ELC With Processor - Manual

Sr. No. Contents Page No.

1. Specifications of ELC Unit 1

2. Principle of Operation 1

3. Construction 1

4. Operation Procedure 2

5. Drain Discharge 3

6. Draining/Removing Cleaned Oil from the tank 3

7. Application 3

8. Life of Collectors 4

9. Replacement of Collectors 4

10. Warranty 4

11. Caution for Safety 5

12. Electric Circuit 5

13. Standard Spares Supplied with Machine 5

14. Control and Annunciator Functions 6

15. Setting Parameters 6

16. Error Displays or Annunciation 9

17 Trouble Shooting 11

CONTENTS

Helping you ... work better ... under pressure

1

1. SPECIFICATIONS:

2. PRINCIPLE OF OPERATION:

3. CONSTRUCTION:

ELC-8 LP / 25 A / 50 C / 100 LP

Power Consumption 200 / 200 / 450 / 550 w

Power Source 415 V AC -3 Phase / 220 V 1 Phase 50hz

Pump Capacity 8 LP : 2 Ltrs. / Min at 1425 rpm

25 A, 25 D : 3.5 Ltrs. / Min at 1425 rpm

50 C, 100 LP : 10 Ltrs. / Min at 1425 rpm

Specifications ELC 8 LP ELC 25A ELC 50C ELC 100LP

Dimensions (Approx) (L) 610 mm 805 mm 805 mm 870 mm

(W) 380 mm 480 mm 480 mm 620 mm

(H) 540 mm 720 mm 920 mm 940 mm

Weight (Approx) 70 kgs. 100 kgs 140 kgs 180 kgs

Collector (pcs/set) 4 12 12 16

The ELC system uses the principle of electrostatics to collect fluid contaminants. FERROCARE

ELC's unique design permits it to take advantage of the natural charge of each contaminant.

Contaminants that have a positive charge are drawn towards the negative electrode plate and

those with a negative charge are drawn towards the positive plate. Neutral contaminants are drawn

and deposited by gradient force to the edge of the collectors where the intensity of the deformed

electric field is the strongest.

As the fluid flows freely through the system, the ELC removes contaminants - submicronic particles

even smaller than 0.01 micron, dust, dirt and products of oxidation such as tars or sludge and

varnishes. Contaminants are trapped on cellulose collectors for easy disposal. The ELC does not

affect soluble additives.

A) The ELC consists of the electrical panel (A) and the condenser unit (B). The latter works as the

Cleaning Cell of the ELC unit.

B) The condenser (cleaning tank) is designed for pressure 1.5 kg/cm2.

The total head of oil between the oil reservoir to be cleaned and the ELC 8LP / 25A / 50C / 100LP

unit should not exceed 3 meters. In case the head exceeds 3 meters, use our ‘D’ type machine.

OPERATION MANUAL


4. OPERATION PROCEDURE:

4a. STARTING AND STOPPING THE MACHINE

Refer figures 1, 2, 3 & 4.

Before starting the machine, ensure the following:

1. Confirm that the oil temperature, moisture content are

within limits specified for the machine, i.e., below 60°C,

500ppm.

2. Check the power switch (ELCB +MCB) of the ELC is off.

3.Confirm that the collectors are in place between the

electrodes, and fasten the cleaning tank cover evenly.

4. Shut the drain valve (E) and open the sample cock (D).

5.Ensure that the pump is filled with oil and suction line is

fully immersed in oil.

6. Check that the suction and discharge hoses are

connected at both ends.

7. Open flow control valve (F) in line after the pump.

8. Switch on the ELCB after ensuring proper electrical

connections.

9. Press the FWR/REV button to bring the pump to

“Forward” operation as shown by LED in figure below.

10. Press the Start button (START/STOP). Both LED “ON”

means Forward. Start LED “ON” and FWR LED “OFF”

means pump running reverse. Both LED “OFF” means

machine stopped.

11. The ELC will start and the pump will fill the tank with oil.

The float switch gets activated as the top level is reached.

The pump will automatically stop when the cleaning cell

tank is filled with oil. The pump will automatically restart

after the preset interval and cleaning will start.

