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S-Series Service Manual - ASL Technologies, LLC!

1. 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 pressing 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 wi
2. dish PROY piseInq noS OOSTL LLVTL Z8 vV LO0Zd LL vE LOLd LS vE LOLd Le ve LOld 8 6VT1L L 6V1b S 6V1L 6V1L L VTL v 902d V vZ371H00 V rZ3100 vz371H00 vz3100 023130 99 0ZA310 29 02A310 023710 7800 b zes00 6ztXW r g0 S00 v 80 L00 v 80 S00 v 80 700 v 80 9100 H ZZ SOld H b2 00ld JequNN Hed dnoiy dung l Y THWHLAL 07 6 gL L 9L eg SL N 2 57 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 00 LEV 040 CC A S 40 Pum NOILdO 3A VA dal 13qd q 100 OL vl L ZL gt LL S ynu ujooe ynu yeyse6 1 Aoo deo yeyseb deo anjea yeyseb deo anjea mas Bunsn pe Jouleyol ASL 40 Spring Jabunjd uondusIag woon mmm wooiymadwndiuyn ewe 00S SZ Buds jeuondo yZ 021 Buuds jeuondo 6914 1474 Buuds jeuondo rs sg Buuds jeuondo y 0 Buuds jeuondo 0 S Buuds jeuondo 071 SS Buuds puepueys 953710 8253710 V v9310 9SAM10 L0ZX r940 bLL 0bd Z6NS0 XE 9A10 9Ad10 f9HAM10 662X 2990 L0ZX 2990 X 0840 9AM10 LOZX 8SA10 Jequinn Hed 6980 88E 804 Xe4 00SZ 68 802 IAL dnoiy duu nd i oseumsemaunosoosa THLAL vL eb zL kL OL 38 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Ph
3. ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com ASL Technologies LLC Quality Policy ASL Technologies LLC was founded with the commitment to be the industry leader in product quality customer service and customer satisfaction in the market places we serve Our patented product line of Electrostatic Fluid Filtration equipment is designed built tested and delivered with these goals in mind Congratulations on the purchase of your new Finite Particle Removal System FPRS This manual covers models FPRS S30 Cab and FPRS S40 Cab ASL Technologies FPRS S Series Units provide state of the art fluid filtration that allows superior filtration capability at a minimum investment Affordable electronics and compact design are combined to provide economic filtration without compromising the effectiveness of Electrostatics Though compact in size the S Series can provide up to a year of replacement free filtration It also provides effective cost recovery of valuable fluids and extension of component life in hydraulic dielectric and solvent systems ASL encourages you to read through this manual completely Information has been provided in order that our customers can experience the maximum benefits resulting from extreme fluid cleanliness Every situation cannot be anticipated and ASL is
4. 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 50 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom 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 properly 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 t
5. will also trap larger particulate and should be replaced at least once each year 40 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com FPRS S SERIES CABINET FLUID FLOW DIAGRAM OUTLET Cust supplied I O hoses Grey Hose Electrostatic Cell Water Absorb Hydraulic Oil eles sorber Reservoir x Throttle Valv Note these hoses are both Black on Phosphate ester units 41 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com S Series Cabinet Dimensions Not to Scale See next page for Lid open dimensions lt as eim 14 375 gt ooooooo lf 1 NPT RT SIDE Inlet Outlet 25 125 Outlet 6 00 Inlet 8 00 ue 1 0 Y Io 0 625 Wall Mounting Keyhole Detail 42 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com S Cabinet Units Right Side View Lid Open Dimensions Not to scale OUTLET Finite Particle Removal 26 0 System 43 ASL Techn
6. zL gt ynu usooe ynu yeyseb 1900 deo yoyseB deo anjen yoyseBb deo ane maS Bunsn pe Jauleyol o0S SZ Buuds jeuondo 28 024 Buuds jeuondo 6914 1474 Buuds jeuondo vS G Buuds jeuondo _ 0 Buuds jeuondo 0 S Buds jeuondo 0Z1 SS Buds psepue s Jabunjd uondr5s eq ASL 30 Spring WOON MMM uuoo liuunmeduundiliuim ewo 953710 825310 V v9310 9SAM10 L0ZX r940 bLL E0Ld Z6NS0 X 9A10 9Ad10 E9HAM10 662X 2990 b0ZX 2990 X 0840 9AM10 LOZX 8SA10 Jequinn Hed 6980 88 802 xe4 OOSZ 6eE 804 11 dnog dung i 4 prownsara anes cos THLOL vb eb zL LL oL Z 9 w y END OF SERVICE MANUAL 60
7. Code L H P FR 48 YZ Phase 1 RPM 1725 1425 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 Time Cae 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 T 5 Lo Volt Factory Wired this wa 9 3 1 Black 1 LI 3 2 Hi Volt 208 230 Volt ONLY 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 S40 Cabinet is 0OLEV 040 CC A S 30 units use 30 LEV CC A 9821 The manual is reprinted with permission from the Tuthill Pump Group 45 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom Wwww aslfilter com TUTHILL 12500 South Pulaski Road Alsip Illinois USA Pump Group ea Thien a a email tuthillpump tuthillcom www tuthill com Installation and Service Instructions S 40 00 LEV 040 CC A S 30 30 LEV CC A 9821 46 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom www aslfilter com General Description Tuthill s LA and LE Series are com
8. F fet o Fluid Delivery Pump Motor The self contained pump and motor delivery system allows for continuous filtration even during machine downtime Installation Is convenient and maintenance does not require shutting down the hydraulic system A pump motor assembly is provided which is designed to be compact and is for continuous duty maintenance free and has been sized for the correct flow rate Hydraulic Connections All the connections between the reservoir and the cabinet can be with hard piping or hose connections On the S Series units 1 2 NPT bulkhead fittings are provided for your convenience on the right power cord side 16 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 4 Mounting Surface The S Series Cabinet Model has cooling vents on both the back and bottom allowing wall mounting or floor placement For wall mounting keyhole slots are provided on the back panel of the unit An optional floor dolly can be purchased or fabricated locally to provide mobility of the cabinet to so it can be moved for servicing machinery that it is in close proximity However you decide to mount the cabinet allow 6 inches of space between the back or bottom louvers for pump motor cooling See the outline drawings on pages 42 amp 43 for dimensions 5 Remote A
9. Rev 9 01 18 12 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Quick Startup Guide This section is intended for experienced users only Please be sure to read the entire manual 1 aed o 90 11 12 13 14 15 16 17 Unpack FPRS Unit from shipping box skid Open Top Cover by grasping rolled lip and lifting up like a car hood Swing the top cover all the way back to the stop The cover is hinged at the top rear sides and held closed with magnets Use caution when the top cover is open shock or jarring may cause it to close suddenly and could cause personnel and or equipment damage Remove front cover by pulling the top rolled edge toward you about 2 inches to disengage the magnets and lift front cover clear of unit The front cover fits outside the case sides and rests inside the case at the bottom 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 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 Remove the cardboard shipping spacer underneath the hydraulic pump motor Make sure the float switch is correctly position
10. Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www 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 Zi 10 11 12 13 14 15 WARNING Turn OFF the FPRS on the control panel and at the electrical source Open the top hinged cover and remove the front cover Disconnect the high voltage wires as follows WARNING Short across the positive and negative electrodes using a screwdriver with an insulated handle to dissipate static electricity WARNING Each cell has a positive red lead and a negative green lead connected to it NEVER touch both leads at the same time Disconnect the high voltage wire connections leading to the top of the cell using one hand grasp the boot connected to the green wire and pull up Repeat with the boot connected to the red wire Remove the input and output hoses by releasing the quick disconnects Loosen 4 attaching screws from outside of the cabinet and lift the cell out of the cabinet Replace with a new or rebuilt cell Ensure that the cell is inserted correctly with high voltage electrodes pointing upwards Attach quick disconnects with blue hose to the bottom of the cell and gray hose to the
11. also supplies power to the pump motor assembly Hence the meter only runs when the pump is receiving power In troubleshooting a defective hour meter with the system running check for 120V AC power at relay CR3 3 if no voltage present the pump is not running either If voltage is present and the pump is running check for power at the red wire on the back of the meter If voltage is present check the white neutral also replace the meter If voltage is not present check the wire running from CR3 3 to the meter Note that two wires are installed on CR3 3 black goes to the pump and red goes to the meter If the pump and motor AND the meter are not running no other abnormal system indications check for 120VAC at the coil of CR3 8 If voltage is present there should be power on CR3 3 If no voltage on CR3 3 replace the relay If no voltage present on the coil of CR3 8 trace backwards to CR2 1 CR2 5 CR4 1 CR4 5 CR1 3 CR1 5 Refer to the wiring diagram on page 28 of this manual REMOTE ALARM CIRCUIT The remote alarm circuit consists of two sets of dry contacts in relays CR 1 and CR 3 CRI 6 amp 4 are closed during normal operation as are CR3 4 amp 6 Two wires lead out to a two pin male spade connector which accepts 250 inch female spade terminals This connector is located on the right side of the cabinet just below the power cord During normal operation these two pi
