Operations and Maintenance Manual

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IMPORTANT: READ THIS MANUAL THOROUGHLY BEFORE INSTALLING AND OPERATING UNIT. INSURE THERE IS ALWAYS LUBRICATING OIL IN THE FRONT FILTER LUBRICATOR FOR THE FLUID PUMP AIR MOTOR.

1 IMPORTANT: READ THIS MANUAL THOROUGHLY BEFORE INSTALLING AND OPERATING UNIT. INSURE THERE IS ALWAYS LUBRICATING OIL IN THE FRONT FILTER LUBRICATOR FOR THE FLUID PUMP AIR MOTOR. CHECK OIL LEVEL REGULARLY AND REFILL Phoenix C4XA Compressed Air Driven Membrane Based Portable Lube and Hydraulic Oil Purifier and Dehydrator Cart Operations and Maintenance Manual Rev 1-PHXADNL KB MSC Filtration Technologies 198 Freshwater Blvd Enfield, CT Phone :

2 INDEX PAGE 1 SECTION 1: SPECIFICATIONS PAGE 2 4 SECTION 2: DESCRIPTION AND OPERATION PAGE 5 7 SECTION 3: COMPONENT LIST AND DESCRIPTION PAGE 7 SECTION 4: CRANE RIGGING PAGE 9-12 SECTION 5: INSTALLATION AND STARTUP PROCEDURE PAGE SECTION 6: OPERATION AND OPERATIONAL CHECK LIST PAGE 16 SECTION 7: SPARE PARTS PAGE 17 SECTION 8: OIL FLUSHING PROCEDURE PAGE 18 SECTION 9: DATA SHEETS

3 SECTION 1 PHOENIX SPECIFICATIONS PAGE 1 OF 20 FLOW RATE: MAX OPERATING Oil VISCOSITY VARIABLE GPM AT 8 GPM 3 cst to 1000 cst AT 4 GPM - 3 cst to 3000 cst FLUID/OIL COMPATIBILITY MAX RECOMMENDED OUTLET PRESSURE MIN/MAX OPERATING AMBIENT TEMP MIN/MAX STORAGE TEMP MIN/MAX OPERATING FLUID TEMP EMPTY WEIGHT INLET/OUTLET CONNECTIONS MINERAL BASED, PAO AND POLYOLESTER (Phosphate Ester Membrane Optional) 20 PSIG 1 50 C C - 15C 80 C 250 LBS 1 Male JIC DIMENSIONS 20 W X 22 D X 51 H UTILITIES OILLESS COMPRESSED AIR PSIG PARTICULATE REDUCTION ISO 16/14/12 SCFM USAGE 4 GPM 30 SCFM SCFM USAGE 8 GPM 50 SCFM WATER REDUCTION (OIL TEMP, RESERVOIR SIZE & WATER < 50 PPM INGRESSION LEVEL DEPENDENT)

SECTION 2: PAGE 2 OF 20 Compressed Air Driven Phoenix Portable Lube and Hydraulic Membrane Oil Purifier and Dehydrator (Description and Operation) The Phoenix oil purifier is a compact and portable

gallons. It is completely driven by compressed air and requires no electric hookup.

The Phoenix utilizes a cutting edge maintenance free hollow fiber membrane bundle to remove water contamination from oil.

4 SECTION 2: PAGE 2 OF 20 Compressed Air Driven Phoenix Portable Lube and Hydraulic Membrane Oil Purifier and Dehydrator (Description and Operation) The Phoenix oil purifier is a compact and portable oil purifier car and membrane vacuum oil dehydrator with the capability to remove particulate along with free, emulsified and dissolved water from lube and hydraulic systems of between 20 and 2000 gallons. It is completely driven by compressed air and requires no electric hookup. Because it is driven by compressed air the variable speed air motor and fluid pump can be adjusted manually to flows of between 1 and 8 gpm depending on the oil viscosity being filtered. The Phoenix utilizes a cutting edge maintenance free hollow fiber membrane bundle to remove water contamination from oil. Moisture is pulled out of the oil by a vacuum as wet oil passes across the outside of the membrane. A vacuum created by a supplied air driven venturi vacuum generator pulls moisture through the membrane where it is expelled as water vapor from the vacuum generators exhaust port. Water levels as low as 25 ppm are achievable depending on oil sump size and water ingression levels. This cutting edge technology has no limit to the quantity of water it can remove and requires minimal maintenance and operator attention. It should provide years of worry and trouble free operation before replacement. IMPORTANT NOTE: The membrane bundle is not serviceable in the field and should be returned for replacement when its useful life is complete. Never try to disassemble the membrane housing in the field or damage to the bundle may occur. Figure 1

