INSTALLATION GUIDE VARIFLOW HIGH-PRESSURE COOLANT SYSTEMS

The VariFlow Gen4 high pressure coolant system offers top of the line performance in a small, economic package. Utilizing our Adaptive Flow Control, the VariFlow dynamically adjusts the flow of coolant to output the desired pressure that can be set from the VariFlow’s HMI or the machine’s RS-232 port. This variable flow system can reduce energy consumption, coolant foaming and heat generated from a pump running at a fixed flow. The new VariFlow Gen4 sets a new standard for high pressure coolant systems by bringing top of the line technology to a small platform that is priced similarly to the...

SYSTEM OVERVIEW Unit Specifications Voltage 3 Phase, 230 Volts, 50/60 Hertz Full Load Amperage Mounted suction hose w/ foot valve Features • Adaptive Flow Control (switch with the push of a button) • 250 PSI (17.2 bar) • 500 PSI (34.4 bar) • 750 PSI (51.7 bar) • 1,000 PSI (69 bar) • Up to 8 GPM (3.8 L/min) Single Plug Electrical Interface 25 Gallon Reservoir IOT Connectivity User Interface Caster Wheels 2 Year Warranty System Status Light Less than 80 dB running Included with your system Coolant feed hose High-pressure hose Clamps (coolant feed hose) 3/8” and 1/2” JIS fittings 3/8” and 1/2” JIS...

LIFT POINTS LOCATION Hoist the system from both lift points. The top of the system has two 3/8-16 threaded holes. Eye bolts are included. Note: Both side doors must be mounted while lifting. Lift Points

INSTALL FEED/RELIEF MOUNT 1. Find a suitable location on the coolant tank to pull coolant. Coolant must be pulled from the clean side of the tank. If no suitable location can be found, remove the pump that’s being replaced by the VariFlow system and use that space for the feed/relief mount. 2. Install the feed/relief mount. Drilling may be required if the existing tank holes don’t line up or none are available. 3. Attach the feed and relief pipes to the mount. Ensure the barb fittings are at the top. Adjust height so the foot valve is close to the bottom of the tank but not making contact. Adjust...

CONNECT COOLANT HOSES The rear of the system has three coolant connections and the power cable. ❶ Coolant feed 1. Connect the coolant feed tube. One end to the feed pipe. Other end to the rear of the VariFlow. 2. Connect the relief hose. One end to the relief pipe. Other end to the rear of the VariFlow. 3. Connect the high-pressure hose. One end to the high-pressure outlet on rear of the VariFlow. Other end to the high-pressure through-spindle line on the machine tool. Note: A high-pressure hose may need to be custom made depending on length and fittings that come with the machine. The install...

FEMALE CONNECTOR MOUNTING 1. Find a suitable location for the female connector housing. The connector (included in the install kit) should be within reach of the cable coming off the VariFlow while leaving slack so the VariFlow can be moved around without disconnecting. 2. Mount connector to the machine. Once mounted, determine the wire routing and wire length from the connector to the machine’s electrical box. Ensure wires can be safely placed away from moving parts so they don’t get damaged. Note: Connector comes with whip/pigtail pre-wired. If whip/pigtail isn’t long enough, extend on your...

CNC ELECTRICAL CABINET WIRING Note: The relay is used to trigger the run signal. Typically, a 230v coil relay is provided so it can be triggered from the through spindle coolant contactor. If a contactor is not present in the machine a 24v relay should be requested. Electrical Connections Plug Pin Number Wire Color Wire Label Green/Yellow (ground) Black (power) Blue (control signal) Run signal. Contact close to +24VDC. 20AWG Blue (control signal) Alarm signal. Contact close to 1451. 20AWG Blue (control signal) Run signal. Contact close to 1520. 20AWG Blue (control signal) Alarm signal. Contact...

ALARM SIGNAL WIRING Alarm Signal Diagram VariFlow NC (normally closed relay) Connect CNC alarm signal to the VariFlow PLC. Note: The PLC is located in the VariFlow’s electrical box. Locate and attach blue wires (1440, 1451) from the VariFlow PLC relay to the CNC machine. ■ 1440 to CNC +24VDC ■ 1451 to CNC alarm signal Note: From the factory, the VariFlow comes wired with a Normally Closed (NC) Alarm Signal. If your application needs a Normally Open (NO) Alarm Signal, you will need to change the alarm wires from Relay 27 (NC) to Relay 26 (NO) on the PLC. VariFlow PLC alarm signal

PRIMING THE SYSTEM 1. Verify system is ready for priming. Ensure all filters, O-rings, hoses, and clamps are in place and properly sealed. 2. Remove fill port plug. The plug is located on top of the coolant feed hose port on the back of the VariFlow system. 3. Fill with coolant. Pour coolant/water into the fill port. Ensure all air bubbles are removed from the pump and the coolant feed hose. 2. Replace fill port plug. Use thread tape to ensure the plug is properly sealed. Fill port plug

CHECK SYSTEM PHASING IMPORTANT! Before first start-up, follow the steps below to check the rotation of the feed pump to confirm system phasing is correct. Note: The system comes with a fill pump switch on the side of the electrical box. The fill pump switch is set to “off” when shipped so it will not run dry on initial power up. 1. Attach power cable. If not already done, connect the male end of the power cable from the VariFlow to the female connector. 2. Manually run the priming pump. There are two ways to run the priming pump: ■ Use the switch on the outside of the electrical box (circled...

OPERATION Check to make sure the VariFlow power is turned on. Once turned on, the VariFlow has a main power disconnect on the electrical box, which allows for the system to turn on/off with a signal from the CNC machine. Once installation is complete, the operation of the system is pretty straight-forward, typically requiring pressure adjustments as the only “operation”. How it works The VariFlow system is equipped with our Adaptive Pressure Control, which regulates the flow of coolant to output the desired pressure regardless of the orifice size in the tool (within capabilities of the pump)....