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FPRS-S200 Service Manual

1. ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve asifilter 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 available to help in
2. FPRS S200 Wiring Diagram Sw On ror comin Hoa ca His Hier 1 maa Power On Lt Pump Star Relay Pump Motor 1234 H Hour Meter PS 2LVLt ssu O PS LV L Float Sw Relay Float Sw Lt Press Sw Relay a 61 Press Sw Lt ea Opens at 750A i 71 3 Pist IV Yellow i cf PowerSupplyt Backflush Or I Backiush Lt phon TiVo NEG Pos Meter a Ps2 Remote Alarm LV Relay Powersupply Backflush Or Closed Noiti joes A Open Alarm Ft LV Relay ia PowerSupply3N 1 j Backflush Or 1 a alow _ i 54 LV Relay poner suppys 87 Backflush Or irony Piss TV Yellow Powersupply Backflush Or 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 custsve asifilter com Www aslfilter com Cover Elect
3. 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 custsve aslfilter com 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 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 supply 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 5 amp 3 open stopping the flow of power to the coil of CR 8 which in tum 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 El
4. 4 are closed during normal operation as are 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 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve asifilter com 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 the power supply CR 1 or the Pump CR 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 44 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 REPLACEME
5. DESCRIPTION PART NUMBER Call ASL for any parts not listed High Voltage Power Supply ALL CS 2223 P8 S 200 Pump Motor coupler ASSY SG 0570 GOV 5 200 Pump only 56 0570 S 200 Motor only Baldor CL 3501 5 200 Coupler only Lovejoy 2 Water Absorber Element WAEB 18 Water Absorber can ring Buna R40 0009 Electrostatic Cell R6ICS 115 See red tag on top of cell for our exact part number Pressure Gauge E 1401 UC Lid Safety Switch O7F 038 Lid Front Cover Magnet 11242 Hour Meter 711 0130 60Hz Microamp Meter 13260 5 200 Service Manual This Manual S 200 Series Cabinet Service Manual Laminated wiring diagram Inside front cover 5 200 Series Wiring Diagram Power Switch 7500K14 Circuit Breaker 4A045 Green Power Lamp Assy 1052 5 Amber Lamp Assy Backflush 1050 QC3 Red Lamp Assy Low Voltage Float 1050 QCI Switch Over Pressure Relay CR 1 through CR 8 120 10 Amp contacts Float Switch M8700 Pressure Switch PDA 4 4R4M C FL Remote Alarm Connector DC68 2 2 Power Cord 9 70355 K34 Oil Sample Test Port Push to test type KP14N V 1 Viton Cell Q D Female 3 Pressure Gauge tubing 24004 100 Cell Inlet Blue hose 3 8 Aeroquip FC662 06 BLU Cell Outlet Gray hose 3 8 Aeroquip FC662 06 GRA Lid hold open prop rod assy LOK 0401024
6. 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 3 Hydraulic Connections All the connections between the reservoir and the cabinet can be with hard piping or hose connections On the S Series units NPT bulkhead fittings are provided for your convenience on the right power cord side ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve 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 Ifa 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 are closed during normal tem operation During an alarm condition such as overload the relay will open A second access hole is provided if hardwiring is requir
7. 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve asifilter com Www aslfilter com 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 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 interrupted Refer to the Maintenance s
8. 3 Rotating in the wrong direction 4 The motor does not come up to speed 5 The strainer is clogged 8 The bypass valve is open pressure relief valve set too low or pressure relief valve Poppet stuck open 7 The pump is worn out 8 Any changes in liquid system or operation that would Palp explain the trouble e g new liquid additional ines or process changes Pump starts then loses its prime 1 The supply tank is empty 2 The liquid is vaporizing in the suction line 3 There is an air leak or air pockets in the suction line 4 The pump is wom out Pump is noisy 1 The pump is cavitating liquid vaporizing in suction line or being starved heavy liquid Cannot get to pump fast enough Increase the suction pipe size and or reduce the length or decrease the pump speed If the pump is abava tha liquid raise the liquid level clocor to the center line ofthe inlet port Ifthe iquid is above the pump increase the head of the liquid 2 Chock alignment 3 Anchor the base or piping to eliminate vibration Pump not delivering up to capacity 1 The pun is starving or cavitating see Pump is noisy 1 2 The strainer partially clogged 3 Air leak somewhere in the suction 4 Running too slow Is the motor the correct speed and wired up correctly 5 Pressure relief valve is set too low stuck open or has damaged poppet seat 6 The bypass line around the pump partially opened 7 The pump is wom out
9. 51 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve asffilter com www asifilter com Pump takes too much power stalls motor 1 Liquid is more viscous than the is unit sized to handle 2 The system pressure relief valve set too high 3 The pump is misaligned DO S AND DON TS Do s and Don ts for installation operation and maintenance of Viking pumps to promote safe long trouble free operation Installation 1 DO install the pump as close to supply tank as possible 2 DO leave working space around the pumping unit 3 DO use large diameter pipe with short and straight runs 4 DO install a strainer in the suction line 5 00 a double check of alignment after unit is mounted and piping is hooked up 6 DO provide pressure relief valve for discharge side of pump 7 DO check for proper rotation 9 DO use piping hose and fittings rated for maximum system pressure 10 DO check to make sure guards are in place Operation 1 DON T run the pump at speeds faster than 3600 RPM 2 DON T allow the pump to develop pressure higher than those shown in catalog for your pump 3 DON T operate pumps at temperatures above or below limits shown in catalog for your pump 4 DON T operate unit without all guards in place 5 DON T operat thout a pressure relief valve in disch be sure the valve is
