ELC With Processor - Manual

CONTENTS Sr. No.

Contents

1.

Specifications of ELC Unit

1

2.

Principle of Operation

1

3.

Construction

1

4.

Operation Procedure

2

5.

Drain Discharge

3

6.

Draining/Removing Cleaned Oil from the tank

3

7.

Application

3

8.

Life of Collectors

4

9.

Replacement of Collectors

4

10.

Warranty

4

11.

Caution for Safety

5

12.

Electric Circuit

5

13.

Standard Spares Supplied with Machine

5

14.

Control and Annunciator Functions

6

15.

Setting Parameters

6

16.

Error Displays or Annunciation

9

17

Trouble Shooting

Helping you ... work better ... under pressure

Page No.

11

OPERATION MANUAL

1.

SPECIFICATIONS:

ELC-8 LP / 25 A / 50 C / 100 LP

Power Consumption

200 / 200 / 450 / 550 w

Power Source

415 V AC -3 Phase / 220 V 1 Phase 50hz

Pump Capacity

8 LP

: 2 Ltrs. / Min at 1425 rpm

25 A, 25 D

: 3.5 Ltrs. / Min at 1425 rpm

50 C, 100 LP : 10 Ltrs. / Min at 1425 rpm Specifications

ELC 8 LP

ELC 25A

ELC 50C

ELC 100LP

Dimensions (Approx) (L) (W) (H)

610 mm 380 mm 540 mm

805 mm 480 mm 720 mm

805 mm 480 mm 920 mm

870 mm 620 mm 940 mm

Weight (Approx)

70 kgs.

100 kgs

140 kgs

180 kgs

4

12

12

16

Collector (pcs/set)

2.

PRINCIPLE OF OPERATION:

The ELC system uses the principle of electrostatics to collect fluid contaminants. FERROCARE ELC's unique design permits it to take advantage of the natural charge of each contaminant. Contaminants that have a positive charge are drawn towards the negative electrode plate and those with a negative charge are drawn towards the positive plate. Neutral contaminants are drawn and deposited by gradient force to the edge of the collectors where the intensity of the deformed electric field is the strongest. As the fluid flows freely through the system, the ELC removes contaminants - submicronic particles even smaller than 0.01 micron, dust, dirt and products of oxidation such as tars or sludge and varnishes. Contaminants are trapped on cellulose collectors for easy disposal. The ELC does not affect soluble additives. 3. CONSTRUCTION: A) The ELC consists of the electrical panel (A) and the condenser unit (B). The latter works as the Cleaning Cell of the ELC unit. B) The condenser (cleaning tank) is designed for pressure 1.5 kg/cm2. The total head of oil between the oil reservoir to be cleaned and the ELC 8LP / 25A / 50C / 100LP unit should not exceed 3 meters. In case the head exceeds 3 meters, use our ‘D’ type machine.


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4. OPERATION PROCEDURE: Refer figures 1, 2, 3 & 4. 4a. STARTING AND STOPPING THE MACHINE Before starting the machine, ensure the following: 1. Confirm that the oil temperature, moisture content are within limits specified for the machine, i.e., below 60°C, 500ppm. 2. Check the power switch (ELCB +MCB) of the ELC is off. 3.Confirm that the collectors are in place between the electrodes, and fasten the cleaning tank cover evenly. 4. Shut the drain valve (E) and open the sample cock (D). 5.Ensure that the pump is filled with oil and suction line is fully immersed in oil. 6. Check that the suction and discharge hoses are connected at both ends. 7. Open flow control valve (F) in line after the pump. 8. Switch on the ELCB after ensuring proper electrical connections. 9. Press the FWR/REV button to bring the pump to “Forward” operation as shown by LED in figure below. Fig. 4

The Control Panel face for

ELC 100LP

ELC 8LP / 25A / 50C

HV-1

mA

mA

HV-2

KV

KV

WAIT

WAIT

FWR REV

START STOP

FWR REV

START STOP

PMP FWR

PMP FWR

PMP REV

PMP REV

HV

µ - ELECTROSTATIC LIQUID CLEANER

FERROCARE

LV

HV


LV

FERROCARE

10. Press the Start button (START/STOP). Both LED “ON” means Forward. Start LED “ON” and FWR LED “OFF” means pump running reverse. Both LED “OFF” means machine stopped. 11. The ELC will start and the pump will fill the tank with oil. The float switch gets activated as the top level is reached. The pump will automatically stop when the cleaning cell tank is filled with oil. The pump will automatically restart after the preset interval and cleaning will start.

