HNP21 Manual
Contents
1. 48 12 Ec cca a oa cc ee 49 21 FLUID CONDITIONING PURIFIERS 2 Foreword This service manual is provided to serve as the installation operation and maintenance guide for the equipment supplied in accordance with the details given in the customer s purchase order The contents should be read before attempting any phase of installation operation and maintenance The equipment and any optional items are packed individually for assembly by the customer Unpack carefully and check all items received against the invoice This equipment has been tested and quality controlled in accordance with Pall standard procedures and also in accordance with the tests specified in the contract when required However the equipment as shipped may have been opened or disassembled for draining cleaning etc after testing The customer should satisfy himself that no nuts bolts flanges pipes closures or any other components have worked loose during shipment these should be tightened wherever necessary A nameplate has been permanently attached to the equipment When requesting information service or spare parts please refer to the information given on this plate It is the user s responsibility to check actual operating conditions to ensure that the filter elements cartridges vessel and sealing materials are compatible with the application and are w2. 24 7 3 3 Appreciation of Reservoir Internal 24 St MANO21_EN 3 HNP0O21 Service Manual FLUID CONDITIONING PURIFIERS 1 34 Location of SUSTION Reservoir 25 L caion A A E E EE 26 7 4 ENN E E ee E E E E E se eceertteess 26 7 9 Operati Minien E E R 27 76 Diagnostic FUN raain aea aaae 28 TEA ACCESSING ModE gt deere rer ee ner eer errr 28 glo ame Diagnostic Mode Or PPP ener reer Perey rer OESR 29 Diagnosi a re 29 8 Operating EE A rE a aasar 30 8 1 Prestart Checks and FONG a eA E EE REE 30 8 2 Staring and RUNNIN gesein e E AE OEE 31 8 3 SNUG Beer er cae peter ee me PoE en Ser pet ee may eer mn renner Ores rer Cee mere ree rere 31 831 Emergency Shut ee ene er ce Om nent error eee eee oe rere 32 8 32 Resetting Unit After a 32 9 7 09 2 siss a E E a Eai 33 9 1 Maintenance SC INGO asian neces ocit cc wadacareecancecennsceceace tuceeceaeysaaescisepacecnacehniteteaiateceateaieeacucas 34 9 2
3. 40 21 21 Service Manual 7 FLUID CONDITIONING PURIFIERS FAULT Vessel Vacuum Low CAUSE Vacuum adjustment valve set incorrectly Troubleshooting SOLUTION Set vacuum to desired level using adjustment valve Fluid is very aerated e Fully close adjustment valve Can a vacuum in excess of 0 7bar g 21 Hg be attained If less aerated fluid can be drawn from another point in the circuit relocate the purifier connections Fluid trap bowl is full Empty fluid trap Primary oil mist separator blocked Clean or replace separator and refit The fluid has a very high water content i e gt 5 There is a large amount of water vapour visible at the vacuum pump exhaust Oil level in the vacuum pump is outside normal limits Internal vacuum pump oil separator element blocked Vacuum pump exhaust restriction e Drain free water from the reservoir drain e The vacuum will increase as the water content is reduced Fill drain vacuum pump to restore normal oil level Replace internal vacuum pump oil separator element Remove obstruction Air leaks in the system Vacuum pump gas ballast is open Locate and repair leaks Fully close gas ballast If the fault cannot be rectified by completing the above contact Pall for advice 21 41 Troubleshooting HNP0O21 Service Manual FLUID CONDITIONING PU
4. 23 Troubleshooting ersi ei 40 INStANAUGM 8 U L disposal E 39 Local 8 LOCATION EEE E P AEO T 25 V Low inlet 40 13 15 Low vessel fluid 43 Vessel VACUUM 41 Voltage Relay iE 46 wW 21 22 21 INDEX 49 50 PALL Pall Corporation Pall Europe Limited A division of Pall Corporation Europa House Havant Street Portsmouth PO1 3PD 023 9230 3303 telephone 023 9230 2507 fax Because of developments in technology these data or procedures may be subject to change Consequently we advise users to review their continuing validity annually Part numbers quoted are protected by the Copyright of Pall Europe Limited Pall are trade marks of Pall Corporation Filtration Separation Solution is a service mark of Pall Corporation 1999 Pall Europe Limited Filtration Separation Solution sm 21 HNP0O21 Service Manual FLUID CONDITIONING PURIFIERS Visit us on the web at www pall com Pall Corporation has offices and plants throughout the world in locations including Argentina Australia Austria Belgium Brazil Canada China France Germany Hong Kong India Indonesia Ireland Italy Japan Korea Malaysia Mexico the Netherlands New Zealand Norway Pol
5. 12 30 DiaGnosticTUNClOns 28 Principles Of 11 Dive Syste 13 17 Power om lamp rainn na 47 PUMP 44 46 Electrical 13 19 20 Emergency 31 Reservoir internal 24 PSS CL 32 F epee ee eee tere mene np teers rere 31 Fluid 13 15 16 18 5 5 Sale 7 G Safety of 9 General vasre 12 Safety systems 15 16 17 18 19 20 21 22 GOWN a 31 H Spare Pans 5 42 SPAMMING dean ds 31 te 23 I Suction port 25 22 12 24 23 Technical 12 26 Terms Of 5 Installation
6. Rectify leaks e Reset and or remove and clean e Check inlet filter FLO1 If the fault cannot be rectified by completing the above contact Pall for advice 21 21 Service Manual 7 FLUID CONDITIONING PURIFIERS FAULT Low Vessel Fluid Level CAUSE Interruption to fluid supply or defective inlet check valve Troubleshooting SOLUTION e Check fluid supply e Replace faulty check valve Closed recirculation ball valve Open valve Unit is not standing on level ground lt 10 slope Relocate unit Inlet flow is interrupted by large amounts of air e Connect purifier where to a part on the system where continuous flow will be achieved e Repair air leaks within or to purifier Recirculation solenoid valve is failing to open Possible failure of low level control float switch relay or valve malfunction e Check function of low level control switch by actuating manually and monitoring signal at local switch connections e Replace faulty float switch e Check continuity of wiring relays Aux contacts etc e Rewire or replace components as required e Possible defective actuator on recirculation valve or jammed valve Insufficient inlet flow Inlet pressure reading is fluctuating slightly and a ringing sound is evident from the main manifold block e Fluid is not within service viscosity range of the purifier Ra
7. 4 Clean and inspect all threads and sealing surfaces for condition Check the O ring seal for damage and replace if necessary 5 Lubricate the threads with system fluid and re fit bowl 9 7 Replacement of Primary Mist Seperator FL04 STEP ACTION COMMENTS 1 Stop the unit and allow vacuum to dissipate from the system 2 Remove the air line from the plate on top of the vacuum vessel 3 Unfasten the dome nuts around the filter mounting plate Withdraw the filter 4 Replace the element For element part number options see spares lists on PCS drawing included with this manual appendix Re assemble the filter and air line Check the oil level in the fluid trap and drain if necessary 21 37 Maintenance 21 Service Manual FLUID CONDITIONING PURIFIERS 9 8 Motor Maintenance ACTION COMMENTS 1 Stop the unit and allow vacuum to dissipate WARNING ELECTRICAL from the system HAZARD DO NOT ATTEMPT Isolate the power supply WITHOUT ISOLATING POWER SUPPLY 2 Clean the outside of the motors ensuring that the cowl intake vents are not choked 3 Check the security of the electrical connections and the retaining bolts 4 Lubrication Bearings are packed with Refer to manufacturer s service grease on assembly and there should be instructions sufficient lubrication for at least two years con
