JENFAB Lean Clean 360-1, Manual

Page 1: ...JENFAB 11996 Lean Clean 360 1 Cleaning System LC360 1 001 11 14 06 ...

Page 2: ...rials Safety Data Sheets Material safety data sheets provide safety information about common cleaning chemistries Available from JENFAB upon request Support Services Call the JENFAB customer support team to receive answers to your technical questions and order spare parts You can reach the JENFAB customer support team Monday through Friday 8 00 a m to 5 00 p m Eastern Standard Time at 1 860 828 65...

Page 3: ...an Clean 360 Cleaning System 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 ...

Page 4: ...ents Overview 12 Controls 14 Installation and Setup Introduction 16 Unpacking the Lean Clean 360 16 Choosing a Location 17 Connecting Optional Equipment 18 Utility Requirements and Connections 24 Operating the Lean Clean 360 Cold Startup 28 Starting the Oil Separator 30 Operating the Lean Clean 31 Running the Lean Clean Manually 32 Shutting the Lean Clean 360 Down 32 Using the Operator Interface G...

Page 5: ...d 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 52 Mechanical Parts List 53 Electrical Parts List 55 Specifications Technical Specifications 56 Appendix A Operator Interface Windows ...

Page 6: ...future consultation In an emergency pressing the Emergency Stop button will immediate stop all machine functions Guards covers and interlocks protect operators from moving parts and unintended operation Do not operate the cleaning machine unless all guards and interlocks are in place Do not run the machine with process chamber door open This can only be done by passing the safety interlock Before ...

Page 7: ...h information that will help you use JENFAB cleaning machines in the most effective way Caution Caution flags notify you of actions that could damage the equipment or your products and provides you with information to prevent damage Warning Warning flags notify you of action that could cause bodily harm or death and provide you with information to prevent harm Statement of Proper Use JENFAB design...

Page 8: ...ine continually recirculates filters and delivers the cleaning solution to the basket of parts through high pressure submerged jets The Lean Clean turns over the entire volume of the cleaning chamber more than twice a minute flushing away chips soils and oils and keeping fresh clean solution in contact with the parts After washing the cleaning machine drains the washing solution and completes an e...

Page 9: ...asket rotates and drains solution from parts as the process chamber empties into holding tank Rinsing rinse spray begins to impinge as the process tank fills for a combined soak and spray rinse Fresh Water Rinse fresh water spray begins to impinge for final rinse as parts rotate Drain parts rotate to drain solution and dryer starts Dry 1500 cfm recirculating hot air convection dryer directs heated...

Page 10: ...h FCC Part 18 and CE mark An OEM user manual is supplied with this option Fresh Water Spray Rinse The fresh water spray rinse maximizes removal of washing chemistry by providing a fresh water rinse after the rinse tank rinse cycle The fresh water rinse option includes an additional water line separate spray bar in the wash chamber and a program controlled solenoid valve Fresh water rinse water flo...

Page 11: ...oubleshooting costs Stack Light A red amber green stack light located on the top of the control panel indicates a ready standby or fault condition Auto Rust Inhibitor The rust inhibitor option enables rust inhibitor to be applied to parts during the fresh water rinse fresh water rinse option required A Dosatron injector metering valve added to the fresh water line automatically mixes rust inhibito...

Page 12: ...rates mechanical sound waves in the washing chamber during washing or rinsing to enhance the cleaning process The ultrasonic generator is located on top of the control panel the transducer not shown is located inside the washing chamber Access doors two side doors and one back door with latching handles provide access to the piping tanks and automated controls for maintenance Other panels are remo...

Page 13: ...generator unit Access door Main power disconnect Controls Emergency stop button Electrical control panel Customer supplies electrical compressed air and water service Basket holds parts Loading door Forklift pockets Operator interface Door interlock Prevents operator from opening door while machine is running ...

Page 14: ...the basket rotation speed from 1 to 6 rpm Start button with green indicator light pressing this button starts the cleaning cycle Blinking light indicates system is ready Steady light indicates system is running Stop button with red indicator light pressing this button stops the cleaning cycle Power button and yellow indicator light pressing this button energizes the system components upon startup ...

Page 15: ...f the touch screen monitor Power button with yellow indicator light Emergency stop button Touch screen monitor Rotation speed control knob Start button with green indicator light Stop button with red indicator light The touch screen monitor enables you to navigate the process monitoring and control windows ...