This on delay timer switches off the pump every time the float switch is operated after the machine is started, even after a power failure or shutdown. This ensures that the contaminants from the collector, which may have been dislodged into the oil in the ELC tank during power failure or shut down are redeposited on the collectors before the oil flow is restarted. 4b. STOPPING THE MACHINE: Press the Stop button (START/ STOP) to stop the machine. The LED will switch off to indicate pump stoppage. 5. DRAIN DlSCHARGE When the ELC is continuously operated for a long time, it is advisable to discharge about 1 litre of the oil from the drain valve (E) at an interval of 50 hours. This ensures discharge of heavy contaminants from the drain. 6. DRAINING/ REMOVING CLEANED OIL FROM THE TANK a) b) c) d) e) f) g) h)

Switch off the ELC Put plastic oil pan under the Y type strainer of suction hose. Unscrew the cap of the Y type strainer remove wire mesh and clean. Replace the wire mesh after cleaning and retighten the cap of the strainer Open air cock on the top cover of the cleaning tank (Sampling cock(D)) Open the control panel door and set internal toggle switch "ON" Set the Forward /Reverse button (FWR/ REV) to reverse. The LED will be off. Press the Start button. The pump will start in reverse and drain the tank.

PRECAUTION: Do not pump out all the oil, care has to be taken to switch off the pump if dirty oil starts flowing out of the machine. i) The oil at the bottomshould bedrainedinto the oil pan fromthedrainvalve. NOTE: If final oil is required to be NAS grade 7 (ISO code16/13) and better, do not drain oil from the cleaning tank back to the reservoir. j) IMPORTANT: The oil pump can only be reversed by pressing the push button inside the panel and the FWR/REV button on the control panel together, after opening the panel. 7. APPLICATION The Electrostatic Liquid Cleaner "ELC" unit can be used for cleaning hydraulic and lubricating oils of the following general specifications. Temperature - below 60 degrees C and Moisture - below 500 ppm The ELC unit cannot be used for cleaning of: a) Oils with moisture in excess of 500 ppm b) Oils with detergent dispersant additives c) Some synthetic oils d) Conductive oils


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8. LIFE OF COLLECTORS The life of collectors depends on the contamination level in the oil. If contamination level is 7 to 10 mg/100 ml., a new collector set can clean about 5,000 litres (ELC-50C) of oil. The average life of a collector is 2,000 hours. A rough indication of collector life is as follows: Type of ELC Contaminant Level/ 100ml

ELC-8 LP

ELC-50 C

ELC-100LP

7.0-10.0mg

10-15mg

7.0-10.0mg

10-15mg

7.0-10mg

10-15mg

7.0-10mg

10-15mg

800 -

500 -

2,000 -

1,500-

4,000 -

3,000 -

8000 -

6000 -

Life of

Collectors

ELC-25 A

1,000 Ltrs 800 Ltrs 2,500Ltrs 2,000Ltrs 5,000 Ltrs 4,000 Ltrs 10,000 Ltrs 8,000 Ltrs in 1,500 in 800 in 800 in 500 in 1,500 in 800 in 1,500 800 to 2,000 hrs to 1,000 hrs to 1,000 hrs to 800 hrs to 2,000 hrs to 1,000 hrs to 2,000 hrs to 1,000 hrs

