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What
is a Sumpcleaner?
A Sumpcleaner is a specialized tool for cleaning
the coolant sumps of machine tools. The sump contents usually consist
of coolant and solids. The solids consist of metal chips and swarf.
In just a few minutes, a Sumpcleaner will pick up everything in
the sump - fluid, as well as solids. The filter separates the solids
from the fluid. Filtered coolant is returned to the machine tool
sump or transported for additional processing.
Why
is good sump cleaning important? Clean
coolant lasts longer.
Buy less coolant.
Increasing costs for the purchase, use and
disposal of coolant have made extending the life of coolant very
important to metalworking shops. An important part of cleaning coolant
is filtration or solids separation. Filtration involves passing
coolant through a porous material that will remove the chips, swarf
and fines.
Metal
chips in the coolant can mar the workpiece.
One of the functions of coolant is to wash
the metal chips away from the machine tool and cutting area. The
chips and fines follow the coolant to the sump where most settle.
Those remaining are recirculated through the machine and can damage
the workpiece by marring the finish.
Chips
and fines in sumps cause microbial growth leading to stinky coolant
and dermatitis.
Most chips and fines settle to the bottom
of the sump forming a sludge. This sludge promotes bacterial and
fungal growth. Biocides added to the coolant to control the growth
of bacteria do not reach the coolant that is mixed with the sludge
at the bottom of the sump.
Failure
to remove the chips and fines can reduce the sump volume.
Some of the water in water-based coolant is
lost by evaporation. Coolant is also lost when it is carried out
on parts. Chips and fines settle in the sump, making the sump continue
to appear full, even though the volume of coolant moving through
the machine has been reduced.
Excessive
solids can cause increased fluid temperature.
Less coolant moving through the machine, means
less time spent cooling in the sump. Fluid is pumped back through
the machine quicker resulting in higher coolant temperatures. Also,
solids have different heat transfer properties than coolant.
Excessive
solids may deplete coolant ingredients - coolant is not as effective.
Among the ingredients added to coolant are
rust inhibitors, fungicides and biocides, wetting agents, emulsifiers
and coalescents. Solids may absorb desirable ingredients and lessen
their effectiveness. Many of these problems can be eliminated or
greatly reduced by cleaning the sump regularly. CECOR Sumpcleaners
deliver high suction lift to remove all solids in the coolant sump
along with the metalworking fluid. The filter separates solids from
the coolant for re-use right at the machine tool. Filtered coolant
is pumped back into the sump in minutes.
Save
labor costs and reduce downtime.
A pail and shovel or the machine’s internal
coolant pump may seem like the cheapest way to clean a sump, but
when you consider the hours or perhaps, even days needed for an
employee to do a thorough job, the costs mount quickly.
By
using a CECOR Sumpcleaner you can save money two ways. Save labor
costs. How much are you paying that employee per hour? High suction
lift from a CECOR Sumpcleaner sucks the sludge and the muck out
fast...much faster than a shovel. Also machine downtime is less.
How much production time and money do you lose when the machine
tool sits idle? A CECOR Sumpcleaner will reduce machine downtime
to a minimum.
Improve
Employee Morale
It sure beats a pail and shovel. When sump
cleaning is easier and faster, it will get done more often. With
regular cleaning the build-up of impacted swarf and layers of scum
in the sump will not occur and the job will be more pleasant and
faster. Regular sump cleaning will reduce the odor and mess in and
around machine tools and reduce the risk of dermatitis, making for
an overall cleaner and more productive work setting.
How
does a Sumpcleaner work?
Vacuum Lift…..How a sumpcleaner works.
Long
before a child can pronounce "atmospheric vacuum" he has
learned a great deal about how it works though experience with soda
straws. He discovers very quickly, for example, that small straws
are fine for soft drinks, but that larger straws are better for
thick milk shakes. He knows that when his mouth is full, the flow
cuts off automatically. He learns that thick fluids call for harder
sucking, and that he must keep the bottom of the straw unobstructed
by solid matter, and that if he is to avoid the snorkling noise,
he must keep the bottom of the straw submerged.