8. If the fault cannot be rectified by completing the above contact Pall for advice 44 21 21 Service Manual FLUID CONDITIONING PURIFIERS FAULT Outlet Filter Element requires frequent replacement CAUSE Excessive dirt loading Troubleshooting SOLUTION e Install a settling tank in the supply system and ensure suction outlet is above tank bottom minimum of 150mm off the bottom of the tank e Install a pre filter unit Purifier filtration is much finer than main system filtration Consider using a coarser grade of elements in the purifier Alternatively fit finer system filtration If the fault cannot be rectified by completing the above contact Pall for advice 21 45 Troubleshooting 21 Service Manual FLUID CONDITIONING PURIFIERS 10 2 Causes of Common Electrical Faults FAULT CAUSE SOLUTION Motor Overload The nozzle gaps are blocked e Remove and clean e Check inlet filter FLO1 Excessive fluid viscosity Increase fluid temperature Failure of outlet check valve Remove valve and check operation replace if required Serious failure of pump or motor Repair pump or motor as e g bearing failure manufacturer s instructions Earth fault short circuit Check and repair wiring High back pressure on exhaust of Clear vacuum pump exhaust vacuum pump If the fault cannot be rectified b
9. service manua Pall Corporation HNPO21 Service Manual FLUID CONDITIONING PURIFIERS Filtration Separation Solution sm Copyright clause 21 Service Manual FLUID CONDITIONING PURIFIERS Document Number 21 EN Revision Level M Original Information Originator Checker Approver 1 Approver 2 Approver 3 Approver 4 Approver 5 Name A D MIN Date 3 NOV 2006 Revision M Information Reviser Checker Approver 1 Approver 2 Approver 3 Approver 4 Approver 5 Name RS ARCHER Date 2 JUL 2007 Copyright clause Reprints even of extracts hereof are permitted only if the source is quoted and permission has been granted by Pall The main components devices arrangements as well as software control and instrumentation equipment on all of our machines are protected both at home and abroad by patent applications design registrations or copyright Copyright by Pall Europe Limited Europa House Havant Street Portsmouth PO1 3PD N 21 02 Service Manual coments FLUID CONDITIONING PURIFIERS 1 Contents Sinemet er rE ree ener ee enn ee er eee eee ne 3 2 EE T T E 5 2 1 NS BEN Eene e A E E E E EAT 5 2 2 Trademarks amp Intellectual Property sssssnsssssrsnsneeseessensnsnnnnorrrnnnnnnnnnnenrnnnnnnnnen
10. ELEMENT RUNNING UNIT 21 Se HNP021 Service Manual Installation and Operation FLUID CONDITIONING PURIFIERS 7 5 Operation In order to energize the unit the isolator should be turned to the T On position The unit now has power supplied to the main and control circuits Three phase units only If when power is first applied to the purifier the phase rotation does not correspond to the required pump direction the Phase Failure Relay will inhibit operation and all fault lamps will flash simultaneously on the main panel The Phase Failure Relays themselves will indicate this fault as follows a For units running on 480V AC or below failure to illuminate the red light on the phase failure relay mounted within the control box 1 only a green light will be illuminated b For units running on 500V AC or above the illumination of the red light on the phase failure relay mounted within the control box 1 both red and green lights will be illuminated Reversing any two of the three wires on the incoming supply can rectify this problem The phase failure or voltage relay will also inhibit operation if the supply voltage is 10 or more below the nominal operating voltage with the same indication as listed above To start the unit the control selector switch should be turned clockwise to the spring return position The operator may release the switch immediately In circumstances where it is necessary to overr
11. protection against the effects of undervoltage or loss of supply phase For three phase options the phase failure and undervoltage relay PRO1 is employed as protection against the effects of undervoltage loss of supply phase or incorrect phase rotation The undervoltage setting as indicated by the dial on the front of VRO1 or PRO1 is 10 below the normal supply voltage This setting must not be changed and must be maintained on replacement parts In cases where a fault is detected by VRO1 or PRO1 the unit will shut down and will require operator intervention For single phase options the power supply is also used at full voltage for the solenoid valve AVO1 and lamps LP01 LP08 This is then converted by PU01 24V dc and is used to supply the programmable logic controller 1 and contactors 1 and 02 For three phase options the power supply is stepped down by transformer TX01 to a single phase supply of 230Vac This is used to supply the solenoid valve AVO1 and lamps 1 01 1 08 This is then converted by PU01 to 24V dc and is used to supply the programmable logic controller 1 and contactors 1 and 02 The programmable logic controller controls the functionality and safety of the unit eee 21 19 Components Details and Safety 21 Service Manual Systems FLUID CONDITIONING PURIFIERS 6 8 1 Control Box Except for the motors solenoid valves and all sensing units th
12. remedial action 9 Once the unit is running adjust the Use the appropriate lamps in the recirculation valve to achieve a filling time of diagnostic mode to trim the approximately one minute filling emptying time of the vessel between 1501 and 1502 This adjustment will depend on the viscosity of the fluid and the back pressure on the purifier outlet 8 3 Shutting Down STEP ACTION COMMENTS 1 Turn the control switch to Stop position 2 Switch the isolator to 0 3 Close the inlet isolating valve The inlet Outlet is isolated by check valve check valve will prevent flooding of the unit for long periods but the unit should be isolated using the inlet valve ES 21 31 Operating Procedures 21 Service Manual FLUID CONDITIONING PURIFIERS 8 3 1 Emergency Shut Down AN EMERGENCY STOP SHOULD BE PERFORMED BY THE SAFEST MEANS STEP ACTION COMMENTS 1 Turn the isolator to 0 Safety devices fitted to unit make serious emergencies unlikely 2 If unit cannot be approached switch off electricity supply at remote position 3 Close inlet isolating valve as soon as possible The inlet check valve will prevent flooding of the unit for long periods but the unit should be isolated using the inlet valve 8 3 2 Resetting Unit After a Fault ACTION COMMENTS 1 Once the fault has been cleared press the Fault co
13. required Use lamp test button to scroll through the last ten unit shutdowns 21 Operating Procedures HNP0O21 Service Manual FLUID CONDITIONING PURIFIERS 30 8 Operating Procedures 8 1 Pre start Checks and Actions STEP ACTION COMMENTS 1 Remove all blanking plugs Install the unit Blanking plugs are fitted to liquid and inlet and outlet connections and ensure that air ports they are tightly secured 2 Ensure an outlet filter element of suitable For element part number options see rating is installed prior to running unit spares lists on PCS drawing included with this manual appendix 3 Check the vacuum pump lubricator reservoir See separate instructions for oil type and drain or fill via the filler cap as and volume Pump is filled with oil necessary before leaving factory 4 Connect the electricity supply and ensure Check lamp is illuminated that a The supply fuse rating is correct b If operating on 110 V the power supply transformer rating is adequate 3 kVA c The voltage monitor is set 10 below supply voltage 5 Three phase options only Turn control Vacuum pump motor rotation should selector switch anticlockwise until vacuum be as indicated on pump body pump starts turning Turn to Stop once vacuum pump starts Check rotation of vacuum pump 6 Three phase options only If rotation All rotations were correct when unit direction i
