maintenance manual - chip compactor product documentati… · maintenance manual - chip compactor...

2010-13 Bazell Technologies Corporation. All rights reserved.

May not be reproduced in whole or in part without the express written consent of Bazell Technologies.

Maintenance Manual - Chip Compactor

Distributed Exclusively by Satisloh

Manufactured for Satisloh by:

Bazell Technologies Corporation 5066 Commercial Circle Concord, CA. 94520

Tel: (925) 603-0900 Fax (925) 603-0901 Email: [email protected] Web: www.bazell.com

Bazell Technologies Corporation is a Satisloh Technology Partner

M000023_C October 2013

mailto:[email protected]://www.bazell.com/



PRODUCT DESCRIPTION .............................................................. 3

OPERATOR SAFETY ........................................................................ 4

GENERAL WARNINGS: .................................................................. 5

FOAM BLOCKS: .................................................................................... 5

COMPACTOR INSPECTION AND MAINTENANCE ................... 7

DAILY: ............................................................................................... 7 CLEANING THE COMPACTOR: ................................................................ 7 REMOVE SWARF COMPRESSION ASSEMBLY: ........................................... 9 REMOVING DEBRIS: ............................................................................. 9 NYLON PISTON BUSHING INSPECTION ................................................. 10 INSTALL THE SWARF COMPRESSION ASSEMBLY: ................................... 11

APPENDIX ....................................................................................... 22

STANDARD TORQUE VALUES ............................................................... 22 DRAWING 6SBTJ001 ........................................................................ 23 DRAWING 6SBTJ058 ........................................................................ 25 DRAWING 6SBTJ059 ........................................................................ 26 DRAWING 6SBTJ061 ........................................................................ 27 DRAWING 6SBTJ063 ........................................................................ 28 DRAWING 6SBTJ064 ........................................................................ 29 DRAWING 6SBTJ065 ........................................................................ 30 DRAWING 6SBTJ066 ........................................................................ 31 DRAWING 6SBTJ067 ........................................................................ 32 LIMITATIONS OF WARRANTY .............................................................. 33 CONTACTING BAZELL TECHNOLOGIES .................................................. 33



Product Description

The Chip Compactor Module is part of a coolant recovery and

filtration system used for the clarification of synthetic coolant used in the manufacturing of ophthalmic lenses. This product is

designed for use on Bazell Products and an integral part of the swarf removal and coolant filtration process.

For use on HC-X systems or retrofits for existing Chip Separator modules.

PC/HI chip compaction with tall discharge height allowing large disposal containers/bags

Coolant flow of up to 60 L/m from pump station

Bazell Part Number: SYS-6SBTJ-001



Operator Safety

All personnel responsible for operating and maintaining the Chip Compactor Module shall be required to read these safety notices prior to maintenance. Important safety devices are built into

each system. Please carefully observe the following safety notices.

Warning: General warning, read noted areas in this manual.

Pinch point: Danger of injury due to possible trapping or

severing of limbs. Ensure any hanging or loose objects, ties, necklaces, badges, long hair, etc. are secured or removed to prevent entanglement. System must be operated with all covers

properly installed. Crush: Danger of crushing or dismemberment due to moving

parts. Ensure any hanging or loose objects, ties, necklaces, badges, long hair, etc. are secured or removed to prevent entanglement. System must be operated with all covers properly

installed. Electrical shock: Risk of potentially fatal electrical shock.

Qualified electricians or personnel working under the direct supervision of qualified electrician shall perform any electrical

work on the the system during installation, maintenance, service.



General Warnings:

Always disconnect and lock out the power source before working on or near the ICS Pro.

The chip compactor module must be operated with the covers on and properly installed.

Do not place hands, hanging badges, rags or other foreign objects into the piston/inlet area while running.

Coolant is corrosive/toxic. Do not ingest, wear nitrile gloves when working with debris or cleaning system and

wash hands with soap and cold water upon completion of task.

Practice good housekeeping and maintain a Safety

Training and Safety Equipment Operation/Maintenance Program for all employees.