10. A rise in temperature will cause a liquid to expand If there is no provision for pressure relief in the closed off section there is a chance that the pump piping will rupturo Danger Before starting pump be sure all drive equipment guards are in place Failure to properly mount guards may result in serious injury or death START UP Before pushing start button check the following 1 Are vacuum and pressure gauges liquid filled mounted on or near the pump Gauges are the quickest and most accurate way of finding out what is happening in the pump 2 Is the pump is correctly aligned with the drive equipment 3 Make sure there is no pipe strain un the pump ports 4 Rotate the pump shaft by hand to be sure it tums freely 46 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com EXPLODED VIEW TYPICAL 36 04 36 05 56 07 2 EXPLODED VIEW 7 Tem DESCRIPTION mem DESCRIPTION 1 _ Bracket bearing section 5 Rete vaive kit 2 Hach ground casing amp 2 gears driver amp a 3 Separation plate amp bearing assy 7 Ong Head and alignment sieeve assy Assembly capscrews 47 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 73
11. L The number one reason for power supply high voltage section failure is operating the Electrostatic Cell beyond one year 8700 hours 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 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 directly 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 3
12. 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 two wire 250 male spade connector that can be interfaced to remote alarm PLC The signal runs through two dry sets of contacts in relays 1 and CR 8 When the system is operating normally these contacts are closed In the event of intemal failure these contacts open If these connections are used do not exceed 24 VDC OIL SAMPLE PORT The oil sample port is located on
13. 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 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve 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 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 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 Elemental Analys The presence of elements in solution i e additives wear metals and contamination elements FT IR Estimation of oxidation levels PIXIE Analysis of c
14. and connect to a grounded 10 amp 120 VAC outlet Note that the FPRS unit and your system reservoir must both have earth ground Reinstall the front cover and close the top cover There is a safety switch on the top cover that must be closed to allow incoming power to reach the power supply 5 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com Tum the Power Switch to the ON position The green Power lamp should illuminate Note that all 5 Red Low Voltage lamps illuminate momentarily and then go out The Fluid Delivery System pump motor will immediately start and begin drawing fluid from your reservoir 13 Note that the pump may need to be primed before any outlet flow is observed 14 Your system was tested with fluid but the water absorber element canister and the Electrostatic cells are dry when you receive your unit It may take a few minutes for them to fill before any fluid output is seen If output flow and or pressure rise on the gauges is not observed within 3 4 minutes turn power OFF and make sure the inlet hose is primed The FPRS 200 system has a flow rate of 3 4 GPM and the system holds approximately 13 gallons of fluid a IMPORTANT SAFETY INFORMATION READ CAREFULLY BEFORE ATTEMPTING TO INSTALL OPERATE OR MAINTAIN THE FINI
15. 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 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 custsve aslfilter com www aslfilter com Table of Contents Subject Page Quick Startup Guide a Important Safety Information 4 Introduction System Overview Important Guidelines S 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 ZI Spare Replacement Parts List 28 Wiring Diagram 29 Cover Electrical Component Locations 30 Maintenance and Troubleshooting 31 Removal and Replacement of Components 3H Pump and Pressure Switch Adjustments 40 Scheduled Maintenance Tasks 41 Fluid Flow Diagram 42 Electric Motor Service Data 43 Hydraulic Pump Vendor Service Manual 44 Orig 03 01 07 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Fr
16. from cavitation misalignment or damaged parts Pressure Gauge Discharge Port High reading would indicate 1 High viscosity and small diameter and or lengthy discharge line 2 The strainer or fiter is plugged 3 The pressure relief valve is set too high 4 Valve in the discharge line partially closed 5 Line may be partially plugged from build up on the inside of the pump solidified product foreign object 6 Liquid in the pipe is not up to temperature Low reading would indicate 1 Pressure relief may be set too low 2 Pressure relief valve poppet is not seating property 3 Pump mounting capscrews not torqued to specifications 56 04 and SG 05 Series 12 15 fLbs 4 Pump assembly bolts not torqued to specifications SG 07 Series 50 55 ft bs 5 The bypass around the pump is partially open 6 Pump is damaged or worn 7 The pump has too much intemal clearance Fluttery jumping erratic reading would indicate 1 Cavitation 2 Liquid is coming to the pump in slugs 3 Air leak in the suction line 4 Vibrating from misalignment or mechanical problems 50 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve asffilter com www aslfilter com Miscellaneous Pump does not pump 1 The pump has lost its prime from air leak or low level in tank 2 The auction liftis too high
