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Instruction Manual: Version:08/2018 Original Language © Mayfran 2018, Landgraaf All Rights Reserved
Instruction Manual: Version:08/2018 Original Language © Mayfran 2018, Landgraaf All Rights Reserved
Version:08/2018
Original language
© Mayfran 2018, Landgraaf
All rights reserved
SEITE 2
Content
1 GENERAL ...................................................................................................................................... 4
1.1 ILLUSTRATIONS ........................................................................................................................... 4
1.2 SAFETY ...................................................................................................................................... 4
1.3 NAME PLATE ............................................................................................................................... 4
2 BASIC INFORMATION .................................................................................................................. 5
2.1 OPERATING INSTRUCTIONS .......................................................................................................... 5
2.2 IDENTIFICATION OF SAFETY NOTICES ............................................................................................ 5
2.3 STICKERS AND EXPLANATION OF SYMBOLS ................................................................................... 6
2.4 W ARRANTY AND LIABILITY ............................................................................................................ 6
3 SAFETY ......................................................................................................................................... 7
3.1 SAFETY AND ORGANISATIONAL PRECAUTIONS ............................................................................... 7
3.2 OBLIGATIONS OF THE OPERATOR / QUALIFICATION OF THE STAFF ................................................... 7
3.3 HAZARDS WORKING WITH THE MACHINE........................................................................................ 7
3.4 PERSONAL PROTECTIVE EQUIPMENT AND ORGANISATIONAL MEASURES .......................................... 7
3.5 INFORMATION ABOUT GENERAL HAZARDS ..................................................................................... 8
3.5.1 HAZARDS FROM ELECTRICAL ENERGY ................................................................................... 8
3.5.2 BEHAVIOUR IN CASE OF AN EMERGENCY................................................................................ 8
3.5.3 FIRE.................................................................................................................................... 8
3.5.4 OIL, FAT AND OTHER CHEMICALS........................................................................................... 8
3.5.5 NOISE EMISSION .................................................................................................................. 8
4 TRANSPORT STORAGE AND PUTTING OUT OF SERVICE ..................................................... 9
4.1 TRANSPORT................................................................................................................................ 9
4.2 LIFTING INSTRUCTIONS ................................................................................................................ 9
4.3 STORAGE ON SITE IN PROPERY SPACES...................................................................................... 10
4.4 PUTTING OUT OF SERVICE AND DISPOSAL ................................................................................... 10
4.5 PUTTING OUT OF SERVICE, STORAGE AND RECOMMISSIONING...................................................... 10
4.6 PUTTING OUT OF SERVICE AND DISPOSAL ................................................................................... 10
5 SAFETY INSTRUCTION WHEN WORKING WITH THE MACHINE .......................................... 11
5.1 CHECKING THE SAFETY DEVICES ................................................................................................ 11
5.2 EXCHANGE OF MACHINE PARTS .................................................................................................. 11
6 MACHINE DESCRIPTION ........................................................................................................... 12
6.1 TASK OF THE MACHINE .............................................................................................................. 12
6.2 INTENDED USE OF THE MACHINE................................................................................................. 12
6.3 FUNCTIONAL DESCRIPTION ........................................................................................................ 12
6.3.1 CONTROL SYSTEM - OPERATION MODES ............................................................................. 13
7 INSTALLATION ........................................................................................................................... 14
7.1 DELIVERY ................................................................................................................................. 14
7.2 TRANPORT DAMAGE .................................................................................................................. 14
7.3 SITE OF INSTALLATION ............................................................................................................... 14
7.4 CONNCTION TO THE LIFT PUMP................................................................................................... 15
7.5 ELECTRICAL CONNECTION ......................................................................................................... 15
8 OPERATION OF THE PAPER BELT FILTER DPF .................................................................... 16
8.1 INSTRUCTIONS FOR COMMISSIONING .......................................................................................... 16
8.2 SAFE USE ................................................................................................................................. 16
8.3 SWITCH ON AND OFF ................................................................................................................. 16
8.4 CHANGING THE FILTER PAPER ROL ............................................................................................. 17
9 MAINTENANCE AND REPAIR ................................................................................................... 21
9.1 MAINTENANCE PLAN .................................................................................................................. 21
9.2 CONDITION OF FILTER PAPER ..................................................................................................... 21
9.3 LEVEL SWITCH .......................................................................................................................... 22
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1 GENERAL
Before putting the machine into operation, read and observe the operating instructions and safety
instructions.
Commissioning of this machine is prohibited until it has been determined that the installation of the
machine is in compliance with the provisions of the Machinery Directive, the harmonized standards,
European standards or the corresponding national standards.
1.1 ILLUSTRATIONS
The illustrations in this manual may represent similar machines and may differ from the delivered
version. All instructions apply to all machines covered in this manual.
1.2 SAFETY
The following pages describe the safety instructions and safety requirements.
It is essential that you read the instructions and also the safety
NOTICE instructions that follow in further chapters before commissioning the
machine. The responsible specialist must know these instructions.