9. REPLACEMENT OF COLLECTORS (Refer Fig. 2) Unscrew all bolts of the condensor (cleaning tank) cover and remove the contaminated corrugated type collectors (H) (dielectric media), and electrode covers. At this time, make sure to clean electrodes before replacing with new collectors. 10. WARRANTY a) The manufacturer shall repair all defects, except consumable parts for a period of 12 months from the date of shipment. in any event, t he manufacturer shall not be responsible for any and all damage or failure due to incorrect operation, malpractice, mishandling and negligence. b) In the event that the user finds any defect in the ELC, the user shall advise the details of such defect in writing to the manufacturer. The manufacturer shall correct such defects promptly. The manufacturer reserves the right to make final judgement on claims made by the user. c) In no event shall the manufacturer be liable for any and all consequential loss, damage or expenses howsoever arising from all claims upon and all liability of the manufacturer.

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C B A Fig. 5

Seal Nut

Fig. 6

Hi-Volt Cable

14. CONTROL AND ANNUNCIATION FUNCTIONS

HV-1

mA

mA

HV-2

KV

KV

WAIT

WAIT

FWR REV

FWR REV

START STOP

START STOP

PMP FWR

PMP FWR

PMP REV

PMP REV

HV

HV


LV

FERROCARE

100LP


LV

FERROCARE

8LP / 50C / 25A

The panel displayed indicates that High Voltage is 10.6 kV and that machine is running with pump in forward mode for ELC 100LP (fig. on left). The panel displayed (fig. on right) indicates that current is 0.6 mA and the machine is running with pumpin forward modefor ELC 8LP / 25A / 50C . For 100LP - indicator for HV-1 is green and display is V for Voltage. The 100LP machine uses TWO High Voltage transformers, hence the LEDs are divided as HV-1 and HV-2. For other ELCs - Indicator for milliamps is green and current is 0.6 mA. Since the machines have only one transformer, the LED lights are separate for mA and kV. The Pump Switch LED is ON, meaning pump is running forward. The display will scroll across four parameters, namely, mA, kV (milliampere current and Voltage across the electrodes), temperature and running hours in sequence. Each parameter will be displayed for the duration set in Scroll Time setting

15 a. SETTING PARAMETERS: Pressing the "SETTING" button will select the next parameter for display.

Pressing the (value) "ARROW" button will increment the parameter by one point.

16 b. SAFETY SETTINGS: There is a push button inside the panel which allows the programming functions, so that the set parameters cannot be disturbed by anyone playing with the push buttons. Display of different parameters can still be selected, but settings cannot be changed until the internal switch is activated after opening the panel cover.

6


The following parameters can be set or displayed: 1. Set Current: 2 to 10 mA /for 100LP/ 50C : 5mA for 25A/ 8LP

Set current : 10.0 mA ( 2 to 12 mA)

This is the set current across the electrodes. This setting is required to protect the heart of the machine viz., High Voltage Transformer. If the current increases there is conduction across the electrodes i.e., they are getting "shorted" or a short circuit path is available which would overload the transformer. The HVT is therefore protected by setting it to trip at this "set current" which can be varied from 2 to 10 mA. The current across the electrodes can increase if water is mixed in the oil or it contains excessive metal particles.

2. Set Temperature:

Set Temp. : 60ºC (30 to 65 C)

This setting is for the temperature of oil passing through the ELC. Insulators in the ELC are made of PVC and cannot withstand sustained high temperatures. The SET temperature between 30 and 60 degrees, is selected to trip the pump if hot oil is passing through the unit. Temperatures above 50 deg C are harmful to the oil aswell asthe ELC. Note: All units are not equipped with oil temperature sensor.

3. L. V. Setting:

LV Setting: 05 (1 to 10)

This the setting for the Low Voltage operation of the ELC. This sets the tripping current for the transformer when ELC is operating on low voltage of 5 KV. In the particular case above, the ELC will trip at 2 mA (for 25 A/ 8LP, 5mA for 50C/100 LP). This setting ensures safety of the transformer.