Fig. 4 The Control Panel face for

ELC 100LP ELC 8LP / 25A / 50C

µ - ELECTROSTATIC LIQUID CLEANER

mA

KV

WAIT

PMP FWR

PMP REV

HV

LV

FERROCARE

STARTSTOP

FWRREV

HV-1

HV-2


mA

KV

WAIT

PMP FWR

PMP REV

HV

LV

FERROCARE

STARTSTOP

FWRREV

This on delay timer switches off the pump every time the float switch is operated after the machine is

started, even after a power failure or shutdown. This ensures that the contaminants from the collector,

which may have been dislodged into the oil in the ELC tank during power failure or shut down are

redeposited on the collectors before the oil flow is restarted.

4b. STOPPING THE MACHINE:

6. DRAINING/ REMOVING CLEANED OIL FROM THE TANK

PRECAUTION:

Press the Stop button (START/ STOP) to stop the machine. TheLED will switch off to indicate pump stoppage.

a) Switch off the ELC

b) Put plastic oil pan under the Y type strainer of suction hose.

c) Unscrew the cap of the Y type strainer remove wire mesh and clean.

d) Replace the wire mesh after cleaning and retighten the cap of the strainer

e) Open air cock on the top cover of the cleaning tank (Sampling cock(D))

f) Open the control panel door and set internal toggle switch "ON"

g) Set the Forward /Reverse button (FWR/ REV) to reverse. The LED will be off.

h) Press the Start button. The pump will start in reverse and drain the tank.

Do not pump out all the oil, care has to be taken to switch off the pump if dirty oil

starts flowing out of the machine.

i) The oil at the bottom should be drained into the oil pan from the drain valve.

NOTE: If final oil is required to be NAS grade 7 (ISO code16/13) and better, do not drain oil from

the cleaning tank back to the reservoir.

j) IMPORTANT: The oil pump can only be reversed by pressing the push button inside the

panel and the FWR/REV button on the control panel together, after opening the panel.

5. DRAIN DlSCHARGE

7. APPLICATION

When the ELC is continuously operated for a long time, it is advisable

to discharge about 1 litre of the oil from the drain valve (E) at an interval of 50 hours. This

ensures discharge of heavy contaminants from the drain.

The Electrostatic Liquid Cleaner "ELC" unit can be used for cleaning hydraulic and lubricating

oils of the following general specifications.

Temperature - below 60 degrees C and Moisture - below 500 ppm

The ELC unit cannot be used for cleaning of:

a) Oils with moisture in excess of 500 ppm

b) Oils with detergent dispersant additives

c) Some synthetic oils

d) Conductive oils

Helping you ... work better ... under pressure 3

8. LIFE OF COLLECTORS

9. REPLACEMENT OF COLLECTORS

10. WARRANTY

The life of collectors depends on the contamination level in the oil.

If contamination level is 7 to 10 mg/100 ml., a new collector set can clean about 5,000 litres

(ELC-50C) of oil. The average life of a collector is 2,000 hours.

A rough indication of collector life is as follows:

(Refer Fig. 2)

Unscrew all bolts of the condensor (cleaning tank) cover and remove the contaminated

corrugated type collectors (H) (dielectric media), and electrode covers. At this time, make

sure to clean electrodes before replacing with new collectors.

a) The manufacturer shall repair all defects, except consumable parts for a period of

12 months from the date of shipment. in any event, the manufacturer shall not be

responsible for any and all damage or failure due to incorrect operation, malpractice,

mishandling and negligence.

b) In the event that the user finds any defect in the ELC, the user shall advise the details of

such defect in writing to the manufacturer. The manufacturer shall correct such defects

promptly. The manufacturer reserves the right to make final judgement on claims made by

the user.

c) In no event shall the manufacturer be liable for any and all consequential loss, damage or

expenses howsoever arising from all claims upon and all liability of the manufacturer.

