PALL MACHINERY & EQUIPMENT COMPANY

PALL HVP-902 PORTABLE FLUID PURIFIER

CUSTOMER NAME:________________________ MODEL NO._______________________________ S/N________________________________________

OPERATION AND MAINTENANCE MANUAL

PART NUMBER

HVP 902 480 KZ H W N

220 KP Z P C 575 KN F 380(50 Hz)

Issued: August 1999

TABLE OF CONTENTS GENERAL INFORMATION AND OPERATING INSTRUCTIONS Section I. GENERAL INFORMATION

A. General Description....................................................................................... 1 B. Principals of Operation ..................................................................................2 C. Specifications ................................................................................................4

Section II. OPERATION

A. Precautions ....................................................................................................6 B. Controls and Indicators .................................................................................7 C. Purifier Set-up..............................................................................................10 D. Purifier Start-up ...........................................................................................13 E. Purifier Shut-down.......................................................................................15

MAINTENANCE Section III. SERVICING

A. Recommended Spares ................................................................................16 B. Routine Maintenance ...................................................................................17 C. Flushing Procedures ....................................................................................22 D. Drain Procedures ........................................................................................23 E. Vacuum Pump Purge Procedures ................................................................24

Section IV. TROUBLE-SHOOTING

A. Trouble-Shooting Guide ..............................................................................25 Section V. APPENDIX

1) Supplementary Spare Parts List 2) Vacuum Pump – Manufacturer’s Information 3) Electrical Schematic 4) Hydraulic Schematic

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GENERAL INFORMATION AND OPERATING INSTRUCTIONS

Section I. GENERAL INFORMATION

A. GENERAL DESCRIPTION

The Pall HVP-902 portable fluid purifier (hereinafter referred to as the purifier) is a product which removes water, solid particulate contamination, air, and gases from lube, hydraulic, and insulating oils. The water removal principle used is simple and reliable, and will dependably remove water to well below the saturation point even under the adverse condition of 100% relative humidity ambient air.

The mechanical components of the system are uncomplicated and require little routine maintenance. Most components can be field repaired without special tools.

This manual is designed to serve as the basic handbook for Pall HVP-902 Oil Purification Systems. Persons concerned with installation, operation, and/or maintenance, should be thoroughly familiar with the contents of this manual to ensure satisfactory performance of the unit. This purifier has been thoroughly factory tested to ensure satisfactory operation. If questions arise during start-up, contact your local distributor or the Technical Services Group of Pall Machinery & Equipment Company at 1-888-333-7255.

Damage Claims:

Inspect the unit upon arrival for possible damage incurred during shipment. In the event that the equipment has been damaged during shipment, immediately enter a claim with the shipping carrier. Pall Corporation or our representative should also be contacted for assistance, if necessary.

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B. PRINCIPLES OF OPERATION

Purifier Flow (See Figure 1)

The purifier employs the principles of mass transfer and vacuum dehydration to achieve highly efficient removal of water, solvents, and gases. Contaminated oil is drawn into the purifier by tower vacuum maintained via a vacuum pump (11) driven by the drive motor (25). The oil enters the purifier through a 10 mesh strainer (18) and proceeds through an inlet valve (1) and a heater (2), which is thermostatically controlled to maintain the temperature of the oil. The oil proceeds through two 2-way solenoid valves. The small solenoid, bypass valve (5) is open whenever the purifier is running to allow a small amount of oil to always flow through the heater. The larger solenoid valve (3) cycles to regulate the main flow of oil through the purifier, maintaining a predetermined range of oil level in the vacuum tower (4). This valve is controlled by high and low level float switches in the lower portion of the tower. The oil enters the top of the tower through a sight glass (6) and flows downward over dispersion material which greatly increases the surface area per unit volume of oil.

Free and dissolved water and air are removed by exposing the contaminated oil to a low relative humidity atmosphere which is obtained by maintaining the tower at 15 - 22 inches Hg on gauge (J). Ambient air is drawn into the purifier vacuum tower through an inlet air filter (7) and a restrictor needle valve (20).

Air enters near the middle of the tower and travels upward, against the downward flow of oil. Water and gases are absorbed by the upward air flow, and exit at the top of the tower through the mist eliminator (9), which removes any excess oil mist returning it to the inlet of the discharge pump (16). The air/vapor mixture then enters the rotary vane vacuum pump (11). If the vacuum pump inlet becomes obstructed, air will enter the pump through a relief valve (12), to prevent damage to the pump. The vacuum pump is equipped with an oil reservoir (13) which circulates lubricating oil to the pump bearings and vanes. The reservoir contains internal coalescing element(s) to minimize carryover of lubricant with the vapor flow. A final coalescing filter (14) removes excess oil mist carryover, prior to discharging the moisture laden air to the atmosphere. If these coalescing filters become clogged, a differential pressure switch (15) will shut the purifier down, and a HIGH EXHAUST PRESSURE will be indicated on the display panel. With this condition, the unit cannot be operated until the final coalescer elements, and/or the vacuum pump internal coalescer elements are changed.

Purified oil collected at the bottom of the tower is removed by a discharge pump (16) which directs the oil through the outlet filter (17) and back to the reservoir. Outlet oil pressure is monitored by the OUTLET PRESSURE gauge (K) on the panel. The discharge pump is equipped with a bypass relief valve factory preset at 75 PSI.

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The purifier employs a programmable logic controller (PLC) which monitors and sequences its operation. The PLC monitors the level of oil in the tower, the condition of the discharge filter, the outlet coalescing filters, and the status of the electric motor (overload or short circuit conditions). The front of the control enclosure includes a PanelMate LCD control panel along with a lighted start/stop button and a red alarm lamp. These controls will start and operate the purifier, indicating operating and alarm status, and total operating hours. Automatic controls will safely shut down the purifier if internal oil levels exceed normal limits (high and low oil level monitors). This ensures a constant throughput of 15 gpm.

Note: The part identification numbers used in this section refer to Figure 1 only and do not match the drawing identification numbers on the blue prints inserted in the Appendix. PanelMate is a registered trademark of Cutler HammerIDT.

