FPRS 40 ABH OPERATIONS MANUAL
Contents
1. FPRS 40 ABH OPERATIONS MANUAL ANALYTIC SYSTEMS 3 LABORATORIES INC ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 219 733 2777 Fax 219 733 2779 FPRS 40 ABH Operations Manual Congratulations on the purchase of your new Finite Particle Removal System FPRS ASL Technologies LLC s FPRS 40 ABH provides state of the art cost recovery of valuable fluids and extension of component life in hydraulic systems Please read this manual from start to finish Critical information has been supplied to assist you with the theory operation and maintenance of your Finite Particle Removal System Feel free to contact ASL any time via our Customer service email address at custsvcQaslfilter com FPRS 40 ABH Operations Manual TABLE OF CONTENTS IMPORTANT SAFETY INFORMATION SECTION 1 Introduction SECTION 2 Important Guidelines SECTION 3 System Safety Features SECTION 4 System preparation Hose Connections for Start up System Start up Hose Connections for Normal Operation SECTION 5 Normal Operation Backflush Operation Cell Removal Changing Water Absorber Element SECTION 6 Maintenance SECTION 7 Trouble Shooting the System SECTION 8 Cell Rebuild Program SECTION 9 Warranty Information SECTION 10 Ordering Spare and Replacement Parts SPARE PARTS LIST PRODUCT SPECIFICATIONS ELECTRICAL SCHEMATIC PUMP OPERATING MANUAL Nant R W 122. FPRS 40 ABH Operations Manual Safety devices such as interlocks and fuses should not be disconnected or shunted out CAUTION The power source must be fused for 20 amps 1 The motor is designed for operation on the voltage and frequency specified on 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 A CAUTION If the wires of the motor which lead to the starting coil are interchanged the direction of rotation will be reversed A label on the motor describes the possible wiring configurations There are many different combinations possible so only the diagram provided with the motor should be used 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 units outdoors or unprotected from the elements Do not use in a damp or wet location FLUID SAFETY W ARNING Do not pump flammable or explosive fluids such as gasoline Do not use in explosive atmospheres Failure to follow this warning can result in personal injury and or property damage and will void the product warranty ii FPRS 40
3. Do make sure that if the pump is still hooked to 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 Do make sure any pump that has handled a corrosive flammable hot or toxic liquid has been drained flushed vented and or cooled before it is disassembled Do record pump model number and serial number and file for future Do obtain read and keep maintenance instructions turnish ed with pump TECHNICAL SERVICE MANUAL INSTALLATION START UP TROUBLE SHOOTING PREVENTATIVE MAINTENANCE DO S amp DON TS SERIES SG 04 SG 05 and SG 07 SPUR GEAR PUMPS WARRANTY Viking warrants all products manufactured by it to be free from defects in workmanship or material for a period of one 1 year from date of startup provided that in no event shall this warranty extend more than eighteen 18 months from the date of shipment from Viking If 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 or repaired free of charge F O B Cedar Falls Iowa Viking assumes no liability for consequential of any kind and the purchaser by
4. 14 15 16 17 18 19 20 21 FPRS 40 ABH Operations Manual IMPORTANT SAFETY INFORMATION READ CAREFULLY BEFORE ATTEMPTING TO ASSEMBLE INSTALL OPERATE OR MAINTAIN THE FINITE PARTICLE REMOVAL SYSTEM PROTECT YOURSELF AND OTHERS BY OBSERVING ALL SAFETY INFORMATION FAILURE TO COMPLY WITH INSTRUCTIONS COULD RESULT IN PERSONAL INJURY AND OR PROPERTY DAMAGE RETAIN INSTRUCTIONS FOR FUTURE REFERENCE SAFETY ALERT SYMBOL AND SIGNAL WORDS The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instructions A A A This safety alert symbol is used with signal words WARNING and CAUTION to call to safety statements WARNING Statements identify procedures or practices which must be followed to avoid serious personal injury or damage to this equipment CAUTION Statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment ELECTRICAL SAFETY A WARNING ELECTRIC SHOCK can kill Your FPRS uses a high direct current voltage of 15 000 volts Do not touch live electrical parts Always disconnect power source before working on the system Avoid accidental starting Make sure unit is turned OFF and is unplugged before working on system Protect the power cable from coming in contact with sharp objects Replace or repair damaged or worn cord immediately