(SECTION 2: Description and Operation - Continued) PAGE 3 OF 20 Figure 2 Oil is pumped into the Phoenix Cart by (item 3) a 4-8 gpm variable flow gear pump with an integrated (item 4) 65 psid built in

5 (SECTION 2: Description and Operation - Continued) PAGE 3 OF 20 Figure 2 Oil is pumped into the Phoenix Cart by (item 3) a 4-8 gpm variable flow gear pump with an integrated (item 4) 65 psid built in relief valve. This gear pump is driven by an air motor (item 2) which is variable speed and can be controlled by setting (item 5) filter, regulator, lubricator to between psig. The speed of the motor can then be adjusted up or down by adjusting the throttle valve (item 20) to your desired oil pumping speed of between 4 and 8 gpm. Oil then flows into (item 6) a non-bypass particulate 7-micron beta 2000 spin on filter. There is a visual filter plugged indicator on the filter housing to tell when the filter element is plugged. If the filter plugs fully and is not replaced, then pressure relief will occur through (item 4) the fluid pump 65 psid relief valve and flow out of the Phoenix will cease. (Item 1) is a vacuum gauge which shows the inlet vacuum that the fluid pump is pulling. A vacuum reading above 25 is an indication of restriction in the fluid line. To prevent cavitation and potential damage to the fluid pump never run the Phoenix for prolonged periods of time with a vacuum reading above 25 on (Item 1). Increase suction hose size, reduce hose length or reduce flow velocity to reduce suction vacuum. Oil then passes into (item 14) the maintenance free and non-replaceable water removal membrane. A 10 psid spring loaded check valve (Item 7) is piped in parallel with the water removal membrane housing to provide pressure relief across the membrane bundle in the event of excess differential pressure. The membrane housing may handle up to 150 psig of total pressure however (Item 7) limits the total pressure drop possible across the membrane bundle to about 10 psid. This total pressure may be read from (item 9) a psig liquid filled pressure gauge installed on the back of the Phoenix purifier.

(SECTION 2: Description and Operation - Continued) PAGE 4 OF 20 After oil enters the membrane housing it is forced across the water removal membrane bundle and then exits the housing.

6 (SECTION 2: Description and Operation - Continued) PAGE 4 OF 20 After oil enters the membrane housing it is forced across the water removal membrane bundle and then exits the housing. Water is removed from the oil as it passes across the membrane. If the spring loaded bypass (item 7) is open, then partial flow from the membrane housing will recombine with partial non dewatered oil passing through the check valve. Both combined flows exit the purifier and return to the oil reservoir through (item 8) - a sight glass with a spinning oil flow indicator. A vacuum is generated by the (item 16) maintenance free vacuum venturi which pulls atmospheric sweep air through (item s 11,12 &13) the (vent filter, vacuum control valve and leak prevention check valve) and then through the center of the hollow fiber membrane. (Item 18) is a filter pressure regulator where shop air of a minimum psig is connected. The shop air is what generates the vacuum in the venturi (item 16). (Item 15) An air eliminator is installed between the membrane housing and vacuum generator in order to prevent any large amounts of oil leakage to the vacuum side in the unlikely event that the membrane is compromised. The air eliminator (Item 15) and the check valve installed (Item 13) allow the Phoenix to automatically seal itself completely off in the unlikely event of a membrane break or rupture. The total vacuum generated by (Item 16) vacuum generator is controlled by maintaining psig on the regulator (item 18) and manually throttling down on the control valve (item 12) and may be read in inches of mercury on the vacuum gauge (item 10). Vacuum is typically set between 25 and 27 of mercury but may vary as water levels in the oil rise and fall. Do not close the control valve (item 12) completely since there is always some sweep air needed for efficient water removal. There is a sight glass and drip leg located on the membrane housing in order to drain any potential condensation or small amounts of oil that can get through the membrane from the line. Figure 3