12. located within this manual Please refer to them to reinforce your knowledge of this product Remember that ASL Technicians are just a phone call away should you need any advice or assistance ELECTRICAL THEORY OF OPERATION Refer to the wiring diagram on page 28 the wiring diagram is also laminated and pasted inside the front cover The FPRS S series units use the following wiring conventions Black wires 120VAC Power White wires 120 VAC Neutral Green Wires Ground Yellow wires H V Power Supply Low Voltage alarm circuit Orange wires H V Power Supply Backflush alarm circuit Blue wires Remote Alarm Circuit Red wires 120VAC switched signal Exceptions a The green wire on the pressure switch is capped and not used but will have 120VAC present when the pressure switch is open normal condition b The float switch comes standard with two white wires pre installed on the switch These white wires pass 120VAC through the switch in case of an internal FPRS leak The red pink hi voltage wire coming out of the right side of the power supply carries 15 000 VDC to the Electrostatic Cell THE 120VAC POWER CIRCUIT 120VAC power from the incoming power cord source goes first to a 4 position terminal strip on the back wall of the cabinet TB 1 located in the upper right corner of the cabinet H is Hot black N is Neutral white and G is earth ground green From there power black wire runs to another termin
13. 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 24 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslfilter com PRODUCT SPECIFICATIONS FPRS S Series Cabinet Units PHYSICAL DIMENSIONS Filter Cabinet 26 1 8 High x 19 3 8 Wide x 14 7 8 Deep Cabine
14. 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 37 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 5 10 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 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 o
15. 00 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 for the particles and holds them in place This collection of particles is a phenomenon known as strawing Your FPRS comes equipped with a water absorption unit that can remove free and emulsified water down to 50 PPM This feature covers a wide range of water problems Each fluid to be cleaned has its own characteristics which may require modifications in magnetic field density and the dedicated collection media used within the electrostatic cell The cell provided in your unit has been built to meet your specific requirements Therefore when discussing your unit with us or when ordering cells be sure to state the correct model number of the cell The model number is shown on a red tag on top of the cell i e R61CS 115 R62CS 115 etc Note that Phosphate ester fluid compatible cells have a B in the parts number i e RB64CS 115 etc Mineral oil cells have a Gray tube and Phosphate Ester Cells have a Black tube The long term benefits of continuous filtrat
16. 733 2779 or e mail custsvc aslfilter ccom _ Wwww 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 IPB Starts on Pg 57 HOUSING IDLER Z SAW Sr lt WA ZE BWA SSS 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 changed 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 Remov
17. A Connect the input and output hoses to the FPRS Connect the input hose to the fluid reservoir If there is no place to secure the hose simply place the hose in the fluid near the bottom of the tank Place the output hose into the fluid reservoir at the top of the tank When installing an FPRS S Series on an elevated reservoir where the lowest fluid level of the reservoir is higher than the FPRS it is recommended that shut off valves be installed in the line running from the reservoir to the FPRS pump inlet Also the line running from the FPRS back to the reservoir outlet CAUTION HANDLE THE HOSES SO THAT SPILLS CANNOT TAKE PLACE SYSTEM START UP o ff Connect the FPRS to a grounded 120VAC power source Both the FPRS and the hydraulic system reservoir must have earth ground Ensure that the shut off valves on the input and output lines are open Locate the drain valve on the bottom of the water absorber canister and verify it is in the closed position Locate the Throttle valve on the inlet side of the water absorber canister and verify that it is in the open position Place the front cover in position and close the top cover Turn the POWER switch on the front panel to the ON position The green POWER lamp will illuminate and remain on Note that the red LOW VOLTAGE lamp will flash and then remain off The FPRS pump will start running and draw fluid from the reservoir in
18. IGH VOLTAGE CR 1 CR 2 CR 3 Power Supply Low l Float I Pump w i i Wire Runs TB 2 Connections e Power Signal HVDC 1 Yellow To Low Voltage relay l 2 Orange To Backflush indicator 3 Red Black Switched 120VAC AN Sad 4 Black Incoming 120VAC TB 1 Connections x 5 White Incoming 120VAC Neutral H Incoming 120 VAC i N Incoming 120VAC Neutral u G Incoming Ground x TB 3 Connections Gnd Ground Stud 2 MNGESPP KIASI wae amp A TB 3 Connections To Electrostatic Cell M Black Motor Start N White Neutral G Green Ground F Red Float Switch Fault Signal Sp Black Float amp Press Switch Power P Red Press Switch Fault Signal 29 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com MAINTENANCE AND TROUBLESHOOTING The FPRS system is designed to give years of trouble free service with little attention The front panel lights microammeter and system pressure gauge 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
19. Particle Removal System Patent Numbers 5 149 422 5 242 587 and 5 891 315 other Patents pending uses the most advanced technology available to clean and reuse oil i e transformer hydraulic turbine lubricating and solvents There are basically five 5 major factors contributing to the contamination of industrial fluids Air Heat Water Particulate matter Oxidation of by products Contamination of industrial fluids is a great concern because their condition is directly related to the condition of the overall system they function in Controlling these five factors is foundational to maintaining a trouble free system The following preventative measures do much to extend the life of the fluid and the hydraulic system One must minimize the external ingression of air and particulate in the fluid Breather bags and air intake filters have been used effectively for this purpose Maintaining the fluid temperatures within the specified limits can be achieved through proper care and maintenance of the cooling system We have equipped your filtration system with continuous water removal capability to prevent build up due to condensation to keep the fluid dry Finally the fluid must be kept as clean as possible not only by removing particulate such as Dirt Fibers Wear metals Also the Submicronic Contaminants such as Silts Tars Varnishes Tars and Varnishes are the byproducts of oxidation and
20. accumulation of an excessive amount of particulate particularly ferrous particulate a Turn power off and un plug the FPRS from the power source b Using a screwdriver with an insulated handle short across both POS and NEG terminals of the Electrostatic Cell to dissipate any static electricity c Remove the red POS spark plug boot terminal from the Electrostatic Cell Remove relay CR 3 to prevent the pump from starting Re connect power and turn on the power switch Note that you will have to A defeat the cover safety switch to continue USE CAUTION f If the low voltage light is now off the Electrostatic Cell is shorted and should be backflushed and or replaced g If the low voltage light is on with the 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 1 Note that a defective CR 1 relay and associated wiring can also cause a low voltage indication 31 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 2 Defective Power Supply If the internal normally closed low voltage relay in the power supply is defective a low voltage indication will result Trouble shoot this failure as f
21. al strip located on the inside of the top cover to the right of the relays TB 2 4 from TB 2 4 power then runs to the 10A circuit breaker on the front panel From the circuit breaker power is fed to the ON OFF switch on the front panel Power then flows to the cover safety switch and on to TB 2 3 Once power leaves the cover safety switch it is called switched power or Sp There are four wires connected to TB 2 3 One is the incoming switched power from the cover safety switch two goes to the Hi Voltage power supply H terminal three goes to TB 3 on the back wall of the cabinet above the pump motor terminal Sp where it splits and sends power to the pressure switch and the float switch and Four goes to relay CR 3 5 then to Relay CR 1 5 then to the green power on light Note that the normally closed contacts of CRI 5 amp 1 will momentarily pass 120VAC to the red Low Voltage light 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 CRI via the yellow wire The action of CR1 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 closed the contacts of CR1 5 amp 3 close allowing power to flow through the normally closed contacts of CR4 5 amp 1 and CR2 5 a
