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3
Copyright Clause
Reprints, even of extracts hereof, are permitted only if the source is quoted and permission has been granted by Pall Corporation. The main components, devices, arrangements, as well as software, control and instrumentation equipment on all of our varnish removal filters are protected both at home and abroad by patent applications, design registrations or copyright.
MAN-HLP6-R0-USA August 15, 2009 Page 2
Table of Contents
2
3
FORWARD
SAFETY & GUARANTEE
3.1 General Safety Instructions
3.2 Uncrating and Inspection
3.3 Choosing the Installation Site
3.4 Electrical Safety
3.5 Safety of Personnel
3.6 Training Services
3.7 Terms of Guarantee
4 SPECIFICATIONS
4.1 General – HLP6 Oil Purifier
4.2 Materials of Construction & Piping Codes
4.3
4.4
Environmental
Utilities
4.5 Weights, Dimensions and Volumes
4.6 Miscellaneous
5
INSTALLATION
5.1 Installation Site Guidelines/Considerations
5.2 Installation Tips
5.3 Connecting the HLP6 to a Fluid Supply
5.4 Returning Fluid Back to the Reservoir
6
HLP6 OPERATOR INTERFACE
6.1 Controls and Gauges
13
13
13
13
13
14
14
15
15
15
16
18
6
7
7
8
9
10
10
11
11
19
19
7
ELECTRICAL CONNECTION
7.1 Connecting the Supply Voltage to the HLP6
7.2 Motor Rotation Check
MAN-HLP6-R0-USA August 15, 2009 Page 3
21
22
23
8
8.1
8.2
8.3 Pre-startup Checks
8.4 HLP6 Energizing and Boot-Up
8.5 Starting the HLP6 Purifier
8.6 Running and Adjusting the Purifier
8.7 Gauge Observations
8.8 Enabling the Heater & Changing Heater Set Point
8.9
BASIC HLP6 OPERATING PROCEDURES
Oil Flow Path through HLP6
Air Flow Path through HLP6
8.10 Stopping the Purifier
8.11 Draining the Purifier
9
Cold Startup Conditions
THEORY OF OPERATION & COMPONENT ID 35
9.1 General Claims
9.2 Theory of Operation
9.3 Component Identification
10
MAINTENANCE
10.1 General Maintenance List
10.2 Checking Vacuum Pump Timing Gear Oil
10.3 Changing Vacuum Pump Timing Gear Oil
10.4 Replacing Exhaust Coalescer
35
35
36
37
10.5 Replacing Inlet Air Breathers
10.6 Cleaning the Inlet Strainer
10.7 Replacing the Polishing Filter
10.8 Replacing the Demisting Pad
11
ALARM CONDITIONS & TROUBLESHOOTING
45
40
41
42
43
37
37
38
39
Major Alarms
11.1 Phase Reversal / Low / High Voltage
11.2 High System Temperature Shutdown
11.3 Inlet Pump Motor Contactor Failure
11.4 Vacuum Pump Motor Contactor Failure
11.5 Inlet Pump Cavitation
11.6 Change Exhaust Coalescer
11.7 High Tower Level Shutdown
11.8 Low Tower Level Shutdown
54
56
57
59
47
48
50
52
25
29
30
31
32
25
26
27
28
33
33
34
MAN-HLP6-R0-USA August 15, 2009 Page 4
11.9 Outlet Pump Motor Drive Overload
11.10 Inlet Pump Motor Overload
11.11 Vacuum Pump Motor Overload
11.12 Dirty Filter Warning – Dirty Filter Shutdown
11.13 Tower Fluid Level Sensor Signal Loss
11.14 Outlet Pump Motor Drive Faults
11.15 Outlet Pump Motor Drive Comm. Loss
Minor Alarms
11.16 Heater Thermocouple Signal Loss
11.17 Saturation Probe Signal Loss
11.18 Temperature Probe Signal Loss
11.19 High Water Saturation Alarm
11.20 Heater Contactor Failure
Warnings
11.21 Service Vacuum Pump Soon
11.22 PLC Battery Low……Replace Soon
12 HMI SCREENS
12.1 Home Page
12.2 TIM Button – System Run Time Screens
12.3 FIL Button – Filter Status Screen
12.4 VAC Button – Vacuum Pump Status Screen
12.5 HEA Button – Heater Control Screen
12.6 SAT Button – Water Sensor Control Screen
12.7 VFD Button – Outlet Pump VFD Status Screen
12.8 TOW Button – Tower Level Control Screen
12.9 CON Button – Pall Corporation Contact Screen
71
73
74
76
76
78
78
61
62
64
66
68
69
70
79
82
82
83
83
83
79
79
80
81
MAN-HLP6-R0-USA August 15, 2009 Page 5
2.0 FORWARD
This service manual is provided to serve as the installation, operation and maintenance guide for the equipment supplied by Pall Corporation. The contents should be read before attempting any phase of installation, operation and maintenance.
The Pall Corporation HLP6 Hydraulic-Lubricating Oil Purifier requires installation by the customer or prearranged contractor. Unpack carefully and check all items received against the invoice.
The Pall Corporation HLP6 Oil Purifier has been tested and quality-controlled in accordance with Pall Corporation standard procedures and also in accordance with the tests specified in the contract when required. However, the equipment as shipped may have been opened or dissembled for draining, cleaning, etc., after testing. The customer should confirm that no nuts, bolts, flanges, pipes, closures or any other component have not become loose during shipment; these should be tightened wherever necessary.
An identification tag has been permanently attached to the equipment. If/when requesting information, service or spare parts, please be prepared to furnish the part number and serial number located on the identification tag.
It is the user’s responsibility to check actual operating conditions to ensure the filter elements, cartridges, vessel and sealing materials are compatible with the application and are within local safety codes.
Pall reserves the right to modify the contents of this service manual without notification.
Trademarks & Intellectual Property
Pall, are trademarks copyright of of
Pall Corporation.
Filtration. Separation. Solution. is a service mark of Pall Corporation.
The design of this equipment and all associated documentation is
Pall Corporation 2009.
MAN-HLP6-R0-USA August 15, 2009 Page 6
3.0 SAFETY & GUARANTEE
3.1 General Safety Instructions
In’t important that all personnel in charge of installing, setting-up, operating, maintaining or repairing the HLP6 Oil Purifier and its components read and understand this manual, and, in particular, the section on safety.
Care must be taken when referring to this manual to ensure adherence to all warnings, cautions and important notes. These carry information related to the safety of personnel and the integrity and satisfactory operation of the equipment.
If necessary, in-house instruction should be provided, taking into account the technical qualifications of the personnel concerned.
The following symbols are used in this manual:
WARNINGS: THESE ARE INSTRUCTIONS THAT DRAW
ATTENTION TO THE RISK OF INJURY OR DEATH.
Cautions: These are instructions that draw attention to the risk of damage to the product, the process, the equipment or the surroundings.
!
Important: These are instructions that draw attention to information that will aid installation, operation or maintenance.
MAN-HLP6-R0-USA August 15, 2009 Page 7
3.2 Uncrating and Inspection
Prior to uncrating the HLP6, inspect the exterior crating for obvious damage that may have occurred during shipment. All damage should be reported to both the freight carrier and
Pall Corporation. Obtain the full part number and serial number from the identification tag
(shown below) then contact Pall’s Technical Support Department at (888) 333-7255 to open a COR.
While uncrating the HLP6, take care to avoid damaging the wiring of critical electrical and mechanical components.
After removing the HLP6 Oil Purifier from its crate, carefully inspect the skid for damage that may not have been obvious during the initial inspection. It is good practice to ensure all fittings, flanges, nuts, bolts, etc are tight and have not come loose during shipment.
Tighten loose items as required.
Pall Corporation recommends the user to completely read through this Operation/Service
Manual prior to installing or starting the HLP6 skid. Pall Corporation provides one electronic copy (in CD form) of the Operation/Service Manual. If needed, Pall
Corporation can supply printed Operation/Service Manual’s for a nominal fee. Contact your local Pall Corporation representative for a quote.
MAN-HLP6-R0-USA August 15, 2009 Page 8
3.3 Choosing the Installation Site
WARNING: EXPLOSION & FIRE HAZARD!
The standard HLP6 Oil Purifier is designed for operation in Non-Hazardous environments. When selecting the HLP6 installation site, ensure that the location is suitable for operating Non-Hazardous rated equipment. If in doubt, check with your plant manager.