Page 16: ...he pallet and remove the cardboard box Remove the bolts holding the Lean Clean 360 to the pallet Finally and remove the 2x4 wooden lip on the pallet Remove the Lean Clean from the pallet using forklift with a 2 000 pound lifting capacity The Lean Clean s bottom frame includes forklift pockets to make transportation of the machine convenient and safe Remove Documentation and Ancillary Parts Documen...

Page 17: ...nd process water Caution If hot strong cleaning chemistries contact skin or eyes bodily injury can result To minimize harm in the event of accidental contact with hot cleaning chemistries users should locate the Lean Clean in an area with emergency eye wash and showers or install an emergency eye wash and showers in the area where the Lean Clean is installed Post Installation Checks After position...

Page 18: ...mming port and modem You must connect these options upon delivery Ultrasonic generator Factory technicians install the transducer at the factory You must install the ultrasonic generator flowing the instructions below Oil separator the oil separator is a stand alone unit and ships separately You must place the separator near the Lean Clean and connect hoses as described below Drain Station the dra...

Page 19: ...erator 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 Figure 4 Typical ultrasonic generator showing connections on the back panel Interface connection Ultrasonic cable Electric power cable ...

Page 20: ... pump to your drain or waste collection tank Expert Advice Depending upon the contaminates you are removing with the 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 5 Connect the compressed...

Page 21: ... Flexible hose from drain station outlet to pump inlet Air operated pump Solenoid valve automatically opens air line and starts pump when tank is full Wash and rinse water from the Lean Clean To waste collection 5 gallon drain station tank Tank inlet High and low level sensors send signal to the Lean Clean control system to control pump operation Solenoid control cable from Lean Clean Compressed a...

Page 22: ... clamps 2 1 inch airplane clamps 2 Locate the oil separator near the Lean Clean 360 To ensure precise oil skimming level the separator using shims 3 Connect the 1 inch hose from the oil separator outlet to the wash tank return pipe using two 1 inch airplane clamps Figure 6 4 Connect the 1 inch hose from the float outlet on the wash tank to the pump inlet on the oil separator using two inch airplan...

Page 23: ...aning System 23 Air driven pump Air pressure regulator inch hose water inlet 1 inch hose water outlet Compartment drain outlet 1 4 inch air line Oil Separator Unit AIr Skimmed oil outlet Tubing supports Water inlet Compartment drain outlet ...

Page 24: ... qualified technicians make the following connections Electrical Connections Connect the power source to the main power disconnect and verify that all motors are rotating in the proper direction phased Expert Advice To check motor rotation turn power on by pulling the emergency stop button and pressing the power button Using the operator interface put the machine in manual mode Then press motors p...

Page 25: ...onnector Warning If you use a potable water line to supply water to the Lean Clean system rinse and wash water could siphon back into plant s potable water system causing bodily injury through ingestion of contaminated water To prevent bodily injury through ingestion of contaminated water connect the system to a process water line and install a customer supplied backflow preventor on the line to p...

Page 26: ...rds can cause damage Be sure to check phase before running in automatic mode Warning Operating the machine without all guards and panels in place or with the chamber door open can lead to crushing injuries or other bodily harm To avoid crushing injury and other bodily harm ensure all guards and panels are in place and the washing chamber door is closed before operating the machine Warning Opening ...

Page 27: ...lds 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: ...t with 15 gallons of water or allow the wash tank liquid level controls to automatically fill the oil separator once the oil separator s pump is started 6 Check the wash and rinse inline filters to ensure they are installed and sufficiently clean following the procedure described on page 47 7 Power up the system by pulling out the Emergency Stop button pressing the yellow Power button on the contr...

Page 29: ...ank 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 11 Place the machine in automatic mode and open the washing chamber door The machine is ready to operate ...

Page 30: ...regulator to between 30 and 40 psig 3 Turn the oil separator air flow valve so that the air driven pump pumps about 1 gpm of wash solution through the oil coalescer As a starting point listen to the pump cycle and adjust the air flow so the pump cycle once per second 4 Adjust the slotted oil skimmer pipe in the center compartment by rotating it to desired oil skim level Moving the slot to the high...

Page 31: ...one 2 Load the basket of parts into the washing chamber and close the door Figure 9 3 Set the rotator speed using the rotator speed knob on the control panel 4 The green Start light should be flashing indicating the machine is ready to run To start the washing cycle press the Start button 5 At the end of the cleaning cycle the red Stop light will continue to flash Press the Stop button 6 Open the ...