22. 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 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Table of Contents Subject Page Quick Startup Guide 3 Important Safety Information 4 Introduction System Overview 6 Important Guidelines 8 System Safety Features Indicators Switches and Lights 8 Front Panel Controls Indicators Photo 11 Internal Components Photo 12 Drip Tray and Float Switch Photo 13 System Preparation 14 Installation Considerations 15 Fluid Maintenance 19 Cell Backflush Operation 20 Cell Removal Installation 21 Water Absorber Replacement 22 Electrostatic Cell Rebuild Program 2 Warranty Information 24 Product Specifications 25 Parts Ordering Information 26 Spare Replacement Parts List 27 Wiring Diagram 28 Cover Electrical Component Locations Drawing 29 Maintenance and Troubleshooting 30 Removal and Replacement of Components 36 Pump and Pressure Switch Adjustments 39 Scheduled Maintenance Tasks 40 Fluid Flow Diagram 41 Cabinet Dimensional Drawings 42 Electric Motor Service Data 44 Hydraulic Pump Vendor Service Manual 46 Hydraulic Pump Illustrated Parts Breakdown 57
23. ater has entered the Electrostatic Cell concentrations of 600 ppm and higher will short it out rapidly Replacement of the water absorber and Backflushing the Electrostatic Cell perhaps several times will restore proper operation Changes in microammeter readings will also occur under the following fluid conditions 1 HEAT Current Increases Fluid temp will cause the uA to increase A rise from 80 F to 110 F can sometimes double the uA In turn as fluid temp decreases so will the uA 2 COOLING Current decreases 3 WATER Water can make the base current appear higher than it really is 4 VARNISH Although the Electrostatic Cell is capable of capturing a lot of varnish before it will effect the operation of the Cell at some point as the oil oxidizes varnish will cause the efficiency of the cell to decrease and the Cell will need to be replaced 34 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 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 single phase power which comes from CR3 3 This relay contact
24. 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 53 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom _ 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
25. cabinet Transfer the black Heyco wiring fitting and locknut to the wiring box of the new motor 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 Install the new motor onto the cabinet studs and secure with four 14 20 locknuts and flat washers 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 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 the SO cord through the Heyco fitting and re connect wiring in accordance with the diagram on page 44 of this manual Tie up any loose wiring and return the unit to service Note that pump adjustments should not be required when replacing the motor only 38 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Pressure Switch Replacement Replacement of the pressure switch will normally never be required due to the fact that correct operation of the switch will occur only after failure of the pump by pass and system pressure has exceeded 43 to 45 psi There are other instances that could cause illumination of the overpress
26. coming back down from CR1 3 provides power through the now closed contacts of CR4 4 amp 6 keeping the overpressure light on and the coil of CR 4 closed Thus even though the pressure switch may only bump closed momentarily the red light and fault will remain latched on until an operator intervenes Cycle power off then on As designed when the overpressure circuit is operating properly it indicates a failure of the pump assembly and or the pump relief valve Repairs on the pump should only be undertaken by experienced hydraulic pump repair persons New spare pumps can be purchased through ASL Troubleshooting this circuit is straightforward The only components are the pressure switch itself relay CR 4 and the associated wiring See the Removal and Replacement of Components section starting on page 36 MICROAMMETER The microammeter located on the front panel between the elapsed time meter and the over pressure light 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 S
27. d to oxidation or contamination with an acidic product Particle Count Monitors the oil cleanliness level to provide indication of filter efficiency and potential wear failures Water Indicates the presence of moisture of coolant in the oil For detection of water content below 1000ppm the Karl Fischer method can be used Spectrochemical Elemental Analysis The presence of elements in solution i e additives wear metals and contamination elements FT IR Estimation of oxidation levels PIXTE Analysis of contaminant residue on patches 3 When the condition of the oil is in question it is usually more economic with small reservoirs to simply replace the oil than it is to spend money on extensive testing Tests should be used to analyze potential problems in the machinery not necessarily to determine oil life in these cases 19 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com CELL BACKFLUSH OPERATION Backflushing of the cell is unique to ASL s Finite Particle Removal System This operation allows the cell to be reused without being replaced under normal use Under normal operation Electrostatic Cell and water absorber should be changed annually When the cell becomes filled with contaminants about 500 microamps and or the amber BACK FLUSH lamp il
28. d ty wrapped when you receive your FPRS The hose is stowed behind the absorber canister WATER ABSORBER INLET SHUT OFF BALL THROTTLE VALVE This Normally Open valve located just above the pressure gauge is used during water absorber replacement and when setting the pump by pass and pressure switch pressure Note that this valve is located on the pressure side of the pump and should always be open unless pump pressure switch adjustments are being made COVER SAFETY SWITCH Once the power switch is placed in the ON position power flows to one side of the cover safety switch With the cover in the open position power is interrupted preventing operation of the FPRS 10 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com Www aslifilter com S Series Front Panel Controls and Indicators See pages 8 10 for detailed function ASL Tecunovocies LLC Fiuw PURIFICATION SYSTEM System Pressure Gauge 10 11 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com S Series Internal Component Locations Refer to descriptions on pages 8 10 Numbers in refer to descriptions Hour Meter 9 Cover Safety Switch 15 Microammete
29. d 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 48 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom 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 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 2 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 rotatio
30. e cabinet Your system was tested with fluid but the water absorber element canister and the Electrostatic cell 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 3 4 minutes turn power OFF and make sure the inlet hose is primed ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter 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 Ae 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 mi
31. e 7 16 locking nut with a wrench by turning counterclockwise Slowly close the throttling ball valve above the pressure gauge until the system pressure is at 50 psi 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 6 If the pressure reaches 50 psi before the throttling valve is completely closed turn the adjusting screw outward counterclockwise until 50 psi is reached Adjusting counterclockwise lowers the pressure setting 7 The pressure switch may close during the above adjustment shutting the system down with an Over Pressure fault If this happens remove the 1 8 inch Allen lock screw from the pressure switch and set aside The pressure switch adjustment is also a 1 8 inch Allen and can be adjusted after removing the lock screw Turn the pressure switch adjustment clockwise to raise the switch closing point above the pump by pass setting 8 Once the by pass is set at 50 psi with the throttling valve closed open the throttling valve for a few minutes to let the system flow Operation with the pump in full bypass for long periods will cause excessive heat buildup and could cause damage to the pump ARwWN 9 Slowly close the throttling valve until the pressure gauge reads approximately 43 to 45 psi Adjust the pressure switch slowly counterclockwise until the system
32. e DC power supply which supplies 15 000 VDC to the Electrostatic Cell The signal to illuminate this light comes from a relay internal to the high voltage power supply yellow wire which opens at approximately 700 micro amps If this lamp illuminates it indicates that the high voltage DC power supply output voltage is low and could be caused by a variety of reasons When the LOW VOLTAGE lamp is illuminated power to the pump motor is interrupted Refer to the Maintenance section 5 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 internal 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 20 of this manual 6 RED FLOAT SWITCH LIGHT Illumination of this lamp indicates that there is either a fluid leak inside the FPRS or the float switch has been upset during shipping or recent movement of the unit Note that this is a latching fault and will not reset itself even if the float switch re opens Power must be turned OFF and then back ON after correcting the fault The float switch which activates this fault is located in the drip tray in the right rear corner on the bottom of the FPRS cabinet Note also that even though the pump stops the 15 000 VDC
33. e 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 52 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom 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 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