7 PAGE 5 OF 20 SECTION 3: Component Lists and Description Figure 4 Figure 5 Figure 6

8 SECTION 3: Component Lists and Description Continued PAGE 6 OF 20 Figure 7 Figure 8 Figure 9

9 SECTION 3: Component Lists and Description Continued PAGE 7 OF 20 Item Description 1 Compound Vacuum Pressure Gauge Reads Suction Pressure to Fluid Pump 2 Variable Speed Fluid Pump Air Motor Compressed Air Driven Gast Model 6AM-FRV Gear Pump Variable Flow 1-8 GPM 4 Integrated 65 PSIG Pump Relief Valve. Relieves back to suction if upstream pressure increases above 65 PSIG. 5 Air Motor Filter, Regulator, Lubricator. Set Pressure to between PSIG. Monitor Oil Level Regularly only use SAE 10 Pneumatic Lube Oil Only. See Parts List. 6 Non Bypass Particulate Filter. 7 micron Beta 2000 with integrated filter plugged indicator. Indicates plugged above 35 psid of differential pressure. Only use filter replacements recommended in this manual (see part list) or warranty may be voided psid membrane bypass check valve. 8 Spinning Oil Flow Indicator Sight Glass Outlet Flow of Phoenix. 9 Water Removal Membrane Upstream Pressure Gauge 10 Vacuum Gauge Set Vacuum Side Breather Filter See Spare Parts for Replacement Replace 12 Months 12 Vacuum Adjustment Valve See Item 10 Vacuum Gauge when Adusting. 13 Back Flow Preventer Check Valve 14 Water Removal Membrane Housing 15 Oil Leak Preventer Air Eliminator 16 Water Removal Vacuum Generator Venturi 17 Water Removal Vacuum Generator Compressed Air Shut Off Valve. 18 Water Removal Vacuum Generator Compressed Air Pressure Regulator and Filter. Set to PSIG 19 Fluid Pump Air Motor Compressed Air Supply Shut Off Valve 20 Fluid Pump Air Motor Variable Speed Control Valve. Adjusts speed of fluid pump air motor. 1-8 gpm at SCFM 21 Inlet Oil Sample Valve Upstream of Particulate Filter 22 Air Motor Muffler Gast Model Number AL Vacuum Side Condensate Drain Valve Condensed Moisture and small amounts of oil that may get through membrane. Turn off Unit and Check Intermittently.

10 Section 4: Crane Rigging PAGE 8 OF 20 To lift unit with a crane connect strap from this point figure 11 only! Figure 11

Section 5: Installation and Startup Procedure IMPORTANT PAGE 9 OF 20 DO NOT CONNECT THE PHOENIX PURIFIER OUTLET LINE TO ANY POINT OR PRESSURE LINE WHERE THE BACK PRESSURE COULD EXCEED 20 PSIG OR

11 Section 5: Installation and Startup Procedure IMPORTANT PAGE 9 OF 20 DO NOT CONNECT THE PHOENIX PURIFIER OUTLET LINE TO ANY POINT OR PRESSURE LINE WHERE THE BACK PRESSURE COULD EXCEED 20 PSIG OR DAMAGE TO THE MEMBRANE BUNDLE COULD OCCUR AND REPLACEMENT MAY BE NECESSARY. IT IS IDEAL TO CONNECT THE RETURN LINE OF THE PHOENIX TO A POINT OF LOWEST PRESSURE AS POSSIBLE SUCH AS ON A T DOWNSTREAM OF A BREATHER FILTER There are several ways to connect the Phoenix membrane purifier to a reservoir with some being better than others. Figures 10 shows two ideal ways since they both allow suction from the bottom of the reservoir where water and particulate can collect and return to the top away from the suction. This provides the maximum turnover of oil while the siphon breaks provide a level of safety in the event of a hose or fitting break/leak preventing the possibility of accidentally completely draining the reservoir. The return pipe should be unobstructed and end below the oil line to prevent aeration of the oil upon return to the reservoir. Figure 10