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C. SPECIFICATIONS

Process Fluid Type: Hydraulic, lubricating and dielectric oils having a minimum flashpoint of 200°F (93°C) per ASTM D92 or 180°F (82°C) per ASTM D93. Compatibility dependent on purifier seal material used. See below.

Seal Compatibility:

Code

Seal Material

Fluid Serviced

H

Buna N

Petroleum Based

Z

Fluorocarbon

Petroleum Based, Certain Synthetics

Inlet Fluid Temperature (maximum) +160°F (66°C) Inlet Pressure 14 inches Hg. to 15 psig (a positive

pressure at the purifier inlet may require one or both of the inlet restricter orifices. (Refer to the matrix on the next page).

Fluid Circulation Rate 15 gpm (57 LPM)

Operating Viscosity 1300 SUS (260 cSt) Max.

Vacuum Tower, Operating Vacuum 15 - 22 in. Hg.

Discharge Filter Element Rating 1,3, or 6 micron (βx ≥ 200)

Electrical Power Requirements 380 (50Hz), 240,480,575 VAC, 3 phase,

60 Hz with neutral, 22 kW maximum

Motor 3 HP

Heater capacity: 18 KW - 480V & 240V, 13KW - 575V, 16.7KW - 380V

Hose Connections: Inlet 1-1/2" NPT I.D. minimum x 20 feet maximum,

rated for suction and return line service per SAE 100R4. (max. lengthvaries with viscosity).

Outlet 1-1/4" SAE straight thread I.D. minimum

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Dimensions: Height (maximum) 78 inches Width (maximum) 31 inches Length (maximum) 54 inches Weight (dry) 1250 lbs. maximum - Standard. Unit

(without options) Matrix for determining if additional orifices are required for purifier operation. Ref. Fig. 1

INLET CONDITIONS

Oil viscosity

(At purifying temp)

15" Hg vacuum to 5 psig

5 psig to 15 psig

≥ 150 ssu

None

B

<150 ssu

A

A+B

A = 1/8" Orifice for heater bypass line B = 1/2" Orifice for main inlet line NOTE: For extremely low viscosity oils (less than 60 ssu) additional throttling of the inlet gate

valve may also be required. Installation of restricter orifices: (Orifice Kit P/N B-15743) A. Heater Bypass Line - Install downstream of heater bypass line solenoid valve (3/4" line).

Disconnect heater bypass line at vacuum tower. Install 1/8" orifice in line fitting and reattach to vacuum tower.

Note: This adapter piece has one male and one female set of threads. B. Main Inlet Line - Install between the main inlet fitting and 1 1/2" (customer supplied) suction

line.

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SECTION II. OPERATION A. PRECAUTIONS

WARNING: DO NOT USE PURIFIER ON ANY OIL CONTAMINATED WITH EXPLOSIVE OR

FLAMMABLE SUBSTANCES. DO NOT USE PURIFIER ON ANY OIL WITH A FLASHPOINT BELOW 200°F (93°C) PER ASTM D92, OR 180°F (82°C) PER ASTM D93.

WARNING: IF A POSSIBILITY EXISTS THAT THE PROCESS OIL CONTAINS CONTAMINANTS THAT

MAY PRODUCE HAZARDOUS VAPORS (TOXICANTS, IRRITANTS), ENSURE THAT ADEQUATE PRECAUTIONS ARE TAKEN TO CAPTURE OR VENT AWAY VAPORS IN ACCORDANCE WITH LOCAL SAFETY CODES AND APPLICABLE SAFETY PRACTICES. CONNECT A SUITABLE OUTLET LINE (3/4" ID MINIMUM) TO THE COALESCING FILTER OUTLET.

CAUTION: PROCESS OIL MUST BE COMPATIBLE WITH PURIFIER SEALS (SEE SPECIFICATIONS). IF

ANY DOUBTS EXIST ABOUT PROCESS OIL COMPATIBILITY WITH REGARD TO A PARTICULAR PURIFIER UNIT, CONTACT THE PALL MACHINERY & EQUIPMENT COMPANY, EAST HILLS, NEW YORK, APPLICATIONS ENGINEERING DEPARTMENT. (516) 671-4000

CAUTION: ENSURE OIL COMPATIBILITY EXISTS BETWEEN OIL TO BE PROCESSED AND THE

IMMEDIATELY PREVIOUSLY PROCESSED OIL. IF UNIT IS TO BE USED FOR THE FIRST TIME, DETERMINE COMPATIBILITY BETWEEN FACTORY TEST OIL AND THE PROCESS OIL. SEE FACTORY TEST SHEET (ATTACHED TO PURIFIER) TO DETERMINE OIL USED DURING FACTORY TESTING. IN BOTH CASES, IF INCOMPATIBILITY EXISTS, FLUSH THE PURIFIER THOROUGHLY USING THE FLUSHING PROCEDURES IN THE MAINTENANCE SECTION OF THIS MANUAL.

CAUTION: THIS EQUIPMENT IS TO BE INSTALLED IN ACCORDANCE WITH THE NATIONAL

ELECTRICAL CODE AND LOCAL CODES AND ORDINANCES. INSTALLATION IS TO BE PERFORMED BY A LICENSED ELECTRICIAN AND INSPECTED BY LOCAL AUTHORITIES.

CAUTION: IF OIL LEVEL IN VACUUM TOWER EXCEEDS VISIBLE LEVEL IN THE TOWER SIGHT

GLASS OR IF OIL APPEARS TO BE VENTING FROM THE INLET AIR BREATHER, DRAIN THE VACUUM TOWER UNTIL AIR CAN BE SEEN IN THE TOWER SIGHT GLASS IN THE REAR LOWER SECTION OF THE VACUUM TOWER BEFORE STARTING THE PURIFIER.

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B. CONTROLS AND INDICATORS (Table 1 lists and describes purifier controls and indicators.)

TABLE 1

CONTROLS AND INDICATORS CONTROL/INDICATOR

FUNCTION

CONTROL ENCLOSURE

The purifier control enclosure contains the electric service disconnect, operating controls and indicators, electric motor and heater line-protection and contactors, and is equipped with a programmable logic controller (PLC) which monitors and sequences the operation of the purifier. The PLC monitors the level of oil in the tower, the condition of the discharge and coalescing filters, control and status of the electric motor (overload or short circuit conditions), and the heater.

