stardelta.netstardelta.net/downloads/Globecore_CMM- 6.0 Oil purifier.docx · Web viewThis manual will inform you of all necessary regulations related to installation, commissioning

CMM00000GU CMM00000GU

Contents page

1 General information 2

2 Safety 4

3 Technical information 6

4 Technical description of the equipment 8

5 Transportation and packaging 19

6Installation of the equipment Storage conservation and de-

conservation19

7 Commissioning 21

8 Maintenance 26

9 Troubleshooting 29

10 List of consumables 33

11 Disposal of the equipment and consumables 33

12 Factory acceptance and conservation certificate 34

13 List of appendices 35

This manual will inform you of all necessary regulations related to installation commissioning

and operation of the unit In the course of operation and maintenance of the unit it is required to strictly

observe all recommendations of this manual

Failure to observe the requirements of this manual andor unauthorized alteration of the parts

and components supplied by us will make it impossible to make warranty claims

If you require assistance or advice in the course of unit operation contact the manufacturer or the

supplier of the equipment

The unit design is under constant development therefore some parts and component may differ

from descriptions in this manual Such differences have no negative impact on the unitrsquos functionality

CMM-00000GU CMM-00000GU

1 General information

11 Manufacturer warranty

111 The manufacturer guarantees normal and stable operation of the product if all installation

operation maintenance transportation and storage regulations laid out in this manual are observed

112 Warranty period is 12 months from the date of dispatch

113 If any manufacturing defects or failure of the product or itrsquos components through

manufacturerrsquos fault are uncovered during warranty period the user is entitled to make a claim to the

manufacturer (seller) without disassembling the unit or itrsquos components In the course of five days the

user draws up a preliminary act and notifies the manufacturer of the defect

114 Warranty is void in case of

- incorrect or insufficient maintenance procedures

- incorrect operation

- inappropriate operation materials

- alteration of the unit design

- use of defective tools

- use of non-original spare parts

- unauthorized alteration of the unit or its components

- malfunction of the unit due to damage from foreign objects particulate matter

contamination etc

115 The product is put into operation at the userrsquos facility _________________________________________________

(Date of commissioning)________________________________________________

(Signatures of persons responsible for acceptance)The user is obligated to keep a maintenance log of the unit running hours and maintenance

procedures use of spare parts in compliance with this manual

Attention Use the product to process only the types and brands of oils listed in

this manual The user MUST contact the manufacturer for authorization before using the

product to process any type of oil NOT LISTED in this manual

Attention Operation of the product is allowed only at an ambient air temperature

from +5 оС to +40 оС and relative humidity not exceeding 70 Operation in

other conditions is allowed only after agreement with the manufacturer

Attention When working with the generator it is necessary to control the power settings they

should match that shown in the table of technical characteristics of equipment Unstabilized

voltage supply can lead to equipment failure

12 Attention ndash important

121 Before commissioning the product be sure to study this operation manual

122 A power supply and safety devices (automatic switches) must conform to those

mentioned in specifications or other technical documentation

123 Check oil level in vacuum pumps

124 When connecting the product to the power supply ensure correct phasing If necessary

reconnect phases A and C

125 Regular and timely maintenance is required to keep the product in operational condition

126 Operation of the unit with overloads or in modes not provided for by this operation manual is

not allowed

127 In case of failures first check basic and start-up equipment (automatic switches thermal

relays etc)

128 Maintenance and repair procedures are carried out by qualified and authorized personnel

129 When ordering spare parts indicate item type its serial number and description

13 Symbols and explanations

Read the instruction before commissioning or servicing of the unit

Attention do not operate with open doors or removed case

Attention hot surface

Transportation instructions

Attention electrical shock danger

Active environmental protection

Earthing wire connection location

Warning Other dangers

No smoking

No open fire

Hearing protection required

Protective clothing required

Protective gloves required

2 Safety

21 Safety measures when operating the unit

These instructions apply to the product in general For third-party components additional third-

party manufacturerrsquos safety rules also apply

Beside generally accepted safety rules for this kind of equipment its components and accessories

it is necessary to observe the following safety measures

211 Operating personnel must use proven techniques and methods of operation and observe all

local safety regulations Use protection gear

212 No smoking and open fire allowed at work place

213 The user must maintain the product in good condition and service it in a timely manner

If any parts or components are deemed unfit for operation such parts or components must be

immediately replaced

214 Installation operation maintenance and repairs must be done only by qualified and

authorized personnel

Product operation with open control cabinet or other powered elements exposed is prohibited

215 Before operation the product must be earthed

216 Limiting values must be marked and such markings must be durable

217 If any of the instructions herein especially those related to safety contradict local

regulations the higher safety rule applies

218 These safety measures are of general nature and are relevant for various equipment and

machinery types Therefore some regulations are subject to semantic interpretation for specific unit

219 When operating the product special care must be taken to avoid burns when touching hot

surfaces Always wear special clothing when operating the unit

2110 Installation of the product must allow for unobstructed evacuation of personnel in

emergency situations requiring such immediate evacuation from the workplace

2111 Noise generated by the product may exceed 80 dB Use hearing protection

2112 Recommended maximum speed on general purpose roads is 40 kmph

22 Installation

Beside general industry rules which meet local safety regulations the following specific

instructions must be observed

221 Lift the equipment with lifting devices compliant with local safety regulations

All loose or movable parts must be secured before lifting Acceleration and deceleration

during transportation must be kept within reasonable limits

222 All plugs covers caps packages with adsorbent etc must be removed before installation

Plugs and pipe connections must have correct dimension types and be rated for correspondent pressure

and capacity

223 Installation of the product requires hard flat surface

224 The design of the product allows for outdoor operation

225 Oil input must not contain solid particles larger than 500 micron

226 Use thermal compensators when connecting input and output hoses to allow for thermal

expansion The hoses must be kept clear of flammable materials

227 Safety valves on input line must be kept clear and unobstructed at all times Ensure no

external force is applied to the valves

228 When placing the unit ensure safe and secure connection of pipelines and cables Use

warning signs and take other precautionary measures as required to prevent damage to communication