Section 5: Installation and Startup Procedure Continued PAGE 10 OF 20 STEP 1: AIR MOTOR LUBRICATOR IMPORTANT BEFORE STARTIING UNIT Allways insure there is adequate oil level in the air

Insure that there is atleast 1 drip of oil per minute seen in the see through knob at the top of the lubricator. Failure to do so will lead to damage to the air motor.

5 hoses may be required to minimize restriction at suction to purifier. Connection to Purifier is 1 JIC so hoses shoule have 1 JIC swivel. Tighten thouroghly to insure there are no leaks.

12 Section 5: Installation and Startup Procedure Continued PAGE 10 OF 20 STEP 1: AIR MOTOR LUBRICATOR IMPORTANT BEFORE STARTIING UNIT Allways insure there is adequate oil level in the air motor lubricator. Check this level regularly and shut down unit and refil oil as necessary. See spare parts for the correct oil type. Only use SAE 10 Pneumatic Lubricating Oil. Insure that there is atleast 1 drip of oil per minute seen in the see through knob at the top of the lubricator. Failure to do so will lead to damage to the air motor. STEP 2: SUPPLY HOSE CONNECTION Use at minimum 1 full vacuum rated hydraulic hoses for oil suction and return. In the event of viscocity above 1500 cst then 1.5 hoses may be required to minimize restriction at suction to purifier. Connection to Purifier is 1 JIC so hoses shoule have 1 JIC swivel. Tighten thouroghly to insure there are no leaks. Open all oil supply valves both suction and return from oil reservoir. STEP 3: AIR VALVE START POSTIONS 1. Close Air Motor Speed Adjustment Valve all the way. 2. Insure Upstream Oil Sample Valve is Closed 3. Close Vacuum Venturi Air Supply Valve

Section 5: Installation and Startup Procedure Continued PAGE 11 OF 20 STEP 4: AIR VALVE POSTIONS Cont 1.

can provide atleast 80-85 psig of oilless compressed air at a continuous flow of atleast 30 SCFM.

13 Section 5: Installation and Startup Procedure Continued PAGE 11 OF 20 STEP 4: AIR VALVE POSTIONS Cont 1. Open Main Air Motor Air Supply Valve STEP 5: CONNECT COMPRESSED AIR Connect main compressed air source that can provide atleast psig of oilless compressed air at a continuous flow of atleast 30 SCFM. Use the correct size and pressure air hoses and connection types needed to handle pressure. STEP 6: Pressure Regulator Settings. 1. Set Vacuum Venturi Regulator to between psig to insure maximum potential water removal. 2. Set Air Motor Regulator to between psig see motor flow chart on next page for desired oil flow vs pressure settings.

Section 5: Installation and Startup Procedure Continued STEP 7: VACUUM ADJUSTMENT PAGE 12 OF 20 1.

Adjust Vacuum Adjustment Valve till Vacuum Gauge reads 27.

Vacuum level will vary naturally depening on how much water is being removed between 24 and 27 during operation.

flow. It may take a minute or two for flow to be present. See estimated flow vs pressure chart below.