CONTROL PANEL

The front panel of the control enclosure includes controls to start and stop the purifier, and the PanelMate LCD display to indicate operating status. See next section for details on the PanelMate display.

MAIN ELECTRICAL DISCONNECT

The electrical service disconnect is engaged by a throw-lever on the front of the enclosure. The enclosure cannot be opened when this lever is in the "ON" position. When the lever is in the "OFF" position all circuits within the enclosure are disabled. This disconnect can be locked out.

START/STOP BUTTON

This is a lighted, momentary contact, pull-to-start/push-to-stop switch used to start and stop the purifier. The green light will begin flashing four seconds after control power is applied. This flashing light indicates the unit is ready to run. A steady light indicates the purifier is in operation. PUSH TO RESET ALARMS PRIOR TO RESTARTING.

PUMP MOTOR

A three horse-power electric motor, runs continuously to power the vacuum and discharge pumps. An IEC type motor controller provides short circuit and overload protection.

HEATER CONTROL

The heater is protected by a 3-phase current limiting breaker in the control cabinet, and is controlled by a IEC type controller and circuit protection in the cabinet along with two thermostats. The main system control thermostat adjustment is accessed through the Panel Mate. See footnote * at end of this section. Do not adjust this thermostat above 160°F. A second thermostat for over temperature safety shutdown is located on top of the heater vessel under a cover with eight 1/4-20 bolts. This is factory preset at 165°F and should never exceed 185°F. Maintain at least a 25°F difference between the two thermostats. Either one of these thermo stats will prevent overheating of the oil in the heater chamber, even if the flow of oil should be interrupted.

PanelMate is a registered trademark of Cutler-Hammer IDT

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CONTROLS AND INDICATORS CONTROL/INDICATOR

FUNCTION

PLC

The programmable logic controller (PLC) monitors the condition of the controls and feedback devices of the purifier. The PLC contains a program specifically designed for the HVP-902 purifier. This program is stored on board the PLC in EEPROM memory. The program does not require any modification for normal use of the purifier.

GAUGES

A panel with three dial-type gauges is located on the purifier tower shroud. Below is a brief description of each gauge.

INLET OIL PRESSURE/VACUUM GAUGE

Combination pressure/vacuum gauge, indicates the inlet condition of the purifier. The inlet condition may depend on oil viscosity, elevation difference between the purifier and oil source and the plumbing between the purifier inlet and the oil source. Normally the gauge will read from 12-14 inches Hg. to 10 psig.

TOWER VACUUM GAUGE

This gauge indicates the vacuum condition in the purifier tower. This gauge should read from 15 to 22 inches Hg. A metering valve in the air inlet line is used to adjust the vacuum within the tower. This valve is factory preset and under normal operating conditions should not be adjusted.

OUTLET OIL PRESSURE GAUGE

This gauge indicates the pressure at the outlet of the discharge oil pump. The outlet condition may depend on oil viscosity, elevation difference between the purifier and the oil source and the plumbing between the purifier and the oil source. The discharge pump is equipped with a bypass relief valve factory set at 75 psig (5 bar).

TOWER OIL TEMPERATURE

Current oil temperature going into the tower is shown on the PanelMate Display. Purifier efficiency depends on the temperature of the oil. Initial oil temperature may vary depending on the oil source. Typically, the purifier should not be run on oil at a temperature of less than 70°F. The maximum temperature may vary with the oil being purified. Normally the maximum recommended oil temperature is 160°F.

*Temperature setting can be lowered for specific fluids/applications. For systems with constant visible water ingression where high water removal performance is required, one of the three settings below is generally recommended: 1. 160°F; for high viscosity fluids (>300 SSU at equipment operating temperature). 2. 145°F; for medium viscosity fluids (100-300 SSU at equipment operating temperature). 3. 130°F; for low viscosity fluids (<100 SSU at equipment operating temperature). For fluids with moderate water contamination, a 20°F lower temperature should be considered for energy savings. Contact Pall Machinery & Equipment Company Technical Services Group if questions exist 1-888-333-7255.

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1. LCD Panel - Alarms

Six key functions of the HVP 902 Oil Purifier are monitored and displayed on the LCD panel mounted on the control box. Status conditions are displayed for “Current Temp” , “Filter” , and “Heater” on the LCD panel. The other functions only are displayed if an alarm condition occurs. A shutdown or overload condition will illuminate the red light mounted below the panel. A shutdown will also cause an alarm relay to switch for customer remote alarm if connected.

FUNCTION

STATUS

COMMENTS

1. Exhaust Pressure

Normal High (shutdown)

Vacuum pump, Exhaust Pressure switch is set for a maximum of 10 psi (.7 Bar). There is a 5 second start up delay during tower evacuation.

2. Tower Level

Normal High (shutdown) Low (shutdown)

Tower level is measured by 4 floats inside tower @ a max. height of 16”. At high level a 60 second delay to shut down. *** At low level a 120 second delay to shutdown.

3. Current Temp.

Shows Current Oil Temp. @ Control Valve

Available in °F & °C.

1. Filter Alarm

Filter Status

Normal (green) Change (red or yellow) Shutdown (shutdown) (red)

Filter Pressure Drop is measured by a differential indicator on the discharge filter. “Change” = Delta P at or exceeding 16 psid. After 24 hours “shutdown”, purifier will shutdown.

5. Pump Motor

Overload

Should the motor OVERLOADS TRIP, unit will shutdown and show “Hydraulic Pump Overload”.

6. Heater Control Heater Contactor Status

Off (yellow) Running (green) Overload (red)

“Off” = heater is enabled and not running (at or above set point). “Running” = heater is enabled, running (below set point). “Overload” = heater protection circuit has been tripped. (Short circuit or beyond high temp set point). Heater turns off @ set point (+1°), back on @ set point (-1°).

*** When this condition exists, the purifier tower should be drained prior to re starting. Failure to do so could result in vacuum pump flooding and failure. Also, vacuum pump inlet line may need purging to avoid pumping liquid and damaging the vacuum pump. See section III D and E for instructions. The following page shows a layout of the various displays of the LCD.