17. mounted and sel correctly 6 DON T operate the pump with all the liquid bypassing through the internal pressure reliet valve with out any flow of liquid going through the pump for more than 30 seconds Operation under either of these conditions may result in heat build up and damage to the pump 7 DON T work on the pump unless driver has been locked out so it cannot be started while work is being done on the pump Maintenance 1 DO record pump model number and serial number and file for further use 2 DO have spare parts pump or stand by units available particularly if pump is essential of key operation process 3 DO obtain read and keep all maintenance instructions furnished with pump 4 DO make sure any pump that has residual system pressure in it or that has handled high js vapor pressure liquids has been vented through the suction or discharge lines or other openings provided for this purpose FPRS S 200 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com 5 DO make sure that if the pump is still hooked to the driver while maintenance is being performed that the driver has been locked out so that it cannot be inadvertently started While work is being done on the pump 6 DO make sure any pump that has handled a corrosive flammable hot
18. 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 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve 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 ete 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 Orientation Ambient temperature less than 160 F 2 Fluid Delivery Pump Motor The self contained pump and motor delivery system allows for
19. or toxic liquid has been drained flushed vented and or cooled before it is disassembled VIKING PUMP WARRANTY Viking warrants all products manufactured by it to be fraa from dafects in workmanship ar material for a period of one 1 year from date of startup provided that in event shall this warranty extend more than eighteen 18 manths from the date of shipment from Viking during said warranty period any products sold by Viking prove to be defective in workmanship or material under normal use and service and if such products are returned to Viking s factory at Cedar Falls lowa transportation charges Prepaid and if the products are found by Viking to be defective in workmanship or material they will be replaced repaired free of charge FOB Cedar Falls lowa Viking assumes no liability for consequential damages ot any kind and the purchaser by acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser his employees others Viking will assume field expense for service parts unless authorized by it in advance Equipment and accessories purchased by Viking from outside sources which are incorporated into any Viking product are warranted only to the extent of and by the original manufacturer s warranty or guarantee if any THIS 15 VIKING S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED WHICH ARE HEREBY EXC
20. 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 backtlush 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 period of time is not recommended and the cells should be backflushed or replaced as soon as practical 35 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve asifilter 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 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
21. 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 on the sample valve and push the thumb button in for a few seconds to flush the sample port Using clean sample bottle remove the lid and invert it to prevent ambient dust or dirt from contaminating the sample the bottle to within 14 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 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 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 custsve asifilter com www aslfi
22. 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 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 remove the 1 8 inch Allen lock screw from the pressure switch and set aside The pressure switch adjustment is also a 1 8 inch Allen and can be adjusted after removing the lock screw Turn the pressure switch adjustment clockwise 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 WAYNE s 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 40 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D
23. 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 14 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 43 of this manual 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 With the wiring and hoses disconnected remove the four 7 20 nuts and washers and remove the pump motor assembly from the cabinet With both the old and new pumps motors on the workbench transfer the inlet outlet hose fittings and the black Heyco wiring
24. 0 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 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve 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 owne This warranty does not include damage to the product resulting from accident misuse or abuse improper installation or operation lack of reasonable 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 su
25. 3 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 custsve aslfilter com 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 Tum power on Note that you will have to defeat the cover safety switch to continue A USE CAUTION 4 Using 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 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 I
26. 3 2777 Toll Free 888 333 2990 5 Before connecting to the motor jog it to be sure it is running in the correct direction Refer to General on page 1 6 Is the pressure relief valve installed properly 7 Make sure suction piping is properly connected and sealed and valves are open Make sure the discharge pipingis property connectedand sealed valves areopen andthereis a place for the liquid to go 9 Make sure all guards are in place 10 The above checklist is a general guideline to be used prior to starting the pump Since Viking Pump cannot foresee every application for our product and possible system design the final responsibility is with the user The pump must be utilized within the catalog specifications and the pump system must be designed to provide safe working conditions The start button may now be pushed The pump should begin to deliver liquid within 15 seconds If not push the stop button Do not the pump without liquid flow longer than 30 seconds or the pump may be ruined Review Startup steps 1 through 10 Consider what the suction and discharge gauges may indicate If everything appears in order re prime pump Refer to Mounting page 2 item 8 Push the start button If nothing is flowing within 30 seconds stop the pump The pump is not a compressor it wll not build up much air pressure It may be necessary to vent discharge line until liquid begins to flow I pump stil does