Nature
abhors a vacuum. Chances are he couldn't
care less that this principle of vacuum lift is used in removing
oil and suspended sludge in machine tool sump tanks. What appears
to be a fluid-sucking action sets up atmospheric differentials which
cause room air to force fluids through a tube to an area where less
pressure exists.
The
speed with which a fluid will travel from the high to the low side
of the pressure zone is determined by
The diameter of the suction tube.
The
viscosity of the fluid.
The
distance from intake to exit ports.
The
ability of the suction system to maintain vacuum at a constant
level.
This
means for optimum performance, heavier sludges require deeper vacuum,
larger diameter suction hoses, and short- coupled hose length to
reduce frictional drag as the sludge moves from the machine sump
to a storage tank.
Intake
and Filtering of Dirty Coolant Figure
1 shows how a sumpcleaner works on the suction cycle
for removing liquids and solids from the sump. The pump at point
A generates a deep vacuum in the tank. The tank is opened to atmosphere
through the suction hose at point D drawing the liquids and solids
from the sump directly into the tank. The coolant never contacts
the pump.
A
Vacuum/Pressure Pump Unit
B Float Control
(Prevents Overfill & Protects Pump Unit against
Liquid Entry)
C Filter
D Suction Intake
E Pressure Discharge
Pressure
Discharge of Filtered Dirty Coolant Figure
2 shows how a sumpcleaner can also generate a pressure
in the tank using the same pump configuration. Although the pressures
are less than 10 p.s.i., it is sufficient for quick and easy emptying
of the tank through the discharge port at point E.
A Vacuum/Pressure Pump Unit
B Float Control
(Prevents Overfill & Protects Pump Unit against
Liquid Entry)
C Filter
D Suction Intake
E Pressure Discharge
What
about a wet/dry vac?
The vacuum lift in a Sumpcleaner is superior
to wet/dry vacuums. In fact, the vacuum is measured differently.
With wet/dry vacs, the vacuum lift is measured in inches of water,
sumpcleaners in inches of mercury. A good wet/dry vac can generate
90 inches of water or 6.6 inches of mercury (Hg). A good Sumpcleaner
will generate between 160” and 360” of water (12”
to 26” (Hg) mercury) which is at least twice that of a wet/dry
vac. With the increased suction lift, a sumpcleaner will be able
to lift and remove even the heaviest of sludge in the bottom of
the sump.
Wet/dry vacuums need air to cool the motor. Without air moving through
the hose, the motor will overheat and burn out. A Sumpcleaner is
designed to work with the hose totally submerged in the fluid. Sumpcleaners
are designed and built for cleaning machine tool sumps. Use the
right equipment for the job.
Sumpcleaner vs. Wet/Dry Vac
Sump
Cleaner
Wet/Dry
Vacuum
Attributes
Deep suction
lift with low nozzle air flow.
Low suction
lift with high nozzle air flow.
Use
Used for
picking up pools of liquid, submerged sludge and viscous liquids
in concentrated areas.
Used for
picking up dry substances and puddles or shallow spills of liquid.
Total submersion in liquid will cause motor to burn out.
Ratings
Suction
lift measured in inches of mercury (Hg) and pump rate measured
in GPM (gallons per minute).
Suction
lift in inches of water and air movement measured in CFM (cubic
feet per minute).
What
about those continuous loop systems where you never have to shut
down the machine tool?
Instead of changing the oil and oil filter
in your car, would you just change the filter? No. Using continuous
loop systems is like only changing your oil filter. These expensive
units may slightly improve coolant life but do not solve the complete
problem. The sludge and solids in the bottom of the sump are not
removed. These systems clean the surface area of the sumps, but
do not address the sludge and solids that lie at the bottom. Coolant
recycling takes commitment. It does not have to be expensive, but
it is not always easy. First you start with quality coolant, monitor
the coolant mix, completely clean the sump on a regular basis and
remove the tramp oil.