Prior to installing or operating the HLP6, consult your safety manager or plant manager regarding the possibility of explosive or flammable gases coming in contact with the HLP6 skid. Do not install or operate the skid in or near environments that contain explosive or flammable gases. Special hazardous environment-rated versions of the HLP6 are available from Pall Corporation and will be quoted upon request. Contact your local Pall representative for more details.
WARNING: TRIPPING HAZARD!
When choosing the HLP6 installation site, ensure that all hoses and wires are installed in a manner that doesn’t present trip hazards to personnel.
!
WARNING: DO NOT BLOCK ESCAPE
ROUTES!
Ensure that the HLP6 Oil Purifier does not block designated walkways and escape routes. Consult your plant or safety manager before starting the installation.
Installation Tips!
The HLP6 skid must be installed on level ground
Allow sufficient/adequate access to all sides of the skid for operating, maintaining and cleaning (Pall recommends 36” clearance on all sides)
Do not place objects in front of or on top of the skid.
Observe all Federal, State, Local and plant regulations.
MAN-HLP6-R0-USA August 15, 2009 Page 9
3.4 Electrical Safety
WARNING - High Voltage!
Lock out & tag out prior to beginning any electrical work.
The HLP6 Oil Purifier skid is powered by high voltage. All safety procedures associated with the operation of the equipment at high voltage must be observed! Lock out and tag out for safety before starting any electrical work!
Warning – Danger to Personnel!
Personal injury may result if the HLP6 Oil Purifier safety devices are disconnected or disabled.
• Never disable or dismantle any safety devices.
• Malfunctions and defects concerning safety devices should be reported immediately to Pall Corporation Technical Support @ 1-888-333-7255.
• Always shut down, lockout and depressurized the HLP6 skid before starting any electrical or pipe work.
• Always observe Federal, State, Local and plant safety regulations.
3.5 Safety of Personnel
Avoid practices which:
• Endanger the health and safety of the user or third parties
• Is detrimental to the health and safety of the operator
• Prevents safe operation of the HLP6 Oil Purifier
• Does not comply with the HLP6 Oil Purifier safety instructions
Service and maintenance work for the HLP6 should only be conducted by trained individuals who have read the operation and service manual and are familiar with potential hazards.
MAN-HLP6-R0-USA August 15, 2009 Page 10
3.6 Training Services
Pall Corporation offers customized field training services for the HLP6 Oil Purifier skid.
For more information regarding on-site training, contact your local Pall Corporation representative.
3.7 Terms of Guarantee
The Pall Corporation HLP6 skid carries a warranty specified within the terms and conditions of the original sale (please refer to Pall Corporation’s standard terms and conditions for exact details).
Pall Corporation is not liable for damage or poor performance resulting from:
• Improper use
• Failure to observe warnings and guidelines in this manual
• Purchase of spare parts from parties other than Pall Corporation or its distributors.
This includes but is not limited to:
Fluid pumps and motors
Vacuum pump and motor
Filter cartridges
Vacuum pump gear oil
• Employment of insufficiently qualified personnel
• Unauthorized modifications of the HLP6 and its components
In these cases Pall Corporation’s warranty/guarantee is rendered void.
!
Caution – Impaired Operation When Using
Incorrect Spare Parts!
Major components such as the fluid pumps, motors, and vacuum pump have been modified by Pall Corporation to work properly with the HLP6 Oil Purifier.
Purchasing these parts directly from the OEM WILL NOT guarantee proper
HLP6 operation.
Only use spare parts purchased from Pall Corporation unless otherwise instructed by Pall Corporation or its agent. When using unapproved spare parts, correct operation of the HLP6 can no longer be guaranteed.
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4 SPECIFICATIONS
4.1 General – HLP6 Oil Purifier
System Flow Rate
Seals / Elastomers
Polishing Filter Element
Polishing Filter Housing
Quantity
6 GPM @ 60 Hz N/A
N/A
1
1
Part Number
Fluorocarbon (Viton) standard
UE319 A* 20 Z
UR319 CA24 ++ 20ZB9 YR85
4.2 Materials of Construction & Piping Codes
Wetted Materials
System Electrical Enclosure
System Piping
System Piping Code (HLP6 conforms to)
Carbon Steel, Stainless Steel, Copper, Brass,
Aluminum, Bronze, Fluorocarbon, Teflon, Cast Iron
NEMA 4 Painted Carbon Steel
Stainless Steel Tubing
ANSI B31.1- Power Piping Code
ANSI B31.3- Process Piping Code
4.3 Environmental
Design Pressure
Maximum Operating Pressure
Maximum Operating Temperature
Maximum Operating Humidity
150 psig (10.3 Barg)
85 psig (5.9 Barg)
160 o
F (71
100% RH
Long Term Storage Temperature & Humidity 33 to 120 o o
C)
F (0.5 to 49
10 to 85% RH o
C)
4.4 Utilities
Electrical Supply (check HLP6 name plate)
Customer must provide a ground fault protected voltage supply
(standard) 480V / 60 Hz / 3P / 12 FLA
(optional) 380V / 50 Hz / 3P
(optional) 575V / 60 Hz / 3P
MAN-HLP6-R0-USA August 15, 2009 Page 13
4.5 Weights, Dimensions and Volumes
Dry Weight
Dimensions
Approximately 1150 lbs (521 Kg)
Width - 32 inches (81 cm)
Length - 48 inches (122 cm)
Height - 72 inches (183 cm)
(caster wheel models and floor mount models will have the same height)
4.6 Miscellaneous
Inlet / Outlet Connections
Inlet / Outlet Hoses and or Piping
Inlet Pressure Range
Maximum Inlet Oil Temperature
Maximum Inlet Viscosity
(inlet) 1.5-inch FNPT
(outlet) 1.0-inch FNPT
Recommended:
Inlet - Minimum 1.5 inches ID
- Suction-rated hose or pipe
- 20 feet (6 m) maximum length
- Avoid 90 degree bends/elbows
Recommended:
Outlet - Minimum 1.0-inch ID
- 25 feet (7.6m) maximum length
- Avoid 90 degree bends/elbows
-14”Hg – 10 psig
165 o
F (74 o
C)
4650 SSU (1000 cSt)
MAN-HLP6-R0-USA August 15, 2009 Page 14
5 INSTALLATION
5.1 Installation Site Guidelines/Considerations
Before attempting to install the HLP6 Oil Purifier consider the following:
•
•
•
•
Allow for 36 inches of clearance on all four sides of the HLP6 skid
Choose a location with cool ambient temperature (100 o
F [38 o
C] or less is ideal)
Position the HLP6 on equal height with reservoir
The HLP6 skid should be positioned on the same level as the oil reservoir (inlet pressure range must be within the specifications of section 4.6 and/or the inlet pressure gauge placard located on the gauge cluster). Avoid installing the HLP6 skid below the reservoir, as this may cause flooding.
•
The inlet hose/pipe must be suction-rated with a minimum inside diameter of 1.5 inches
(3.8 cm).
•
The inlet hose/pipe length should not exceed 20 feet (6 m) in length. Avoid 90 degree bends/fittings. Long inlet hose/pipe runs along with 90 degree bends will cause a low pressure in the inlet plumbing and potential difficulty starting the HLP6 Oil Purifier.
5.2 Installation Tips
!
Installation Tips!
SEAL MATERIAL: Ensure the HLP6 seal material is compatible with the process fluid.
ELECTRICAL SUPPLY: Must match the HLP6 electrical requirement.
AVOID HIGH HEAD PRESSURE: Limit Head pressure to 10 psi (0.68 bar) or less
ACCESSIBILITY: Allow 36 inches of clearance on all four sides of the HLP6
CODES & REGULATIONS: Always observe Federal, State, Local and plant regulations
MAN-HLP6-R0-USA August 15, 2009 Page 15
5.3 Connecting the HLP6 to a Fluid Supply
!
!
Caution – Suction Hose Required!
When connecting the reservoir to the inlet port of the HLP6 Oil Purifier it is absolutely critical that hard piping or a hose rated for suction be used. Non-suction-rated hoses can collapse internally and restrict the flow of oil to the skid. These internal collapses are often not visible from the outside of the hose.
Use hard piping or suction-rated hose on
the inlet!