229 The unit must be installed on a horizontal surface Maximum inclination of the unit is 3о

23 Maintenance

Servicing and repairs must be carried out only under control of a qualified authorized

specialist familiar with this manual

ATTENTION

Before connecting oil supply and oil output lines to the unit the hoses must be cleared of dirt

mechanical impurities old oil residue and other waste

231 Only use proper tools for maintenance and servicing

232 Use only original spare parts (The spare parts from the spare parts kit are consumables and

shall not be replenished)

233 The unit must be switched off and securely disconnected from power supply for servicing

and maintenance operations

234 Prior to disassembling pressurized components release high pressure to atmospheric level

235 Prior to disassembling hot components let the part cool down to below +43оС

236 It is not recommended to use solvent or tetrachloride carbon to clean parts of the

product

Attention If toxic cleaning substance is used take additional safety measures

237 Keep the area clean during repairs and servicing Parts and openings must be covered with

cloth paper or adhesive tape

238 Welding and other heat intensive work in vicinity of oil lines is forbidden

239 Do not leave tools rags and other foreign articles in the unit

2310 Check correct automation system settings as well as flawless operation of shutoff and

control devices before resuming work after repairs or servicing

2311 Protect motors and other electric components from moisture during oil treatment and

purification

2312 During operation it is recommended to use oils in rotary pumps (for circulation systems)

according to the ambient temperatures

Oil viscosity class Ambient temperature о C

32 lt 0 о С

46 0 ndash 15 о С

68 15 ndash 30 о С

100 30 ndash 40 о С

The manufacturer bears no responsibility for any damage or injury if the regulations and

guidelines of this manual as well as general safety rules are not followed and observed even if such

regulations rules and guidelines are not specifically emphasized in this manual

24 General instructions

This operating manual gives an idea of methods and procedures of product operation

providing safe use with optimal economic performance and maximum life-time

Learn the operation modes control and service procedures in this manual before

commissioning so that the above modes and procedures are familiar to the user from the start

The list of maintenance procedures includes all basic measures which allow keeping the product

in good condition

This operating manual must be accessible for service personnel Service work must be monitored

Record all work in a log book along with date last name and signature of persons completing the

service

Repairs must be carried out by qualified authorized personnel Repairs must be coordinated with

the manufacturer When contacting manufacturer indicate equipment type and serial number from its

name plate

You will find all special data not mentioned in the text in the section Specifications or

in appropriate sections

The producer reserves the right to carry out technical improvements without the special notice

3 Technical information

31 Application

Mobile oil station CMM referred to as the unit throughout this manual is designed for thermo-

vacuum drying filtration removal of mechanical impurities and heating of transformer oil used in

transformers up to 1150 kV

The unit may be used for heating of oil-filled electrical equipment by hot transformer oil

vacuum transformer drying and vacuumizing The unit is used by installation repair and

maintenance companies which are dealing with transformer oil treatment

The unit is not fit for operation in explosive or toxic environment as well as environment

reactive to lubrication materials

When operating the unit indoors install gas exhaust line to evacuate gases into the

atmosphere

The unit can process mineral oils with the following qualities6

Dynamic viscosity mm2sec at 50 degС 2hellip12Density at 20degС kgm3 800hellip950Moisture content ppm max 100Purity class ISO 4406 at least 14

32 Specifications

Table 1

Note - Initial oil parameters- gas content ndash no more than 105- moisture content ndash 001 (100 ppm)- temperature ndash above 0 ordmС

33 Scope of supplyTable 2

Title Amount1 Mobile oil station CMM assembled 1

Parameter1 Processing rate m3hour no less than

- degassing nitrogentation drying and filtration modes 6- heating and filtration mode 7

2 Capacity adjustment range m3hour 2-73 Processed oil parameters

- volumetric gas content max 01- moisture ppm max 10- industrial purity ISO 4406 9- particulate matter gton max 8- filtration micron 5- dielectric strength kV min 70

4 Oil temperature in heating mode ordmС 855 Filtration coefficient ge506 Output pressure bar 27 Oil supply head m 208 Oil heater power kW 1009 Mean surface power of the oil heater Wcm2 max 11510 Max power consumption kW 11211 Power supply parameters

- voltage V 415- AC frequency Hz 50

Dimensions mm max- length 3550- height 2050- width 1850

Weight pound max 1780

2 Spare parts- spare parts kit as per packing list CMM00000UL 1 kit

3Documentation

- User manual and certificates 1- User manual and certificates 1 kit

4 Unit description

41 Unit design

411 The unit (Figure 21) is an assembled container with all components and

assemblies The container is installed on a single axle trailer The sides of the container are

equipped with doors for easy access An inventory storage compartment is located in the front

part of the container

Figure 21 Unit general view

The unit consists of the following components vacuum chamber 1 input pump 2 heater

5 output pump 3 fine filter 6 control cabinet pipelines with valves 4 vacuum pumps -

booster 8 and backing pump 7 Process parameters are controlled by Mitsubishi α2 with

WIKA transducer thermostat ТС-2 flow switch level and foam sensors ЕС 3016 РРАSL

as well as vacuum regulator Autonics with temperature sensor TCM Pirani vacuum meter

visual monitoring of pressure on filters are facilitated by manometers М1 М2 М3 OGM

flowmeter for total processed oil control

Figure 22 ndash Unit general view

1 ndash vacuum chamber 2 ndash input pump (supply) 3 ndash output pump 4 ndash piping 5 ndash oil heater 6 ndash

fine filter 7 ndash vacuum backing pump СР 40-620 8 ndash booster pump RVB-2220 412 A mesh filter is installed at the unit inlet and removes solids from incoming oil Filtration

fineness is defined by the 200 micron mesh in the case To rinse the filter element remove the filter

from the inlet and rinse in clean transformer oil

413 Pumps 2 and 3 are designed for input and output of oil into and from the unit respectively

The pumps are controller from the control panel

414 Fine filter 6 is designed for filtration of the processed oil Filtration fineness is 5 micron

Refer to Figure 3 for filter general view

The filter consists of cover and case which houses FE-23 type filter element The cover features a

plug (valve) for releasing of air when oil enters the filter and for inlet of air when oil leaves the filter