5. HANDLE THE HOSES SO THAT SPILLS CANNOT TAKE PLACE SYSTEM START UP 4 8 1 WARNING Turn OFF and unplug system 4 8 2 Open the lid remove the front panel and locate the Valve Position Function label on the water absorber canister 4 8 3 Locate the corresponding 3 way large selector valve on the bottom of the water absorber canister 4 8 4 Set the valve to the Water Absorber Only position 4 8 5 Replace the front panel close the lid and plug the FPRS into a grounded 110V AC outlet 4 8 6 Turn the power switch to the ON position A 15 second delay will occur prior to system turn on The water absorber will take a few minutes to fill with fluid When fluid begins to flow from the system output hose allow 3 gallons to fill the pail Place the system input hose into the pail and allow the water absorber to run close loop for 5 minutes 4 8 7 WARNING Turn OFF and unplug system Open the lid and remove the front panel Check to ensure there are no leaks and set the selector valve to Water Absorber and Particle Filter 4 8 9 Replace the front panel and close the lid FPRS 40 ABH Operations Manual 4 9 0 HOSE CONNECTIONS FOR NORMAL OPERATION 4 9 1 Move the input hose back to the fluid reservoir as in 4 7 2 above 4 9 2 The black hose with the quick disconnect socket is the system output hose and should be connected to the top of the fluid reservoir FPRS 40 ABH Operations Manual SECTION 5 NORMAL OPERATION Your FPRS syste
6. and straight suction piping 4 DO install a strainer in suction line 5 DO double check 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 8 DO use piping hose and fittings rated for maximum system pressure 9 DO check to be sure all guards are in place Operation 1 DONT run pump at speeds faster than shown in catalog for model 2 DONT allow pump to develop pressures higher than those shown in catalog for model 25 DONT operate pumps at temperatures above or below limits shown in catalog for model DON T operate pumps without all guards being in place DONT operate pumps without pressure relief valve in dis charge piping be sure valve is mounted and set correctly DON T operate the pump with all of the liquid bypassing through the pump internal pressure relief valve or without any flow of liquid going through the pump for more than 30 seconds Operation under either of these conditions may result in a heat buildup and damage to the pump Do have spare parts pump or standby units available particularly if the pump is an essential part of a key operation or process Maintenance Do make sure any pump that has residual system pressure in it or that has handled high vapor pressure liquids has been vented through the suction or discharge lines or other openings provided for this purpose
7. e g new liquid additional lines etc Pump starts then loses its prime 1 supply tank empty 2 liquid vaporizing in the suction line 3 air leaks or air pockets in the suction line 4 pump worn out Pump is noisy 1 pump is being starved heavy liquid cannot get to pump fast enough Increase suction pipe size reduce length or slow down pump 2 pump is cavitating liquid vaporizing in suction line In crease suction pipe size or reduce length If pump is above liquid raise the liquid level closer to the pump If the liquid is above increase the head of liquid 3 check alignment 4 anchor base or piping to eliminate vibration Pump not up to capacity 1 starving or cavitating increase suction pipe size or reduce length 2 strainer partially clogged 3 air leak in suction line or along pump shaft 4 running too slowly is motor the correct speed and is it wired up correctly 5 pressure relief valve set too low or stuck open 6 bypass line around pump partially open 7 Pump worn out Pump takes too much power stalls motor 1 liquid more viscous than unit sized to handle 2 system pressure relief valve set too high 3 pump misaligned Do s and Don ts for installation operation and maintenance of Viking pumps to assure safe long trouble free operation Installation 1 DO install pump as close to supply tank as possible 2 DO leave working space around the pumping unit 3 DO use large short
8. lid 4 6 0 Take a sample of the fluid to be cleaned 4 6 1 Use a clean bottle to take the sample 4 6 2 The sample should be taken from the lowest point of the reservoir preferably the drain cock or valve because this is where the FPRS input hose will draw from Free water should be drained from the reservoir before the FPRS is hooked up 4 6 3 Test the sample to ensure that the fluid does not surpass the guidelines of the system as set forth im Section 2 FPRS 40 ABH Operations Manual 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 4 7 0 4 8 0 HOSE CONNECTIONS FOR START UP It is recommended that connections to reservoirs be made with quick disconnects to minimize ingression of contaminants when hooking up and operating the FPRS Your unit has been supplied with two black 15 hoses to be used for connections 4 7 1 Connect the hoses to the FPRS using the quick disconnects 4 7 2 The hose with the quick disconnect plug is the system input hose and should be secured to the lowest point of 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 4 7 3 The hose with the quick disconnect socket is the system output hose and at this point should be placed into an empty 5 gallon container 4 7 4 CAUTION
