operation manual lvdh 100 cu el

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FERROCARE MACHINES PVT.LTD. PUNE

OPERATION MANUAL LVDH 100- CU EL



TABLE OF CONTENTS

INDEX

Sr. No. Contents Page No

1. Introduction 4 2. Water Contamination & Its Harmful Effects on Oil 5 3. Advantages of LVDH 5 4. Construction 6 5. Schematic Mechanical Circuit Diagram 7 6. Technical Specifications of LVDH -100 8 7. Application 9 8. Procedure for Installation 10 9. Operation & Control Scheme 11 10. Operation 12 11. Control Panel display 12 12. Chiller Unit Indication 12 13. Processor Operation Password for Manual

Operation 13

14. Microprocessor Set Parameters 14 15. Fault Indication 15 15.a. Resetting the LVDH 15 16. Safety Provisions 16 17. Operation Tips dos and Donts 16 18. Intermittent Operations 17 19. Trouble Shooting & Maintenance 18 20. Oil Testing 19 20.a. Inlet Oil condition 19 20.b. Sampling Procedure 19 20.c. Oil Tests 20 21 Electrical Circuit Diagram 21

Annexure II Chiller Unit Operation Manual 22-26 Annexure III Vacuum Pump Operation Manual Annexure IV Test certificates

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Overview

About This Manual

The information in this manual has been carefully checked and is believed to be accurate. However, Ferrocare Machines Pvt.Ltd. assumes no responsibility for any inaccuracies that may be contained in this manual.

In no event will Ferrocare Machines Pvt.Ltd. be liable for direct, indirect, special, incidental, or consequential damages resulting from any defect or omission in this manual, even if advised of the possibility of such damages.

In the interest of continued product development, Ferrocare Machines Pvt.Ltd. reserves the right to make improvements in this manual and the products it describes, at any time, without notice or obligation.

All rights reserved. No part of the contents of this manual may be reproduced or transmitted in any form or by any means without the written permission of Ferrocare Machines Pvt.Ltd.



Instructions and Operation Manual for LOW VACUUM DEHYDRATOR (LVDH)

1.0. INTRODUCTION

Thank you for purchasing the Low Vacuum Dehydrating Machine (LVDH). This manual contains operation & instructions for safe use of this equipment. To operate this equipment properly & safely, this manual must be read & thoroughly understood before operation is attempted.

After reading this Manual, keep it in an accessible place so that it can be referred to at any time. Operating this equipment in a manner that does not comply with instructions in this manual may lead to accidents. Therefore the comprehension of this manuals safety precautions section should be especially thorough. (This device may be improved & mechanical specification may be changed without notice)

To facilitate comprehension each of the warning shown in this manual or/on the device, has one of the following headings, depending on the gravity of risk.

Note: A note is used to indicate important information or instructions that should be considered before operating the equipment.

This manual must be read & thoroughly understood before using this equipment. The person in charge of this equipment should not permit anyone who is not familiar with operation of this equipment, to handle it.


WARNING : A warning is used to indicate a condition which, if not met, could cause serious personal injury and/or death.

CAUTION : Caution warns you of a potential hazard. If you do not read and follow the instructions very carefully at this point , the product could be damaged or important data could be lost .



1. INTRODUCTION The VACCUM DEHYDRATON UNIT, MODEL LVDH - 100-CU is a mobile compact unit to remove free and emulsified moisture from mineral and synthetic oils at low temperature.

Oil contaminated with water is passed through an indirect heating chamber and dispersed into a vacuum distillation chamber. The vacuum chamber vaporizes water, gases and other volatile impurities which are excavated via a condenser, to the atmosphere.

Dehydrated oil is pumped back into the oil reservoir through a mechanical filter.

The water removal is supported by a Tandem Mounted Refrigeration Type Condensing unit, which ensures immediate and maximum condensation of separated moisture. Thus by reducing the vapor pressure of released steam, more vapors are extracted in the same cycle of operation.

2. WATER CONTAMINATION AND ITS HARMFUL EFFECTS ON OIL Water in oil leads to: a. Corrosion of metal parts b. Low bearing life c. Sludge formation and reduced oil life

Water in oil can be: A. DISSOLVED WATER (upto saturation level) in the form of water vapor in oil. B. FREE WATER in the form of water vapor in oil. C. Emulsified in oil, due to churning in pumps, etc, some water will enter oil as an emulsion, which is difficult to separate.

