Schmalz NLS 431x276x615 AD F PNT Assembly Instructions

Brand: Schmalz

Model: NLS 431x276x615 AD F PNT

Type: Assembly Instructions

This manual is also suitable for

The Schmalz NLS 431x276x615 AD F PNT is a liquid separator designed to remove liquids from compressed air systems. It is a compact and efficient unit that can be used in a variety of industrial applications. The separator features a high-performance coalescing filter element that removes oil aerosols, water droplets, and solid particles from the compressed air stream. The separated liquids are collected in a reservoir and can be drained manually or automatically. The separator is easy to install and maintain, and it comes with a variety of accessories to meet specific application requirements.

Assembly Instructions

Liquid Separator

WWW.SCHMALZ.COM EN-US · 30.30.01.03301 · 01 · 12/22

Note

The Assembly instructions were originally written in German. Store in a safe place for future reference.

Subject to technical changes without notice. No responsibility is taken for printing or other types of er-

rors.

Published by

This document is protected by copyright. J.SchmalzGmbH retains the rights established thereby. Repro-

duction of the contents, in full or in part, is only permitted within the limits of the legal provisions of

ten agreement from J.SchmalzGmbH.

Contact

J. Schmalz GmbH

Johannes-Schmalz-Str. 1

72293 Glatten, Germany

T: +49 (0) 7443 2403-0

[email protected]

www.schmalz.com

Contact information for Schmalz companies and trade partners worldwide can be found at:

www.schmalz.com/salesnetwork

2 / 30 EN-US · 30.30.01.03301 · 01 · 12/22

Contents

EN-US · 30.30.01.03301 · 01 · 12/22 3 / 30

Contents

1Important Information ...................................................................................................................................5

1.1 Note on Using this Document.............................................................................................................5

1.2 The Technical Documentation Is Part of the Product........................................................................ 5

1.3 Type Plate.............................................................................................................................................5

1.4 Symbol .................................................................................................................................................. 6

1.5 Other Applicable Documents..............................................................................................................6

2Fundamental Safety Instructions...................................................................................................................7

2.1 Intended Use ........................................................................................................................................ 7

2.2 Non-Intended Use................................................................................................................................7

2.3 Personnel Qualifications......................................................................................................................7

2.4 Warnings in This Document ................................................................................................................ 8

2.5 Danger Zone ........................................................................................................................................8

2.6 Environmental and Operating Conditions ......................................................................................... 9

2.7 Technical Condition ............................................................................................................................. 9

2.8 Responsibility of the Operating Company ....................................................................................... 10

2.9 Country-Specific Regulations for the Operating Company............................................................. 10

3Description of the Liquid Separator ............................................................................................................11

4Technical Data...............................................................................................................................................13

4.1 General Parameters ...........................................................................................................................13

4.2 Variants ..............................................................................................................................................13

4.3 Dimensions ......................................................................................................................................... 14

4.4 Circuit Diagram .................................................................................................................................. 15

5Transportation and Storage.........................................................................................................................17

5.1 Checking the Delivery........................................................................................................................17

6Installation ....................................................................................................................................................18

6.1 Installation Instructions ..................................................................................................................... 18

6.2 Mechanical Attachment ....................................................................................................................19

6.3 Pneumatic connection ....................................................................................................................... 19

6.4 Electrical Interface .............................................................................................................................19

6.5 Software Integration ......................................................................................................................... 20

7Start of Operations.......................................................................................................................................21

7.1 Personnel Qualification ..................................................................................................................... 21

7.2 Before Initial Start of Operations .....................................................................................................21

7.3 Test Run..............................................................................................................................................22

8Operation ......................................................................................................................................................23

8.1 Preparations ....................................................................................................................................... 23

9Troubleshooting ...........................................................................................................................................25

9.1 Safety..................................................................................................................................................25

9.2 Faults, Causes, Solutions....................................................................................................................25

10 Maintenance .................................................................................................................................................26

Contents

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10.1 Safety..................................................................................................................................................26

10.2 Maintenance Schedule ......................................................................................................................26

11 Disposing of the Product..............................................................................................................................27

12 Declarations of Conformity..........................................................................................................................28

12.1 EU Declaration of Incorporation.......................................................................................................28

12.2 UKCA Declaration of Incorporation .................................................................................................29

1 Important Information

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1Important Information

1.1Note on Using this Document

J.SchmalzGmbH is generally referred to as Schmalz in this document.