14. EVEL HIGH AND INLET VACUUM HIGH ALARMS REMAIN ACTIVE ACTIVE CONDITION INDICATION ACTION MODES FUNCTION PS01 lt 0 45 barg ILLUMINATED Shutdown Running Prevention of 13 Hg ineffective running whilst unattended PS01 gt 0 45 barg FLASHING Warning Shut down Prevention of 13 Hg damage to unit 1 open gt 30 components seconds 1501 open gt 20 1 04 ILLUMINATED Shutdown Running Prevention of seconds air ingression into customer system 1501 closed LP04 FLASHING Shutdown Running Prevention of fluid loss te through air lines 1503 Open gt 10 1 05 ILLUMINATED Shutdown Running Prevention of seconds fluid loss through air lines 1503 Open 1 05 ILLUMINATED Shutdown Running Prevention of fluid loss Aan gt 20 through air lines LS03 failure to 1 05 FLASHING Shutdown Running Prevention of close fluid loss through air lines PS02 lt 0 8 barg 1 06 ILLUMINATED Shutdown Running Protection of 24 inlet pump from under pressure DPO1 open LPO7 FLASHING Warning Running Elimination of unnecessary MB01 closed lt 2 hours 21 21 Components Details and Safety HNP0O21 Service Manual Systems FLUID CONDITIONING PURIFIERS CONDITION INDICATION action MODES DPO1 open LPO7 ILLUMINATED Shutdown Running Prevention of
15. HIS WARNING IS NECESSARY TO PREVENT THE POSSIBILITY OF FIRE OR EXPLOSION If the equipment is not to be installed immediately Store the equipment in clean dry and cool conditions and wherever practical in the packaging supplied DO NOT remove packaging until ready to install To prevent accidental internal contamination retain the port blanking plugs in position until ready to connect to the system 7 2 Pre Installation Inspection Prior to installation check that the equipment is suitable for use on the intended system Such factors as pressures flow rate and seal materials should be considered Remove all protective shipping framework covers and shipping packaging To prevent the ingress of local contaminants it is recommended that all of the blanking plugs are left in place until connection is made to the system pipe work Inspect the unit upon arrival for possible damage incurred during shipment In the event that damage has occurred immediately enter a claim with the carrier If necessary Pall or its representative may be consulted 21 23 Installation and Operation HNP021 Service Manual FLUID CONDITIONING PURIFIERS 73 Connection of the Unit to Fluid Supply 7 3 1 Inlet Line Design Sizing The unit inlet line must be sized and designed so as to avoid excessive pressure drops in the inlet line It is recommended that inlet pressures are not allowed to fall below 0 bar g 0 psi g Low pressures
16. MBO1 closed gt 2 running whilst unattended and prevention of element collapse LS04 Open 1 08 ILLUMINATED Shutdown Running Prevention of fluid spillage VRO1 open LP03 LP04 LP05 LP06 LP07 LP08 Shutdown Running Prevention FLASHING TOGETHER undervoltage single phase options only PRO1 open LP03 LP04 LP05 LP06 LP07 LP08 Shutdown Running Prevention of FLASHING TOGETHER reverse three phase l operation of options only motors r undervoltage MB01 Open LP03 LP04 LP05 LP06 LP07 LP08 Shutdown Running Protection FLASHING SEQUENTIALLY LEFT TO from RIGHT overcurrent MB02 Open LP03 LP04 LP05 LP06 LP07 LP08 Shutdown Running Protection FLASHING SEQUENTIALLY RIGHT TO from LEFT overcurrent N N 21 21 Service Manual Installation and Operation FLUID CONDITIONING PURIFIERS 7 Installation and Operation D D 7 1 Storage WARNING IF THERE IS ANY POSSIBILITY THAT THE FLUID TO TREATED HAS BEEN CONTAMINATED WITH A TOXIC FLUID THE VAPOURS OF WHICH COULD CAUSE A HAZARD THIS PALL EQUIPMENT SHOULD NOT BE USED UNLESS ADEQUATE PRECAUTIONS ARE TAKEN TO VENT THE VAPOURS IN ACCORDANCE WITH SAFETY STANDARDS AND LOCAL CODES THIS WARNING IS NECESSARY TO PREVENT THE POSSIBILITY OF TOXIC INJURY TO PERSONNEL WARNING THE EQUIPMENT CANNOT BE USED WITH A FLUID WITH A FLASH POINT BELOW 93 C OR WITH FLUIDSINATED WITH OTHER FLAMMABLE OR COMBUSTIBLE FLUIDS T
17. MMENTS 1 Switch off the unit and allow pressure to dissipate before starting work Close inlet isolating valve MV01 Unscrew inlet port fitting This is identified The inlet strainer is mounted within with the strainer part number and the text the main manifold block Inlet Strainer Remove to Service 4 Clean the element in accordance with the For strainer part number options see operator s own procedures or contact Pall for spares lists on PCS drawing included details of the cleaning service offered to with this manual appendix customers If element is to be discarded it must be in accordance with local Health and Safety Procedures 5 Clean threads and sealing surfaces Check condition of o ring seal Replace if necessary 6 Lubricate the threads with system fluid and re install the filter element and bowl ES 21 35 Maintenance 21 Service Manual FLUID CONDITIONING PURIFIERS 9 4 Replacement of Outlet Filter FLO2 STEP ACTION COMMENTS 1 Stop the unit and allow pressure to dissipate before starting work Close inlet isolating valves MV01 Open the filter drain plug in the bottom of the outlet filter bowl and drain the fluid Close drain plug on completion 4 Unscrew the filter bowl using a suitably sized spanner on the hex at the base of the bowl 5 Remove and discard the element in For element part number options see accordance with lo
18. RIFIERS FAULT CAUSE SOLUTION High Vessel Fluid Return line to the tank restricted Remove obstruction Level Defective outlet check valve Replace faulty check valve Vacuum is not set within acceptable limits Adjust vacuum to acceptable value Unit is not standing on level ground lt 10 slope Relocate unit Recirculation solenoid valve is faulty Possible failure of high level control float switch or wiring The fluid supply reservoir is excessively aerated foamy e Check function of low level control switch by actuating manually and monitoring signal at local switch connections e Replace faulty float switch e Check continuity of wiring relays Aux contacts etc e Rewire or replace components as required e Possible defective actuator on recirculation valve or jammed valve e Try running the vessel vacuum at 0 5 bar g 15 Hg If this cures the problem set the vacuum as high as possible and monitor at the new vacuum e Run unit from a clean barrel of oil If the problem persists there is possibly an application problem consider relocating the unit Assess modes of fluid contamination Leakage across outlet pump relief valve causing diminished outlet flow Indicated by noise from pump relief valve segment Reset or replace internal parts Check the line from the vessel to the outlet pump for air leaks The nozzle gaps are blocked or set incorrectly
19. RT AT THE BOTTOM OF THE FLUID RESERVOIR SHOULD BE AVOIDED e WHENEVER POSSIBLE Typically there may be dirt and silt deposits and free water present at the bottom of the reservoir If this is likely then the following protective measures should be taken A drain valve should be provided at the bottom of the reservoir allowing regular and frequent drainage of free water from the bottom of the reservoir e f short element life is encountered then a coarse grade of element should be fitted CAUTION REMOVAL OF THE PURIFIER OUTLET FILTER ELEMENT MAY RESULT IN THE INTRODUCTION OF PARTICULATE CONTAMINATION INTO THE PROCESS SYSTEM IN THE EVENT OF A COMPONENT FAILURE WITHIN THE PURIFIER Select a point of maximum turbulence where possible ES 21 25 Installation and Operation 7 3 5 7 4 HNP0O21 Service Manual FLUID CONDITIONING PURIFIERS Location of Unit Installation Placement of the unit above the reservoir should be avoided if possible Where it cannot allowance for the subsequent pressure drop to the inlet should be made at the rate of 0 1 bar g 1 5 psi for every 1 metre 34 through which the fluid is raised Further conditions which should be considered when locating the unit are as follows e Vibration High levels of vibration can cause malfunction of electrical equipment and switches e Temperature Ambient temperature levels should be less than 40 C 104 F e Contamination In
