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FPRS-S200 Service Manual

1. Manufactured in the U S A 26 A FPRS S 200 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com ORDERING SPARE AND REPLACEMENT PARTS A Spare Parts List for your FPRS is included on the following page Prompt service can be given for spare or replacement parts if ASL has the following information 1 The part number s of the item s you need The Spare Parts List includes the most frequently requested items 2 The quantity needed Please remember to order spares if needed 3 Order fulfillment information v SANA Preferred shipping carrier information ASL is an On Line daily UPS shipper Ground Next Day Second Day etc Bill To Address Ship To Address we cannot ship to a P O Box Purchase Order Number Parts will be invoiced F O B Wanatah IN at the prices in effect at the time of the shipment Terms will be Net 30 days We also accept Visa MasterCard and American Express Order Address ASL Technologies LLC Parts Department 10525 W US Hwy 30 Bldg 3D Wanatah IN 43690 Telephone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 E Mail custsve aslfilter com Internet www aslfilter com 27 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219
2. Activate the main power source and then turn ON the power switch on the control panel After fluid is dispensed oidi the output hose shut down the system and check for leaks ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com Electrostatic Cell Rebuild Program The Electrostatic Cells in your FPRS Finite Particle Removal System are designed to provide many hours of superior filtration Like anything else it occasionally needs care and maintenance It is strongly recommended that the Cell be replaced once each year to insure optimum cleaning performance The re build exchange program has been organized to provide minimum downtime and maximum performance When you receive your replacement Electrostatic Cells please note that the red tag affixed to the top of the cell contains part number information as well as the date the cell was made A blank area is left open for you to fill in the date the cell was installed in your system This will help you determine when the cell should be exchanged When you are ready to replace your Electrostatic Cell please follow these steps l Look at the red tag on the top of the cell to locate your part number R61CS 115 for example 2 Send your P O to ASL via Phone Fax mail or e mail custsvc aslfilter com with the quantity and part n
3. _ 5 Lo Volt Factory Wired this wa 8 3 1 Black Do not reverse rotation Baker R80 0007 3 GPM Pump ASL Pump is 3U Type The following pages contain the vendor service manual for the 3U Type pump used in ASL 200 systems 44 Haight Pumps For Superior Performance Operating Maintenance and Instruction Manual 45 DIVISION OF BAKER MANUFACTURING COMPANY HPOM1 06 Operating Manual for Haight Positive Displacement Rotary Gear Pumps Pre Installation l Choose a location that is easily accessible for pump servicing Ensure adequate electrical service is available Locate the pump for direct piping Special attention should be given to the suction piping which should be as large or larger than the pump intake port For efficient operation it is essen tial the suction side of a gear pump not be restricted Avoid tees elbows valves and other flow devices within 12 pipe diameters of the pipe inlet Provide adequate support for the piping The pump should not be used to support piping Pumps are shipped with the suction port marked IN the discharge port marked OUT The suction port on pumps with relief valves is the port nearest to the relief valve adjusting screw Pumps will operate in either direction However the relief valve will only function in one direction Relief valve components are symmetrical and can be installed to operate with either clockwise or counter clockwise shaft
4. 13 14 15 WARNING Turn OFF the FPRS on the control panel and at the electrical source Open the top hinged cover and remove the front cover Disconnect the high voltage wires as follows WARNING Short across the positive and negative electrodes using a screwdriver with an insulated handle to dissipate static electricity WARNING Each cell has a positive red lead and a negative green lead connected to it NEVER touch both leads at the same time Disconnect the high voltage wire connections leading to the top of the cell using one hand grasp the boot connected to the green wire and pull up Repeat with the boot connected to the red wire Remove the input and output hoses by releasing the quick disconnects Loosen 4 attaching screws from outside of the cabinet and lift the cell out of the cabinet Replace with a new or rebuilt cell Ensure that the cell is inserted correctly with high voltage electrodes pointing upwards Attach quick disconnects with blue hose to the bottom of the cell and gray hose to the top of the cell Replace the high voltage wires to the cell Red is positive Green is negative The label at the top of the cell notes the POS and NEG electrodes Be sure to fill in the Date Hours Installed on the cell tag Replace the front cover and close the hinged top cover Restart the FPRS and operate system for a few minutes Ensure that fluid is being dispensed through the output hose WARNING
5. 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com 2 SYSTEM CIRCUIT BREAKER Located between the ON OFF switch and the Green Power lamp the system circuit breaker is rated at 10 Amps GREEN POWER LIGHT With the cover closed and the power switch is on power flows to the green POWER lamp which illuminates to indicate power is applied to the system The green POWER lamp is a neon tube lamp that is designed to glow for many hundreds of hours These lights are non relampable and must be replaced when defective See the MAINTENANCE section for instructions 4 RED LOW VOLTAGE LIGHT s When the system is first turned on or power is restored following a power interrupt condition the 5 red LOW VOLTAGE lamps will illuminate briefly and then go off The LOW VOLTAGE lamps do not indicate trouble with the incoming 120 VAC power but relate to the high voltage DC power supply which supplies 15 000 VDC to the Electrostatic Cells The signal to illuminate this light comes from a relay internal to the high voltage power supply yellow wire which opens at approximately 700 micro amps If this lamp illuminates it indicates that the high voltage DC power supply output voltage is low and could be caused by a variety of reasons When any of the LOW VOLTAGE lamps are illuminated power to the pump motor is interrupte
6. In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com IMPORTANT SAFETY INFORMATION READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE OR MAINTAIN THE FINITE PARTICLE REMOVAL SYSTEM PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY INFORMATION FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND OR PROPERTY DAMAGE RETAIN THESE INSTRUCTIONS FOR FUTURE REFERENCE SAFETY ALERT SYMBOL AND SIGNAL WORDS The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions A safety alert symbol is used with signal words WARNING and CAUTION to call attention to safety statements WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life JN cretion statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment ELECTRICAL SAFETY WARNING ELECTRIC SHOCK can kill Your FPRS uses a high Direct Current voltage of 15 000 volts Do not touch live electrical parts Always disconnect power source before working on the system Avoid accidental starting Make sure unit is turned OFF and is unplugged or disconnected from its power source before beginning any maintenance tasks This product and the flu
7. be required Replace the front cover and close the top cover You are now ready to begin normal operations Your FPRS system has been designed to operate continuously on a fluid reservoir with little operator attention However it is recommended to check the control panel daily to monitor system condition See page 41 for Scheduled maintenance Tasks 19 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com FLUID MAINTENANCE The following recommendations are made in the interest of maximizing the benefits available with the S Series FPRS system 1 Periodically monitor the condition of the machine fluid The following is a list of recommended tests that should be performed e Viscosity When compared to values for virgin oil the viscosity gives an indication of excessive thinning or thickening resulting from oil breakdown TAN When compared to values from virgin oil an increase on the TAN indicates oil serviceability with regard to oxidation or contamination with an acidic product Particle Count Monitors the oil cleanliness level to provide indication of filter efficiency and potential wear failures e Water Indicates the presence of moisture of coolant in the oil For detection of water content below 1000ppm the Karl Fischer method can be used Spectrochemical Elem
8. the Hydraulic Institute offers guidelines for proper pipe support design Seals Haight Pump offers three standard type seals each with specific operating characteristics e Lip seals Available in Buna N Viton Teflon Silicone and Kalraz seals Lip seals are inexpen sive but have certain limitations which include e Expected operating life of 2 000 3 000 hours e Should not be used with system pressures over 75 psig e Should not be used in vacuum applications over 3 Hg 49 General Information Seals cont d e Packing gland Available in Graphfoil or Teflon and other materials upon request Packing glands are useful at high temperatures and pressures resist shock and vibration and can be adjusted to accommodate wear However packing glands must weep to function properly and require adjustment during the start up operation During start up or after repacking run the pump to pressurize the stuffing box Steady weepage should occur in less than ten 10 minutes If steady weepage has not begun within ten 10 minutes stop the pump and allow it to cool Overheating the gland will damage the packing gland and shaft Do not loosen the gland adjustment screws Repeat this process until steady weepage is established Adjust the packing gland screws 1 6th of a turn in a cross bolt tightening pattern Allow to run ten 10 minutes Continue this process until the weepage rate is approximately one 1 drop per minute Periodic in
9. 4 CR3 6 amp 4 CR4 6 amp 4 and CR5 6 amp 4 allowing power to flow through the normally closed contacts of CR6 5 amp 1 and CR7 5 amp 1 thus energizing the coil of CR8 Once CR8 closes power is allowed to flow through the now closed contacts of CR8 5 amp 3 Power then simultaneously goes to the hour meter on the front panel and through terminal strip TB 1 M and to TB 2 M to start the pump motor At the same time CR 1 thru CR 5 close the normally closed contacts of CR1 thru CRS pins 5 amp 1 open turning the red Low Voltage lights on the front panel off At this point the system is operating normally Green Power lamp lit hour meter running pump motor running 15KV supplied to the Electrostatic Cells SO ay 31 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter ccom Www aslfilter com TROUBLE INDICATING CIRCUITS and TROUBLESHOOTING LOW VOLTAGE INDICATOR The red Low Voltage lights indicate that the Electrostatic Cell High Voltage DC power supply is no longer putting out enough voltage to hold particulate trapped within the Electrostatic Cell Note that these lights will illuminate briefly when power is first turned on The low voltage indication is controlled by a normally closed relay within the high voltage power supply This relay the yellow wire coming out of the power supp
10. Orientation Ambient temperature less than 160 F fete Oo o Fluid Delivery Pump Motor The self contained pump and motor delivery system allows for continuous filtration even during machine downtime Installation is convenient and maintenance does not require shutting down the hydraulic system A pump motor assembly is provided which is designed to be compact and is for continuous duty maintenance free and has been sized for the correct flow rate Hydraulic Connections All the connections between the reservoir and the cabinet can be with hard piping or hose connections On the 200 unit 3 4 NPT bulkhead fittings are provided for your convenience on the right power cord side 17 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com 4 Mounting Surface The S Series Cabinet Model has cooling vents on the back of the cabinet behind the Motor These slots must remain open and free of restrictions which could interrupt the flow of cooling air to the motor The system must be kept in a level position when operating 5 Remote Alarm If a signal is desired to provide remote indication of an alarm condition the S Series Cabinet Models provide dual quick connect interface with two internal dry relay contacts to interface with a signal not exceeding 24 volts The relays a