The document contains important notes and information about the different

operating phases of the product:

• Transport, storage, start of operations and decommissioning

• Safe operation, required maintenance, rectification of any faults

The document describes the product at the time of delivery by Schmalz and is aimed at:

• Installers who are trained in handling the product and can operate and in-

stall it

• Technically trained service personnel performing the maintenance work

• Technically trained persons who work on electrical equipment

1.2The Technical Documentation Is Part of the Product

1. For problem-free and safe operation, follow the instructions in the documents.

2. Keep the technical documentation in close proximity to the product. The documentation must be ac-

cessible to personnel at all times.

3. Pass on the technical documentation to subsequent users.

ðFailure to follow the instructions in these Assembly instructions may result in life-threatening in-

juries!

ðSchmalz is not liable for damage or malfunctions that result from failure to heed these instructions.

If you still have questions after reading the technical documentation, contact Schmalz Service at:

www.schmalz.com/services

1.3Type Plate

The type plate (1) is permanently attached to the product and must always be clearly legible.

It contains product identification data and important technical information.

4For spare parts orders, warranty claims or

other inquiries, have the information on the

type plate to hand.

1 Important Information

6 / 30 EN-US · 30.30.01.03301 · 01 · 12/22

1.4Symbol

This symbol indicates useful and important information.

üThis symbol represents a prerequisite that must be met prior to an operational step.

4This symbol represents an action to be performed.

ðThis symbol represents the result of an action.

Actions that consist of more than one step are numbered:

1. First action to be performed.

2. Second action to be performed.

1.5Other Applicable Documents

The following operating instructions must also be referred to when setting up the liquid separator:

• Operating instructions 30.30.01.01046 for the vacuum switch

• The operating instructions for the bus module, depending on the variant

• The mechatronics plan, depending on the variant

• The spare and wearing parts list, depending on the variant

2 Fundamental Safety Instructions

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2Fundamental Safety Instructions

2.1Intended Use

The product is intended for use between the vacuum clamping device of a machine tool and the vacuum

generator for the vacuum clamping device. It is intended to separate any coolant/lubricant (oil/water mix-

ture) that may have been sucked in without interrupting the system vacuum.

The coolant/lubricant must have a water content of at least 70%.

The system must be operated only at the supply voltage specified for the components.

The liquid separator is built in accordance with the latest standards of technology and is delivered in a

safe operating condition. Nevertheless, dangers may arise during use. Observe the warnings in these as-

sembly instructions.

The product is intended for industrial use.

Intended use includes observing the technical data and the installation and operating instructions in this

manual.

2.2Non-Intended Use

Schmalz accepts no liability for damages caused by the use of the product for purposes other than those

described under “Intended Use.” The use of the product with media other than the coolant/lubricant for

machining centers, and particularly the use of the product with flammable or explosive media such as

acids or alkalis, is considered to be improper use.

The product is not intended to pump coolants/lubricants or other liquids from a container, for instance.

The product is not intended to be used like a wet/dry vacuum.

2.3Personnel Qualifications

Unqualified personnel cannot recognize dangers and are therefore exposed to higher risks!

The operating company must ensure the following points:

• The personnel must be commissioned for the activities described in these in-

structions.

• The staff must be at least 18 years of age and physically and mentally capa-

ble.

• The product must be operated only by persons who have undergone appro-

priate training.

• Personnel must receive regular safety briefings (frequency as per country-

specific regulations).

• Work on electrical equipment must be carried out only by qualified electri-

cal specialists.

• The customer is responsible for installing the liquid separator in the com-

plete system.

Maintenance work and repairs may only be carried out by specialists of

J.SchmalzGmbH or by persons who can prove that they have undergone

appropriate training at Schmalz.

The following target groups are addressed in these instructions:

• Mechanical and electrical specialists who are responsible for installing, trou-

bleshooting and maintaining the product.

The operator of the system must comply with country-specific regulations regarding the age, ability and

training of the personnel.

2 Fundamental Safety Instructions

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Applicable for Germany:

A qualified employee is defined as an employee who has received technical training and has the knowl-

edge and experience – including knowledge of applicable regulations – necessary to enable him or her to

recognize possible dangers and implement the appropriate safety measures while performing tasks. Qual-

ified personnel must observe the pertinent industry-specific rules and regulations.

2.4Warnings in This Document

Warnings warn against hazards that may occur when handling the product. The signal word indicates the

level of danger.

Signal word Meaning

DANGER

Indicates a high-risk hazard that will result in death or serious injury if not

avoided.

WARNING

Indicates a medium-risk hazard that could result in death or serious injury if

not avoided.

CAUTION

Indicates a low-risk hazard that could result in minor or moderate injury if

not avoided.

NOTE

Indicates a danger that leads to property damage.