9. of the other alternating as positive and negative particles the foam filter inside the cell becomes a home for the particles and holds them in place This collection of particles is a phenomenon known as strawing In addition your FPRS comes equipped with a water absorption unit which can remove free and emulsified water Each fluid to be cleaned has its own characteristics which require modifications in voltages amperages magnetic field density and the dedicated collection media used within the electrostatic cell The cell provided in your unit has been built to meet a standard known requirement When discussing your unit with us or when ordering cells be sure to state the correct model number of the cell The cell model number is labeled in red on top of the cell i e R62CS 115 R614S 115 gt The cell manufacture date is included on the top of the cell A space for the installation date 1s conveniently located with this information FPRS 40 ABH Operations Manual SECTION 2 IMPORTANT GUIDELINES 2 1 0 2 2 0 2 3 0 2 4 0 2 6 0 Oil temperature should not exceed 150 F for cells Viscosity of the oilto be cleaned cannot exceed 1 800 SUS The minimum fash point of the oil should not be below 100 F Concentrations of water should not exceed 300 ppm If in excess the water absorber feature should be used to reduce the water content to an acceptable level less than 300 ppm before the electrostatic cell is employ
10. ABH Operations Manual A CAUTION Secure the discharge line before starting the program An un secured discharge line may whip causing personal injury and or property damage e Do not exceed 40 psi on any component in the system e Protect fluid lines from damage or puncture e Maximum fluid temperature is 150 iii FPRS 40 ABH Operations Manual SECTION I INTRODUCTION SYSTEM OVERVIEW The Finite Particle Removal System Patent Nos 5 149 422 and 5 242 587 uses the most advanced technology available to clean your oil The FPRS is designed to connect directly to your machine s reservoir using quick disconnects for maximum efficiency The FPRS draws the fluid into its system using its own pump The pump sends the fluid through a water absorber and an electrostatic cell to accomplish the cleaning process The fluid is then discharged through an output hose back into your reservoir The FPRS utilizes a combination of electrostatic and magnetic fields to remove submicronic particles from non flammable oils This is accomplished by electrically influencing the particles in the oil The influenced particles are attracted to one another and are retained by polyolefin foam used within ASL s patented electrostatic cell 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
11. BETWEEN THESE SURFACES WITH INSIDE CALI PERS OR FEELER GAUGE TO BE CERTAIN THE FACES ARE EQUAL DISTANCE APART AND PARALLEL FIGURE 3 2 Make final check on alignment after piping is hooked up Piping Hose The cause of many pumping problems can be traced to suction piping It should always be as large and short as possibie Before starting layout and installation of your piping system consider the following points 1 Never use piping smaller than pump port connections Piping larger in diameter than the port connection is some times required to reduce suction losses 2 Be sure the inside of pipe is clean before installing 3 When approaching an obstacie in suction line go around obstacie instead of over it Going over obstacle creates an air pocket Where practical slope piping so no air or liquid pockets will be formed Air pockets in suction line make it hard for the pump to prime 4 Astrainer on the suction side of the pump should always be considered in any pumping system The strainer will keep out foreign matter from entering the pump The strainer mesh or perforation size should be large enough so that it does not cause excessive pressure drop but it should be 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 discharge line See Pressure Relief Valves
12. General page 1 Item 4 6 Pump must not be used to support piping Weight of pipe must be carried by hangers supports stands etc 7 When fastening piping to pump do not impose any strain on pump casing Springing or drawing piping up to pump will cause distortion possible misalignment and probable rapid wear of pump Do not use pump to correct errors in piping layout or assembly 8 All joints of piping system must be tight pipe dope or tefion tape will help assure leak free threaded joints Since teflon has excellent lubricity be careful not to overtighten your fittings causing damage Leaks in suction line permitting air to be drawn in will cause a noisy pump and a 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 A rise in temperature will cause liquid to expand If there is no provision for pressure relief in the closed off section there is a chance that the pump or piping will rupture Before pushing start button check following 1 Vacuum and pressure gauges liquid filled on or near the pump Gauges are quickest and most accurate way of finding out what is happening in pump 22 For specific part numbers Refer to Repair Section 341 2 Alignment 3 There is no pipe strain on pump casing 4 Pump shaft turns freely whe
