KLEENTEK OWNER'S MANUAL DOC-R10SP DOC-R25SP DOC-R50SP

Transcription

1 KLEENTEK OWNER'S MANUAL DOC-R10SP DOC-R25SP DOC-R50SP PART NO C 10/2002 Serial #

2 TABLE OF CONTENTS 1. INTRODUCTION TO ELECTROSTATIC OIL CLEANING SAFETY TIPS APPLICATIONS INSTALLATION PLANNING INSTALLATION OPERATION ROUTINE MAINTENANCE OPERATOR CONTROL TROUBLESHOOTING PUMP SERVICING WARRANTY APPENDIX Replacement Parts Illustration, Model DOC-RxxSP Illustration, Model DOC-RxxSP-A Illustration, Model DOC-RxxSP-B Wiring Diagram, Model with UAS supplied pump/motor Wiring Diagram, Model with Customer supplied pump/motor Alarm Status Codes Illustration, Digital Control Panel TROUBLESHOOTING CHART i

3 1. INTRODUCTION TO ELECTROSTATIC OIL CLEANING A. Principles of Electrostatic Oil Cleaning The electrostatic oil cleaning system utilizes an electrical field as a means to capture foreign contaminants in a liquid. This electrical field is generated by high voltage electrodes contained within the cleaning chamber of the system. As fluid flows through the field, particulate contaminant including the resinous products of oxidation are subsequently attracted to the electrodes due to several acting laws of physics. The contaminant then becomes lodged on the dielectric media (collectors) located between the electrodes within the cleaning chamber. B. Unit Construction 1. All DOC Models are ETL Listed for use in the US and Canada. 2. Unit specifications are listed in Table 1. Alist of the replacement parts for the electrostatic oil cleaning unit types is included in Appendix 1. Should it be necessary to replace any parts on an electrostatic oil cleaning unit, the part description and part number should be used to identify them in the ordering process. 3. Illustrations can be seen in the Appendix. Important components and features have been labeled for ease of identification. Cleaning Chamber Power Model Capacity Flow Rate Width Length Height Weight Consumption Number Gal./Liters gpm/lpm in./cm in./cm in./cm. lb./kg. (Watts) DOC-RlOSP1 3.3/ / / / / / DOC-R25SP1 5.1/ / / / / / DOC-R50SP1 9.3/ / / / / / DOC-RlOSP-A/Bl 3.3/ / / / / / DOC-R25SP-A/Bl 5.1/ / / / / / DOC-R50SP-A/Bl 9.3/ / / / / / D.C. D.C. Voltage Model System Voltage Voltage Cut Off HV Power Quantity of Collector Number Volts/Phase/HZ Output Point Supplies Collectors Replacement ALL 115/l/ KV 3.0 KV 1 1 Cartridge hrs of use Table 1 UNIT SPECIFICATIONS Page 1

4 2. SAFETY TIPS A. The electrostatic oil cleaning unit is a high voltage machine and should be treated as such. B. Should it be necessary to remove the console panel, make sure power is disconnected before removing the panel. C. It is strongly suggested that only qualified electricians check or touch electrical parts. D. Be sure to ground the unit properly (green wire is the ground wire). E. Check all valve positions before operating the optional pump to prevent pump cavitation, excess tank pressure or leakage. 3. APPLICATIONS A. The DOC unit can be used to clean any non-conductive fluid such as hydraulic or lubricating oils, provided the oil conforms to the following limitations: 1. The temperature of the oil is below 140 F. 2. The viscosity of the oil is below 200 cst (926 S.U.S.). 3. The water content of the oil is below 500 ppm. B. The DOC unit should N0Tbe used for the following applications: 1. Oils with a water content greater than 500 ppm. 2. Oils with a high level of detergent dispersant additives. 3. Oils which are conductive (such as water-based fluids). Page 2

5 OIL RESERVOIR NOTE: WHEN OIL LEVEL IS ABOVE UNIT IT IS RECOMMENDED THAT A SERVICE VALVE BE INSTALLED IN THE RETURN LINE. Figure 1 PREFERRED INSTALLATION DIAGRAM 4. INSTALLATION PLANNING A. Relative Height of Units (See FIGURE 1) The cleaning chamber of a standard electrostatic oil cleaning unit is designed to withstand pressure up to 42 psi. Therefore, each unit should not be installed in a manner as to apply more than 42 psi of back pressure from the reservoir. The unit should not be more than ten (10) feet above or below the reservoir. B. Electrical Requirements The DOC units are wired for 115 volts/single phase/60 hertz. A power cord is provided for connection. A Power On/off Switch is provided for unit operation. The unit should be disconnected from the power source before servicing. The DOC units also have one (1) available "Dry" contact alerting to loss of high voltage, for connection to the machine's control panel. Page 3