Why
a CECOR Sumpcleaner?
CECOR has designed and manufactured its own
Coolant Sumpcleaner line since 1955 (the longest in the industry).
Coolant maintenance equipment is our main focus. Our experience
has enabled us to design the most efficient sumpcleaners for cleaning
machine tool sumps. We use only high quality components, such as
long wearing, chemically resistant industrial pumps, hoses, valves
and wheels. CECOR offers the broadest line of Sumpcleaners to fit
a wide range of applications.
Here are a few features that make CECOR Sumpcleaners unique:
CECOR
Sumpcleaners have vacuum/pressure gauges to prevent over pressurization.
Units
have multiple backup pressure relief systems. Air units include
a rupture disk as an additional safety feature.
All
discharge ports have a valve to prevent accidental spills and
to control the discharge of coolant from the Sumpcleaner.
CECOR
Sumpcleaners feature a flush to the tank bottom clean out door
to make clean up easier.
CECOR's
patented filter system features a reverse taper design to prevent
bridging. The filter is narrower at the top and wider at the bottom.
This prevents solids from becoming trapped in the filter. The
filter empties completely.
CECOR's
unique filter pack design features a continuous reusable filter
membrane unbroken by slits or openings. Some competitive sumpcleaners
have slits in their filter membranes to accommodate lifting eyes
located inside the basket and may also have an open bottom. If
the coolant can bypass the filter through even the smallest opening,
it is not being filtered.
CECOR
uses a mechanical (non-electric) overflow control valve to protect
against spills and air pump damage. We do not use electrical overflow
controls in order to prevent electrical components from coming
in contact with fluid and to insure dependable operation in all
coolant/oil environments.
CECOR
has qualified support people to help you, and stocks a full line
of repair parts for immediate shipping.
CECOR
is able to provide high quality Sumpcleaners at competitive prices
because our focus is designing and building Sumpcleaners. This focus
allows us to buy and build with maximum efficiency.
Which
sumpcleaner is best for my application? 1. Style of Machine.
CECOR Sumpcleaners are available in two basic
styles, single and combination tank. The single tank is designed
for collection, filtration, transportation and discharge of coolant.
The Combination tank was designed for use in connection with a coolant
reclamation system. The twin tanks allow the operator to clean out
and filter a sump and immediately recharge the sump with fresh coolant.
2. Size
of Machine.
CECOR Sumpcleaners are available from 90 to
600 gallon tank size for single tank and from 60/60 to 300/300 gallon
on the combination units.
3. Power
Source.
CECOR Sumpcleaners are available with three
power sources; air, electric and propane. All have certain advantages
and disadvantages.
(see Table 1.)
4. Type
of Transport.
CECOR Sumpcleaners are either hand push/power
tow or towed with a power mover depending on tank size. See individual
specification sheets for details. Custom bases are available, including
self-propelled and trailer- mounted units.
5. Filter
Selection
All sumpcleaners use a bag style filter consisting
of a metal filter assembly with a perforated basket that holds a
filter bag or sleeve. The filter bags or sleeves are available in
a variety of mesh sizes and materials. Three filter sizes are offered;
1.0 cubic foot, 2.3 cubic foot and 5.0 cubic foot.
There
are five factors to consider when matching a sumpcleaner to a particular
application.
Air,
Electric or Propane?
Performance
Level
Performance
Level
Drawbacks
Propane
1
Fastest
pumping rate.
Power source included on unit – no need to “plug
it in.”
More costly
than air or electric units.
Electric
–
3 Phase
2
Fast pumping
rate.
Lower cost than propane.
Requires
three-phase electricals.
Air
3
Low initial
cost.
Low cost to operate.
Simple piece of equipment –
no moving parts.
Fairly high pumping rate.
Requires
adequate air volume and pressure. Need air drops in areas of
usage.
Electric
–
Single Phase
4
Can be
used wherever standard electricals are available.
Most basic
model.