13. PUMP INC e A Unit of IDEX Corporation Cedar Fails lowa 50613 USA 21 Mounting 1 Surfaces pump mounts against must be clean and flat 2 Use only SAE Grade 5 capscrews for mounting pump 3 The 4 mounting capscrews for SG 04 and SG 05 pumps must have a minimum of inch thread engagement and must be torqued evenly to 12 15 ft Ibs 4 The 2 mounting capscrews for SG 07 pumps must have a minimum of Ve inch thread engagement 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 Donot strike or press pump drive coupling to install Internal pump damage will result If coupling does not slide on shaft inspect coupling shaft and key for nicks or burrs and remove If pump is to be belt or gear driven the overhung load option must be specified 8 Once pump has been mounted and coupling installed pump must be primed Squirt oil in suction port and turn pump by hand to make sure it turns freely Alignment Check alignment after mounting 1 If the pump is driven by a flexible coupling remove any coupling guards or covers and check alignment of coupling halves A straight edge piece of key stock works good across coupling must rest evenly on both rims at top bottom and sides Refer to Figure 3 USE STRAIGHT EDGE THESE SURFACES MUST BE PARALLEL 4 CHECK WIDTH
14. SBO C FPRS 40 80 ABH Other Custom Please call ASL 1 Low Conductivity 9 A 6 High Conductivity 6 6 Daimeter T 12 Diameter N New Spare R Rebuilt Common translations System Old Cell No New Cell No FPRS 40 ABH DS14M 115 N61CS 115 FPRS 40 ABH RC 06 115 R61CS 115 FPRS 40 SBO DS14M 115 N614S 115 FPRS 40 SBO RC 06 115 R614S 115 FPRS 80 SBO DS14M 115 N618S 115 FPRS 80 SBO RC 06 115 R618S 115 FPRS 200 HS23M 100 N622S 100 ABH FPRS 200 RC 06 100 R622S 100 ABH 18 PRODUCT SPECIFICATIONS FPRS 40 ABH PHYSICAL DIMENSIONS 49 H x 21 W x 22 5 D SHIPPING WEIGHT 300 lbs MOTOR 1 3 HP 1725 RPM 110 VAC 60 Hz 6 amps continuous 13 amps startup PUMP 40 gph w 100 SUS Fluid 1 2 NPT Side Ports Inlet and Outlet WATER ABSORBER 18 Stacked Water Absorber Element INLET amp OUTLET CONNECTIONS 1 2 Quick Disconnects SYSTEM VOLTAGE Input 110 VAC 60 Hz Circuit Breaker 10 Amp Output 15 Kv DC Manufactured in the U S A ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Ph 219 738 2777 Fax 219 733 2779 Email custsvc aslfilter com www aslfilter com 19 20 TECHNICAL SERVICE MANUAL INSTALLATION START UP TROUBLE SHOOTING PAGE 1 PREVENTATIVE MAINTENANCE DO S amp DON TS ISSUE A VIKING SERIES SG 04 SG 05 and SG 07 SPUR GEAR PUMPS PUMP General The following items must be considered prior to pump installa tion 1 Locatio
15. acceptance of delivery assumes all liability for the consequences of the use or misuse of Viking products by the purchaser his employees or others Viking will assume no field expense for service or 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 IS VIKING S SOLE WARRANTY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED WHICH ARE HEREBY EXCLUDED INCLUDING IN PARTICULAR ALL WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE No officer or employee of IDEX Corporation or Viking Purnp Inc is authorized to alter this warranty Copyright 1987 D in USA VIKING PUMP INC e A Unit of IDEX Corporation e Cedar Fails lowa 50613 USA End of Service Manual 26 VIKING a PUMP
16. ally When the cell becomes filled with contaminants and the amber Backflush light turns on the cell must be backflushed 3 1 3 2 3 3 3 4 A u M m u QR OW 3 6 AN 3 7 Qr 5 3 8 WARNING Turn OFF and unplug the FPRS Open the lid and remove the front panel Disconnect the input and output hoses from the cell and set aside Locate the 2 backflush hoses coiled inside the system Attach a hose to the quick disconnect at the bottom of the cell Place the end of the backflush hose into a 5 gallon pail Using the second backflush hose connect plant air supply REDUCED TO 10 PSTto the quick disconnect at the top of the cell Allow 10 psi of air to flush the contaminants out of the cell and into the pail for disposal Leave the air pressure on until contaminants are no longer dispensed out of the backflush hose A CAUTION Backflush hose will jump around as air reaches It 5 8 9 3 10 3 11 u u M 5 8 12 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 bottom of cell and gray hose to top of cell Replace the front panel close the top lid and plug m the FPRS Restart the system and check the Low Voltage light to ensure that it has gone out If it remains on refer to the Trouble Shooting section of this book FPRS 40 ABH Operations Manual 5 4 0 CELL REMOVAL Under normal operat
17. ber s of the item s you need The Spare Parts List includes the most frequently requested items The quantity needed Please remember to order spares if needed Order fulfillment information Preferred shipping carrier information Regular Second Day or Next Day Air Service Bill to Address Shipping Address we cannot ship to a P O Box Purchase Order Number Parts will be invoiced F O B Wanatah IN at the prices in effect at the time of the shipment Terms will be Net 30 days The ASL Representative for your area will be glad to assist you in obtaining prices and receiving purchase orders Should you prefer please contact ASL directly Order Address Telephone Toll free FAX E mail ASL Technologies LLC Parts Department 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 219 733 2777 888 333 2990 219 733 2779 custsvc aslfilter com ASL Technologies LLC SPARE PARTS Cabinet Interior For Cells see page 18 P 8 Power Supply Absorber Element Spark Plug Boot Spark Plug Terminal Interlock Switch Float Switch Pump Assembly Viking Pump Motor 40GPH Viking Pump Motor 80GPH Sample Port Control Panel Controls Circuit Breaker 10 amp Fuse 10 amp Relay 10 amp Relay Socket 10 amp Hour Meter Timer Solid State Current meter On Off Switch Assembly Rotary Knob Connector Contact Block Lamp Holder Lamp Lens red Lamp Lens Amber Lamp Lens White Lamp Amber Lamp Green Lamp Red On Off Switch Pr