6 C. Equipment Required The DOC comes complete with all necessary parts and components for dedicated operation. Fittings for oil supply, return and drain are provided. A pressure compensated flow control valve is available for connection without a pump/motor assembly (.5gpm - DOC-R10SP, 1.5 gpm - DOC-R25SP, 2.8 gpm - DOC-R50SP). An external relief valve is recommended to be installed on the supply piping to protect the cleaning chamber from excessive pressure and a check valve is also recommended for the return line to prevent back flow from the reservoir during collector changes. Motor start/stop control is provided for the optional pump/motor assembly as well as a connection for automatic solenoid valve operation (supplied by customer). Either a pump/motor assembly or solenoid valve must be used to control inlet flow. A suction strainer must be used on the supply side of the optional pump to protect it from malfunction. This is provided with the hose kit (optional). 5. INSTALLATION A. Installing Collectors 1. Prior to installation of collector media for the initial unit start-up or for replacement of fully loaded media, be sure the Power Switch is in the "Off" position. 2. To install a collector cartridge in the electrostatic oil cleaning unit, begin by removing the cleaning chamber top (cover). Release the cleaning chamber cover fastener and remove. Remove the cleaning chamber cover. 3. Place a collector cartridge over the center post with the metal tabs facing down and slide it into the cleaning chamber. The metal tabs on the outside of the cartridge should make contact with the cleaning chamber wall and the metal tab in the center of the cartridge should make contact with the center post. One cartridge is needed per change out. Make sure the triangular insulator plate is in the bottom of the chamber with the ridges facing upward. 4. Check to ensure that the 0-ring gasket which provides the seal between the cleaning chamber cover and the cleaning chamber is in the top flange within the cleaning chamber. 5. Replace the cleaning chamber cover and press down lightly until the cover has a snug fit with the cleaning chamber. 6. Replace the cleaning chamber fastener and tighten until securely fastened. Page 4

7 6. OPERATION A. Start-Up 1. Confirm that the oil to be cleaned conforms with limits stated in Section Install the collector media per instructions in Section 5A. 3. Close drain, sample and air bleed valve on cleaning chamber. 4. Ensure that supply and return lines are open to machine reservoir. 5. Turn the Power Switch "On." The light, signifying operation, should be illuminated. 6. A float switch located in the cleaning chamber of the unit will be actuated when the oil level is such that the electrodes are completely covered. The actuation of the switch will illuminate the "Chamber Full" light and apply the high voltage. 7. During normal operation the operating, chamber full and high voltage lights should be illuminated. If the chamber full light is not on within 10 minutes the unit will turn off. Consult Troubleshooting Chart on page 24. B. Draining the Cleaning Chamber Draining the clean oil in the cleaning chamber is necessary for cleaning chamber maintenance (i.e. changing collectors) and when servicing the electrostatic oil cleaning unit. To drain the oil: 1. Turn the power switch OFF. NOTE: Some DOC models are supplied with a factory installed pump. 2. Close any valves furnished by the customer in the return line. 3. Turn the power switch on and immediately depress and hold the FWD/REV button to reverse the oil flow and drain the chamber. 4. Open the air bleed valve at the top of the chamber lid. Allow all the oil to drain from the bottom inlet of the cleaning chamber. 5. Continue holding the FWD/REV button until the chamber is empty, then turn the power switch OFF. Page 5

8 6. The remaining inch of sediment and oil can be drained via the bottom drain valve. 7. It is advisable to clean the cleaning chamber thoroughly before further use. 7. ROUTINE MAINTENANCE ALWAYS disconnect the unit from the 115 VAC supply power source before servicing. A. Maintenance Scheduling The following schedule is for hydraulic oil with moderate contamination (7-10 mg/100 ml). If heavily contaminated oil is to be cleaned, the amount of time between maintenance operations will be less. It should be noted, these schedules are not absolute. The time for the maintenance procedures will vary from one application to the next. DOC-UNITS lst Collector Cartridge Replacement Replacing Collector Cartridges Rinsing Cleaning Chamber with Kerosene 2,000 hrs of operation *Every 180 days, or 4000 hours operation When changing collector * Dependent upon application, collector life could be extended up to one year. However, collectors must be changed at least once every year! Table 2 MAINTENANCE TABLE Page 6