27. ARNING 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 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 few minutes Ensure that fluid is being dispensed through the output hose WARNING 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
28. ART UP TROUBLESHOOTING PREVENTIVE MAINTENANCE DO S amp DON TS SERIES SG 04 SG 05 amp SG 07 SPUR GEAR PUMPS CONTENTS Installation Mounting Start Up Troubleshooting Miscellaneous Do s and Don ts Warranty 10 FIGURE 1 INSTALLATION General The following items must be considered prior to pump installation 1 Location locate the pump as close as possible to the liquid supply If possible locate the Pump below the liquid supply Viking pumps are self priming but the better the suction conditions the better the pump will perform 2 Accessibility the pump must be accessible for inspection maintenance and repair 3 Suction Discharge SG Series pumps are designed for clockwise rotation as standard Viewed from end of shafi Refer to Figure 1 4 Pressure Relief Valve the SG Series is a positive displacement pump and requires some form of over pressure protection Without pressure protection if the discharge line is blocked becomes closed pressure will build up until the motor stalls drive equipment fails pump part breaks or the piping and or other equipment in the system bursts To prevent the possibility of any one or more of the above from occurring the use of a pressure relief valve is recommended 5 Storage drain the pump and apply a light coat of non detergent SAE 30 weight to all internal pump parts Apply grease to the pump shaft extension Viking suggests rotating t
29. LUDED INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No officer or employee of IDEX Corporation Viking Pump Inc is authorized to alter this warranty OF SERVICE MANUAL 33
30. NT OF COMPONE 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 nut driver remove the four nuts and lockwashers securing the meter to the cover Push the meter out from 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 toward 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
31. PORTANT 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 Use a clean bottle to take the sample sample should be taken from the lowest point of the reservoir preferably the drain cock or valve because this is where the input hose will draw from Free water should be drained from the reservoir before the FPRS is hooked up the sample to ensure that the fluid 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
32. TE 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 At safety alert symbol is used with signal words WARNING and CAUTION to call attention to safety statements Awe statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life Acero statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com ELECTRICAL SAFETY Avene ELECTRIC SHOCK 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 fluid reservoir it services must both be ea
33. 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 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 120 power at relay 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 3 to the meter Note that two wires are installed on CR8 3 black goes to the pump 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 CRS 3 If no voltage on CR8 3 replace the relay If no voltage present on the coil of 8 trace backwards to CR7 1 1 ete 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 6 amp
34. Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve asifilter com www aslfilter com 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 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 stays at 40 psi with the throttling valve fully closed Re adjust if necessary 14 all adjustments are complete open the throttling valve completely and replace the acorn nut on the pump by pass valve and the 1 8 inch Allen lock screw in the pressure switch 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 2 Check that pump motor and hour meter are running 3 Check system pressure gauge below 35 psi 4 Check Microammeter below 500 microamps illuminated WEEKLY 1 Lea
35. anatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com IMPORTANT GUIDELINES Oil temperature should not exceed 165 F for electrostatic cells 175 for black tube Phosphate Ester Cells Ambient air temperature should not exceed 160 F Vis osity 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 retuned 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 inlet As well as t
36. 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 occur under the following fluid conditio 1 HEAT Current Increases Fluid temp will cause the uA to increase A rise from 80 F to 110 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 effect 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
37. ap free and emulsified water will also trap larger particulate and should be replaced at least once each year ctions FPRS S 200 SERIES CABINET FLUID FLOW DIAGRAM a Hoses Customer Oil Reservoir W Cell Outlet Manifold 4 14 14 Electrostatic ix Blue Hos Cells ae ee NS Water Absorber Pump Motor Cell Inlet Canister Manifold ASL Technologies LLC 4 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 nile 219 733 2779 or e mail cu asifilter com www aslfilter com Motor Wiring Data Motor is ASL Factory wired Lo Volt CCW Rotation Q 2 White Lo Volt lt Factory Wired this way ________ __ a y Black Do not reverse rotation The following pages contain the Installation and Service Instructions for the Viking Series SG 04 SG 05 and SG 07 Spur Gear pumps The model used in the ASL FPRS S200 is SG 0570 This manual is reprinted with permission from Viking Pump 43 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www asifilter com VIKING TECHNICAL SECTION TSM 340 PUMP service MANUAL PASE 1 ISSUE INSTALLATION ST