11. S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 7 Remove the two 6 32 nuts and washers from the studs and remove the power supply from the unit Note that the red high voltage lead and spark plug terminal boot remain attached to the power supply 8 Install the new power supply in the reverse order Note that replacement power supplies have a relatively long Positive lead with the boot and terminal installed at the factory 9 Plug in the three spade connectors to the power supply observing wire color codes and power supply connector labels Red wire to HOT Green wire to GND and white wire to HOT Connect the two pin yellow orange connector to the harness and re install the wire trough cover Electrostatic Cell See page 22 in this manual Water Absorber Element See page 23 in this manual Pump Motor COMBINATION Replacement of the pump and motor is straightforward The pump motor is secured to studs in the back of the cabinet with four 4 20 locknuts and flat washers Secure power to the unit before any servicing 1 Start by removing the motor wiring box cover and disconnecting the wire nuts tying the SO cord to the motor leads The green ground wire is secured with a green screw to the motor inside the motor wiring box Pull the SO cord out of the motor wiring box and plastic Heyco connector Note that wire connections and numbers are located on the motor nameplate as well as page 44 of this
12. SAMPLE PORT The oil sample port is located on the lid of the Water Absorber canister This test port makes a convenient leak and contamination free port to draw oil samples The FPRS S200 system uses a KP series thumb push sample valve requiring no special tools or fittings to use To sample unscrew the cap on the sample valve and push the thumb button in for a few seconds to flush the sample port Using a clean sample bottle remove the lid and invert it to prevent ambient dust or dirt from contaminating the sample Fill the bottle to within 2 of the top Immediately install the cap securely Note that this port is before any FPRS filtration Note also that the FPRS must be running to draw the sample This valve is also used to bleed off trapped air in the canister on initial start up or when the water absorber element has been replaced WATER ABSORBER DRAIN BALL VALVE This Normally Closed drain valve located at the bottom of the water absorber canister is used to drain the canister when replacing the water absorber element An 18 long gray drain hose is attached to the drain valve and the hose end is folded and ty wrapped when you receive your FPRS The hose is stowed behind the absorber canister COVER SAFETY SWITCH Once the power switch is placed in the ON position power flows to one side of the cover safety switch With the cover in the open position power is interrupted preventing operation of the FPRS 11 ASL Te
13. in personal injury and or property damage and will void the product warranty CAUTION Secure the discharge line before starting the system An unsecured discharge line may whip causing personal injury and or property damage Explosive or flammable flash point below 200 F fluids must never be filtered with this product Electrostatic arcing is a potential ignition source Please refer to Fluid Specification prior to filtering fluid Do not exceed 45 psi on any components in the system Protect fluid lines from damage or puncture Maximum fluid temperature should not exceed 165 F The Electrostatic Cell body can distort at higher temperatures draining the reservoir and creating a floor hazard and severely damaging the hydraulic system ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com INTRODUCTION SYSTEM OVERVIEW The Finite Particle Removal System Patent Numbers 5 149 422 5 242 587 and 5 891 315 other Patents pending uses the most advanced technology available to clean and reuse oil ie transformer hydraulic turbine lubricating and solvents There are basically five 5 major factors contributing to the contamination of industrial fluids Air Heat Water e Particulate matter Oxidation of by products Contamination of industrial fluids is
14. manual 2 The hose connections to the motor are of the push lock type and will have to be cut Slit the inlet and outlet hoses the minimum amount necessary to allow removal of the hoses from the push lock fittings Trim the hose ends square for re installation Excessive slitting and or trimming will render the hoses too short and they will have to be replaced There is enough excess hose length to remove and replace the pump at least once or twice 3 With the wiring and hoses disconnected remove the four 4 20 nuts and washers and remove the pump motor assembly from the cabinet 4 With both the old and new pumps motors on the workbench transfer the inlet outlet hose fittings and the black Heyco wiring fitting to the new pump motor Take care to align the fittings the same way they were Use a suitable thread sealer on all pipe threads 5 Install the pump motor into the cabinet by reversing the above instructions A drop of lubricant on the push lock fittings will ease installation of the hoses 6 Secure all wiring and hoses and proceed to PUMP and PRESSURE SWITCH ADJUSTMENTS on page 40 Replacement of PUMP only If you have determined that only the pump needs to be replaced the motor and it s electrical connections can remain attached to the cabinet 1 Remove the pump inlet and outlet hoses The fittings are of the push lock type and the hoses must be cut Slit the inlet and outlet hoses the minimum am
15. pressure gauge shows system pressure at the entrance to the Water Absorber Canister Under normal operating conditions warm fluid fresh water absorber element fresh Electrostatic Cells no output hose restrictions etc the gauge will read approximately 10 to 25 psi A higher initial reading may be caused by cold or thick fluid Over time it is normal for the gauge to indicate progressively higher pressure due to accumulation of water in the water absorber element and or excessive particulate accumulation in the Electrostatic Cell At 35 to 38 psi it s time to find the cause of the excessive pressure which can only be caused by a clogged water absorber element or Electrostatic Cell or some restriction in the lines downstream of the pump CELL PRESSURE GAUGE The Cell Pressure gauge shows pressure at the entrance to the cell inlet manifold Under normal operating conditions the cell pressure gauge will read 5 to 7 psi less than the Water absorber pressure gauge REMOTE ALARM CONNECTOR The Remote Alarm connector located on the right side of the cabinet beneath the power cord entrance is a two wire 250 male spade connector that can be interfaced to a remote alarm or PLC The signal runs through two dry sets of contacts in relays CR 1 and CR 8 When the system is operating normally these contacts are closed In the event of any internal failure these contacts open If these connections are used do not exceed 24 VDC OIL
16. rotation Have an electrician connect the motor using sound practice Provide adequate overload protection Note When checking the direction of rotation the pump must be full of liquid Pumps fitted with mechanical seals must not run dry not even momentarily Determine the direction of rotation by watching the motor fan The motor selected meets the requirements of the specified operating conditions Changed conditions for example higher viscosity higher specific gravity or lower head losses can over load the motor When changing operating conditions or whenever there is any doubt please contact your local distributor with the full details Installation l 2 Provide a solid foundation free from excessive vibration Shim to prevent distortion of the pump mount base Securely anchor the pump and motor to the foundation All pipe connections on the suction side of the pump must be air tight An air leak on the suc tion side of the pump will result in the loss of prime Provide priming tee on the discharge line of the pump If the media pumped contains solids a suction strainer is recommended to exclude solid particles from the pump Contact Haight Pump for a recommendation Support the piping independent of the pump Excessive strain on the pump casing can interfere with gear alignment When the piping is complete loosen the bracket set screws and allow the pump to align with the piping Tighten the bracket set screw
17. stop and start as the power supply tries to reset itself If you observe a flashing low voltage light you should shut down the system immediately and investigate the cause Remember that the low voltage indicator light should reflect the microamps being consumed so a low voltage light should be confirmed by observing the microammeter indicating 700 or more microamps Causes for a low voltage light The low voltage light can be caused by one or more of the following 1 Shorted Electrostatic Cell The Electrostatic Cell can short due to ingestion of water or accumulation of an excessive amount of particulate particularly ferrous particulate a Turn power off and un plug the FPRS from the power source b Using a screwdriver with an insulated handle short across both POS and NEG terminals of the Electrostatic Cell to dissipate any static electricity c Remove the red POS spark plug boot terminal from the Electrostatic Cell d Remove relay CR 8 to prevent the pump from starting e Re connect power and turn on the power switch Note that you will have to A defeat the cover safety switch to continue USE CAUTION f If the low voltage light is now off the Electrostatic Cell is shorted and should be backflushed and or replaced g If the low voltage light is on with the corresponding Cell disconnected the power supply is defective and should be replaced h Note that it is possible to have both a shorted Cell and a bad power supp
18. valve in the pump should fail system pressures could rise drastically very quickly The pump is easily capable of pressures exceeding 200 psi Such a sudden pressure rise if not checked could blow the seals in the Electrostatic Cells water absorber canister and rupture hoses within the system causing significant equipment damage and or personnel injury The pressure switch located on the water absorber canister is adjusted at the factory to close at approximately three to five psi higher than the pump bypass relief valve i e 43 to 45 psi When the contacts of the pressure switch close power which has been sitting on the black wire is allowed to travel through the red pressure switch wire to the red overpressure light the coil of CR 7 and contact CR7 6 Once CR 7 is energized the normally closed contacts of CR7 5 amp 1 open stopping the flow of power to the coil of CR 8 When CR 8 opens power is removed from the pump and hour meter The wire coming back down from CRS 4 provides power through the now closed contacts of CR7 4 amp 6 keeping the overpressure light on and the coil of CR 7 closed Thus even though the pressure switch may only bump closed momentarily the red light and fault will remain latched on until an operator intervenes Cycle power off then on As designed when the overpressure circuit is operating properly it indicates a failure of the pump assembly and or the pump relief valve
19. 733 2779 or e mail custsvc aslfilter com Www aslfilter com FPRS S 200 Cabinet Spare Replacement Parts DESCRIPTION PART NUMBER Call ASL for any parts not listed O S High Voltage Power Supply ALL CS 2223 P8 S 200 Pump Motor coupler ASSY FPRS 200 Pump Motor Assy includes bellhousing amp coupler S 200 Pump only Water Absorber can O ring Buna R61CS 115 See red tag on top of cell for your exact part number Laminated wiring diagram Inside front S 200 Series Wiring Diagram cover Red Lamp Assy Low Voltage Float 1050 QC1 Switch Over Pressure Oil Sample Test Port Push to test type KP14N V 1 Viton Serial s 006 and up Relay CR 1 through CR 8 LY2 120VAC 10 Amp contacts 28 FPRS S200 Wiring Diagram Safety Sw p off A 10 A C B T Ei 10 A C B E G Power On Lt CR 1 1CR2 1CR3 i CR 4 i CR 5 1CR6 1CR7 1 CR8 I li li li li 14 li 1 I 1 i i i i li LE li 1 Cs Pump Start 1 ty ty toy to ty l 1 I Relay 15 31 6 4 16 4 16 4i16 4i 5 1 15 1 18 7 Pa WT pete 2 ol el eee E hate He Htc cal al UE I bee somone Vile ese I torso I 1 CRB O Pump Motor i B 1 M B 2 M l 5 3i 1234 Hour Meter i CR 1 1 1 1 PS 1 LV Lt cana 7 R I 15 1 ae Set i CR2 1 i PS 2 LV Lt aye R 1 15 1 a ae crs R PS 3 LVL i I I t 1 1 5 1 Loe i CR 4 Li 1 i PS 4 LV Lt l R i Li PS 5 LV Lt _ Float Sw Relay Float Sw Lt Press S