The bottom of the case has a valve and an outlet The case has oil inlet and outlets welded in To replace

filter elements drain contamination from the filter by opening the valve 3 Turn handle 7 of the pressing

screw several turns counterclockwise turn the cover in the same direction and remove it from the filter

undo the pressing nut and remove the filter element Install new filter element secure with pressing nut

Place the cover on the filter by reversing the process described above

415 The oil heater 5 is a vessel with a heating section oil inlet and oil outlet For general view of

the heater refer to Figure 4

The heater is controlled from the control panel

Figure 3 Cartridge filter

1 ndash oil inlet2 ndash clean oil outlet3 ndash contaminant drain valve4 ndash filter element5 ndash air release plug6 ndash magnets7 ndash pressing screw

Oil temperature after the heater is controlled by measuring regulator connected to thermistor Т

and by thermostat ТS

To protect the heaters flow switch FS is installed signaling presence or absence of flow through

the heater

416 The vacuum column 1 is designed for degassing of transformer oil For column general view

refer to figure 5

The chamber is equipped with vacuum valve MV3 for connection to the vacuum system as well as

foam sensor LS4 and level sensors LS1 ndash LS3

During oil degassing the residual pressure in the column is below 267 Pa The oil goes into the

column through the pipeline and then through the manifold to activator filters (sprayers)

The design facilitates rapid release of moisture and gas

Figure 4 Oil heater

1 ndash oil heating section2 ndash cold oil inlet3 ndash hot oil outlet

Figure 5 Vacuum column

1 ndash inlet2 ndash vacuum system connector3 ndash activator filter4 ndash processed oil outlet5 ndash level sensors 6 ndash sight glass

417 The control cabinet houses electric systems necessary for operation of the unit The metal

cabinet has a lockable door Inside the panel are the electric connection and control circuits The cabinet

features control buttons and light signals For general view of the control cabinet refer to figure 6

Figure 6 Control cabinet general view

Pos ItemFunction Electrical diagram designation

1 Mitsubishi α2 controller U42 Heating onoff button S103 Mode select button S44 Р1 pump startstop button S95 Р2 pump startstop button S86 VР1 VР2 vacuum pump startstop button S11

7Sound alarm off and fault message reset button

8 Emergency stop button S19 Correct power connection indicator light HL210 Power light HL1

11 Autonics temperature controller U5

12 Pirani vacuum controller

13 Manual power switch

418 Instruments

The unitrsquos operation is managed by the Mitsubishi α2 controller and the following devices

- contamination of filter elements in cartridge filters F1 F2 and the unitrsquos outlet pressure are

indicated by manometers М1-М3

- residual pressure in the vacuum system is controlled by Mitsubishi α2 controller and Pirani

vacuum controller

- oil level in the vacuum chamber is controlled by level sensors and foam sensor

- the amount of processed oil is indicated by flow meter LC

The oil heater is controlled by the following instruments

- by the thermostat the heater is disengaged when the oil temperature exceeds the setting

- by the flow relay which disengages the heater if the oil is not flowing through the heater

- by the Autonics controller which manages oil temperature at the outlet of the heater

Attention

Autonics device has been set up at the factory at the time of factory acceptance testing

Attention

When programming oil temperature keep in mind that transformer oil flashpoint usually lies

within the range from +95ordmС to +140 ordmС depending on oil type

4181 Temperature regulator

General settings

In OPERATION mode settings are entered by pressing the buttons and are saved after

pressing the MODE button

To enter PROGRAMMING mode press and hold the MODE button for 2 seconds Then using

buttons select settings group 1 through 5 (Par1 ndash Par5) and press MODE to enter the

corresponding group The mode is entered by pressing any of the buttons saving is done by

pressing the MODE button Enter all data as described below

419 Booster pump 8 creates the required vacuum in the vacuum chamber along with the backing

pump 7

4110 10 The vacuum trap OT (See Figure 8) is designed to trap oil that enters the vacuum system

This device is equipped with WIKA vacuum sensor LS5 level sensor and ball valve MV14 for

oil draining

4111 The container is designed to house the unit and its components and to protect it from the

ambient factors The container is equipped with hoisting lugs

4112 The trailer is a platform on a torsion suspension axle two pneumatic wheels lug supports

brake and a manual parking brake and electrical system

42 Principle of operation

Flow diagram is shown in Figure 7

Figure 7 ndash Flow diagram

VC ndash vacuum column P1 divide P2 ndash oil pumps MV1 divide MV2 MV4 divide MV16ndash ball valves MV3 ndash

vacuum valve MV15 ndash gate valve H ndash oil heater ВV2 divide BV3 ndash return valves F1 F2 ndash fine filters

М1 divide М3 ndash manometers Т ndash temperature sensor ТS ndash thermostat FS ndash flow switch V1 divide V3 ndash

electromagnetic valves DG divide DG1 ndash vacuum sensors LS1 divide LS3 LS5 ndash level sensors VP1 VP2 ndash

vacuum pumps

LS4 ndash foam sensor LS6 ndash oil leak sensor MF ndash mesh filter OT ndash trap LC ndash oil meter CL1 divide CL3 ndash

quick coupling connections

421 The unit can be operated in the following modes

ndash laquoHeating and filtration (HampF) and vacuumizing of external equipment (VAC)raquo

ndash laquoThermovacuum heating (DRY) and degassing (DEG)raquo

422 In oil heating and filtration mode unprocessed oil enters the unit through ball valve MV1

pre-filter MF is supplied by pump P1 through valve MV10 oil heater H cartridge filter F1 electric

valve V2 return valve ВV3 oil meter LC valve MV2 to the outlet of the unit

The oil is filtered and heated in this mode

In this mode the heater and the pump P1 can be controlled Control of the P2 pump is

locked

It is also possible to control vacuum pumps VP1 and VP2 for vacuumizing external

equipment

Vacuumizing of a transformer is performed by pumps VP1 and VP2 through the vacuumizing

connector

423 Transformer oil is degassed by heat and vacuum

In the thermovacuum drying and degassing mode the unitrsquos inlet is connected to the oil container

and the outlet is connected to

- transformer tank gate valve if the pressure in the transformer during filling is above 267 Pa

