Service Home How To Procedures HPC-1000/TSC-1000 - Operator's Manual Supplement - AD0086
Last updated: 10/06/2020

HPC-1000/TSC-1000 - Operator's Manual Supplement

AD0086

Introduction

This document tells you how to operate the HPC-1000 and TSC-1000. The HPC-1000 is a high-pressure coolant system for lathes. The TSC-1000 is a through-spindle coolant system for mills. This system can pump coolant at 1000 psi (68.9 bar). The maximum flow rate is 7.00 gpm (26.5 lpm). The flow rate is different for different tools.

Power Requirements

For correct operation and maximum coolant pressure, supply the correct power.

  1. 230-240 V 50/60 Hz (3-phase), 20 A
  2. 480 V 50/60 Hz (3-phase), 10 A

Note: The pump assembly is wired with a NEMA L15-20 male connector. If this connector does not match the power source, you must replace the connector. If you replace the connector, use the diagrams that follow to rewire the pump motor. 480 V requires rewiring.

1

Low Voltage (230-240 V) Wiring Diagram

  • A - Circuit Breaker
  • B - Contactor
  • C - Pump Motor
  • Pump Motor Leads: [1] Blue, [2] White, [3] Orange, [4] Yellow, [5] Black, [6] Purple, [7] Pink, [8] Red, [9] Gray

2

High Voltage (480 V) Wiring Diagram

  • A - Circuit Breaker
  • B - Contactor
  • C - Pump Motor
  • Pump Motor Leads: [1] Blue, [2] White, [3] Orange, [4] Yellow, [5] Black, [6] Purple, [7] Pink, [8] Red, [9] Gray

Note: Make sure the pump is producing correct output pressure and is wired correctly. Reverse the pump motor rotation by interchanging any (2) line conductors (L1), (L2), and (L3).

Main Features

  • Hydra-Cell D-12 diaphragm pump.
  • 5 hp 3-phase induction motor.
  • The pump produces a maximum of 7.00 gpm (26.5 lpm) at 60 Hz, and more than 1000 psi (68.9 bar) with a tool opening diameter of 0.051 in (1.3 mm).
  • There are (3) internal diaphragm pump chambers that deliver a pulsating high-pressure output.
  • A swash plate rotates to operate the diaphragms.
  • Oil sump lubrication - the pump can operate safely if the coolant tank runs dry.
  • The pump can rotate either direction - no need to observe the rotation of the motor.

Main Components

1

Main Componets

  • A - Coolant Manifold Assembly
  • B - Oil Reservoir
  • C - Auxiliary Filter
  • D - Pump Motor

2

Coolant Manifold Assembly

  1. Coolant Supply In
  2. To Auxiliary Filter and Pump
  3. From Auxiliary Filter and Pump (high pressure)
  4. Air Bleed Valve Assembly
  5. Purge Loop
  6. Prime Line (optional)
  7. High-Pressure Relief Valve (inside the manifold)
  8. Bypass Line to Tank
  9. High-Pressure Coolant Outlet to Spindle/Turret

Programming

1

Use M-codes to operate the HPC-1000 /TSC-1000 system.

M88: Turns On HPC-1000/TSC-1000.

M89: Turns Off HPC-1000/TSC-1000.

Manual Activation:

Mills:

Press [AUX CLNT].

Lathes:

Press [SHIFT] and then Press [COOLANT].

Press [COOLANT] again to turn off HPC-1000 and turn on the standard coolant pump.

Press [COOLANT] a third time to turn off both HPC-1000 and the standard coolant pump.

Start-Up Modes and Operation Modes

1

There are (2) start-up modes:

  1. Dry Start
  2. Wet Start

There are (2) operation modes:

  1. HPC-1000/TSC-1000 with a small through-hole tool
  2. HPC-1000/TSC-1000 with a large through-hole tool

2

Dry Start

A dry start is when you turn on the pump for the first time after you do maintenance, or when the pump or supply hoses are full of air.

  • There is no tool or toolholder in the spindle.
  • The hoses are connected correctly to the machine and the coolant tank.
  • The auxiliary coolant filter tank is full.

3

In MDI mode, command the HPC-1000/TSC-1000 to run with an M88 command; or press AUX CLNT.

The process to automatically prime the pump begins:

  • The air bleed valve assembly [4] is normally open, and a mixture of coolant and any trapped air in the supply hoses evacuates through the purge loop [5], and out the bypass line [8] to the coolant tank.

    Note: The air bleed valve assembly [4] remains open for less than 2 minutes, and closes when coolant pressure builds.

  • The pump may run roughly during this time (usually less than 1 minute) until all three chambers in the pump are primed.
  • When all of the trapped air is purged from the system, the air bleed valve assembly [4] closes.
  • You hear a "click" or "clicks" when the air bleed valve assembly [4] closes. This is the sound the ball makes when it seats in the valve.
  • The pump now runs smoothly, and a steady stream of coolant comes out of the spindle or turret tool block nozzle.
  • Look through the lid of the auxiliary coolant filter tank to see the coolant enter the tank.