34. ed in the bracket tray The hinged float should be hanging down toward the bottom of the tray such that a build up of fluid will raise the float and close the switch Verify that the THROTTLE VALVE on the inlet side of the W A canister is OPEN Verify that the W A drain valve on the bottom of the W A canister is CLOSED Remove the plastic 1 2 NPT shipping plugs from the right side inlet and outlet bulkhead fittings Plumb inlet and outlet hoses to your reservoir Use Teflon tape or equivalent Inlet to the lowest point on the reservoir and outlet to the opposite side top of the reservoir Make sure to drain any free water which may have accumulated at the bottom of your reservoir Unwrap the power cord and connect to a grounded 10 amp 120 VAC outlet Note that the FPRS unit and your system reservoir must both have earth ground Reinstall the front cover and close the top cover There is a safety switch on the top cover that must be closed to allow incoming power to reach the power supply Turn the Power Switch to the ON position The green Power lamp should illuminate Note that the Red Low Voltage lamp illuminates momentarily and then goes out The Fluid Delivery System pump motor will immediately start and begin drawing fluid from your reservoir Note that the pump may need to be primed before any outlet flow is observed The S Series pumps will only lift fluid about 18 inches from the bottom of th
35. er supply high voltage section failure is operating the Electrostatic Cell beyond one year 8700 hours BACKFLUSH INDICATOR AMBER Backflushing of the Electrostatic Cell in your unit is unique to the FPRS system Backflushing the contaminates out of the cell allows for much longer filtration life than with conventional mechanical filters The amber backflush light is controlled directly by the high voltage power supply orange wire A normally open relay inside the high voltage power supply closes when the power supply senses 500 microamps As shown on the wiring diagram once the internal relay closes the amber backflush light receives power directly A backflush light should always be confirmed by observing the microammeter reading of approximately 500 microamps Note that the microammeter is connected between system ground and the NEG terminal on the Electrostatic Cell The orange wired backflush relay inside the power supply also senses 500 microamps and lights the light but in a different manner Under normal circumstances when the backflush light comes on and the microammeter reads 500 microamps it s time to backflush the cell in accordance with the Backflush procedure on page 20 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 tha
36. ernal failure these contacts open If these connections are used do not exceed 24 VDC 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 On earlier models a Parker sample valve was used To use this style port unscrew the cap from the port the chain prevents cap loss and use a suitable sampling push to test valve from Parker Stauff or others to draw the sample On later models a KP series thumb push sample valve is employed requiring no special tools of 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 On models equipped with the KP push to test sample valve a sample hose and bottle are attached at the factory 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 an
37. f lubricant on the push lock fittings will ease installation of the hoses Proceed to PUMP and PRESSURE SWITCH ADJUSTMENTS on page 39 Replacement of MOTOR only If you have determined that only the motor needs to be replaced the pump and its attached hoses can remain in the cabinet 1 10 11 12 Start by removing the motor wiring box cover and disconnecting the wire nuts tying the SO cord to the motor leads The green ground wire is secured with a green screw to the motor inside the motor wiring box Pull the SO cord out of the motor wiring box and plastic Heyco connector Note that wire connections and numbers are located on the motor nameplate as well as page 44 of this 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 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 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 out of the
38. fault the over pressure fault is a latching non resetting fault As stated elsewhere in this manual the bypass relief valve on the pump in your FPRS unit is adjusted at the factory so that the pump will be in full bypass at approximately 40 psi If for some reason the bypass relief valve in the pump should fail system pressures could rise drastically very quickly The pump is easily capable of pressures exceeding 200 psi Such a sudden pressure rise if not checked could blow the seals in the Electrostatic Cell water absorber canister and rupture hoses within the system causing significant equipment damage and or personnel injury The pressure switch located just below the test port is adjusted at the factory to close at approximately three to five psi higher than the pump bypass relief valve i e 43 to 45 psi When the contacts of the pressure switch close power which has been sitting on the black wire is allowed to travel through the red pressure switch wire to the red overpressure light the coil of CR 4 and contact CR4 6 Once CR 4 is energized the normally closed contacts of CR4 5 amp 1 open stopping the flow of power to the coil of CR 3 When CR 3 opens power is removed from the 33 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com pump and hour meter The wire
39. he 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 or 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 51 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219
40. he elapsed time indicator shows in hours and hundredths of hours how long the system has been running Note that power is supplied to the hour meter from the pump motor start signal and will only run when the pump is receiving power The hour meter reads to 99 999 99 hours 11 years SYSTEM PRESSURE GAUGE The system pressure gauge viewable through the hole in the front cover shows system pressure downstream of the pump 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 progressively higher pressure due to accumulation of water in the water absorber element and or excessive 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 REMOTE ALARM CONNECTOR The Remote Alarm connector located on the right side of the cabinet near the power cord entrance is a two wire 250 male spade connector that can be interfaced to a remote alarm or PLC The signal runs through two dry sets of contacts in relays CR 1 and CR 3 When the system is operating normally these contacts are closed In the event of any int
41. hour meter are running 3 Check system pressure gauge below 35 psi 4 Check Microammeter below 500 microamps WEEKLY 1 Leave the Power switch in the ON position open the top cover and observe that the unit shuts down 2 Check for any internal leaks 3 Check for loose relays wiring and connections for security 4 Close the top cover and observe that the unit re starts 5 Perform the daily checks after the unit has re started MONTHLY In addition to the weekly checks above perform the following additional checks 1 Using a soft cloth wipe down the exterior surfaces of the cabinet The static electricity forces at work inside your FPRS unit will attract dirt and dust from the air around the unit Pay particular attention to the cooling vents on the bottom and back of the cabinet as well as the motor end bell and motor cooling fan 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 YEARLY In addition to the monthly checks above perform the following additional maintenance actions and checks 1 Replace the Electrostatic Cell 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
42. hut down the system and backflush the Cell in accordance with the instructions on page 20 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 replaced 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 other than one or two seconds at initial power up of the system The microammeter on your FPRS system should be checked frequently When the system is new and the oil in your reservoir is clean microamp readings will be low Normally the meter will climb very slowly over time and may take months to reach 500 On other systems the meter could start at 200 and slowly climb or even go down over time The main thing to watch for is erratic movements rapid climbing etc A rapid climb most always indicates water has entered the system and finding and correcting the source of the water intrusion should be paramount Once w
43. ing 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 generally 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 cleara
44. ion with this product as the contaminants are purged from your system will become evident through reduced downtime and maintenance expenditures extended machine life and greatly improved fluid life Coupled with our water absorber this product will protect the lifeblood of your hydraulic system from three of the five major factors that contribute to fluid degradation Water Particulate Matter Oxidation by products ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com IMPORTANT GUIDELINES Oil temperature should not exceed 165 F for electrostatic cells 175 F for black tube Phosphate Ester Cells Ambient air temperature should not exceed 160 F Viscosity of the oil to be cleaned cannot exceed 1800 SUS 100 F The minimum flash point of the oil should not be below 200 F FPRS S Series units will automatically restart if input power is momentarily lost Concentrations of water should not exceed 500 ppm If in excess a water absorber should be used to reduce the content to an acceptable level less than 500 ppm before the electrostatic cell is employed It is recommended the FPRS input hose be connected to or draw from the lowest point of the reservoir Therefore when hooking up to a reservoir for the first time or after a period of non filtration always drain free water fr