HLP6 Inlet Plumbing Tips!
PIPING: Use hard piping wherever possible. Limit the use of 90° bends.
HOSE: Inlet hose must be rated for suction.
PIPE/HOSE DIAMETER: Inlet plumbing to HLP6 must be 1-1/2” (3.8 cm) ID minimum
PIPE/HOSE LENGTH: Inlet plumbing length should not exceed 20 feet (6 m) unless instructed otherwise by Pall Corporation
ADDITONAL FITTINGS: Remove unneeded fittings minimize leaks & pressure drop
Inlet Plumbing Line Leaks
Leaks in the inlet plumbing may be difficult to detect due to the low pressure condition inside the inlet line. Drips or fluid loss may not be apparent. Ensure that a minimum number of connections are used and properly tighten all connections. Avoid NPT-type fittings if possible.
MAN-HLP6-R0-USA August 15, 2009 Page 16
Inlet Line Connection to the Reservoir
!
Caution – Avoid connecting the HLP6 to the very bottom of the reservoir!
Pall Corporation advises not to draw fluid into the HLP6 from the very bottom of the reservoir. Although every oil reservoir is different a layer of sludge and or free water may reside at the bottom of the oil reservoir. Ingesting sludge into the HLP6 may prematurely plug the inlet strainer and other filters on board the purifier. Free water will not harm the
HLP6, but operators are advised to manually drain collected free water and take advantage of the mechanical separation.
The diagram below is an example of best practice water prevention and monitoring techniques. Pall Corporation recommends plumbing the HLP6 as shown. Alternative configurations may be acceptable; check with Pall prior beginning the plumbing project.
Recommended hookup of HLP6 to reservoir
MAN-HLP6-R0-USA August 15, 2009 Page 17
5.4 Returning Fluid Back to the Reservoir
!
HLP6 Return Line Plumbing Tips!
DIAGRAM: Refer to plumbing diagram (above) for general layout plumbing
PIPING/HOSE: MUST be rated for 150 PSI (10.3 Bar) operation.
PIPE/HOSE DIAMETER: Return plumbing must be 1” (2.54cm) ID minimum
RETURN LOCATION: Avoid oil splash: return oil below fluid level line.
RETURN LOCATION: Return fluid to opposite side or end.
RETURN LINE PRESSURE: The pressure in the line returning fluid from the
HLP6 back to the reservoir should not exceed 60 PSI (4.1 Bar) on HLP6 outlet gauge.
ADDITONAL FITTINGS: Remove unneeded fittings to minimize backpressure.
MAN-HLP6-R0-USA August 15, 2009 Page 18
6 HLP6 OPERATOR INTERFACE
6.1 Controls and Gauges
The front panel is the control center for the HLP6 skid. The control panel and gauge cluster are shown below.
A = HMI (human machine interface)
B = Main Disconnect
C = Alarm Beacon
D = Start Button
E = Stop Button
F = Heater Enable/Disable Switch
G = Alarm Reset Button
H = Electrical Enclosure Door Locks
1 = Inlet Pressure
2 = Tower Vacuum Gauge
3 = Outlet Pressure Gauge
4 = Oil Temperature Gauge
5 = Differential Pressure Gauge
(polishing filter)
6 = Vacuum Pump Backpressure Gauge
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7 ELECTRICAL CONNECTION
WARNING - High Voltage!
Prior to beginning any electrical work, isolate the source voltage supply and locked out and tagged out for safety. The HLP6 Oil
Purifiers electrical panel should not be opened unless the supply voltage is isolated and locked out.
The HLP6 is to be installed in accordance with the National
Electrical Code and all local codes and ordinances. The electricity supplied to the HLP6 skid must be ground fault protected.
Installation is to be performed by a licensed electrician and inspected by local authorities. Failure to do so could lead to personal injury or death.
WARNING – Verify Supply Voltage!
• The voltage supplied to the HLP6 must be ground fault protected.
• Supply voltage must match the VRF design specification!
• Match HLP6 identification tag and motor identification tag with supply voltage.
• Severe motor damage will occur if wrong voltage is supplied.
MAN-HLP6-R0-USA August 15, 2009 Page 21
7.1 Connecting the Supply Voltage to the HLP6
Read all cautions and warnings above.
In order for Pall Corporation to meet the needs of all end-users the HLP6 electrical enclosure is not provided with a supply voltage “knock out” port. The end-user must drill a hole in the electrical enclosure for delivery of the HLP6 supply voltage.
The supply voltage to the HLP6 should be connected where shown below. The HLP6 electrical panel is suitable for WYE configured electrical service only. Contact factory if Delta configuration is desired. The end-user must provide supply voltage to the HLP6 with adequate ground fault and circuit breaker protection in accordance with Federal, State, Local and plant regulations.
HLP6 Electrical Enclosure Supply Voltage Termination Points
(480VAC shown)
MAN-HLP6-R0-USA August 15, 2009 Page 22
7.2 Motor Rotation Check
The HLP6 will automatically detect if the sequence of the supply voltage has been properly connected. There is no need to bump start the motors to check for rotation. If the supply voltage is out of sequence the purifier will alert the operator with an alarm as shown below. Refer to section 11.1 to correct the situation.
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8 BASIC HLP6 OPERATING PROCEDURES
WARNING – Complete sections 5 & 7 First!
Before proceeding review these sections:
# 5 INSTALLATION
# 7 ELECTRICAL CONNECTION
8.1 Oil Flow Path through HLP6
During normal operation oil will pass through the HLP6 Oil Purifier as indicated by the gold arrows. Key system components are identified with numbers which correspond directly to the number found on the hydraulic schematic drawing.
Oil is drawn into the HLP6 via the pump/motor group (# 4 - 6). The fluid passes the inlet gate valve (#31) and inlet strainer (#1), then through the pump/motor group. Fluid travels through the check valve (#7), heater (#9), sight glass (#10), and delivered to the vacuum tower (#15). Sight glass (#16) shows the tower fluid level. Oil is removed from the vacuum tower via a second pump/motor group (#4/18). The oil is passed through a polishing filter (#20) and check valve
(#22) then returned to the oil reservoir.
MAN-HLP6-R0-USA August 15, 2009 Page 25
8.2 Air Flow Path through HLP6
When running, the HLP6 Oil Purifier will maintain a steady flow of air through the vacuum tower.
The air flow path is indicated by the green arrows. Key system components are identified with numbers corresponding directly to the number found on the hydraulic schematic drawing.
Shortly after starting the HLP6 oil purifier the vacuum pump & motor (#25 & #26) will start and air within the vacuum tower will be exhausted. Ambient air will be drawn into the vacuum tower through the inlet breather filter (#10) and vacuum adjustment valve (#12). Filtered air will travel upwards through the vacuum tower, through the demisting pad (# 15A) and into the vacuum pump
(# 26). Air leaves the vacuum pump, travels through a final coalescer (#29), and exhausts to atmosphere.
MAN-HLP6-R0-USA August 15, 2009 Page 26
•
•
•
•
•
8.3 Pre-startup Checks
•
Check vacuum pump gear oil level (photo below, see maintenance section for oil type and fill procedure)
Close all drains and vents (locations indicated below).
Completely open the inlet gate valve (#31).
Open all valves in the oil supply line to the purifier.
Open all valves in the oil return line from the purifier to the reservoir.
Verify condition of inlet air breather (see maintenance section for change-out procedure).
MAN-HLP6-R0-USA August 15, 2009 Page 27
8.4 HLP6 Energizing and Boot-up
Turning the main disconnect to the “ON” position will “boot up” the HLP6 Oil Purifier. During the boot-up process the HMI will display screens as shown below. When the boot-up process is completed the HMI will display the HOME page with the words “PURIFIER READY”.
Purifier Booting Up Purifier Booted Up Ready to Start
MAN-HLP6-R0-USA August 15, 2009 Page 28
8.5 Starting the HLP6 Purifier
Complete sections 7.1, 8.3, & 8.4 first! Ensure all valves connecting the HLP6 to the reservoir are
100% open. Only after the HLP6 has booted up and the HMI displays “PURIFER READY” can the HLP6 be started. To start the purifier press the red “START” button on the front panel. The start button will illuminate immediately after the start button is pressed.
Purifier is ready to start
Purifier Running
Special Note about lamp colors: The HLP6 uses the Power Generation standard lamp coloring scheme. Green light for safe / purifier off / purifier not running.