20. TED WITH THE OPERATION OF EQUIPMENT AT HIGH VOLTAGE MUST BE OBSERVED The HNP series Purifier is a fluid purification system designed to remove the following e Water 100 of free water and as much 90 of dissolved water depending upon running vacuum setting e Gases 100 of free and entrained gases and in excess of 80 of dissolved gases depending upon running vacuum setting e Dirt including silt and other solids or particulate contaminants Reference should be made to the P amp ID included with the Product Claims and Specifications PCS drawing included in the appendices 10 21 21 Service Manual Description of Operation FLUID CONDITIONING PURIFIERS 42 Principles of Operation The contaminated oil is passed through the purifier vessel via the nozzles Fluid sprays outward from the nozzles and falls under gravity to the bottom of the vessel air and water being removed through the top of the vessel by the airflow Air is drawn out of the top of the vessel by the vacuum pump In flowing through the vessel the contaminated oil presents a large and constantly changing surface area to the dry airflow The dry air passes over the wet oil and moisture is transferred from the oil into the airflow The dry air is obtained by producing a vacuum inside the purifier vessel When ambient air is drawn into the side of the vessel through the vacuum adjustment valve it expands to approxima
21. Vacuum Pump EE 35 9 3 Replacement Cleaning of Inlet Strainer 101 35 9 4 Replacement of Outlet Filter FOZ ci ccctccceccctssactessnssseaccessscctacsesacessaneceteereinaseneere sia 36 9 5 Replacement of Air Inlet Filter FOS 37 9 6 Emptying Fluid Trap F TOT BO 37 9 7 Replacement of Primary Oil Mist Seperator 04 37 9 8 Motor Mantenan g E a SA 38 9 9 Vacuum Pressure Adjustement When 38 9 10 Replacement of Fluid Pump Seals if 38 911 Unt 39 10 7 Osii ea raa a 40 O 40 10 2 Causes OF Common Electrical Faults sacs 46 11 Appendix
22. and Puerto Rico Russia Singapore South Africa Spain Sweden Switzerland Taiwan Thailand United Kingdom United States and Venezuela Distributors are located in all major industrial areas of the world Your distributor is
23. cal Health and Safety spares lists on PCS drawing included Procedures Install a new element with this manual appendix 6 Clean and inspect all threads and sealing surfaces for condition Check the O ring seal for damage and replace if necessary 7 Lubricate the threads with system fluid and Torque tighten to 40 Nm re install the filter element and bowl Re fit bowl 36 MANO21_EN 21 Service Manual Maintenance FLUID CONDITIONING PURIFIERS 9 5 Replacement of Air Inlet Filter FLO3 When the vacuum becomes very high and the adjusting valve has little effect the breather element requires replacement The element cannot be cleaned STEP ACTION COMMENTS 1 Stop the unit and allow vacuum to dissipate from the system 2 Remove air inlet filter by unscrewing anti Replace every six months or as clockwise indicated by operating conditions The vacuum indicator should be retained and fitted to the new filter 3 Fit the element onto mounting Hand tighten only 9 6 Emptying Fluid Trap FT01 Bowl STEP ACTION COMMENTS 1 Stop the unit and allow vacuum to dissipate from the system 2 Unfasten the bowl from the head by turning anti clockwise as viewed from underneath 3 Discard the fluid from the bowl taking care If the unit has shutdown due to low to retain the spherical float vacuum it may be necessary to release the float from the head by easing away using a finger
24. cate a E 15 6 2 Vacuum System ENR ER E EEE REN 15 6 3 Fud Outlet 16 6 4 Ar Dischargs 17 6 5 Drive Syste Meenen en aE R E O RE 17 6 6 Base Assembly 17 6 7 sariaren a aa 18 6 8 19 ir 20 6 82 Alarms and 5 21 7 23 7 1 Slag e a E E RARER E 29 7 2 Prenstallation INSPECTION enpensa a E 23 7 3 Connection of the Unit to Fluid 24 7 3 1 Inlet Line Design 24 73 2 Outlet Line Reservoir
25. e electrical equipment is housed inside the control box This is equipped with door interlocked isolator in order to prevent access to the equipment when it is live The following controls and indications are included on the control panel e Control selector switch Start Stop CS01 Alarm reset pushbutton ARO1 Lamp test pushbutton LT01 e Power on information lamp LP01 Pumps running information lamp 02 Vessel vacuum low information lamp LP03 e Fluid level low information lamp LP04 Fluid level high information lamp LP05 Inlet cavitation information lamp LP06 e Outlet filter blocked information lamp LP07 Drip tray full information lamp LP08 e Power isolator Red Yellow used as emergency stop facility and enclosure interlock 1501 20 21 21 Service Manual Components Details and Safety FLUID CONDITIONING PURIFIERS Systems 6 8 2 Alarms and Warnings The equipment is also provided with a number of interlocks and switches to ensure that it operates correctly and safely The following tables list all alarm conditions for the equipment The active mode refers to the times at which the alarm may be invoked The action shows the result of each alarm THERE IS A RUNNING PERIOD OF 3 MINUTES DURING WHICH NON ESSENTIAL ALARMS ARE DEACTIVATED THIS ALLOWS THE e VACUUM AND FLUID LEVEL TO RISE TO THE PRE DETERMINED SET LEVELS DURING THIS PERIOD THE FLUID L
26. endix Contents HNP0O21 Service Manual FLUID CONDITIONING PURIFIERS 11 Appendix Contents 1 Pall 21 Series Drawing Numbers e 21 INST DHFNO21A4D0 1 single phase options DHFNO21A4D0 3 three phase options Includes e Spares lists e Electrical Schematic e Hydraulic Schematic e Dimensional drawing of purifier 2 Manufacturers Data Sheets Instructions 48 21 021 Service Manual FLUID CONDITIONING PURIFIERS 12 INDEX A M Air discharge 17 33 ANAM Seena EE 21 22 Maintenance 34 crea at 47 Materials of 14 Motor and drive 13 B Mota OVEROAG 35 Base assembly pipe 17 27 Component 15 16 17 18 19 20 21 22 Outlet 45 GOMMEGCUION Gs 24 Outlet 45 COMODO 2 aS 20 OPIONS scoa EN 14 D P Description of 10 Phase failure 46 Design operating
27. essure switch DP01 Inlet pressure gauge tapping 01 Outlet pressure gauge tapping PGO3 Fluid temperature gauge bulb TG01 18 21 21 Service Manual Components Details and Safety FLUID CONDITIONING PURIFIERS Systems 6 8 Electrical System Refer to the schematic wiring diagram included with this manual Internal short circuit and overload protection is provided by means of the following Single phase options Motor protection circuit breakers with adjustable thermal trips and a miniature circuit breaker Breakers MB01 and MB02 provide protection to the pump motors whilst CB01 protects voltage relay VRO1 and power supply PU01 from the effects of over current Three phase options Motor protection circuit breakers with adjustable thermal trips Breakers MB01 and MBO2 provide protection to the pump motors whilst protects transformer TX01 and phase failure relay PRO1 from the effects of over current WARNING AN EARTHED POWER SUPPLY MUST BE USED FOR CONNECTION TO THIS EQUIPMENT THE SUPPLY MUST BE FITTED WITH A FUSE OR CIRCUIT BREAKER SUITABLE FOR THE LOAD OF THE UNIT AS DEFINED IN TECHNICAL DATA For both single phase and three phase options the incoming power supply is used at supplied voltage to drive both pump motors via contactors 1 and CT02 which are switched by the PLC in order to control their operation For single phase options the voltage relay VRO1 is employed as