18. conds OVERPRESSURE FLUID LOW TEMP WHITE LIGHT LOW VOLTAGE RED LIGHT To determine causes Shut power off on control panel Unhook cell high voltage lead and turn on power Momentarily depress cover safety switch and check microamp meter action high PUMP DOES NOT RUN POSSIBLE CAUSE FPRS unplugged Fuse on display blown Power switch defective Light bulb burned out Flow restricted down stream of pump Check oil temperature If oil temp is lt 95 F cold high viscosity oil If oil temp is gt 95 F Absorber filled with water or cell filled with dirt If red light flashes and microamp meter pulses near 0 power supply is malfunctioning If red light turns off and microamp meter steady 0 electrostatic cell has a high dirt or water content System has 15 second delay Electricity not getting to pump 12 REMEDY Plug unit in Replace fuse Call ASL for replacement Restart system If pump comes on in 15 replace bulb Check hoses for kinks check cell quick dis connects to make sure they are properly seated check return line valves to make sure they are fully open Heat oil gt 95 F Set selector valve on bottom of canister to Water Absorber Only and restart system If absorber pressure drops to normal lt 25 psi backflush cell 10 PSI MAXIMUM If absorber pressure stays high change absorber Change power supply Backflush cell checking progress by turni
19. d 3 Suction lift is too great or suction piping is too small 4 Liquid is vaporizing in the suction line before it gets to the pump If after consideration of these points pump still does not deliver liquid review again all points given under Startup Read through the following TROUBLE SHOOTING guide and try again If it still does not pump contact your Viking pump supplier A Viking pump that is properly installed and maintained will give long satisfactory performance If trouble does develop one of the first steps toward finding the difficulty is to install a vacuum gauge in suction line and a pressure gauge in discharge line Readings on these gauges often give a clue on where to start looking for trouble BEONE OPENING ANY VIKING PUMP OR OTHER APPROPRIATE OR CONNECTIONS 5 TURBINE ENGINE ere i ETOS HAS BEEN LOCKED OUT OR MADE NON K a VACUUM GAUGE SUCTION PORT High reading would indicate 1 suction line blocked valve closed strainer plugged pinch ed suction hose 2 line too small 3 liquid too viscous to flow through piping 4 litt too high Low reading would indicate 1 air leak in suction line 2 end of pipe not in liquid 3 pump is worn 4 pump is dry should be primed Fluttering jumping or erratic reading would indicate 1 liquid vaporizing 2 liquid coming to pump in slugs possibly an air leak or insufficient liquid above the end of the suction pipe 3
20. ed It is recommended the FPRS input hose be connected to or draw from the lowest point of a reservoir Therefore when hooking up to a reservoir for the first time or after a period of non filtration always drain free water from the bottom of the reservoir before using the FPRS The output hose should be returned to the highest point at the opposite end of the reservoir to ensure maximum distance between the input and output hoses FPRS 40 ABH Operations Manual SECTION 3 SYSTEM SAFETY FEATURES Your FPRS comes equipped with several features which are designed to provide operator and environmental safety Following is a brief description of these features 3 1 0 Safety switch If the cabinet lid is lifted while the FPRS is running the system will stop completely and red Low Voltage light will turn on 3 2 0 Float switch Ifa fluid leak develops and fills the drip pan in the bottom of the cabinet the float switch will be activated the system will stop completely and the red Float Switch light will turn on 3 3 0 Absorber Overpressure Fluid Low Temp If the fluid pressure within the absorber canister rises above normal operating limits the white Absorber Overpressure Fluid Low Temp light will turn on This feature has two stages 3 8 1 At 38 psi the warning light will turn on and the system will continue running 3 8 2 At 40 psi the warning light will remain on the system will continue running and the pump will
21. ells 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 50 days you will be invoiced separately for a core charge of 175 00 for each cell Thanks for your cooperation FPRS 40 ABH Operations Manual SECTION 9 WARRANTY INFORMATION ASL Technologies LLC ASL warrants this product to be free from defects in material and workmanship for a period of one 1 year from date of shipment excluding expendables in accordance with the following terms and conditions This warranty extends only to the original purchaser owner This warranty does not include damage to the product resulting from accident misuse or abuse improper installation or operation lack of 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 supplied under this warranty may be new or rebuilt at our option Labor charges will be without cost to the purchaser owner during the first ninety 90 days of the warranty period up to 335 hours of operation Owner will be responsible for all labor charges after this period The expense of delivering the product to ASL for warranty work and the expense of returning it back to the owner after repair or replacement will be paid for by owner ASL will assume no field
