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80 SBO Service Manual - ASL Technologies, LLC!

1. TAN When compared to values from virgin oil an increase on the TAN indicates oil serviceability with regard to oxidation or contamination with an acidic product Particle Count Monitors the oil cleanliness level to provide indication of filter efficiency and potential wear failures e Water Indicates the presence of moisture of coolant in the oil For detection of water content below 1000ppm the Karl Fischer method can be used Spectrochemical Elemental Analysis The presence of elements in solution i e additives wear metals and contamination elements FT IR Estimation of oxidation levels PIXIE Analysis of contaminant residue on patches 20 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww 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 In any case DO NOT exceed 8700 operating hours on Electrostatic Cells When the cell becomes filled with contaminants about 500 microamps and or the amber BACK FLUSH lamp illuminates the cell needs to be backflushed 1 2 10 11 12 13 14 WARNING Turn OFF the FPR
2. ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con 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 This manual covers the FPRS 80 SBO Mineral Oil Electrostatic System 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
3. See 15 below as well as the Transformer Section SERVICE SWITCH JUNCTION BOX The service switch interrupts the main power from the power cord to the control panel and is installed as an extra safety feature Inside the service switch box a terminal board carries power neutral grounds and the motor power On 220 240V systems the step down transformer is located on the back side of the backplane and 120 V power from the transformer is routed to the service switch box See 14 above as well as the Transformer Section OIL SAMPLE PORT The oil sample port is located in the pump outlet line just below the system pressure gauge This test port makes a convenient leak and contamination free port to draw oil samples A KP series thumb push sample valve is employed requiring no special tools or fittings to use In either case push the sample valve in for 30 to 60 seconds and flush the sample port into a waste bucket Using a clean sample bottle remove the lid and invert it to prevent ambient dust or dirt from contaminating the sample Fill the bottle to within 1 2 of the top Immediately install the cap securely Note that this port is before any FPRS filtration Note also that the FPRS must be running to draw the sample 11 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com 17
4. 18 19 20 21 22 23 24 25 26 27 28 29 30 PRESSURE SWITCH The pressure switch mounted on the water absorber canister is an adjustable normally open switch This switch is factory adjusted to turn on the Over Pressure Low fluid temp light 4 when pressure in the canister reaches approximately 39 psi FLUID INLET PORT Connect your fluid inlet line from the bottom of your reservoir to this 1 2 NPT port 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 ELECTROSTATIC CELL BY PASS VALVE This two position red handle valve is used to direct fluid flow through the system With the valve in the horizontal position as shown fluid is directed from the water absorber through the electrostatic cells and on to the outlet port This is the normal operating position The second position vertical can be used to direct flow from the water absorber directly back to the outlet port by passing the Electrostatic Cells This position may be used for water absorber only filtration of the fluid A legend showing and describing this valve is located on the water absorber canister jus
5. Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com CELL REMOVAL INSTALLATION Under normal operating conditions cells should be changed annually When you replace your electrostatic cell perform the following steps A A A 1 2 10 11 12 13 14 15 WARNING Turn OFF the FPRS on the control panel and at the electrical source Remove the front cover Disconnect the high voltage wires as follows WARNING Short across the positive and negative electrodes using a screwdriver with an insulated handle to dissipate static electricity WARNING Each cell has a positive red lead and a negative green lead connected to it NEVER touch both leads at the same time Disconnect the high voltage wire connections leading to the top of the cell using one hand grasp the boot connected to the green wire and pull up Repeat with the boot connected to the red wire Remove the input and output hoses by releasing the quick disconnects Loosen 4 attaching screws from outside of the cabinet and lift the cell out of the cabinet Replace with a new or rebuilt cell Ensure that the cell is inserted correctly with high voltage electrodes pointing upwards Attach quick disconnects to the cell s Replace the high voltage wires to the cell Red is positive Green is negative The label at the top of the cell notes the
6. Power applied to the rotor is transmitted to the idler gear with which it meshes The space between the outside diameter of the idler and the inside diameter of the rotor is sealed by the crescent As the pump starts the teeth come out of mesh increasing the volume This creates a partial vacuum drawing the liquid into the pump through the suction port The liquid fills the spaces between the teeth of the idler and the rotor and is carried past the crescent partition through the pressure side of the pump When the teeth mesh on the pressure side the liquid is forced from the spaces and out through the discharge port 43 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com JN WARNING Failure to follow these instructions could result in serious bodily injury or death These pumps should not be used for handling plain water corrosive or abrasive liquids or liquids not possessing adequate lubricity Do not attempt to work on any Tuthill pump installation before completing the steps below Disconnect the drive so that it cannot be started while work is being performed Review the Material Safety Data Sheet MSDS applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling Vent all pressure within the pump throug
7. These P units will have all BLACK hoes and the Electrostatic Cells will have BLACK TUBES with WHITE ends Check with ASL prior to filtering fire resistant lubricants as these are extremely destructive to certain plastics and seal materials ASL sells or can modify existing units for Phosphate Ester fluid filtration S Series units built for Phosphate ester operation will have P in the Model number i e FPRS S80P SBO 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 or greatly reduced to less than 500 ppm 3 Contamination Rate systems that produce excessive contamination may quickly overwhelm this product especially if the contaminant is conductive i e EDM grinding and polishing systems etc 17 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww 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 APPROPRIATE LOCATION Avoid locations that expose this product
8. Using an insulated screwdriver short across the POS and NEG terminals of the Electrostatic Cell to dissipate any static electricity 2 Using one hand remove the POS terminal from the Electrostatic Cell 3 Remove the six allen head screws securing the lid to the Cell cabinet and carefully swing the lid upward to expose the lid wiring 4 Cut all ty wraps securing the POS and NEG leads from the cell to the power supply 5 Locate the two pin 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 7 Remove the two 8 32 nuts from the studs and remove the power supply from the unit Note that the red high voltage lead and spark plug terminal boot remain attached to the power supply 8 Install the new power supply in the reverse order Note that replacement power supplies have a relatively long Positive lead with the boot and terminal installed at the factory Take care when coiling up the excess length to tie it out of the way of the cover 9 Plug in the three spade connectors to the power supply observing wire color codes and power supply connector labels Red wire to HOT Green wire to GND and white wire to HOT Connect the two pin yellow orange connector to the harness and re install the wire trough cover if changing P S 2 Electrostatic Cell See page 22 in this manual Wat
9. e Remove the cover screws e Rotate the cover 180 so that the boss on the cover points to the new suction inlet port e Align the mounting holes and reinstall the cover screws Note Location of the suction port cannot be changed in the field on RLEV pumps unless the housing is replaced Troubleshooting No fluid is delivered e Power is not on e Net positive suction head available NPSHA is lower than required for the inlet conditions and the vapor pressure of the liquid pumped Calculate NPSHA and redesign piping if necessary e Leaks in suction line or port passages These can be detected by submerging the pressure line from the discharge side of the pump into a pail of liquid where the air will be seen in the form of bubbles e Direction of shaft rotation is incorrect e Pump shaft is not rotating The coupling is defective or the tongue and groove are not engaged e The relief valve setting is too low Liquid is discharging through the by pass port On ASL Filtration Systems the by pass should be set so the pump enters full bypass at 40 psi maximum Capacity is too low e There are air leaks in the suction line e Suction losses are too high The suction lift is too great or the suction line too small or too long This can be detected by installing a vacuum gauge directly at the pump suction The maximum vacuum at the pump suction should never exceed 15 of mercury Vaporization caused by higher vacuums will gen
10. the amber BACK FLUSH lamp will illuminate and at 700 microamps the red LOW VOLTAGE lamp will illuminate and the system will shut down FLUID OUTLET RETURN TO RESERVOIR The fluid outlet port is located on the back side of the backplane and is a 2 female NPT port Connect your return to reservoir hose to this port WATER ABSORBER PRESSURE GAUGE This gauge located at the inlet side of the water absorber indicates pressure in the water absorber canister Under normal conditions warm fluid fresh water absorber element this gauge should read approximately 10 to 20 psi As water is trapped and held in the canister this indicator will gradually rise and is an indication of impending water absorber element change At 43 psi the pressure switch 17 will close illuminating the 4 white over pressure fluid low temp indicator WATER ABSORBER BLEED VALVE This valve is used to bleed any entrapped air in the water absorber canister during initial startup or when the water absorber element has been replaced POWER CORD A three prong standard grounded power cord is wired into the terminal board in the service switch box This cord is approximately 9 feet long Note that if your system is factory set up for 220 240 VAC input there will be no power cord attached to the service switch box Instead input power wiring will come from the step down transformer located on the rear of the backplane behind the Service Switch box