3. ADVANTAGES OF LVDH Merits of Vacuum Distillation Unit LVDH are: B) ECONOMY: Requires no consumables except electricity. B) FLUID COMPATIBILITY: It has good fluid compatibility viz: can be used for petroleum based oil as well as synthetic oils. C) Ultimate moisture removal is below 500 ppm allowing dehydrated oil to be subject to Electrostatic Liquid cleaning to remove suspended solid impurities. D) NO MEDIA MIGRATION: This unit is closed system without any disintegration of filter media during its operation. E) Removes even emulsified water.

Advantages of Vacuum Dehydration Unit are: A. Easy to operate. B. Efficient method for continuous removal of moisture from oil. C. No damage to oil. D. The unit offers dry, dehydrated oil.

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4. CONSTRUCTION LVDH machine consists of three parts: A) Heating chamber D) Vacuum Chamber C) Refrigerated Type Condensing Apparatus D) CONTROL PANEL (MICROPROCESSOR BASESD)

Oil is passed through a strainer in heating chamber where it is indirectly heated to about 50 -55 C. The oil so heated is dispersed in a thin film in the vacuum chamber. Dispersing the oil into a thin film increases the surface area exposed to vacuum. As water will boil at low temperatures in vacuum, it evaporates and is excavated through the condenser where it is condensed into water and drained out. Dehydrated oil is pumped back into the oil reservoir. Vacuum, temperature gauges and moisture sensor are installed on the equipment

The schematic flow chart (refer fig 1.1) is self explanatory.

4 a. Heating Chamber Description: The heating chamber is a cylindrical fabricated reservoir with a bolted cover of nominal volume of 20 liters of oil handling capacity. Two low watt density heaters are diced in a tube covering the coil on the top cover of heating chamber. Oil to be dehydrated flows through the heating chamber. Heat is radiated from these coils to the tube & in turn to the oil. Oil thus heated is fed into the vacuum chamber.

4 b. Vacuum Chamber : The vacuum chamber of 100 liters nominal capacity has a specially designed baffle tray which enables the hot oil to be sprayed into a thin film exposing the entrapped water to low vacuum and enabling boil off and excavation from oil. The oil subsequently collects by gravity at the bottom of the vacuum chamber tank from where it is pumped back into the oil reservoir. Float switches in the vacuum chamber regulate oil flow into and out of the chamber by controlling the operation of vacuum and discharge pumps respectively.

4 c. Refrigerated Type Condensing Apparatus

The steam cooler designed to extract heat continuously from the steam to which it is attached in order to reduce the steam temperature so as to allow condensation. The unit consists of Mechanical Refrigeration System, utilizing refrigerant R-134 , condenser and drier. Steam from the vacuum chamber is drawn into the top inlet of Copper submerge type heat exchanger with the help of vacuum. It will get cooled and condense in form of water after passing through Copper submerge type teat exchanger. Free water will come out from bottom of heat exchanger & will collect in the condensate pot provided & the cycle will be repeated. 4.d.Control Panel The electrical controls are housed in a sheet metal panel mounted on the main structural frame of the unit. The refrigerated type condensing unit has its own manual controls. Electrical circuit diagram is attached.

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Fig 1.1



6. 0 Technical Specifications of LVDH-100-CU-EL

1 ELECTRICAL SUPPLY 415 V, 3PH 50Hz, 4 WIRE

2 CONTROAL PANEL PLC CONTROL

3 OIL INLET/ OUT LET RUBBER HOSES WITH 3/4 , HYDRAULIC END FITTINGS

4 DISCHARGE PUMP DETAILS

A TYPE MEG-50 MONOBLOCK

B NOMINAL FLOW RATE 50Ltrs /min

C OPERATING PRESSURE 1 TO 10 Kg/sq.cm.