28. ety devices regularly for correct operation e Malfunctions and defects concerning the safety devices must be reported immediately to the after sales service of Pall e Repairs to pipe work and tanks must be carried out only when the system is depressurised and the unit has been switched off e Observe the applicable safety data sheets and corresponding disposal information from suppliers as well as any relevant local safety regulations when handling chemicals WARNING ELECTRICAL HAZARD Ensure that the power supply is switched off before carrying out maintenance work on the electrical system Any safety devices removed for set up maintenance or repair purposes must be refitted and checked immediately upon completion of maintenance and repair work In the above case particular attention should be paid to accident prevention and safety regulations 21 9 Description of Operation 21 Service Manual FLUID CONDITIONING PURIFIERS 4 Description of Operation 41 General The HNP purifier conditions high and low viscosity hydraulic and lubrication fluids by removing water particulate contamination and gases It is designed for a power supply given on the identification plate which is used at full voltage for the pump motors but transformed to 230V AC for solenoid and ball valve control and thereafter to 24V DC for the remainder of the control circuit WARNING ALL SAFETY PROCEDURES ASSOCIA
29. he vacuum vessel by outlet pump P02 via outlet filter FLO2 a 0 34 barg 4 93 psig check valve CV02 The float switch assembly high and low level floats LS02 and LS01 respectively control the operating level of the fluid in the vessel By returning part of the outlet pump flow back to the vessel via the solenoid valve AV01 when the fluid level actuates the lower switch and using the flow advantage of the outlet pump to empty the vessel when the level reaches the higher switch The PLC controls the actuation of the recirculation solenoid valve applying a signal to open the valve when the fluid reaches high level control switch LS02 and removing the signal to close the valve when the fluid reaches low level control switch LS01 If the fluid level falls below low level control switch LS01 for longer than its alarm set point the unit will shut down showing a low level fault Actuation of high level switch LS03 will shut the unit down showing a high level fault When the outlet filter becomes blocked and the differential pressure reaches 2 4 bar 35 psi the unit will give warning that the outlet filter element will need to be changed If the unit is allowed to run for more than 2 hours after the warning is actuated the unit will shut down In most applications this warning phase will offer adequate time to source a replacement element from stores The outlet system is protected from the effect of a blocked outlet or accide
30. ide an alarm condition to start the unit e g where high fluid level shutdown has occurred then holding the control selector switch in the Start position will allow running whilst an alarm is active CAUTION ALARMS SHOULD ONLY BE OVERRIDDEN WHEN THE OPERATOR 15 SURE THAT THE PROBLEM WHICH CAUSED THE ALARM HAS BEEN REMEDIED Immediately following starting of the unit the vacuum pump is energised by contactor CT01 The vacuum builds up as may be observed the vacuum gauge Once the vacuum reaches 0 45 barg 13 Hg contactor CT02 is energised hence starting the fluid pump The Running lamp should now be illuminated If during the initial 3 minutes the vacuum does not reach 0 45 barg 13 Hg the unit will shut down the Vessel Vacuum Low lamp being illuminated Following the starting of the unit there is a running period of 3 minutes during which non essential alarms are deactivated This allows the vacuum and fluid level to rise to the pre determined set levels During this period the Fluid Level High and Inlet Vacuum High alarms remain active With the fluid pump running fluid is supplied to the vessel This should result in the accumulation of a running level of fluid in the vacuum vessel If the fluid level does not reach the upper control float switch during the initial 3 minute period then the unit will shut down the Fluid Level Low lamp being illuminated If both vacuum and leve
31. important notes These carry information related to the safety of personnel and the integrity and satisfactory operation of the equipment If necessary in house instruction should be provided taking into account the technical qualifications of the personnel concerned The following symbols are used in this manual WARNING THESE ARE INSTRUCTIONS THAT DRAW ATTENTION TO THE RISK OF INJURY OR DEATH CAUTION THESE ARE INSTRUCTIONS THAT DRAW ATTENTION TO THE RISK OF DAMAGE TO THE PRODUCT THE PROCESS THE EQUIPMENT OR THE SURROUNDINGS IMPORTANT THESE ARE INSTRUCTIONS THAT DRAW ATTENTION TO INFORMATION THAT WILL AID INSTALLATION OPERATION OR MAINTENANCE WARNING ELECTRICAL HAZARD THESE ARE INSTRUCTIONS THAT DRAW ATTENTION TO ANY POTENTIAL ELECTRICAL HAZARDS THAT COULD INJURE PERSONNEL THE PROCESS OR THE EQUIPMENT 21 7 Safety 3 2 Installation Site 21 Service Manual FLUID CONDITIONING PURIFIERS When selecting an installation site for the equipment and relevant components the specified escape routes must be kept clear The unit must be positioned horizontally This installation location must offer the system firm and level support The ambient temperature for operation should correspond to that stated on the Technical Data section The ambient temperature for transport and storage 10 C to 40 C 14 F to 104 F Ensure sufficient space for operating maintaining and cleaning the u
32. in amparaiu 40 C 104 F max Ambient humidity 85 RH max Maximum service viscosity stated is under normal running conditions Short term cold start conditions with higher viscosity may be accommodated using the unit although such usage should be approved by Pall and or its agent prior to installation Minimum service temperature is limited by the vacuum pump lube oil viscosity 12 21 FLUID CONDITIONING PURIFIERS 5 4 Fluid System Mean circulating rate 21 I min 5 5 USgpm 50 Hz 25 l min 6 6 USgom 60 Hz 5 5 Vacuum System Flow rate 18 m hr 635 7 ft hr 50 Hz 21 m hr 741 6 ft hr 60 Hz 5 6 Electrical System and Motor amp Drive System Power supply See unit nameplate Supply voltage tolerance 10 of nominal voltage Supply frequency 2 short term aoe 1 extended Control voltage 230Vac amp 24V dc Total motor power 2 15 kW 2 82 Hp 50Hz 10 2 22 kW 2 98 60Hz 10 2 05 kW 2 75 50Hz 30 2 16 kW 2 90 Hp 60Hz 30 For individual motor powers refer to the PCS drawing included in the appendices Power supply fuse rating To suit full load current shown on unit nameplate Motor circuit breaker To suit full load current shown on motor nameplates settings Control circuit breaker 2A setting Ingression rating to IP54 EN60529 ee 21 13 Technical Data 21 Service Manual FLUID CONDITIONING PURIFIERS 5 7 Materials of Constructio
33. in the inlet line can cause problems associated with the following e Increased likelihood of leakage It should be noted that where a suction exists in the inlet line air will be drawn in through a leak rather than fluid being lost e Expansion of air out of solution forming air bubbles These conditions will lead to a loss of treatment efficacy Where hoses are used they should be rated for duty for the inlet line where suction is envisaged the hose should be rated to SAE100R4 The hose should be retained and sealed to the fittings using swage ferrules or high load bolt clamps not jubilee clips as these often do not seal against the ingression of air 7 3 2 Outlet Line Reservoir Return It is counter productive if once the purifier has removed substantial amounts of gas from the fluid it is allowed to cascade from a height into the fluid reservoir This line should be terminated below the fluid level 7 3 3 Appreciation of Reservoir Internal Form The unit should be supplied from an area of the reservoir where it has a supply of de aerated fluid If air bubbles are present at atmospheric pressure then a loss of pump efficiency will be encountered The unit should always be located on the process feed side of the reservoir 24 21 21 Service Manual Installation and Operation FLUID CONDITIONING PURIFIERS 7 3 4 Location of Suction Port on Reservoir IMPORTANT THE LOCATION OF THE SUCTION PO