4. L.V. Skip: This sets the "Low" mode of the HVT. If this parameter is set to "n" the transformer will change to "Low" mode after the current set for Hi mode i.e., 10 mA is exceeded (with a delay of 1 sec.) If the current exceeds the "Low" (5 mA) also, the machine will trip. If this parameter is set to "y", the machine will trip directly when "High" current is exceeded.


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5. Scroll time parameter:

Scroll Time 03 (0 to 10)

The display scrolls across parameters i.e., it displays 4 set parameters one by one. It will display, turn by turn mA , KV, temp., and running hours. In this case each parameter will be displayed for 5 seconds, and then the next one will be displayed for 3 seconds. If the scroll time is set to zero, then the selected parameter will not be continuously displayed. Other parameters will have to be manually selected for display using the "SETTING" button.

6. Service life setting:

SErv - Service If Op. Hrs. = 1, then 250 Hrs. Controller Trip on "SERV" Recommended Settings: 50C . . . . . . . . 06 hrs. 100LP . . . . . . 06 hrs. 25A . . . . . . . . 05 hrs. 8LP . . . . . . . . 03 hrs.

The collectors which hold contaminants removed from oil being cleaned, have a specific service life. This means that the collectors should be changed after a specified running hours. Each unit on this setting is 250 hours. When the set running hours are completed the unit will display "SErv", meaning that the service life is completed. The collectors should be removed, examined, and if necessary replaced (Service life is 1000 hrs. for 25A, 1500 hrs. for 50C & 2000 hrs. for 100LP) The setting is based on a unit of 250 hours. Therefore H006 as shown above means 1500 hours service life. H004 would mean 1000 hours. H008 means 2000 hours. Setable parameters should be distributed from the f actory setting except when necessary and by people trained for instrument calibration.

7. Auto Restart Pump: If the pump trips on overload, "P_ol ", it can be restarted automatically if " Ar" is set to "Y".

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16. ERROR DISPLAYS OR ANNUNCIATION:

LS - Limit Switch

This error display means that the ELC tank cover is open. When properly secured the cover operates a limit switch and switches off this error message. Trouble Shooting: Put back the top cover, if not in place and tighten all the bolts securely. Check that the limit switch is OK.





FS - Float Switch

There is a float switch which does not allow the electrodes to be charged. If not totally immersed in oil. When the float switch is activated, the motor will trip for a five minute interval and restart. It will now run continuously. This interruption is provided so that contaminants from previous operation do not flow out with the new oil, and are redeposited on the collectors. if the pump does not start, or the float switch is faulty, then also this error signal will appear. This error means that there is insufficient oil in the tank. One reason is that oil is not available to the pump. This alarm will come due to Hi-volt fuse blown out. Trouble Shooting: Check that the oil pump is running. Check if oil is available and the suction hose is properly immersed in the oil. Check "Y strainer" to ensure there is no blockage. Check float switch operation manually.

 

 

This indicates that overload relay of the pump motor has operated. The preset here is Auto. The pump will start automatically on cooling. A manual setting is possible. PoL - Pump over load

Trouble Shooting: Check that there is no obstruction to the discharge. Check the pump / motor are aligned and secured to the foundation. Check the pump motor windings electrically. Check capacitor overload relay and contactors.

 

 


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This indicates that the tripping current of the HVT is reached in "Hi" mode. H-oL - Current Over Load in "Hi" mode

Trouble Shooting: Check whether there is moisture in the oil. Check if oil contains an excess of metal particles If low switch over is "y" the machine will now switch to low and if the current exceeds even the low setting the machine will trip.

 

This indicates that the tripping current of the HVT is reached in "Lo" mode. L-oL - Current Over Load in "Lo" mode

Trouble Shooting: Check whether there is moisture in the oil. Check if oil contains an excess of metal particles.

 

Temperature overload : This indicates that the temperature of the oil flowing through the machine is too high and the machine will stop. ot - Temp Over Load

Trouble Shooting: Check the setting is not too low. Check the oil cooler in the equipment. Heavy moisture in oil.