2 BASIC INFORMATION
In addition, local rules and regulations for accident prevention, inspection and maintenance work must
be observed.
NOTICE
The operating instructions are to inform you and to avoid dangers during operation. The operating
instructions provide information and instructions for maintenance, repair and assembly of the
machine.
DANGER
This is a hazardous situation which, if not avoided, will result in death or serious injuries.
WARNING
This is a hazardous situation which, if not avoided, could result in death or serious injuries.
ATTENTION
This is a hazardous situation which, if not avoided, could result in minor or moderate injuries
NOTICE
This is a situation which, if not avoided, could result in material and/or environmental damage.
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Warning of dangerous electrical voltage means "stop" for hazardous areas containing
live parts.
In this area there is an increased risk of being hurt by suspended loads. Only stay for a
short time in this area.
3 SAFETY
The target group of this machine and the operating instructions is the commercial use. The operator
needs to have specialized knowledge with regards to cooling lubricant systems.
The operator is obliged to let qualified personnel only work on the machine.
Qualified personnel are persons who - on the basis of their training, experience, instruction and
knowledge of relevant standards and regulations, accident prevention regulations and operating
conditions - have been authorized by the operator to carry out the required activities.
The personnel have the appropriate training and expertise in the field of mechanical and / or plant
engineering as well as in the fields of electric and pneumatic / hydraulic machinery and
• have been instructed in the operation of the machine
• have read and understood the operating instructions
3.5.3 FIRE
• Read and follow the instructions for fire detection and escape routes posted at the facility or
workplace
• The use of unsuitable extinguishing agents for firefighting
o can produce toxic gases (vapours);
o should be determined based on the electrical system and the risks;
o may present a danger to life due to the risk of electric shock.
Consequently:
o Never use water for firefighting!
o Only use class ABC fire extinguishers
o Only use fire extinguishers with CO2 filling for electric fires!
4.1 TRANSPORT
CAUTION
Risk of injury from heavy load falling down.
Do not stay beneath floating load.
• Prior to transport, all used and generated energy (such as electricity, compressed air, etc.)
must be removed.
• Only use suitable, standardized and tested lifting gear (forklift truck, mobile crane, bridge
crane) and lifting accessory (round slings, lifting slings, slinging ropes, chains) for transport.
• When transporting the machine, pay attention to the weight, a stable centre of gravity and
sufficient manoeuvring distance.
• Transporting the machine by forklift, hoist, etc. is only allowed at the intended lifting points.
For crane transport, a chain or wire rope slings with four hooks must be used.
• Always make sure that the machine is transported without impact and shock.
• Always secure loads to be transported against falling or tipping over!
During Storage protect the machine from aggressive, humid environment or outdoors.
For installation, observe the installation instructions in chapter ‘Installation site‘.
CAUTION
When putting out of service and (partially) dismantling the machine, please note that:
• Assembly / disassembly work may only be carried out by trained and instructed personnel
with specialist knowledge. (see chapter obligations of the operator / qualification of the staff)
• For reasons of safety, do not disconnect any lines, connections and components while the
system is under pressure. The machine must be switched off and secured against being
switched on again. (see chapter Residual risks of the machine and safety).
Risk of injury from reaching into the discharge Don’t reach into the discharge opening
opening when dirt bin has been removed. while the machine is in operation.
Components may only be disassembled for repair to the extent described in the component-specific
operating instructions.
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6 MACHINE DESCRIPTION
The machine is only designed to operate with cooling lubricants (emulsion as well as neat oil).
When using neat oil the filtration capacity will be reduced.
The paper belt filter DPF can filter dirt as described below:
• Broken metal swarf (of limited suitability for aluminium swarf)
• Metal sludge from grinding application
Floating dirt, as aluminium swarf or plastic material can only be filtered in limits.
The machine may only be used under the intended operating conditions. These include the following:
• Ambient temperature Min./Max. +10°C to +35°C
• Max. humidity (not-condensing) 85%
The machine may only be used to the extent described in chapter “Task of the machine”. Any other or
further use does not correspond to the intended use.
Intended use also includes:
• observing all instructions in the manual and the accompanying documents
• complying to inspection and maintenance work
Mayfran is not liable for damage resulting from improper use of the machine.
Swarf accumulates on the filter paper. Periodically the coolant level rises and is detected by the level
sensor. The filter paper is moved towards the dirt bin.
The paper belt filter DPF moves the filter paper automatically. A paper reserve and an out-of-paper
switch detect when the filter paper gets empty.
In case of overflow the level switch acts as an emergency prompt.
The gear motor and sensors need to be electrically connected and protected in the electrical cabinet
on site. The paper belt filter DPF needs to be controlled from the electrical cabinet on site.
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Alarm messages
Non critical alarms – action required at next available opportunity e.g. before machining next
component
7 INSTALLATION
7.1 DELIVERY
NOTICE
The delivered goods must be examined immediately upon receipt for any damage or defects.