D MOTOR POWER 1 hp, 1440RPM , 3PH

5 VACUUM CHAMBER CAPACITY 100 Ltrs (NOMINAL) 6 OPERATING VACUUM UPTO 750 mm of Hg @ MSL

7 HEATER TYPE LOW WATT DENSITY HEATER

8 HEATER LOAD 8Kw 440-VAC-50Hz WITH CONTINUOUS RATING

9 VACUUM PUMP DETAILS

A CAPACITY 180 Ltrs/min

B DRIVE BELT DRIVEN

C MOTOR POWER 0.5 Hp , 1440 RPM , 3PH

10 OVERALL DIMENSIONS

A LENGTH 1560 mm

B WIDTH 740 mm

C HEIGHT 1480 mm

11 WEIGHT OF UNIT

A EMPTY 425 Kgs

B FULL(WITH OIL & WATER) 525 Kgs 12 UNIT PROVIDED WITH TWO FIXED CASTOR WHEELS, TWO SWIVELL

13 DUTY CONDITIONS CONTINUOUS

14 COLOUR SHADE CRIMSON & BLACK

15 WATER DISCHARGE AUTOMATIC

16 CONDENSOR

TANDEM MOUNTED REFRIGERATION TYPE CONDENSOR UNIT WITH PROPRIETARY 0.5 TR COOLING UNIT




7. APPLICATION

The Low Vacuum Dehydrating Machine " can be used for cleaning hydraulic and lubricating oils of the following general specifications. a) Mineral Based oils b) Synthetic Oils

NOTE: Separate models available for Flame / Explosion proof requirements.

Models are available with Moisture sensors at the inlet / Outlet for continuous measurement of moisture content in the oil being dehydrated.




8 . PROCEDURE FOR INSTALLATION : Refer fig 8.1 for installation details

FIG 8.1

Inlet to the LVDH should be connected from the bottom of the oil tank ( ref fig 8.1). Outlet from the LVDH to be given from the top of the oil tank Ensure that a valve is provided at the inlet point of the LVDH so as to isolate the inlet flow

during shut down or servicing of the LVDH unit. Ensure that inlet valves are opened when LVDH machine is put in to operation. Ensure that the outlet valve of LVDH is open before the machine is put into operation. Ensure that water is filled in the chiller unit condensing chamber before unit is switched on. Ensure that the Vacuum release valve and manual water drain valve are closed . Check oil level in the Vacuum pump prior to starting the unit. In case oil level is low use VM4

grade oil for top up LVDH is provided with single phase preventor and will not start if the phase sequence is not

proper. In case the unit does not start even after giving power supply check and change the phase sequence.

NOTE : USE ONLY VM 4 GRADE OIL FOR VACUUM PUMP

The unit must not be installed in a place where it will be subject to significant vibration, to fire, or to other similar hazards.

The unit should only be installed/ used in a covered area and not exposed to the elements. The unit should be installed in a place where it can be easily accessed for inspection & maintenance. Connect the equipment to 3 phase power supply.




To prevent electric shock machines should be properly grounded.

Breakage of a pipe cause oil to flow out.Consider this & other factors when CAUTION selecting pipe materials.

9. Operation and Controls Scheme:

The electrical controls are housed in a sheet metal panel mounted on the main structural frame of the unit. The refrigerated type condensing unit has its own manual controls. Electrical control Panel consist of 1. ELCB+MCB 415 V AC Trip the electrical supply of the unit and heater in case of short circuit or overload current & leakage current that may occur during operation. 2. OVERLOAD RELAY 1 AND 2: To protect the motors of oil pump and vacuum pump from overload. The relay should always be kept on manual reset mode. 3. LVDH is fitted with PLC based control panel to control and display the parameters during operation of the LVDH machine . Ref fig 9.1

Fig.9.1. CONTROL PANEL FOR LVDH MACHINE

NOTE: The keys provided on the panel are soft touch hence care should be taken while operating the same. Avoid pressing the keys if not required.


Make sure that the unit is properly grounded . WARNING



10 .OPERATION:

Ensure that the suction and discharge pipes are connected properly to the oil tank. The suction should be from a point at the bottom so that water will be available for removal. If the tank is partitioned, the suction should be from the section likely to have most moisture. A suction strainer should be fitted at the suction hose inlet. The discharge pipe should be to a point away from the suction.

Switch on the ELCB+MCB to start supply. 415V 50Hz, 3 phase supply in correct RYB sequence is required. The unit is fitted with a single phase preventor so it will not start if the phase sequence does not match.

Start the LVDH using the start /stop button, the vacuum pump will start and the display will indicate the LVDH operating hours. It is recommended that the vacuum pump be run for 20 minutes before allowing oil into the unit. During this time, heater should be Off. The vacuum pump will then be warmed up, and this will prevent the steam vapors from condensing and mixing with the vacuum pump oil. This time delay is provided in the processor program hence only the vacuum pump will start initially and the oil inlet and the heater will start only after 20 min of delay time set.

After the vacuum pump has run for 20 minutes, the inlet solenoid valve will open and the heaters will Come On . The continuous scrolling display will indicate the heater temperature T once the heaters are on.