As there is more back pressure there will need to be more air pressure adjusted to the air motor to keep turning at

14 Section 5: Installation and Startup Procedure Continued STEP 7: VACUUM ADJUSTMENT PAGE 12 OF Open Vacuum Venturi Air Supply Valve. Insure pressure on regulator maintains psig. 2. Adjust Vacuum Adjustment Valve till Vacuum Gauge reads 27. Do not close valve all the way since some sweep air is required for maximum water removal membrane efficiency. Vacuum level will vary naturally depening on how much water is being removed between 24 and 27 during operation. STEP 8: FLUID PUMP FLOW START Open Air Motor Flow Control Valve and inspect outlet spinning flow indicator for oil flow. It may take a minute or two for flow to be present. See estimated flow vs pressure chart below. This flow will need to be adusted over time as the particulate filter plugs and backpressure occurs on the pump. As there is more back pressure there will need to be more air pressure adjusted to the air motor to keep turning at the same speed. EXPECTED PHOENIX OIL FLOW WITH 0 SYSTEM BACKPRESSURE AND FLOW CONTROL VALVE COMPLETELY OPEN. PRESSURE REGULATOR SETTING APPROXIMATE OUTLET OIL FLOW AIR USAGE SCFM 10 PSIG 4 GPM 30 SCFM 20 PSIG 6 GPM 45 SCFM 35 PSIG 8 GPM 50 SCFM

Section 6: OPERATION AND MAINTENANCE PAGE 13 OF 20 INSPECT LUBRICATOR OIL FILL PORT REGULARLY Inpect Clear Knob on top of air motor lubricator to insure atleast 1 drip of oil per minute is occuring

Refill by removing slotted gray cap ontop of lubricator. Replace cap when done.

15 Section 6: OPERATION AND MAINTENANCE PAGE 13 OF 20 INSPECT LUBRICATOR OIL FILL PORT REGULARLY Inpect Clear Knob on top of air motor lubricator to insure atleast 1 drip of oil per minute is occuring when purifier is running. Close Air Motor air supply valve and insure pressure gauge on regulator goes to 0. Then refill lubricator with SAE 10 Pneumatic Oil when level reaches critical. Refill by removing slotted gray cap ontop of lubricator. Replace cap when done. INSPECT PARTICULATE FILTER INDICATOR REGULARLY There is a particulate filter plugged indicator with a white indicator which will move from green to red as the particulate filter plugs. Check regularly and replace element when necessary or every 6 months of usage whichever comes first. FILTER ELEMENT REPLACEMENT PROCEDURE It is recommended that the Phoenix be pumped out before the element is changed inorder to limit oil spillage. To pump out 1. Shut down oil flow. 2. Disconnect Supply Hose From Reservoir 3. Disconnect any Quick Disconnect Fittings from hose so to allow air to be pumped through Phoenix 4. Start oil flow and allow phoenix to pump out back to reservoir for approximately 2-3 minutes. Do not run fluid pump for more than 5 minutes dry. 5. Stop Oil Flow Again. 6. Use a strap wrench to remove spin on filter 7. Lubricate top oring of new spin on filter element. 8. Thread on new filter making sure proper alignment so not to strip threads on head. 9. Tighten Snug. 10. Restart Phoenix.

Section 6: OPERATION AND MAINTENANCE Continued PAGE 14 OF 20 Inspection Checklist Date

3/4,1/2,1/4,Empty) Lubricator Drip Rate/Minute (Note watch clear knob ontop of

-27 HG Recommended. 2. Pump Inlet Gauge Less than 25 HG Recommended 3.

16 Section 6: OPERATION AND MAINTENANCE Continued PAGE 14 OF 20 Inspection Checklist Date Completed Time Completed Location Measurement Lubricator Oil Level - (Full, 3/4,1/2,1/4,Empty) Lubricator Drip Rate/Minute (Note watch clear knob ontop of lubricator 1 Drip per minute minimum) 1. Vacuum Gauge HG Recommended. 2. Pump Inlet Gauge Less than 25 HG Recommended 3. Membrane Pressure Gauge Less than 20 PSIG Recommended 1. Vacuum Air Regulator PSIG Recommended. 2. Fluid Pump Air Regulator PSIG Recommended

Section 6: OPERATION AND MAINTENANCE Continued PAGE 15 OF 20 Inspection Checklist Date Completed Time Completed Location Measurement Spinning Flow Indicator: (Spinning, Not

In this case check pump inlet gauge to see if there is vacuum/suction on gauge which would also indicate flow.