Red light for energized / purifier running / purifier live.
MAN-HLP6-R0-USA August 15, 2009 Page 29
8.6 Running and Adjusting the Purifier
A few seconds after pressing the start button the inlet and outlet pumps will start (which one starts first depends on the oil level within the tower). Several seconds later the vacuum pump will start and tower vacuum will begin to build. Oil will be seen flowing in the upper sight glass. The oil level within the tower will become stable in the lower sight glass. Shortly thereafter, if the heater is enabled, it may come on depending on the heaters set point in relation to the current temperature.
With the purifier running make the following adjustments and observations:
Adjust the tower vacuum to approximately 18” Hg using the needle valve (#13). Clockwise rotation of the needle valve will increase tower vacuum. Counter-clockwise rotation will decrease tower vacuum.
Caution: When adjusting the needle valve, use only ½-turn (180 degree) or ¼-turn (90 degree) increments. It may take up to 60 seconds for the tower vacuum to stabilize. Do not over adjust.
Vent air trapped within the polishing filter housing using the needle valve (32).
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8.7 Gauge Observations
The HLP6 gauge cluster is shown below. After approximately 60 seconds all gauges should be within the range stated on the placard located below the gauge. If the operator observes a reading outside the stated ranges the HLP6 may issue an alarm condition. The operator should turn to the troubleshooting section of this manual for further instructions.
MAN-HLP6-R0-USA August 15, 2009 Page 31
8.8 Enabling the Heater & Changing Heater Set Point
The HLP6 heater is enabled/disabled using the ON/OFF switch located on the front panel. When the heater is enabled the heater logic determines when to energize the heater.
When the heater is
energized the switch will illuminate.
Heater Enabled, not energized Enabled & energized Heater disabled
The heater set point is factory set at 120 o
F (49 o
C). The set point is adjustable using the purifier’s
HMI (human machine interface). The set point can be changed if the purifier is running or not.
From the HMI home, page press F4, which corresponds to “HEA” which is short for “heater”.
After pressing F4 the operator is taken to the heater control screen (shown below).
MAN-HLP6-R0-USA August 15, 2009 Page 32
Heater control screen Heater set point screen
From the heater control screen press F5 to bring up the heater set point screen. The heater set point can now be adjusted. Heater control is not password protected.
Use the F3 & F4 keys to raise or lower the heater set point temperature.
Pressing the F3 or F4 key one time will adjust the temperature by one degree.
Press and hold the F3 or F4 key to scroll the numbers more quickly.
When the desired set point is reached, press F1 to return to the home page.
8.9 Cold Startup Condition - Oil Viscosity Above 1000 cSt (4650 SUS)
The HLP6 Oil Purifier will not run properly with fluids having a viscosity above 1000 cSt. The user should be aware of cold fluid conditions resulting from hoses laying on cold floors. During colder months of the year, users are advised to drain fluid from purifier supply line hoses when the oil purifier is not being used. It is especially important to keep fluid supply lines to the oil purifier as short as possible to minimize the effects of cold fluid introduction to the HLP6.
8.10 Stopping the Purifier
To stop the HLP6 press the “stop” button. All pumps and motors will stop and the stop button will illuminate as shown below.
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8.11 Draining the Purifier
Considerations Prior to Draining: The HLP6 Oil Purifier is equipped with an automatic draining feature. To maximize the effectiveness of the drain mode, the user should disconnect the fluid supply line from the inlet of the purifier. This will prevent additional fluid from being drawn into the purifier and allow for better drainage overall. If the above-mentioned procedure is followed the purifier will have approximately 1 gallon of fluid still left on board.
If more draining is desired, the user should manually drain the heater, vacuum tower and polishing filter using the manual ball valves located at the bottom of each of these components.
Enabling Drain Mode: The operator should read and understand the section above: titled
“Considerations Prior to Draining”.
• To activate the drain mode the purifier must be stopped and the power energized.
• Press and hold the stop button for 5 seconds. After 5 seconds the HMI screen will display the screen below and the user can release the stop button.
• The user can now start the automatic drain mode by pressing the start button. At that time the inlet pump will run for 45 seconds, and the outlet pump for 90 seconds.
• The user may also start and stop either the inlet or outlet pump individually. Pressing the
F2 key will start the inlet pump; pressing the F4 will start the outlet pump
• When draining is complete, exit to the “Home Page” by pressing F3 (HOM)
MAN-HLP6-R0-USA August 15, 2009 Page 34
9
THEORY OF OPERATION & COMPONENT IDENTIFICATION
9.1 General Claims
The HLP6 Oil Purifier can be used as a portable or stationary vacuum dehydration unit. It has been designed to purify hydraulic, lubricating, insulating and gear oils by removing water, particulate contamination, and gases.
•
Water – 100% of free water, 75% of dissolved water
•
Gases – 100% of free & entrained gases, 75% of dissolved gases
•
Dirt – including silt and other solids or particulate contaminants.
9.2
Theory of Operation
Oil contaminated with water, gas, and particulate is purified on-board the HLP6 purifier.
Dry air in the tower is obtained by expansion: Ambient air is drawn into the tower by the vacuum pump, and expanded to approximately 4 times its former volume (depending on vacuum set point). As the inlet air volume expands 4-fold, the relative humidity of that air decreases 4-fold.
The resulting air inside the tower has effectively been dried.
The contaminated oil is drawn into the purifier via the inlet fluid pump. The oil passes through the heater and enters the top of the tower. The oil cascades from the top of the tower to the bottom via gravity, passing through a column of stainless steel rings in the process.
While the contaminated oil travels down the column, water trapped in the oil converts from a liquid phase to a gaseous phase. The gasses trapped in the oil will expand as per Boyles Law. As the oil travels down the column the vacuum pump maintains airflow through the tower. Water vapor and expanded gases are removed through the top of the tower by the vacuum pump and are discharged to atmosphere downstream of the vacuum pump.
Dry, degassed oil at the bottom of the tower is drawn out via the fluid pump and passed through the absolute rated filter before returning to the reservoir.
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9.3
Component Identification
Major HLP6 Oil Purifier components have been identified below. Not all components have been identified. For more details please refer to the Pall Corporation drawings package enclosed with this operator manual.
Front View
A = Gauge Cluster
B = Electrical Enclosure
15A = Demisting Pad
25 = Vacuum Pump Motor
26 = Vacuum Pump
28 = Vacuum Pump Back Pressure
Gauge
Rear View
1 = Inlet Strainer
4 = Inlet & Outlet Fluid Pump
6 = Inlet Pump Motor
9 = Heater
10 = Flow Sight Glass
11 = Inlet Air Breather Element
15 = Vacuum Tower
15A = Demisting Pad
16 = Oil Level Sight Glass
18 = Outlet Pump Motor
20 = Polishing Filter
22 = Check Valve (outlet)
29 = Coalescing Filter (air)
31 = Inlet Gate Valve
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10 MAINTENANCE
WARNING: No maintenance procedure should be attempted while the purifier is running, with the exception of adjusting the tower vacuum valve.
Prior to starting any maintenance procedure lock out and tag out the HLP6 purifier, close the inlet gate valve, and isolate the outlet line.
10.1 General Maintenance List
Section 10.2 Checking Vacuum Pump Timing Gear Oil
Section 10.3 Replacing Timing Gear Oil
Section 10.4 Replacing Exhaust Air Coalescer
Section 10.5 Replacing Inlet Breather
Section 10.6 Cleaning Inlet Strainer
Section 10.7 Replacing Polishing Filter
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10.2 Checking Vacuum Pump Timing Gear Oil
The HLP6 vacuum pump is located on the deck, under the gauge cluster. The timing gear oil level should be checked weekly (proper level shown below). Timing gear oil requires changing after
208 days (5000 hours) of use. See next section for oil type and change-out procedure.
10.3 Changing Vacuum Pump Timing Gear Oil
The HLP6 Oil Purifier will issue a warning in the HMI screen when the vacuum pump timing gear oil requires changing. To view a screen shot of the warning and also view the run-time hours remaining until the warning turn to section 12.4 of this manual.
Pall Corporation uses only the highest quality oil to lubricate the vacuum pump timing gear. The
HLP6 vacuum pump is shipped from the factory with Jax Syncomp-P ISO 150 oil (www.jax.com).