Type of ELC ELC-8 LP ELC-25 A ELC-50 C ELC-100LP

Collectors

Contaminant 7.0-10.0mg 10-15mg 7.0-10.0mg 10-15mg 7.0-10mg 10-15mg 7.0-10mg 10-15mg

Level/ 100ml

Life of 800 - 500 - 2,000 - 1,500- 4,000 - 3,000 - 8000 - 6000 -

1,000 Ltrs 800 Ltrs 2,500Ltrs 2,000Ltrs 5,000 Ltrs 4,000 Ltrs 10,000 Ltrs 8,000 Ltrs

in 1,500 in 800 in 800 in 500 in 1,500 in 800 in 1,500 800

to 2,000 hrs to 1,000 hrs to 1,000 hrs to 800 hrs to 2,000 hrs to 1,000 hrs to 2,000 hrs to 1,000 hrs

4 Helping you ... work better ... under pressure

A

BC

Fig. 5

Fig. 6

SealNut

Hi-VoltCable

14. CONTROL AND ANNUNCIATION FUNCTIONS

15 a. SETTING PARAMETERS:

16 b. SAFETY SETTINGS:

The panel displayed indicates that High Voltage is 10.6 kV and that machine is running with pump

in forward mode for ELC 100LP (fig. on left).

The panel displayed (fig. on right) indicates that current is 0.6 mA and the machine is running with

pump in forward mode for ELC 8LP / 25A / 50C .

For 100LP - indicator for HV-1 is green and display is V for Voltage. The 100LP machine uses

TWO High Voltage transformers, hence the LEDs are divided as HV-1 and HV-2.

For other ELCs - Indicator for milliamps is green and current is 0.6 mA. Since the machines have

only one transformer, the LED lights are separate for mA and kV.

The Pump Switch LED is ON, meaning pump is running forward.

The display will scroll across four parameters, namely, mA, kV (milliampere current and Voltage

across the electrodes), temperature and running hours in sequence. Each parameter will be

displayed for the duration set in Scroll Time setting

Pressing the "SETTING" button Pressing the (value)

will select the "ARROW" button

next parameter will increment the parameter

for display. by one point.

There is a push button inside the panel which allows the programming functions, so that the set

parameters cannot be disturbed by anyone playing with the push buttons.

Display of different parameters can still be selected, but settings cannot be changed until the

internal switch is activated after opening the panel cover.



mA

KV

WAIT

PMP FWR

PMP REV

HV

LV

FERROCARE

STARTSTOP

FWRREV

HV-1

HV-2

100LP


mA

KV

WAIT

PMP FWR

PMP REV

HV

LV

FERROCARE

STARTSTOP

FWRREV

8LP / 50C / 25A

The following parameters can be set or displayed:

1. 2 to 10 mA /for 100LP/ 50C : 5mA for 25A/ 8LP

This is the set current across the electrodes. This setting isrequired to protect the heart of the machine viz., HighVoltage Transformer. If the current increases there isconduction across the electrodes i.e., they are getting"shorted" or a short circuit path is available which wouldoverload the transformer.

The HVT is therefore protected by setting it to trip at this"set current" which can be varied from 2 to 10 mA.

The current across the electrodes can increase if water ismixed in the oil or it contains excessive metal particles.

2.

This setting is for the temperature of oil passing throughthe ELC. Insulators in the ELC are made of PVC andcannot withstand sustained high temperatures.

The SET temperature between 30 and 60 degrees, isselected to trip the pump if hot oil is passing through theunit. Temperatures above 50 deg C are harmful to the oilas well as the ELC.

Note: All units are not equipped with oil temperaturesensor.

3.

This the setting for the Low Voltage operation of the ELC.This sets the tripping current for the transformer when ELCis operating on low voltage of 5 KV. In the particular caseabove, the ELC will trip at 2 mA (for 25 A/ 8LP, 5mA for50C/100 LP). This setting ensures safety of thetransformer.

4.

This sets the "Low" mode of the HVT.

If this parameter is set to "n" the transformer will change to"Low" mode after the current set for Hi mode i.e., 10 mA isexceeded (with a delay of 1 sec.)

If the current exceeds the "Low" (5 mA) also, the machinewill trip.

If this parameter is set to "y", the machine will trip directlywhen "High" current is exceeded.