38. e 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com ORDERING SPARE AND REPLACEMENT PARTS Spare Parts List for your 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 Preferred shipping carrier information ASL is an On Line daily UPS shipper Ground Next Day Second Day ete Bill To Addres Ship To Address we cannot ship to a Box Purchase Order Number Parts will be invoiced 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 219 733 2779 custsve aslfilter com Internet www aslfilter com 27 FPRS 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 custsve aslfilter com www aslfilter com FPRS S 200 Cabinet Spare Replacement Parts
39. ection 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 RED FLOAT SWITCH LIGHT Illumination of this lamp indicates that there is either a fluid leak inside the FPRS or the float been upset during shipping or recent movement of the unit Note that this is a 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 comer 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 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 Power must be tumed OFF and then back aft
40. ectrostatic Cell 2 on so 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 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 stop and start as the power supply tries to reset itself If you observe 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 Turn power off and un plug the FPRS from the power source b Using a screwdriver wi
41. ed 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 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 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve 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 reservoir 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 rec
42. ee 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com Quick Startup Guide This section is intended for experienced users only Please be sure to read the entire manual 1 Unpack FPRS Unit from shipping box skid 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 2 Open Top Cover by grasping rolled lip and lifting up like a car hood The white foam pad was inserted to protect the top cover safety switch during transit and can be discarded Swing the top cover all the way up until the prop rod engages into the locking slot The cover is hinged at the top rear sides and held closed with magnets Use extreme caution when the top cover is open shock or jarring may cause it to close suddenly and could cause personnel and or equipment damage To close the top cover raise the cover an inch or so with one hand With the other hand grasp the upper rod between thumb and forefinger and rotate it clockwise approximately 1 4 turn Slowly lower the lid to it s fully closed position 3 With the Top Cover open the Front Cover can be removed by pulling the top rolled edge toward you about 2 inches to disengage the magnets and lift front cover clear of unit The front cover fits outside the case sides and rest
43. er 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 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 10 12 13 14 15 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve asifilter com Www aslfilter com LOW VOLTAGE illuminated lamp will illuminate the system will shut down with the lamp remaining 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 pressure gauge shows system pressure at the entrance to the
44. er on the suction side of the pump should always be considered in any pumping system The strainer will keep foreign matter from entering the pump The strainer mesh porforation eizo should be largo enough that it doos not cause exceasive pressure drop but fine enough to protect the pump Use of a strainer is particularly important at start up to help clean the system of weld beads pipe scale and other foreign objects 5 A pressure relief valve is required in the discharge line See Pressure Relief Valves General page 1 item 4 6 The pump must not be used to support the piping Hangers supports stands etc must carry the weight of the pipes 7 When fastening piping to the pump do not impose any strain on the pump casing Springing drawing the piping up to the pump will cause distortion possible misalignment and probable rapid wear of the pump Do not use the pump to correct errors in piping layout or assembly 8 All joints in the piping system must be tight liquid thread sealant will help assure leak free treaded joints careful not to over tighten the fittings to the pump as this can damage the pump Leaks in the suction line can permit air to be drawn in and will cause a noisy pump and reduction in capacity 9 Drive alignment must be checked after piping is hooked up 10 Provide a pressure relief device in any part of a pump and piping system that can be valved off and thus completely isolated
45. 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 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 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 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 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 38 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 custsve asifilter com www 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 Remove the four bolts 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 ro
46. g 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 raising system pressures to higher hormal 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 acorn nut on the pump relief valve 1 1 16 wrench size Insert a screwdriver into the slot of the adjusting screw and hold it steady Loosen the 1 1 8 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