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C. PURIFIER SET-UP

1. GENERAL

The HVP-902 Oil Purifier is a portable system; therefore it only requires an open space with fresh air ventilation close to the contaminated oil reservoir and the required electrical source. It is suggested that all operators of this equipment familiarize themselves with this instruction book.

2. EQUIPMENT CHECK

Because of vibration and possible mishandling of equipment in transit, all connections and indicating lights should be checked for tightness. Tighten connections as required. Damage Claims: Inspect the purifier upon arrival for possible damage incurred during

shipment. In the event that the equipment has been damaged during shipment, immediately enter a claim with the shipping carrier. Pall Machinery & Equipment Company and your distributor should also be contacted for assistance, if necessary.

3. INSTALLATION

a. Electrical Connection

i) Use only voltage specified on purifier name plate. If a voltage different

than that specified on the name plate is to be used, contact Pall Machinery & Equipment Company, Applications Engineering Department at (516) 484-3600.

ii) Refer to the label attached to the purifier electrical control box and

specification sheets in this manual to insure that proper voltage and current is supplied to the unit.

For 480 Volt Models: *

iii) Recommended fuse sizes are:

Transformer primary = Bussman FNQ-R 2.5 A Transformer secondary = Bussman F.M.- 4.5 A.

iv) In control box, check that all circuit breakers are closed.

NOTE: This equipment is to be installed in accordance with the National Electric Code

and local codes and ordinances. Installation is to be performed by a licensed electrician and inspected by local authorities.

*Recommended fuse and light bulb sizes are given on a black label inside the control cabinet door, for the actual voltage and options on your particular unit.

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WARNING: REVERSE ROTATION WILL DAMAGE VACUUM PUMP.

b. Motor Rotation

Proper motor rotation is imperative to purifier operation. This must be checked each time the HVP-902 is moved to a new location. Proper motor rotation eliminates possible damage to pumps.

Check motor rotation by supplying power to the unit and jogging the on/off switch. An arrow on the motor designates correct motor rotation. If it is necessary to reverse motor rotation, disconnect and lockout supply power and swap any two (2) power input leads labeled L1 , L2 ,L3 on the disconnect. This procedure should be performed by a licensed electrician only. Purifier main electrical disconnect and/or supply power should be turned off and locked out first for safety.

Reconnect input power and proceed with set-up.

c. Vacuum Pump Pre-start

After proper rotation of motor is determined, the vacuum pump oil in the

reservoir should be checked for proper fill level - up to the bottom edge of the top sight glass (27). To fill the reservoir, remove cap (10) and fill with a synthetic Polyalfolefin (PAO) non-detergent ISO VG 100 oil as noted below. DO NOT OVERFILL, and never add oil to a running pump. If the top sight glass is completely full, drain some oil out through the drain valve (19). Ref. Pg. 4 Fig. 1

Recommended Vacuum Pump Oil (approx. 2 quart capacity) See Section III

d. Inlet and Outlet Plumbing

Connect a 1-1/2" I.D. minimum x 20 feet max. length hose between inlet port of purifier and the fluid reservoir. The inlet port has a 1-1/2" NPT port. Maximum length of hose is dependent upon oil viscosity and purifier elevation above reservoir. Inlet hose must be rated for suction and return service per SAE 100R4. Quick disconnect and 90° bends should be avoided in the inlet hose. Use Max. Dia. and the shortest possible length to insure good performance.

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Customer Reservoir

i) Suction connection at customer's reservoir should be at least 6" (150 mm) above the bottom of the reservoir to prevent heavy sediment from being drawn into the purifier.

ii) The reservoir oil level should be not lower than 20 feet below the base

of the oil purifier. (20 feet maximum under optimum conditions; such as oil viscosity #150 ssu, negligible horizontal distance, no 90° bends and minimum aperture size 1-1/2 inches). If there is a question, contact Pall Applications Engineering.

iii) Reservoir should also be equipped with a drain connection at the

bottom to remove free water and heavy sediment. Connect a 1-1/4"I.D. hose between outlet port of purifier and the fluid reservoir. The outlet port has a 1-1/4" SAE straight thread.

e. Pressurized feed

The HVP-902 runs continuously provided the oil feed pressure to the purifier is above 12-14 inches Hg. (560 mm) vacuum and below 15 psig pressure at purifier inlet. For installations where the feed pressure is above 10 psig, one or both of the inlet restricter orifices listed on page 7 may be required. These orifices are located in a plastic bag on the back of the purifier. See page 7 for installation directions.

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D. PURIFIER START-UP

CAUTION: THE PURIFIER MUST BE WIRED AND PLUMBED

ACCORDING TO ALL INSTALLATION INSTRUCTIONS. ALL HYDRAULIC FITTINGS AND ELECTRICAL CONNECTIONS MUST BE TIGHT.

Check level of the vacuum pump oil reservoir. If necessary, add recommended lubricant (refer to Section II. C.3.c. of this manual and Section III. A. Table 2).

1. Open the inlet valve (1-1/2" gate valve) located at the bottom of the heater. To open this

valve turn the handle counter-clockwise until the stop is reached.

2. Turn the Main Electrical Disconnect switch to "ON". The "Pull-to-Start" button light will start flashing after approximately four (4) seconds.

3. Pull and release the Pull-to-Start/Push-to-Stop button. The electric motor should start

and continue to run. It may take several start ups at first if the oil being purified is cold, or if the purifier is empty.

4. As the vacuum level in the tower rises, oil should be drawn through the inlet and into the

tower. This may take some time depending on inlet conditions. If an insufficient amount of oil enters the tower, the purifier will shut down after two minutes. If this occurs check the inlet line from the purifier back to the source for obstructions or loose fittings. Restart the purifier. If purifier does not remain operating after two more minutes, please refer to the Trouble-Shooting section of this manual.

5. As oil accumulates in the bottom of the tower its level may be viewed through the sight

glass. The level in the bottom of the tower may change depending on inlet conditions.

WARNING: TOO HIGH A VACUUM LEVEL MAY DAMAGE THE

VACUUM PUMP.