Set Current:

Set Temperature:

L. V. Setting:

L.V. Skip:

7Helping you ... work better ... under pressure

LV Setting: 05

(1 to 10)

Set Temp. : 60ºC

(30 to 65 C)

Set current : 10.0 mA( 2 to 12 mA)

5.

The display scrolls across parameters i.e., it displays 4 set

parameters one by one. It will display, turn by turn mA , KV,

temp., and running hours.

In this case each parameter will be displayed for

5 seconds, and then the next one will be displayed for

3 seconds. If the scroll time is set to zero, then the selected

parameter will not be

Scroll time parameter:

continuously displayed. Other

parameters will have to be manually selected for display

using the "SETTING" button.

6.

The collectors which hold contaminants removed from oil

being cleaned, have a specific service life. This means

that the collectors should be changed after a specified

running hours.

Each unit on this setting is 250 hours. When the set

running hours are completed the unit will display "SErv",

meaning that the service life is completed. The collectors

should be removed, examined, and if necessary replaced

(Service life is 1000 hrs. for 25A, 1500 hrs. for 50C &

2000 hrs. for 100LP)

The setting is based on a unit of 250 hours. Therefore

H006 as shown above means 1500 hours service life.

H004 would mean 1000 hours. H008 means 2000 hours.

Setable parameters should be distributed from the factory

setting except when necessary and by people trained for

instrument calibration.

7.

If the pump trips on overload, "P_o ", it can be restarted

automatically if " Ar" is set to "Y".

Service life setting:

Auto Restart Pump:

l


Scroll Time 03

(0 to 10)

SErv - Service

If Op. Hrs. = 1, then 250 Hrs.

Controller Trip on "SERV"

Recommended Settings:

50C . . . . . . . . 06 hrs.

100LP . . . . . . 06 hrs.

25A . . . . . . . . 05 hrs.

8LP . . . . . . . . 03 hrs.

9

FS - Float Switch

PoL - Pump over load


16. ERROR DISPLAYS OR ANNUNCIATION:

This error display means that the ELC tank cover is open.

When properly secured the cover operates a limit switch

and switches off this error message.

Trouble Shooting:

Put back the top cover, if not in place and tighten all the

bolts securely.

Check that the limit switch is OK.

There is a float switch which does not allow the

electrodes to be charged. If not totally immersed in oil.

When the float switch is activated, the motor will trip for

a five minute interval and restart. It will now run

continuously. This interruption is provided so that

contaminants from previous operation do not flow out

with the new oil, and are redeposited on the collectors. if

the pump does not start, or the float switch is faulty, then

also this error signal will appear. This error means that

there is insufficient oil in the tank. One reason is that oil

is not available to the pump. This alarm will come due to

Hi-volt fuse blown out.

Trouble Shooting:

Check that the oil pump is running.

Check if oil is available and the suction hose is properly

immersed in the oil.

Check "Y strainer" to ensure there is no blockage.

Check float switch operation manually.

This indicates that overload relay of the pump motor has

operated. The preset here is Auto. The pump will start

automatically on cooling. A manual setting is possible.

Trouble Shooting:

Check that there is no obstruction to the discharge.

Check the pump / motor are aligned and secured to the

foundation.

Check the pump motor windings electrically.

Check capacitor overload relay and contactors.

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LS - Limit Switch

This indicates that the tripping current of the HVT is

reached in "Hi" mode.

Trouble Shooting:

Check whether there is moisture in the oil.

Check if oil contains an excess of metal particles

If low switch over is "y" the machine will now switch to low

and if the current exceeds even the low setting the

machine will trip.

This indicates that the tripping current of the HVT is

reached in "Lo" mode.

Trouble Shooting:

Check whether there is moisture in the oil.

Check if oil contains an excess of metal particles.

Temperature overload :

This indicates that the temperature of the oil flowing

through the machine is too high and the machine will stop.

Trouble Shooting:

Check the setting is not too low.

Check the oil cooler in the equipment.

Heavy moisture in oil.