Foam Blocks:

Retain both foam blocks shipped with the system and located in the compactor ejection chute. One of the blocks is used during initial startup, and after maintenance, to prevent coolant ejection

until there is sufficient swarf buildup in the swarf compression and ejection chute. The other foam block is a spare.

Foam Block Location



With Compactor powered off, insert foam block into compactor ejection chute with angled side of block facing forward as shown. Slide block all of the way down to the bottom of chute.

Note: This step is only required when the Compactor is first placed into service or after cleaning / maintenance of the compactor. If necessary, an elastic band can be used to hold the foam block in place if initial water pressure pushes it out before swarf compression in the compactor begins. A debris receptacle is required to catch the compressed swarf

that is ejected from the compactor chute. A 20 gallon (80L) or larger bin is placed underneath the compactor as shown. For ease of debris removal the receptacle should be lined with a trash

bag.

Angled Side



Compactor Inspection and Maintenance

Daily: Compactor debris receptacle: empty and in place

Quarterly:

Compactor should be inspected and cleaned.

Cleaning frequency increases with higher percentages of

polycarbonate type lenses. Cleaning the Compactor:

SAFTEY GOGGLES and NITRILE GLOVES must be worn!

Tools Required:

3mm Allen wrench 6mm Allen wrench

Putty knives, various sizes and thicknesses

Stainless Steel wire brush Leather or synthetic work gloves

Paper towels or wipes High pressure air hose with safety nozzle

Powering down the system:

With one operator looking through the window at the piston and another operator manning the enable switch, flip the switch off once the piston is fully retracted. Power the system down. Lock

and tag out per facility procedures.

Picture shows pistons fully retracted



Remove Window Cover: Using a 3mm Allen wrench, unscrew the 6 button head socket

screws and set aside. Lift Window Cover off and set aside.

Remove Front Cover: Using a 3mm L key Allen wrench, unscrew the 4 button head socket screws and set aside. Remove front cover and set aside.

Remove Cover Assembly: Using a 3mm L key Allen wrench, unscrew the 4 button head socket screws inside of Cover assy and 1 button head socket

screw

Window Cover Supply\\\\\\\\\

Front Cover



Remove Swarf Compression Assembly: Use a 6mm Allen wrench to remove the front outer screws (on

left and right sides) leaving both middle screws in place. Remove the 2 back screws. Loosen the upper screws of the swarf compression assy. Grasping both sides of the swarf compression

assy, lift while angling back. Set aside.

Removing Debris: Don a pair of nitrile gloves and a pair or work gloves over top. Use a putty knife to remove as much debris as possible. Use the

stainless steel wire brush or thin side of the putty knife to remove particulates from between wedge wires, both sides and bottom.

Do not use excessive force or damage to the wedge wire assemblies may result.

Once all surface debris and wedge

wire are clean, blow off surface area with air hose and wipe

down mating surfaces for chute assembly. Ensure no

debris has fallen down screw inserts.



Nylon Piston Bushing Inspection There is a nylon bushing located at the front lower edge of the

piston. This should be inspected for excess wear, especially on the left and right ends. Some grooving is normal as pictured below, but if the edges are worn significantly it should be

replaced.

To replace: Manually move the piston assembly forward to gain access to the

two hex head screws holding the bushing in place. Remove the screws and remove the bushing.

Insure area below the bushing area is free of any debris. Reinstall a new bushing by sliding it into place. The busing is not symmetrical. The two holes are offset to the top when installed

correctly.

Normal Wear

36in-lb (2X)



Apply a small amount of blue Loctite fastener retainer to the threads of the hex head screws and hand tighten insuring the

nylon bushing is fully contacting the bottom wedge wire. Tighten screws evenly to 36in-lb (4N-m). Do not over tighten.

Install the Swarf Compression Assembly: Lifting the swarf compression assy by its base set the assembly into place. Ensure rear is flush against the tube assembly plate.

Check that left and right sides are aligned with base. Install rear screws finger tight. Tighten the 2 upper swarf compression

screws with Allen wrench. Torque all four screws to 140in-lb (16N-m).

Install Foam Block: Foam block orientation

Reinstall Front Cover:

Set the front cover into place and install using 4 button head socket screws. Tighten screws down as you insert.