- transformer top gate if the pressure in the transformer is below 267 Pa

Transformer oil is pumped by P1 through valve MV1 and pre-filter MF the valve MV10 oil heater

H filter F1 electric valve V1 to vacuum chamber VC Hot oil (55hellip60ordmС) with particulate matter

removed passes through the activator filter (sprayer) in the chamber The vacuum in the chamber is

maintained by vacuum pumps VP1 VP2 The vacuum in the chamber is controlled by Pirani device with

DG1 sensor

Moist air is then expelled into the atmosphere through valve MV3 and oil trap OT by pumps VP1

and VP2

The oil from the chamber is pumped by pump P2 through valve MV9 filter F2 return valve ВV2

and ball valve MV2 and oil meter LC into the transformer

The vacuum in the chamber is maintained by the vacuum pumps Residual pressure (up to 267 Pa)

created in the vacuum chamber allows to achieve the required oil quality

When the oil passes through the chamber vacuum causes moisture and air to be removed from

the oil

In this mode the oil is filtered dried and degassed

To eliminate the chance of supplying poorly processed oil in the initial period of operation the unit

has a warm-up mode In this mode the vacuum chamber is filled with transformer oil then the oil is

heated by the hot oil which circulates in the following order

- vacuum chamber VС

- oil pump P2

- ball valve MV9

- filter F2

- ball valve MV4

- oil heater H

- filter F1

- electric valve V1

During circulation it is possible that the output pump stops due to oil level falling below the low

level sensor To avoid this fill the unit with oil to the level higher than the low level sensor

To prevent oil (or foam) from entering the vacuum system the vacuum chamber is equipped with a

foam sensor LS4 which opens valve V3 to reduce foam level Also oil trap OT is equipped with a level

sensor LS5 When oil or foam enters the vacuum system and activates LS5 an alarm is counded the

input and output pumps P1 and P2 stop as well as vacuum pumps VP1 VP2 Electromagnetic valve V1

stops the flow of oil into the vacuum chamber Electromagnetic valve V3 opens to facilitate foam

removal

If the unit loses power supply the electromagnetic valve V1 stops oil input into the vacuum

chamber it also closes in case of overheating of oil in the oil heater

In this mode all components can be controlled

424 For electric diagram refer to appendix

The unit operates on 415V To turn on the power

- open control cabinet

- connect power of correct voltage

- turn the automatic switches to the ON position

- close control cabinet

- turn on the main switch on the control cabinet door

- release the EMERGENCY STOP button

The POWER LED will come on when power is available in the control cabinet as well as

PHASING LED if the phases were connected correctly

The electric circuitry includes protection from incorrect phase connection by phase control relay

as well as protection from disagreement of power supply and power switch on the front panel of the

control cabinet

The electric system facilitates protection of power motor lighting heater control and socket

circuits from short circuiting as well as protection of motors from overloads with heat relays

The phase relay prevents operation of the unit with incorrect phase sequencing or breach of one of

the phases

For electric diagram refer to appendix В

The temperature of the processed oil is set on the controller which automatically maintains the

temperature selected

The thermostat automatically disengages the heater if the temperature exceeds the maximum limit

+(70divide90) ordmС

Operation of the unit is managed by the controller the screen of the controller shows all

information regarding operation of the unit and parameters of the processes

43 Description of information displayed on the controller screen (pos1 fig 6)

The unit is equipped with Mitsubishi α2 AL2-24MR-D controller

Firmware versionVR-001-921

The controller screen contains four 12 symbol lines

431 The first line shows possible modes of operation selected by pressing the MODE button

(pos3 fig6)

The following modes of operation are possible

- Heating and filtration (HampF) and vacuumizing of the external equipment (VAC)

- Thermovacuum drying (Dry) and degassing (Deg)15

If the EMERGENCY STOP button is pressed the unit stops and the ldquoEmergency stoprdquo message is

shown on screen

432 The second line shows indications of heater operation vacuum sensor data and several other

indications and fault messages

- indication of heater operation

The heater is engaged by pressing the HEATING1 or HEATING2 button (pos2 fig6) the screen

displays H on message This indicates that the heater is in standby mode

If the vacuum sensor fails or is disconnected ldquoVacuum sensor Disconnectrdquo running line is

displayed

The following fault messages may be displayed

- ldquoTSrdquo ndash when TS thermostat trips

- ldquoMSrdquo ndash when of the heat protections of pump drive Q1 Q2 Q3 Q4 trip

The end of the second line displays the presence of oil flow or flow related fault messages

- Stable oil flow through the heater is indicated as follows

If the oil is not flowing through the heater for a certain duration of time the unit stops

automatically and the screen will display

- If the flow relay is faulty (pumps off no vacuum in the system) the screen displays the

following

433 The third line shows indication of input pump Р1 and the output pump Р2 and vacuum pumps

VP and indication of vacuum as follows

For Р1

- Pump Р1 in standby mode (operation authorized) (P1 on)

- Pump Р1 running (P1 x)

P1 is engageddisengaged by pressing the button (pos4 fig6)

For Р2

- Р2 in standby mode (operation authorized) (P2 on)

- Р2 pump is running (P2x)

Р2 is engageddisengaged by pressing the button (pos5 fig 46)

For VР pumps

- VР pumps on

After turning on the pumps vacuum pressure is controlled If there is no vacuum within 2 minutes

the screen displays the following message

If there is no vacuum for another 2 minutes the unit stops immediately and line four of the

controller screen indicates the following

434 Life four of the screen indicates information on sensor tripping for low level L3 mid level

L2 high level L1 foam sensor L4 (up to 5 seconds)