6. Check the TOWER VACUUM gauge. This should read about 15 to 22 inches

Hg.(Tower Vacuum will be on the lower side of this range with oil having a significant amount of water contamination, >1%. The tower vacuum gauge will fluctuate slightly during solenoid valve cycling. This is normal.

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WARNING: AIR INLET METERING VALVE IS PRESET AT

THE FACTORY AND SHOULD NOT BE ADJUSTED. IMPROPER ADJUSTMENT CAN LEAD TO VACUUM PUMP DAMAGE.

7. Check the OUTLET PRESSURE gauge. The discharge pump internal relief valve is

factory set at 75 psig (5 bar). If the OUTLET PRESSURE gauge approaches this pressure there may be an obstruction in the outlet line. Check the outlet line from the purifier back to the source for any restriction. Discharge filter may also be plugged.

8. Bleed air out of discharge filter into a container via air bleed valve located on the top of

the filter housing. Open valve until all air bleeds out. Close bleed valve.

9 . Check the control panel. During normal operation the following status should be observed:

START/STOP Lamp . . . . . . . . . . . . . . . . . . . . . . Steady Green ALARM LED . . . . . . . . . . . . . . . . . . . . . . . . . . . Green LED HEATER CONTROL . . . . . . . .. . . . . . . . . . . . . . Yellow or Green LED

RED ALARM LIGHT . . . . . . . .. . . . . . . . . . . . . . Off FILTER STATUS . . . . . . . . . . . . . . . . . . . . . . . . Green LED

Display “Home Page” Reads Current Temperature in °F and Temperature Set Point in °F. Note Page 12.

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E. PURIFIER SHUTDOWN

NOTE: THE PURIFIER WILL SHUT DOWN AUTOMATICALLY IF OIL LEVEL INSIDE THE VACUUM TOWER FALLS BELOW A PREDETERMINED POINT (LOW LEVEL SHUTDOWN) OR RISES ABOVE A PREDETERMINED POINT (HIGH LEVEL SHUT DOWN) IT WILL ALSO SHUT DOWN DUE TO HIGH EXHAUST PRESSURE (INDICATING A CLOGGED COALESCER FILTER ELEMENT OR A FULL COALESCER SUMP), OR FROM A FILTER ALARM (INDICATING A PLUGGED DISCHARGE FILTER ELEMENT).

1. Shut inlet gate valve and run purifier until low level shuts unit down.

2. Push Pull-to-Start/Push-to-Stop button to the "OFF" position and turn MAIN

DISCONNECT to "OFF".

3. If you intend to use the purifier on a different type of oil, drain and flush to prevent cross contamination. See flushing procedure, Section III, C.

4. Shut reservoir ball valves and purifier inlet gate valve.

5. Disconnect hoses from unit and install JIC plugs in hoses and caps on fittings.

6. Check vacuum pump oil reservoir level and top off if necessary. (This makes it easier for the next user).

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MAINTENANCE SECTION III. SERVICING

A. Recommended Spares

Table 2 lists recommended spares that should be stocked to support basic purifier maintenance. Table 2

RECOMMENDED MAINTENANCE SPARES PART NUMBER

DESCRIPTION

QTY

HC8314F**39H*

Discharge Oil Filter Element

6

HC0293SEE5

Inlet Air Breather Element

2

1325037

Exhaust Coalescer Element

2

Vacuum Pump Oils - Requires Synthetic Polyalfolefin (PAO)

ISO VG100

Conoco-Syncon R & O 100 (800-255-9556) Texaco - Pinnacle 100 (800-782-7852) Royal - Royco 786 (800-989-7692) Summit SHV-100 (903-534-8021) Chemlube 530, or equal

2 Gallons

1353447

Vacuum Pump Coalescer Element

2

* HC8314FKZ39H β1 ≥ 200

HC8314FKP39H β3 ≥ 200 HC8314FKN39H β6 ≥ 200

Replacement fuses: 480 volt model

Transformer primary = Bussman FNQR- 2.5 A Transformer secondary = BussmaF.M.NM 4.5 A PLC output = Bussman AGC-2A

Replacement indicator lamps:

Standard pilot lights = Sylvania or G. E. #755 (6 volt) Push/pull switch = Sylvania or G. E. #12 (6 volt) *Recommended fuses and light bulb sizes are given on black label inside the control cabinet door, for the actual voltage and options on your particular unit.

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B. ROUTINE INSPECTION AND MAINTENANCE

Perform routine maintenance at specified intervals or as warranted by operating conditions.

1. DAILY SERVICE

A) Check that the unit is operating with all alarms reading “Normal” or “Running”

and that gauges are within acceptable limits (See Section II B. Controls and Indicators). Service those items requiring service per procedures shown in section 4. below.

Check Vacuum Pump Oil Reservoir level.

WARNING: DO NOT ALLOW THE VACUUM PUMP OIL RESERVOIR

TO RUN DRY OR TO OVER FILL. VACUUM PUMP DAMAGE MAY OCCUR.

2. WEEKLY SERVICE

A) Drain exhaust coalescer by opening the petcock at the bottom of the bowl.

Allow fluid to drain into suitable container. Dispose of properly.

3. MONTHLY SERVICE

A) Change Vacuum Pump Oil every 500 hours of operation or monthly if the purifier is used continuously. Drain the used oil from the reservoir into a suitable container through the drain valve (19), and fill with approximately 2 quarts of the recommended lubricant. DO NOT OVERFILL, and never add oil to a running pump. If the top sight glass is completely full, drain some oil out through the drain valve (19).

Use Recommended Vacuum Pump Oil (approx. 2 quart capacity) See Table 2 of previous page

4. SERVICE AS REQUIRED

a) Discharge Filter Element

The purifier will shut down when bypass of this filter is imminent. The FILTER ALARM on the control panel will indicate if this is the cause of shutdown. Follow the instructions below for removal and replacement of the filter element.