Reinstall Window Cover: Install the Window Cover into place ensuring the upper lip is inserted below the top cover. Start all 6 button head socket

screws into place. Note: Tightening screws down before all screws are installed will cause the window cover to become misaligned. Tighten all screws until fully seated.



Piston alignment procedure: Remove all covers as instructed and swarf chute.

Remove Compactor Splash Guard: Using a 3mm L key Allen wrench, unscrew the 3 button head

socket screws and set aside. Use a 6mm Allen wrench to remove the 2 screws from the pipe compactor assy. Remove front cover and set aside.

Remove Pipe Compactor Assembly:

Use a 6mm Allen wrench to remove the 4 screws (on left and right sides). Grasping both sides of the pipe compactor assy, lift while angling back. Set aside.

Rotate Piston Assembly to fully retracted position: Using Motor Arm and Connecting Rod rotate the Piston to full

forward position as shown. Caution pinch hazard (Motor Arm and Connecting Rod)!

Splash Guard Pipe Compactor assembly



Compactor wedge wire cleaned

Use a 6mm Allen wrench to loosen the 12 screws securing the Clevis Piston, Bushing Shafts to the Piston Mount.



Use a 17mm wrench and an adjustable wrench to remove Crank Shoulder bolt from Motor Arm and Connecting Rod.

Install Piston Alignment fixture:

Piston alignment fixture attaches to the Piston and Side Wedge wire assemblies.



Set Alignment fixture Pins facing downwards toward the Piston

Pin holes and screw down to Piston Assembly. Use a 5mm Allen wrench to install 2 screws loosely securing alignment fixture to piston.

Now Align fixture 6mm screw holes with Side Wedge wire assemblies and tighten down screws. Use a 5mm Allen wrench

to install 4 screws loosely securing piston alignment fixture to piston. Tighten all screws in piston alignment fixture.



Now adjust Bushing Mount to be centered to Piston assembly

hole and tighten using a 6mm Allen wrench to tighten 4 Bushing Mount screws. Use a 6mm Allen wrench to tighten 4 Shaft Mount screws.

Verify Compactor Rear Bushing Alignment: Use Service Bulletin SB00012_A - HCX Compactor Rear

Bushing Alignment Procedure Remove Piston Alignment Fixture:

Place Piston Alignment Fixture in safe location or ship back to Bazell Technologies.

Install Pipe Compactor Assembly: Grasping both sides of the pipe compactor assy set on to Wedge Wire Side plates. Use a 6mm Allen wrench to install the 4 screws

(on left and right sides). Install Compactor Splash Guard:

Set Splash Guard Cover in place. Using a 3mm L key Allen wrench, screw the 3 button head socket screws and set aside. Use a 6mm Allen wrench to install the 2

screws from the pipe compactor assy.

Bushing Mount centered to Piston assembly hole using 22awg bare wire



Install the Swarf Compression Assembly: Lifting the swarf compression assy by its base set the assembly

into place. Ensure rear is flush against the tube assembly plate. Check that left and right sides are aligned with base. Install rear screws finger tight. Tighten the 2 upper swarf compression


Install Foam Block:

Foam block orientation

Reinstall Front Cover: Set the front cover into place and install using 4 button head socket screws. Tighten screws down as you insert.

Reinstall Window Cover: Install the Window Cover into place ensuring the upper lip is

inserted below the top cover. Start all 6 button head socket screws into place. Note: Tightening screws down before all screws are installed will cause the window cover to become misaligned. Tighten all screws until fully seated.



Removal of Broken Right or Left Bushing Shaft:

Remove all covers as instructed and swarf chute. Remove Compactor Splash Guard:

Using a 3mm L key Allen wrench, unscrew the 3 button head socket screws and set aside. Use a 6mm Allen wrench to remove the 2 screws from the pipe compactor assy. Remove front cover

and set aside.

Remove Pipe Compactor Assembly: Use a 6mm Allen wrench to remove the 4 screws (on left and right sides). Grasping both sides of the pipe compactor assy, lift

while angling back. Set aside.