34. ing Every 3 Months increases against historical values Check conditions of all hoses seals Every 6 Months Check cable conduits for signs of deterioration Every 6 Months Change air breather element FLO3 Every 6 Months or when blocked Replace outlet filter element Every 6 Months or on indication Check linkage couplings of fluid and vacuum pumps Every 6 Months Clean inlet strainer Every 3 Months Clean diaphragm solenoid valve internals inspect for Annually or upon sluggish operation wear and replace parts as required or failure to close Check accuracy of vacuum switches and all gauges Annually Check operation of all safety interlocks Vacuum pump minor service See manufacturer s Annually instructions appendix Electrical safety tests to EN60204 or local equivalent Annually Touch up paintwork Replace corroded parts Annually Fluid pump set and motor See manufacturer s 2 Years instructions appendix Vacuum pump major service See manufacturer s 3 Years instructions appendix 34 21 21 Service Manual Maintenance 7 FLUID CONDITIONING PURIFIERS 9 2 Vacuum Pump Maintenance All vacuum pump maintenance should be carried out in accordance with the manufacturers service instructions included in the appendices Vacuum Pump Lubricating Oil Corena VNE non emulsifying oil 9 3 Replacement Cleaning of Inlet Strainer FLO1 STEP ACTION CO
35. ise fluid temperature or change purifier e Service nozzles if blocked by dirt check that inlet strainer is fitted If the fault cannot be rectified by completing the above contact Pall for advice 21 43 Troubleshooting 21 Service Manual FLUID CONDITIONING PURIFIERS FAULT CAUSE SOLUTION Outlet Pressure High Defective outlet check valve Replace faulty check valve System backpressure is too high Relocate purifier if outlet pressure is greater than 4 barg Possible failure of outlet pressure e Check outlet pressure reading is gauge PG03 correct e Replace gauge Outlet filter is blocked e Check function of DP02 and circuit e Change element Outlet line is obstructed e Check and remove obstruction e Possible undersized outlet line If the fault cannot be rectified by completing the above contact Pall for advice FAULT CAUSE SOLUTION Excessive Vacuum Insufficient vacuum pump Top up pump reservoir via filler Pump Noise lubrication cap Blocked coalescer element Replace element Pump casing fouled Consult manufacturer s service instructions Broken pump vane Consult manufacturer s service instructions Excessive back pressure on Check for obstructions on mesh in vacuum pump the exhaust of the vacuum pump If pipe work has been fitted to the exhaust it should be not smaller than 3 4 diameter
36. ithin local safety codes Pall reserve the right to modify the contents of this service manual without notification 21 Terms of Guarantee The manufacturer is not liable for damage resulting from improper use failure to observe this manual the employment of insufficiently qualified personnel or unauthorised modifications to the unit and unit components supplied by Pall In these cases the manufacturer s warranty guarantee is rendered void CAUTION IMPAIRMENT OF CORRECT UNIT OPERATION WHEN USING INCORRECT SPARE PARTS When using components that have not been approved correct operation of the unit can no longer be guaranteed Only use spare parts approved by Pall MANO21_EN 5 FLUID CONDITIONING PURIFIERS 2 2 Trademarks amp Intellectual Property Pall and Deltadyne are all trade marks of Pall Corporation Filtration Separation Solution is a service mark of Pall Corporation The design of this equipment and all associated documentation is copyright of Pall Corporation 1999 6 21 21 Service Manual Safety FLUID CONDITIONING PURIFIERS 3 Safety 3 1 General Safety Instructions Personnel in charge of installing setting up operating maintaining or repairing the unit and its components must have read and understood this manual and in particular the section on safety Care must be taken in referring to this manual so as to ensure adherence with all warnings cautions and
37. l requirements are satisfied within the initial 3 minute period then the unit alarms are all re energised allowing the unit to be left unattended whilst running 21 21 21 Service Manual FLUID CONDITIONING PURIFIERS Two diagnostic modes are provided on the unit in order to aid fault finding and general service activity These are detailed below 7 6 Diagnostic Functions 7 6 1 Accessing Diagnostic Modes ACTION COMMENTS 1 Press Lamp test button and Reset button Use reset button to scroll through diagnostic modes Mode 1 1st amber lamp will illuminate Mode 2 2nd amber lamp will illuminate If a fault occurs during any of the diagnostics modes then the unit will return to normal operation and display the fault alarm 21 21 Service Manual FLUID CONDITIONING PURIFIERS 7 6 2 Diagnostic Mode 1 This displays the state of the switches on the unit using the 6 amber fault lamps This is intended for use in determining a fault where the actuation of a switch is suspected to be faulty or transient STEP ACTION COMMENTS 1 Press Lamp test button and Reset button 1st amber lamp illuminates indicating once that diagnostic mode 1 is activated 2 Release push buttons Lamps are now displaying switch status if a lamp is illuminated this indicates a closed switch if the lamp is not illuminated then the switch state is open For norma
38. l switch states see table below The table below illustrates the lamps used in conveying PLC input states LAMP No DEVICE NORMAL RUNNING STATE LPO3 Vessel Vacuum Switch On start up switch should be open when vacuum Vessel reaches 0 45 barg 13 5 Hg the switch state Vacuum should become closed Low LP04 Low Fluid Level Control Switch Normally open closed when fluid is above the Low Fluid switch This should momentarily extinguish at the Level bottom of each level control cycle LPO5 High Fluid Level Control Switch Normally closed open when fluid is above the High Fluid switch This should momentarily extinguish at the Level top of each fluid level control cycle LPOG Inlet Cavitation Switch Normally closed When inlet pressure is less than Inlet 0 8 barg 24 Hg this lamp should extinguish Cavitation LPO7 Outlet Filter Blocked Switch Normally closed When filter differential pressure Outlet exceeds 2 4 bar 35 psi this lamp should Filter extinguish Blocked 1 08 Drip Tray Float Switch Normally Closed When the float is lifted to the Drip Tray extent of its travel the lamp should extinguish Full 7 6 3 Diagnostic Mode 2 This displays the last ten shutdown faults using the 6 amber fault lamps STEP ACTION COMMENTS 1 Hold Lamp test button down and press 2nd amber lamp illuminates Reset button twice 2 Release all push buttons Last unit shutdown is displayed 3 Press lamp test button as
39. n Frame vessel Stainless steel Electrical control box Stainless steel Fittings Carbon steel zinc plated Hoses seals Refer to the PCS drawing included in the appendices Solenoid valve Brass body with optional diaphragm as per seal material Inlet strainer Stainless steel Outlet filter Carbon steel painted Fluid pump Cast iron painted Vacuum pump Aluminium painted For a full list of materials of construction contact Pall and or their agent 5 8 Options Available The following options are available for the Pall HNP021 series fluid conditioning purifiers e Panels e Electrical Cable and Plug e High Dirt Capacity Filtration e Inlet Outlet Hoses e Non Resettable Mechanical Hour Run Meter e Remote Functionality e Water Sensor e Larger Castors If any of the above options are fitted refer to the PCS drawing included in the appendices and Pall service manual MANO21 KITS for more information 14 21 21 Service Manual Components Details and Safety FLUID CONDITIONING PURIFIERS Systems 6 Components Details and Safety Systems Throughout the description of the unit those items which are contained within the main manifold block are shown by asterisks See later text for description of main manifold block 6 1 Fluid Inlet System The nozzles are protected from the ingression of large particulate debris by an inlet filter 225 FLO1 As the filter becomes blocked or if the inlet line become