11. turn the pump adjusting screw inward clockwise until the desired pressure is reached Adjusting clockwise raises the pressure setting GOST ION OP Os Bat 37 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com 10 11 12 13 14 15 16 17 Loosen the Phillips retaining screw on the pressure switch wiring connector and separate the connector from the switch Using a small flat blade screwdriver remove the brass screw from the bottom of the pressure switch and set aside Pressure switch adjustments are made with an 1 8 allen wrench into the bottom of the pressure switch through the hole where the brass screw was removed in step 10 With 38 psi showing on the water absorber pressure gauge temporarily re connect the pressure switch connector If the white light is lit remove the connector and using the 1 8 allen wrench turn the adjusting screw in the pressure gauge counterclockwise to lower the pressure at which the switch closes and lights the white light Re connect the pressure switch connector temporarily to observe the results of your adjustment Turning the pressure switch adjustment screw clockwise raises the set point counterclockwise lowers the set point Continue to make small adjustments to the pressure switch until the white light just comes on
12. Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww 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 120 VAC present and the power switch 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 completely when defective See the MAINTENANCE section for instructions RED OVER PRESSURE FLUID LOW TEMP LIGHT Illumination of this lamp indicates an overpressure condition has occurred The overpressure light is actuated by a pressure switch located on the water absorber canister The pressure switch is set to close illuminating the light at approximately 43 psi on the water absorber pressure gauge Illumination of this lamp can be caused by water accumulation in the water absorber element or by low fluid temperature Note that at approximately 40 psi the pump will go into by pass to prevent over pressurization of the system AMBER BACKFLUSH LIGHT This lamp comes on when the Electrostatic Cell needs to be back flushed with shop air The signal to illuminate this light comes from a relay inte
13. Number ANNAN Parts will be invoiced F O B Wanatah IN 46390 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 46390 Telephone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 E Mail custsve aslfilter com Internet www aslfilter com 27 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com FPRS S80 SBO Spare Replacement Parts DESCRIPTION PART NUMBER Call ASL for any parts not listed O O i O Water Absorber Housing with lid clamp AST 8018 and O ring Electrostatic Cell R61CS 115 See red tag on top of cell for Pewweeh sewenetparamiay Laminated wiring diagram Inside front FPRS S80 Wiring Diagram cover Power Switch Control Panel 7500K14 White Lamp Assy Over press 1050 QC4 44045 Green Neon Power Lamp Ass 1052 QC5 Amber Lamp Assy Backflush 1050 QC3 Relay CR 1 through CR 3 LY2 120VAC 10 Amp contacts Red Lamp Assy Low Voltage 1050 QC1 PDA 4 4M C HN HNV 38 NPT F V Oil Sample Test Port and Water Absorber KP14N V 1 bleed port Push to test type Viton Transformer step down 50Hz QICSXEKF 1 5 KVA ASL Technologies LLC 10525
14. 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 custsvc 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 10 minutes at 10 psi to drain as much fluid as possible You should order your re built cells early so you won t be down waiting for your new Cells to arrive Please remember to backflush returned cells prior to sending them back to us This will save you on shipping costs a re built cell weighs 16 pounds and most Returned cells weigh in at 28 pounds as well as saving the environment as we have to dispose of the used contaminated oil and internal components Note that if the used cells are not returned to us within 30 days you will be invoiced separately for a core charge for each cell not returned If you want to stock spare cells the 30 day core charge return can be extended 24 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 33
15. com 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 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 J N safety alert symbol is used with signal words WARNING and CAUTION to call attention to safety statements WARNING statements identify procedures or practices which must be followed to avoid serious personal injury or loss of life JN caution statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment ELECTRICAL SAFETY WARNING ELECTRIC SHOCK can kill Your FPRS uses a high Direct Current voltage of 15 000 volts Do not touch live electrical parts Always disconnect power source before working on the system Avoid accidental starting Make sure unit is turned OFF and is unplugged or disconnected from its power source before beginning any maintenance tasks This product must be earth grounded to operate safely and properly This product is not explosion proof Do not use near combustible or highly fla
16. for the particles and holds them in place This collection of particles is a phenomenon known as strawing Your FPRS comes equipped with a water absorption unit that can remove free and emulsified water down to tolerable levels The 8 X 18 element in your FPRS 80 SBO unit is capable of holding 2 1 quarts of water This feature covers a wide range of water problems Each fluid to be cleaned has its own characteristics which may require modifications in magnetic field density and the dedicated collection media used within the electrostatic cell The cell provided in your unit has been built to meet your specific requirements Therefore when discussing your unit with us or when ordering cells be sure to state the correct model number of the cell The model number is shown on a red tag on top of the cell i e R61CS 115 R62CS 115 etc Note that Phosphate ester fluid compatible cells have a B in the part number i e RB66CS 115 etc 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 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 B
17. for you and your company ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww 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 an Electrostatic Cell 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 electromagnetic 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 400 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 filter inside the cell becomes a home
18. from the shaft on all models except 2LA 2LE and 5LE e Mark the cover and housing of the pump for proper re assembly e Remove cover screws cover idler and rotor from the housing Check the pump housing rotor idler gear idler pin and cover for wear and chipped or broken teeth The housing bore and rotor OD may be checked for wear by positioning the rotor in the housing and checking for clearance in the bearing The shaft must turn freely without any detectable side play Any side play will require replacement of the housing and or rotor If either of these two parts must be replaced it is economically advisable to replace the entire pump Assembly of Pump The following must be carefully followed when the pump is re assembled e Clean all parts thoroughly using great care to eliminate all dirt e Install the rotor in the pump housing e Apply the gasket to the cover Use a new gasket if the old one is damaged Models 30LA 30LE and 5LE are also supplied with an O ring in the cover Replace if damaged e Place the idler gear on the pin in the cover assembly e Place the cover assembly with gear on the pump aligning the matching marks for proper location e Install the cover screws Tighten gradually alternating from a screw on one side to a screw on the opposite side e Install the snap ring on the shaft except models 2LA 2LE and 5LE ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2
19. 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 CR 2 or the Pump TR will cause a change of state in CR 3 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 42 The pump and motor consists of three basic parts which are all easily field replaceable The pump itself is attached to the motor housing with 3 20 x 4 long bolts and lock washers Coupling the pump to the motor is a three piece tang coupler which consists of two hard plastic splines and a center metal adapter Note that the pump shaft has the male tang and the motor shaft is the female end Replacement of the pump or coupler is straightforward and should present no problem for maintenance See the following section for removal and replacement of the pump along with required adjustments REMOVAL AND REPLACEMENT OF COMPONENTS Front Panel Indicator Lights These lights are the non relampable type and are a snap fit into the top cover Remove the two 186 spade connectors and compress the tangs on the sides of the lamp using thumb and forefinger Push the lamp from the back out through the front cover Replacement lights are available fr
20. input power see the Transformer Section on page 3 8 Turn on the service switch then the Power Switch to the ON position The green Power lamp should illuminate Note that the Red Low Voltage lamps illuminate momentarily and then go out 9 The Fluid Delivery System pump motor will start following a 15 second time delay and begin drawing fluid from your reservoir 10 Note that the pump may need to be primed before any outlet flow is observed 11 The S Series pumps will only lift fluid about 24 inches 12 Your system was tested with standard hydraulic 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 gauge is not observed within 4 5 minutes turn power OFF and make sure the inlet hose is primed 13 As the system fills with fluid bleed off entrapped air in the water absorber canister by opening the brass valve on the canister lid Close the valve when air has been bled off 14 Once positive flow is observed from the system outlet check for any leaks inside the Electrostatic Cell cabinet and re install the front cover ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter
21. positive and negative electrodes Be sure to fill in the Date Installed on the cell tag Replace the front cover Restart the FPRS and operate system for a 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 Remove the front cover and check for leaks Replace the front 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 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com WATER ABSORBER ELEMENT REPLACEMENT If the pressure gauge on the water absorber element is above its normal running pressure it 10 11 12 13 may need to be replaced 35 psi WARNING Turn OFF the FPRS on the control panel and at the power source 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 the Water Absorber bleed plug on top of the water absorber canister When the oil flow stops loosen the 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 ho
