 24 VDC power supply optional https cdn automationdirect com static specs rhinopsp pdf Digital Panel Meters optional https cdn automationdirect ...

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