The customer has to report any damage or defects within 5 days in writing.
NOTICE
If transport damage is discovered during machine inspection, the following procedure must be
followed:
• Notify deliverer
• Record damage report (include pictures, if possible)
• Inform manufacturer
NOTICE
Ensure the installation site is stable and safe for access, operation and maintenance, as well as the
arrangement and installation of components and systems.
Only put the system in service after all electrical connections have been installed and all components
are ready for use.
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NOTICE
The inlet pressure may not exceed 1.5 bar.
NOTICE
Only qualified personnel with electrical expertise may make the electrical connections.
The electrical connection of the machine must be in accordance with the attached wiring diagram or
terminal diagram. The connection is made in the terminal box of the machining center.
WARNING
It is essential to read and understand chapter Safety before using the machine for the first time.
If you have problems commissioning the machine, please contact Mayfran customer service.
WARNING
• Never reach into the discharge chute of the paper belt filter DPF, as long as the machine is
live. The filter paper is moved also during rest period.
• Make sure that the power supply to the machine / system is interrupted (main switch off and
secure) before maintenance, adjustment, lubrication, cleaning and repairs
• Do not remove covers or safety guards without first disconnecting the power supply!
• If defects occur during operation, switch off the machine immediately and eliminate them.
• After repairs, checks or servicing the machine first reinstall all mechanical and electrical parts
that have been removed. Then carry out a visual inspection of the machine and its
surroundings, to make sure no disturbance is to be expected during further operation.
The machine needs to be switched on and off via the machining center / the electrical control cabinet.
SEITE 17
CAUTION
Risk of injury from being crushed
Before changing the filter paper roll switch off the machine and protect
the switch from being switched on unintentionally.
WARNING
Fire hazard
The filter paper is made from synthetic resin and is easily burnable.
Keep naked flames away from the machine.
m
10 c
WARNING
It is essential to read and understand chapter Safety before every maintenance or repair.
If you have problems with maintenance and repair of your machine, please contact customer service
(see chapter Address)
CAUTION
Risk of injury from swarf and coolant
During maintenance and repair always wear safety gloves.
Activity Maintenance/inspection
intervals
Empty dirt bin If necessary
The gear units are intended for mounting in dry spaces. They are suited for all mounting positions.
The gears are of shaft-mounted design and provided with a hollow shaft. A torque arm serves to secure
the unit. It is designed with a special fixing structure provided with disk springs.
Electrical connection:
Check before starting:
1. The required power supply
2. If the required power supply is the same as the supplied power supply
The motors are suitable for 200V (3pH) or 400V (3pH) at 50 or 60 Hz.
The gears are filled before delivery with a sufficient amount of lubricant and sealed so as to be oil-tight.
For refilling the gears please refer to the lubrication chart below.
To prevent fretting corrosion between motor bearing and the bore of the worm wheel, the motor bearing
must be coated with a suitable lubricant when the unit is installed.
Mayfran recommends the use of Klüber Microlube GL 261.
The gearbox is to be regularly checked to detect leakage, contamination and suspicious noise in due
time.
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10 TROUBLE SHOOTING
Standard Filter
DPF-300D DPF-400D DPF-500D DPF-700D
paper*
Quality 150 g/m2 150 g/m2 150 g/m2 150 g/m2
Width 500 mm 500 mm 700 mm 1000 mm
Roll diameter (length) Max. 250 mm Max. 220 mm Max. 250 mm Max. 250 mm
(ca. 50 m) (ca. 50 m) (ca. 50 m) (ca. 50 m)
*The table shows the standard filter paper. The filter paper used in your application can differ from the
standard filter paper. Consult the valid part list of your filter.
NOTICE
Use genuine Mayfran filter media to ensure proper functioning of the machine. Other filter media can
lead to malfunctioning or f the machine.
When other filter media is required please consult Mayfran.
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12 SPARE PARTS
12.1 DPF300
*Standard filter paper. The filter paper used in your application can differ from the standard filter paper.
Consult the valid part list of your filter.
C Consumable
S Spare part
W Wear part
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12.2 DPF400
*The standard filter paper. The filter paper used in your application can differ from the standard filter
paper. Consult the valid part list of your filter.
C Consumable
S Spare part
W Wear part
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12.3 DPF500
*Standard filter paper. The filter paper used in your application can differ from the standard filter paper.
Consult the valid part list of your filter.
C Consumable
S Spare part
W Wear part
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12.4 DPF700
*Standard filter paper. The filter paper used in your application can differ from the standard filter paper.
Consult the valid part list of your filter.
C Consumable
S Spare part
W Wear part
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13 CONTACT
http://www.mayfran.com
info@mayfran.eu sales@mayfran.eu
www.mayfran.nl www.mayfran.de
sales@mayfran.eu sales@mayfran.eu
www.mayfran.co.uk www.mayfran.fr
+1 440 461-4100
+1 440 461-0147 (fax)
info@mayfran.com
www.mayfran.com