9 B. Replacing Collectors and Cleaning the Cleaning Chamber It will be necessary to change collectors when changing to a different type of oil as well as when they are dirty. At this time, the inside of the cleaning chamber should be cleaned as well. The cleaning procedure is as follows: 1. Drain the cleaning chamber per instructions in 6B. 2. Remove the cleaning chamber cover. 3. Remove the contaminated collector cartridge. 4. Clean the inside of the cleaning chamber with kerosene. Wipe down the inside of cleaning chamber with lint free cloths until they are free of any contaminants or kerosene. 5. Allow chamber to dry. 6. Install the new collector cartridge per instructions in 4A. 7. Replace the cleaning chamber cover. 8. Turn power switch "ON." 9. Reset Timer by depressing the unit status button to "Filter (hrs)" then simultaneously press and hold the pump reset button for 5 seconds. 8. OPERATOR CONTROL and ALARMS 1. To reset the hour counter, first press and hold the "UNIT STATUS" button ("UNIT STATUS" should display hours), while holding the button, press and hold the "PUMP RESET" button for 5 seconds ("UNIT STATUS" should display zero hours). 2. The first time the hour counter accumulates 2,000 hours, the "UNIT DISPLAY" will flash 2,000; thereafter each time the hour counter accumulates 4,000 hours, the "UNIT DISPLAY" will flash 4,000 hours. When the 2,000 or 4,000 hour point is reached, the pump motor and HV power supply will turn off, and the "ALARM" light will be illuminated. See page 23, ALARM STATUS CODES for instructions. 3. The "ALARM" light will be illuminated when the hour counter has accumulated 2,000 or 4,000 hours, or when any of the alarm codes are being displayed. Page 7

10 4. Motor forward/reverse operation - The default setting is forward. Running the motor in reverse is accomplished by pressing and holding the "FWD/REV" button. There is a 2 second coast down delay, then the motor will run in the reverse direction while the "FWD/REV" button is depressed. When the button is released, there is a two second coast down delay, then the motor runs in the forward direction. 5. The unit has solid-state motor current overload sensing. In the event of a motor overload, the motor and HV power supply are turned off, the "ALARM" light is illuminated, and the display will read "0001". 6. When the chamber float switch is closed (up), the "CHAMBER FULL" light is illuminated. If the chamber does not fill within 10 minutes the unit will turn off, the "ALARM" light will illuminate, and the display will read "0002". 7. When the microprocessor senses HV is present, the "HIGH VOLTAGE" light is illuminated. If the voltage falls below 3.0KV for 10 seconds the unit will turn off, the "ALARM" light will illuminate, and the display will read "0004". The HV power supply is turned OFF when the motor is not running, the motor is running in reverse, or the HV power supply voltage is below 3.0 KV for 10 seconds. 8. When the chamber lid is not in place the unit will turn off, the "ALARM" light will illuminate, and the display will read "0003". 9. Resetting of alarms: (CODE:) MOTOR OVERLOAD CHAMBER NOT FULL CHAMBER LID NOT ON LOSS OF HV (0001) - Press "PUMP RESET" button (0002) - Resets automatically when chamber is full (0003) - Resets automatically when lid is in place (0004) - Power must be turned off momentarily 9. TROUBLESHOOTING (See Chart on page 24) ALWAYS disconnect the unit from the 115 VAC power source before servicing. A. Loss of High Voltage When the electrical voltage in the cleaning chamber falls below 3.0 KV, the power to the HV power supply will be interrupted. The alarm contact will also be open. The minimum voltage is 3.0 KV for all units. Should this occur, the unit can be reset by the following: Page 8