22. enter a bypass condition to ensure the pressure in the absorber canister does not rise above 40 psi 3 3 3 These conditions can be triggered by several causes 3 3 3 1 The system output has become obstructed i e the hose is kinked 3 3 3 2 The water absorber element has become saturated with water 3 3 3 3 The temperature of the oil being filtered has dropped to a point that it creates excessive pressure 3 3 4 For instructions on troubleshooting this warning condition please refer to Section 7 Trouble Shooting FPRS 40 ABH Operations Manual SECTION 4 SYSTEM PREPARATION NOTE IT IS EXTREMELY IMPORTANT THAT THE FOLLOWING STEPS BE DONEIN ORDER TO ENSURE PROPER SET UPAND OPTIMUM RESULTS FROM THE FPRS A 4 1 0 CAUTION Before plugging in this ASL unit check the polarity of your power source Also verify that earth ground Is present 4 2 0 Open the cabinet lid and remove the front panel to expose the internal mechanisms 4 3 0 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 4 4 0 Check the quick disconnects of the cells to ensure that they are locked in place The outer ring of the quick disconnects slide back to lock and unlock the disconnect A 4 5 0 CAUTION Do not operate the system with the front panel removed Replace the front panel and close the
23. essure Gauge 0 100 psi Water Absorber Assembly O Ring Buna Pressure Switch Pressure Switch Drain Valve Ball Valve 3 Way selector Valve Pressure Gauge 0 60 psi Hose amp Accessories Blue Push on Hose ft Gray Push on Hose ft 3 8 Gray Push on Hose ft 15 Input Output Hoses 2 ea NPT x Hose Barb 3 8 NPT x w Hose Barb 3 8 NPT x 3 8 Hose Barb Couplings QD Male QD Female 3 8 QD Male 3 8 QD Female Telephone R61CS 115 CS2223P8 WAEB18 727402 727006 07F038 M8700 SGO518 GOV SGO535 GOV TCM20 1 4 4A045 MDLI10 2W928 2 2A582E 711 0130 KMKRS5A115 S13260 B4KL2 B3M B4T10 B4F B4RH RED B4RH YELLOW B4RH WHITE 1050 QC3 1052 QC5 1050 QCI 7500K14 103D 208E R40 0009 PDA 4 4R4M C FL PDA 4 4R4M C HN MV608 4 VMEI1 A9 76 603 1 102D 204D 7212 501 BL 7212 501GY 7212 381GY AC708 15 30182 8 8 30182 6 8 30182 6 6 DHP880 DHS880 DHP660 DHS660 219 733 2777 Fax 219 738 2779 17 40 80 ABH 40 80 SBO AK KK KKK KKM KAKKKAKKK L L L L K KKK KK M A K E K lt s AK KK AK KK KKK KK KMK KKK AK KKM x KKKKK KK KKK ASL TECHNOLOGIES LLC ELECTROSTATIC CELL PART NUMBERS X X X X X F X Cell Type Cell Size Configuration System Press Temp Foam Size 100 Basic 115 Standard 150 Fine S Standard H High Press temp 2 FPRS 200 ABH 4 FPRS 40 SBO 8 FPRS 80
24. expense for service or parts unless authorized by it 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 arise 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 which 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 not allow limitation on how long an implied warranty lasts or the exclusion or 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 instructions on how to obtain warranty service contact ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Telephone 219 733 2777 Fax 219 733 2779 FPRS 40 ABH Operations Manual SECTION 10 ORDERING SPARE AND REPLACEMENT PARTS A Spare Parts List for your FPRS is included on the following page Prompt service can be given for spare or replacement parts if ASL has the following information l The part num
25. gh the output hose 5 4 14 WARNING Once fluid is dispensed through the output hose turn system OFF and unplug the FPRS 15 Open the lid remove the front panel and check for leaks 16 Replace the front panel and close the lid The FPRS is now ready to resume operation D 5 5 p 5 4 5 4 FPRS 40 ABH Operations Manual Under normal operating conditions water absorber elements should be changed out annually 5 5 0 CHANGING WATER ABSORBER ELEMENT 5 5 1 If the white Overpressure light is on and the oil temperature is gt 95 F the water absorber element may need to be replaced A 5 5 2 WARNING Tum OFF and unplug the FPRS 5 5 8 Open the lid and remove the front panel 5 5 4 Remove top and bottom hoses from cell at quick disconnect 5 5 5 Backflush cell See Section 5 3 0 5 5 6 Reattach only the blue hose to the bottom of the cell Leave the top hose disconnected 5 5 7 Ensure that the selector valve is set to Water Absorber amp Particle Filter position 5 5 Close the system output valve on back of the cabinet 8 5 9 Disconnect the fluid inlet hose quick disconnect at the pump 10 Open the drain valve on the bottom of the absorber can and place the hose in a pail 5 11 Apply 10 Ibs air to the top of the cell 12 When the oil flow stops loosen the T Bar at top of canister and remove lid 18 Remove used absorber element 14 Unpack new element Check to ensure that the gasket on the top and bott