Rotate Piston Assembly to fully retracted position: Using Motor Arm and Connecting Rod rotate the Piston to full

forward position as shown. Caution pinch hazard (Motor Arm and Connecting Rod)!

Splash Guard Pipe Compactor assembly



Use a 6mm Allen wrench to loosen the 4 screws securing the

Shaft Mounts. Push Shaft forward to remove through the front of the compactor. Remove broken Bushing mount. Use a 6mm Allen wrench to remove 4 screws securing Bushing Shaft to Piston

Mount.

Install new Bushing Shaft: Place new Bushing Mount in to Piston Mount assembly.

Use a 6mm Allen wrench to install 4 screws loosely securing the Shaft Mounts. Push Shaft rearward to insert through the front of the Shaft Mount and aligning with new Bushing Mount and in to

the rear Shaft Mount.

Shaft and Shaft Mounts

Bushing Mount screws



Now adjust Bushing Mount to be centered to Piston assembly hole and tighten using a 6mm Allen wrench to tighten 4 Bushing

Mount screws. Use a 6mm Allen wrench to tighten 4 Shaft Mount screws.

Verify Compactor Rear Bushing Alignment:

Use Service Bulletin SB00012_A - HCX Compactor Rear Bushing Alignment Procedure

Remove Piston Alignment Fixture: Place Piston Alignment Fixture in safe location or ship back to

Bazell Technologies. Install Pipe Compactor Assembly:

Grasping both sides of the pipe compactor assy set on to Wedge Wire Side plates. Use a 6mm Allen wrench to install the 4 screws (on left and right sides).

Install Compactor Splash Guard: Set Splash Guard Cover in place.

Using a 3mm L key Allen wrench, screw the 3 button head socket screws and set aside. Use a 6mm Allen wrench to install the 2 screws from the pipe compactor assy.

Bushing Mount centered to Piston assembly hole using 22awg bare wire



Install the Swarf Compression Assembly: Lifting the swarf compression assy by its base set the assembly

into place. Ensure rear is flush against the tube assembly plate. Check that left and right sides are aligned with base. Install rear screws finger tight. Tighten the 2 upper swarf compression


Install Foam Block:

Foam block orientation

Reinstall Front Cover:

Set the front cover into place and install using 4 button head socket screws. Tighten screws down as you insert.

Reinstall Window Cover: Install the Window Cover into place ensuring the upper lip is inserted below the top cover. Start all 6 button head socket

screws into place. Note: Tightening screws down before all screws are installed will cause the window cover to become misaligned. Tighten all screws until fully seated.



APPENDIX

Standard Torque Values

Unless specified elsewhere in this manual the standard torque values for all hardware should be as below



Drawing 6SBTJ001



Drawing 6SBTJ058



Drawing 6SBTJ059



Drawing 6SBTJ061



Drawing 6SBTJ063



Drawing 6SBTJ064



Drawing 6SBTJ065



Drawing 6SBTJ066



Drawing 6SBTJ067



Limitations of Warranty

Bazell Technologies Corporation shall not be liable, to any extent whatsoever, for any damages resulting from or arising out of the

use or performance of this product and related documentation or the procedures specified in this manual, regardless of foreseeability or the form of action, whether in contract, tort

(including negligence), breach of warranty, strict liability or otherwise, and including but not limited to damages resulting

from loss of data, loss of anticipated profits, or any special, indirect, incidental or consequential damages. In no event shall Bazell Technologies Corporation liability to the user exceed the

amount paid by the user to Bazell Technologies Corporation hereunder. The user assumes full responsibility for the results obtained from the use of this product and related documentation

and for application of such results. Document Representation

This documentation is provided in good faith but without warranty as to correctness, accuracy, reliability, omissions, or

otherwise except as provided in writing by an officer of Bazell Technologies Corporation.

Contacting Bazell Technologies Bazell Technologies Corporation

5066 Commercial Circle Concord, CA. 94520

Tel: (925) 603-0900 Fax: (925) 603-0901 Email: [email protected] web: www.bazell.com

mailto:[email protected]://www.bazell.com/

[Type text]



This Page Intentionally Left Blank

maintenance manual - chip compactor product documentati… · maintenance manual - chip compactor...

Documents