20. A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com IMPORTANT GUIDELINES Oil temperature should not exceed 160 F for electrostatic cells 175 F for black tube Phosphate Ester Cells Ambient air temperature should not exceed 160 F Viscosity of the oil to be cleaned cannot exceed 1800 SUS 100 F The minimum flash point of the oil should not be below 200 F FPRS S Series units will automatically restart if input power is momentarily lost Concentrations of water should not exceed 500 ppm If in excess a water absorber should be used to reduce the content to an acceptable level less than 500 ppm before the electrostatic cell is employed It is recommended the FPRS input hose be connected to or draw from the lowest point of the reservoir Therefore when hooking up to a reservoir for the first time or after a period of non filtration always drain free water from the bottom of the reservoir before using the FPRS The output hose should be returned to the highest point at the opposite end of the reservoir to ensure maximum distance between the input and output hoses When installing an FPRS S Series unit on an elevated reservoir where the lowest fluid level of the reservoir is higher than the FPRS it is recommended that shut off valves be installed in the line running from the reservoir to the FPRS pump i
21. HE 120VAC POWER CIRCUIT 120VAC power from the incoming power cord source goes first to a four position terminal strip on the back wall of the cabinet TB 1 above and to the right of the pump motor From there power black wire runs to another terminal strip TB 3 located on the inside of the top cover to the right of the relays Power then runs to the 10A circuit breaker on the front panel From the circuit breaker power is fed to the ON OFF switch on the front panel Power then flows to one side of the cover safety switch The other side of the safety switch then goes to TB 3 3 and from there spreads to CR1 5 CR8 5 CR2 5 CR3 5 CR4 5 CR5 5 Float switch power black wire the Pressure switch power wire thel120VAC in connector on all 5 High Voltage power supplies and finally to the Power lamp on the front panel Note that the normally closed contacts of CR1 thru CRS pins 5 amp 1 will momentarily pass 120VAC to the red Low Voltage lights on the front panel Once the H V power supplies receive power a normally closed relay inside the power supply sends power to the coil of CR1 thru CRS via the yellow wires The action of CR1 thru CRS energizing starts the sequence of events to run the system Note that as soon as the power supply receives incoming power 15 000 VDC is immediately applied to the terminals of the Electrostatic Cells With CR1 thru CR5 coils energized the contacts of CR1 5 amp 3 close along with CR2 6 amp
22. Note that you will have to defeat the cover safety switch to continue A USE CAUTION 4 Using a voltmeter check for 120VAC on the orange wire If 120VAC is present replace the amber backflush lamp assy Note that all of the indicator lights are of the non relampable type and must be replaced completely 5 If 120VAC is not present on the orange wire the power supply is defective FLOAT SWITCH INDICATOR RED The float switch prevents an internal FPRS leak from draining the reservoir and is designed to be a non resetting safety fault The float switch itself is located in a bracket on the drip tray in the bottom of the base cabinet in the right front corner below the Water Absorber canister In case of a fluid leak the float switch will slowly rise on the fluid until the internal magnetic contacts close Once these contacts close several things happen at once When the contacts of the float switch close power which has been sitting on one side of the switch is allowed to travel to the red float switch light the coil of CR 6 and contact CR6 6 Once CR 6 is energized the normally closed contacts of CR6 5 amp 1 open stopping the flow of power to the coil of CR 8 When CR 8 opens power is removed from the pump and hour meter The wire coming back down from CRS 4 provides power through the now closed contacts of CR6 4 amp 6 keeping the red float switch light on and the coil of CR 6 closed Thus even thoug
23. Once fluid is dispensed through the output hose turn OFF the FPRS on the control panel and at the electrical source Open the top cover and remove the front cover and check for leaks Replace the front cover and close the top cover The FPRS is now ready to resume operation 22 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com WATER ABSORBER ELEMENT REPLACEMENT may need to be replaced gt 35 psi WARNING Turn OFF the FPRS on the control panel and at the power source Open the top cover and remove the front cover If the pressure gauge on the water absorber element is above its normal running pressure it Locate the absorber drain hose It is folded over and tie wrapped Cut the tie wrap and place the hose in a pail Open the drain valve on the bottom of the absorber canister Loosen and remove the V band Clamp at the top of the canister and remove the lid Remove the element hold down bolt and lift out the old element by the wire handle Unpack the new element and install into the canister Re install the element hold down bolt hand tight Clean the O ring and apply a thin coat of your oil Replace the canister lid and clamp Close the drain valve on the bottom of the absorber canister and stow the drain hose Replace front cover and close top cover
24. R 8 will cause an open between the two remote alarm contacts PUMP MOTOR ASSEMBLY The pump and motor assembly used in your FPRS is designed for continuous duty and will give many years of trouble free service For your convenience the pump manufacturers service manual is located in the last section of this manual starting on page 45 The pump and motor consists of three basic parts which are all easily field replaceable Coupling the pump to the motor is a lovejoy type coupler Replacement of the pump or coupler is straightforward and should present no problem for maintenance See the following section for removal and replacement of the pump along with required adjustments REMOVAL AND REPLACEMENT OF COMPONENTS Front Panel Indicator Lights These lights are the non relampable type and are a snap fit into the top cover Remove the two 186 spade connectors and compress the tangs on the sides of the lamp using thumb and forefinger Push the lamp from the back out through the front cover Replacement lights are available from ASL Microammeter The microammeter is a special Simpson DC Microamperes design Using a meter not intended for your FPRS is not recommended and could result in damage to the equipment To replace the meter remove the two 5 16 nuts which secure the green wires to the back of the meter Using a Y nut driver remove the four nuts and lockwashers securing the meter to the cover Push the meter out fro
25. Repairs on the pump should only be undertaken by experienced hydraulic pump repair persons New spare pumps can be purchased through ASL Troubleshooting this circuit is straightforward The only components are the pressure switch itself relay CR 7 and the associated wiring See the Removal and Replacement of Components section starting on page 37 MICROAMMETER The microammeter located on the front panel between the elapsed time meter and the Absorber pressure gauge indicates in micro amps how much current the 1 Electrostatic Cell is pulling from the high voltage power supply The microammeter shows the general condition of the cell and is a good way to predict impending maintenance actions As stated previously in this manual the microammeter has two readings that are related to two indicator lights on the front panel 1 At approximately 500 microamps the amber Backflush light will light indicating that Electrostatic Cell backflush is required Shut down the system and backflush the Cells in accordance with the instructions on page 21 of this manual Note that under normal operating conditions the microammeter will rise slowly toward 500 giving maintenance adequate warning that backflush time is approaching Note that the system will continue to operate beyond 500 microamps all the way up to 700 microamps when the Low Voltage light comes on and the system shuts down Operation above 500 microamps for any extended perio
26. This Manual for Unit Serial s 006 amp up ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com ASL Technologies LLC Quality Policy ASL Technologies LLC was founded with the commitment to be the industry leader in product quality customer service and customer satisfaction in the market places we serve Our patented product line of Electrostatic Fluid Filtration equipment is designed built tested and delivered with these goals in mind Congratulations on the purchase of your new Finite Particle Removal System FPRS ASL Technologies FPRS S Series Units provide state of the art fluid filtration that allows superior filtration capability at a minimum investment Affordable electronics and compact design are combined to provide economic filtration without compromising the effectiveness of Electrostatics Though compact in size the S Series can provide up to a year of replacement free filtration It also provides effective cost recovery of valuable fluids and extension of component life in hydraulic dielectric and solvent systems ASL encourages you to read through this manual completely Information has been provided in order that our customers can experience the maximum benefits resulting from extreme fluid cleanliness Every situation cannot be anticipated and ASL is always ava
27. a great concern because their condition is directly related to the condition of the overall system they function in Controlling these five factors is foundational to maintaining a trouble free system The following preventative measures do much to extend the life of the fluid and the hydraulic system One must minimize the external ingression of air and particulate in the fluid Breather bags and air intake filters have been used effectively for this purpose Maintaining the fluid temperatures within the specified limits can be achieved through proper care and maintenance of the cooling system We have equipped your filtration system with continuous water removal capability to prevent build up due to condensation to keep the fluid dry Finally the fluid must be kept as clean as possible not only by removing particulate such as Dirt Fibers Wear metals Also the Submicronic Contaminants such as Silts Tars e Varnishes Tars and Varnishes are the byproducts of oxidation and typically occur and are encouraged because of the presence of air heat and water Oxidation is usually observed in lubricants and hydraulic oils and results in the formation and deposition of tars and varnishes on the components of the hydraulic system Removing these contaminants continuously from the system will prevent the majority of problems that plague maintenance departments and cause expensive downtime Keeping the fluid as clean as possible is
28. able care or unauthorized repair or alteration Should this unit fail during the warranty period ASL will repair or replace it at our option Replacement products supplied under this warranty may be new or rebuilt at our option Labor charges will be without cost to the purchaser owner during the first ninety 90 days of the warranty period up to 500 hours of operation Owner will be responsible for all labor charges after this period Owner will pay for the expense of delivering the product to ASL for warranty work and expense of returning it to the owner after repair or replacement ASL will assume no field expense for service or parts unless authorized in advance This warranty is the only warranty extended by ASL to suppliers and or purchasers of this product No other warranty written or oral is authorized ASL disclaims all other warranties express or implied that arises by operation of law except that implied warranties of merchantability or fitness for a particular purpose are limited to the duration of the warranty period ASL shall not be liable for any incidental consequential or other damage that may have resulted from any alleged breach of warranty including any cost or expense of providing substitute equipment or service during periods of malfunction or non use Some states do no allow limitation on how long an implied warranty lasts or the exclusion limitation of incidental or consequential damages so the above stated limita