11 1. Turn the Power Switch "OFF," then "ON." 2. If the high voltage is cut off again within 10 seconds and the alarm signal is received, turn "OFF" the Power Switch. 3. Test the moisture content in the oil. This can be done in one of two ways. The first way involves obtaining a small sample of oil from the drain valve and examining it under a microscope. If several round spots can be observed, this is confirmation of a moisture content greater than 500 ppm. The second method involves heating a metal teaspoon using a gas flame or lighter and then placing a sample of oil on the heated spoon. If bubbles begin to appear in the oil then the moisture content is greater than 500 ppm. If the moisture content is greater than 500 ppm, the oil must be pre-treated to remove the water from the oil. B. Alarm Contact After Collector Change If the alarm signals within 5 hours of operation with the new collectors, check the following: Test the moisture content in the oil. This can be done in one of two ways. The first way involves obtaining a small sample of oil from the drain valve and examining it under a 50X power microscope. If several round spots can be observed, this is confirmation of a moisture content greater than 500 ppm. The second method involves heating a metal teaspoon using a gas flame or lighter and then placing a sample of oil on the heated spoon. If bubbles begin to appear in the oil then the moisture content is greater than 500 ppm. If the moisture content is greater than 500 ppm, the oil must be pre-treated to remove the water from the oil. C. Testing - High Voltage If the DOC unit is not removing contaminants from the oil or is functioning below the designed standard level of operation, this could be due to a lack of high voltage in the cleaning chamber. In this case, the voltage being generated in the cleaning chamber will need to be tested. To test the voltage in the cleaning chamber, proceed with the following instructions: 1. Attain a high voltage probe. It is recommended to use a Fluke 23 multi-meter and 40KV high voltage probe or equivalent. 2. Drain the DOC unit per instructions in Section 6B. 3. Ensure that flow is stopped and Power Switches are "OFF". 4. Remove the cleaning chamber cover. 5. Remove the collector cartridge. 6. Disconnect the electrical connector leading to the pump/motor. Page 9

12 7. Replace cleaning chamber cover fastener (band clamp) to provide signal to Proximity Switch. 8. Be sure that no one is touching anything within the cleaning chamber and turn the Power Switch "ON." 9. The center post is the means by which high voltage is transmitted to the cleaning chamber cartridge. In order to attain a voltage reading from the center post, it will require two people to perform the next step. One person, with an insulated tool, must defeat Float Switch located inside the cleaning chambers Be careful! The high voltage is now ON in the cleaning chamber. The cleaning chamber is grounded; however, there will be no danger unless the center post is contacted. 10. The ground clip from HV probe must be connected to the grounded tank. Using the high-voltage probe, the second person will contact the center post and attain a voltage output reading. 11. Once the reading is taken, turn "OFF" all power and restore the DOC unit to its normal operating configuration by replacing collector cartridge, cleaning chamber cover and pump/motor wires. Be sure the metal tabs on the cartridge are facing down and are making contact with the center post and the cleaning chamber wall. 12. The voltage output should be 10-12KV. If a value substantially less than 10KV is attained, contact the KLEENTEK representative. D. Pump Problems - What to Look For 1. No Oil is Delivered. a. Suction lift too high for vapor pressures of liquid pumped. While pump will develop as high as 27 inches of vacuum, it is good engineering practice to reduce the vacuum to a minimum. b. Bad leaks in suction line or port passages can be detected by submerging pressure line from discharge side of pump into a pail of oil, where the air will be seen in the form of bubbles. c. Pump shaft not rotating. Coupling defective - tongue and groove or gear not engaged. 2. Capacity is too Low. a. Suction lift too high. b. Air leaks in suction line. Page 10

13 c. Suction line is too small. Can be detected by installing a vacuum gauge directly at the pump suction. The maximum vacuum at the pump suction should never exceed 15 inches of mercury. It is necessary to keep below 15 inches, not because of the inability of the pump to handle a higher vacuum, but primarily because of the vaporization that is liable to take place at a higher vacuum. Vaporization caused by higher vacuums will generally result in capacity drop-off. d. Pump speed too slow. e. Strainer too small or obstructed. f. Suction pipe or port not immersed in the liquid deep enough. g. Piping improperly installed, permitting air pocket to form in pump. h. Increased clearances or wear in the pump will sometimes cause the pump to deliver an insufficient supply of liquid. 3. Pump Works Spasmodically. a. Suction lift too high. b. Air or vapor in liquid. c. Coupling slipping on pump shaft. 4. Pump Wastes Power. a. Pressure is too high. b. Liquid more viscous than desired. c. Suction or discharge lines obstructed. d. Mechanical defects. 1) End thrust on pump shaft. (Pump is not designed to take end thrust toward the pump cover and extreme care must be taken to prevent thrust in this direction). 2) Driving shaft and pump shaft misaligned. 3) The pump may be binding due to insufficient end clearance. 4) Pump shaft bent. Page 11

