Operation Manual LVDH - 100-Cu - El: Owners Manual Page 1 of 26

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OWNERS MANUAL Page 1 of 26
OPERATION MANUAL
LVDH – 100- CU – EL
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FERROCARE MACHINES PVT.LTD. PUNE

TABLE OF CONTENTS
INDEX
Sr. No. Contents Page No

1. Introduction 4
2. Water Contamination & Its Harmful Effects on Oil 5
3. Advantages of LVDH 5
4. Construction 6
5. Schematic Mechanical Circuit Diagram 7
6. Technical Specifications of LVDH -100 8
7. Application 9
8. Procedure for Installation 10
9. Operation & Control Scheme 11
10. Operation 12
11. Control Panel display 12
12. Chiller Unit Indication 12
13. Processor Operation Password for Manual 13
Operation
14. Microprocessor Set Parameters 14
15. Fault Indication 15
15.a. Resetting the LVDH 15
16. Safety Provisions 16
17. Operation Tips do’s and Don’t’s 16
18. Intermittent Operations 17
19. Trouble Shooting & Maintenance 18
20. Oil Testing 19
20.a. Inlet Oil condition 19
20.b. Sampling Procedure 19
20.c. Oil Tests 20
21 Electrical Circuit Diagram 21
Annexure II Chiller Unit Operation Manual 22-26

Annexure III Vacuum Pump Operation Manual
Annexure IV Test certificates
Helping you… work better… under pressure


Overview
About This Manual
The information in this manual has been carefully checked and is believed to be accurate. However,
Ferrocare Machines Pvt.Ltd. assumes no responsibility for any inaccuracies that may be contained in
this manual.
In no event will Ferrocare Machines Pvt.Ltd. be liable for direct, indirect, special, incidental, or
consequential damages resulting from any defect or omission in this manual, even if advised of the
possibility of such damages.
In the interest of continued product development, Ferrocare Machines Pvt.Ltd. reserves the right to
make improvements in this manual and the products it describes, at any time, without notice or
obligation.
All rights reserved. No part of the contents of this manual may be reproduced or transmitted in any
form or by any means without the written permission of Ferrocare Machines Pvt.Ltd.



Instructions and Operation Manual for
“LOW VACUUM DEHYDRATOR (LVDH)”
1.0. INTRODUCTION
Thank you for purchasing the “Low Vacuum Dehydrating Machine“ (LVDH). This manual
contains operation & instructions for safe use of this equipment. To operate this equipment
properly & safely, this manual must be read & thoroughly understood before operation is
attempted.
After reading this Manual, keep it in an accessible place so that it can be referred to at any
time. Operating this equipment in a manner that does not comply with instructions in this
manual may lead to accidents. Therefore the comprehension of this manuals safety
precautions section should be especially thorough. (This device may be improved &
mechanical specification may be changed without notice)
To facilitate comprehension each of the warning shown in this manual or/on the device, has
one of the following headings, depending on the gravity of risk.
WARNING :
A warning is used to indicate a condition which, if not met, could cause serious personal
injury and/or death.
CAUTION :
Caution warns you of a potential hazard. If you do not read and follow the instructions very
carefully at this point , the product could be damaged or important data could be lost .
Note:
A note is used to indicate important information or instructions that should be considered
before operating the equipment.
This manual must be read & thoroughly understood before using this equipment. The person
in charge of this equipment should not permit anyone who is not familiar with operation of this
equipment, to handle it.


1. INTRODUCTION
The VACCUM DEHYDRATON UNIT, MODEL LVDH - 100-CU is a mobile compact unit to remove
free and emulsified moisture from mineral and synthetic oils at low temperature.
Oil contaminated with water is passed through an indirect heating chamber and dispersed into a
vacuum distillation chamber. The vacuum chamber vaporizes water, gases and other volatile
impurities which are excavated via a condenser, to the atmosphere.