2.5Danger Zone

Constant vibrations occur due to the function of the liquid separator. As a result, mechanical and fluid

connections may loosen or even become disconnected.

The danger zone of the liquid separator includes the following areas:

• The area directly below the liquid separator.

• The immediate vicinity of the liquid separator.

CAUTION

Vacuum close to the eye

Severe eye injury!

4Wear eye protection.

4Do not look into vacuum openings such as suction lines and hoses.

CAUTION

Noise pollution caused by exhaust air or leakage during operation

Hearing damage

4In the event of leakage, check connections and lines and remedy leakages

4Wear ear protectors.

2 Fundamental Safety Instructions

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2.6Environmental and Operating Conditions

The liquid separator must not be operated under the following conditions:

• In potentially explosive atmospheres

• Use in an environment with acidic or alkaline media

The liquid separator is installed in the vacuum supply line of a machine tool/machining center.

To ensure that the workpiece is securely held on the clamping plate, you must check the vac-

uum level directly on the clamping device.

If an excessive amount of liquid enters the liquid separator, the vacuum connection to the machine tool

may be interrupted.

The maximum separation capacity with consistent liquid entry is 1l/min.

Up to 4l/min can be separated for a short time as long as the total quantity is less than 5l/5

min.

DANGER

Releasing the workpiece from the clamping table

Serious injury or death!

4The vacuum level in the machine tool must be measured directly on the vacuum clamp-

ing device.

4The vacuum sensors on the clamping device and liquid separator are connected to the

system controller. The signals must be correctly evaluated and processed by the con-

troller.

4If in doubt, consult Schmalz before the start of operations.

2.7Technical Condition

If the product is operated while in a defective state, safety and function will be impaired.

• Only operate the liquid separator when in perfect working order as origi-

nally delivered.

• Follow the maintenance plan (> See ch. Maintenance).

• Use only original spare parts from Schmalz.

• If the operating behavior changes, check the liquid separator for faults. Rec-

tify faults immediately.

• Do not independently modify or alter the liquid separator.

• Safety features must not be disabled under any circumstances.

Schmalz assumes no liability for consequences of modifications over which it has no control.

2 Fundamental Safety Instructions

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2.8Responsibility of the Operating Company

The operating company is obligated to perform a risk assessment for the environmental conditions at the

installation location.

The liquid separator is integrated into the machine controller of the machining center. The operating

company is responsible for programming this controller. The operating company is therefore responsible

for ensuring that the liquid separator is controlled correctly and the signals coming from the liquid sepa-

rator are evaluated correctly.

The operating company is also responsible for third parties in the working area of the liquid separator.

The operating company must ensure that they have the appropriate qualifications and skills.

• Ensure that the liquid separator cannot be started up by unauthorized per-

sons.

• During maintenance or repair work, ensure that the liquid separator cannot

be operated.

• Clearly define the responsibilities for the various activities performed with

the gripper.

• Ensure that these responsibilities are observed.

2.9Country-Specific Regulations for the Operating Company

1. Observe the country-specific regulations regarding accident prevention, safety testing and environ-

mental protection.

2. The product is used in combination with a machine tool/machining center.

Ensure that the appropriate country-specific regulations and safety regulations are adhered to.

3 Description of the Liquid Separator

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3Description of the Liquid Separator

The liquid separator is used in a machining center together with the separately supplied vacuum pump.

The liquid separator is used to separate coolant/lubricant that is sucked in by the vacuum clamping device

of the machining center.

It operates based on the two-chamber principle. In the upper chamber (24), the sucked-in liquid is sepa-

rated from the gas flow and returned via the lower chamber (23). During the recirculation process, the

chambers are separated in an airtight manner. This maintains the vacuum in the upper chamber (24) so

processing does not have to be interrupted.

Pinch valves (5/6) are mounted on the inlet side (connection for clamping device (4).

• The machine control unit can use the pinch valve marked as item 6 to inter-

rupt the vacuum connection to the clamping device.

• The pinch valve marked as item 5 can be used to vent the line to the clamp-

ing device.

There is a pre-filter (7) between the pinch valve (6) and the liquid separator, which filters out any coarse

dirt that may have been sucked in (particularly chips). Liquids that have been sucked in can pass through

the filter (7) unhindered and are separated and pumped away by the liquid separator during operation.

The pre-filter must be checked regularly and cleaned where necessary. (See maintenance

plan).

The pre-filter can be cleaned only when the vacuum is switched off.

The float switch (9) in the lower chamber switches when the chamber is about two-thirds full.