29. arts locate the pump serial number stamped on the machined face of the cover or body of the pump housing Haight Pump maintains a repair service shop that will rebuild test and return pumps promptly Remove pipes coupling and mounting bracket before returning the pump to the factory Contact Haight Pump for a Return Authorization number before sending the pump to the factory 48 General Information The following is general information about Haight rotary gear pumps Due to the variety of options and configurations available it is not possible to provide detailed information in this manual Detailed drawings and bill of materials will be provided upon request Never operate a pump with the discharge line closed or plugged Severe damage to the pump and or system will result Haight Pump does not accept responsibility or liability for damage or injury resulting from improper application and or operation of the pump and or system Direction of Rotation Haight pumps are designed to operate in either direction by simply changing the shaft rotation Pumps supplied with relief valves are the exception to this rule Failure to reverse the relief valve components will render the relief valve inoperable The procedure for reversing the flow direction in the relief valve is covered in the Assembly and Disassembly instructions Pump Alignment Bedplate mounted pumps and motor combinations are aligned and tested at the factory Vibration d
30. ate only in one direction Badly supported pipe or bedplates causing resonant vibration Relief valve chattering Pressure too low an increase in pressure can prevent gear noise in low pressure applications Cavitation due to inlet or outlet conditions Packing hard and shaft scored Pressure on pump too high or pressure relief passage blocked Shaft run out excessive When re packing a gland all the old packing must be removed it is not good enough to just add extra rings as the original packing becomes compressed 51 1U through 5U Haight Pump w o Relief Valve 1U through 5U Haight Pump with Relief Valve Optional Relief Valve Co a T a a 17 I 14 eo 4 12 5 Op Q 9 z 0 i 12 7 Keyed Shaft 19 Item Qty Item Qty Number Description Required Number Description Required 1 Screw cover 4 27 O ring Relief Valve 1 2 Cover 1 28 Spring Standard 1 3 Shaft bearing 1 29 Poppet 1 4 Wiper Seal 1 30 Cap 1 5 O Ring Cover 1 31 Relief Valve Body 1 6 Rotor C l 32 Pipe Plug 2 7 Shaft amp Pinion Assembly 1 33 Screw Valve Body 4 7A Tanged Shaft amp Pinion Assy 1 34 Pin 1 7B Outboard Bearing Shaft amp Pinion Assy 1 Not shown 8 Shaft Keyed Not sold separately 8A Shaft Tang Not sold separately 9 Pinion Steel Not sold separately 10 Key 1 8 sq x 1 2 Long 1 11 Shaft Bearing 12 Set Screw Vent 1 13 Case 1 2 ports D I 1 14 O ring Gland 1 15 Lip Seal 15A Mechanical T 21 Seal 16 Washer 2 17 Mechanical Seal 18 Thrus
31. chnologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com FPRS S200 Front Panel Controls and Indicators See pages 9 11 for detailed function 11 10 12 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com FPRS S200 Internal Component Locations Refer to descriptions on pages 9 11 Numbers in refer to descriptions Cover Safety Switch 15 Front Panel controls indicators Relays CR 1 thru CR 8 TB 3 High Voltage Power Supplies 1 thru 5 Lid hold Open rod TB 2 TB 1 Remote Alarm Connector on side 12 Oil Sample Valve 13 Pump Motor Water Absorber Canister Cell outlet manifold Cell Inlet manifold Water Absorber Drain 14 Drip Tray Float Switch Connector Drip Tray ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com Drip Tray and Float Switch Disconnect 2 pin Molex Grasp tray by handles Carefully slide out for service Switch stays in tray 14 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 o
32. d Refer to the Maintenance section 5 AMBER BACKFLUSH LIGHT This lamp comes on when the Electrostatic Cells need to be back flushed with shop air The signal to illuminate this light comes from a relay internal to the high voltage power supply s orange wire which closes at approximately 500 micro amps Note that all five power supplies orange wires are tied to the backflush light The theory being that if one Cell needs backflushing they all do If this lamp illuminates back flush the Electrostatic Cells in accordance with the instructions on page 21 of this manual 6 RED FLOAT SWITCH LIGHT Illumination of this lamp indicates that there is either a fluid leak inside the FPRS or the float switch has been upset during shipping or recent movement of the unit Note that this is a latching fault and will not reset itself even if the float switch re opens Power must be turned OFF and then back ON after correcting the fault The float switch that activates this fault is located in the drip tray in the right front corner on the bottom of the FPRS cabinet Note also that even though the pump stops the 15 000 VDC is still applied to the terminals of the Electrostatic Cells while power is on 7 RED OVER PRESSURE LIGHT Illumination of this lamp indicates an overpressure condition has occurred Note that this is a latching fault and will not reset itself even if the overpressure condition clears Pow
33. d of time is not recommended and the cells should be backflushed or replaced as soon as practical 35 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 2 At approximately 700 microamps the red Low Voltage light will come on and the system will shut down Unless the reservoir is suddenly flooded with water or the high voltage power supply fails you should never see the Low Voltage light come on other than one or two seconds at initial power up of the system The microammeter on your FPRS system should be checked frequently When the system is new and the oil in your reservoir is clean microamp readings will be low Normally the meter will climb very slowly over time and may take months to reach 500 On other systems the meter could start at 200 and slowly climb or even go down over time The main thing to watch for is erratic movements rapid climbing etc A rapid climb most always indicates water has entered the system and finding and correcting the source of the water intrusion should be paramount Once water has entered the Electrostatic Cell concentrations of 600 ppm and higher will short it out rapidly Replacement of the water absorber and Backflushing the Electrostatic Cell perhaps several times will restore proper operation Changes in microammeter readings will also
34. d the PIP pin be inserted through the lift strut when performing maintenance To close the top cover raise the cover slightly with one hand and remove the PIP pin With both hands raise the lid so that the locking mechanism disengages and slowly lower the lid to its fully closed position With the lid locked in the open position the front cover also held by magnets can be removed by pulling outward on the top of the cover to disengage the magnets and then lifting the cover clear of the unit Note that a system schematic is laminated and bonded to the inside of the front cover Note that the system has 4 full swivel casters all with brakes which were locked when the unit was packaged If you ordered extra Water Absorber elements they will be packed in a box inside the unit Additionally there is a back flush hose and fitting inside the unit for Electrostatic Cell servicing as well as an Operation and Service manual Extra copies of this document as well as the Service Manual can be downloaded in PDF format on the ASL website www aslfilter com Check for any loose hoses electrical connections etc that may have occurred during shipping A laminated wiring diagram is pasted on the inside of the front cover Make sure the float switch is correctly positioned in the bracket tray The hinged float should be hanging down toward the bottom of the tray such that a build up of fluid will raise the float and close the switch shutti
35. echnologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com uick Startup Guide FPRS 200 Quick Start Guide Serial 006 amp later Remove packing material and strapping from the unit There is a forklift pocket on the bottom of the unit The open ends of the pocket are on the sides of the unit Adjust your forks for a 23 width outside to outside The unit weighs 625 pounds empty and approximately 733 pounds when full of fluid Open Top cover by grasping rolled lip and lifting up like a car hood The white foam pad between the lid and front cover was inserted to protect the top cover safety switch during transit and can be discarded The control panel lid is held closed with magnets and opens like a car hood A force of about 35 pounds is required to disengage the lid from the magnets Lift the lid and swing the top cover all the way up until the slide lock goes over center and then slowly lower the lid until locked in the open position The lift strut locking mechanism is strong enough to hold the lid open for quick checks on the inside of the unit however for additional safety there is a 5 16 T Handle PIP pin on a lanyard attached to the lower strut mounting above the pump which can be inserted through the lift strut locking hole just above the lock mechanism It is highly recommende
36. ental Analysis The presence of elements in solution i e additives wear metals and contamination elements FT IR Estimation of oxidation levels PIXITE Analysis of contaminant residue on patches 3 When the condition of the oil is in question it is usually more economic with small reservoirs to simply replace the oil than it is to spend money on extensive testing Tests should be used to analyze potential problems in the machinery not necessarily to determine oil life in these cases 20 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com CELL BACKFLUSH OPERATION Backflushing of the cell is unique to ASL s Finite Particle Removal System This operation allows the cell to be reused without being replaced under normal use Under normal operation Electrostatic Cell and water absorber should be changed annually When the cell becomes filled with contaminants about 500 microamps and or the amber BACK FLUSH lamp illuminates the cell s need to be backflushed gt EK WARNING Turn OFF the FPRS on the control panel and at the electrical source A Disconnect the input and the output hoses from the cell and set aside Connect a backflush hose to the quick disconnect at the bottom of the cell Place the end of the bottom backflush hose into a suitable container Us
37. er must be turned OFF and then back ON after correcting the fault A pressure switch on the water absorber canister actuates the overpressure light As in 6 above 15 000VDC is still applied to the Electrostatic Cell while this fault is latched 8 MICROAMP METER The Microamp meter indicates the amount of high voltage DC power being consumed by the 1 Electrostatic Cell Under normal conditions the Microamp meter will indicate between zero and 400 and is a way to determine the general condition of the Cell Note that high concentrations of water or excessive accumulations of ferrous particulate can cause high microamp readings At 500 microamps the amber BACK FLUSH lamp will illuminate and at 700 microamps the red 10 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com 10 11 12 13 14 15 LOW VOLTAGE lamp will illuminate the system will shut down with the lamp remaining illuminated ELAPSED TIME INDICATOR The elapsed time indicator shows in hours and hundredths of hours how long the system has been running Note that power is supplied to the hour meter from the pump motor start signal and will only run when the pump is receiving power The hour meter reads to 99 999 99 hours 11 years ABSORBER PRESSURE GAUGE The Absorber