22. 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 120VAC power at relay TR T 9 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 33 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com present check the white neutral also replace the meter If voltage is not present check the wire running from TR T 9 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 TR T 1 If voltage is present there should be power on TR T 11 and after 15 seconds on TR T 9 If no voltage on TR T 9 replace the TR relay If no voltage present on the coil of TR T 1 trace backwards to CR2 4 CR2 6 CR1 3 CR1 5 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 relay CR 3 These contacts are brought out to the lid terminal board and labels RAC common RA1 normally open and RA2 normally closed These two contacts are for customer interface with an outside
23. shipped with port plugs in the top ports To adapt to a 90 porting arrangement the plugs must be relocated Because of its size the 5LE will not mount onto a NEMA 48 frame motor unless the motor is shimmed approximately 1 With the ports facing up and viewing the pump from the shaft end the inlet port is on the right for clockwise rotation and on the left for counter clockwise rotation Pumps with built in relief valves are directional Therefore rotation must be specified at time of order The adjusting screw of the internal relief valve must always be located on the suction side of the pump Pumps should be filled with oil at installation and should never be allowed to run dry Every pump installation should have a good foundation Its structure should be sufficiently strong to hold the pump rigid and to absorb any strain or shock that may be encountered The installation should be leveled checked for proper piping alignment and then fastened securely Method of Drive Direct drive through a traditional flexible coupling is recommended However do not expect the flexible coupling to compensate for misalignment Contact the coupling manufacturer to determine the maximum amount of misalignment to which the coupling can be subjected LA and LE Series pumps can be driven in either direction of rotation unless outfitted with an internal relief valve The seal chamber communicates with the neutral zone and therefore the seal is subjecte
24. the contacts of the pressure switch close power which has been sitting on terminal 1 of the PS1 pressure switch is allowed to travel through terminal 3 and on to the white light on wire 1061 This fault will not shut the system down It s cause is either improper adjustment excessive water accumulation in the canister or low fluid temp MICROAMMETER The microammeter located on the front panel 28 indicates in micro amps how much current the Electrostatic Cell is pulling from the high voltage power supply The microammeter shows the general condition of the cell and is a good way to predict impending maintenance actions As stated previously in this manual the microammeter has two readings that are related to two indicator lights on the front panel 1 At approximately 500 microamps the amber Backflush light will light indicating that Electrostatic Cell backflush is required Shut down the system and backflush the Cell in accordance with the instructions on page 21 of this manual Note that under normal operating conditions the microammeter will rise slowly toward 500 giving maintenance adequate warning that backflush time is approaching Note that the system will continue to operate beyond 500 microamps all the way up to 700 microamps when the Low Voltage light comes on and the system shuts down Operation above 500 microamps for any extended period of time is not recommended and the cell should be backflushed or repl
25. 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 cells and water absorber element Finally avoid installing in high traffic areas where this product may be easily damaged by vehicles forklifts etc SYSTEM CONSIDERATIONS 1 Main Power Supply Source 120 volts AC 60 Hz single phase Or 220 240 VAC 50 60 Hz if Transformer equipped 10 amps Circuit Breaker 16 ga Power cord provided on 120 Volt domestic models only Earth Ground Vertical Orientation Ambient temperature less than 160 F o o oO Fluid Delivery Pump Motor The self contained pump and motor delivery system allows for continuous filtration even during machine downtime Installation is convenient and maintenance does not require shutting down the hydraulic system A pump motor assembly is provided which is designed to be compact and is for continuous duty maintenance free and has been sized for the correct flow rate Hydraulic Connections All the connections between the reservoir and the FPRS System can be with hard piping or hose connections On the S Series units 2 NPT bulkhead fittings are provided for your convenience Note that on SBO units the inlet to the FPRS is directly to the pump also 1 2 NPT 18 ASL Tech
26. 3 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com WARRANTY INFORMATION ASL Technologies LLC ASL warrants this product to be free from defects in material and workmanship for a period of one 1 year from date of shipment excluding expendables in accordance with the following terms and conditions This warranty extends only to the original purchaser owner This warranty does not include damage to the product resulting from accident misuse or abuse improper installation or operation lack of 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 original purchaser owner during the first ninety 90 days of the warranty period up to 500 hours of operation except in the case of FPRS units which were sold and shipped outside the United States In those cases ASL will only be responsible for supplying repair parts once the original parts are returned to ASL and determined to be defective 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 unle
27. 777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Assembly of Seal e Clean all parts thoroughly using great care to eliminate all dirt e Oil the shaft with a suitable lubricating oil If the pump has an EPR seal apply a silicon based lubricant instead e Apply the appropriate lubricant to the inside of the new seal assembly For standard full length shafts with flat and or keyway e Place seal assembly on the pump shaft e Push seal down with your fingers to a position approximately half way down the shaft For modification A tang shafts The ASL Pump is a Mod A shaft e Use tapered plastic sleeve available from Tuthill as part number 1LPF 531 7010 e Lubricate the sleeve e Place seal assembly on the sleeve The tapered end of the sleeve fits into the spring end of the seal assembly e Place the slotted end of the sleeve on a bench Press down on the carbon face of the seal with your fingers and slide the seal to about the midpoint on the sleeve e Place the slotted end of the sleeve over the tang on the pump shaft Line up the outside diameters of the sleeve and shaft by eye e Push seal down with your fingers so that it passes from the sleeve to a position approximately halfway down the shaft e Press the stationary face into the housing plug The lapped surface must be up Protect this lapped surface by covering it with a piece of paper when pres
28. ASL is always available to help in any way possible Critical information has been supplied to assist you with the theory operation and maintenance of the S Series Finite Particle Removal System Questions or concerns should be addressed to ASL Phone numbers FAX numbers and email address are at the top of each page in this manual ASL Trcmovocrs LLC Fup Purmcanon 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 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con Www aslfilter com Table of Contents Subject Page Transformer section for 50Hz input models only 3 Quick Startup Guide 4 Important Safety Information 5 Introduction System Overview 7 Important Guidelines 9 System Safety Features Indicators Switches and Lights 9 Front Panel Controls Indicators Cell Side Photo 14 Front Controls Water Absorber Side Photo 15 Front Control Panel Inside Photo 16 Installation Considerations 17 Fluid Maintenance 20 Cell Backflush Operation 21 Cell Removal Installation 22 Water Absorber Replacement 28 Electrostatic Cell Rebuild Program 24 Warranty Information 25 Product Specifications 26 Parts Ordering Information 2a Spare Replacement Parts List 28 Wiring Diagram 29 Maintenance and Troubleshooting 30 Removal and Replacement of Components 34 Pump and Pressure Switch Adjustments sf Scheduled Maintenance Tasks 38 Fluid Flow Diagram 39 Unit D
29. Cell can short due to ingestion of water or accumulation of an excessive amount of particulate particularly ferrous particulate a Turn power off and un plug the FPRS from the power source b Using a screwdriver with an insulated handle short across both POS and NEG terminals of the Electrostatic Cell to dissipate any static electricity Remove the red POS spark plug boot terminal from the Electrostatic Cell Remove the wire from TR terminal T 11 to prevent the pump from starting Re connect power and turn on the power switch USE CAUTION If the low voltage light is now off the Electrostatic Cell is shorted and should be backflushed and or replaced g If the low voltage light is on with the Cell disconnected the power supply is defective and should be replaced h Note that it is possible to have both a shorted Cell and a bad power 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 or CR 2 relay and associated wiring can also cause a low voltage indication mono A 2 Defective Power Supply If the internal normally closed low voltage relay in the power supply is defective a low voltage indication will result Trouble shoot this failure as follows Turn power off and un plug the FPRS from the power source Remove the wire from TR terminal T 11 to prevent the pump from starting Remove the POS spark plug boot terminal from the Electrostatic Ce
30. S on the control panel and at the electrical source Remove the front cover Disconnect the input and the output hoses from the cell and set aside Connect a backflush hose to the quick disconnect at the bottom of the cell Place the end of the bottom backflush hose into a 5 gallon pail 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 flush the contaminants out of the cell and into the pail for disposal Leave the air pressure on until contaminants are no longer dispensed out of the backflush hose about 10 minutes CAUTION BACKFLUSH HOSE WILL JUMP AROUND AS AIR REACHES IT Repeat this procedure for the other Electrostatic Cell Remove the backflush hoses and replace the input and output hoses to the top and bottom of the cell at their original configuration Blue hoses to the bottom of the Cells and Gray hoses to the top of the cells The top of the cell connects directly to the bulkhead output fitting Turn ON the electrical service to the FPRS Restart the system and check the amber BACK FLUSH light to ensure that it has gone out If it remains on refer to the Maintenance section of this manual Observe that the microamp meter is now below 500 microamps Over time backflushing may no longer be effective and the Electrostatic Cell must be replaced 21 ASL Technologies LLC 10525 W US Hwy 30