40. nditions must be corrected Alarm Reset pushbutton before attempting to restart the unit CAUTION ALARMS SHOULD ONLY BE RESET WHEN THE OPERATOR 15 SURE THAT THE PROBLEM WHICH CAUSED THE ALARM HAS BEEN REMEDIED 32 21 021 Service Manual Maintenance FLUID CONDITIONING PURIFIERS 9 Maintenance WARNING NO MAINTENANCE PROCEDURE SHOULD BE ATTEMPTED WHILE THE UNIT IS OPERATING WITH THE EXCEPTION OF ADJUSTING THE VESSEL VACUUM REGULATING VALVE BEFORE ANY OTHER MAINTENANCE OPERATION ENSURE THAT THE SYSTEM IS ELECTRICALLY SAFE ISOLATING THE SUPPLY AND CLOSING THE INLET VALVE For consistent performance and long system life routine maintenance is essential The following work should be completed at the intervals stated in the Maintenance Schedule Go Oo 21 Maintenance HNP0O21 Service Manual FLUID CONDITIONING PURIFIERS 9 1 Maintenance Schedule ITEM INTERVAL Check vacuum pump oil level Daily Empty fluid trap bowl Daily Replace vacuum pump oil Every 1000 Hours operation Replace vacuum pump oil separator element Every 2000 Hours operation or when blocked Test lamps Monthly Primary oil mist separator element Every 3 months or when blocked Clean unit paying particular attention to areas around Every 3 Months intakes pipe joints air flow paths etc Measure motor currents and main unit current not
41. nit CAUTION DANGER OF DAMAGE Do not place objects in front of or on top of the unit Observe relevant technical and building regulations Hoses and electrical cables must be laid such that there is e danger of tripping e Protection from damage When selecting an installation site the applicable safety regulations and manufacturer s instructions concerning substances used for or located near the machine must be observed CAUTION INSTALLATION REGULATIONS It is the customers responsibility to ensure that all installations including the disposal and treatment of materials meet the requirements of local regulations Pease refer to the Installation and Operation section for more information 21 02 Safety FLUID CONDITIONING PURIFIERS 3 3 Safety of Personnel Avoid any working practice which Endangers the health and safety of the user or third parties e 5 detrimental to the unit or others the safety and operation of the unit e Does not comply with safety instructions Servicing and maintenance should only be completed by suitably qualified persons who are familiar with the unit and who have been informed of all potential hazards WARNING DANGER TO PERSONNEL There is an increased risk of injury if the safety devices are put out of operation e Never dismantle any safety device or put out of operation e Check the saf
42. nnneeennnnnne 6 cae hsp ces E E E A E E 7 3 1 Bere Ceo Nail grt ee n oP Pre nr en mE Or 7 3 2 instalation 55 WS scauctastesasnctectdeaynensotanetalepeaaneasole A E E NE 8 3 3 aI ol Personnel sersan 9 4 of Operation ssis aea aE aaas SEa a aAa 10 4 1 acre ences acest ec E ES 10 4 2 Principles or Operati e en 11 5 Technical Date 12 5 1 E EE E EE Eai 12 5 2 Gener DO aeee A E E 12 5 3 Design Operating 12 5 4 Fluid EE R EERE 19 5 5 PT SyS teI sss E E i 13 5 6 Electrical System and Motor Drive 13 57 Materials of 14 5 8 AVAA D E sainn neat ine EE 14 6 Components Details Safety 15 6 1 Flad Mlet SYSTE pats a di
43. ntal closing of the outlet isolating valve while running by outlet relief valve RV02 This valve is integral to the outlet stage of the fluid pump The purifier outlet pressure may also be referenced on the pressure gauge mounted on the front of the unit The purifier is protected from back flow and consequent flooding by check valve CV02 When necessary residual fluid may be drained from the vessel by fully closing the recirculation ball valve 02 during normal running operation This prevents any fluid returning to the vacuum vessel and the flow advantage of the outlet pump will empty the vessel 16 21 21 Service Manual Components Details and Safety FLUID CONDITIONING PURIFIERS Systems 6 4 Air Discharge System 6 5 Drive System On units were the fluid to be processed is very aerated it could be possible for an excessive number of fluid droplets to be carried through the air line form the vacuum vessel This purifier is fitted with a fluid trap FT01 installed between the vacuum vessel and vacuum pump The fluid trap will catch any large amounts of oil that are carried over The float inside the housing will block the outlet port should a large amount of fluid be allowed to fill the housing This will result in a shut down of the unit thus preventing the vacuum pump from spilling oil onto the floor Any oil can be drained by loosening the drain plug in the base of the fluid trap The fluid trap sho
44. order to avoid excessive air inlet filter usage and contamination during maintenance sites of high levels or airborne contamination should be avoided e Accessibility Consideration should be given to the need for access to the unit for maintenance e Mounting Stability The unit should be mounted on level ground with the castors locked in the case of mobile units e Avoid areas of high humidity e g near a pipe with a steam leakage This will severely impair the function of the unit CAUTION APPROPRIATE LOAD RATED LIFTING EQUIPMENT MUST BE USED AND SAFE LIFTING PROCEDURES OBSERVED DURING ALL MOVEMENTS OF THE UNIT Units with H option seals are tested with mineral oil those with Z option seals with industrial phosphate ester fluid and those with J option seals with Skydrol 500B Some fluid will be present in the unit upon delivery If it is desirable to remove this fluid it will be necessary to flush the unit with system oil Remove all blanking plugs before connecting the unit to the system pipe work Ensure that the isolator switch is set to 0 Also ensure that mains power is isolated from the power lead upon which any work is carried out Connect an electrical supply in accordance with the specification given on the identification plate attached to the unit OF SUITABLE FILTRATION RATING IS INSTALLED PRIOR TO CAUTION THIS UNIT DOES NOT HAVE AN OUTLET FILTER ELEMENT FITTED WHEN SUPPLIED ENSURE OUTLET
45. s restricted pressure will fall in the line between the strainer and the inlet pump The pressure can be read on the pressure gauge mounted on the front of the unit An inlet pressure of below 0 8 bar g 24 Hg will cause an amber warning lamp to illuminate The unit will shut down to avoid cavitation which can cause severe wear to the inlet pump Inlet pressure switch 502 controls all inlet pressure alarms The oil from inlet pump P01 passes through check valve CV01 the function of which is to prevent flooding when the unit is not in use The fluid then passes into the vacuum vessel via the nozzles The float switch assembly 1501 1502 and 1503 is provided to control the fluid running level and to switch off the unit should the fluid level in the vacuum vessel rise or fall beyond the intended limits No pressure indication is provided on the delivery side of the inlet pump P01 but the pump is protected from over pressure by a relief valve RV01 6 2 Vacuum System Vessel vacuum is maintained by the vacuum pump P03 Vessel vacuum is controlled by the vacuum adjustment valve which is used to set the vacuum level on the unit The factory setting is 0 7 bar g 21 Hg as indicated on the vacuum gauge mounted on the front of the unit 21 5 Components Details and Safety 21 Service Manual Systems FLUID CONDITIONING PURIFIERS 63 Fluid Outlet System Fluid is pumped from the base of t