The following messages may also be displayed

- Alarm foam ndash foam in the vacuum column

- Oil in trap ndash oil in the vacuum system trap

- Oil in tray ndash oil spilled into the unitrsquos spill tray

False tripping of sensors is checked In case of a false reading the screen displays a blinking XX

over the indication of the sensor

5 Transportation and packaging

The unit shipment is performed in corresponding packaging depending on the chosen way of

delivery

Independently of safety measures taken at the factory there is a possibility of damage during

transportation Hence it is necessary to check the load on a presence of such damages Issues regarding

transportation damage are to be settled with the shipping organization

In such cases it is in your interests to draw the attention of the forwarderrsquos responsible person to

the fact of the damage ie

а) a visible damages or shortage

- make corresponding remarks in covering documents when accepting the unit If transporting

over the rail road demand that acceptance act should be signed by the rail road

- in case of postal delivery (courier delivery) obtain a written confirmation of the unit damage or

its packaging from the forwarding organization prior to accepting the unit

b) damage not immediately visible

- damage visible when unpacking the unit must be immediately reported to the transporting

organization in writing

- packaging material and damaged parts should be stored unchanged until acceptance act is

drown up

6 Unit installation

The unit must be positioned on a flat hard surface When mounting the equipment sufficient

space must be reserved for maintenance connection of pipelines and power supply and safe operation

Observe any additional local requirements

The area where the product shall be mounted should have a drainage system allowing

unobstructed removal of fluid

Operating ambient temperature must be within the range of +5 оС to + 40 оС air humidity up to

70 These limits may be exceeded with manufacturer approval on a case-by-case basis

61 Connecting threadmounting

Fasteners with metric thread are provided for the product Keep in mind that exceeding of

maximum torque when tightening the fasteners IS NOT ALLOWED If there are no additional

requirements use the data from table 6

Table 6

Screwblock type Thread Max torqueBolt with external hexahedron

Screw with internal hexahedron М6 10 Nm (7ftlbs)М8 25 Nm (18ftlbs)М10 45 Nm (32ftlbs)

М12 75 Nm (53ftlbs)М14 120 Nm (85ftlbs)М16 180 Nm (126ftlbs)

Tube thread (self-threading connections )

Manually until limit reached +12 turn

Recommendation Tighten the fastening with a torque wrench

62 De-conservation of the unit received from the manufacturer

For de-conservation of the product it is required to

- remove packing

- remove rust-preventing grease

- remove packing from measuring devices and control cabinet (if present)

- mount the product (as necessary)

- before connecting instruments installation of stop valves (removed for transportation) and supply

pipeline connection it is necessary to remove plugs from the end pipe connectors and connection ports

63 Conservation in operating conditions

Conservation is required for long-term storage of the equipment on-site

Conservation procedure requires ambient temperature above +15ordmC and relative humidity below

During conservation it is necessary to

- drain oil from tanks (heater vacuum column filters) pipelines and base if necessary

- cover all unpainted surfaces of components with rust-preventing grease

- openings of pipes valves taps gates openings for measuring instrument connection (in if

removed) must be tightly closed with plugs

- if measuring instruments are removed from the unit wrap them in wax paper and put into a box

which must be secured with the unit or to stored in special premises

- renew paint coating if damaged

Store the product indoors

Long-term conservation requires re-conservation of the unit at least every 6 months

64 Re-conservation of the unit

Storing the unit for over 6 months requires re-conservation of the unit including

- check state of rust-preventing grease at the unit Restore if necessary

- check plug presence in the openings of pipe connectors valves gates instrument connection

ports (if removed) Reinstall as required

- check measuring instruments packing (if removed) Restore or replace as required

ATTENTIONIn case of storage at consumerrsquos place for more than 12 months it is necessary to perform

preparation and startup procedures of the unit at typical operation mode for 20 minutes After the normal stop complete the conservation procedure according to paragraph 63 of this Manual

65 De-conservation of the unit after conservation on site

For de-conservation

- remove measuring devices and control panel from packing (if present)

- mount the unit (if required)

- before connection of instruments installation of stop valves (removed for transportation) and

connection of input and output pipelines remove plugs from pipe connectors and ports

7 Commissioning

71 Preparation for commissioning

Study this operation manual and complete general safety briefing

Please note that every component of the unit undergoes acceptance testing at the

manufacturerrsquos factory before shipping The acceptance testing confirms that the unit

complies with required parameters and works faultlessly However observe the unit operation carefully

during startup and commissioning to uncover possible deviations from normal operation

I Prior to first start pay particular attention to the following

1 Correct mounting and assembly of components removed for transportation

2 Installation of the unit on a flat horizontal surface and installation of wheel chocks and supports

3 Compliance of power supply parameters with the unitrsquos specifications

4 Compliance of ambient conditions with the unitrsquos specifications (temperature humidity etc)

5 Grounding the equipment using wires of corresponding cross-section

6 Insulation resistance of power electrical equipment (electric motors electric heaters etc) must be

above 1 MOhm

7 Connection of the unit to power supply adjustment of automation devices are to be done by a

qualified authorized electrician

8 Check for correct oil level in the unitrsquos components and assemblies (see maintenance section 8 of this

manual)

II Rotation direction control

During startup and commissioning as well as after any changes in electric wiring the

direction of electric motor rotation must be checked Start electric motors for a very brief period of

time 2 to 3 seconds

Rotation in the wrong direction for more than 3 seconds will cause damage to the pump units

Change the connection cable terminals if required

III Trial start

The unit which has been disconnected for more than 1 month or stored must be also subjected to

trial start

The duration of the trial start must be sufficient for general operation check as well as for control

and automation system signal check

In case of any deviation from normal operation during trial start check the assembly or component

causing such deviation

72 Preparation for operation

ATTENTION

721 Complete de-conservation of the unit according to item 6

722 The unit must be placed horizontally level on a flat surface with hard top or compacted

ground Ensure unobstructed access to controls Install wheel chocks and extend the four supports

around the trailer

723 Ground the unit by a copper wire not less than 35 mm2 Grounding clip is located on the

frame on supply cable input side

724 Turn the main switch to the OFF position and open the control cabinet Turn on the automatic

switches

Connect power supply to the unit by a four-wire cable with main wire cross-section not less than