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i) Shut down purifier by pushing the Push-to-Start button in and releasing. ii) Turn the MAIN DISCONNECT switch to the "OFF" position. iii) Lock out the MAIN DISCONNECT. iv) Open bleed valve on top of filter housing cover. v) Drain oil from filter housing using drain valve at bottom of housing. vi) Turn T-handle on top of filter counterclockwise and remove cover. vii) Remove element and dispose of properly. viii) Insert new Pall Coreless element and replace cover. Turn T-handle clockwise

until hand-tight. Do not over-tighten handle. NOTE: In order to maintain the achieved system cleanliness use only genuine Pall filter elements of the same media grade.

ix) With the bleed valve open on top of filter, use a suitable container to catch the bleed oil.

x) Remove lock out from the MAIN DISCONNECT. xi) Reference starting instruction sequence (section II.4) xii) Bleed until oil comes out of the bleed valve on top of the filter housing cover

freely without air present. xiii) Close bleed valve.

b) Exhaust coalescer

Drain or change exhaust coalescing filter element whenever a “HIGH” EXHAUST PRESSURE is indicated on the PanelMate LCD display. To replace filter element proceed as follows:

i) Place a suitable container under the coalescer bowl drain valve, allow fluid to

drain completely before closing valve. Dispose of fluid properly. ii) Attempt to restart unit. If purifier operates, no further action is required. If not,

continue with step (iii), below, and check vacuum pump oil reservoir level. Fill or drain to correct level as needed.

iii) Loosen and remove V-band clamp securing bowl to filter head. iv) Remove filter bowl and slide filter element off the filter head nipple. v) Lubricate O-ring on new filter element before installing. Install new filter

element into head and slip bowl over the element. vi) Secure the filter bowl to the filter head using the V-band clamp.

Check internal vacuum pump @ this time. See Page 22 – Exhaust Oil Separator Filter

c) Inlet Air Breather

Assuming the metering valve is properly adjusted at factory setting (purifier operates at 19-22" Hg tower vacuum), change air breather element whenever the TOWER VACUUM gauge indicates 24" Hg or above, otherwise replacement is dependent on the purifier operating environment. For a dusty or

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heavily contaminated environment, the suggested service interval is weekly (40 operating hours). For an exceptionally clean operating environment, replacement may be done on a monthly basis. Replace breather element as follows: i) Prior to removing the element, thoroughly clean the old element threads and

connection to prevent contaminants from entering the vent pipe and metering valve during removal.

CAUTION: DO NOT USE PIPE TAPE OR SEALING COMPOUNDS ON

BREATHER ELEMENT THREADS. ASSEMBLE THE NEW FILTER DRY. TAKE PARTICULAR CARE TO PREVENT CONTAMINANTS FROM ENTERING THE CONNECTION. SEALANTS OR CONTAMINANTS ENTERING THE CONNECTION MAY OBSTRUCT THE INLET AIR METERING VALVE, CAUSING EXCESSIVE CHAMBER VACUUM, DISCHARGE PUMP CAVITATION, LOW AIR FLOW RATE, AND REDUCED EFFICIENCY.

ii) Unscrew the old breather element and discard. Replace with new element, p/n

HC0293SEE5, reusing the differential pressure indicator. Hand-tighten only.

d) Vacuum Pump, Discharge Pump and Motors

Regular inspection may prevent extensive repairs. Occasionally examine the shafts for side and/or end play by moving it manually while the pump is stopped. If the pump or motor shows evidence of over-heating or excessive noise, stop immediately and check for necessary repairs.

i) Vacuum Pump

Lubrication - use of the correct oil and proper amount of oil is important. See Section III B.1.c. of this chapter.

Vacuum pump lubricating oil must be changed every 500 operating hours. Drain all old oil out of the reservoir through drain valve (19). Refill with the correct oil and proper amount as specified in Section III B.1.c. Change oil more often if the oil in the sight glasses looks dark brown in color.

Vacuum Pump Servicing - most failures to produce a vacuum are due to leaks in connecting lines, dirty filters, or sluggish vanes, which may stick in rotor slots due to too much oil, or too heavy an oil. If foreign

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particles are present in pump chamber an experienced mechanic may remove the end plate opposite the drive shaft. This will permit the removal of (4) sliding vanes for thorough cleaning with a solvent and will also provide accessibility to any particles which must be removed. The original body gaskets are only .001 - .005" thick, therefore, replace accordingly. If thicker gaskets are used in the pump, efficiency will be greatly reduced. If thinner gaskets are used (not enough clearance), motor may stall and trip breaker.

Water Condensate Removal - Periodically, depending on amount of water in process fluid, drain off the water which collects on the bottom of the vacuum pump oil reservoir. Open the drain valve (19) and drain until effluent looks free of water. The need to do this is usually indicated by the oil level increasing above the top of the vacuum pump lube oil sight glass (27). After draining off water, always check for proper oil level.

Exhaust Oil Separator Filter - The vacuum pump oil separator filter elements may become contaminated after a long period of operation, resulting in high pump temperature and motor overload. It is recommended to change the elements (Rietschle Part #312850) every 2000 hours, or when the gauge mounted on the lube oil reservoir reads into the red area on start-up (not after vacuum has been established in the tower). Replace the oil separator filter elements as follows:

Drain out the vacuum pump lube oil at drain valve (19) and remove the 11 bolts holding the large cover on the side of the lube oil reservoir. Remove the cover, then remove the bolts holding the filter elements. Replace the elements and reassemble in reverse order. Refill the reservoir to correct level. See Page 19. Location of Exhaust Oil

Separator Filter shown by the circle inside the lube oil reservoir.

Sight Gauge Glasses - Remove sight level gauge glasses and clean or

replace as necessary. Gas Ballast Valve Filter - This vacuum pump is equipped with a gas ballast Valve with filter to bleed ambient air into the pump to help avoid condensation of water vapor in the oil reservoir. Inspect the gas ballast filter (28) occasionally and replace or clean with compressed air as necessary. Remove the black plastic cap to access the filter screens and felt disk.

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ii) Electric Motors

Suggested re-lubrication interval for motor is 12 month or 5000 operating hours whichever occurs first. At this interval one of the following greases should be added; Shell Dolium R, Chevon SRI No. 2, Texaco Premium RB, or equivalent, using the Alemite fittings in the motor.