38. g box cover and disconnecting the wire nuts tying the SO cord to the motor leads The green ground wire is secured with a green screw to the motor inside the motor wiring box Pull the SO cord out of the motor wiring box and plastic Heyco connector Note that wire connections and numbers are located on the motor nameplate as well as page 43 of this manual 2 Loosen the two allen set screws securing the pump to the motor 3 Loosen the setscrews securing the Lovejoy coupler to the pump and motor shaft 4 Separate the pump from the motor by pulling straight up on the pump body while rotating the pump 5 With the pump and motor separated and the wiring removed remove the four 14 20 nuts and flat washers securing the motor to the cabinet studs and lift the motor out of the cabinet 6 Transfer the black Heyco wiring fitting and locknut to the wiring box of the new motor 7 Install and align the Lovejoy coupler to the motor shaft 8 Install the new motor onto the cabinet studs and secure with four 4 20 locknuts and flat washers 9 Using a twisting motion install the pump onto the motor taking care to align the Lovejoy coupler Secure the coupler set screws 10 Tighten the two allen set screws securing the pump to the motor 11 Re install the SO cord through the Heyco fitting and re connect wiring in accordance with the diagram on page 44 of this manual 12 Tie up any loose wiring and return the unit to service No
39. h the float switch may only bump closed momentarily the red light and fault will remain latched on until an operator intervenes If a red float switch light is observed immediately investigate the source of the leak and make any necessary repairs To reset the fault turn power off and then back on This circuit can be tested by intentionally closing the float switch and observing that the light illuminates and the pump and hour meter stop Opening the switch will not reset the light or start the motor Troubleshooting this circuit is straightforward The only components are the float switch itself relay CR 6 and the associated wiring 34 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Wwww aslfilter com OVERPRESSURE RED The overpressure light circuit in the FPRS S series units is wired differently than earlier ASL ABH or mobile cart units In the S series units the overpressure is utilized as an absolute upper pressure limit and will shut the unit down when activated Like the float switch fault the over pressure fault is a latching non resetting fault As stated elsewhere in this manual the bypass relief valve on the pump in your FPRS unit is adjusted at the factory so that the pump will be in full bypass at approximately 40 psi If for some reason the bypass relief
40. id reservoir it services must both be earth grounded to operate safely and properly Protect the power cable from coming in contact with sharp objects Replace or repair damaged or worn cords immediately Safety devices such as interlocks fuses and circuit breakers should not be disconnected or shunted out A CAUTION The power source must be fused for 10 amps ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com 1 The motor is designed for operation on the voltage and frequency specified on the motor nameplate 2 Normal loads will be handled safely on voltages not more than 10 above or below the specified voltage 3 Running unit on voltages not within range may cause overheating and motor burnout 4 Heavy loads require the voltage at motor terminals be not less than the voltage specified Follow all local electrical and safety codes as well as the National Electrical Code NEC and the Occupational Safety and Health Act OSHA Install and maintain equipment according to USA Standard C1 National Electric Code Do not install FPRS unit s outdoors unless at least partially protected from the elements Do not use in an excessively damp or wet location FLUID SAFETY WARNING Do not pump flammable or explosive fluids such as gasoline Failure to follow this warning can result
41. ide the cell becomes a home for the particles and holds them in place This collection of particles is a phenomenon known as strawing Your FPRS comes equipped with a water absorption unit that can remove free and emulsified water down to 50 PPM This feature covers a wide range of water problems Each fluid to be cleaned has its own characteristics which may require modifications in magnetic field density and the dedicated collection media used within the electrostatic cell The cell provided in your unit has been built to meet your specific requirements Therefore when discussing your unit with us or when ordering cells be sure to state the correct model number of the cell The model number is shown on a red tag on top of the cell i e R61CS 115 R62CS 115 etc Note that Phosphate ester fluid compatible cells have a B in the parts number i e RB64CS 115 etc Mineral oil cells have a Gray tube and Phosphate Ester Cells have a Black tube The long term benefits of continuous filtration with this product as the contaminants are purged from your system will become evident through reduced downtime and maintenance expenditures extended machine life and greatly improved fluid life Coupled with our water absorber this product will protect the lifeblood of your hydraulic system from three of the five major factors that contribute to fluid degradation Water Particulate Matter Oxidation by products ASL Technologies LLC
42. ilable to help in any way possible Critical information has been supplied to assist you with the theory operation and maintenance of the S Series Finite Particle Removal System Questions or concerns should be addressed to ASL ea SS Ww iaa fa b Ma ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com Table of Contents This Manual covers Serial s 006 and subsequent Subject Page Quick Startup Guide 3 Important Safety Information 5 Introduction System Overview 7 Important Guidelines 9 System Safety Features Indicators Switches and Lights 9 Front Panel Controls Indicators Photo 12 Internal Components Photo 13 Drip Tray and Float Switch Photo 14 System Preparation 15 Installation Considerations 16 Fluid Maintenance 20 Cell Backflush Operation 21 Cell Removal Installation 22 Water Absorber Replacement 23 Electrostatic Cell Rebuild Program 24 Warranty Information 25 Product Specifications 26 Parts Ordering Information 27 Spare Replacement Parts List 28 Wiring Diagram 29 Cover Electrical Component Locations 30 Maintenance and Troubleshooting 31 Removal and Replacement of Components 37 Pump and Pressure Switch Adjustments 40 Scheduled Maintenance Tasks 41 Fluid Flow Diagram 43 Electric Motor Service Data 44 Hydraulic Pump Vendor Service Manual 45 Rev 2 04 27 11 ASL T
43. ing a second backflush quick disconnect fitting connect plant air supply REDUCE TO 10 PSD to the quick disconnect at the top of the cell Allow 10 psi of air to flush the contaminants out of the cell and into the pail for disposal Leave the air pressure on until contaminants are no longer dispensed out of the backflush hose about 10 minutes CAUTION BACKFLUSH HOSE WILL JUMP AROUND AS AIR REACHES IT Remove the backflush hoses and replace the input and output hoses to the top and bottom of the cell at their original configuration blue hose to the bottom of the cell disconnect and gray hose to top of cell The top of the cell connects directly to the outlet manifold Turn ON the electrical service to the FPRS Restart the system and check the amber BACK FLUSH light to ensure that it has gone out If it remains on refer to the Maintenance section of this manual Observe that the microamp meter is now below 500 microamps 21 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com Over time backflushing may no longer be effective and the Electrostatic Cell must be replaced CELL REMOVAL INSTALLATION Under normal operating conditions cells should be changed annually When you replace your electrostatic cell perform the following steps A A A 1 2 10 11 12
44. ing pattern to re assemble the housing and covers Periodically turn the pump shaft Check for unusual noise Improper tightening will cause the pump to bind as The pump will function best if primed first Return the pump to service and check for leaking and loose connections Air leaks on the suction side of the pump will reduce pump performance Relief Valve Components l 2 3 See precautionary notes To change the relief valve for reverse rotation a Loosen the locknut on the adjusting screw while holding the adjusting screw stationary b Remove the bonnet and bonnet washer c Remove the adjusting screw spring and poppet d Remove the cap and cap washer Reassemble in reverse order Remember the spring and adjusting screw must be on the suction side of the pump for the relief valve to operate Special Seal Components 1 Standard 1 through 40 D DR pumps use a lip seal as the main shaft seal and two wiper seals function to keep the bearings clean These seals are available in Buna N or Viton synthetic materials Packed pumps use 4 or 5 element V cup Teflon shaft seals Shaft seals are also available in Graphite rope Graphfoil and virgin Teflon A gland is included to provide tension for the packing Crane Type 9 and Type 21 mechanical seals are available Contact Haight Pump for special drawings for pumps with mechanical seals Maintenance Parts or Factory Repair I When ordering p
45. ldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com YEARLY In addition to the monthly checks above perform the following additional maintenance actions and checks 1 Replace the Electrostatic Cells Even though the system appears to be operating properly the Electrostatic Cells should be replaced on an annual basis due to internal wear which can cause arcing and deterioration 2 Replace Water Absorber element This throw away element although designed primarily to entrap free and emulsified water will also trap larger particulate and should be replaced at least once each year 42 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Wwww aslfilter com FPRS S 200 SERIES CABINET FLUID FLOW DIAGRAM Gray Hoses Cell Outlet Manifold Customer Oil Reservoir Electrostatic ee Water Absorber Canister Cell Inlet Manifold Pump Motor Cell inlet hoses are equal length 16 5 43 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Wwww aslfilter com Motor Wiring Data Leeson 102930 2 White
46. luid does not surpass the guidelines of the system as set forth in this manual For in service oil analysis a sample port has been provided and is located on the lid of the water absorber canister See page 11 for sample port operations 15 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com INSTALLATION CONSIDERATIONS APPLICATION COMPATIBILITY While this product can provide effective filtration over a wide range of applications there are some applications that are an exception e Type of fluid to be filtered Contamination source or sources The rate of contamination The following guidelines should be considered before installing this product 1 Fluid Specification this product is suitable for filtering nonconductive and semi conductive fluids with viscosity rating less than 1800 SUS 100 F Water based fluids cannot be filtered with this product Typically compatible fluids include Petroleum based lubricants Solvents Synthetic lubricants Dielectric fluids Phosphate Ester fireproof fluids Requires different Electrostatic Cell hoses seals gaskets etc Phosphate Ester Cells are BLACK with White ends 2 Contamination Type non discrete type contamination cannot be filtered with electrostatics This includes contamination from other fluids or chemical
47. ly remains closed until the power supply senses a load of 700 or more microamps At that point the internal relay opens and the 120 VAC that was present on the yellow wire drops to zero This starts a chain of events that commences with the coil of CR 1 relaxing When CR 1 opens contacts CR1 5 amp 3 open stopping the flow of power to the coil of CR 8 which in turn stops power to the hour meter and pump motor At the same time the contacts of CR1 5 amp 1 close allowing power to illuminate the low voltage light for power supply 1 The other four power supplies work in the same manner CR 2 for power supply 2 CR 3 for power supply 3 etc Note also that power supply 1 is connected to Electrostatic Cell 1 power supply 2 to Electrostatic Cell 2 on so on Refer to the wiring diagram on page 29 of this manual The schematic is also laminated and glued to the inside surface of the front cover The idea here is that if any one of the high voltage power supplies no longer has enough voltage output to keep particulate trapped within the Electrostatic Cell the pump needs to be stopped immediately The backflush procedure depends on this phenomena to operate i e Once power is removed from the cell contaminant can then be blown out with shop air The system will try to keep running however and the power supply will reset itself and try to turn on again If the conditions that caused the low voltage indication are still present the pump will