HLP6 users are encouraged to use the same oil. If an alternative oil must be used the oil must meet the following specifications:
Viscosity: ISO 150
Type: PAO (poly alpha olafin) - 100% synthetic
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STEP
1
2
3
4
5
ACTION
Stop the purifier and depressurize
Lock out for safety
Open gear oil drain port, Open gear oil fill port
Collect & discard vacuum pump gear oil
Close drain port, Refill with fresh oil, close fill port
COMMENT
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10.4 Replacing Exhaust Coalescer (Vacuum Pump Coalescer)
The HLP6 Oil Purifier is fitted with an oil vapor coalescer downstream of the vacuum pump. The
HMI screen will alert the operator when change out is required.
STEP
1
2
3
4
5
ACTION
Stop the purifier and depressurize
Lock out for safety
Locate the exhaust coalescer, remove the sealing collar and bowl
Replace the coalescer element (p/n OL4C :: cat# 1305787)
Re-install bowl and sealing collar
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10.5 Replacing Inlet Air Breather
While running, the HLP6 Oil Purifier introduces filtered air into the vacuum tower through the inlet air breather. The breather is fitted with a visual indicator. The inlet air breather should be changed upon indication.
Note: The HMI screen will not alert the operator when to change the breather; it is the operators responsibility to check the indicator on a regular basis (weekly).
Note: Do not discard the indicator it can be unscrewed and re-used on the new breather filter.
STEP
1
2
3
4
5
Stop the purifier and depressurize
ACTION
Lock out for safety
Locate the inlet air breather, unscrew by hand
Remove the indicator from the plugged breather and install on new breather
Install new breather and hand-tighten only
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10.6 Cleaning the Inlet Strainer
The HLP6 Oil Purifier is fitted with a strainer to protect the inlet fluid pump. If the inlet strainer becomes blocked a warning will be displayed on the HMI (turn to section 11.5 for details). To clean the inlet strainer, follow the instructions below.
STEP
1
2
3
4
5
6
ACTION
Stop the purifier and depressurize
Lock out for safety
Close the inlet gate valve
Remove the strainer locking screw, Remove strainer cover
Remove and clean inlet strainer basket
Re-install strainer, cover, and locking screw
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10.7 Replacing the Polishing Filter Element
The fluid processed by the HLP6 Oil Purifier is passed through a polishing filter element before returning to the tank or reservoir. If an elevated differential pressure is detected across the filter element the HMI screen will issue a warning (see section 11.12 for details).
STEP
1
2
3
4
5
6
7
8
9
ACTION
Stop the purifier and depressurize
Lock out for safety
Close the inlet gate valve
Open filter housing drain, Open filter housing vent, drain fluid
Remove filter housing cap and extract filter element
Wet o-rings of new filter element, install new filter element
Re-install filter cap
Close filter housing drain, Close filter housing vent
After restarting the purifier remember to vent air from filter housing
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10.8 Replacing the Demisting Pad
The demisting pad located at the top of the vacuum tower should be replaced annually or after
10000 hours of run time (which ever comes first).
STEP
1
2
3
6
7
4
5
8
9
ACTION
Stop the purifier and depressurize
Lock out for safety
Close the inlet gate valve
Remove the screws that secure the demister lid (see photo above)
Remove and set aside the gasket, it can be re-used
Using needle-nosed pliers, grab the second ring of the roll (as shown above)
Pull upwards with steady force to remove the demister
Install the new demister
Re-install the sealing gasket, cover and screws
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11 ALARM CONDITIONS, WARNINGS & TROUBLESHOOTING
Investigate Alarm/Warning Conditions!
If an alarm or warning condition occurs the root cause of the condition must be determined to protect the safety of the operator and also the equipment.
The HMI (human machine interface) located on the front panel of the HLP6 Oil Purifier will alert the operator of current running conditions and alarm or warning conditions. If a “major” or
“minor” alarm condition is detected the HMI will turn red and scroll a message across the screen.
If a “warning” condition is detected the HMI will alternate red and green and scroll a message across the screen.
List of Major Alarms
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Section 11.1 Phase Reversal / Low or High Voltage
Section 11.2 High System Temperature Shutdown
Section 11.3 Inlet Pump Motor Contactor Failure
Section 11.4 Vacuum Pump Motor Contactor Failure
Section 11.5 Inlet Pump Cavitation
Section 11.6 Change Exhaust Coalescer
Section 11.7 High Tower Level Shutdown
Section 11.8 Low Tower Level Shutdown
Section 11.9 Outlet Pump Motor / Drive Overload
Section 11.10 Inlet Pump Motor Overload
Section 11.11 Vacuum Pump Motor Overload
Section 11.12 Dirty Filter Warning / Shutdown
Section 11.13 Tower Fluid Level Sensor Signal Loss
Section 11.14 Outlet Pump Motor Drive Fault <###>
Section 11.15 Outlet Pump Motor Drive Comm.Loss Alarm
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List of Minor Alarms
•
•
•
•
•
Section 11.16 Heater Thermocouple Signal Loss
Section 11.17 Saturation Probe Signal Loss
Section 11.18 System Temperature Probe Signal Loss
Section 11.19 High Water Saturation Alarm
Section 11.20 Heater Contactor Failure
List of Warnings
•
•
Section 11.21 Service Vacuum Pump Soon
Section 11.22 PLC Battery Low….Replace Soon
MAN-HLP6-R0-USA August 15, 2009 Page 46
11.1 Phase Reversal / Low / High Voltage
•
•
•
The HLP6 Oil Purifier will announce the “PHASE REVERAL/LOW/HIGH VOLTAGE” alarm when the supply voltage is out of the expected range. Listed below are the 4 possible causes for this alarm. The HMI does not identify which of the 4 conditions is causing the alarm, only that an alarm condition exists.
Phase Reversal – supply voltage is out of phase, switch 2 of 3 supply voltage legs.
Phase Loss – one or more of the supply voltage legs is not energized
Low Voltage – the voltage supplied to the purifier is below the lower threshold.
•
High Voltage – the voltage supplied to the purifier is above the upper threshold.
To determine which of the 4 possibilities is causing the alarm the operator must open the electrical panel and view the lights on the sensor.
Explanation of LED Light Sequences
Normal Operation – Green LED on & Red LED’s off
Phase Reversal – Alternating flashing of Green & Red LED’s
Low Voltage – Green LED flashing & Red Low Voltage LED on
High Voltage – Green LED flashing & Red High Voltage LED on
Phase Loss – Green LED flashing
WARNING – Do Not Adjust Supply Voltage Sensor!
The sensor is designed to protect the HLP6 Oil Purifier from damage caused by fluctuating supply voltage conditions. The sensor is factory set and should not be adjusted unless instructed to do so be Pall
Corporation. Adjusting the sensor outside of the factory set points will void the HLP6 Oil Purifiers warranty.
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11.2 High System Temperature Shutdown
When the HLP6 Oil Purifier detects a temperature 180 o
F (82 o
C) the “HIGH SYSTEM
TEMPERATURE SHUTDOWN” alarm will be announced on the HMI screen.
!
Operational Tip!
High temperature alarms may occur during the initial installation of the purifier or if the purifier is being moved to a new location. The root cause is usually unstable oil flow due to poor air in the supply lines. Operators are advised to leave the heater disabled until the purifier has demonstrated it can run stable.
Probable Alarm Causes
The oil delivered to the purifier is
180 o
F (82 o
C)
Thermocouple short-circuited or damaged
Damaged thermocouple signal conditioner
Solutions
Oil within the reservoir or tank should be cooled below 165 o
F (74 o
C).
Follow flow chart below
Contact Pall Corporation
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11.3 Inlet Pump Motor Contactor Failure
The contactor for the inlet fluid pump motor of the HLP6 Oil Purifier is monitored for proper operation at all times. Whenever the inlet fluid pump motor is engaged the PLC monitors input
X11 for a 24 VDC acknowledgement signal. If the signal differs from what is expected the
“INLET PUMP MOTOR CONTACTOR FAILURE” alarm will be announced on the HMI screen.
Inlet Pump Motor Contactor 24 VDC Power Supply
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STEP
1
2
3
4
5
6
7
8
ACTION
Stop the purifier and depressurize
Lock out for safety
Verify the integrity of Fuse FU4, replace if needed.