50 mm2 to the input terminals of the main switch and the PE grounding clip Close the control cabinet

and turn the main switch to the ON position Release the EMERGENCY STOP button

When power is supplied to the control cabinet the POWER light comes on Also if the phases are

connected correctly the PHASING light comes on

If the phasing control LED is not on and nothing is displayed on the controller screen open the

control cabinet and swap connections of phase wires A and C

If fault messages are displayed on the controller screen complete the recommended

troubleshooting procedures which can be found in the troubleshooting section of this manual

725 Vacuum pumps must be filled up with vacuum oil correct types of oil are listed in relevant

chapters of respective component manuals Check oil level at least once a day Check visually If the oil

level is below the maximum mark on the sight glass add oil to the max mark (If the mark is not visible

the maximum level is frac34 of the sight glass) The pumps are filled with oil at the factory during unitrsquos

acceptance testing

726 Check heating elements for insulation resistance In cold state insulation resistance must not

be less than 05 MOhm

727 Set the controller and ТS devices to the correct operation mode as per Table 7

Table 7

Mode Measurement limitTemperature controller

Controller ordmС (ТS) SK1 ordmС

Transformer oil degassing 50 65Transformer heating with hot oil 75 85

729 Check the unit for airtightness

- close valves

- press the MODE button to select DRY DEG mode

- press VACUUM to engage and start the vacuum pumps

- open valve MV3 create no more than 27 Pa vacuum in the vacuum chamber as indicated by the

vacuum meter DG

- press VACUUM again to stop vacuum pumps VP2- VP1

- after one hour check pressure in the vacuum chamber VC ndash increase of residual pressure due to leaks

and emission of gas from construction materials must not exceed 267 Pa otherwise repair leaks and do

this test again

73 Operation of the unit

The unit may operate in the following modes

- thermovacuum drying and degassing of transformer oil (DRY DEG)

- heating of transformer with hot oil (HampF VAC)

- vacuumizing of external equipment (HampF VAC)

731 Operation procedure

7311 Connect all pipelines Check stop valves of the unit from which the oil is processed used in

the process

7312 Adjust control and measuring devices according to the modes in table7

731 Select the required mode of operation by pressing the MODE button Pressing the button

cycles the modes in the following order

- heating and filtration (HampF) and external equipment vacuumizing (VAC)

- thermovacuum drying and degassing (DRY DEG)

732 Themovacuum drying and degassing ( DRY DEG )

Note Start the backing and vacuum pumps only when the required oil level is available

if necessary add some oil NEVER activate dry pumps

After mode selection check the temperature settings on the controller and the thermostat

Then start the preparation process

73211 Warm up the vacuum pumps Open the gas ballast valve (located near the inlet) of pump

VP1 to 45deg Press VACUUM to start the vacuum pumps Open valve МV3 The booster pump VP2

starts when vacuum in the system is 2000 Pa Let the pumps operate for 20-30 minutes Vacuum in the

system must not exceed 67 Pa Press VACUUM again to stop the vacuum pumps

73212 Fill the inlet hose and Р1 pump with oil To do so open valves MV1 MV10 Then press

INLET PUMP and fill vacuum chamber VС with oil to the level of LS1 which stops the pump Р1 turn

off the Р1 pump Open valve MV4 and start pump Р2 OUTLET PUMP open valve MV9 engage the

first heating stage HEATING1 engage vacuum pumps pressing VACUUM

When foam rises to the foam level sensor LS4 electric valve V3 opens momentarily and air enters

the chamber to reduce foaming When the foam level subsides the valve will close

If the foam level is not dropping or is rising close vacuum valve MV3

Continue drying the unit until oil temperature reaches 55 ndash 60 degС and foaming in the vacuum

chamber ceases Vacuum must not exceed 67 Pa

Note If filling of the inlet hose and pump P1 is difficult open valves MV1 MV10 and press

the OUTLET PUMP button Valve V1 opens the pipes the pump and the inlet hose will be filled

with oil and oil will enter the unit Continue operation as normal

7322 Then close valve MV4 and slightly open valve MV2 oil will go to the outlet of the unit

Close MV2 half way until the specific noise disappears (if any) and the output pressure is at least 1 - 15

7323 Start the pump P1 and process the oil to meet the required parameters If oil temperature is

not reaching the setting engage the second heating stage HEATING2

7324 After processing is complete disengage oil heater H five minutes later stop pumps P1 P2

and vacuum pumps VP1 VP2 by pressing the corresponding buttons and close valves MV1 and MV2

7325 Turn the main switch on the control cabinet to the OFF position

7326 Clean up spilled oil and wipe the unit dry Close all valves

NOTE Three level sensors L 1 L 2 L3 are mounted on the column allowing for automatic oil

level maintenance in the column Upon achieving upper level L 1 input pump P 1 stops with oil level

reduction in the column to sensor L 2 input pump P 1 starts Upon achieving minimal level L 3 output

pump stops with oil level in the chamber reaches sensor L 2 pump P 2 starts again To operate in this

mode pumps P1 P2 must be activated the pumpsrsquo start buttons must be pressed on control panel

Attention if intense foam formation occurs it is recommended to reduce capacity of the

unit by closing valve MV10

Attention in order to resume operation of the unit in case foam gets into vacuum collector

drain oil from it To do this connect hose DN15 to valve MV14 Open valve MV14 and drain

oil out to any tank Close valve check oil level in vacuum pumps and perform other necessary actions

to activate the unit

Attention Monitor the pressure difference at inlet and outlet of fine and coarse filters this

must not exceed 25 bar If the pressure difference on the filter is 25 bar change the filter

733 Transformer heating mode (HampF VAC)

For transformer heating connect the unitrsquos inlet to the transformer drain valve and the unitrsquos outlet

to the top valve of the transformer

7331 After selecting this mode check the operating temperature setting on the measuring regulator

and the thermostat Set the correct parameters according to Table 7

7332 open ball valves MV1 MV10 and MV2 wait several minutes while pump P1 primes then

engage the pump by pressing the INLET PUMP button

Note if priming of the pump is difficult use vacuum to do so as instructed above by select DRY

DEG mode on the controller after filing the piping and priming pump Р1 select HampF VAC mode