48. ly at the same time If you have a spare cell try it first before replacing the power supply i Note that a defective CR 1 thru CR 5 relay and associated wiring can also cause a low voltage indication 32 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter ccom Www aslfilter com 2 Defective Power Supply If the internal normally closed low voltage relay in the power supply is defective a low voltage indication will result Trouble shoot this failure as follows a Turn power off and un plug the FPRS from the power source b Remove relay CR 8 to prevent the pump from starting c Remove the POS spark plug boot terminal from the Electrostatic Cell associated with the Low Voltage light The convention is P S 1 is related to Cell 1 and Relay CR 1 P S 2 Cell 2 Relay CR 2 etc d Restore power to the FPRS and turn the power on Note that you will have A to defeat the cover safety switch to continue USE CAUTION e Using an AC voltmeter check for 120VAC at the L HOT terminal on the high voltage power supply in question f If OK check for 120V AC on pin 8 yellow wire of the associated relay CR 1 for P S 1 etc g If 120VAC is present at the power supply L HOT terminal and no power is present on the yellow wire the power supply must be replaced h If 120VAC is present on both the ab
49. m pressure gauges will show signs of trouble weather caused by contaminant buildup or component failure The system was designed to make troubleshooting and repair as painless as possible while providing maximum safety system protection and trouble indication The following theory of operation and troubleshooting guides make reference to drawings and charts located within this manual Please refer to them to reinforce your knowledge of this product Remember that ASL Technicians are just a phone call away should you need any advice or assistance ELECTRICAL THEORY OF OPERATION Refer to the wiring diagram on page 31 the wiring diagram is also laminated and pasted inside the front cover The FPRS S 200 series units use the following wiring conventions Black wires 120V AC Power White wires 120 VAC Neutral Green Wires Ground Yellow wires H V Power Supply Low Voltage alarm circuit Orange wires H V Power Supply Backflush alarm circuit Blue wires Remote Alarm Circuit Red wires 120VAC switched signal Exceptions a The green wire on the pressure switch is capped and not used but will have 120VAC present when the pressure switch is open normal condition b The float switch comes standard with two white wires pre installed on the switch These white wires pass 120VAC through the switch when closed Cc The red pink Hi Voltage wires coming out of the bottom of the power supplies carry 15 000 VDC to the Electrostatic Cells T
50. m the back to the front Install the new meter make sure it s right side up and secure the four 4 nuts lockwashers taking care not to over tighten Re install the wiring to the two posts making sure that the wire on the terminal goes to the 1 Electrostatic Cell Hour Meter The hourmeter is held in place with two 6 32 screws and locknuts Remove the two spade wiring terminals from the meter by pulling straight up Remove and retain the attaching screws and nuts Remove the meter by pushing it out from back to front Install the new meter make sure it s right side up using the retained screws and nuts and re attach the spade terminals Hi Voltage Power Supply Secure power to the FPRS before replacing the power supply 1 Using an insulated screwdriver short across the POS and NEG terminals of the Electrostatic Cell to dissipate any static electricity 2 Using one hand remove the POS terminal from the Electrostatic Cell 3 Cut all ty wraps securing the POS and NEG leads from the cell to the power supply 4 Remove the wiring trough cover above the power supplies 5 Locate the two pin Molex connector for the Yellow and Orange wires coming from the power supply and disconnect it by pulling the two halves apart 6 Pull the three spade connectors Power Neutral and Ground from the power supply 37 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS
51. ng the unit down The float switch stays in the tray and is disconnected by disconnecting the 2 pin Molex connector on the side wall near the bottom of the Water Absorber canister Grasping the two drip tray handles slowly slide the tray out for servicing When sliding the tray back in make sure it goes all the way in past the front edge of the false bottom Verify that the Water Absorber 3 10 11 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com drain valve 3 8 gray hose on the bottom of the canister is CLOSED Note that the lid contains a safety switch which interfaces with the front cover This switch must be closed to start the unit Connect your fluid lines to the unit as follows The ASL unit s INLET to a low point on your reservoir Be sure to drain any accumulated water Connect the ASL unit s OUTLET to the top of your reservoir A stand pipe may be used to return fluid below the reservoir fluid level The ASL unit is provided with 4 NPT INLET and OUTLET bulkhead fittings Make sure the ASL unit s INLET line is flooded The ASL unit cannot be force fed With both INLET and OUTLET lines connected plug the unit s power cord into a 120 VAC 60 Hz single phase grounded 10 Amp Outlet Note that this system and fluid reservoir must both have the same earth gr
52. nlet As well as the line running from the FPRS back to the reservoir outlet When installing an FPRS S Series unit above the highest level of fluid of the reservoirs it is required that the pump be primed Once primed the cabinet of the S Series can be elevated as high as 24 above the highest level of the reservoir SYSTEM SAFETY FEATURES INDICATORS SWITCHES AND LIGHTS Your FPRS S Series unit comes equipped with several enhanced safety features and light gauge indications that are designed to provide operator and environmental safety ease of operation and troubleshooting The following paragraphs contain a brief description of these features Refer to the photos on pages 12 13 and 14 and the wiring diagram on page 29 Note that the wiring diagram is also laminated and glued to the inside of the system front cover The Maintenance section beginning on page 31 provides further details on operation and troubleshooting 1 POWER SWITCH This switch controls power application to the system and is in the power line after the 10 amp circuit breaker which is located next to the power switch When the system is plugged in to a 120 VAC power source power will be present on one side of this switch Note that if incoming 120 VAC power is interrupted while the POWER switch in the ON position the system will automatically restart as soon as incoming AC power is restored ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In
53. occur under the following fluid conditions 1 HEAT Current Increases Fluid temp will cause the uA to increase A rise from 80 F to 110 F can sometimes double the uA In turn as fluid temp decreases so will the uA 2 COOLING Current decreases 3 WATER Water can make the base current appear higher than it really is 4 VARNISH Although the Electrostatic Cell is capable of capturing a lot of varnish before it will affect the operation of the Cell at some point as the oil oxidizes varnish will cause the efficiency of the cell to decrease and the Cell will need to be replaced ELAPSED TIME METER The elapsed time indicator on the front panel reads in hours and hundredths of hours The meter is very accurate and reads to 99 999 99 hours The meter runs on 120 VAC 60 cycle single phase power which comes from CR8 3 This relay contact also supplies power to the pump motor assembly Hence the meter only runs when the pump is receiving power In troubleshooting a defective hour meter with the system running check for 120V AC power at relay CR8 3 if no voltage present the pump is not running either If voltage is present and the pump is running check for power at the red wire on the back of the meter If voltage is present check the white neutral also replace the meter If voltage is not present check the wire running from CR8 3 to the meter Note that two wires are installed on CR8 3 black goes to the p
54. ound Note that the front cover must be in position and control panel lid closed Turn on the Power switch All 5 Low Voltage lights will illuminate briefly and the fluid delivery system pump motor will immediately start and begin drawing fluid from your reservoir The unit was tested with fluid at the factory but the Electrostatic Cells and water absorber element are dry when shipped so it will take a few minutes before flow from the unit s OUTLET port will be observed On the cover of the water absorber canister there is a sample port bleeder push button valve Unscrew the cap and press the sample valve button to bleed off trapped air as the absorber canister fills with fluid Of course performing this will require that the lid safety switch be temporarily disabled It may take a few minutes to fill before any fluid output is seen If output flow and or pressure rise on the gauges is not observed within 4 5 minutes turn power OFF and make sure the inlet hose is primed Once entrapped air is bled from the water absorber canister the Electrostatic Cells will fill and fluid flow will be observed at the OUTLET port bulkhead Under normal operation with warm 100 120 F fluid pressure on the Cells and water absorber will be in the 10 to 20 psi range The FPRS 200 system has a flow rate of 3 GPM and the system holds approximately 13 gallons of fluid ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah
55. ount necessary to allow removal of the hoses from the push lock fittings Trim the hose ends square for re installation Excessive slitting and or trimming will render the hoses too short 38 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Wwww aslfilter com and they will have to be replaced There is enough excess hose length to remove and replace the pump at least once or twice 2 Loosen the two allen set screws securing the pump to the motor 3 Using a suitable Allen wrench loosen the setscrews on the Lovejoy coupler 4 Separate the pump from the motor by pulling straight up on the pump body while rotating the pump 5 With the old and new pumps on the workbench transfer the inlet and outlet fittings to the new pump Take care to align the fittings as they were Use a suitable thread sealer on all pipe threads 6 Assemble pump to motor in reverse order remembering to align and tighten the Lovejoy coupler set screws 7 Re install inlet and outlet hoses A drop of lubricant on the push lock fittings will ease installation of the hoses 8 Proceed to PUMP and PRESSURE SWITCH ADJUSTMENTS on page 40 Replacement of MOTOR only If you have determined that only the motor needs to be replaced the pump and its attached hoses can remain in the cabinet 1 Start by removing the motor wirin
56. ove terminals check for 120VAC at pin 8 of the appropriate relay If no voltage present repair wiring If 120VAC is present check for voltage at pin 3 of CR 1 If no voltage present replace Relay CR 1 i Note that all relays in the FPRS S200 are the same and can be swapped for troubleshooting purposes Once repairs are completed remember to re install relay CR 8 With respect to the High Voltage DC section the best way to confirm a bad power supply is to obtain a times 1000 high voltage probe for your voltmeter Using the Hi Voltage probe plugged into the red spark plug terminal boot a properly operating power supply will indicate 15 00 to 16 00 VDC 15 000 to 16 000 VDC Defective power supplies will read 0 to4 KVA l The number one reason for power supply high voltage section failure is operating the Electrostatic Cell beyond one year 8700 hours w BACKFLUSH INDICATOR AMBER Backflushing of the Electrostatic Cell in your unit is unique to the FPRS system Backflushing the contaminates out of the cell allows for much longer filtration life than with conventional mechanical filters The amber backflush light is controlled directly by the high voltage power supply orange wire A normally open relay inside the high voltage power supply closes when the power supply senses approximately 500 microamps As shown on the wiring diagram once the internal relay closes the amber backflush light receives power direc