17 Section 6: OPERATION AND MAINTENANCE Continued PAGE 15 OF 20 Inspection Checklist Date Completed Time Completed Location Measurement Spinning Flow Indicator: (Spinning, Not Spinning) Note: Spinning Indicator may not spin even when there is oiil flow if oil is cold and thick. In this case check pump inlet gauge to see if there is vacuum/suction on gauge which would also indicate flow. Filter Plugged Indicator (Green, Middle, Red) Condensation Drain Note: Shut of Vacuum Air Supply to occasionally open condensation drain valve. There may be a little oil drain from the system or potentially condensed water. However if large amounts of oil are present contact your Phoenix Sales Representative.

18 Section 7: RECOMMENDED SPARE PARTS PAGE 16 OF 20 PART NUMBER MSCP MSCAD220 DESCRIPTION 7 MICRON PARTICULATE FILTER ELEMENT BLUE SPIN ON 1 QUART OF SAE 10 PNEUMATIC LUBRICATING OIL RECOMMENDED REPLACEMENT AS NEEDED OR EVERY 6 MONTHS WHATEVER COMES FIRST AS NEEDED CHECK OIL LEVEL REGULARLY AND REFILL MSCK208 AIR FLUID PUMP MOTOR REPAIR KIT RECOMMENDED EVERY 2 YEARS OF OPERATION SEE MOTOR INSTRUTIONS IN NEXT SECTION. ALONG WITH ONLINE VIDEO INSTRUCTIONS. FS VACUUM BREATHER FILTER EVERY 6 MONTHS 1 YEAR

19 Section 8: Oil Flushing Procedure PAGE 17 OF 20 IT IS RECOMMENDED THAT WHEN USING THE PHOENIX WITH MORE THAN ONE TYPE OF OIL THAT IT BE FLUSHED OUT BEFORE CHANGING TO ANOTHER OIL. THIS WILL PREVENT OIL CROSS CONTAMINATION IN RESERVOIRS. STEP 1 STEP 2 STEP 3 - STEP 4 - Close air supply valve to fluid pump motor to stop oil flow through phoenix. Disconnect inlet suction hose from oil reservoir. Remove any quick disconnect hydraulic Coupling from end of hose if used so that air can be pumped through Phoenix. Leave outlet hose connected to oil reservoir so any oil in Phoenix can be pumped Back to reservoir without loss. Open air supply valve to fluid pump motor and allow oil to pump out and back into reservoir. Watch outlet oil flow sight glass (see page 6 item 8 figures 8) till there is no more oil coming out. Run for 2 minutes max. STEP 5 - Place Bucket under membrane housing drain valve (Page 6, Figure 7 item 24). Open valve and let drain for 5 10 minutes. Close Valve when completely drained. STEP 6 - STEP 8 - STEP 9 - To prevent cross contamination of oil it is recommended that the Particulate Element be changed each time a different oil is used. Install a new Particulate element into filter housing. See page 13 for filter element change-out procedure. Empty approximately 2-3 gallons into a 5 Gallon bucket with whatever type of oil the Phoenix is to filter next. Close all valves on Phoenix, disconnect outlet hose from oil reservoir and now insert inlet and outlet hoses into bucket and flush new oil through Phoenix for About 5 minutes. Phoenix is now flushed out and ready to run on new oil.

20 SECTION 9: DATA SHEETS

Phoenix C4XE - Membrane Based Portable Lube and Hydraulic Oil Purifier Cart For use in Hazardous Duty Locations.

Phoenix C4XE - Membrane Based Portable Lube and Hydraulic Oil Purifier Cart For use in Hazardous Duty Locations. IMPORTANT: READ THIS MANUAL THOROUGHLY BEFORE INSTALLING AND OPERATING UNIT. IT IS THE CUSTOMERS RESPONSIBILITY TO WIRE UNIT WITH THE APPLICABLE ELECTRICAL CORD AND PLUG FOR USE IN HAZARDOUS DUTY ENVIRONMENTS