The condensing unit switches ON after a time delay of 3 mins.

11. Control Panel Display The control panel will show following Operating hours and Oil temperature in scrolling Mode

LED indicators are provided for: 1. Heater on (Bottom right) 2. Vacuum pump On 3. Discharge Pump on (Bottom right) this will show whether the discharge pump is running. In auto mode the discharge pump is controlled by float switches and will switch on and off to maintain oil level in the vacuum chamber within set limits. 4. Vacuum release this indicator will come on when the condensate pot is filled with water and Auto Discharge operates to empty out the water.

12. Chiller unit indications

1. Power On: There is a 3 mins on delay timer. 2. Digital display temperature of return air after cooling the steam to water. 3. Digital display will indicate LT 15 when set temperature is reached. 4. Thermostat cutout: The compressor switches off at limit temperature.




13.0 PROCESSOR OPERATION PASSWORD FOR MANUAL OPERATION

Access to the programming in the Processor is through password. Procedure to be followed for the programming of the LVDH controller.

Password Operation

The face of the processor display show 2 buttons, namely setting and arrow.

When you press the setting button, the display will change to P100

Now press the Arrow button and the display will increase by one point. Bring it to P106 and press the settings button again.

With this password, the parameters can now be displayed and changed , pump can be set to manual, scroll time can be changed. This window for changing is open for 8 seconds. If no changes are made in 8 seconds, password has to be re-entered. To access a parameter, use the SETTING KEY. Parameters will be displayed one by one. To change the value, press the Arrow UP, the parameter will increase one point.

Do not change factory settings; use this only for scroll time setting. DO NOT change any of Caution the parameters given below. Changes if required will be made by company personnel only.

To operate discharge pump in manual mode, enter password, and follow the above procedure to change the discharge pump setting to manual mode.




14.0 MICROPROCESSOR SET PARAMETERS

Parameter Display The display box will show the following parameters in continuous scrolling or when the Arrow button is pressed.

1. Temperature Set temperature. This is the temperature at which the heaters are set to cut off.

2. Operating hours. The vacuum pump oil tends to collect some of the moisture removed from the oil begin dehydrated, and over a period of time this deteriorates the performance of the pump. The service hours for the vacuum pump are indicated as H 002 . The settings are from 001 to 006. Each unit is of 250 hours (001 = 250 hours..002= 500 hours) ..the vacuum pump oil must be changed at the 500 hours.

3.Scroll time n 03 This indicates the time for which scrolling parameters (Oil temperature and Running Hours) are displayed. This parameter can be set form 0 to 10 secounds. When set to 0 the display will not scrol.

4. Heater on h on in some cases when the oil from the system is available hot, it may not be necessary to put on the heater, or when the equipment is being used only to Degassify oil, the heater may not be required.

5 .Auto Discharge the LVDH will discharge the water removed automatically when the condensate pot is filled up. A float switch in the condensate pot will operate and vacuum pump will switch off. At the same time, Vacuum release solenoid will open and vacuum will be released. The water release solenoid will open after 30 seconds and remain open for 17 min allowing water to drain out.




15. Fault Indications

Fault Indications The following fault indications are available FL 3 FL 4. this means the float switch of that number is faulty. FS 1 and FS 2 control the discharge pump in auto mode. FS 3 is the high level safety switch which will prevent oil from being sucked further from the vacuum chamber. It stops the vacuum pump. It indicateds that the discharge pump is not giving full discharge running the LVDH on a barrel of the same clean oil may help to solve the problem, or service should be called for.

V OL indicates the vacuum pump motor is overloaded. Reset the OVerl button for vacuum pump after it cools and restart. 1.Change the oil in the vacuum pump. 2. Check and change the belt driving the pump if necessary. If the problem persists, call for service.

P OL indicates that the discharge pump is overloaded. Reset the button for the discharge pump after it cools down. Check that the heater cutoff is operating at the set temperature. If the problem persist, call for service.

15.a )RESETTING THE LVDH MACHINE AFTER FAULT INDICATION

1) PROCEDURE TO RESET THE LVDH FOR SERV FAULT INDICATION

When the LVDH machines stops due to service indication to reset press key to reset and start the LVDH machine. If the LVDH does not reset repeat the procedure.

2) PROCEDURE TO RESET THE LVDH FOR ALL OTHER FAULT MESSAGES OTHER THAN SERV

When LVDH stops due to any other fault indication other than SERV press key to reset and start the LVDH machine.