45. is still applied to the terminals of the Electrostatic Cell while power is on 7 RED OVER PRESSURE LIGHT Illumination of this lamp indicates an overpressure condition has occurred Note that this is a latching fault and will not reset itself even if the overpressure condition clears Power must be turned OFF and then back ON after correcting the fault The overpressure light is actuated by a pressure switch between the pump outlet and the water absorber canister As in 6 above 15 000VDC is still applied to the Electrostatic Cell while this fault is latched 8 MICROAMP METER The Microamp meter indicates the amount of high voltage DC power being consumed by the Electrostatic Cell Under normal conditions the Microamp meter will indicate between zero and 400 and is a way to determine the general condition of the Cell Note that high concentrations of water or excessive accumulations of ferrous particulate can cause high microamp readings At 500 microamps the amber BACK FLUSH lamp will illuminate and at 700 microamps the red LOW VOLTAGE lamp will illuminate the system will shut down with the lamp remaining illuminated ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 10 11 12 13 14 15 ELAPSED TIME INDICATOR T
46. ither 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 56 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslifilter com S 40 Pump 00 LEV 040 CC A ZL J L SL LSI1 SLYVd 4100 37 Bnid 6uisnou Bull O Yd3 Jeuojdo Bull O uO jeuondo Buy O u ido N jeuondo Bull O N eung psepue s jeas Yd3 jeuondo Bes UOJIA Ieuondo jeas u ido N jeuondo leas N eung piepue s Bulusnq Bui BululejaJ 1O O1 V UOBOYIPOW 10 01 V UONE pow 319 40 04 H37 37 0104 319 Buisnoy A31 Buisnoy 37 Buisnou 37 Buisnoy H37 4286 Jajpi a7 4296 131p 313 Joxse6 437 39586 H37 391826 39 oxse5 39 oyse5 31 Ajquiasse 13409 8 319 majos 8 37 maos uondiiss q WODY AA WO NDGWNA NINI mewe 6980 88E 804 xe3 0057 68 802 IAL 0809 VSN sioulji
47. l 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 Failure to follow this warning can result in personal injury and or property damage and will void the product warranty CAUTION Secure the discharge line before starting the system An unsecured discharge line may whip causing personal injury and or property damage Explosive or flammable flash point below 200 F fluids must never be filtered with this product Electrostatic arcing is a potential ignition source Please refer to Fluid Specification prior to filtering fluid Do not exceed 45 psi on any components in the system Protect fluid lines from damage or puncture Maximum fluid temperature should not exceed 165 F 175 F for Black Phosphate Ester Cells 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 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com INTRODUCTION SYSTEM OVERVIEW The Finite
48. larm If a signal is desired to provide remote indication of an alarm condition the S Series Cabinet Models provide dual quick connect interface with two internal dry relay contacts to interface with a signal not exceeding 24 volts The relays are closed during normal system operation During an alarm condition such as overload the relay will open A second access hole is provided if hardwiring is required by your electrical codes These connections are located on the right side of the cabinet just below the power cord 6 Water Absorption Equipping the filtration system with water absorption capabilities maintains constant fluid dryness and prevents moisture build up from condensation in the reservoir The S Series units are equipped with a water absorber unit that is installed between the fluid delivery system pump and the cell This filter will also trap contaminants 5 microns and larger and should be replaced whenever water content increases or pressure rises above 30 35 psi Replacement elements are available from ASL 17 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com HOSE CONNECTIONS It is recommended that connections to reservoirs be made with quick disconnects or hard plumbed to minimize ingression of contaminants when hooking up and operating the FPRS
49. luminates the cell needs to be backflushed lt T gt WARNING Turn OFF the FPRS on the control panel as and at the electrical PN J Fi source Disconnect the input and the output hoses from the cell and set aside Connect a backflush hose to the quick disconnect at the bottom of the cell Place the end of the bottom backflush hose into a suitable container Using a second backflush quick disconnect fitting connect plant air supply REDUCE TO 10 PSD to the quick disconnect at the top of the cell Allow 10 psi of air to flush the contaminants out of the cell and into the pail for disposal Leave the air pressure on until contaminants are no longer dispensed out of the backflush hose about 10 minutes CAUTION BACKFLUSH HOSE WILL JUMP AROUND AS AIR REACHES IT Remove the backflush hoses and replace the input and output hoses to the top and bottom of the cell at their original configuration blue hose to the bottom of the cell disconnect and gray hose to top of cell The top of the cell connects directly to the 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 20 ASL
50. ly 1 Using an insulated screwdriver short across the POS and NEG terminals of the Electrostatic Cell to dissipate any static electricity 2 Using one hand remove the POS terminal from the Electrostatic Cell 3 Cut all ty wraps securing the POS and NEG leads from the cell to the power supply 4 Remove the 8 inch long wiring trough cover to the left of 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 6 32 nuts and washers from the studs and remove the power supply from the unit Note that the red high voltage lead and spark plug terminal boot remain attached to the power supply 8 Install the new power supply in the reverse order Note that replacement power supplies have a relatively long Positive lead with the boot and terminal installed at the factory Take care when coiling up the excess length to tie it out of the way of the cover and cover magnets 9 Plug in the three spade connectors to the power supply observing wire color codes and power supply connector labels Red wire to HOT Green wire to GND and white wire to HOT Connect the two pin yellow orange connector to the harness and re install the wire trough cover Electrostatic Cell See page 21 in this manual 36 ASL Technologies LLC 10525 W US H
51. member to order spares if needed 3 Order fulfillment information v Preferred shipping carrier information ASL is an On Line daily UPS shipper Ground Next Day Second Day etc Bill To Address Ship To Address we cannot ship to a P O Box Purchase Order Number SANNA Parts will be invoiced F O B Wanatah IN at the prices in effect at the time of the shipment Terms will be Net 30 days We also accept Visa MasterCard and American Express Order Address ASL Technologies LLC Parts Department 10525 W US Hwy 30 Bldg 3D Wanatah IN 43690 Telephone 219 733 2777 Toll Free 888 333 2990 Facsimile 219 733 2779 E Mail custsve aslfilter com Internet www aslifilter com 26 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com FPRS S Series Cabinet Spare Replacement Parts DESCRIPTION PART NUMBER Call ASL for any parts not listed O o CS 2223 P8 j High Voltage Power Supply ALL CS 2223 P8 S 40 Pump Motor coupler ASSY ASL 83930 and O ring Water Absorber can O ring Buna Black Water Absorber can O ring Viton ASL 4005 Brown your exact part number Laminated wiring diagram Inside front S Series Wiring Diagram cover Red Lamp Assy Low Voltage Float 1050 QC1 Switch Over Pressure Oil Sample Test Port P
52. mp 1 thus energizing the coil of CR3 Once CR3 closes power is allowed to flow through the now closed contacts of CR3 5 amp 3 Power then simultaneously goes to the hour meter on the front panel and through terminal strip TB 1 to start the 30 SON eS ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com pump motor At the same time CR 1 closes the normally closed contacts of CR1 5 amp 1 open turning the red Low Voltage light 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 Cell 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 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 drop
53. mp motor assembly from the cabinet With both the old and new pumps motors on the workbench transfer the inlet outlet hose fittings and the black Heyco wiring fitting to the new pump motor Take care to align the fittings the same way they were Use a suitable thread sealer on all pipe threads Install the pump motor into the cabinet by reversing the above instructions A drop of lubricant on the push lock fittings will ease installation of the hoses Secure all wiring and hoses and proceed to PUMP and PRESSURE SWITCH ADJUSTMENTS on page 39 Replacement of PUMP only If you have determined that only the pump needs to be replaced the motor and it s electrical connections can remain attached to the cabinet 1 Remove the pump inlet and outlet hoses The fittings are of the push lock type and the hoses must be cut Slit the inlet and outlet hoses the minimum 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 motor During pump motor