Dehydrated oil is pumped back into the oil reservoir through a mechanical filter.
The water removal is supported by a Tandem Mounted Refrigeration Type Condensing unit, which
ensures immediate and maximum condensation of separated moisture. Thus by reducing the vapor
pressure of released steam, more vapors are extracted in the same cycle of operation.
2. WATER CONTAMINATION AND ITS HARMFUL EFFECTS ON OIL

Water in oil leads to:
a. Corrosion of metal parts
b. Low bearing life
c. Sludge formation and reduced oil life
Water in oil can be:

A. DISSOLVED WATER (upto saturation level) in the form of water vapor in oil.
B. FREE WATER in the form of water vapor in oil.
C. Emulsified in oil, due to churning in pumps, etc, some water will enter oil as an emulsion, which is
difficult to separate.
3. ADVANTAGES OF LVDH
Merits of Vacuum Distillation Unit LVDH are:
B) ECONOMY: Requires no consumables except electricity.
B) FLUID COMPATIBILITY: It has good fluid compatibility viz: can be used for petroleum based oil
as well as synthetic oils.
C) Ultimate moisture removal is below 500 ppm allowing dehydrated oil to be subject to Electrostatic
Liquid cleaning to remove suspended solid impurities.
D) NO MEDIA MIGRATION: This unit is closed system without any disintegration of filter media
during its operation.
E) Removes even emulsified water.
Advantages of Vacuum Dehydration Unit are:

A. Easy to operate.
B. Efficient method for continuous removal of moisture from oil.
C. No damage to oil.
D. The unit offers dry, dehydrated oil.
Helping you ... work under better ... under pressure


4. CONSTRUCTION
LVDH machine consists of three parts:
A) Heating chamber
D) Vacuum Chamber
C) Refrigerated Type Condensing Apparatus
D) CONTROL PANEL (MICROPROCESSOR BASESD)
Oil is passed through a strainer in heating chamber where it is indirectly heated to about 50 -55 ºC.
The oil so heated is dispersed in a thin film in the vacuum chamber.
Dispersing the oil into a thin film increases the surface area exposed to vacuum. As water will boil at
low temperatures in vacuum, it evaporates and is excavated through the condenser where it is
condensed into water and drained out.
Dehydrated oil is pumped back into the oil reservoir.
Vacuum, temperature gauges and moisture sensor are installed on the equipment
The schematic flow chart (refer fig 1.1) is self – explanatory.
4 a. Heating Chamber Description:

The heating chamber is a cylindrical fabricated reservoir with a bolted cover of nominal volume of 20
liters of oil handling capacity. Two low watt density heaters are diced in a tube covering the coil on
the top cover of heating chamber. Oil to be dehydrated flows through the heating chamber. Heat is
radiated from these coils to the tube & in turn to the oil. Oil thus heated is fed into the vacuum
chamber.
4 b. Vacuum Chamber :
The vacuum chamber of 100 liters nominal capacity has a specially designed baffle tray which
enables the hot oil to be sprayed into a thin film exposing the entrapped water to low vacuum and
enabling boil off and excavation from oil.
The oil subsequently collects by gravity at the bottom of the vacuum chamber tank from where it is
pumped back into the oil reservoir.
Float switches in the vacuum chamber regulate oil flow into and out of the chamber by controlling the
operation of vacuum and discharge pumps respectively.
4 c. Refrigerated Type Condensing Apparatus
The steam cooler designed to extract heat continuously from the steam to which it is attached in
order to reduce the steam temperature so as to allow condensation.
The unit consists of Mechanical Refrigeration System, utilizing refrigerant R-134 , condenser and
drier. Steam from the vacuum chamber is drawn into the top inlet of Copper submerge type heat
exchanger with the help of vacuum. It will get cooled and condense in form of water after passing
through Copper submerge type teat exchanger. Free water will come out from bottom of heat
exchanger & will collect in the condensate pot provided & the cycle will be repeated.
4.d.Control Panel
The electrical controls are housed in a sheet metal panel mounted on the main structural frame of the
unit. The refrigerated type condensing unit has its own manual controls. Electrical circuit diagram is
attached.
Helping you ... work under better ... under pressure