Note

FL 1 and FL 2 control the discharge pump in auto mode. FL3 is the high level safety switch which will prevent oil from being sucked further from the vacuum chamber. It stops the vacuum pump. It indicates that the discharge pump is not working to capacity. Run the LVDH on a barrel of the same clean oil this may help to solve the problem, or service should be called for.




16. Safety Provisions Following are the safety provisions provided in the unit. A) 415 V ELCB+MCBs To trip the electrical supply of the unit under short circuit, overload current conditions. B). MCB To protect control circuit and heater, in case current exceeds, due to short circuit, overload etc. C) OVERLOAD RELAYS To protect the discharge pump and vacuum pump motor. D) FLOAT SWITCHES 1&2 To prevent flooding of the vacuum chamber or to prevent dry running of the discharge pump. E) FLOAT SWITCHES 3&4 To prevent flooding of the vacuum chamber and condensing chamber. F) SOLENOID VALVE / NON RETURN VALVE - To provide unidirectional flow. G) PHASE PREVENTOR / PHASE SENSOR To prevent direction change of vacuum pump and discharge pump.

Cooling Unit A. Timer to prevent restart of compressor on load B. Thermostat cutout to prevent frosting on steam condenser.

17. Operating Tips Dos and Donts

FL-3 is indicated on the control Panel

Fig 14.1 FL-3 means float switch 3 activated. This occurs when oil is not being evacuated from the vacuum chamber at a sufficient rate, and oil level has gone up to the 3rd float switch. Oil input is more than Oil output.

1. Release Vacuum by opening ball valve for manual vacuum release on condensate pot. (Refer to the mechanical circuit diagram fig. 1.1 item no. 6.1 ) 2. Restart the discharge pump in manual mode. To restart the discharge pump on manual mode follow the instructions as per PARA . 11 and change the discharge pump mode to manual.

This may happen sometimes because of some variation in oil flow, since the oil viscosity changes with temperature and moisture content. Check the discharge flow physically. The discharge will increase if vacuum is reduced. If it happens consistently, pump requires service.

Dos a. Run the vacuum pump for 20 min before allowing oil into the machine (with Heater Off). b. Check that the oil contains moisture, with crackle tester provided with the machine. (Procedure for crackle test is given in PARA 20 of OIL TESTING) Condensation on exposed areas of tanks is not the correct indication that oil contains moisture. c. Drain free water from the system before connecting LVDH. It saves energy and time. d. Check the vacuum pump oil is clear. If it is milky, change it. Use oil of viscosity 150 cst @40 0C. Enklo 150 recommended, or it is better to use a good engine oil, rather than continue with emulsified oil. e. Check the discharge and idle timings for 2-3 cycles. If idle time is more that 2-3 times discharge timings, clean the strainers in the circuit. f. Check that full vacuum is reached in about 5 minutes of starting the vacuum pump. Vacuum should be within 20mm Hg of Barometric Pressure at your location. At sea level, it should be >740mm Hg. On the Deccan plateau in South India it should be above 680mm Hg. h. Release the vacuum when LVDH is stopped.




Donts a) Do not allow free water into the LVDH. b) Do not open parts other than strainers. c) Do not use the LVDH for degasifying aggressive gases like Ammonia. d) Do not use heater while degasifying oil. e) Do not repeatedly restart the cooling unit in case of fault indication.

The vacuum distillation unit model LVDH-100 cannot be used for the following: a. Water based fluids. b. Oils with volatile additives.

18. INTERMITTENT OPERATION

18a. Temporary Stoppage: 1. Switch off main supply from ELCB. 2. Close the oil inlet valve. 3. Release the vacuum by opening the ball valve for manual vacuum release on condensate pot

(Refer fig 1.1 of schematic diagram item no. 6.1), and then open the Manual water drain ball valve (Refer fig 1.1 of schematic diagram item no. 6.1) to drain out condensed water.

4. Close both valves after release 0f vacuum and condensed fluid.

18b. Shutting Down the Unit: a. Follow the procedure 6a for temporary stoppage b. Position a tray below the strainer of the inlet hose. c. Drain oil from vacuum chamber by operating discharge pump on manual. d. Close the inlet valve of the unit. e. Close the outlet valve of the unit. f. Open the strainer cap and remove strainer basket and clean. g. Put back the strainer basket and tighten the strainer cap. h. Disconnect suction and delivery hoses and drain all the oil from the hoses to the tank. i. Cover the inlet and outlet ports of quick release coupling ends with suitable rubber or polymer

caps. j. Drain the condensate pot and water from filters and heating chamber drains.