54. n a pail Open the drain valve on the bottom of the absorber canister Loosen and remove 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 hold down bolt hand tight Clean the O ring and apply a thin coat of your oil Replace the canister lid and clamp Close the drain valve on the bottom of the absorber canister and stow the drain hose Replace front cover and close top cover Activate the main power source and then turn ON the power switch on the control panel After fluid is dispensed through the output hose shut down the system and check for leaks inside the cabinet ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com Www 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 The re build exchange program has been organized to provide minimum downtime and maximum performance When you receive your
55. n 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 subjected 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
56. nces 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 55 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom 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 Air 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 e
57. nd is in the power line after the 10 amp circuit breaker which is located next to the power switch When the system is plugged in to a 120 VAC power source power will be present on one side of this switch Note that if incoming 120 VAC power is interrupted while the POWER switch in the ON position the system will automatically restart as soon as incoming AC power is restored ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 2 SYSTEM CIRCUIT BREAKER Located between the ON OFF switch and the Green Power lamp the system circuit breaker is rated at 10 Amps 3 GREEN POWER LIGHT With the cover closed and the power switch is on power flows to the green POWER lamp which illuminates to indicate power is applied to the system The green POWER lamp is a neon tube lamp that is designed to glow for many hundreds of hours These lights are non relampable and must be replaced completely when defective See the MAINTENANCE section for instructions 4 RED LOW VOLTAGE LIGHT When the system is first turned on or power is restored following a power interrupt condition the red LOW VOLTAGE lamp 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 voltag
58. ndicator Lights These lights are the non relampable type and are a snap fit into the top cover Remove the two 186 spade connectors and compress the tangs on the sides of the lamp using thumb and forefinger Push the lamp from the back out through the front cover Replacement lights are available from ASL Microammeter The microammeter is a special Simpson DC Microamperes design Using a meter not intended for your FPRS is not recommended and could result in damage to the equipment To replace the meter remove the two 5 16 nuts which secure the green wires to the back of the meter Using a 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 goes toward the Electrostatic Cell Hour Meter The hourmeter is held in place with two 6 32 screws and locknuts Remove the two spade wiring terminals from the meter by pulling straight up Remove and retain the attaching screws and nuts Remove the meter by pushing it out from back to front Install the new meter make sure it s right side up using the retained screws and nuts and re attach the spade terminals Hi Voltage Power Supply Secure power to the FPRS before replacing the power supp
59. nor personal injury or damage to this equipment ELECTRICAL SAFETY WARNING ELECTRIC SHOCK can kill Your FPRS uses a high Direct Current voltage of 15 000 volts Do not touch live electrical parts Always disconnect power source before working on the system Avoid accidental starting Make sure unit is turned OFF and is unplugged or disconnected from its power source before beginning any maintenance tasks This product and the fluid reservoir it services must both be earth grounded to operate safely and properly Protect the power cable from coming in contact with sharp objects Replace or repair damaged or worn cords immediately Safety devices such as interlocks fuses and circuit breakers should not be disconnected or shunted out ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com A CAUTION The power source must be fused for 10 amps 1 The motor is designed for operation on the voltage and frequency specified on the motor nameplate 2 Normal loads will be handled safely on voltages not more than 10 above or below the specified voltage 3 Running unit on voltages not within range may cause overheating and motor burnout 4 Heavy loads require the voltage at motor terminals be not less than the voltage specified Follow all local electrical and safety codes as wel
60. ns will have continuity between them and are for customer interface with an outside indication or warning system such as a PLC When attaching an external system do not exceed 24 VDC Thus any problem that stops the power supply CR 1 or the Pump CR 3 will cause an open between the two remote alarm contacts PUMP MOTOR ASSEMBLY The pump and motor assembly used in your FPRS is designed for continuous duty and will give many years of trouble free service For your convenience the pump manufacturers service manual is located in the last section of this manual starting on page 45 The pump and motor consists of three basic parts which are all easily field replaceable The pump itself is attached to the motor housing with 3 1 4 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 35 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com REMOVAL AND REPLACEMENT OF COMPONENTS Front Panel I
61. ollows a Turn power off and un plug the FPRS from the power source b Remove relay CR 3 to prevent the pump from starting c Remove the POS spark plug boot terminal from the Electrostatic Cell d Restore power to the FPRS and turn the power on Note that you will have A to defeat the cover safety switch to continue USE CAUTION e Using an AC voltmeter check for 120VAC at the L HOT terminal on the high voltage power supply Or terminal 3 on TB 2 f If OK check for 120VAC on terminal 1 of TB 2 yellow wire 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 of CR 1 If no voltage present repair wiring If 120VAC is present check for voltage at pin 3 of CR 1 If no voltage present replace Relay CR 1 i Note that all four relays are the same and can be swapped for troubleshooting purposes Once repairs are completed remember to re install relay CR 3 With respect to the High Voltage DC section the best way to confirm a bad power supply is to obtain a times 1000 high voltage probe for your voltmeter Using the Hi Voltage probe plugged into the red spark plug terminal boot a properly operating power supply will indicate 15 00 to 16 00 VDC 15 000 to 16 000 VDC Defective power supplies will read 0 to4 KVA l The number one reason for pow
62. ologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Motor Service Data Nameplate Data P N 88514 Grey Baldor Motor S 30 amp S 40 Only Model 34G510 5506 P N 88514 Volts 115 208 230 Hz 60 KVA Code L H P 1 4 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 Time 4 ont 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 n m D 5 Lo Volt lt Factory Wired this wa 9 3 1 Black 1 LI 3 ki 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 S40 Cabinet is OOLEV 040 CC A S 30 units use 30 LEV CC A 9821 The manual is reprinted with permission from the Tuthill Pump Group 44 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Motor Service Data Nameplate Data P N 88471 50Hz Grey Baldor Motor S 30 amp S 40 Only Model 34G510W773G1_ P N 88471 Volts 115 230 Hz 50 60 KVA
63. om 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 the FPRS back to the reservoir outlet When installing an FPRS S Series unit above the highest level of fluid of the reservoirs it is required that the pump be primed Once primed the cabinet of the S Series can be elevated as high as 24 above the highest level of the reservoir SYSTEM SAFETY FEATURES INDICATORS SWITCHES AND LIGHTS Your FPRS S Series unit comes equipped with several enhanced safety features and light gauge indications that are designed to provide operator and environmental safety ease of operation and troubleshooting The following paragraphs contain a brief description of these features Refer to the photos on pages 11 12 and 13 and the wiring diagram on page 28 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 a
64. on 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 47 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom www aslfilter com N 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 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 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 vac
65. one 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 30 LEV CC A 9821 S 30 Pum 37 6njd Buisnoy LEVI Buu O d3 Ieuondo 18 p L0d Bul O uoy jeuondo LLZ vE L0Ld Bul O u sdo y jeuondo LS VE LOLd Bull O N eung piepuels LE vE LOLd Pa lees Yd3 jeuoydo 8 6V 11 yw Jeas UOJIA jeuondo L6V1b Jeas u do y jeuondo S 6V1L leas N eung piepue s 6V1L Bulysnq LLV10 i VSL Buu Bulute 1 ve 90 d 40 04J V UONEIIJIPOLW V rZ3108 JOJOJ pZA OE A37 Buisnoy 22 0ZA3108 oz Si ai A31 Buisnoy 9 0ZA3108 37 Buisnoy 023710 TA H37 1886 131p T 10 Ja 37 4286 Jajpi Sdd ze10 J But O Yd3 Ieuondo Z8 L61L L02d Z WA Buu O uoy jeuondo LL L6b L0Ld ol lt Buu O auasdoan jeuondo es 6L L0Zd Buu O N eung piepue s 2 264402d SL uid LETOE Algwesse 13409 970 g maos H L 00 d uonduos q 1 qtuunN Hed isi Suuvd WODINI MMM WOOTUIN Awndyjiyyny ewe 6980 88 802 X84 00SZ 68E 80Z IAL 0809 YSN Sioul disty peoy biseInd unos 00524 3 106 dnog dwing i T TIHLAL 07 6 8L Lb 9 eg SL s 59 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 30 LEV CC A 9821 S 30 Pum NOILdO 3A VA 4413H 105 OL vl eb