Test and repair continuity of wire #37 from the contactor (shown above) and input
X11 at the PLC. Wire should be continuous, repair as needed.
Manually press in the contactor, simultaneously test continuity of wire #37 & #3
(shown above). Circuit should be continuous when contactor is pressed in.
Replace contactor if continuity test fails.
Test and repair the continuity of wire #3 at the contactor and wire #3 at the 24VDC supply.
After completing the above, energize the purifier but do not start. Carefully verify
24 VDC on wire #3 at the inlet motor contactor. Replace the 24 VDC supply if no voltage is detected.
Re-start the purifier
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11.4 Vacuum Pump Motor Contactor Failure
The contactor for the vacuum pump motor of the HLP6 Oil Purifier is monitored for proper operation at all times. Whenever the inlet fluid pump motor is engaged the PLC monitors input
X13 for a 24 VDC acknowledgement signal. If the signal differs from what is expected the
“VACUUM PUMP MOTOR CONTACTOR FAILURE” alarm will be announced on the HMI screen.
Vacuum Pump Motor Contactor 24 VDC Power Supply
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STEP
1 Stop the purifier and depressurize
ACTION
2 Lock out for safety
3 Verify the integrity of Fuse FU4, replace if needed.
4 Test and repair continuity of wire #39 from the contactor (shown above) and input
X13 at the PLC. Wire should be continuous, repair as needed.
5 Manually press in the contactor, simultaneously test continuity of wire #39 & #3
(shown above). Circuit should be continuous when contactor is pressed in.
Replace contactor if continuity test fails.
6 Test and repair the continuity of wire #3 at the contactor and wire #3 at the 24VDC supply.
7 After completing the above, energize the purifier but do not start. Carefully verify 24
VDC on wire #3 at the inlet motor contactor. Replace the 24 VDC supply if no voltage is detected.
8 Re-start the purifier
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11.5 Inlet Pump Cavitation
•
•
•
•
•
•
Low pressure upstream of the inlet pump (often called Pump Cavitation) may damage the seals of the inlet pump. The HLP6 Oil Purifier is equipped with a pressure sensor upstream of the inlet pump to monitor inlet line pressure. When a low pressure is detected the HMI will display
“INLET PUMP CAVITATION”.
Possible causes of this alarm are:
Closed valve in the fluid supply line to the purifier
Obstruction within the fluid supply line
Cold oil (high viscosity) in the fluid supply line
Clogged purifier inlet strainer
Collapsed fluid supply line (hoses not rated for suction may experience this)
Faulty inlet pressure sensor
Use the flow chart on the next page to troubleshoot this alarm.
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11.6 Change Exhaust Coalescer
•
•
•
Downstream of the vacuum pump, near the discharge filter housing resides the vacuum pump exhaust air coalescer. The HLP6 Oil Purifier is fitted with an analog gauge and a pressure sensor to detect high pressure conditions upstream of the coalescer. The HMI will display “CHANGE
EXHAUST COALESCER” alarm when the pressure exceeds the set point of 10 psi (0.7 bar).
Possible Causes of this alarm are:
High line pressure caused by clogged coalescer element
Operator inadvertently capping/plugging the exhaust air port
Faulty pressure sensor
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STEP
1
2
3
4
5
6
ACTION
Stop the purifier
Lock out for safety
Remove the coalescer element from its housing (see section 10.4 for details)
Re-start the purifier, if the alarm does not re-occur replace the coalescer element
If the alarm re-occurs, verify that no obstructions exist within the tubing connecting the vacuum pump to the coalescer housing
Re-start the purifier, if the alarm re-occurs, verify that the pressure sensor changes state at approx 10 psi. Replace the sensor if needed.
11.7 High Tower Level Shutdown
•
•
•
•
•
•
•
•
•
The fluid level within the vacuum tower of the HLP6 is monitored by level floats. The fluid level can be viewed in the lower sight glass (shown below). Under normal conditions the fluid level will stay virtually unchanged about half-way up in the sight glass. Conditions may arise when the fluid level is above the expected range, under those conditions the HLP6 Oil Purifier will issue a
“HIGH TOWER LEVEL SHUTDOWN” alarm.
Possible causes of this alarm are:
Closed valve in fluid discharge line (between purifier and reservoir)
High backpressure in fluid discharge line resulting from head pressure or other obstruction
Tower vacuum level too high (fluid pump can not pull fluid out of the tower)
Fluid viscosity increase resulting from temperature decrease
Broken or obscured outlet check valve (not opening fully)
Suction leak or obstruction at the inlet to the purifiers discharge pump
Coupling failure or broken pump shaft between discharge pump and motor
Damaged or failed outlet pump relief valve
Large amount of “foam” in the fluid entering the discharge pump
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11.8 Low Tower Level Shutdown
The fluid level within the vacuum tower of the HLP6 is monitored by level floats.
The fluid level can be viewed in the lower sight glass (shown below). Under normal conditions the fluid level will stay virtually unchanged about half-way up in the sight glass. Conditions may arise when the fluid level is below the expected range; under those conditions the HLP6 Oil Purifier will issue a “LOW
TOWER LEVEL SHUTDOWN” alarm.
Possible causes of this alarm are:
• Fluid is too viscous 1000 cSt (warm the fluid in the supply line and tank)
• Air leak on inlet line (loose fittings, inlet line not submerged in tank)
• Large amount of “foam” in the fluid entering the purifier inlet pump
• Coupling failure or broken shaft between inlet pump and motor
• Broken or obscured inlet check valve (not opening fully)
• Failed pressure relief valve on inlet fluid pump
11.9 Outlet Pump Motor/Drive Overload
•
•
•
The outlet (discharge) pump of the HLP6 Oil Purifier has a variable speed and is controlled by a variable frequency drive (VFD). The overload protection for the variable frequency drive is monitored for “trip” conditions at all times. Whenever the purifier is energized the PLC monitors input X10 (wire #36) for a 24 VDC acknowledgement signal. If the signal drops for any reason the “OUTLET PUMP
MOTOR DRIVE OVERLOAD” alarm will be announced on the HMI screen.
Possible causes of this alarm are:
VFD has drawn too much current and “tripped” overload breaker
Loose wiring
Failed 24 VDC power supply
Outlet Pump Motor Drive Overload 24 VDC Power Supply Variable Frequency Drive
STEP
1
2
3
4
5
6
7
8
9
Stop the purifier and depressurize
ACTION
Lock out for safety
Ensure 3 phase wires entering the top of the overload are secure and continuous up to the main disconnect. Secure connections as needed
Test continuity of 3 phase wires leaving the bottom of the overload traveling to the VFD. Secure connections as needed.
Test and repair continuity of wire #36 from the overload (shown above) and input X10 at the PLC. Wire should be continuous; repair as needed.
Test and repair the continuity of wire #3 at the contactor and wire #3 at the
24VDC supply.
After completing the above energize the purifier but do not start. Carefully verify 24 VDC on wire #3 at the inlet motor contactor. Replace the 24 VDC supply if no voltage is detected.
Re-start the purifier
If alarm repeats contact Pall Corporation
11.10 Inlet Pump Motor Overload
•
•
•
•
The inlet fluid pump of the HLP6 Oil Purifier is protected against current overdraw. Whenever the purifier is energized the PLC monitors input X12 (wire
#38) for a 24 VDC acknowledgement signal. If the signal drops for any reason the “INLET PUMP MOTOR OVERLOAD” alarm will be announced on the HMI screen.
Possible causes of this alarm are:
Inlet pump motor has drawn too much current and “tripped” overload
Misadjusted current setting on the overload
Loose wiring
Failed 24 VDC power supply
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Inlet Pump Motor Overload 24 VDC Power Supply Amperage Setting (480V units)
STEP
1
2
3
ACTION
Stop the purifier and depressurize
Lock out for safety
Inspect the overload for a “trip” condition. If the overload has tripped the blue overload reset button will have popped (moved) outward. To reset the overload, press in the blue button.
Test the actuation of the “trip” condition by pulling on the red test button. When the test button is pulled, the blue button will pop
4
5
6
7
8
9 outward. Before continuing on, press the reset button in.
Caution – Inspect only: Inspect (note) the setting of the current adjustment wheel located on the overload. The amperage setting is factory set and should not be adjusted. The proper setting for 480V machines has been shown above.