19. Trouble Shooting & Maintenance

1. Does not start Check phase sequence 2. Try to start the heater Off. If it starts, one or both heaters are defective and should be replaced. 3. Vacuum level low Vacuum pump service vacuum pump, check oil level and top up if necessary. 3a. Leakage from quick release coupling Fix properly the inlet and release coupling outlet hose connection. 3b. Solenoid Valve Check the valve 4. Oil temperature low a) Heater operation. Check supply. b) Check heater condition for continuity and insulation resistance and replace if burnt. 5) OL indicates the vacuum pump motor is overloaded. Reset the over load button for vacuum pump after it cools and restart. Change oil in the vacuum pump. Check and change the belt driving the pump if necessary. If the problem persists, call for service.

P OL indicates that the discharge pump is overloaded. Reset the button for the discharge pump after it cools down. Check that the heater cutoff is operating at the set temperature. If the problem persists, call for service

2. Maintenance Schedule of Unit: It is recommended that proper records of the unit be maintained and updated periodically. Format for the log should to be maintained in given below. All the irregularities in operation, any malfunction, failure of components etc. must be immediately and properly recorded and intimated to the authorized personnel for any needed corrective action.

LOG SHEET FOR LVDH PERFORMANCE AND MAINTENANCE

DATE HR METER READ

VACUUM TEMP. MOISTURE IN OIL VACUUM PUMP OIL CHANGE

REMARK

3. TIPS FOR SMOOTH OPERATION a. VALVES: Check all values for , smooth operation and leak tightness. b. VACUUM PUMP: i) Check oil daily ii) Change oil after every 500 hours of operation. c. The unit should achieve full vacuum in 4-5 minutes, and the vacuum pressure should not drop after standing idle for 2 hours. This test should be done monthly. Call for service if the unit does not pass this test.




4. Cleaning of Strainers: When the oil flow to the vacuum chamber is very low or zero (which can be seen from the long time elapsed for filling of vacuum chamber i.e. more than half an hour), the indications are that the suction strainer or line strainer is choked and requires cleaning. Clean manually and reinstall.

5. MAINTEANANCE OF CONDENSOR The condenser is of robust, maintenance-free design. It is a refrigerated type cooling unit, with its own protection and hermetically sealed compressor. It is designed to handle large moisture removal rates, During operation, the cooling unit fan should be checked by placing a band over the discharge grille. If the cooling unit is running, and indicator does not show Lt, the fan should also be running.

6. Loading and Unloading: a. The unit is provided with four caster wheels which make the mobility of the unit easy and convenient. B Four lifting points are provided on the top of the unit.

20. OIL TESTING

20.a. Inlet Oil Condition: a. Temperature: About 50 0C b. Max. free moisture content : 3% c. Solid contents : Less than 0.5% by weight d. Oil Flow : 15 liters per minute average.

20.b. Sampling Procedure: Mark the sample bottles with following details: a. Type of oil and quantity. b. Wet oil label. c. Provide sample bottles with labels e.g. initial after 1 hour of dehydration, 2 hours, 3 hours, etc.

Do not forget to properly seal and place the sample bottles in a secure place till they are analyzed. Important Note: a. Any improper sampling procedure or wrong labeling will lead to wrong and erroneous oil analysis. b. Minimum quantity of oil for each analysis should be at least 250 cc.




20.c. Oil Tests:

FOLLOWING ARE THE TESTS PERFORMED FOR EVALUATION OF MOISTURE CONTENT IN THE HYDRAULIC OIL. Whenever free water is present in the oil it will be generally hazy or cloudy. A simple crackle test provides a qualitative on the spot confirmation. A.CRACKLE TEST: By heating oil sample on a spoon an audible crackling or popping and momentary frothing will indicate that there is water in the oil.Refer to fig 20.1. Heater with spoon provided along with the LVDH machine.

Fig : 20.1 Crackling test

B.LABORATORY TEST: By Karl Fischer Titration Method.

C.MOISTURE SENSOR: Moisture sensor supplied along with the equipment give direct readout of the saturated moisture content in ppm. Refer fig 20.2 for moisture sensor.

Fig 20.2 MOISTURE SENSOR


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Annex II OPERATION MANUAL FOR CHILLER UNIT.