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10

ot - Temp Over Load

H-oL - Current Over Load

in "Hi" mode


L-oL - Current Over Load

in "Lo" mode

NO. PROBLEM CHECK SOLUTIONS

1. ELC B + MCB is "ON" 1. Power supply from socket 1. Switch "ON" power supplyBut (power light off). 2. fuse no. 1 (central fuse) 2. Replace if fused.Machine does not 3. Loose connections at source 3. Tighten properlySwitch on.

2. ELC B + MCB 1. Motor connection loose 1. Rectifytrips earth leakage 2. Winding insulation low 2. Overhaul motor

3. Motor Capacior leakage to 3. Replace if faultythe body.

4. MS1, MS2, OLR power contact 4. Replace if faultyshort circuit

5. Loose connection at plug point 5. Tighten properlyphase and neutral or phase tophase wire touch or phase toearth

3. ELC B + MCB is not 1. Use the test button of ELCB 1. Replace ELCB if faultyTripping + MCB to trip it

4. Motor does not operate 1. Overload relay not working 1. Push reset and turn to "Auto"(oil tank empty) and it Replace if faulty.Indicates (P-OL) 2. Input supply 2. Ensure input power supply

3. Loose contact of power supply 3. Tighten properlyline

4. Motor + pump alignment 4. Readjust properly5. Pump jam 5. Open and clean the6. Centrifugal switch Rotor, and strainer mesh7. Motor connection and winding 6. Replace if faulty

and capacitor leakage 7. Replace if capacitorfaulty rectify connection

8. Contactor contacts (power) 8. Replace if faulty

5. Excessive pump noise 1. Flow control valve is closed 1. Open valve2. Y-strainer 2. Clean if choked

6. Pump does not draw 1. Pump suction by placing hand 1. If suction is good checkoil on suction port suction hose is dipped in oil

2. If no pump suction 2. a) Overhaul and cleanthe relief valveb) Replace the pump

7. Oil leakage from pump 1. Check the oil seal 1. Replace if necessary2. Loose bolts 2. Tighten properly

17. TROUBLE SHOOTING

11Helping you ... work better ... under pressure

NO. PROBLEM CHECK SOLUTIONS

8. Motor trips frequently 1. Thermal OLR 1. Set current with requiredwhen machine is in motor name plate ratingsoperation and it 2. Y- strainer 2. Open and clean meshIndicates (P_OL) 3. Motor pump alignment 3. Re-adjust properly

4. Motor winding weak 4. Repair if necessary5. Power supply voltage (230/415) 5. Ensure power supply of

correct voltage6. Loose contact of contactor 6. Tighten properly and

power contact and OLR replace if faulty

9. Fuse-1 blows 1. MS1 or MS2 motor contactor coil Replace if faultyrepeatedly. open

2. Timer Replace if faulty

10. Indicates H-OL and 1. More moisture in oil check with 1. Replace collector and startL-OL and / or HVT fuse CC kit. the machine after moisture isblows repeatedly. 2. Open top cover and check if removed from the oil

SS electrodes are correctly 2. Ensure electrodes placedplaced In the slot properly

3. Collector heavily contaminated 3. Replace, if necessary

11. ON PLC indicates 'ot' 1. Oil temperature & setting. 1. It should not exceed 60°C2. Open the top cover and check 2. Place correctly, if not.

electrodes are correctly placedin the slot

3. Check moisture in oil 3. Should be below 500 ppm4. Transformer earthing cable

loose. 4. Connect properly

12. HV' led is 'ON' and the 1. The oil has high detergents 1. It takes about 10 timesMA' reading is below (HLDP) longer to clean than5 mA, oil is not being ordinary oilCleaned 2. Check if viscosity is high 2. Viscous oil takes longer

to clean3. Contamination ingression rate 3. Use larger ELC

is high4. Oil oxidation if oil has been 4. Drain out about 10% oil

used for many years or oil from the oil reservoir.generation of oxidation matter is Top up with the new oilhigh. or add.

5. Collector is contaminated. 5. Replace with newcollector.


ELC With Processor - Manual

Documents

elc unit

elc system

fluid contaminants

oil temperature

oil reservoir

neutral contaminants

led onmeans

fwr led offmeans pump