CAUTION: OVER-GREASING IS A MAJOR CAUSE OF BEARING AND MOTOR FAILURE. MAKE SURE DIRT AND CONTAMINANTS ARE NOT INTRODUCED WHEN ADDING GREASE.

Procedure for re-lubrication - clean tip of Alemite fitting and apply grease gun. Use 1 to 2 full strokes of grease gun to add grease.

iii) Discharge Pump

Discharge Oil Pump - Increased noise or reduced outlet flow or pressure may indicate wear to the discharge gear pump. Shaft seals and bearings are available for this pump. Any further repair may require pump replacement.

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C. FLUSHING PROCEDURE

The following flushing procedure should be used when oil to be purified is incompatible with previously purified oil.

Take note of new oil's compatibility with unit seals. Check Operating Precautions and check with the manufacturer if there is doubt.

1. Close purifier inlet gate valve and allow purifier to shutdown on low level. 2. Disconnect inlet hose (supplied by customer) from purifier, drain and flush. 3. Operate Purifier until all oil is exhausted through discharge hose. 4. Disconnect discharge hose (supplied by customer), drain and flush. 5. Drain all remaining oil from the tower and heater by opening the drain valves. (See

drain procedures on next page). 6. Drain discharge filter housing and remove element. 7. Replace drained and flushed inlet and discharge hoses. 8. Flush unit (15) minutes using approximately (20) gallons of the new oil to be purified. 9. Repeat step 1-7. 10. Dispose of flushing oil in accordance with local codes. 11. Purifier is now ready for new oil type purification.

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D. DRAIN PROCEDURES

In order to drain fluid from vacuum tower, heater, and discharge filter prior to repair or normal operation, proceed as follows:

1. Drain port on heater, tower and discharge filter all use 3/4" JIC fittings. A drain tube

that can be connected to the fittings is attached to the inside of the tower shroud. Connect the drain tube to either vacuum tower, heater, or discharge filter. Heater will drain faster if a fitting near the top is loosened.

2. Open drain valve and allow oil to drain out. Be careful of hot oil. Recycle oil if possible.

Open air bleed valve on discharge filter to speed up draining.

3. Be sure drain valves and air bleed valves are closed before restarting purifier.

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E. VACUUM PUMP PURGE PROCEDURES Purge the vacuum pump whenever purifier vents oil from the coalescing filter outlet, or if the vacuum tower overflows from the inlet air filter (7).

CAUTION: NEVER RESTART A UNIT WHICH HAS VENTED OIL FROM THE

COALESCER FILTER OUTLET WITHOUT PURGING THE VACUUM PUMP AND COALESCER FILTER OF ALL OIL. IF OIL HAS VENTED FROM THE COALESCER, PURGE VACUUM PUMP AS FOLLOWS BEFORE RESTARTING THE

1. Disconnect the tube running from the outlet of the mist eliminator filter (9) to the vacuum

pump inlet (Disconnect at the mist eliminator).

2. Drain and remove coalescer bowl and remove element. Open the vacuum pump lube oil drain valve (19) and drain out all oil. Apply air pressure, 30 psi (2 bar) max., to the vacuum pump inlet via the disconnected tubing until all oil is purged from the drain and pump outlet. Refill oil reservoir as described previously.

3. Reconnect tubing to the mist eliminator outlet.

4. Reinstall coalescer element and bowl (replace element if necessary).

5. Investigate why the oil overflowed and correct the problem to avoid a repeat. 6. If vacuum tower overflows, additionally drain the tower as follows:

A) Connect the drain tube, attached to the inside of the tower shroud, to the vacuum tower drain port. B) Open drain valve and allow oil to drain out. Be careful of hot oil. Recycle system oil if possible. C) Be sure drain valve is closed prior to restarting.

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SECTION IV. TROUBLE-SHOOTING Listed below are several possible conditions which may occur during the operation of the purifier, along with probable causes and suggested remedies. To aid trouble-shooting, please refer to the hydraulic and electrical schematics in the Appendix of this manual. Should an problem which is not listed occur or if a suggested remedy fails to correct a problem, contact Pall Machinery & Equipment Company or authorized Distributor Personnel for further assistance.

CONDITION/SYMPTOM

PROBABLE CAUSE

REMEDY

Purifier shuts down, alarm condition indicates “TOWER LEVEL LOW” INLET OIL PRESSURE gauge indicates high vacuum. (Above 15" Hg).

Partially or fully closed inlet valve.

Open inlet valve fully. Inlet pressure should read between 14" Hg. and +10 PSI while unit is running.

Undersized or otherwise clogged inlet line, or length of inlet line exceeds recommended length, or too many 90° elbow restrictions.

Use correct inlet line size; clean inlet line as needed. Reduce the number of 90Ε elbows (3 max), and remove other restrictions (quick disconnects, reservoir bungs, etc.)

Excessively high fluid viscosity (1300 ssu max) possibly due to cold oil.

Check the oil temperature at the source. For hydraulic oils a minimum operating temperature is 70°F (21°C); for heavier lubricating oils, a higher temperature may be necessary. Reduce oil viscosity by careful heating.

Reservoir is lower than recommended drop from purifier.

Move purifier closer to reservoir and shorten length of inlet line or use boost pump (10 psi max) to supply oil to purifier.

Inlet strainer screen plugged with contaminants

Clean the inlet strainer basket

Inlet line stuck on bottom or side of reservoir

Free inlet line and angle cut opening to prevent recurrence.

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CONDITION/SYMPTOM

PROBABLE CAUSE

REMEDY

Purifier shuts down, alarm condition indicates “TOWER LEVEL LOW” INLET OIL PRESSURE gauge reads normal (between 14" Hg and +10 psi.

Leak in suction plumbing between fluid reservoir and vacuum chamber.

Find and repair leaks as required. To find leaks, carefully apply positive oil pressure to purifier inlet, + 15 psig, maximum.

Inlet line not fully submerged below reservoir oil level.

Correct condition.

Inlet solenoid valve not opening.

Repair or replace solenoid valve.

High pressure indicated on INLET OIL PRESSURE gauge above 10 psig (1.0 bar).