26. ing conditions electrostatic cells should be changed out annually When you replace your electrostatic cell perform the following steps A A A A 5 4 1 WARNING Turn OFF and unplug the FPRS 5 4 2 Open the lid and remove the front cover 5 4 3 Disconnect the high voltage wires as follows 5 4 4 WARNING Short across the positive and negative electrodes using a screw driver with an insulated handle to dissipate static electricity 5 4 5 WARNING Each cell has a positive red lead and a negative white or green lead connected to it NEVER touch both leads at the same time 5 4 6 Disconnect the high voltage wire connections leading to the top of the cell using one hand grasp the boot connected to the white or green wire and pull up Repeat with the boot connected to the red wire 5 4 7 Remove the input and output hoses by releasing the quick disconnects 5 4 8 Loosen 4 attaching screws from outside of cabinet and lift the cell out of the cabinet 5 4 9 Replace with a new or rebuilt cell Ensure that the cell is inserted correctly with the high voltage wire leads pomting upwards 5 4 10 Attach quick disconnect with blue hose to the bottom of the cell and gray hose to the top of the cell 5 4 11 Replace the high voltage wires to the cell Red is positive White or green is negative 12 Replace the front panel and close the lid 4 13 Restart the FPRS and operate system for a few minutes Ensure that fluid is being dispensed throu
27. m has been designed to operate continuously on a fluid reservoir with little operator attention However it is recommended to check the control panel daily to monitor system condition 5 1 0 During normal operation the control panel should display the following 5 1 1 The green Power On light should be on 5 1 2 The red Low Voltage light should be off 5 1 8 The red Float Switch light should be off 5 1 4 The yellow Backflush light should be off 5 1 5 The white Absorber Overpressure Fluid Low Temp light should be off 5 1 6 The Microamperes meter should read between 0 and 650 microamps This meter provides a way for you to measure the amount of contamination collected inside the electrostatic cell The higher the reading the more contamination in the cell a prediction of how soon backflushing will be necessary 1 7 The Cell Pressure gauge should read between 0 and 40 psi 1 8 The Absorber Pressure gauge should read between 0 and 40 psi ny Gt Ji 0 5 2 0 If any of the warning lights 5 1 2 5 1 8 5 1 4 or 5 1 5 come on turn the Power Switch OFF and refer to the Trouble Shooting section of this book FPRS 40 ABH Operations Manual 5 3 0 BACKFLUSH OPERATION Backflushing of the cell is unique to the Finite Particle Removal System This operation allows the cell to be reused without being replaced under normal use Under normal operating conditions electrostatic cells should be changed out annu
28. n locate the pump as close as possible to supply of liquid being pumped If possible locate pump below liquid supply Viking pumps are self priming but the better the suction conditions the better the pump will perform 2 Accessibility pump must be accessible tor inspection maintenance and repair 3 Suction Discharge SG Series pumps are designed for clockwise rotation as standard viewed from shaft end Reter to Figure 1 SERIES SG 07 Pump Cutaway View Pressure Relief Valve the SG Series is a positive dis placement pump and therefore requires a pressure relief device in the discharge line to provide over pressure protec tion for the system Without pressure relief protection if the discharge line is blocked or becomes closed pressure will build up until motor stalls drive equipment fails a 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 items from occurring the use of a pressure reliet valve is recommended The pressure relief valve will relieve the pressure at a predetermined value thus protecting the entire system Storage if pump is to be stored drain pump and pournon detergent SAE 30 weight oil into pump port and rotate shaft to circulate oll Apply grease to pump shaft extension Viking suggests rotating pump shaft by hand one complete revolu tion every 30 days to circulate oil VIKING
29. n rotated by hand 5 Motor has been jogged and is runnng in right direction Refer to General page 1 Item 3 6 Pressure relief valve is installed properly 7 Suction piping is connected and tight and valves are open 8 Discharge piping is connected and tight valves are open and there is a place for liquid to go 9 All guards are in place 10 The above check list is a general guideline to be used prior to starting the pump Since Viking Pump can not foresee every application for our product and possible system de sign final responsibility is with the user The purnp must be utilized within the catalog specifications and the pump sys tem must be designed to provide safe working conditions The start button can now be pushed Pump must begin to deliver liquid within 15 seconds If not push the stop button Do not run pump without liquid flow longer than 30 seconds or pump will be ruined Review steps just outlined Consider what suction and discharge gauges indicate If everything appears in order re prime pump Refer to Mounting page 2 Item 6 Push start button If nothing is flowing within 30 seconds stop pump The pump is not a compressor it will not build up much air pressure It may be necessary to vent discharge line until liquid begins to flow It pump still does not deliver consider one or more of the following 1 Suction line air leaks 2 End of suction pipe not submerged deep enough in liqui