47. he pump shaft by hand one complete revolution every 30 days to circulate the oil 44 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 custsve asffilter com www asifilter com MOUNTING 1 Surfaces to which the pump mounts must be clean and flat 2 Use SAE Grade 5 or better capscrews to mount pump 3 The 4 mounting capscrews for the 50 04 and SG 05 pumps must have minimum of inch thread engagement and must be torqued evenly to 12 15 ft lbs 4 The 2 mounting capscrews for the 55 07 pumps must have a minimum of inch thread engagement and be evenly torqued to 50 55 flbs 5 Standard SG Series pumps are designed to be used with jaw type couplings that do not induce axial thrust on the pump shaft If an improper type of coupling is used internal damage may result 6 Do not strike or press the pump drive coupling to instail pump damage will result If the coupling does not slide onto the shaft inspect the coupling shaft and key for nicks or burrs and remove 7 the pump is to be belt or gear driven the overhung load option must be specified 8 the pump has been mounted and the coupling installed it is recommended to put lube into the suction port and turn the pump by hand to make sure it turns freely Alignment Check alignment after mounting 1 Ifthe unit has a flexible c
48. he 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 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733
49. ines or other appropriate openings or connections 2 That the driving means motor turbine engine etc has been locked out or made non operational so that it cannot be started while work is being done on the pump 3 That you know what liquid the pump has been handling and the Precautions necessary to safely handle the liquid Obtain a material safety data sheet MSDS for the liquid to be sure these precautions are understood Failure to follow the above listed precautionary measures may result in serious injury or death Vacuum Gauge Suction Port High vacuum reading would indicate 1 The suction line is blocked valve closed a strainer is plugged a pinched suction line 2 The suction line is too small 3 The liquid is too viscous to flow through the piping 4 The lift required is too high Low reading would indicate 1 There may be an air leak in the suction line 2 The end of the pipe is not in the liquid The pump is wom 4 The pump is dry and should be primed 49 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve asffilter com www aslfilter com Fluttery jumping or erratic reading would indicate 1 The liquid is vaporizing 2 Liquid is coming in to the pump in slugs possibly an air leak or insufficient liquid above the end of the suction pipe 3 Vibration
50. 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 custsve aslfilter com 25 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail istsve 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 1725 RPM 120 VAC 60 Hz single phase 4 amps continuous 6 amps start up PUMP 200 GPH w 100 SUS Fluid 1725 RPM 1 2 NPT Inlet amp Outlet Ports WATER ABSORBER 5 micron wood paper element Mineral Oil Units INLET amp OUTLET CONNECTIONS NPT Bulkhead Fittings SYSTEM VOLTAGE Input Voltage 120 VAC 60 Hz single phase 10 Circuit Breaker 10 Amps Output Voltage of Power Supply 15 Nominal 1 9 miliamp 600uA Manufactured in the U S A ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Fre
51. irectly 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 Submicronic Contaminants such as Silts Tars 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 what this product will accomplish for you and you
52. is located on the lid of the water absorber canister See page 11 for sample port operations ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve 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 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 property altering contaminants Systems with chronic water ingression cannot be filtered effectively unless the source of water can be eliminated
53. leaks Replace the front cover and close the top cover The FPRS is now ready to resume operation 22 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslilter com www aslfilter com WATER ABSORBER ELEMENT REPLACEMENT may need to be replaced gt 35 psi WARNING 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 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 Activate the main power source and then tum ON the power switch on the control panel After fluid is dispensed through the output hose shut down the system and check fo
54. lter com FPRS S200 Front Panel Controls and Indicators See pages 9 11 for detailed function 10 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve asifilter 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 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com Drip Tray and Float Switch Disconnect 2 pin Molex Grasp tray by knobs Carefully slide out for service Switch stays in tray ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com SYSTEM PREPARATION NOTE IT IS EXTREMELY IM
55. minal 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 ete 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 If OK check for 120VAC on pin 8 yellow wire of the associated relay CR I for P S 1 etc If 120VAC is present at 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 above 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 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 04
56. n 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 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 though the float switch may only bump closed momentarily the red light and fault will remain latched until an operator intervenes 1 red float switch light is observed immediately investigate the source of the leak and make necessary repairs To reset the fault turn power off and then back 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 10525 W US H
57. nd holds them in place This collection of particles is 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 when ordering cells sure to state the correct model number of the cell The model number is shown on a red tag on top of the cell ic 61 115 R62CS 115 ete Note that Phosphate ester fluid compatible cells have 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 10525 W US Hwy 30 Bldg 3D W
