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PulseJet - Installation - AD0454

Service Home How To Procedures PulseJet - Installation - AD0454

PulseJet - Installation - AD0454

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Recently Updated Last updated: 02/09/2021

PulseJet - Installation


AD0454

Introduction

This procedure will show you how to install a PulseJet on VMC/UMC mills.

Machine Requirements:

  • VMC/UMC built on October 2019 or later.
  • 100.19.000.1123 Software Version or higher.
  • Programmable Coolant option

Video Instructions

Hoses and Sensor Cable Installation

Note:  This section is required for field installations, go to the next section if the Pulsejet option was purchased from the factory.

1

The illustration shows the PulseJet hose routing on a VF-2: 1: Top View 2: Side View.

Route the nozzle air hose (1/4 inch black hose) from the CALM cabinet, through spindle head,  towards the PulseJet/PCool location.

Route the nozzle oil hose (5/32 inch clear hose): from the Oil reservoir, up onto the roof, into cable carrier, through spindle head, towards the PulseJet/Pcool location.

Route the Oil Reservoir air hose (1/4 inch clear hose) from CALM cabinet solenoid towards the Oil Reservoir location.

Note:  Make sure you leave enough slack at both ends.

2

Route the Oil Reservoir level sensor cable from the Oil Reservoir location, to the top of the roof to the electrical cabinet.

Note: Make sure you leave enough slack to connect the cable to the Oil Reservoir sensor.

Plug in the cable to the I/O PCB at P71.

PulseJet & Tank Installation

1

Turn off air to the machine.

Locate the air manifold [1], remove the third NPT plug below the air gauge.

Install the adapter fitting P/N 58-1521 [2] into the manifold.

Install the solenoid valve [3] oriented as shown.

Connect the solenoid cable to the connector panel labeled "PULSEJET".

2

Unpack the PulseJet nozzle assembly.

Loosen the clamp screw [1] and slide the clamp and the PulseJet assembly onto the P-COOL nozzle.

Adjust the PulseJet nozzle so that the oil inlet fitting [2] is on the bottom. 

Aim the nozzle approximately at the spindle centerline (it will be adjusted later).

Tighten the clamp set screw.

Find the 1/4” black air hose [3] and connect it to the air fitting on the nozzle assembly.
Find the 5/32” clear oil hose [4] but DO NOT connect it to the oil fitting.  This hose will be connected during the prime procedure.

3

Mount the Oil Reservoir to the machine enclosure, refer to the illustration.

The oil resevoir assembly has magnets for easy mounting. 

Important: Do not slide the magnets on the enclosure. Instead, if you need to move the reservoir, tilt it to detach the magnets and then gently set it back down.

4

Connect the cable and air hoses to the Oil Reservoir assembly refer to the diagram.

Connect the air hoses to the solenoid. 

  Important: Make sure to connect the correct hoses to the solenoid, matching the color zip ties. If the hoses are swapped, it will send high pressure to the tank and could rupture the tank.

5

Slide the strain relief [1] into the slot on the reservoir assembly and tighten the retaining nut.

Apply the supplied spiral wrap [2] from the enclosure to the top of the machine to help neatly organize and secure the cables.

Make sure the drain valve on the bottom of the reservoir is in the closed (horizontal) position [4].

Remove the reservoir cap and fill the tank with oil [3].  Do not overfill the tank.
Note: The tank requires air space above the oil to maintain positive pressure above the oil.

Reinstall cap.

Prime the Oil Line

Make sure there is oil in the PulseJet reservoir and that the lid is tightly installed. Make sure the reservoir air and oil lines are connected. 

Disconnect the oil line [1] from the PulseJet nozzle and let it drape over a container placed on the mill table.

Press [DIAGNOSTIC] and navigate to the Maintanance then to the PulseJet tab [2]. 

Press [F4] to begin a priming cycle. Each cycle lasts 10 minutes.  The reservoir will be pressurized during the cycle. 

Note: Small machines may take only 1 cycle to fully prime the line. Larger machines may take 3 or 4 cycles. Heavier oils may take longer to prime. Continue running priming cycles until oil [4] begins to drip out of the oil line into the container. 

Note: While the machine is in the prime cycle the user can start a program.   However the user will not be able to start the prime cycle again while the program is running.

Reconnect the oil line to the PulseJet nozzle.

In MDI run:

M162 P10;
G04 P10.;
M30;

Test the PulseJet until a strong stream develops. 

PulseJet M-codes

M-CODE

DESCRIPTION

WHAT IT’S USED FOR

M160

Cancel Active PulseJet

To cancel an active PulseJet M-code.

M161 Pnn

Continuous Mode

Will turn PulseJet on whenever a feed move is active in a program. Pnn is how many seconds between oil pulses. Min = 1 sec Max = 99 sec

M162 Pnn

Single Event Mode

Will turn on PulseJet for a defined number of pulses. Pnn is how many pulses. Best used for drilling and tapping or to manually lubricate a tool.
Note:  M162 Pnn Is a non-blocking code.  Anything after the code will be executed immediately.

M163 Pnn

Modal Mode

Activates PulseJet to turn on during any canned drill or tap cycles. Pnn is how many pulses for each hole.

Note: Any PulseJet M-code will override any active previous PulseJet M-code.  
Note: Settings 369 and 370 can be used to change the default values for M161 and M162 when no P is specified.

Tips and Troubleshooting

1.       PulseJet will produce a consistent, fast, and tight oil pulse if the line is well primed, the dispenser needle is not clogged, and a recommended oil is being used.

2.       To always keep the line well primed:

  • Place the reservoir assembly near or above the spindle elevation
  • never let the tank run completely dry

3.       If you suspect that the dispenser needle is clogged, replace it. To do this, unscrew the knurled nozzle cap from the nozzle and gently twist and pull the yellow base of the needle off of the nozzle.

Note: This will expose the small check valve spring, do not lose it. Firmly press the replacement needle onto the nozzle taper. Re-install the nozzle cap finger tight.

4.       Use recommended oil: light viscosity oils and tapping or cutting fluids work the best. Heavy viscosity oils such as motor oil, gear oil, or heavy tapping oils may not produce a high-quality stream.

5.       If the oil line does get air bubbles inside, the pump inside the PulseJet nozzle will pass them through the system. While bubbles are moving through the nozzle, the stream will appear weak, aerated, and inconsistent. After the bubbles pass through, the stream will return to its proper form.

6.       Always make sure the reservoir cap is installed and tightened when running PulseJet to maintain the proper tank pressure.

PulseJet Lubrication

Refer to Lubricant Grease, and Sealant Table to see our recommended oil list.

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