The applied compressed air (0.5bar) closes the non-return valve between the lower and upper chamber.

The resulting excess pressure presses the separated liquid from the lower chamber (23) back into the col-

lection container of the machine tool.

After the preset time passes (recommendation: 10 seconds), the compressed air is switched off and the

non-return valve opens the connection to the upper chamber (24).

The liquid collected in the upper chamber in the meantime then flows into the lower chamber (23) until

the float switch (9) of the lower chamber switches back and a new pump-off cycle begins.

The liquid is separated and pumped off while the workpiece is being processed. That is, the system vac-

uum and therefore the holding force of the vacuum clamping device remain unchanged.

If more liquid accrues than the amount that can be separated or pumped out, the liquid level in the upper

chamber (24) rises.

When the upper chamber (24) is filled to approx. 50%, a signal is sent to the machine control unit via a

float switch (21) to initiate appropriate countermeasures (stopping the entry of liquid into the separator,

interrupting workpiece processing, etc.). When the liquid level falls below the critical level, the float

switch (21) opens and workpiece processing can continue.

However, if the liquid level continues to rise when the upper chamber (24) is approximately 80% full, the

connection to the vacuum generator is mechanically interrupted (25) to protect the vacuum pump from

damage caused by the liquid that is sucked in. The vacuum in the liquid separator and in the clamping de-

vice dissipates, the workpiece is no longer clamped or held in the device.

If the vacuum is interrupted, the liquid separator must be disconnected from the vacuum supply and the

vacuum supply line must be vented. If the ventilation is insufficient, the line must be briefly supplied with

overpressure ≤0.5bar.

The liquid separator can then be put back into operation.

If the liquid separator was not drained manually beforehand via the drain connection (10), the remaining

liquid in the container is pumped off after restarting operations.

The vacuum/pressure switch (8) measures the vacuum between the liquid separator and the vacuum

clamping device. You can read the current value on the digital display.

The gauge on the top (13) shows the system vacuum in the upper chamber (24).

3 Description of the Liquid Separator

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10 11

16/17

1 Purge connection for upper chamber 15 Grounding connection

2 Pump-off valve 16 Compressed-air distributor

3 Bus module (optional) 17 Compressed-air distributor

4 Connection for clamping device 18 Compressed air supply

5 Pinch valve for venting of clamping device 19 Pressure-reduction valve for pinch valves

6 Vacuum on/off pinch valve 20 Pressure-reduction valve for pump-off

7 Filter 21 Float switch for upper chamber

8 Pressure/vacuum switch 22 Purge connection for upper chamber

9 Float switch for lower chamber 23 Lower chamber

10 Drain/purge connection 24 Upper chamber

11 Purge connection for lower chamber 25 Emergency shutdown

12 Purge connection for lower chamber 26 Wall mounting plate (2x)

13 Gauge 27 Liquid recirculation

14 Connection to vacuum generator

4 Technical Data

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4Technical Data

4.1General Parameters

Parameter Description Value

Dimensions (L x B1 x H) approx. 616 x 430 x 276 mm

Vacuum input/output connection Hose diameter 38mm

Connection for liquid recirculation Hose diameter 12mm

Compressed air Plug-in screw union for VSL 6/4 Nominal width NW 4

Input pressure 6bar

Operating pressure 4bar

Pump-off 0.5bar

Nominal diameter Minimum flow diameter in the

vacuum system

20mm

Installation position Suspended vertically

Volume of upper chamber approx. 4.6l

Volume of lower chamber approx. 1.9l

Maximum separation capacity 1) 60l/h

Weight

(depending on variant)

approx. 15kg

1) The maximum separation capacity with consistent liquid entry is 1l/min.

The maximum entry of liquid may be higher for a short period of time until the two chambers are filled.

4.2Variants

The variants of the liquid separator differ with regard to the bus module

Part number Designation Bus system

10.01.27.01831 NLS ... PNT PROFINET

10.01.27.01883 NLS ... EIP EtherNet/IP

10.01.27.01884 NLS ... Bus system provided by customer

4 Technical Data

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4.3Dimensions

L L2 L3 L4 L5 B B1 B2 B3 H

616 479 40.2 313 214 265 430 70 132.5 276

All specifications are in mm

4 Technical Data

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4.4Circuit Diagram

4 Technical Data

16 / 30 EN-US · 30.30.01.03301 · 01 · 12/22

Legende:

Schaltzustände Vakuumpumpe

Schaltzustände am Wasserabscheider

QV = Quetschventil

EMVP = Elektromagnetventil

P = Druck

Pu = Vakuum

Schritt 0: Befehl von Steuerung: Werkstück spannen (Vakuum ein, Belüften aus)