66. one side of the switch is allowed to travel to the red float switch light the coil of CR 2 and contact CR2 6 Once CR 2 is energized the normally closed contacts of CR2 5 amp 1 open stopping the flow of power to the coil of CR 3 When CR 3 opens power is removed from the pump and hour meter The wire coming back down from CRI 3 provides power through the now closed contacts of CR2 4 amp 6 keeping the red float switch light on and the coil of CR 2 closed Thus even though the float switch may only bump closed momentarily the red light and fault will remain latched on until an operator intervenes If a red float switch light is observed immediately investigate the source of the leak and make any necessary repairs To reset the fault turn power off and then back on This circuit can be tested by intentionally closing the float switch and observing that the light illuminates and the pump and hour meter stop Opening the switch will not reset the light or start the motor Troubleshooting this circuit is straightforward The only components are the float switch itself relay CR 2 and the associated wiring OVERPRESSURE RED The overpressure light circuit in the FPRS S series units is wired differently than earlier ASL ABH or mobile cart units In the S series units the overpressure is utilized as an absolute upper pressure limit and will shut the unit down when activated Like the float switch
67. pact 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 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 partiti
68. r 8 Indicator Lights 3 7 Power Switch 1 Circuit Breaker 2 High Voltage Power Supply TB 2 Relays CR 1 to CR 4 Cell Hi Voltage Leads Water Absorber Canister Power Cord Remote Alarm 11 Cell Outlet Hose Throttle Ball Valve 14 System Pressure Gauge 10 System Outlet Port Unit Model Serial No Tag Electrostatic Cell Oil Sample Port 12 Pressure Switch System Inlet Port Cell Inlet Hose Water Absorber Drain 13 Drip Tray Vt tc 12 A S Series Cabinets ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Drip Tray and Float Switch Electrostatic Cell removed for clarity Disconnect 2 pin Molex and carefully remove tray for draining Float Switch stays in Tray 13 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com SYSTEM PREPARATION NOTE IT IS EXTREMELY IMPORTANT THAT THE FOLLOWING STEPS BE DONE IN ORDER TO ENSURE PROPER SET UP AND OPTIMUM RESULTS FROM THE FPRS A CAUTION Before making power connections to this ASL unit check the polarity of your power source Also verify that earth ground is present Open the hinged top cover two magnets hold
69. 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 49 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom 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 back 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 otherwi
70. replacement Electrostatic Cell please note that the red tag affixed to the top of the cell contains part number information as well as the date the cell was made A blank area is left open for you to fill in the date the cell was installed in your system This will help you determine when the cell should be exchanged When you are ready to replace your Electrostatic Cell please follow these steps l Look at the red tag on the top of the cell to locate your part number R61CS 115 for example 2 Send your P O to ASL via Phone Fax mail or e mail custsvc aslfilter com with the quantity and part 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 ex
71. s to zero This starts a chain of events that commences with the coil of CR 1 relaxing When CR 1 opens contacts CR1 5 amp 3 open stopping the flow of power to the coil of CR 3 which in turn stops power to the hour meter and pump motor At the same time the contacts of CRI 5 amp 1 close allowing power to illuminate the low voltage light 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 pump 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 Cell can short due to ingestion of water or
72. se 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 adjusting 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
73. shuts down 10 Open the throttling valve and re start the system 11 Slowly close the throttling valve while observing the pressure gauge until the system shuts down The system should shut down with the Over Pressure fault at approximately 43 to 45 psi Repeat the pressure switch adjustment until the switch closes at approximately 43 to 45 psi 39 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com 12 Open the throttling valve and re start the system Slowly close the throttling valve until the pressure gauge reads 40 psi Turn the pump by pass adjusting screw counterclockwise until the pressure just begins to drop Tighten the nut to lock the setting in place 13 Open the throttling valve for a few minutes and then slowly close it fully Observe that the system pressure stays at 40 psi with the throttling valve fully closed Re adjust if necessary 14 Once all adjustments are complete open the throttling valve completely and replace the acorn nut on the pump by pass valve and the 1 8 inch Allen lock screw in the pressure switch SCHEDULED MAINTENANCE TASKS The following is a recommended scheduled maintenance plan which is intended to provide maximum performance from your FPRS unit DAILY 1 Check that green Power lamp is illuminated 2 Check that pump motor and
74. slfilter com www aslfilter com INSTALLATION CONSIDERATIONS APPLICATION COMPATIBILITY While this product can provide effective filtration over a wide range of applications there are some applications that are an exception 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 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 S40P Cab 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 effecti
75. t Construction 14 Gauge Steel Water Absorber Canister 14 High x 5 Diameter SHIPPING WEIGHT 125 pounds GROSS WEIGHT DRY 105 pounds GROSS WEIGHT WET 121 pounds MOTOR S 30 amp S 40 14 HP 1725 RPM 120 VAC 60 Hz single phase 4 amps continuous 6 amps start up MOTOR 50 Hz Models 14 HP 1425 RPM PUMP S 30 amp S 40 30 40 GPH w 100 SUS Fluid 1725 RPM 1 2 NPT Inlet amp Outlet Ports WATER ABSORBER 5 micron wood paper element Mineral Oil Units 5 micron nominal synthetic fiber Phosphate Ester Units INLET amp OUTLET CONNECTIONS 17 NPT Bulkhead Fittings SYSTEM VOLTAGE Input Voltage 120 VAC 60 Hz single phase 10 Circuit Breaker 10 Amps Output Voltage of Power Supply 15KV Nominal 1 9 miliamp 600uA Manufactured in the U S A 25 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com ORDERING SPARE AND REPLACEMENT PARTS A Spare Parts List for your FPRS is included on the following page Prompt service can be given for spare or replacement parts if ASL has the following information 1 The part number s of the item s you need The Spare Parts List includes the most frequently requested items 2 The quantity needed Please re
76. t the on the meter goes toward the Electrostatic Cell 32 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com The opposite case of a microammeter reading 500 with no accompanying backflush light should be troubleshot as follows 1 Secure power to the FPRS 2 Open the cover and locate the orange wire on terminal 2 of TB 2 3 Turn power on Note that you will have to defeat the cover safety switch to A continue USE CAUTION 4 Using a voltmeter check for 120VAC on the orange wire If 120VAC is present replace the amber backflush lamp assy Note that all of the indicator lights are of the non relampable type and must be replaced completely 5 If 120VAC is not present on the orange wire the power supply is defective FLOAT SWITCH INDICATOR RED The float switch prevents an internal FPRS leak from draining the reservoir and is designed to be a non resetting safety fault The float switch itself is located in a bracket on the drip tray in the bottom of the base cabinet in the right rear corner behind the Cell In case of a fluid leak the float switch will slowly rise on the fluid until the internal magnetic contacts close Once these contacts close several things happen at once When the contacts of the float switch close power which has been sitting on
77. tended 23 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com WARRANTY INFORMATION ASL Technologies LLC ASL warrants this product to be free from defects in material and workmanship for a period of one 1 year from date of shipment excluding expendables in accordance with the following terms and conditions This warranty extends only to the original purchaser owner This warranty does not include damage to the product resulting from accident misuse or abuse improper installation or operation lack of reasonable care or unauthorized repair or alteration Should this unit fail during the warranty period ASL will repair or replace it at our option Replacement products supplied under this warranty may be new or rebuilt at our option Labor charges will be without cost to the purchaser owner during the first ninety 90 days of the warranty period up to 500 hours of operation Owner will be responsible for all labor charges after this period Owner will pay for the expense of delivering the product to ASL for warranty work and expense of returning it to the owner after repair or replacement ASL will assume no field expense for service or parts unless authorized in advance This warranty is the only warranty extended by ASL to suppliers and or purchasers of this
78. th 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 54 ASL Technologies LLC A 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter ccom _ 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 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 Troubleshoot