Page 32: ...e main operating screen press the Selects Manual Mode Control button 2 Press the Motor Pumps Drains button to open the process monitoring screen 3 Press the Options button to open the password window 4 Enter your password and press the Enter button 5 Using the control buttons in the window operate the machine manually Shutting the Lean Clean 360 Down Shutdown for Overnight or Weekend Storage To sh...

Page 33: ...rter start and stop heaters and so on Manual mode is useful for testing the system and to recover from a power failure or malfunction where you may have to manually finish the cleaning cycle Modifying a Program The Lean Clean 360 typically ships with either three default cleaning programs or three customer specified cleaning programs Programs are normally labeled Program 1 Program 2 and Program 3 ...

Page 34: ...m you want to run select auto or manual modes of operation and open other windows Cycle Time indicates total cycle time of the cleaning program Pressing the Auto Mode Ready and Manual Mode Control buttons enable you to switch between automatic and manual mode Text boxes display real time temperature in the wash tank rinse tank and dryer In automatic or manual mode pressing these buttons will bring...

Page 35: ...indow where you can select the cleaning program you want run When selecting the cleaning program use the numeric keypad to enter the program number Then press the Enter button Pressing Del deletes the numbers you entered Pressing Enter causes the new number to be entered into the current program Pressing Done closes the window without saving changes ...

Page 36: ...e Main Message window In this window display boxes indicates the preset cycle time and real time accumative cycle time in seconds for each of the keys In this window display boxes indicates the preset cycle time and real time accumative cycle time in seconds for each of the key Returns you to the Main Message window Pressing the options button brings you to a password protected window form which y...

Page 37: ...of the parameter Note the maximum and minimum values are displayed below the setpoint values If you have a password and authority to change process parameter enter your password by pressing the numbers and then Enter While entering your password you can cancel clear or backspace by pressing the Cancel CLR or BKSP buttons respectively Pressing Del deletes the numbers you entered Pressing Enter caus...

Page 38: ...indow Pressing the Program Cycle Data Entry button displays the window where you can changes process cycle times For example you could change the rinse time from 150 seconds to 120 seconds Using the On and Off buttons you can enable or disable the tank and dryer heaters Returns you to the Main Message Window Pressing the Program Cycle Status Display return you to process monitoring screen Pressing...

Page 39: ...nd they enable you to control the motors pumps and drains manually The pumps blower and rotator buttons allow you to control the equipment manually Theses buttons open and close the washing chamber drain valve If you attempt to drain rinse water into the wash solution tank or wash water into the rinse tank these warning lights will illuminate The system will not allow you to complete the action Th...

Page 40: ...shing chamber door is open 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 Brings you to the next Program Cycle Entry Screen Returns you to the Main Message window These parameter buttons display the current process parameter Pressing the parameter button opens the ...

Page 41: ...ay 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 Returns you to the Main Message window These buttons display the current ON OFF times Pressing the button opens the numeric window where you can change the ON OFF times ...

Page 42: ...n or off in rinse if equipped Sonication time in wash and rinse cycles if equipped Rotation on and off in wash and rinse Tilt on or off if equipped Tilt cycle time if equipped Tilt angle if equipped Cool down cycle time Steps to Modify a Program These are the steps you follow to modify a cleaning program 1 Ensure the Lean Clean is in idle mode and the washing chamber door is open 2 Using the touch...

Page 43: ...am you want to modify press the button for the process parameter you want to modify The numeric window opens and displays the current value for the process parameter you are modifying 8 Using the numeric window change the process parameter to the new target value and press the Enter button 9 Modify any other process parameters you want by repeating steps 7 and 8 10 When you are done modifying the ...

Page 44: ...e automatic mode No power to machine Main power switch in Off position Move main power switch to On position Main supply breaker in Off position Check plant circuit breaker for lockout tagout condition Wiring damaged Have electrician check wiring Parts not clean after washing No detergent in wash water Ensure detergent is in wash water Check chemistry effectiveness against contaminates being remov...

Page 45: ...ull Before powering up the heaters Temperature controls Check for accuracy Every six months Tank heaters Check for salts build up Weekly Warning Some inspection cleaning and maintenance operations expose operators to risks release of compressed air release of hot process solution in pressurized lines electrical energy pinching from unexpected startup These risks can cause bodily harm and death To ...

Page 46: ...owing these steps 1 Shut of the machine by pressing the front panel Emergency Stop button 2 Open the side panel door 3 Remove chip baskets from the wash and rinse tanks by lifting the baskets out 4 Dispose of the chips and clean the baskets 5 Reinstall the baskets in the wash and rinse tanks 6 Close the side panel door 7 Reenergize the machine ...