Schritt 1: Flüssigkeit im unteren Behälter so weit gestiegen, dass Schwimmerschalter im unteren Behälter schließt

Schritt 2: Flüssigkeit im unteren Behälter so weit gefallen, dass Schwimmerschalter im unteren Behälter öffnet

Schritt 3: Flüssigkeit im oberen Behälter so weit gestiegen, dass Schwimmerschalter im oberen Behälter schließt

Schritt 4: Flüssigkeit im oberen Behälter so weit gefallen, dass Schwimmerschalter im oberen Behälter öffnet

Schritt 5: Befehl von Steuerung: Werkstück lösen (Vakuum aus, Belüften ein)

Schritt 6: Freigabe für Bearbeitung

(Schritt 7: Alternative Freigabe für Bearbeitung und programmierbaren Vakuumwert x)

(übermäßiger Flüssigkeitseintrag)

5 Transportation and Storage

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5Transportation and Storage

5.1Checking the Delivery

The scope of delivery can be found in the order confirmation. The weights and dimensions are listed in

the delivery notes.

1. Compare the entire delivery with the supplied delivery notes to make sure nothing is missing.

2. Damage caused by defective packaging or occurring in transit must be reported immediately to the

carrier and J.SchmalzGmbH.

6 Installation

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6Installation

6.1Installation Instructions

CAUTION

Improper installation or maintenance

Personal injury or damage to property

4Prior to installation and before maintenance work, the product must be disconnected

from the power supply, depressurized (vented to the atmosphere) and secured against

unauthorized restart.

NOTE

Formation of condensation at high humidity levels due to the vacuum in the liquid

separator

Water drips from the liquid separator and soils or damages the surrounding area.

4In order to collect or discharge this water in a controlled manner, place a collection

tray under the liquid separator.

3.1

1 Purge connection for upper chamber 15 Grounding connection

3.1 Bus module (optional) connections 18 Compressed air connection

4 Connection for clamping device 19 Pressure-reduction valve for pinch valves

10 Drain/purge connection 20 Pressure-reduction valve for pump-off

11 Purge connection for lower chamber 22 Purge connection for upper chamber

12 Purge connection for lower chamber 26 Mounting plate 2x

14 Connection to vacuum generator 27 Connection for liquid recirculation

6 Installation

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6.2Mechanical Attachment

4Install the liquid separator suspended verti-

cally on the mounting plates on the rear. (>

See ch. 4.3 Dimensions,p. 14)

6.3Pneumatic connection

1. Shorten the hoses and pipelines as much as possible.

2. Keep hose lines free of bends and crimps.

3. Lay hose lines in such a way that they do not rub.

CAUTION

Vacuum close to the eye

Severe eye injury!

4Wear eye protection.

4Do not look into vacuum openings such as suction lines and hoses.

6.4Electrical Interface

The liquid separator sensors and actuators must be integrated into the higher-level control unit for the

complete system via the bus system.

Variants with Installed Bus Module

Connect the bus module in accordance with the instruction manual supplied. Connect all sensors and ac-

tuators.

6 Installation

20 / 30 EN-US · 30.30.01.03301 · 01 · 12/22

Variant without Bus Module

The operator is responsible for selecting a suitable bus module and for correct mounting on the valve

unit.

The following sensors/actuators must be connected:

• 1x 3/2-way pneumatic valve (QM1), SIO connection

• 2x 5/2-way pneumatic valve (QM2, QM4), SIO connection

• 2x float switch (BG1, BG2), SIO connection

• 1x vacuum switch (BP1), SIO or IO-Link connection

All sensors/actuators are equipped with M12, 5-pin connectors.

Depending on the means of controlling the vacuum switch, the bus module must have the following spec-

ifications:

• Vacuum switch with SIO control

– Digital inputs: 4x

– Digital outputs: 3x

• Vacuum switch with IOL control

– IO-Link-enabled, 1x IOL port

– Digital inputs: 2x

– Digital outputs: 3x

If you have any questions, you can also contact your Schmalz representative

Grounding

4Ground the liquid separator at position 15.

6.5Software Integration

The liquid separator is controlled by the higher-level system control unit and by the bus module.

Schmalz provides a software function module for the most common control systems. Please contact your

Schmalz representative.

If no function module is available, the sequence shown in the circuit diagram must be programmed.

When using an individual bus module, you are responsible for carrying out the software integration. If

you have any questions, you can also contact your Schmalz representative (> See ch. 4.4 Circuit Dia-

gram,p. 15).

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