79. the cover closed and swing it back Remove the front cover by pulling it toward you also held in place with magnets and lifting it out of the way to expose the internal mechanisms Check the wire and hose connections to and from the FPRS Itis important that these connections are tight and have not shaken loose during shipment Tighten the connections if they are loose Do not over tighten Check the quick disconnects on the cell to ensure that they are locked in place The outer ring of the quick disconnects slide back to lock and unlock the disconnect The S Series CABINET models will not operate with the front cover removed Take a sample of the fluid to be cleaned Usea clean bottle to take the sample The sample should be taken from the lowest point of the reservoir preferably the drain cock or valve because this is where the FPRS input hose will draw from Free water should be drained from the reservoir before the FPRS is hooked up Test the sample to ensure that the fluid does not surpass the guidelines of the system as set forth in this manual For in service oil analysis a sample port has been provided and is located at the inlet to the water absorber canister just below the pressure gauge See page 10 for sample port operations 14 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc a
80. to the FPRS Check for any external leaks Turn the POWER switch OFF Open the top cover and remove the front cover Check to ensure there are no leaks internally Locate the red tag on top of the Electrostatic Cell Fill in the Date Installed in the space provided This will assist you in determining when an annual cell exchange will be required Replace the front cover and close the top cover You are now ready to begin normal operations Your FPRS system has been designed to operate continuously on a fluid reservoir with little operator attention However it is recommended to check the control panel daily to monitor system condition See page 40 for Scheduled maintenance Tasks 18 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com FLUID MAINTENANCE The following recommendations are made in the interest of maximizing the benefits available with the S Series FPRS system 1 Periodically monitor the condition of the machine fluid The following is a list of recommended tests that should be performed Viscosity When compared to values for virgin oil the viscosity gives an indication of excessive thinning or thickening resulting from oil breakdown TAN When compared to values from virgin oil an increase on the TAN indicates oil serviceability with regar
81. top of the cell Note that Phosphate Ester Units use all Black Hose The hose connected to the TOP of the Electrostatic Cell leads directly to the cabinet Outlet port Replace the high voltage wires to the cell Red is positive Green is negative The label at the top of the cell notes the positive and negative electrodes Be sure to fill in the Date Installed on the cell tag Replace the front cover and close the hinged top cover Restart the FPRS and operate system for a few minutes Ensure that fluid is being dispensed through the output hose WARNING Once fluid is dispensed through the output hose turn OFF the FPRS on the control panel and at the electrical source Open the top cover and remove the front cover and check for leaks Replace the front cover and close the top cover The FPRS is now ready to resume operation 21 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com WATER ABSORBER ELEMENT REPLACEMENT may need to be replaced gt 35 psi WARNING Turn OFF the FPRS on the control panel and at the alle source Open the top cover and remove the front cover If the pressure gauge on the water absorber element is above its normal running pressure it Locate the absorber drain hose It is folded over and tie wrapped Cut the tie wrap and place the hose i
82. typically occur and are encouraged because of the presence of air heat and water Oxidation is usually observed in lubricants and hydraulic oils and results in the formation and deposition of tars and varnishes on the components of the hydraulic system Removing these contaminants continuously from the system will prevent the majority of problems that plague maintenance departments and cause expensive downtime Keeping the fluid as clean as possible is what this product will accomplish for you and 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 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com The FPRS is designed to connect directly to your machine s reservoir The FPRS draws the fluid into its system using a pump that sends the fluid through a water absorber and 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 magnetic fields to remove submicronic particles from the host reservoirs fluid This is accomplished by electrically influencing the particles in the oil to opposite polarities These and influenced particles are attracted to one another and are retained by polyolefin foam used within ASL s patented Electrostatic Cell Because the foam is polyofin water in concentrations of 5
83. ure light such as back feed pressure from the outlet side which could be caused by incorrect installation Adjustment of this switch however is critical and will be required following replacement of the pump or the pressure switch Replacement of this switch is straightforward and only requires un screwing it from the water absorber inlet manifold and connecting the black and red wires The green wire is not used and should be capped Following pressure switch replacement proceed to the PUMP and PRESSURE SWITCH ADJUSTMENTS below PUMP and PRESSURE SWITCH ADJUSTMENTS The following procedure should be followed after replacement of the pump and or pressure switch Note that these adjustments are CRITICAL to proper system operation and should be read and understood before continuing 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 This procedure will also require that the cover safety switch be defeated Maintenance personnel are cautioned to take extra care when operating the system with the covers removed Refer to the pump vendor service manual starting on page 45 of this manual Start system and wait until output flow is observed Remove the acorn nut on the pump relief valve 5 8 for S 30 11 16 for S 40 Insert a screwdriver into the slot of the adjusting screw and hold it steady Loosen th
84. ush to test type KP14N V 1 Viton 27 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com WIRING DIAGRAM S SERIES CABINET UNITS 120 VAC 60Hz 1Ph ON OFF 1 2 10A C B DE I CR 1 Low Volt Cover Safety CR 2 Float Sw A nai Switch CR 3 Pump Start System Power On CR 4 Over Press C Pump Start Relay 7 Remote Alarm CR 1 S B 5 1 5 1 8 Pump Motor Closed Norm 6 14 Hour Meter Open Alarm CR 3 Low Voltage Light Relay Configuration Float Switch Shutdown Relay Float Switch Light Overpressure Shutdown Relay Shown Relaxed Overpressure Light Adjusted to 43 psi Pressure Switch Green N C Black Red Backflush Light Closes 43 psi CS2223 P8 Power Supply Backflush Orange Closes at 500 ua Low Voltage Shutdown Relay Relay Socket Pin Outs Electrostatic Cell Microamp POS NEG Meter E 28 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Cover Cabinet Electrical Component Locations Serial Numbers 1007 and Subsequent Power Circuit Power Low Back Float Over Current Hour On Sw Breaker On Voltage Flush Switch Press Meter Meter i CS 2223 P8 IAA H
85. uum 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 resulting 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 supplie
86. vely unless the source of water can be eliminated or greatly reduced to less than 600 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 15 ASL Technologies LLC 10525 W US Hwy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com The FPRS is now ready to be charged filled for operation and tested to ensure that no connections have loosened during shipment The FPRS should be charged with the same fluid it has been designated to clean INSTALLATION APPROPRIATE LOCATION Avoid locations that expose this product to excessive moisture and explosive environments This product generates an electrostatic field that may disturb or damage sensitive electronic equipment Also remember that access to this product is required periodically to replace the electrostatic cell 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 120 volts AC 50 Hz single phase if equipped with 88471 Motor 10 amps Circuit Breaker 16 ga Power cord provided Earth Ground Vertical Orientation Ambient temperature less than 160
87. wy 30 Bldg 3D Wanatah In 46390 Phone 219 733 2777 or Toll Free 888 333 2990 S Series Cabinets Facsimile 219 733 2779 or e mail custsvc aslfilter com www aslfilter com Water Absorber Element See page 22 in this manual Pump Motor COMBINATION Replacement of the pump and motor is straightforward The pump motor is secured to studs in the back of the cabinet with four 14 20 locknuts and flat washers For ease of access the Electrostatic Cell should be removed Secure power to the unit before any servicing 1 Start by removing the motor wiring box cover and disconnecting the wire nuts tying the SO cord to the motor leads The green ground wire is secured with a green screw to the motor inside the motor wiring box Pull the SO cord out of the motor wiring box and plastic Heyco connector Note that wire connections and numbers are located on the motor nameplate as well as page 44 of this 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 pu

S-Series Service Manual - ASL Technologies, LLC!

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