Fluid or inlet reservoir pressure exceeds + 10 psig. (1.0 bar)

Lower inlet pressure by orificing the inlet lines. (See matrix pg. 6) Throttle or orifice the inlet valve.

Defective gauge.

Replace gauge.

High vacuum indicated on INLET OIL PRESSURE gauge, above 15" Hg.

Undersized inlet line or clogged inlet line.

Use 1-1/2" I.D. (SAE 100R4) lines (minimum) or clean obstructed lines.

Inlet strainer screen plugged with contaminants.

Clean the inlet strainer basket screen

Excessively high oil viscosity (greater than 1300 SSU).

Reduce oil viscosity by heating (160°F maximum.)

Contaminated oil reservoir too far below purifier, or inlet line too long.

Lower purifier or use boost pump.

Excessively high tower vacuum, greater than 24" Hg. (610 mm Hg.)

Replace breather element and check for obstruction in inlet air metering valve.

Defective inlet pressure gauge.

Replace.

Closed inlet valve.

Open inlet valve all the way.

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CONDITION/SYMPTOM

PROBABLE CAUSE

REMEDY

Purifier shuts down, alarm condition indicates “TOWER LEVEL HIGH”

Undersized or clogged outlet line.

Increase outlet line size or clear line as needed.

Inlet solenoid valve remains open due to obstruction in valve, fault in the wiring, a faulty float switch, or a combination of the above.

The switching of the solenoid valve can be detected audibly. If the valve does not switch as the tower oil level rises to the top of the lower sight glass the problem most likely lies within the float switch or wiring. Consult with Pall service personnel regarding this repair.

Purifier shuts down. Alarm condition indicates “TOWER LEVEL HIGH”. OUTLET PRESSURE gauge reads normal, below 20 psig.

Too much oil passing through bypass valve.

Orifice the bypass valve. (See matrix page 6).

Too much oil passing through main control valve.

Orifice main control valve. (See matrix page 6).

Defective Discharge pump. Confirm this by measuring outlet flow rate (15 gpm).

Repair or replace pump.

Purifier is running, but alarm condition indicates “CHANGE FILTER ELEMENT”

Discharge filter element is dirty. Purifier will shutdown within 24 hours.

Replace filter element.

Excessively high viscosity.

Reduced oil viscosity by heating. Do not exceed +160°F.

Purifier shuts down, Alarm condition indicates “DIRTY FILTER SHUTDOWN”

Discharge filter element is clogged.

Replace filter element..

Excessively high viscosity.

Reduced oil viscosity by heating. Do not exceed +160°F.

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CONDITION/SYMPTOM

PROBABLE CAUSE

REMEDY High vacuum indicated on TOWER VACUUM gauge, (above 24" Hg.).

Clogged inlet air breather element.

Replace.

Obstruction of air inlet or out of adjustment.

Remove air breather element and clear and/or adjust valve as follows: Turn knurled knob clockwise all the way, then back off 4 full turns.

Defective vacuum gauge. Replace gauge.

Low vacuum indicated on

TOWER VACUUM gauge, below 19" Hg. (508 mm Hg)

Leak in inlet or gauge line plumbing.

Find and repair leak.

Defective vacuum gauge. Replace.

Vacuum relief may have been tampered with.

Reset vacuum relief by loosening locknut and turning knurled knob fully clockwise.

NOTE: Vacuum less than 19" Hg is also indicative of high water content and/or highly aerated oil. It is okay to run the HVP as low as 15” Hg.

Vacuum pump malfunction See Condition/Symptom item: Low vacuum pump throughput and/or excessive noise.

Plugged coalescing filter element and defective coalescer pressure switch

Check pressure switch by restricting coalescer exhaust port. If unit does not shut down within seconds, pressure switch is defective. Readjust or replace switch. Also replace coalescing filter element. Restart the unit and check TOWER VACUUM gauge. If level remains below 15-19" Hg (vacuum pump is damaged. Replace vacuum pump.

Pump lube reservoir may be low/empty of oil, or have incorrect type of oil.

Drain remaining oil from reservoir and replenish with new fresh oil.

Fine wire mesh inlet screen inside vacuum pump may be clogged.

Refer to vacuum pump service manual to remove and clean screen.

Exhaust oil separator filter inside vacuum pump may be clogged.

Replace filter elements as described in Section III B

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CONDITION/SYMPTOM

PROBABLE CAUSE

REMEDY Low vacuum pump throughput and/or excessive noise.

Insufficient oil in reservoir Fill reservoir

Broken pump vane. Replace pump.

Loose or defective drive coupling.

Tighten or replace.

Vacuum pump worn out. Replace.

Purifier shuts down, Alarm condition indicates “EXHAUST PRESSURE HIGH”

Plugged outlet coalescer filter element and/or full coalescer bowl.

Drain outlet coalescer bowl. Restart unit. Allow excess oil to blow off coalescing element. If unit shuts down again due to high exhaust pressure, replace coalescing filter element.

Pressure switch out of adjustment, or defective.

Readjust to 7 psi, or replace.

Pressure switch defective. Replace pressure switch.

Exhaust oil separator filter inside vacuum pump may be clogged.

Replace filter elements as described in Section III B.

OUTLET OIL PRESSURE gauge reads above 40 psi. FILTER ALARM is NORAL.

Defective differential pressure gauge

Remove differential pressure switch from discharge filter assembly and replace with "BT" plug Pall part number 1128465. Test differential pressure indicator with Pall test kit part number 1196635. Replace switch if necessary

Undersized or clogged outlet line Increase outlet line size or clear line as needed

Defective gauge Replace gauge. Very short outlet coalescer service intervals and/or excessive oil mist “smoke” emitted from the exhaust port. (Vacuum pump starts but draws high amperage).

Exhaust oil separator filter inside vacuum pump may be clogged.

Replace filter elements as described in Section III.B.2 Drain outlet coalescer bowl as per above.

Vacuum pump lube oil reservoir may be overfilled.

Drain off and adjust oil to proper level in the sight glass

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Appendix

1. Supplementary Spare Parts List 2. Vacuum Pump- Manufacturer’s Information 3. Hydraulic Schematic 4. Electrical Schematic