Test and repair continuity of wire #38 from the overload (shown above) and input X12 at the PLC. Wire should be continuous; repair as needed.
Test and repair the continuity of wire #3 at the overload and wire #3 at the 24VDC supply.
After completing the above energize the purifier but do not start.
Carefully verify 24 VDC on wire #3 at the inlet pump motor overload. Replace the 24 VDC supply if no voltage is detected.
Measure the current draw at the motor. Replace motor if current draw exceeds the value stated on the motor name plate.
Contact Pall Corporation if additional help is needed.
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11.11 Vacuum Pump Motor Overload
•
•
•
•
The vacuum pump of the HLP6 Oil Purifier is protected against current overdraw.
Whenever the purifier is energized the PLC monitors input X14 (wire #40) for a
24 VDC acknowledgement signal. If the signal drops for any reason the
“VACUUM PUMP MOTOR OVERLOAD” alarm will be announced on the HMI screen.
Possible causes of this alarm are:
Vacuum pump motor has drawn too much current and “tripped” overload
Misadjusted current setting on the overload
Loose wiring
Failed 24 VDC power supply
Vacuum Pump Motor Overload 24 VDC Power Supply Amperage Setting (480V units)
MAN-HLP6-R0-USA August 15, 2009 Page 64
6
7
8
STEP
1
2
3
4
5
9
10
ACTION
Stop the purifier and depressurize
Lock out for safety
Inspect the overload for a “trip” condition. If the overload has tripped the blue overload reset button will have popped (moved) outward. To reset the overload, press in the blue button.
Test the actuation of the “trip” condition by pulling on the red test button.
When the test button is pulled, the blue button will pop outward. Before continuing on, press the reset button in.
Caution – Inspect only: Inspect (note) the setting of the current adjustment wheel located on the overload. The amperage setting is factory set and should not be adjusted. The proper setting for 480V machines has been shown above.
Test and repair continuity of wire #40 from the overload (shown above) and input X14 at the PLC. Wire should be continuous, repair as needed.
Test and repair the continuity of wire #3 at the overload and wire #3 at the
24VDC supply.
After completing the above energize the purifier but do not start.
Carefully verify 24 VDC on wire #3 at the inlet pump motor overload.
Replace the 24 VDC supply if no voltage is detected.
Measure the current draw at the motor. Replace motor if current draw exceeds the value stated on the motor name plate.
Contact Pall Corporation if additional help is needed.
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11.12 Dirty Filter Warning – Dirty Filter Shutdown
•
•
•
•
•
The discharge filter of the HLP6 Oil Purifier is constantly monitored for elevated differential pressure (dP) conditions. Whenever the purifier is energized the PLC monitors input X7 (wire #35) for a 24 VDC acknowledgement signal. If the signal drops for any reason the purifier will begin the two-part filter shutdown alarm sequence.
Part 1: “DIRTY FILTER WARNING” – when the dP across the filter element exceeds the set point the purifier will issue a dirty filter warning and begin a 24hour countdown timer. The purifier will continue to run. If the high dP condition continues for 24 hours, the purifier will shut down.
Part 2: “DIRTY FILTER SHUTDOWN” – When the countdown timer from part one reaches “0” and the elevated dP condition still remains, the purifier will shut down and issue an alarm on the HMI (shown above).
Possible causes of this alarm are:
Plugged or obscured filter element
High-viscosity fluid causing elevated dP
Loose wiring
Failed dP gauge
Failed 24 VDC power supply
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11.13 Tower Fluid Level Sensor Signal Loss
•
•
•
The fluid level sensor inside the HLP6 Oil Purifier vacuum tower continuously sends an analog signal to the PLC on wire #48. If the signal drops completely or goes below a predetermined threshold the “TOWER FLUID LEVEL SENSOR
SIGNAL LOSS” alarm will be announced on the HMI screen.
Possible causes of this alarm are:
Failed or damaged 24 VDC power supply
Faulty wiring
Damaged float sensor
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11.14 Outlet Pump Motor Drive Faults
•
•
The outlet fluid pump motor of the HLP6 Oil Purifier is controlled by a variable frequency drive (VFD). If a fault condition occurs within the VFD the purifiers
HMI will issue the “OUTLET PUMP MOTOR DRIVE FAULT <###>” alarm.
The HMI will display the specific fault number. The alarm is triggered by a 24
VDC signal at PLC input X20 (wire #44).
Possible causes of this alarm are:
Failed or damaged 24 VDC power supply
For additional troubleshooting contact Pall Corporation.
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11.15 Outlet Pump Motor Drive Comm. Loss
The HLP6 Oil Purifier monitors the communication between the PLC and the variable frequency drive (VFD). If loss of communication occurs between the
PLC and VFD the purifiers HMI will issue the “OUTLET PUMP MOTOR
DRIVE COMM. LOSS” alarm.
Possible causes of this alarm are:
•
Damaged or unplugged comms cable
Check and secure the comms cable at the PLC. Replace the cable if needed.
PLC to VFD Comms Cable
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Minor Alarms
11.16 Heater Thermocouple Signal Loss
The HLP6 Oil Purifier monitors the communication between the PLC and the heater thermocouple. If loss of communication occurs between the PLC and thermocouple the purifiers HMI will issue the “HEATER THERMOCOUPLE
SINGAL LOSS” alarm.
Possible causes of this alarm are:
•
• open
•
The heater thermocouple transmitter has failed
The wiring from the transmitter to the PLC analog card has shorted or is
Channel #2 of the analog card has failed or is damaged
This alarm is most likely
not caused by a failed or damaged thermocouple.
MAN-HLP6-R0-USA August 15, 2009 Page 71
Inside view of heater wiring box
STEP
1 Stop the purifier and depressurize
ACTION
2 Lock out for safety
3 Locate and open the heater wiring box
4 Test and repair continuity of wire #49 from the transmitter (shown above) and input to the PLC’s analog card at channel #2. Wire should be continuous, repair as needed.
5 Test and repair the continuity of wire #3 at the transmitter and wire #3 at the
24VDC supply.
6 After completing the above energize the purifier but do not start. Carefully verify 24 VDC on wire #3 at the transmitter. Replace the 24 VDC supply if no voltage is detected.
7 At the PLC’s analog card, measure the milliamp output of the transmitter on wire # 49. If output is less than 2 mA replace the transmitter.
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11.17 Saturation Probe Signal Loss
The HLP6 Oil Purifier monitors the communication between the PLC and the Pall
Water Sensor. If loss of communication occurs between the PLC and the water sensor the purifiers HMI will issue the “SATURATION PROBE SINGAL LOSS” alarm.
Possible causes of this alarm are:
•
• open
•
•
Blown fuse F2 or F3 or F4 or F5
The wiring from the water sensor to the PLC analog card has shorted or is
Channel #3 of the analog card has failed or is damaged
Failure of the water sensor itself
MAN-HLP6-R0-USA August 15, 2009 Page 73
STEP ACTION
1 Stop the purifier and depressurize
2 Lock out for safety
3 Locate and open the heater wiring box
4 Test and repair continuity of wire #50 from the water sensor and input to the PLC’s analog card at channel #3. Wire should be continuous, repair as needed.
5 Test and repair the continuity of wire #3 at the water sensor and wire #3 at the 24VDC supply.
6 After completing the above energize the purifier but do not start.
Carefully verify 24 VDC on wire #3 at the water sensor. Replace the
24 VDC supply if no voltage is detected.
7 At the PLC’s analog card, measure the milliamp output of the water sensor on wire # 50. If output is less than 2 mA contact Pall
Corporation.
11.18 Temperature Probe Signal Loss
The temperature of the fluid entering the HLP6 is monitored by the Pall water sensor. Channel #4 of the PLC analog card received the temperature signal on wire # 51. If loss of communication occurs between the PLC and the water sensor the purifiers HMI will issue the “TEMPERATURE PROBE SINGAL LOSS” alarm.
MAN-HLP6-R0-USA August 15, 2009 Page 74
Possible causes of this alarm are:
•
• open
•
•
Blown fuse F2 or F3 or F4 or F5
The wiring from the water sensor to the PLC analog card has shorted or is
Channel #4 of the analog card has failed or is damaged
Failure of the water sensor itself
STEP ACTION
1 Stop the purifier and depressurize
2 Lock out for safety
3 Test and repair continuity of wire #51 from the water sensor and input to the PLC’s analog card at channel #4. Wire should be continuous, repair as needed.