46. s wrong disconnect the supply and left factory This procedure should reconnect the leads to the motor as only be necessary if motors have appropriate Motor rotation should now be been disconnected from control box correct when started 7 Three phase options only Allow vacuum Correct direction of rotation is to build until fluid pump starts Observe indicated on the pump body direction of rotation from fan end and immediately turn control selector to Stop 8 Three phase options only Correct the direction of rotation if necessary as in 5 21 zz HNP0O21 Service Manual Operating Procedures FLUID CONDITIONING PURIFIERS 8 2 Starting and Running STEP ACTION COMMENTS 1 Open the inlet isolating ball valve MV0O1 2 Open the recirculation ball valve MV02 3 Ensure that all system valves are opened 4 Turn on the electricity supply to the unit Check that this corresponds with the voltage shown on the nameplate Turn the purifier isolator switch to Use the lamp test button to check function of Replace defective lamps as all lamps necessary Turn the selector switch to start the unit When unit has attained correct vacuum for operation the fluid pumps will start When the vessel fluid level is sufficient for operation all alarm functions are operative If the vacuum does not exceed 0 45 bar g 13 Hg within 3 minutes of start up then the unit will stop for
47. tely three times its former volume based upon factory vacuum setting of 0 7 bar g 20 7 in Hg The amount of water in grams in the air does not change With the volume having been increased by 3 times it now has a much lower percentage of water the air has effectively been dried The vessel vacuum also expands any dissolved gas within the oil The gases and water vapour are then discharged to atmosphere via the vacuum pump ES 21 Technical Data 21 Service Manual FLUID CONDITIONING PURIFIERS 5 Technical Data 5 1 Identification Model type See nameplate 5 2 General Data Dimensions Refer to the PCS drawing included in the appendices Dry mass 180 Kg 397 Ibs Fluid connections Refer to the PCS drawing included in the appendices Vacuum pump exhaust Refer to the PCS drawing included in the appendices NB Do not restrict vacuum pump exhaust by fitting small bore pipework 5 3 Design Operating Conditions Fluid To be compatible with seal material Operating pressures Inlet 0 4 barg 11 8 Hg min 0 4 barg 5 8 psig max System back pressure 4 6 barg 66 7 psig max Operating vacuum 0 6 barg 18 Hg min 0 9 barg 27 max Vacuum pump exhaust 3 mbarg 0 04 psig max back pressure Fluid viscosity 12 cSt 68 SUS min Refer to the PCS drawing included in the appendices for max Fluid temperature 10 C 50 F min 70 C 158 F max Ambient service 5 C 41 F m
48. tinuous operation without attention under normal conditions 9 9 Vacuum Pressure Adjustement When Necessary STEP ACTION COMMENTS 1 Run the unit 2 Turn the vacuum trim valve MVO1 until IMPORTANT THE VACUUM desired vacuum setting is achieved IS FACTORY SET 0 7 e BAR G 20 7 INHG HIGHER AND LOWER SETTINGS MAY ALSO BE USED 3 Check the running vacuum after adjustment 9 10 Replacement of Fluid Pump Seals if required STEP ACTION COMMENTS 1 Remove fluid pipe work and mounting bolts and lift out the pump P01 Drain the residual fluid 2 Consult the manufacturer s leaflet IMPORTANT ENSURE THAT appendix THE COUPLINGS ARE e SECURE ON THE PUMP MOTOR SHAFTS 3 Refit the pump and replace the fluid pipe work ensuring that flange seals are central 38 MANO21_EN 021 Service Manual Maintenance FLUID CONDITIONING PURIFIERS 9 11 Unit Disposal At the end of its operational life the equipment should be dismantled and disposed of in accordance with all applicable local national and international waste disposal laws and bylaws Where facilities exist component parts of the unit may be recycled Details of the materials of construction are given in the Technical Data section of this manual Some or all of the components parts of the equipment may be contaminated with the service fluid The Manufacturer s Safety Data Sheet MSDS for the fluid should be read
49. to ensure that contaminated components parts are disposed of safely MANO21_EN 39 Troubleshooting 21 Service Manual FLUID CONDITIONING PURIFIERS 10 Troubleshooting 10 1 General CAUTION ALARMS SHOULD ONLY BE RESET WHEN THE OPERATOR IS SURE THAT THE PROBLEM WHICH CAUSED THE ALARM HAS BEEN REMEDIED FAULT CAUSE SOLUTION Low Inlet Pressure Inlet valve is closed Open inlet valve Obstruction in the customer Remove obstruction pipeline Unit is located above fluid supply or Relocate unit at a distance which can cause significant loss of pressure at the inlet The hose to the purifier inlet has e Hoses on the inlet of the collapsed purifiers must be rated for suction service e g SAE 100R4 It is not necessarily apparent when a hose has collapsed as it may be the inner and not the outer layer The likelihood of collapse is increased if the hose material is incompatible with the system fluid e Check and replace hoses if necessary Fluid not within the service Raise fluid temperature viscosity range of the purifier Purifier inlet filter is blocked Clean filter element and refit Faulty pressure switch 502 e Check gauge reading Pressure Gage e Replace switch or gauge as required Inlet pipe work in purifier blocked Remove blockage and ensure strainer if fitted If the fault cannot be rectified by completing the above contact Pall for advice
50. uld be checked regularly and drained when required On passing the fluid trap the air passes through the vacuum pump and its integral coalescing filters before discharging to atmosphere The fluid pump and vacuum pump are directly driven by electric motors No adjustments are necessary 6 6 Base Assembly and Pipework The base assembly is manufactured entirely from stainless steel A non removable drip tray with a high level warning mechanism LS04 is included which shuts down and isolates the unit in case of fluid spillage Most of the pipe work is stainless or corrosion protected carbon steel with flexible hoses connecting items bolted to the base plate to reduce noise and vibration during operation Any fabricated pipe work is manufactured entirely from stainless steel 21 17 Components Details and Safety 21 Service Manual Systems FLUID CONDITIONING PURIFIERS 6 7 Main Manifold Block The main manifold block houses much of the operating equipment of the purifier The block is mounted at the front right hand corner as viewed from the control box end of the unit All equipment mounted within the manifold block is readily accessible for servicing The items which are mounted within the manifold block are as follows Inlet strainer FLO1 Inlet ball valve MV01 Recirculation ball valve MV02 Nozzle relief valve RV01 Inlet depression switch PS02 Outlet filter FLO2 Outlet filter differential pr
51. y completing the above contact Pall for advice FAULT CAUSE SOLUTION Voltage Relay single No incoming supply Check incoming supply voltage and phase options only restore Incorrect supply voltage Correct incoming supply If the fault cannot be rectified by completing the above contact Pall for advice FAULT CAUSE SOLUTION Phase Failure Relay incoming supply Check incoming supply voltage and three phase options restore only One or more phase lost Check phase sequence Switch any two wires at incoming isolator with power supply off three phase units only Incorrect supply voltage Correct incoming supply If the fault cannot be rectified by completing the above contact Pall for advice SOLUTION Main Circuit Breaker or Short circuit Check and repair wiring Fuse Tripped If the fault cannot be rectified by completing the above contact Pall for advice 46 21 FLUID CONDITIONING PURIFIERS FAULT CAUSE SOLUTION Power On lamp fails to Power lamp not On e Turn isolator on Illuminate e Turn main power supply isolator to the On position e Check main power supply circuit breaker or fuse is not tripped e Check lamp in lamp e Assure incoming supply using voltmeter If the fault cannot be rectified by completing the above contact Pall for advice ES 21 47 App
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