31. SIONS Filter Cabinet 27 Hx20 Wx 11 D Backplane 30 H x 40 W Water Absorber Canister 24 H x 10 5 Dia Front to back 15 5 maximum 19 for xformer models Total size when mounted on stand with wheels 40 wide x 36 tall SHIPPING WEIGHT 300 Ibs MOTOR 1 4 HP 1725 RPM 110 VAC 60 Hz 5 amps continuous 8 amps startup PUMP 80 GPH w 100 SUS Fluid 1 2 NPT Side Ports Inlet and Outlet WATER ABSORBER 18 Absorber Element INLET amp OUTLET CONNECTIONS 1 2 NPT SYSTEM VOLTAGE Input 110 VAC 60 Hz Or 220 240 50Hz Circuit Breaker 10 Amp Output 15 Kv DC Manufactured in the U S A 26 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com ORDERING SPARE AND REPLACEMENT PARTS A Spare Parts List for your FPRS is included on the following page Prompt service can be given for spare or replacement parts if ASL has the following information 1 The part number s of the item s you need The Spare Parts List includes the most frequently requested items 2 The quantity needed Please remember to order spares if needed 3 Order fulfillment information Preferred shipping carrier information ASL is an On Line daily UPS shipper Ground Next Day Second Day etc Bill To Address Ship To Address we cannot ship to a P O Box Purchase Order
32. Turn the POWER switch on the Service Switch panel to the ON position and turn the front panel power switch to the ON position The green POWER lamp will illuminate and remain on Note that the red LOW VOLTAGE lamps will flash and then remain off Following a 15 second time delay the FPRS pump will start running and draw fluid from the reservoir into the FPRS Check for any external leaks When output flow is observed Turn the POWER switch OFF Remove the front cover Check to ensure there are no leaks internally Locate the red tag on top of the Electrostatic Cells 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 Your FPRS system has been designed to operate continuously on a fluid reservoir with little operator attention However it is recommended to check the control panel daily to monitor system condition See page 38 for Scheduled maintenance Tasks 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
33. W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com FPRS 80 SBO Wiring Diagram smn Wass ELEELE 29 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww 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 call away should you need any advice or assistance ELECTRICAL THEORY OF OPERATION Refer to the wir
34. aced as soon as practical 2 At approximately 700 microamps the red Low Voltage light will come on and the system will shut down Unless the reservoir is suddenly flooded with water or the high voltage power supply fails you should never see the Low Voltage light come on The microammeter on your FPRS system should be checked frequently When the system is new and the oil in your reservoir is clean microamp readings will be low Normally the meter will climb very slowly over time and may take months to reach 500 On other systems the meter could start at 200 and slowly climb or even go down over time The main thing to watch for is erratic movements rapid climbing etc A rapid climb most always indicates water has entered the system and finding and correcting the source of the water intrusion should be paramount Once water has entered the Electrostatic Cell concentrations of 500 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 ELAPSED TIME METER The elapsed time indicator on the front panel reads in hours and hundredths of hours The meter is very accurate and reads to 99 999 99 hours Over 11 years There are hundreds of ASL systems in the field with 70 and 80 thousand hours on the clock The meter runs on 120 VAC 60 cycle or optionally 50Hz single phase power which comes from TR T 9 wire 1031 This
35. between 38 and 39 psi Use your outlet ball valve to lower and raise the pressure until the setting is correct Once you can slowly raise the pressure and have the light come on at 38 to 39 psi the pressure switch adjustment is complete Re install the brass screw and the wiring connector Open the outlet ball valve and let the system flow for a few minutes as prolonged operation with the outlet restricted can cause pump overheating Slowly close the throttling valve fully Adjust the pump bypass until the gauge on the water absorber canister reads 40 to 41 psi 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 Once all adjustments are complete open the throttling valve completely tighten down the locking nut and replace the acorn nut on the pump by pass valve SCHEDULED MAINTENANCE TASKS The following is a recommended scheduled maintenance plan which is intended to provide maximum performance from your FPRS unit DAILY 1 Check that green Power lamp is illuminated 2 Check that pump motor and hour meter are running 3 Check system pressure gauge below 35 psi 4 Check Microammeter below 500 microamps WEEKLY 1 Remove the front cover and check for any internal leaks 2 Check for loose relays wiring and connections for security 3 Re install the front cover 4 Perform the daily checks a
36. com TUTH LL 12500 South Pulaski Road Pump Group a cine on om email tuthillpump tuthillcom www tuthillLcom On Installation and Service Instructions L Series Pumps S 80 0 LEV 040 CC A 7 42 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com General Description Tuthill s LA and LE Series are compact highly efficient cast iron positive displacement rotary gear pumps with a mechanical seal Built in six sizes they provide nominal capacities from 5 to 14 gallons per minute and pressures up to 500 psi 300 psi in the 5LE They are self priming and particularly suited to handle liquids of 35 to 1000 SSU viscosity Higher viscosities can be handled at reduced speeds The LA Series is supplied with a two bolt flange the LE Series with a three bolt flange Optional mounting feet are available for both Series An internal relief valve is an option with the LE Series Both Series are bi rotational unless outfitted with a relief valve and designed for direct drive at standard motor speeds with modifications available for indirect drive The Pumping Principle Tuthill s LA and LE Series employ the internal gear pumping principle There are only two moving parts Pumping action is based on a rotor idler gear and crescent shaped partition cast integral with the cover
37. d to approximately one half of the discharge pressure All pump and motor units must be properly aligned during assembly and periodically checked since misalignment may occur later due to abuse or other conditions Pipe strain can force the pump and motor shafts out of alignment Therefore all piping to the pump must be properly supported Do not allow the pump to act as a pipe support Provide for proper expansion of pipes when handling hot liquids Allow pump to reach operating temperature slowly Rapid temperature change can result in damage to the cast iron components Recheck the alignment Never align a pump and motor supplied with a pin type coupling without first removing the pins Never depend upon sight or feel Use proper gauges when aligning the pump Never operate the pump without all guards in place 45 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Relief Valve Protection The LA and LE Series are positive displacement pumps As the pump rotates liquid is positively delivered to the discharge side of the pump If the discharge line is closed off pressure will increase until the drive stalls and or fails the pump breaks or ruptures or the piping bursts To prevent this from happening the use of a pressure relief valve is required A relief valve that directs the flow bac
38. ectly into the Service Switch box on the front of the unit The secondary connections X1 amp X3 and X2 amp X4 are paired together and wired for you Black hot to X1 amp X3 and white neutral to X2 amp X4 Following wiring of your input power to the primary side of the transformer perform the following voltage checks 1 Secure incoming power to the transformer 2 Using a small straight blade screwdriver remove the cover from the SERVICE SWITCH box on the front of the FPRS 3 Making sure the service switch is in the OFF position and using caution apply your input power to the transformer 4 Using a suitable voltmeter measure between terminals H and N on the Service Switch terminal board You should read 120 132 VAC If voltage is correct proceed with step 5 If voltage is not between 120 and 132 VAC DO NOT TURN ON THE SERVICE SWITCH Ascertain the cause and repair before continuing 5 Providing the power measured in step 4 above is correct secure incoming power to the transformer and re install the service switch box cover ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww 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 sk
39. ee 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con Www aslfilter com FPRS S80 SBO Dimensions a 40 00 ASL Tecvewouocies LLC 36 LY Fum Purmcanon System gy a 40 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com Motor Service Data Nameplate Data P N 88514 Note 88471 50 60 Hz motor wired the same way Model 34G510 5506 P N 88514 Volts 115 208 230 Hz 60 KVA Code L H P FR 48 YZ Phase 1 RPM 1725 SF 1 35 ENC TEFC Max 40 C FLA 5 0 2 6 2 5 Amb 104 F INS B SFA 5 6 3 2 8 Tine on Baldor Motors Rate Duty NEMA Eff 55 PF 57 Motor Wiring Data Grey Baldor Motor Only Motor is ASL Factory wired Lo Volt CW Rotation 2 White 5 Lo Volt lt Factory Wired this wa 8 3 1 Black 1 L1 3 ake woe 8 5 4 L2 Do not reverse rotation The following pages contain the Installation and Service Instructions for the Tuthill L Series pumps The model used in the ASL FPRS S80 Cabinet is OLEV 040 CC A The manual is reprinted with permission from the Tuthill Pump Group 41 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com 1 www aslfilter
40. elay is installed for those customers desiring a Remote Alarm indication of system operation and is tied to the output of the Time Delay relay See the system schematic on page 29 for wiring options TERMINAL BOARD T 1 This terminal board serves as a connection point for wiring to and from the lid assembly Remote alarm connections are brought out here for facilitation of remote alarm wiring by the customer POWER SUPPLY 2 This power supply connects to the 2 Electrostatic Cell right side of cabinet and supplies 15 KVDC power to the cell Note that a LOW VOLTAGE 2 light indication will come from this power supply Power supply 1 and 2 are identical 13 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con Www aslfilter com FPRS 80 SBO Front Panel Controls amp Indicators Refer to descriptions on pages 9 13 14 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con Www aslfilter com FPRS 80P SBO Front Panel Controls amp Indicators Refer to descriptions on pages 9 13 15 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilte
41. er 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 on the backplane with four 4 20 locknuts and flat washers Secure power to the unit before any servicing 1 Start by removing the motor wiring box cover and disconnecting the wire nuts tying the power leads to the motor leads The green ground wire is secured with a green screw to the motor inside the motor wiring box Disconnect the seal tite connector and pull the wiring out of the motor wiring box and plastic Heyco connector Note that wire connections and color codes are located on the motor nameplate as well as page 41 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 4 20 nuts and washers and remove the pump motor assembly from the backplane With both the old and new pumps motors on the workbench transfer the inlet outlet hose fittings and the black Heyco wiring fitting to the new pump motor Take care t
42. erally result in capacity drop off Suction conditions must be redesigned Pump speed is too slow The strainer is too small or obstructed The suction port or pipe is not immersed deeply enough in the liquid Piping is improperly installed permitting an air pocket to form in the pump e Increased clearances or wear in the pump will sometimes cause the pump to deliver an insufficient supply of fluid This can generally be corrected by reducing the thickness of the cover gaskets A folded gasket or a slight amount of dirt can exaggerate the problem and cause leakage 51 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Pump works spasmodically e Leaky suction line e Varying suction conditions e Air or vapor in the fluid Excessive power draw e Pressure too high e Liquid is more viscous than originally expected e Suction or discharge lines obstructed e Insufficient horsepower e Drive shaft and pump misaligned e Pump binding due to insufficient end clearance e Pump shaft is bent e Misalignment within the pump due to bad piping or poor installation causing strain or distortion Pump is noisy Pump is cavitating due to inadequate suction conditions Misalignment of coupling Coupling is set too close to pump Vibration of pump due to worn or bent shaft Ai
43. fter 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 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 38 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com YEARLY In addition to the monthly checks above perform the following additional maintenance actions and checks 1 Replace the Electrostatic Cells Even though the system appears to be operating properly the Electrostatic Cell should be replaced on an annual basis due to internal wear which can cause arcing and deterioration 2 Replace Water Absorber element This throw away element although designed primarily to entrap free and emulsified water will also trap larger particulate and should be replaced at least once each year FPRS S80 SBO FLUID FLOW DIAGRAM OUTLET Water Absorb Hydraulic Oil sorber Reservoir l Sample Port Drain W A Drain as By pass valve 39 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Fr
44. g 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 WARNING This procedure will involve temporarily raising system pressures to higher than normal levels Care should be taken to avoid gross over pressurization of the system Maintenance personnel are cautioned to take extra care when operating the system with the covers removed Refer also to the pump vendor service manual starting on page 42 of this manual To complete this adjustment a ball valve must be installed in the outlet return to reservoir line of the unit Temporarily install a ball valve on the outlet line of the FPRS unit Move the By Pass yellow handle to the water absorber only position Disconnect both Electrostatic Cell inlet and outlet Q D fittings Start system and wait until output flow is observed Remove the acorn nut on the pump relief valve 13 16 Insert a screwdriver into the slot of the adjusting screw and hold it steady Loosen the 1 2 locking nut turn with a wrench by turning counterclockwise Slowly close your outlet ball valve until the system pressure is at 38 psi If the pressure fails to reach this level with the throttling valve closed
45. g the coil of TR Once TR closes the 15 second time delay begins Following the time delay TR closes and power flows from TR T11 to TR T9 Power then simultaneously goes to the hour meter on the front panel and starts the pump motor At the same time CR 1 and CR 2 close the normally closed contacts of CR1 and CR2 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 15K V supplied to the Electrostatic Cells TROUBLE INDICATING CIRCUITS and TROUBLESHOOTING LOW VOLTAGE INDICATOR The red Low Voltage light indicates that the Electrostatic Cell High Voltage DC power supply is no longer putting out enough DC voltage to hold particulate trapped within the Electrostatic Cell Note that this light will illuminate briefly when power is first turned on The low voltage indication is controlled by a normally closed relay within the high voltage power supply This relay the yellow wire coming out of the power 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 or CR 2 relaxing When CR 1 or CR 2 open contacts CR1 5 amp 3 or CR2 6 amp 4 open stopping the flow of power to the coil of TR which in
46. ged without disassembly of the rest of the pump e Place the pump in a vise with the shaft facing up so that one jaw grips across the two ports Do not tighten excessively as the pump housing may be distorted e Inspect the shaft at the keyway flat or tang Any burrs will interfere with removal of the housing plug and bearing assembly e Remove the housing plug with a spanner wrench available from Tuthill as p n OL 506 e Remove the seal from the shaft The rubber boot will be bonded to the shaft so it is necessary to push down on the seal to break this bond Grasp the metal outer shell with any suitable device and pull the seal assembly upward Remove the spring and washer 48 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com e Models 30LA through 1LA and models 30LE through 1LE have a snap ring on the shaft to back up the seal assembly Do not remove this snap ring unless you are completely disassembling the pump Models 2LA 2LE and 5LE do not have a snap ring A step on the shaft is used as the seal backup e Remove the stationary seal face from the housing plug by pressing out from the opposite side e If damaged remove the O ring from the OD of the housing plug Disassembly of Pump The seal assembly must be removed before the pump can be disassembled e Remove the snap ring
47. h the suction or discharge lines All Tuthill pumps contain residual 200 SSU lube oil from the factory production test Determine if this is compatible with the fluid you are pumping If the fluid is incompatible consult the factory Location LA and LE Series pumps are designed for working pressures up to 500 psi 300 psi in the 5LE and are required to develop 25 mercury vacuum at 0 psi on factory test While these pumps will develop as high as 27 of vacuum it is a sound engineering practice to avoid extreme vacuum whenever possible Select a pipe size to reduce line friction loss to a minimum The pump should be located as close to the source of supply as conditions permit and if possible below the level of the liquid in the reservoir When necessary to locate the pump in a pit provisions should be made to safeguard against flooding Care must be taken to properly support the suction and discharge piping so that no strain is put on the pump due to either weight or expansion Piping strain can result in misalignment hot bearings worn couplings and vibration It is important that the piping used be clean and free of chips or scales Proper Installation Unsatisfactory pump installations are usually characterized by poor suction conditions for the specific liquid being handled Suction conditions should be minimized to prevent vaporization of the liquid If vacuum conditions force the liquid to vaporize cavitation will occur result
48. hat 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 power leads to the motor leads The green ground wire is secured with a green screw to the motor inside the motor wiring box Pull the wiring out of the motor wiring box and plastic Heyco connector Note that wire connections and color codes are located on the motor nameplate as well as page 41 of this manual Remove the three 14 20 bolts and lock washers securing the pump to the motor Separate the pump from the motor by pulling straight up on the pump body while rotating the pump There is a three piece coupler connecting the pump to the motor During pump motor separation one or more of these coupler pieces may come out with the pump Carefully inspect the three piece coupler for signs of wear or damage The coupler should be 36 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com replaced if found defective Note that a new coupler is included with a replacement motor or pump and motor combination but not with a replacement pump 5 With the pump and motor separated and the wiring removed remove the four 4 20 nuts and flat washers securing the motor to the cabinet studs and lift the motor ou
49. id Stand the unit upright on the floor 2 Open the Front Cover by grasping both sides of the cover in the palms of your hands and push the cover up toward the control panel until the bottom edge of the front cover clears the cabinet lower lip At that point pull the bottom edge of the front cover out 1 or 2 inches to disengage the magnets retaining the cover Pull the cover down and out away from the cabinet 3 Remove service manual package oil sampling package and optional backflush hose package Don t lose the backflush hoses you ll need them for unit servicing 4 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 Verify that the W A drain valve on the bottom of the W A canister is CLOSED A 6 Remove the plastic 1 2 NPT INLET shipping plug from the pump The OUTLET shipping plug is one the back of the unit remove it as well Plumb inlet and outlet hoses to your reservoir Use Teflon tape or equivalent Unit 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 7 Unwrap the power cord and connect to a grounded 10 amp 120 VAC 60 Hz 1 phase outlet Note that the FPRS unit and your system reservoir must both have earth ground If your system uses 220 240