7333 Engage the heater by pressing the HEATING button

7334 Adjust the position of valves MV10 and MV2 for 1 ndash 15 bar outlet pressure

7335 Monitor pressure difference on the coarse filter (manometers M1 and M3) Initially when

the filter element is new the difference will be ~ 0 ndash 05 bar As the surface of the cartridge accumulates

contaminants the pressure difference will increase Maximum pressure difference is 25 bar

When the pressure difference reaches 25 bar stop filtration ie stop the unit reload the cartridge

or restore it Resume filtration

7336 When operation is complete disengage oil heater H five minutes later stop pump Р1 close

valves MV1 and MV2

7337 Turn the main switch into the OFF position

7338 Clean up spilled oil and wipe the unit dry

734 External equipment vacuumizing (HampF VAC)

7341 Select the HampF VAC mode

7342 Prepare the vacuum pumps (warm-up refer to section 73211)

7343 Connect the equipment to be vacuumized to the vacuum inlet and start the vacuum pumps

by pressing the VACUUM button

7344 Close valve MV3 monitor vacuum as indicated by the VACUUM device on the control

7345 When operation is complete disengage the vacuum pumps turn the main switch to the OFF

position

Note When HampF VAC mode is selected it is possible to simultaneously heat the transformer

and vacuumize it as described above

735 When operation is complete

- drain oil from the vacuum chamber VC through the valve MV6 form the heater H through the

valve MV7 and from the cartridge filters F1 F2 through the valves MV13 MV8 respectively

- drain remaining oil from the vacuum collector if any by opening the valve MV14

- vacuumize the unit (by starting the vacuum pumps and opening the valve MV3) for 15 minutes

then close all valves and stop the vacuum pumps

- turn off power from the supply cable and disconnect the cable from the unit

- install all stoppers

74 Changing adjusting and tuning process parameters

In the process of operation constantly monitor the following parameters

- the temperature of oil in the process as indicated by the temperature controller

- residual pressure in the chamber and in the oil trap while degassing oil as indicated by the

corresponding instrument on the control panel (VACUUM) and the controller

- pressure difference on cartridge filters F1 F2 and outlet pressure as indicated by manometers

М1 - М3

- oil level in the vacuum chamber as indicated by sensors LS1 LS2 LS3

8 Maintenance

1 The following maintenance procedures are applied

- inspection

- servicing

- repairs

- preparation for operation in cold temperature

2 Servicing and repairs schedule

- inspection ndash prior to start

- servicing ndash every 500 hours of work

First servicing after 100 hours

- repairs ndash every 2000 hours of work Servicing and repairs schedule is approximate

Servicing and repairs of parts components are to be in compliance with their respective operation

manuals

3 Inspection

- check for leaks in fittings and threaded connections

- check condition of connecting cables internal and external electric wiring

- check the unit for cleanness Remove contamination or rust and paint affected spots if required

- check oil level in vacuum pumps

4 Servicing

- inspect the unit

- tighten threaded connection

- clean coarse filters (if required)

5 Repairs

- service the unit

- check state of gaskets replace if necessary

- check condition of grounding Grounding resistance must be below 01 Ohm

- check condition of electric motors

- check starters electric wiring sensors etc

6 Preparation of the unit for operation at low ambient temperature

- it is recommended to change vacuum oil on according viscosity oil type regardless to operated time

Viscosity

Operating temperuatre о C

32 lt 0 о С

46 0 ndash 15 о С

68 15 ndash 30 о С

100 30 ndash 40 о С

- clean mesh filter replace fine and coarse filters if necessary

- drain contaminations from filters body-frames

- drain fluid from receiver OT

Other works specified below should be also performed regardless of exploitation time if it was

caused by a technical necessity such as failure premature deterioration etc

All servicing operations must be registered in a register with indication of executed work surname

and signature of mechanic who executed these operations It is necessary to carry out equipment

checkup with special authorities Periodicity of checkup is specified by territorial requirements where

the equipment is used During draining of contaminants filter washing or its replacement a disposal

must be carried out in accordance with territorial requirements

For general information on work schedule and composition see table 8

Table 8

8 0007 5007 0006 5006 0005 5005 0004 5004 0003 5003 0002 5002 0001 5001 000500

After first 100 hours

fittin

lter e

1 2 3 4 5 6 7 8 9 10 11 12 13

9 TroubleshootingSee the list of the most common problems and solution to them in table 9

Table 9Malfunction

manifestation of malfunction and

additional symptoms

Probable cause Solution

1 Residual pressure in the column at vacuum tightness check exceeds the norm

Vacuum system leakage Tighten flange connection bolts of vacuum column fine filter and oil pipes connecting them as well as flange connection bolts of vacuum circuit

Vacuum unit does not provide required pressure

Check operation of vacuum pumps when vacuum valve MV3 is closed If pressure exceeds 13 Pa perform the following operations- tighten bolt connections of vacuum circuit- change vacuum oil in vacuum pumps

2 Outlet pressure of the unit is less than 15 bar

Filter elements of filters F1 F2 are contaminated

Change filter elements or wash them

3 Drive motors of pumps can not be started

Starterrsquos thermal insertion functions

Define reasons of thermal protection response and eliminateIf ambient temperature is below +10ordmC heat the unit and restart it

Use vacuum oils of correct viscosity

4 Incorrect shaft rotation direction of the drive motor

Phases are commutated incorrectly

Reconnect 2 conductors swapping them

5 The unit can not be started

There is no power voltage Check

Automatic switches tripped Check define the reason of tripping and eliminate

6 Noise and vibration excessive

Insufficient setup stiffness of pump and motor

Tighten piping connections

Pump mechanical failure touching of revolving parts

Repair mechanical failures

7 Low capacity Filters F1 F2 MF contaminated

Open the filter clean it or change

8 Leaks through fittings

Bolted connections are loose Tighten bolted connections

Gaskets damaged Replace gaskets

9 Oil temperature does not increase with heater on

Heater power supply line broken

Check the line clear the break

Wrong settings on measuring regulator (low max temperature setting)