58. nd 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 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 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 custsve 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 i e transformer hydraulic turbine lubricating and solvents There are basically five 5 major factors contributing to the contamination of industrial fluids Air Heat Water Particulate matter Oxidation of by products Contamination of industrial fluids is a great concern because their condition is d
59. not deliver consider one or more of the following 1 The suction tine has air leaks 2 The end of the suction pipe is not submerged deeply enough in the liquid 3 The suction iftis too great or the suction piping is too small 4 Liquid is vaporizing in the suction line before it gets to the pump after consideration of these points the pump still does not deliver liquid review all points given under START UP and read through the TROUBLESHOOTING guide and try again M Pump still will not deliver liquid contact your Viking Pump supplier FPRS S 200 Facsimile 219 733 2779 or e mail custsve asffilter com www asifilter com 48 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www asifilter com TROUBLESHOOTING Viking pump that is property installed and maintained wil give long satisfactory Performance I trouble does develop one of the first steps toward finding the difficulty is to install a vacuum gauge in the suction line and a pressure gauge in the discharge line Readings on these gauges often give clue on where to start looking for trouble DANGER Before opening any Viking pump liquid chamber pumping chamber reservoir relief valve adjusting cap fitting etc be sure 1 That pressure in chamber has been completely vented through the suction or discharge l
60. ommended that shut off valves be installed in the line running from the reservoir to 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 oe 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 pump will start running and draw fluid from the reservoir into the Check for any external leaks Tum 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 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
61. ontaminant 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 life in these cases 20 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve asifilter 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 FLUSH lamp illuminates the cell s need to be backflushed d WARNING 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 backflush hose to the quick disconnect at the bottom of the cell Place the end of the bottom backflush hose into a suitable container Using a second backflush quick disconnect fitting connect plant air supply REDUCE TO 10 PSI to the quick disconnect at the top of the cell Allow 10 psi of air to flu
62. otor 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 14 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 Re install the four bolts thru the pump to the motor 11 Re install the SO cord through the Heyco fitting and re conneet wiring in accordance with the diagram on page 43 of this manual 12 Tie up any loose wiring and return the unit to service Note that pump adjustments should not be required when replacing the motor only 39 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 custsve asifilter com www 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 followin
63. oupling remove any coupling guards or covers and check alignment coupling halves A straight edge piece of key stock will work across the coupling must rest evenly on both rims at the top bottom and sides See Figure 3 2 Make a final check on alignment after the piping is hooked up Use sTRAGHT EDGE THESE te PARAL WOH BETWEEN THESE SURFACES ISIE CALIPERS OR FEELER YO BE CERTAN THe PACES ARE EGUAL DISTANCE APART ANO PARALLEL FIGURE 3 Piping Hose The cause of many pumping problems can be traced to the suction piping It should always be as large in diameter and as short in length ae poesible Before starting the layout and installation of your piping system consider the following points 1 Never use piping smaller than the pump port connections Piping larger in diameter than the connection is sometimes required to reduce friction losses 45 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com 2 Be sure the inside of the pipe is clean before installing 3 When approaching an obstacle to the suction line go around Instead of aver It Going over obstacle can create an air pocket Where practical slope the piping so no air or liquid pockets will be formed Air pockets in the suction line make it hard for the pump to prime 4 A strain
64. plies and finally to the Power lamp on the front panel Note that the normally closed contacts of CRI thru CRS pins 5 amp 1 will momentarily pass 120VAC to the red Low Voltage lights on the front panel Once H V power supplies receive power a normally closed relay inside the power supply sends power to the coil of CRI 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 CRI thru CRS coils energized the contacts of CR1 5 amp 3 close along with CR2 6 amp 4 CR3 6 amp 4 CR4 6 amp 4 and CR5 6 amp 4 allowing power to flow through the normally closed contacts of 5 amp 1 and CR7 5 amp 1 thus energizing the coil of CR8 Once 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 to start the pump motor At the same time 1 thru 5 close the normally closed contacts of CRI 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 15 supplied to the Electrostatic Cells Re
65. pplied 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 allow limitation on how long an implied warranty lasts or the exclusion limitation of incidental or consequential damages so the above stated limitations 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
66. r company ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve 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 inside the cell becomes home for the particles a