50. ight comes on and the microammeter reads 500 microamps it s time to backflush the cell in accordance with the Backflush procedure on page 21 of this manual 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 Open the cover and locate the orange wire outputs wire 1081 2 3 Turn power on USE CAUTION A 4 Using a voltmeter check for 120V AC on the 1081 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 32 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com OVERPRESSURE LOW FLUID TEMP WHITE Illumination of this light is controlled by a pressure switch located just below the water absorber canister pressure gauge is adjusted at the factory to close at approximately 38 to 39 psi When
51. imensions Photo 40 Electric Motor Service Data Baldor 41 Hydraulic Pump Vendor Service Manual 42 Rev 7 0 06 26 09 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com This Page for Transformer Equipped Models Only Your new FPRS System is equipped with a Hammond Power brand QIC5XEKF Encapsulated single phase 1 5 kVA Transformer The transformer will operate on 50 Hz and is securely bolted to the backplane of your FPRS Unit In looking at the rear of the transformer you will see that on the INPUT side of the transformer a Heyco type connector is installed for your input wiring Note also that the output side is labeled 120 VAC The outlet connector is pre wired to the Service Switch box on the front of the FPRS Unit thus making the entire FPRS Unit operate on 120 VAC single phase 50 60 hz Using a 5 16 nutdriver open the cover on the bottom of the transformer Inside you will find primary wires which are labeled H1 H2 etc Connect primary lines as appropriate for your local power as shown on the transformer wiring chart Additionally connect your incoming ground wire to the ground buss inside the transformer You will see that the secondary wires are already connected shrink wrapped and tied as well as a ground wire on the ground buss These wires lead dir
52. ing diagram on page 29 the wiring diagram is also laminated and pasted inside the front cover The FPRS S series units use the following wiring conventions THE 120VAC POWER CIRCUIT 120VAC power from the incoming power cord source goes first to a terminal strip inside the SERVICE SWITCH BOX on the upper left corner of the backplane From there power runs to another terminal strip located on the inside of the top cover to the right of the relays TB 1 Power then runs to the 10A circuit breaker on the front panel From the circuit breaker power is fed to the ON OFF switch on the front panel and then splits with the red wire going to the green power on light and CR1 5 CR2 5 PS1 1 and TR T11 and finally to the 120V AC in on both the High Voltage power supplies Note that the normally closed contacts of CR1 5 amp 1 and CR2 5 amp 1 will momentarily pass 120VAC to the red Low Voltage lights on the front panel Once the H V power supply receives power a normally closed relay inside the power supply sends power to the coil of CR1 and CR2 via the yellow wires The action of CR1 and CR2 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 Cell With CRI and CR2 closed the contacts of CR1 5 amp 3 and CR2 6 amp 4 close allowing power to flow to TR terminal T1 thus energizin
53. ing in loss of capacity premature wear and noisy operation When handling high viscosity liquids the speed of the pump must be reduced and the size of the lines increased to prevent cavitation Note Pipe line friction increases at a rapid rate with an increase in viscosity For a given pump and motor larger pipe lines are necessary to maintain the same pump pressure when changing from a thin fluid to a thick one Most Tuthill LA and LE Series pumps are supplied with both ports on the same plane Pumps with this type of porting arrangement should always be installed with both ports pointing upward to insure proper priming If it is necessary to install the pump with the ports pointing to either side it 44 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com is recommended that the top port be the suction port This will prevent gravity induced drainage of fluid through the suction port When pipe lines are installed an inverted U bend should be incorporated into the suction line close to the pump for priming purposes The multiple port arrangement in the 5LE offers flexibility but is limited to some common sense restrictions There is an inlet and an outlet side to the pump There must always be at least one pipe on each side Units ordered with the side port option modification S are
54. k to the supply tank is recommended The internal relief valve available on LE Series pumps is designed for overpressure protection only It is not intended as a flow control device or for any similar use Continuous operation of the relief valve will result in excessive heat buildup within the pump cavity which could cause serious internal damage Make certain the adjusting screw of the relief valve is located on the suction side of the pump Unless otherwise specified at the time of order all LEV pumps are supplied with the standard spring with a range of 55 120 psi 40 70 in the 5LE set to provide full bypass relief at 55 psi Note that the ASL pump contains a special by pass spring which is factory set to provide full by pass relief at 40 psi To adjust the relief setting within the range of a given spring s capability e Remove the acorn nut Not supplied with model SLEV e Insert a screwdriver into the slot of the adjusting screw and hold it steady e Loosen the locking nut with a wrench by turning counterclockwise e Throttle the outlet line until the differential pressure at the pump port is at the desired level e If the pressure fails to reach this level with the throttling valve closed turn the adjusting screw inward clockwise until the desired pressure is reached Adjusting clockwise raises the pressure setting e If the pressure reaches the desired level before the throttling valve is completely closed turn the adju
55. ld down bolt hand tight Clean the O ring and apply a thin coat of your oil Replace the canister lid and clamp hand tighten V band clamp Install the canister bleed plug leaving it slightly loose to expel any air trapped in the canister Close the drain valve on the bottom of the absorber canister and stow the drain hose Activate the main power source and then turn ON the power switch on the control panel After system re starts it will take a few minutes to fill the Water Absorber canister Once fluid begins to escape from the bleed valve close the valve Check for and correct any leaks Return the system to service 23 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com Electrostatic 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 is strongly recommended that the Cell be replaced once each year to insure optimum cleaning performance 8 700 hours maximum The re build exchange program has been organized to provide minimum downtime and maximum performance When you receive your replacement Electrostatic Cell please note that the red tag affixed to the top of the cell contains part number information
56. ldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com IMPORTANT GUIDELINES Oil temperature should not exceed 160 F for electrostatic cells Ambient air temperature should not exceed 160 F Viscosity of the oil to be cleaned cannot exceed 1800 SUS 100 F The minimum flash point of the oil should not be below 200 F FPRS S Series units will automatically restart if input power is momentarily lost Concentrations of water should not exceed 500 ppm If in excess the water absorber only mode of operation should be used to reduce the content to an acceptable level less than 500 ppm before the electrostatic cells are employed It is recommended the FPRS input hose be connected to or draw from the lowest point of the reservoir Therefore when hooking up to a reservoir for the first time or after a period of non filtration always drain free water from the bottom of the reservoir before using the FPRS The output hose should be returned to the highest point at the opposite end of the reservoir to ensure maximum distance between the input and output hoses When installing an FPRS S Series unit on an elevated reservoir where the lowest fluid level of the reservoir is higher than the FPRS it is recommended that shut off valves be installed in the line running from the reservoir to the FPRS pump inlet As well as the line running from
57. ll Restore power to the FPRS and turn the power on USE CAUTION Using an AC voltmeter check for 120VAC at the L HOT terminal on the high voltage power supply wire 1011 If OK check for 120VAC wire 1091 for P S 1 or wire 1131 for P S 2 yellow wire output g If 120VAC is present at the power supply L HOT terminal and no power is present on the yellow wire the power supply must be replaced h If 120VAC is present on both the above terminals check for 120VAC at pin 8 coil of CR 1 or CR 2 If no voltage present repair wiring If 120VAC is present check for voltage at pin 3 of CR 1 or pin 6 of CR 2 If no voltage present replace appropriate relay opBogP mh 31 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com i Note that all three relays are the same and can be swapped for troubleshooting purposes Once repairs are completed remember to re connect T 11 on TR 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 to 4 KVA lL The n
58. mmable materials Electrostatic arcing is a potential ignition source 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 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww 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 or unprotected from the elements Do not use in a damp or wet location FLUID SAFETY WARNING 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 i
59. njury and or property damage and will void the product warranty CAUTION Secure the discharge line before starting the system An unsecured discharge line may whip causing personal injury and or property damage Explosive or flammable flash point below 200 F fluids must never be filtered with this product Electrostatic arcing is a potential ignition source Please refer to Fluid Specification prior to filtering fluid Do not exceed 45 psi on any components in the system Protect fluid lines from damage or puncture Maximum fluid temperature should not exceed 160 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 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com INTRODUCTION SYSTEM OVERVIEW The Finite Particle Removal System U S Patent Numbers 5 149 422 5 242 587 and 5 891 315 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 by products Contamination of industrial fluids is a great concern because their conditi
60. nologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com 4 Mounting Surface The S Series SBO model has all components mounted on an 11 gauge backplane measuring 40 wide by 30 tall This backplane is mounted on a steel tubing stand with heavy duty full swivel casters and individual wheel locks See the photo on page 40 for overall dimensions 5 Water Absorption Equipping the filtration system with water absorption capabilities maintains constant fluid dryness and prevents moisture build up from condensation in the reservoir The S Series units are equipped with a water absorber unit that is installed between the fluid delivery system pump and the Electrostatic cell s This filter will also trap contaminants 5 microns nominal and larger and should be replaced whenever water content increases or pressure rises above 30 35 psi Replacement elements are available from ASL Note that Phosphate ester units utilize a special water absorption element Water absorption elements not designed specifically to use with Phosphate Ester must not be used Spare elements are available from ASL 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 Connect the input and ou
61. o 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 35 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com 6 Secure all wiring and hoses and proceed to PUMP and PRESSURE SWITCH ADJUSTMENTS on page 37 Replacement of PUMP only If you have determined that only the pump needs to be replaced the motor and it s electrical connections can remain attached to the cabinet 1 9 10 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 and they will have to be replaced There is enough excess hose length to remove and replace the pump at least once or twice Remove the three 14 20 bolts and lock washers securing the pump to the motor Separate the pump from the motor by pulling straight up on the pump body while rotating the pump There is a three piece coupler connecting the pump to the mo
62. om 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 4 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 14 nuts lockwashers taking care not to over tighten Re install the wiring to the two posts making sure that the wire on the terminal wire 1111 goes toward the Electrostatic Cell and the terminal goes to ground Note that the microammeter is connected to Electrostatic Cell 1 only Hour Meter The hourmeter is held in place with two 6 32 screws and locknuts Remove the two spade wiring terminals from the meter 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 34 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con Www aslfilter com Hi Voltage Power Supply Secure power to the FPRS before replacing the power supply 1
63. on is directly related to the condition of the overall system they function in Controlling these five factors is foundational to maintaining a trouble free system The following preventative measures do much to extend the life of the fluid and the hydraulic system One must minimize the external ingression of air and particulate in the fluid Breather bags and air intake filters have been used effectively for this purpose Maintaining the fluid temperatures within the specified limits can be achieved through proper care and maintenance of the cooling system We have equipped your filtration system with continuous water removal capability to prevent build up due to condensation and to keep the fluid dry Finally the fluid must be kept as clean as possible not only by removing particulate such as e Dirt Fibers Wear metals Also the Submicronic Contaminants such as Silts Tars e Varnishes Tars and Varnishes are the byproducts of oxidation and typically occur and are encouraged because of the presence of air heat and water Oxidation is usually observed in lubricants and hydraulic oils and results in the formation and deposition of tars and varnishes on the components of the hydraulic system Removing these contaminants continuously from the system will prevent the majority of problems that plague maintenance departments and cause expensive downtime Keeping the fluid as clean as possible is what this product will accomplish
64. r con Www aslfilter com FPRS 80P SBO Front Panel Controls amp Indicators INSIDE VIEW Refer to descriptions on pages 9 13 Wine ah Oe g Bal aiD i Ji 15 H n Y a 7 ly H ald pr a mf 31 32 33 34 35 36 37 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com INSTALLATION CONSIDERATIONS APPLICATION COMPATIBILITY While this product can provide effective filtration over a wide range of applications there are some applications that are an exception e Type of fluid to be filtered Contamination source or sources The rate of contamination The following guidelines should be considered before installing this product 1 Fluid Specification this product is suitable for filtering nonconductive and semi conductive fluids with viscosity rating less than 1800 SUS 100 F Water based fluids cannot be filtered with this product Typically compatible fluids include Petroleum based lubricants Solvents Synthetic lubricants Dielectric fluids Phosphate Ester fireproof fluids Requires different Electrostatic Cell hoses seals gaskets etc Phosphate Ester Cells are BLACK with White ends e ASL Electrostatic Units with a P in the part number i e FPRS S80P SBO are designed and built specifically for filtration of Phosphate Ester fluids
65. r leaks on suction side of pump or air entrainment in the fluid Pump leaks e Cover bolts need tightening or cover gasket is defective e Worn or defective seal Material Returns If it becomes necessary to return a pump to the factory a Return Goods Authorization RGA must be obtained from either your local Authorized Distributor or our Chicago plant No RGA can be issued until a completed Material Safety Data Sheet MSDS has been forwarded to our Chicago plant and return of the pump approved e Tuthill pumps are precision built and must be handled with care e Pumps must be drained of all fluid and the ports plugged to prevent foreign material from getting into the pump e Pumps must be packaged securely to prevent damage while in transit Contact ASL Technologies for return of Defective pumps installed in ASL Filtration Systems END OF SERVICE MANUAL 52
66. r metal parts Pump Performance Data Size Capacity gpm 30L 3 Note 30LEV CC A 9821 1725rpm 5 gpm OOL 8 Note OOLEV 040 CC A 1725rpm 666 gpm OL 1 6 Note OLEV 040 CC A 1725rpm 1 333 gpm 1L 2 7 2L 4 9 Based on pumping a fluid of 200 SSU 5L 12 9 viscosity at 100 psi and 1750 rpm ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter ccom www aslfilter com WARNING Failure to follow these instructions could result in serious bodily injury or death Do not attempt to work on any Tuthill pump installation before completing the steps below Disconnect the drive so that it cannot be started while work is being performed Review the Material Safety Data Sheet MSDS applicable to the liquid being pumped to determine its characteristics and the precautions necessary to ensure safe handling Vent all pressure within the pump through the suction or discharge lines All Tuthill pumps contain residual 200 SSU lube oil from the factory production test Determine if this is compatible with the fluid you are pumping If the fluid is incompatible consult the factory HOUSING IDLER IDLER PIN COVER ROTOR COVER BOLTS COVER GASKET HOUSING BUSHING RETAINING RING HOUSING PLUG O RING SEAL ASSEMBLY Disassembly of Seal The seal assembly in LA and LE Series pumps can be chan
67. rnal to the high voltage power supply orange wire which closes at approximately 500 micro amps If this lamp illuminates back flush the Electrostatic Cell in accordance with the instructions on page 21 of this manual RED LOW VOLTAGE 1 LIGHT When the system is first turned on or power is restored following a power interrupt condition the red LOW VOLTAGE lamps will illuminate briefly and then go off The LOW VOLTAGE lamp does not indicate trouble with the incoming 120 VAC power but relates to the high voltage DC power supplies which supply 15 000 VDC to the Electrostatic Cells The signal to illuminate these lights comes from relays internal to the high voltage power supplies 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 the LOW VOLTAGE lamp is illuminated power to the pump motor is interrupted There are two high voltage power supplies in the system one for each Electrostatic Cell Refer to the Maintenance section RED LOW VOLTAGE 2 LIGHT Same as above but indicates trouble in Power Supply 2 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 recei
68. roperly reinforced so as not to collapse under 30 Hg vacuum WARNING All Tuthill pumps contain residual 200 SSU lube oil from the factory production test Determine if this is compatible with the fluid you are pumping If the fluid is incompatible consult the factory If the pump is to operate at elevated temperatures it should be brought up to operating temperature gradually Rapid or sudden introduction of liquid at an elevated temperature into the cold liquid chamber of the pump could cause damage to the seal or other internal parts Do not run the pump dry This could cause severe damage to the seal bushings and or metal parts Prior to starting the pump double check the following Pressure and vacuum gauges should be installed as close as possible to the pump Rotate pump shaft to ensure it turns freely without binding Recheck alignment and ensure all guards are in place Make sure piping is independently supported and no strain is being transmitted to the pump Make sure the safety relief valve is installed correctly Check pump rotation Open suction and discharge gate valves Check for any leaks once gate valves are open After completing these checks the pump can be started CAUTION The pump should not be run dry If after approximately 60 seconds there is no discharge of liquid stop the pump and investigate the possible cause Failure to comply with this could cause severe damage to internal seals bushings and o
69. sing down on the face Use your fingers for this operation e Place a new O ring on the OD of the housing plug if required and lubricate e Lubricate the carbon face liberally e Re assemble the housing plug into position over the pump shaft Do not nick the seal face by hitting the pump shaft Tighten the housing plug with the spanner wrench The seal will automatically be positioned by this operation e f the pump is equipped with a ball bearing modification K press the bearing onto the shaft Do not hammer into position or press on the bearing outer race e Check pump for free rotation by turning the shaft with a suitable wench There will be a definite resistance to turning because of the seal load The pump must turn freely without binding 50 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Changing Rotation LA and LE Series pumps are bi directional and will work equally well in either direction with no modification However if outfitted with an internal relief valve model LEV these pumps become rotational Rotation cannot be changed in the field unless the housing is replaced Do Not change rotation on an ASL Filtration System Pump To change the location of the suction port on a pump outfitted with Tuthill s unique automatic reversing feature models RLA and RLE