Note: During normal operation, the level of coolant in the tank should remain near the top.

 Note: HPC-1000/TSC-1000 does not deliver coolant through the spindle until the system purges all of the air through the air bleed valve assembly [4].

If the pump runs roughly for more than 1 minute, cycle the power to the pump to clear the pump's empty chamber(s) of air, and the pump should begin to run smoothly.

4

Wet Start

A wet start is when the pump is turned on after the dry-start automatic priming process is complete.

  • The auxiliary coolant filter tank is full of coolant and the pump is primed.

In MDI mode, command HPC-1000/TSC-1000 to run with an M88 command; or press the [AUX CLNT].

  • The air bleed valve assembly [4] opens and a small amount of coolant evacuates through the purge loop [5] and out the bypass line [8] to the coolant tank.

    Note: The air bleed valve assembly [4] opens for only 1-2 seconds.

  • You hear a "click" or "clicks" when the air bleed valve assembly [4] closes. This is the sound the ball makes when it seats in the valve.
  • The pump now runs smoothly. Coolant now goes through the high-pressure coolant outlet [9], and a steady stream of coolant comes out of the spindle or turret tool block nozzle.

HPC-1000/TSC-1000 with a Small Through-hole Tool

1

A small HPC-1000/TSC-1000 tool has a through-hole less than 0.12" (3.0 mm).

These conditions are normal with a small through-hole tool in the spindle or turret:

  • System pressure is high.
  • The high-pressure relief valve in the manifold [7] may open to return extra coolant to the tank through the bypass line [8].
  • A large volume of coolant may return to the coolant tank through the bypass line [8].
  • The pump runs smoothly, but sounds louder than when there is a large through-hole tool in the spindle or turret.

HPC-1000/TSC-1000 with a Large Through-hole Tool

1

A large HPC-1000/TSC-1000 tool has a through-hole diameter greater than 0.12" (3.0 mm).

These conditions are normal with a large through-hole tool or no tool in the spindle or turret:

  • The system pressure can be much less than 1000 psi (68.9 bar).

    Note: In order to develop 1000 psi (68.9 bar), a tool with a through-hole diameter of 0.060" (1.5 mm) or smaller is required. Larger through-hole tools develop less system back pressure at the maximum pump flow of 7.00 gpm (26.5 lpm) at 60 Hz.

  • The high-pressure relief valve in the manifold [7] is closed or nearly closed.
  • A small volume of coolant returns back to the coolant tank through the bypass line [8].
  • The pump runs smoothly and steadily, with no cavitation or irregular vibration.
  • The pump runs quieter than with a small through-hole tool in the spindle.

Coolant Flow and HPC-1000/TSC-1000 Pressure Effect

1

Coolant Flow

The HPC-1000/TSC-1000 gives maximum pressure through an opening area of 0.002 in2 (1.3 mm2). Tools/coolant blocks with a larger through-hole give less pressure. The following charts illustrate the reduced pressure as tools with larger through-holes are used.

The maximum volume coolant flow through the tool or tool holder nozzle is approximately 7.00 gpm (26.5 lpm). This coolant flow may look weak or slow when you compare it with the "smaller" lower pressure but higher flow standard coolant pump.

2

HPC-1000/TSC-1000 - Size of the Through-hole and Pressure Comparison

The pressure and flow values in the charts are from test instruments. The charts show the through-hole diameters in inches. Actual HPC-1000/TSC-1000 system performance is different for different machine models. The chart starts with a tool with no through-holes [1]. Your tool may have more than one through-hole. Find the flow and pressure for a tool as follows:

  1. Calculate the total area of the tool through-holes.
  2. Find the area on the chart [2].

3

Older machines have a low-pressure switch that causes an alarm when the pressure goes below 4.0 psi (0.28 bar). The low-pressure switch protects:

  • the coolant union when the quantity of coolant is not sufficient
  • the motor from a stall condition

Newer machines have a low-pressure sensor with a pressure value set by machine type.

4

HPC-1000/TSC-1000 Pressure Effects

When you use the HPC-1000/TSC-1000 during cutting operations, the size of the tool through-hole/holes changes the coolant flow.

Correct HPC-1000/TSC-1000 operation supplies different flows and pressures at the through-hole in the tool. The diameter and the number of tool through-holes changes the coolant flow and the coolant pressure.

5

With large through-hole tools, a softer coolant stream is normal. Large tools have larger-diameter coolant through-holes. Coolant flow is high and pressures are lower.

6

Smaller tools have smaller-diameter coolant through-holes. Coolant flow is low and the pressures are high.

Alarms

1

The control monitors coolant pressure. If the control senses low coolant pressure, the contol stops the HPC-1000/TSC-1000 and shows Alarm 151, "LOW THRU SPINDLE COOLANT" for mills and "HPC LOW PRESSURE" for lathes.

If a low-pressure alarm occurs, look for leaks in the system. Make sure the coolant tank is correctly filled.