Page 47: ...place parts as needed 5 Install and spread out new filter bag in filter basket and housing 6 Install o ring in filter housing and replace cover Tighten cover bolts 7 Close the drain valve and vent valve 8 To bleed air from the filter housings and lines use the operator interface to place the machine into manual mode Close the washing chamber door and open the wash chamber main drain 9 Set diverter...

Page 48: ...60 Cleaning System Figure 11 Wash water filter housing Vent valve Cover bolts Wash water inlet Drain line Filter housing Drain line valve One recommended filter type is 1 1725 P 50 PK 01 made by Filtration Group Fluid Systems Chicago IL ...

Page 49: ...ompartment and the tube bundle compartment by sliding it up and out 4 Remove the tube bundle by sliding it towards the inlet and lifting it out 5 Clean the tube bundle by hosing it off or soaking it in a tank with cleaning solution Caution Using steam to clean the tube bundle will damage the tube bundle To prevent damage to the tube bundle do not clean with steam 6 Clean the inside of the coalesce...

Page 50: ...3 Top view of oil separator with cover removed Tube bundle Air pressure regulator and valve Solution air driven pump Solution inlet Outlet drains back to the Lean Clean wash tank Wash water inlet Air driven pump pumps wash water from wash tank to oil separator Skimmed oil outlet Oil skimmer Tube bundle ...

Page 51: ...following these steps 1 Remove the cover from the top of the washing chamber and ensure the metal plate is firmly attached to the rotator gear Reposition or reattach if necessary 2 Run and cleaning cycle and check position of basket at end of cleaning cycle If basket is not horizontal loosen locking nuts on the proximity sensor mounting plate located on the back outside wall of the washing chamber...

Page 52: ...e or replacement parts for your Lean Clean 360 JENFAB recommends checking the OEM manuals on the supplied CD ROM and contacting the OEM manufacturer To obtain JENFAB custom built parts contact the JENFAB customer service team Monday through Friday 8 00 a m to 5 00 p m Eastern Standard Time at 1 860 828 6516 You can also learn more about our products from our website at www jenfab com ...

Page 53: ... pattern 25 7 0 gpm at 40 psi BEX Nozzles Rinse Header 10 1 8F2550 T303SS 1 8 NPT flat V spray pattern 25 5 0 gpm at 40 psi BEX Nozzles Virgin Rinse 3 1 8F9520 T303SS 1 8 NPT flat V spray pattern 95 2 0 gpm at 40 psi BEX Filter Housings 2 L4461NAY30 Stainless steel housing holds 1 size 3 filter bags 4 1 dia x 8 long Krystil Klear Solution Return Plunger 1 9545K82 Tapered rubber stopper size 14 w 1...

Page 54: ...5hp 185T frame 3450 rpm 208 230 460 3 60 Weg Chicago Blower Hose 5 6 SS 6 stainless steel flexible hose JENFAB Heaters 3 KXS 2162 01 U bent finned elements 3350 watt stainless steel Note 230 volt machine has four heaters JENFAB Temp Control 1 PLC temp setpoint OIT Temp Probe 1 G912 RTD AL 12 SS probe 100Ω NPT connection G I C Ultrasonics Transducer 25khz 1 WUSA50400003 Sonopush Mono ultrasonic tra...

Page 55: ...len Bradley RTD card 1 1762 IR4 4 point temperature input Allen Bradley Tank door switch 1 440G S36044 24Vdc w lock solenoid Allen Bradley Plug in Relay 1 700 HF32Z24 DPDT 10A 24Vdc Allen Bradley Terminal relay 1 700 HLT1Z24 SPDT 24Vdc Allen Bradley Dc controller rotator 1 FPM 0850C 0997 hp 130Vdc Bodine Dc controller tilt option 1 0890 F B R directional kit Bodine Door Lock Switch 1 440G S36044 2...

Page 56: ...inless steel Tank heat 6 KW In process filtration Separate 304 stainless steel bag inclusive for wash rinse Chip baskets Separate removable wash and rinse baskets Dryer capacity 1500 cfm Dryer type Re circulating hot air convection Air discharged to plant 75 cfm for 2 5 minutes Atmosphere per cycle 187 CF per cycle Water requirement Process city water typical pressure and flow rate 1 connection on...

Page 57: ...Learning to Use the Lean Clean 360 Cleaning System 57 Appendix A Operator Interface Windows ...

Page 58: ...leaning System 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 ...