70. ss authorized in advance This warranty is the only warranty extended by ASL to suppliers and or purchasers of this product No other warranty written or oral is authorized ASL disclaims all other warranties express or implied that arises by operation of law except that implied warranties of merchantability or fitness for a particular purpose are limited to the duration of the warranty period ASL shall not be liable for any incidental consequential or other damage that may have resulted from any alleged breach of warranty including any cost or expense of providing substitute equipment or service during periods of malfunction or non use Some states do no allow limitation on how long an implied warranty lasts or the exclusion limitation of incidental or consequential damages so the above stated 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 Phone 219 733 2777 or Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsvc aslfilter com 25 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter ccon Www aslfilter com PRODUCT SPECIFICATIONS FPRS 80 SBO PHYSICAL DIMEN
71. sting screw outward counterclockwise until the desired pressure is reached Adjusting counterclockwise lowers the pressure setting e Retighten the nut to lock the setting in place and replace the acorn nut e Recheck the pressure gauge reading If an internal relief valve has not been supplied with the pump some other means of protection must be utilized These include in line safety relief valves pressure shutdown switches or other similar devices Strainer Protection Strainers are used to remove contaminated particles from the fluid system and extend pump life Every pump should be protected from these particles by a strainer in the suction line Strainer size and mesh of screen are determined by the rate of flow and viscosity of the fluid Consult the strainer manufacturer for recommendations 46 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Never use a strainer with a built in automatic by pass on the suction line set to open under 30 Hg vacuum Install the strainer according to the designated direction of flow locating it so that it is accessible for servicing Use a duplex type strainer when shutdown during service is not possible Provide a vacuum gauge in the suction line for determining when the strainer requires cleaning Make certain strainer baskets are p
72. t above the valve POWER SWITCH See 1 above SYSTEM CIRCUIT BREAKER See 2 above ELAPSED TIME INDICATOR See 8 above POWER ON GREEN LIGHT See 3 above RED OVERPRESSURE LOW FLUID TEMP LIGHT See 4 above CELL PRESSURE GAUGE See 9 above AMBER BACKFLUSH LIGHT See 5 above MICROAMMETER INDICATOR See 10 above RED LOW VOLTAGE 1 LIGHT See 6 above RED LOW VOLTAGE 2 LIGHT See 7 above 12 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com 31 32 33 34 35 36 37 HIGH VOLTAGE POWER SUPPLY 1 This power supply connects to the 1 Electrostatic Cell left side of cabinet and supplies 15 KVDC power to the cell Note that a LOW VOLTAGE 1 light indication will come from this power supply Power supply 1 and 2 are identical TIME DELAY RELAY The time delay relay delays the pump and hour meter start for approximately 15 seconds following power on RELAY CR 1 This relay has the coil connected to Power Supply 1 low voltage output signal yellow wire During normal operation the power supply yellow wire output is always at 115 VAC thus holding relay CR 1 closed See the system schematic on page 29 RELAY CR 2 Functions the same as Relay CR 1 but connected to Power Supply 2 See system schematic on page 29 RELAY CR 3 This r
73. t of the cabinet 6 Transfer the black Heyco wiring fitting and locknut to the wiring box of the new motor 7 Install the plastic female tang coupler and the metal center section coupler pieces on the new motor shaft Install the male tang coupler piece on the pump 8 Install the new motor onto the cabinet studs and secure with four 4 20 locknuts and flat washers 9 Using a twisting motion install the pump onto the motor taking care to align the splines of the couplers Once aligned the pump will drop into position 10 Re install the three 4 20 bolts and lock washers thru the pump to the motor Note that these bolts are 34 long Longer bolts will bottom out 11 Re install the wiring through the Heyco fitting and re connect wiring in accordance with the diagram on page 41 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 Pressure Switch Replacement Replacement of the pressure switch is straightforward and should present no problems Adjustment of this switch however is critical and will be required following replacement of the pump or the pressure switch Replacement of this switch is straightforward and only requires disconnecting the wiring connector and un screwing the switch from the water absorber inlet manifold When installing a new switch coat the threads with a suitable thread sealer Followin
74. 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 pump 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 14 15 and 16 as well as 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 30 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 if the SERVICE SWITCH is in the ON position See 15 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
75. tor During pump motor separation one or more of these coupler pieces may come out with the pump Carefully inspect the three piece coupler for signs of wear or damage The coupler should be replaced if found defective Note that a new coupler is included with a replacement motor and a pump and motor combination but not with a replacement pump Before ordering a replacement pump determine if the coupler will need to be replaced so it can be ordered at the same time It is a good idea to replace the coupler when replacing either the pump or the motor 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 Install the plastic female tang coupler and the metal center section coupler pieces on the motor shaft Install the male tang coupler piece on the new pump Using a twisting motion install the pump onto the motor taking care to align the splines of the couplers Once aligned the pump will drop into position do not force Re install the three 4 20 bolts and lock washers thru the pump to the motor Note that these bolts are 34 long Longer bolts will bottom out Re install inlet and outlet hoses A drop of lubricant on the push lock fittings will ease installation of the hoses Proceed to PUMP and PRESSURE SWITCH ADJUSTMENTS on page 37 Replacement of MOTOR only If you have determined t
76. tput hoses to the FPRS e 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 recommended that shut off valves be installed in the line running from the reservoir to the FPRS pump inlet Also the line running from the FPRS back to the reservoir outlet A CAUTION HANDLE THE HOSES SO THAT SPILLS CANNOT TAKE PLACE SYSTEM START UP Connect the FPRS to a grounded 120VAC power source Or 220 240 if transformer equipped 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 Locate the by pass valve on the outlet end of the water absorber canister yellow handle and verify that it is in the desired position water absorber only or water absorber and Electrostatic e Place the front cover in position 19 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com fe o
77. turn stops power to the 30 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com hour meter and pump motor At the same time the contacts of CR1 5 amp 1 or CR2 5 amp 1 close allowing power to illuminate the low voltage light s The idea here is that if the high voltage power supply no longer has enough voltage output to keep particulate trapped within the Electrostatic Cell the pump needs to be stopped immediately The backflush procedure depends on this phenomena to operate i e Once power is removed from the cell contaminant can then be blown out with shop air The system will try to keep running however and the power supply will reset itself and try to turn on again If the conditions that caused the low voltage indication are still present the time delay will stop and start as the power supply tries to reset itself If you observe a flashing low voltage light you should shut down the system immediately and investigate the cause Remember that the low voltage indicator light should reflect the microamps being consumed so a low voltage light should be confirmed by observing the microammeter indicating 700 or more microamps Causes for a low voltage light The low voltage light can be caused by one or more of the following 1 Shorted Electrostatic Cell The Electrostatic
78. umber one reason for power supply high voltage section failure is operating the Electrostatic Cell beyond one year 8700 hours we BACKFLUSH INDICATOR AMBER Backflushing of the Electrostatic Cell in your unit is unique to the FPRS system Backflushing the contaminates out of the cell allows for much longer filtration life than with conventional mechanical filters The amber backflush light is controlled directly by the high voltage power supply orange wire A normally open relay inside the high voltage power supply closes when the power supply senses approximately 500 microamps As shown on the wiring diagram once the internal relay on either power supply closes the amber backflush light receives power directly Note that the backflush relay wires of both power supplies are tied together so that either cell exceeding 500 microamps will illuminate the backflush lamp The theory being that since the pump flow is split evenly to both Electrostatic Cells if one cell is loaded the other one is as well and both cells should be back flushed 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 Electrostatic Cell 1 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 l
79. ving power The hour meter reads to 99 999 99 hours 11 years CELL PRESSURE GAUGE The cell pressure gauge shows the pressure at the outlet of the Electrostatic Cells Under normal operating conditions warm fluid fresh water absorber element fresh Electrostatic Cell 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 10 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah IN 46390 Phone 219 733 2777 or Toll Free 888 333 2990 FPRS 80 SBO Facsimile 219 733 2779 or e mail custsvc aslfilter con WWww aslfilter com 10 11 12 13 14 15 16 progressively higher pressure due to particulate accumulation in the Electrostatic Cell At 35 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 MICROAMPERES INDICATOR The Microamp meter indicates the amount of high voltage DC power being consumed by the 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 as well as conductivity of the fluid Note that high concentrations of water or excessive accumulations of ferrous particulate can cause high microamp readings At 500 microamps

80 SBO Service Manual - ASL Technologies, LLC!

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