Adjust temperature according to p 4181 of this operating manual

10 Pump takes in air during oil pumping

Lower level sensor failure Repair or change

Controller fault messages

1 Second line displays ldquoТ1 Disconnectrdquo

This indicates no signal from the oil temperature sensor (T1 on electric diagram) is available

This fault triggers emergency stop of the unit This fault triggers emergency stop of the unit

Possible causes and solutions

Possible cause Solution Note

No contact Check sensor connection repair

as necessary

Sensor damaged Replace with new

2 Alarm Overheating in the second line

This message indicates oil overheating sensed by T1 Factory temperature limit setting is 950C

Oil heaters failed to disengageCheck oil heating control

circuits and magnetic contactors

Repair as

necessary

3 TS in the second line

This message indicates possible overheating o oil or no signal from the thermostat (TS1 on electric

diagram)

This fault triggers emergency stop of the unit

No contact with the thermostatCheck connection repair as

necessary

Thermostat damaged Replace with new Brand

Max temperature setting below

the process temperature Inter the correct setting Max setting is 85oC

circuits and magnetic contactorsRepair as necessary

4 MS in the second line

This message indicates that thermal protection of one or several components tripped (Q1-Q4 on

electric diagram)

Possible cause Solution Note30

Heat protection of one of

the components tripped

Inspect the component in

question

Set the automatic switch to

Perform a test start

observing the operation of

the component in question

If the thermal protection

trips again determine

malfunction

Contact the

manufacturer

if necessary

5 Alarm Flow in the second line

This message indicates no flow of oil or failure of the flow switch (FS1 on the electric diagram)

No oil flow Ensure the oil is flowing

No contact with the flow switchCheck connection and repair the

contact

Flow switch damaged Replace with new Brand

6 Error Flow in the second line

This message indicates failure of flow switch FS1 or that the oil is flowing while the input or

output pumps are stopped

7 Blinking XX over level sensor symbol in line 4

This message indicates false tripping of the sensors or no contact with the level sensors (L1-L4 on

the electric diagram)

No contact with level sensorsCheck connection repair

contact

Sensor damaged Replace with new Brand

8 Alarm Foam in line 4

This message indicates foaming is occurring in the vacuum chamber (L4 in the electric diagram)31

V3 air inlet valve inoperative Determine cause and repair

No contact with the sensorCheck connection repair

contact

9 Oil in Trap in line 4

This message indicates oil is present in the oil trap of the unitrsquos vacuum system

Oil in the oil trap

Determine cause of oil entering

the trap Drain the oil from the

False positive indication of the

sensor in the oil trap

Adjust sensor sensitivity

Replace with new sensor if

necessary

10 Oil in Tray in line 4 (oil in the spill tray)

This message indicates some oil was spilled into the spill tray

Oil in the spill trayDetermine cause of oil spill

Remove oil from the tray

sensor in the oil tray

necessary

11 Low vacuum indication ldquoVrdquo in line 3

This message indicates that the vacuum is insufficient for processing This parameter is controlled

by the vacuum switch (U5 in the electric diagram)

If this message is displayed the unit will continue operation for 120 seconds attempting to

achieve the required vacuum in the system

If the unit fails to achieve the required vacuum within the allotted time the unit will stop

immediately and the message Low Vacuum will be displayed in line 4

Vacuum system not airtight Repair leaks

The volume of the vacuumized

vessel is too largeAdjust process conditions

12 EMERGENSY STOP message in line 4

This message indicates that the EMERGENCY STOP button has been pressed (S1 in the electric

diagram)

After releasing the button unblock the unit by pressing the ALARM OFF button

10 List of consumables

Material Application Qty1 Filtering element Fine filter FP1 FP2 2

2Vacuum circulation oil Vacuum pumps

RVB-2020 11 lСР 40-620 20 l

11 Disposal of equipment and consumables

During operation of the equipment it is necessary to dispose of consumables as well as of the

equipment when the unitrsquos life time ends

Disposal procedure requires strict adherence to the local territorial regulations with regard

to sanitary environmental and other safety measures

The manufacturer suggests the following procedures for disposal (when such procedures are not

explicitly outlined locally) as follows

- dispose of filtering elements by separation of metal elements from the filtering medium Dispose

of the metal by submitting it to recycling centers the remaining components can be disposed of as is

usual for ordinary waste

- dispose of the equipment by disassembling the unit into separate components and subassemblies

All components are to be disposed of as per their respective manuals Submit the components to

recycling centers (metal rubber etc)

- dispose (if required) of oil and contaminants by burning in furnaces or submit to specialized

agencies for disposal (destruction) of the substance

12 Conservation and acceptance certificates

CONSERVATION CERTIFICATE

Mobile oil station CMM factory No ____________

was conserved according to requirements specified in effective technical documentation

Storage period without reconservation is 6 months

Accepted after conservation by ____________________

STAMP Signature

ACCEPTANCE CERTIFICATE

Mobile oil station CMM factory No ___________ was manufactured and accepted

according to the requirements of normative documents effective technical documentation and was

deemed acceptable for operation

Date of manufacture ______________

STAMP Signatures of responsible persons

___________________________

13 List of appendices

Appendix

numberTitle of appendix

Appendix

location

АPumps СР40

Operational Manual

Separate

booklet

С Filter element data Manual

DVacuum pump RVB-2020

Manual

Separate

booklet

E Electric diagram Separate

booklet

G Autonics ТК4 manual Separate

booklet

Appendix С

FILTER ELEMENT DATA

Primary specifications of filter elements are given in table C1

Table C1

Specification Value

1 Rated filter fineness micron max 52 Min sifting rate 50003 Min nominal flow rate (at oil viscosity

30 cSt) galmin 16654 Flow direction Outside-gt in

5 Pressure drop psi 206 Max pressure psi 757 Max temperature 0F 2248 Filter area m2 2329 Weight kg max 39710 Dimensions

- external diameter (D) mm- internal diameter (d) mm- height (H) mm

15000870037000

Disposal

Dispose of the filter element by separating the shutter and delivering it as consumer waste All other metallic components are disposed of as scrap metal