  

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17. TROUBLE SHOOTING

NO.

PROBLEM

CHECK

SOLUTIONS

1.

ELC B + MCB is "ON" But (power light off). Machine does not Switch on.

1. Power supply from socket 2. fuse no. 1 (central fuse) 3. Loose connections at source

1. Switch "ON" power supply 2. Replace if fused. 3. Tighten properly

2.

ELC B + MCB trips earth leakage

1. Motor connection loose 2. Winding insulation low 3. Motor Capacior leakage to the body. 4. MS1, MS2, OLR power contact short circuit 5. Loose connection at plug point phase and neutral or phase to phase wire touch or phase to earth

1. Rectify 2. Overhaul motor 3. Replace if faulty

1. Use the test button of ELCB + MCB to trip it

1. Replace ELCB if faulty

3.

ELC B + MCB is not Tripping

4.

Motor does not operate 1. Overload relay not working (oil tank empty) and it Indicates (P-OL) 2. Input supply 3. Loose contact of power supply line 4. Motor + pump alignment 5. Pump jam 6. Centrifugal switch 7. Motor connection and winding and capacitor leakage

4. Replace if faulty 5. Tighten properly

1. Push reset and turn to "Auto" Replace if faulty. 2. Ensure input power supply 3. Tighten properly

8. Contactor contacts (power)

4. Readjust properly 5. Open and clean the Rotor, and strainer mesh 6. Replace if faulty 7. Replace if capacitor faulty rectify connection 8. Replace if faulty

5.

Excessive pump noise

1. Flow control valve is closed 2. Y-strainer

1. Open valve 2. Clean if choked

6.

Pump does not draw oil

1. Pump suction by placing hand on suction port 2. If no pump suction

1. If suction is good check suction hose is dipped in oil 2. a) Overhaul and clean the relief valve b) Replace the pump

7.

Oil leakage from pump

1. Check the oil seal 2. Loose bolts

1. Replace if necessary 2. Tighten properly


11

NO. PROBLEM

CHECK

SOLUTIONS

8.

1. Thermal OLR

1. Set current with required motor name plate ratings 2. Open and clean mesh 3. Re-adjust properly 4. Repair if necessary 5. Ensure power supply of correct voltage 6. Tighten properly and replace if faulty

Motor trips frequently when machine is in operation and it Indicates (P_OL)

2. Y- strainer 3. Motor pump alignment 4. Motor winding weak 5. Power supply voltage (230/415) 6. Loose contact of contactor power contact and OLR

9.

Fuse-1 blows repeatedly.

1. MS1 or MS2 motor contactor coil Replace if faulty open 2. Timer Replace if faulty

10.

Indicates H-OL and L-OL and / or HVT fuse blows repeatedly.

1. More moisture in oil check with CC kit. 2. Open top cover and check if SS electrodes are correctly placed In the slot 3. Collector heavily contaminated

1. Replace collector and start the machine after moisture is removed from the oil 2. Ensure electrodes placed properly 3. Replace, if necessary

11.

ON PLC indicates 'ot'

1. Oil temperature & setting. 2. Open the top cover and check electrodes are correctly placed in the slot 3. Check moisture in oil 4. Transformer earthing cable loose.

1. It should not exceed 60°C 2. Place correctly, if not.

12.

HV' led is 'ON' and the MA' reading is below 5 mA, oil is not being Cleaned

1. The oil has high detergents (HLDP) 2. Check if viscosity is high

3. Should be below 500 ppm 4. Connect properly 1. It takes about 10 times longer to clean than ordinary oil 2. Viscous oil takes longer to clean 3. Use larger ELC

3. Contamination ingression rate is high 4. Oil oxidation if oil has been 4. Drain out about 10% oil used for many years or oil from the oil reservoir. generation of oxidation matter is Top up with the new oil high. or add. 5. Collector is contaminated. 5. Replace with new collector.

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ELC With Processor - Manual

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