30. ng switch on every few minutes Backflush until microamp meter reads 100 uA when voltage lead is reattached Wait past delay period Check voltage at CR2 relay If not 110 Volts change CR2 relay FPRS 40 ABH Operations Manual Trouble Shooting Contd PROBLEM POSSIBLE CAUSE REMEDY SLOW OUTPUT FLOW Oil level in reservoir below Add oil or place hose properly intake Water absorber or cell Change or backflush as required over pressure Cold high viscosity oil Heat oil gt 95 F Normal operation of the FPRS will sometimes allow excess water or dirt to enter cells and shut down the system This condition does not damage unit Only cleaning or drying is necessary to return the unit to normal service Like all equipment training or experience is necessary to prevent the inconvenience caused by operator errors The system will not be damaged by operator error but some amount of time may be required to correct those problems Call anytime with questions or comments Customer Service and Satisfaction are ASL s 1 priorities 13 FPRS 40 ABH Operations Manual SECTION 8 CELL REBUILD PROGRAM The Electrostatic Cell in your FPRS Finite Particle Removal System was designed to provide many hours of superior filtration Like anything else it occasionally needs care and maintenance It 1s recommended that the Cell be rebuilt once each year 8 700 operating hours to insure optimum cleaning performance The re build e
31. om are in good condition Place inside canister 5 5 15 Apply a thin coat of your oil to the gasket on the canister lid Replace canister lid Hand tighten the T Bar Do not use a wrench 5 5 16 Close the lever spigot on the bottom of the absorber canister 5 5 17 Open valve on back of cabinet and connect hoses 5 5 18 Under normal circumstances the water absorber element should be changed out annually 10 FPRS 40 ABH Operations Manual SECTION 6 MAINTENANCE 6 1 0 DAILY MAINTENANCE 6 1 1 Check controls Control type Normal Condition Turns On At Red Low Voltage Light Off 700 uA Red Float Switch Light Off Full drip pan Amber Backflush Light Off 500 uA White Absorber Overpressure Off 38 psi Fluid Low Temp Light Green Power Light On N A Microampere Meter 0 500 uA N A Cell Pressure Gauge 0 40 psi N A Absorber Pressure Gauge 0 40 psi N A 6 2 0 MONTHLY MAINTENANCE 6 2 1 Check entire system for loose screws or connections 6 2 2 Inspect power cord for wear 6 2 3 Inspect unit for possible damage or leaks 6 5 0 YEARLY MAINTENANCE 6 8 1 Change out cells 6 8 2 Change out water absorber elements 11 FPRS 40 ABH Operations Manual SECTION 7 TROUBLE SHOOTING THE FPRS 40 ABH The following is a guide to solving problems which may occur while using the FPRS Use it as a guide but don t hesitate to contact an authorized FPRS dealer to answer any further questions PROBLEM NO GREEN POWER LIGHT se
32. vibrating from cavitation misalignment or damaged parts PRESSURE GAUGE DISCHARGE PORT High reading would indicate 1 high viscosity and small and or long discharge line 2 strainer or filter plugged 3 pressure relief valve set to high 24 4 valve in discharge line partially closed 5 line partially plugged from buildup on inside of pipe solified product or by foreign object 6 liquid in pipe not up to temperature Low reading would indicate 1 pressure relief valve set too low 2 pressure relief valve poppet not seating properly 3 pump mounting capscrews not torqued to specifications SG 04 and SG 05 series 12 15 ft Ibs 4 pump assembly bolts not torqued to specifications SG 07 series 50 55 ft Ibs 5 Bypass around pump partially open 6 too much extra clearance 7 pump damaged or worn Fluttering jumping or erratic reading would indicate 1 cavitation 2 liquid coming to pump in slugs 3 air leak in suction line 4 vibrating from misalignment or mechanical problems Pump does not pump 1 lost its prime from air leak or low level in tank 2 suction lift too high 3 rotating in wrong direction 4 motor does not come up to speed 5 suction and discharge valve not open 6 strainer clogged 7 bypass valve open pressure relief valve set too low or pressure relief valve poppet stuck open 8 pump worn out 9 any changes in liquid system or operation that would help explain the trouble
33. xchange program has been organized to provide minimum downtime and maximum performance All re built Electrostatic Cells contain all new internal parts and are subjected to the same final testing criteria as the new cells you received with your ASL FPRS system The only parts re used provided they meet spec are the end caps and outer tube When you receive your Electrostatic Cell 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 Look at the red tag on the top of the cell to locate your part number R61CS 1 15 for example Send your P O to ASL via Phone Fax mail or e mail custsvcQaslfilter com with the quantity and part number requested 3 When you receive your cell install it in your unit and return the used cell in the shipping box Please backflush the return cell for 15 minutes at 10 psi to drain as much fluid as possible no 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 c
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