67. r leaks ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 FPRS S 200 Facsimile 219 733 2779 or e mail custsve aslfilter com www aslfilter com Electrostatic Cell Rebuild Program The Electrostatic Cells in your FPRS Finite Particle Removal System 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 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 1 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 custsve aslfilter com with the quantity and part number 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 1
68. rical Component Locations REED fe Wale is 2107 7 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 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 custsve asifilter com 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 system 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 away should you need any advice assistance ELECTRICAL THEORY OF OPERATION Refer to the wiring diagram on page 29 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 120VAC Po
69. rth 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 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve asifilter com Www aslfilter com A CAUTION The power source must be fused for 10 amps 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 in personal injury and or property damage a
70. s inside the case at the bottom Note that the system has 4 full swivel casters all with brakes 4 Remove the backflush hose package Don t lose the backflush hose and fitting you ll need them for unit servicing 5 Check for any loose hoses electrical connections relays etc that may have occurred during shipping A laminated wiring diagram is pasted on the inside of the front cover 6 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 The float switch stays in the tray and is disconnected by pulling apart the 2 pin Molex connector on the side wall near the bottom of the Water Absorber canister Grasping the two drip tray knobs 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 7 Verify that the Water Absorber drain valve 3 8 gray hose on the bottom of the canister is CLOSED 8 Remove the plastic 14 NPT shipping plugs from the right side inlet and outlet bulkhead fittings Plumb inlet and outlet hoses to your reservoir Use Teflon tape or equivalent Inlet to the lowest point on the reservoir and outlet to the opposite side top of the reservoir Make sure to drain any free water which may have accumulated at the bottom of your reservoir 9 Unwrap the power cord
71. sh 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 If it remains on refer to the Maintenance section of this manual Observe that the microamp meter is now below 500 microamps Over time backflushing may no longer be effective and the Electrostatic Cell must be 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 custsve aslfilter com www aslfilter com Under normal operating conditions cells CELL REMOVAL INSTALLATION should be changed annually When you replace your electrostatic cell perform the following steps WARD ING 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 W
72. sure light the coil of CR 7 and contact CR7 6 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 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
73. tating 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 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 43 of this manual 2 Remove the four bolts 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 m
74. th 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 4 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 Ifthe low voltage light is now off the Electrostatic Cell is shorted and should be backflushed and or replaced If the low voltage light is on with the corresponding Cell disconnected the power supply is defective and should be replaced h that it is possible to have both a shorted Cell and a bad power supply 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 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 custsve asHfilter com Www aslfilter com 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 follo 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 ter
75. the 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 Using one hand remove the POS terminal from the Electrostatic Cell all ty wraps securing the POS and NEG leads from the cell to the power supply Remove the wiring trough cover above the power supplies 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 nawr 37 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 custsve asifilter com www aslfilter com 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 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 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
76. ve the Power switch in the 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 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 bottom and 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 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 custsve aslfilter com www aslfilter com YEARLY In addition to the monthly checks above perform the following additional maintenance 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 entr
77. wer White wires 120 VAC Neutral Green Wires Ground Yellow wires 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 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 c The red pink Hi Voltage wires coming out of the bottom of the power supplies carry 15 000 VDC to the Electrostatic Cells THE 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 10 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 5 5 Float switch power black wire the Pressure switch power wire the120VAC in connector on all 5 High Voltage power sup
78. wy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsve asifilter com www 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 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 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 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 overpres

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