57. property altering contaminants Systems with chronic water ingression cannot be filtered effectively unless the source of water can be eliminated or greatly reduced to less than 500 ppm 3 Contamination Rate systems that produce excessive contamination may quickly overwhelm this product especially if the contaminant is conductive i e EDM grinding and polishing systems etc 16 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com The FPRS is now ready to be charged filled for operation and tested to ensure that no connections have loosened during shipment The FPRS should be charged with the same fluid it has been designated to clean INSTALLATION APPROPRIATE LOCATION Avoid locations that expose this product to excessive moisture and explosive environments This product generates an electrostatic field that may disturb or damage sensitive electronic equipment Also remember that access to this product is required periodically to replace the electrostatic cell s and Water Absorber element Finally avoid installing in high traffic areas where this product may be easily damaged by vehicles forklifts etc SYSTEM CONSIDERATIONS 1 Main Power Supply Source 120 volts AC 60 Hz single phase 10 amps Circuit Breaker 16 ga Power cord provided Earth Ground Vertical
58. r Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com SYSTEM PREPARATION NOTE IT IS EXTREMELY IMPORTANT THAT THE FOLLOWING STEPS BE DONE IN ORDER TO ENSURE PROPER SET UP AND OPTIMUM RESULTS FROM THE FPRS A CAUTION Before making power connections to this ASL unit check the polarity of your power source Also verify that earth ground is present Open the hinged top cover two magnets hold the cover closed and swing it back Remove the front cover by pulling it toward you also held in place with magnets and lifting it out of the way to expose the internal mechanisms Check the wire and hose connections to and from the FPRS It is important that these connections are tight and have not shaken loose during shipment Tighten the connections if they are loose Do not over tighten Check the quick disconnects on the cell s to ensure that they are locked in place The outer ring of the quick disconnects slide back to lock and unlock the disconnect The S Series CABINET models will not operate with the front cover removed Take a sample of the fluid to be cleaned e Usea clean bottle to take the sample The sample should be taken from the lowest point of the reservoir preferably the drain cock or valve because this is where the FPRS input hose will draw from Free water should be drained from the reservoir before the FPRS is hooked up Test the sample to ensure that the f
59. r at the top of the tank When installing an FPRS S Series on an elevated reservoir where the lowest fluid level of the reservoir is higher than the FPRS it is recommended that shut off valves be installed in the line running from the reservoir to the FPRS pump inlet Also the line running from the FPRS back to the reservoir outlet CAUTION HANDLE THE HOSES SO THAT SPILLS CANNOT TAKE PLACE SYSTEM START UP gt o o gt fet o o o Connect the FPRS to a grounded 120VAC power source Both the FPRS and the hydraulic system reservoir must have earth ground Ensure that the shut off valves on the input and output lines are open Locate the drain valve on the bottom of the water absorber canister and verify it is in the closed position Place the front cover in position and close the top cover Turn the POWER switch on the front panel to the ON position The green POWER lamp will illuminate and remain on Note that the red LOW VOLTAGE lamps will flash on and then remain off The FPRS pump will start running and draw fluid from the reservoir into the FPRS Check for any external leaks Turn the POWER switch OFF Open the top cover and remove the front cover Check to ensure there are no leaks internally Locate the red tag on top of the Electrostatic Cell Fill in the Date Installed in the space provided This will assist you in determining when an annual cell exchange will
60. r chipping splitting or missing sections Inspection of the pump seal requires complete removal of the pump from the motor and bracket Complete Disassembly for Repair or Replacement I 2 10 Complete precautionary steps 1 and 2 Loosen the support bracket screws that secure the pump to the bracket a Size 1 8 pumps 3 set screws b Size 10 80 pumps 4 cap screws Remove the coupling and shaft key Inspect the shaft end for burrs or other damage Rotate the pump shaft by hand It should rotate freely Remove the bolts from the drive plate Carefully separate the drive cover and housing Use a soft marker to mark the rotor pinion location Remove the rotor from the housing Remove the shaft pinion assembly from the housing Carefully pry the cover off the housing Inspect repair or replace all damaged parts Note If significant damage is evident to the major pump components it is best to replace the pump If possible determine the cause of the damage and correct the identified problem 47 Reassembly 1 Pump reassembly is the reverse of disassembly However care should be exercised in three areas a Itis good practice to replace elastomer sealing devices and gaskets every time the pump is reassembled This is mandatory for Teflon O rings and lip seals Gently stretch the O rings before placing them in the O ring groove Place the rotor into position with your mark facing out Use a cross bolt tighten
61. raising system pressures to higher an normal levels Care should be taken to avoid gross over pressurization of the system This procedure will also require that the cover safety switch be defeated Maintenance personnel are cautioned to take extra care when operating the system with the covers removed Refer to the pump vendor service manual starting on page 44 of this manual Start system and wait until output flow is observed Remove the jamb nut on the pump relief valve 3 4 wrench size Insert an allen wrench into the hex of the adjusting screw and hold it steady Loosen the locking nut with a wrench by turning counterclockwise Temporarily attach a ball valve to the Outlet port on the right side of the system cabinet Slowly close the ball valve until the system pressure is at 50 psi If the pressure fails to reach this level with the ball valve closed turn the adjusting screw inward clockwise until the desired pressure is reached Adjusting clockwise raises the pressure setting 6 If the pressure reaches 50 psi before the throttling valve is completely closed turn the adjusting screw outward counterclockwise until 50 psi is reached Adjusting counterclockwise lowers the pressure setting 7 The pressure switch may close during the above adjustment shutting the system down with an Over Pressure fault If this happens the pressure switch adjustment is an 1 8 inch Allen Turn the pressure switch adjustment clockwi
62. re closed during normal system operation During an alarm condition such as overload the relay will open A second access hole is provided if hardwiring is required by your electrical codes These connections are located on the right side of the cabinet just below the power cord 6 Water Absorption Equipping the filtration system with water absorption capabilities maintains constant fluid dryness and prevents moisture build up from condensation in the reservoir The S Series units are equipped with a water absorber unit that is installed between the fluid delivery system pump and the cell s This filter will also trap contaminants 5 microns and larger and should be replaced whenever water content increases or pressure rises above 35 38 psi Replacement elements are available from ASL 18 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com HOSE CONNECTIONS It is recommended that connections to reservoirs be made with quick disconnects or hard plumbed to minimize ingression of contaminants when hooking up and operating the FPRS A Connect the input and output hoses to the FPRS Connect the input hose to the fluid reservoir If there is no place to secure the hose simply place the hose in the fluid near the bottom of the tank Place the output hose into the fluid reservoi
63. s and re check the shaft alignment Make sure there is no metal to metal contact of the coupling halves Do not over tighten the pipe pump connections as damage can result A vacuum gauge can be installed in the pipe plug on the relief valve nearest the adjustment screw A pressure gauge can be installed in the opposite pipe plug Check the shaft rotation to ensure it is correct Normal rotation is clockwise as viewed from the shaft side of the pump P Precautionary Notes l Prior to performing any service on the pump or motor a Disconnect and lockout the power source to the motor refer to OSHA 1910 147 b Shut off any liquid heating source c Ifthe unit operates at elevated temperatures allow it to cool to room temperature before performing any service Drain the pump and piping of excess liquid Caution Handle and dispose of liquids in accor dance to the manufacturers Material Safety Data Sheets Disassembly for Inspection Purposes Only l 2 Remove the bolts from the drive plate Carefully separate the drive cover and housing Rotate the pump shaft by hand It should turn freely If resistance is present check for built up residue Use a soft marker to mark the rotor pinion location Remove the rotor from the housing Inspect the housing shaft pinion rotor and drive plate for signs of wear or damage Excessive wear will decrease pump performance Inspect the O rings gaskets and bearings fo
64. se to raise the switch closing point above the pump by pass setting 8 Once the pump by pass is set at 50 psi with the throttling valve closed open the throttling valve for a few minutes to let the system flow Operation with the pump in full bypass for long periods will cause excessive heat buildup and could cause damage to the pump ARwWN 9 Slowly close the throttling valve until the pressure gauge reads approximately 43 to 45 psi Adjust the pressure switch slowly counterclockwise until the system shuts down 10 Open the throttling valve and re start the system 11 Slowly close the throttling valve while observing the pressure gauge until the system shuts down The system should shut down with the Over Pressure fault at 40 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Wwww aslfilter com approximately 43 to 45 psi Repeat the pressure switch adjustment until the switch closes at approximately 43 to 45 psi 12 Open the throttling valve and re start the system Slowly close the throttling valve until the pressure gauge reads 40 psi Turn the pump by pass adjusting screw counterclockwise until the pressure just begins to drop Tighten the nut to lock the setting in place 13 Open the throttling valve for a few minutes and then slowly close it fully Observe that the system pressure s
65. spection and adjustment will be required Do not over tighten the packing gland as damage to the gland and shaft will result Bearings and Rotor Pinion Shaft DU Bearings Recommended for applications over 100 PSI and for thin fluids Teflon Rotor Do not use Teflon rotors in applications exceeding 100 PSI and 200 F The pump is provided with open tolerances Increased slip will reduce efficiency with fluids below 200 SSU Delrin Rotor Do not use above 120 F and 80 PSI Delrin rotors provide better abrasion resistance than Teflon rotors The pump is provided with open tolerances Increased slip will reduce efficiency with fluids below 200 SSU Stainless Steel Rotor and Pinion Manufactured with open tolerances as standard Increased slip will reduce efficiency with fluids below 200 SSU Note For applications above 175 PSI vent both shaft bearings to the suction side of pump Spares and Repairs Haight Pump operates a repair service for all pumps for which records exist To ensure the correct parts are supplied the pump serial number is required The serial number is stamped into the metal of the pump body or cover in a prominent position on the top area of the pump We advise customers whose pumps are custom fabricated to have spare pumps or parts on hand Custom fabricated pumps and parts generally have long delivery times for replacement Pumps That Perform Pumps That Fit 50 Troubleshooting Problem No liq
66. t Bearing 1 19 Gland 1 20 O ring for cover Relief Valve 2 21 Cover Plate 1 22 Screw Cover Plate 4 23 Locking Nut 1 24 Adjustment Screw 1 25 Sealing Washer Std 1 26 Bonnet 1 Viton is a registered trademark of DuPont Dow Elastomers END OF SERVICE MANUAL 52