PRINCIPLE OF OPERATION: The steam condensor is designed to extract heat continuously from the steam to which it is attached in order to condense the steam. The unit consists of Mechanical Refrigeration System, utilizing refrigerant R-22 a condenser, drier. Steam from the machine is drawn into the top inlet of Copper submerged type heat exchanger with the help of vacuum pump provided in the LVDH machine. Steam will get cooled after passing through Copper submerged type heat exchanger & condense into free water which will be collected in the condensate pot. Refrigerant Circuit as follows: Compressed refrigerant R 22 coming from compressor, passes through condenser, filter drier & the capillary tube at which point it enters the copper evaporator coil to bottom, running counter flow to the steam & leaving the heat exchanger at the top and then to the compressor. The Operation of the Temperature controller is as follows: When temperature controller calls for refrigeration because of rising steam temperature as it comes from the machine, it starts the condenser fan and compressor motor after time delay.

BILL OF MATERIAL

1. Compressor : Emerson Climate Control Technology 2. Condensor Coil : 11 X 10 X 3 Row Copper tube Aluminum Fins 3. Drier : Copper Strainer 4. Expansion Device : Capillary Tube 5. Cooling Coil : Submerge deep type 6. Condensor Fan Motor : Axial flow fan 7. Temperature Controller : Make: Subzero

Electrical Part with Compressor Model

Compressor Model Item KCJ 467 HAG KCN 463 HAG

KCE 443 HAE

Relay KARP5641 LT85002 LT85002

Start Capacitor 80-100 Mfd 80-100 Mfd 40-60 Mfd

Running Capacitor

N. A. 15 Mfd 10 Mfd

Overload Protector

MRA 12024112 Or

KAT0733/02

KAT0463/B2 KAT0072/K3 Or

KAT0159/B2




SOME HINTS THAT WILL PREVENT SERVICE CALLS:

1. Problem Steam Condensor (i.e. condensor fan motor) is working but cooling effect is not there. Possible Cause (checks to be made) 1. Check the steam connections (I.e. steam inlet & outlet) are not interchanged. 2. Check the Temperature controller setting. 3. Check the MCB provided on electrical control, if MCB trip reset it. 4. As per the wiring diagram, check the connections. If there is loose contact repairs the same. 5. In case of leakage or breakage of copper tube, follow the procedure given under gas charging. 6. Even after above checks, cooling effect is not there then contact us.

HOW TO CLEAN CONDENSOR COIL: 1. Remove the front cover of chiller unit by removing necessary screws. 2. Clean the condensor coil with the help of compressed air. 3. Care should be taken to avoid damage to copper tubing fins to avoid refrigeration leakage. 4. Refit the FRONT cover after cleaning operation. CONDENSOR FAN MOTOR: Condensor fan motor requires no maintenance. All bearings, shafts etc., are lubricated REFRIGERANT LOSS: The condenser has been thoroughly tested before leaving the factory. Transportation damages require repairs & recharging of the system. This work work should be performed by qualified persons only, generally available in any reputable air conditioning repair & service company. Before recharging make sure that there are no leaks & that the system has been properly evacuated by deep vaccum. GAS CHARGING PROCEDURE FOR CHILLER UNIT : Connect process valve to process lines provided in the system. Pressurize the system with dry Nitrogen to 200 PSI (maximum). Do not use carbon dioxide, air or any other gas. Check the joints with soap solution. If leakage is ovserved, repair & recheck. Release nitrogen pressure & connect the system to vaccum pump. Evacuate for at least six hours. Vaccum of 50 microns (0.5 mm to 11 g.) must be achieved. During evacuation, heat the components (condensor, compressor) by infrared heating unit. While heating care must be taken so that insulation will not melt. After evacuation, charge the system with Refrigerant R22 Qty. 650 gms. It is necessary to run the steam condensor during the charging operation with steam circulation.




MAINTENANCE

Compressor: Compressor requires no maintenance. It is well lubricated and hermetically sealed. If the refrigerant is lost, recharging valves are provided on the suction sides of the compressor for recharging and / or checking. Under no circumstances the refrigerant lines to be lossened, removed or tempered with. They must be attended to only by trained persons. The system contains refrigerant gases under pressure. Inlet Filter: Proper maintenance of the inlet air filter, will assure stable operation of your steam condensor. If filter maintenance is delayed or ignored, the maximum ambient temperature under which the unit is designed to operate will be decreased. As the compressor operating temperature increases above normal due to clogged inlet air filter or plugged condenser coil, the compressor will stop operating due to actuation of the thermal overload cutout switch. As soon as the compressor temperature has dropped within the switch cut-in-setting, the compressor will restart automatically. The above condition will continue to happen until the filter has been cleaned or replaced. It is recommended that power to the chiller unit be interrupted intentionally when abnormally high compressor operating temperature causes automatic shut down of the unit. The shut down is symptomatic of clogged or dirty filters, thus causing reduction in cooling airflow across the surface of the compressor & condenser coil. Continued operation under this condition, can and will damage or shorten compressor life. The Steam condensor features an easily removable inlet filter to facilitate necessary cleaning. There should be no reason to neglect this necessary maintenance. HOW TO REMOVE, CLEAN OR INSTALL NEW FILTER:

1) Remove the screws of front grill. 2) Clean it with the help of compressed air and refit front grill..

It is impossible to recommend a filter cleaning interval, due to vide variation of air quality conditions and operating duty cycle of the steam condensor. Amount of air borne dust/dirt particles are different in every location. It is recommended that when fine layer of dust or lint is visible on the surface of the filter, it should be cleaned with

1) low pressure air 2) Water washed 3) Dried with low pressure air.

Do not run the Steam Condensor for extended period of time with the inlet filter removed. Particles of dust & lint etc., can plug the fins of condenser coil. Condensor Coil: Proper maintenance of condenser coil will ensure stable operation of the chiller unit. If the condenser maintenance is delayed or ignored, maximum ambient temperature under which unit is designed to operate will be decreased.




Temperature Controller Manual

Para. Description

To set the set point of the controller

How to set other parameters

P1 To set Heating or Cooling function.

P2 Max High Temp limit & alarm

P3 Min Low Temp limit & alarm

P4 To set Differential Temp ( Hysterics)

P5 Probe calibration

P6 Time Delay (relay restart after cutoff)

P7 Defrost duration

P8 Defrost frequency

LP Keypad lock

Al Alarm-to activate buzzer

E1 Relay status on probe failure

FS Restore factory defaults

EP End programming & Keypad functions

Operating messages

Wiring diagrams

Panel cutout & dimensions

Ideal set point for your requirement 1) P1 - 0 2) P2- 35 3) P3-15 4) P4-2 5) P5-0 6) P6-3

Message Description Parameter

Ht Temperature above the maximum limit of the set point. P2

Lt Temperature below the minimum limit of the set point. P3

PP Probe short circuit, circuit open or without probe, or temperature > 99 Degree Celsius or < -50 Degree Celsius.

On/Off Comp. Relay on/off SP, P4

Flashing Alarm (Ht, Lt or PP) AL

On/Off Keyboard locked/unlocked LP

On Defrosting in progress P7, P8

Flashing Time delay in progress P6

Set Point of Temperature Controller Manual

P1 0

P2 45

P3 12

P4 3

P5 0

P6 3

P1 1




Trouble Shooting Chart

Sr No Condition Cause Remedy

1. Unit Not Starting No power supply MCB Trip Check incoming supply voltage Reset MCB

2. Fan is on but temperature not maintained

Compressor trip or loose connection In electrical wiring

1)Check unit AMPS (Reqiured 3.5 Amps if compressor on)

3. Fan & Compressor is on but temperature not maintaining

Air Filter chocked Gas leakage

Clean Air Filter and condenser by air Check gas pressure on Gauge. It requires 125 to 150 PSIG (If unit is in OFF Condition) & 30 to 50 PSIG (If unit is in ON condition)

4. Unit not maintaining Temperature even gas pressure is OK (150 PSIG in OFF condition)

Compressor not working First of all confirm that compressor is on by measuring current. It requires to shown 4.0 Amps. If shown 2.5 Amps then there are chances of gas leakage or compressor mechanical breakdown

5. MCB Trip When Unit Start Fan Motor burn out Compressor burn out Short Circuit

Check fan motor ground test Check compressor motor resistance & ground test Check electrical wiring short circuit

6. Unit working but not removing water from Oil

Low water level in tank Check water level in level gauge. Fill water in proper level

7. Gauge showing 150 PSIG pressure in Off condition and 0 PSIG in on condition and not maintaining temperature

Refrigeration system chocked Call refrigeration technician and check gas strainer or capillary to be replace both part and recharge the system

Healthy System: 1. Full load current: 4.0 Amps 2. Only Fan Motor Connect: 0.24 Amps 3. Gas Pressure in unit OFF condition 125 to 150 PSIG 4. Gas pressure in unit ON condition 45 to 60 PSIG


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