14 5) Misalignment within pump due to strains built up by piping or installation. 5. Pump is Noisy. a. Machine or part of it is acting as sounding board. b. Misalignment of coupling. c. Coupling set up too close to pump. d. Vibration of pump. 1) Bent Shaft. 2) Worn pump. e. Air leaks into suction side of pump. f. Suction lift so high that an air pocket forms within liquid. 6. Pump Leaks. a. Cover bolts need tightening, or cover gasket is defective. b. Refer to Seal under service instructions. 7. Handle With Care. If it becomes necessary to remove pump from your equipment to return to the manufacturer, plugs should be inserted in the ports to prevent foreign material from getting into the moving parts. Pumps are precision-built and should be given every reasonable care. 10. PUMP SERVICING A. Disassembly of Seal The seal assembly of the pump may be changed without disassembly of the rest of the pump. 1. Place the pump in vise, shaft facing up, so that one jaw grips across the two ports. Do not tighten excessively as pump housing may be distorted. 2. Inspect shaft at key-way, flat or drive tang. Any burrs will interfere with removal of housing plug bearing assembly. 3. Remove housing plug with face type spanner wrench. Page 12

15 4. Remove the seal from 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 upwards. The spring and washer should also be removed. 5. The pump assemblies 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. A step on the shaft is used as the seal back up. 6. Remove stationary seal face from housing plug by pressing out from opposite side. 7. If damaged, remove the 0-ring from outside diameter (O.D.) of housing plug. B. Disassembly of Pump 1. Seal assembly must be removed before disassembly of pump. Also remove snap ring on shaft. 2. Mark cover and body of the pump for proper reassembly. Remove cap screws, cover, idler and rotor from housing C. Inspection 1. Check pump housing, rotor, idler gear, idler pin and crescent for wear, chipped or broken teeth. 2. Housing bore and rotor O.D. may be checked for wear by positioning rotor in the housing and check for clearance in the bearing. The shaft must turn freely without any detectable side play. Any side play will require replacement of the housing, rotor or both. If both housing and rotor require replacing, it is economically advisable to replace the pump. D. Assembly of Pump The following must be carefully followed when pump is reassembled: 1. Clean all parts thoroughly using great care to eliminate all dirt. 2. Install rotor in pump body. 3. Apply gasket to cover. Use new gasket if old one is damaged. 4. Place idler gear on pin in cover assembly. 5. Place cover assembly with gear on pump. (Align matching marks for proper location.) Page 13

16 6. Install cover cap screws. Pull down gradually and alternate from a screw on one side to one on the opposite side. 7. Install snap ring on shaft. E. Assembly of Seal 1. Clean all parts thoroughly using great care to eliminate all dirt. 2. Oil shaft with suitable lubricating oil. 3. Oil inside of new rotary seal assembly. 4. Press stationary face into housing plug. Lapped surface must be up. Protect this lapped surface by covering it with a piece of paper when pressing down on face. Use your fingers for this operation. 5. Place new 0-ring on O.D. of housing plug, if required, and lubricate with oil. 6. Lubricate carbon face liberally with lube oil. 7. Reassemble housing plug into position over the pump shaft. Do not nick seal face by hitting pump shaft. Tighten the housing plug with spanner wrench. Rotating seal will automatically be positioned by this operation. 8. If pump is equipped with ball bearing, press bearing onto shaft. Press on bearing inner race with suitable sleeve. Do not hammer into position or press on bearing outer race. 9. Check pump for free rotation by turning shaft with suitable wrench. There will be a definite resistance to turning because of the seal load. The pump must turn freely without binding. Page 14

17 1. HOUSING 7. RETAINING RING 2. HOUSING BUSHING 8. SEAL ASSEMBLY 3. COVER 9. "O" RING 4. IDLER PIN 10. IDLER 5. COVER GASKET 11. HOUSING PLUG 6. ROTOR 12. COVER BOLTS Figure 2 PUMP CUTAWAY DIAGRAM Page 15