67. tays at 40 psi with the throttling valve fully closed Re adjust if necessary 14 Once all adjustments are complete open the throttling valve completely and check that the pump by pass adjusting nut is secure SCHEDULED MAINTENANCE TASKS The following is a recommended scheduled maintenance plan which is intended to provide maximum performance from your FPRS unit DAILY 1 Check that green Power lamp is illuminated 2 Check that pump motor and hour meter are running 3 Check system pressure gauge below 35 psi 4 Check Microammeter below 500 microamps WEEKLY 1 Leave the Power switch in the ON position open the top cover and observe that the unit shuts down 2 Check for any internal leaks 3 Check for loose relays wiring and connections for security 4 Close the top cover and observe that the unit re starts 5 Perform the daily checks after the unit has re started MONTHLY In addition to the weekly checks above perform the following additional checks 1 Using a soft cloth wipe down the exterior surfaces of the cabinet The static electricity forces at work inside your FPRS unit will attract dirt and dust from the air around the unit Pay particular attention to the cooling vents on the back of the cabinet 2 Inspect the inlet and outlet fluid hoses for signs of leaks or deterioration 3 Inspect the power cord for evidence of wear or fraying 41 ASL Technologies LLC A 10525 W US Hwy 30 B
68. te that pump adjustments should not be required when replacing the motor only 39 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Wwww aslfilter com Pressure Switch Replacement Replacement of the pressure switch will normally never be required due to the fact that correct operation of the switch will occur only after failure of the pump by pass and system pressure has exceeded 43 to 45 psi There are other instances that could cause illumination of the overpressure light such as back feed pressure from the outlet side which could be caused by incorrect installation Adjustment of this switch however is critical and will be required following replacement of the pump or the pressure switch Replacement of this switch is straightforward and only requires un screwing it from the water absorber canister and connecting the black and red wires The green wire is not used and should be capped Following pressure switch replacement proceed to the PUMP and PRESSURE SWITCH ADJUSTMENTS below PUMP and PRESSURE SWITCH ADJUSTMENTS The following procedure should be followed after replacement of the pump and or pressure switch Note that these adjustments are CRITICAL to proper system operation and should be read and understood before continuing A WARNING This procedure will involve temporarily
69. tions or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state For instructions on how to obtain warranty service contact ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsvc aslfilter com 25 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com PRODUCT SPECIFICATIONS FPRS S 200 Cabinet Units PHYSICAL DIMENSIONS Filter Cabinet 36 High x 36 Wide x 36 Deep Cabinet Construction 10 Gauge Steel Water Absorber Canister 18 High x 8 Diameter SHIPPING WEIGHT 675 pounds GROSS WEIGHT DRY 625 pounds GROSS WEIGHT WET 733 pounds MOTOR 1 3 HP 1725 RPM 120 VAC 60 Hz single phase 5 amps continuous 6 amps start up PUMP 200 GPH w 100 SUS Fluid 1725 RPM 3 4 NPT Inlet amp Outlet Ports WATER ABSORBER 5 micron wood paper element Mineral Oil Units INLET amp OUTLET CONNECTIONS 3 4 NPT Bulkhead Fittings SYSTEM VOLTAGE Input Voltage 120 VAC 60 Hz single phase 10 Circuit Breaker 10 Amps Output Voltage of Power Supply 15KV Nominal 1 9 miliamp 600uA
70. tly Note that in the FPRS S200 all five power supplies orange backflush wires are connected to TB 3 terminal 4 which is connected to the backflush light A backflush light should always be confirmed by observing the microammeter reading of approximately 500 microamps Note that the microammeter is connected between system ground and the NEG terminal on the 1 Electrostatic Cell The orange wired backflush relay inside the power supply also senses 500 microamps and lights the light but in a different manner Under normal circumstances when the backflush light comes on and the microammeter reads 500 microamps it s time to backflush all 5 cells in accordance with the Backflush procedure on page 21 of this manual 33 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter ccom Www aslfilter com A backflush light on with a low microammeter reading most likely indicates a defective power supply relay sensing circuit or a defective microammeter In troubleshooting if you jumper in a spare microammeter note that the on the meter goes toward the Electrostatic Cell The opposite case of a microammeter reading 500 with no accompanying backflush light should be troubleshot as follows 1 Secure power to the FPRS 2 Open the cover and locate the orange wire on terminal 4 of TB 3 3 Turn power on
71. uid delivered Not enough liquid delivered Pump works for awhile then loses suction Pump takes too much power Noisy pump Gland leakage Probable Cause Pump not primed Suction lift too high check with a gauge at the pump suction Wrong direction of rotation Pump not rotating failure of drive from prime mover Air leaks in suction line or through stuffing box Speed too low Suction lift too high or not enough suction head for hot liquids Foot valve too small or obstructed Foot valve or end of suction pipe not immersed deeply enough Piping improperly installed permitting air or gas to pocket in pump Mechanical defects Pump damaged e Pump badly worn e Packing defective e Relief valve not sealing or jammed by foreign matter Leaky suction lines Suction lift too high Air or gases in liquid Plugged lines or filter Speed too high Liquid heavier or more viscous than design condition Suction or discharge line obstructed Mechanical defects e Shaft bent e Rotating element binds e Stuffing boxes too tight e Misalignment due to improper connection of pipe lines or driver Check pressure is being measured at the pump and not some distance away from the pump thus ignoring pressure losses in piping valves etc Poor piping conditions Speed too high Suction lift or viscosity too high piping diameter too small Wrong direction of rotation recesses in the pump covers to prevent hydraulic noise oper
72. umber requested 3 When you receive your cell install it in your unit and return the used cell to ASL in the shipping box Please backflush the return cell for 10 minutes at 10 psi to drain as much fluid as possible You should order your re built cells early so you won t be down waiting for your new Cells to arrive Please remember to backflush returned cells prior to sending them back to us This will save you on shipping costs a re built cell weighs 16 pounds and most Returned cells weigh in at 28 pounds as well as saving the environment as we have to dispose of the used contaminated oil and internal components Note that if the used cells are not returned to us within 30 days you will be invoiced separately for a core charge for each cell not returned 24 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com WARRANTY INFORMATION ASL Technologies LLC ASL warrants this product to be free from defects in material and workmanship for a period of one 1 year from date of shipment excluding expendables in accordance with the following terms and conditions This warranty extends only to the original purchaser owner This warranty does not include damage to the product resulting from accident misuse or abuse improper installation or operation lack of reason
73. ump and red goes to the meter If the pump and motor AND the meter are not running no other abnormal system indications check for 120VAC at the coil of CR8 8 If voltage is present there should be power on CR8 3 If no voltage on CR8 3 replace the relay If no voltage present on the coil of CR8 8 trace backwards to CR7 1 CR6 1 etc The coil of CR 8 can only receive power if all 5 High Voltage Power Supplies are working and there are no faults from the pressure switch or float switch Refer to the wiring diagram on page 29 of this manual REMOTE ALARM CIRCUIT The remote alarm circuit consists of two sets of dry contacts in relays CR 1 and CR 8 CR8 6 amp 4 are closed during normal operation as are CR8 4 amp 6 Two wires lead out to a two pin male spade connector which accepts 250 inch female spade terminals This connector is located on the right side of the cabinet just below the power cord 36 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com 4 www aslfilter com During normal operation these two pins will have continuity between them and are for customer interface with an outside indication or warning system such as a PLC When attaching an external system do not exceed 24 VDC Thus any problem that stops any power supply CR 1 thru CR 5 or the Pump C
74. uring shipment and or poor bedplate mounting conditions can cause premature failure or unacceptable noise and vibration Simple alignment checks can be performed by placing a straight edge on the top and side of the cou pling Improper alignment is indicated by a separation between the coupling and straight edge Ad just the motor and pump location until any separation disappears in both planes Bedplate Mounting Install nuts on the foundation bolts to provide location adjustment Loosely place the bedplate on the foundation bolts Adjust the bedplate height and location to meet the inlet and outlet piping Ensure the bedplate is level and true Fasten in place with lock washers or lock nuts Check coupling alignment Piping Improper suction piping is the leading cause of poor pump performance including cavitation noisy operation inadequate performance and premature pump failure Particular care should be taken to avoid long restricted pipe runs the use of elbows tees valves or other flow devices within twelve 12 pipe diameters of the pump inlet Inlet piping should be at least equal to the pump inlet size The discharge piping arrangement is somewhat less critical than the inlet side however good engi neering practice as defined by the Hydraulic Institute should be followed Pumps are not designed to be used as piping system support devices Piping systems should have adequate independent hangers to provide support Again
75. w Relay Configuration Relay Press Sw 2 Press Sw Lt P S 1 LV Yellow ah Power Supply 1 ne 8 7 Backflush O 7N ackflush Orange Backflush Lt Shown Relaxed DA P S 2 Remote Alarm LV Relay Power Supply 2 N Backflush Orange V to Cell 2 P S 3 LV Yellow a Power Supply 3 NR 8 7 Backflush Orange LY Yellow P S 4 LV Relay Power Supply 4 Backflush Orange V to Cell 4 LY Yellow P S 5 LV Relay Power Supply 5 Ne _ es ite Backflush Orange IHV to Cell 5 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com Cover Electrical Component Locations Y Y ae atte i 3 2 3 amp amp 8 2 A eS Be wee he Wate he MoMo Relays CR 1 thru CR 8 Left to Right TB 3 1 Incoming 120VAC from TB 1 H Black 2 Neutral White 3 Switched Power Red Black 4 Backflush Orange G Grounds Green Power Supplies P S 1 thru P S 5 Left to Right 30 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter ccom Www aslfilter com MAINTENANCE AND TROUBLESHOOTING The FPRS system is designed to give years of trouble free service with little attention The front panel lights microammeter and syste
76. what this product will accomplish for you and your company ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com The FPRS is designed to connect directly to your machine s reservoir The FPRS draws the fluid into its system using a pump that sends the fluid through a water absorber and Electrostatic Cell s to accomplish the cleaning process The fluid is then discharged through an output hose and back into your reservoir The FPRS utilizes a combination of electrostatic and magnetic fields to remove submicronic particles from the host reservoirs fluid This is accomplished by electrically influencing the particles in the oil to opposite polarities These and influenced particles are attracted to one another and are retained by polyolefin foam used within ASL s patented Electrostatic Cell Because the foam is polyofin water in concentrations of 500 ppm or less will not disrupt normal operations although microamp readings of the fluid will be slightly higher due to the conductivity of water The cell operates with alternating electrostatic and magnetic fields If for example a particle is negative it will seek the positive side of a magnetic plate When the particles begin to collect together one on top of the other alternating as positive and negative particles the polyofin foam pads ins

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