Air
units, with no moving parts, are simple to operate and maintain.
They are popular because they cost less initially and are inexpensive
to operate. The unit operates off the plant air supply, requiring
air service headers of 3/4" or larger and 1/2" drops or
larger with a line pressure of 80 to 120 psi. The air-operated venturi
creates a vacuum in the tank with a suction lift to 26” Hg
(Mercury). A good air compressor with adequate air volume and pressure
is necessary to run this unit effectively.
Plug-in
anywhere convenience is the advantage of electric sumpcleaners.
Single-phase electricals plug into standard 110 V outlets. The efficient
motor drives a rotary, vane-type vacuum pump generating suction
rates to 17" Hg and pumping rates to 60 gpm. The electric extra-power
sumpcleaner requires a multi-phase electric circuit. A five hp motor
powers a lobe-type, positive displacement vacuum pump. Pumping rates
to 110 gpm and deep suction lift scour sumps of all coolant, chips
and sludge in a matter of minutes.
Propane
units meet the need in some plants because the sumpcleaner is self-contained.
The twin cylinder engine features overhead cam and valve design.
Electronic ignition insures fast and easy starts. These units have
the highest pumping power and are more costly than air or electric
units. Engine emission meets EPA and California Air Resources Board
(CARB) standards.
Filter
Facts
An important function of a sumpcleaner is
the ability to remove solids from coolant as part of the cleaning
process. As the sumpcleaner uses vacuum to suck coolant from the
sump, the filter, consisting of a reusable filter bag or sleeve,
removes the chips, swarf and other residue from the coolant.
Some
sumpcleaner manufacturers talk about filter pore openings in terms
of micron size. One way to approximate the size of the pore is to
see if you can push a hair through the opening. A human hair is
approximately 75 microns in diameter.
The
pore size, however, is not always indicative of the size of the
particle that may be filtered. A pore opening may be 250 microns,
but it will filter particles much smaller due to the cake that forms
on the filter. As the dirty coolant passes through the filter the
solids build up on the surface. These built-up solids form a "cake"
which enable the filter to trap even finer particles.
Blinding
can occur when filtering oily coolant. Oily solids cling to the
sides of the filter preventing anything from getting through. This
may be more likely to happen with a smaller pore size, so micron
size is not the only factor to consider.
CECOR’s
patented reverse taper design eliminates bridging. Filter empties
completely. Solids do not become trapped in the filter.
CECOR's
unique filter pack design provides a continuous filter medium. All
of the coolant must pass through the filter with none escaping through
slits or openings.
All
sumpcleaners use a bag style filter consisting of a metal filter
assembly with a perforated basket that holds a filter bag or sleeve.
The filter bags or sleeves are available in a variety of mesh sizes
and materials. Three filter sizes are offered; 1.0 cubic foot, 2.3
cubic foot and the 5.0 cubic foot.
F10
- 1.0 Cubic Foot Filter
The F10 strainer basket and fabric liner has
a capacity of 1.0 cubic foot and is standard on the following models:
SA5, SE10, CA5 and CE10. The reusable fabric filter has built in
grips and is small enough for one person to lift.
F23
- 2.3 Cubic Foot Filter
With a 2.3 cubic foot capacity, the F23 filter
is fitted for fork lift or hook hoist handling. Patented compound
linkage and rotary latch control the bottom opening door for easy
emptying. The F23 is optional on sumpcleaner models SA5, SE10, CA5,
CE10. It is standard on SE30, CE30, (CE50 and CP50 200/200 tank
size and smaller).
F50
- Cubic Foot Filter
Extra Power Sumpcleaner has an extra capacity
filter, the F50. The reusable filter consists of perforated metal
outer basket with polypropylene mesh liner. Fittings for fork lift
handling are integral to the two-piece cover. Unit empties from
bottom with built-in safety features of compound linkage and rotary
latch. Standard on all SE50, SP50, CE50, CP50 models (250/250 tank
sizes and larger.)
Filter
Facts 