18 11. WARRANTY All equipment manufactured and sold by United Air Specialists, Inc. (UAS) is guaranteed against defective material and workmanship for one year after date of shipment. UAS will not assume any expense or liability for unauthorized repairs or modifications to its equipment. In no case will UAS' responsibility extend to equipment not manufactured by UAS unless UAS furnished such equipment as an integral part of the system. If, after installation, materials are not suitable for the application, replacements shall only be made at Purchaser's Cost. The foregoing warranties are exclusive and in lieu of all other warranties, whether written, oral or implied in fact, or in law (including any warranty of merchantability or fitness for a particular purpose). Page 16

19 12. APPENDIX Part Number Unit Type Part Description DOC-Rl0SPl/R25SP1 Cleaning Chamber Cover Fastener DOC-R50SP1 Cleaning Chamber Cover Fastener DOC-Rl0SP1 Collector Cartridge DOC-R25SP1 Collector Cartridge DOC-R50SP1 Collector Cartridge DOC-Rl0SP/R25SP1 Collector Supporter/Insulator DOC-R50SP1 Collector Supporter/Insulator All Digital Control Panel All Fuse, 8 Amp, 5X20mm, time-delay All Flexspline Coupling for Pumps All Float Switch All High Voltage Wire DOC-Rl0SP1 * Hose Kit DOC-R25SP1 * Hose Kit DOC-R50SP1 * Hose Kit DOC-Rl0SPl/R25SP1 HV Feed Through Insulator Assembly DOC-R50SP1 HV Feed Through Insulator Assembly All O-Ring, HV Insulator Seal Nut (Included With Insulator Assembly) ALL HV Power Supply DOC-Rl0SP1/R25SP1 O-Ring for Chamber Cover DOC-R50SP1 O-Ring for Chamber Cover All Power Switch DOC-Rl0SP1 * Pump Motor Assembly (0.5 gpm) DOC-R25SP1 * Pump Motor Assembly (1.5 gpm) DOC-R50SP1 * Pump Motor Assembly (2.8 gpm) DOC-Rl0SP1 * Pressure Compensated Flow Control Valve (.5 gpm) DOC-R25SP1 * Pressure Compensated Flow Control Valve (1.5 gpm) DOC-R50SP1 * Pressure Compensated Flow Control Valve (2.8 gpm) All Proximity Switch, 24 volt All Seal Assembly for Pumps * Options Appendix 1 PARTS & ACCESSORIES Page 17

20 Appendix 2 UNIT DOC-RxxSP1 Page 18

21 Appendix 3 UNIT DOC-RxxSP-A1 Page 19

22 Appendix 4 UNIT DOC-RxxSP-B1 Page 20

23 Appendix 5 DOC Wiring Diagram (with UAS supplied pump/motor) Page 21

24 Appendix 6 DOC Wiring Diagram (with customer supplied pump/flow) Page 22

25 ALARM STATUS CODES Display Problem Action ,000 hours since last collector change. Replace collector and reset timer ,000 hours since last collector change. Check collector and replace or reset timer Motor starter overload exceeded. Reset motor starter Chamber oil level low, float switch did Will reset automatically when oil not engage. level increases Chamber lid or retaining strap OFF, Place lid and strap on proximity switch not engaged. tighten. tank and Loss of High Voltage. Collector saturated with conductive contaminants or water level in oil has exceeded 500 ppm Appendix 7 DOC Digital Control Panel Page 23

26 TROUBLESHOOTING CHART TROUBLE CHECKPOINT REASON CORRECTION 1. No power to unit. On/Off switch. Switch is "Off." Turn switch to "On." 2. Switch is "On," but On/Off of Power Source. 1. Power source is Turn switch to "On." unit has no power. "Off." 2. Power source is Consult Electrician. "On." 3. Pump is inoperative. Display flashing "001" Motor exceeding a. Push the "pump indicating overcurrent current limit. reset" button on condition. Factory setting is 4.0A control panel. with UAS supplied motor. b. Check for closed valves. c. Overhaul pump and remove contaminants. Motor failure. Replace the motor. 4. Pump does not a. Ensure supply and Oil is bypassing Open the valve. draw oil, although return valves are open. through the internal operative. relief valve. b. Plug the suction port 1. If pump sucks, the Put the hose end into with the palm of your end of the suction the oil. hand. hose is not in the oil. 2. If pump does not a. Replace the pump suck, the pump drive-coupling. drive-coupling is worn or the pump b. Overhaul and clean relief is open due to the internal relief contaminants. Valve. Page 24