5 Test and repair the continuity of wire #3 at the water sensor and wire #3 at the 24VDC supply.
6 After completing the above energize the purifier but do not start.
Carefully verify 24 VDC on wire #3 at the water sensor. Replace the
24 VDC supply if no voltage is detected.
7 At the PLC’s analog card, measure the milliamp output of the water sensor on wire # 51. If output is less than 2 mA contact Pall
Corporation.
MAN-HLP6-R0-USA August 15, 2009 Page 75
11.19 High Water Saturation Alarm
Conditions may develop in which the water content in the reservoir or tank will spike high. The cause of the water spike can be attributed to many factors which will not be discussed within this IOM. HLP6 Oil Purifier models equipped with a water sensor will measure the dissolved water content of the fluid entering the purifier, upstream of the heater. The HLP6 is factory programmed to issue to issue the “HIGH WATER SATURATION ALARM” if the dissolved water content at the inlet of the HLP6 exceeds 90% saturation. The alarm trigger point can be adjusted, see section 12 of this manual for details.
Anytime the dissolved water content approaches or exceeds 90% saturation the user should take immediate action to pinpoint and arrest the source of the water ingression. If the water ingression rate exceeds the water removal rate the oil reservoir or tank may overfill. The High Water Saturation Alarm should be taken seriously and immediate action must be taken to reduce the source of water ingression.
11.20 Heater Contactor Failure
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The heater contactor for the HLP6 Oil Purifier is monitored for proper operation at all times. This alarm is monitored by auxiliary contacts on the heater contactor.
The auxiliary contacts are wired normally open with wire #3 for 24 VDC and wire
#45 for the signal is wired to input X21 on the PLC. When the PLC engages the heater it looks for a 24 VDC acknowledgment signal on wire #45. If the signal is not detected within 1 second the “HEATER CONTACTOR FAILURE” alarm will be announced on the HMI screen. The purifier will continue to run under this alarm condition.
Heater Contactor 24VDC Power Supply FU1 Fuse Block
STEP
1 Stop the purifier and depressurize
ACTION
2 Lock out for safety
3 Verify the integrity of Fuse FU1, replace if needed.
4 Test and repair continuity of wire #45 from the contactor (shown above) and input X21 at the PLC. Wire should be continuous, repair as needed.
5 Manually press in the contactor, simultaneously test continuity of wire #45 &
#3 (shown above). Circuit should be continuous when contactor is pressed in.
Replace contactor if continuity test fails.
6 Test and repair the continuity of wire #3 at the contactor and wire #3 at the
24VDC supply.
7 After completing the above, energize the purifier but do not start. Carefully verify 24 VDC on wire #3 at the heater contactor. Replace the 24 VDC supply if no voltage is detected.
8 Re-start the purifier
MAN-HLP6-R0-USA August 15, 2009 Page 77
Warnings
11.21 Service Vacuum Pump Soon
The HLP6 oil purifier will issue a vacuum pump service warning after 5000 hours of run time have been logged. The operator should plan on changing the vacuum pump timing gear oil within the next 7 days. Turn to section 10.3 of this manual for instructions on changing the gear oil.
After the gear oil is replaced the service timer needs to be reset to 5000 hours.
This can be done by pressing the “RST” button and then typing in 5000 as shown below.
11.22 PLC Battery Low…….Replace Soon
The PLC used on board the HLP6 oil purifier contains a battery. When the battery becomes drained the HMI screen will announce a PLC Battery Low warning. The user should change the battery within 7 days. The battery type is
CR2354 lithium ion.
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12 HMI SCREENS
12.1 Home Page
The HLP6 Oil Purifier has various screens which can be viewed. The home pages are shown below. When pressing “NXT” (F5) button home page # 2 will be displayed. Section 12 will discuss the various screens and their function.
Home Page #1 Home Page #2
12.2 TIM Button – System Run Time Screens
When the “TIM” (F1) button in pressed the HMI will display the system run time screen.
Total Run Time = total number of run time hours logged by the purifier
Session Run Time = run time hours logged since the machine was last started
To return back to the home page press HOM (F1).
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12.3 FIL Button – Filter Status Screen
When the “FIL” (F2) button in pressed the HMI will display the filter status screen.
Filter Normal = discharge filter differential pressure below indication point
Dirty Filter Warning = discharge filter differential pressure has reached indication point, 24 hour count down timer engaged, hours until shutdown are displayed
Dirty Filter Shutdown = 24 hour countdown timer has elapsed, purifier shutdown
After replacing the discharge filter return to the home page by pressing HOM
(F1).
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12.4 VAC Button – Vacuum Pump Status Screen
When the “VAC” (F3) button in pressed the HMI will display the vacuum pump status screen.
Vacuum Pump Status = shows the elapsed run time and the number of days until the vacuum pump timing gear oil needs replacing
Vacuum Pump Service Time = Number of run time hours that will be logged before the next service alarm. Use the + or – button to increase or decrease the service time.
Vacuum Pump Reset = This button should only be pressed after the vacuum pump timing gear oil has been replaced. Pressing the button will allow the operator to reset the 5000 hour count down timer.
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12.5 HEA Button – Heater Control Screen
When the “HEA” (F4) button in pressed the HMI will display the heater control screen. To access the heater set point screen press the “Set” (F5) button.
Heater Set Point = from this screen the operator can adjust the heater set point and also toggle from degree C to degrees F. Use the + / - buttons to adjust the set point. To lock in the changes pressed the HOM (F1) button.
12.6 SAT Button – Water Sensor Control Screen (this screen can only be accessed from home page #2)
When the “SAT” (F1) button in pressed the HMI will display the water sensor control screen. The operator can set alarm trigger points for inlet oil temperature and dissolved water content (% saturation). The factory default settings are shown below.
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To adjust the water sensor alarm set points press the “SET” (F5) button and the screen below will be displayed. Use the + / - buttons to adjust the set points.
12.7 VFD Button – Outlet Pump VFD Status Screen (this screen can only be accessed from home page #2)
When the “VFD” (F2) button in pressed the HMI will display the outlet pump vfd status screen. The operator should only access these screens under direction of
Pall Corporation or its representative.
12.8 TOW Button – Tower Level Control Screen (this screen can only be accessed from home page #2)
When the “TOW” (F3) button in pressed the HMI will display the tower level control screen. This screen can be used to adjust the tower fluid level. Operators are cautioned not to adjust the default setting unless instructed by Pall
Corporation or its representative.
12.9 CON Button – Pall Corporation Contact Screen (this screen can only be accessed from home page #2)
When the “CON” (F4) button in pressed the HMI will display the contact phone number for Pall Corporation. Pressing any button from this screen to return back to the home page.
MAN-HLP6-R0-USA August 15, 2009 Page 83
FLOW SIGHT
WATER SENSOR
(OPTIONAL)
AIR OUTLET OUTLET CHECK VALVE
32.00
48.00
DETAIL A
SCALE 1/4
MAIN POWER SWITCH
AIR OUTLET PRESSURE SWITCH
SET @ 10 PSI
INLET VACUUM SWITCH
SET AT -22 inHg
VACUUM PUMP/MOTOR
PORTS:
INLET: 1 1/2" FNPT
OUTLET: 1" FNPT
AIR OUTLET: -8 SAE 37 DEG FLARE
DR1 - DR3: -8 SAE 37 DEG FLARE(CAPPED)
UNIT DRY WEIGHT = 1150 LBS
INLET VACUUM/PRESSURE GAUGE
-30 inHg - 30 PSI
TOWER VACUUM GAUGE
-30 inHg - 0
OUTLET PRESSURE GAUGE
0 - 160 PSI
OIL TEMPERATURE GAUGE
0 - 180°F
FILTER ∆P GAUGE
0 - 60 PSID
2x 1/2" DIAMETER
STEEL HANDLES
71.7
1/4" STAINLESS STEEL
HYDRAULIC TUBING
PALL 0923 BREATHER
W/INDICATOR
PALL UR319
BYPASS SET @ 50 PSI
OUTLET PUMP/MOTOR
TOWER FLUID
LEVEL SIGHT
DR3
OUTLET
13.23
6.75
DR2
12.27
13.02
HEATER
VACUUM RELIEF VALVE
INLET PUMP/MOTOR
DR1
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