27 TROUBLE CHECKPOINT REASON CORRECTION 5. Alarm light is on, a. Remove the collector 1. The collector is Replace with dry although collector and check the high wet. collector. was replaced. voltage. 2. The oil is wet Dry the oil with a because of water. dehydrator. 3. The oil is Check your oil conductive. specifications with those listed (front of the Manual) in Section #3A. b. Follow the procedure HV power supply has Replace the HV for testing HV. failed. power supply. c. Proximity switch (red Retaining strap is not Realign retaining light on side). covering the proximity strap. sensor. e. Check float switch. Float switch is broken Clean or replace the or does not move. float switch. 6. Unit starts to run, a. Check for loose HV 1. Causes HV arc Ensure a good HV but turns off when connection at power which disrupts connection. motor starts to run, supply or bottom of microprocessor display may show chamber. in control panel. odd characters, alarm light may or b. Check for water in Remove water from may not be on. bottom of chamber. oil. Unit operates correctly c. Check for broken jumpers Replace collector when HV wire is NOT on bottom of collector cartridge. connected to HV cartridge. power supply. Page 25

28 TROUBLE CHECKPOINT REASON CORRECTION 7. Chamber Full and a. Check the oil. 1. The oil has Detergents oil (HLPD) High Voltage detergents (HLPD). takes at least ten times Operating light longer to clean than is illuminated and ordinary oil (HLP). display is above 6KV, but oil cannot be 2. Viscosity is high. Use an electric heater to cleaned. lower the viscosity. b. Check the ingression of The ingression rate is Use a larger model. contamination. high. (After one year, if the contaminant level is over 10mg/100ml, ingression rate is high.) c. Check oil oxidation, if Production of Remove about 10% oil has been in service contaminant is high. of the oil from the for several years. drain and replace with new oil containing additives. d. Check the high voltage If the voltage does not Replace the HV at the Power Supply match the display or is power Supply. with a High Voltage below 6KV, the output Probe. of the HV Power Supply is too weak. 8. Oil leakage from the a. Leakage from the The bottom screw of Tighten the screw HV insulator. inside of the HV the terminal is loose. with screwdriver. insulator. b. Leakage from outside "O-ring" has failed. Replace "O-ring."' of the HV insulator. 9. Oil Leakage from the a. Check the oil seal of The oil seal is broken. Replace the broken pump. the pump. oil seal. b. Check inlet and outlet Fittings are loose. Tighten fittings. fittings. Page 26

29 UNITED AIR SPECIALIST, INC. LIMITED WARRANTY UAS warrants all equipment manufactured and sold by UAS against defective parts and workmanship for one full year from date of shipment to Purchaser, except that commercial or non-industrial air cleaners (other than engineered systems) are warranted for three years from such date. Where a performance guarantee is specified in UAS's quotation under the heading of "Performance Guarantee", UAS warrants that, for a period of 90 days from the date of installation, the equipment manufactured and sold by UAS will perform as specified in such performance guarantee. These warranties are subject to any limitations in UAS's standard terms and conditions provided to Purchaser. Any unauthorized repairs or modifications or abnormal use or misuse of equipment, will void all warranties. In no case will UAS' responsibility or warranty extend to equipment not manufactured by UAS. There are no warranties covering corrosion of materials selected. Purchaser has approved the materials to be used in the construction of the equipment supplied by UAS. If after the equipment is installed, metals or materials are not suitable for the application, replacements will only be made at Purchaser's cost. THE FOREGOING WARRANTIES IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY, FITNESS FORAPARTICULAR PURPOSE OR NONINFRINGEMENT. As Purchaser's exclusive remedy for any defects in the equipment, UAS will exchange or repair any defective part during the warranty period, provided such parts are returned, prepaid, to UAS's factory. The obligation of UAS is limited to furnishing replacement parts F.O.B. UAS's factory, or making repairs at UAS's factory of any parts which are determined, upon inspection by UAS, to be defective. In no event will UAS be responsible for labor or transportation charges for the removal, reshipment or reinstallation of the parts. UNITED AIR SPECIALISTS, INC Creek Road - Cincinnati, Ohio Telephone Fax