Fig 1.1

6. 0 Technical Specifications of LVDH-100-CU-EL
1 ELECTRICAL SUPPLY 415 V, 3PH – 50Hz, 4 W IRE
2 CONTROAL PANEL PLC CONTROL
3 OIL INLET/ OUT LET RUBBER HOSES WITH 3/4 , HYDRAULIC END FITTINGS
4 DISCHARGE PUMP DETAILS
A TYPE MEG-50 MONOBLOCK
B NOMINAL FLOW RATE 50Ltrs /min
C OPERATING PRESSURE 1 TO 10 Kg/sq.cm.
D MOTOR POWER 1 hp, 1440RPM , 3PH

5 VACUUM CHAMBER CAPACITY 100 Ltrs (NOMINAL)
6 OPERATING VACUUM UPTO 750 mm of Hg @ MSL
7 HEATER TYPE LOW WATT DENSITY HEATER

8 HEATER LOAD 8Kw – 440-VAC-50Hz WITH CONTINUOUS RATING
9 VACUUM PUMP DETAILS
A CAPACITY 180 Ltrs/min
B DRIVE BELT DRIVEN

C MOTOR POWER 0.5 Hp , 1440 RPM , 3PH
10 OVERALL DIMENSIONS
A LENGTH 1560 mm
B WIDTH 740 mm
C HEIGHT 1480 mm
11 WEIGHT OF UNIT
A EMPTY 425 Kgs

B FULL(WITH OIL & WATER) 525 Kgs
12 UNIT PROVIDED WITH TWO FIXED CASTOR WHEELS, TWO SWIVELL
13 DUTY CONDITIONS CONTINUOUS
14 COLOUR SHADE CRIMSON & BLACK

15 WATER DISCHARGE AUTOMATIC
TANDEM MOUNTED REFRIGERATION TYPE
CONDENSOR UNIT WITH PROPRIETARY 0.5 TR
16 CONDENSOR COOLING UNIT


7. APPLICATION
The “Low Vacuum Dehydrating Machine " can be used for cleaning hydraulic and lubricating
oils of the following general specifications.
a) Mineral Based oils
b) Synthetic Oils
NOTE:
Separate models available for Flame / Explosion proof requirements.
Models are available with Moisture sensors at the inlet / Outlet for continuous measurement of
moisture content in the oil being dehydrated.



8 . PROCEDURE FOR INSTALLATION : Refer fig 8.1 for installation details
FIG 8.1
• Inlet to the LVDH should be connected from the bottom of the oil tank ( ref fig 8.1).
• Outlet from the LVDH to be given from the top of the oil tank
• Ensure that a valve is provided at the inlet point of the LVDH so as to isolate the inlet flow
during shut down or servicing of the LVDH unit.
• Ensure that inlet valves are opened when LVDH machine is put in to operation.
• Ensure that the outlet valve of LVDH is open before the machine is put into operation.
• Ensure that water is filled in the chiller unit condensing chamber before unit is switched on.
• Ensure that the Vacuum release valve and manual water drain valve are closed .
• Check oil level in the Vacuum pump prior to starting the unit. In case oil level is low use VM4
grade oil for top up
• LVDH is provided with single phase preventor and will not start if the phase sequence is not
proper. In case the unit does not start even after giving power supply check and change the
phase sequence.
NOTE : USE ONLY VM 4 GRADE OIL FOR VACUUM PUMP
The unit must not be installed in a place where it will be subject to significant vibration, to fire, or to
other similar hazards.
The unit should only be installed/ used in a covered area and not exposed to the elements.
The unit should be installed in a place where it can be easily accessed for inspection & maintenance.
Connect the equipment to 3 phase power supply.


Make sure that the unit is properly grounded .

WARNING
To prevent electric shock machines should be properly grounded.
Breakage of a pipe cause oil to flow out.Consider this & other factors when
CAUTION selecting pipe materials.
9. Operation and Controls Scheme:
The electrical controls are housed in a sheet metal panel mounted on the main structural frame of the
unit. The refrigerated type condensing unit has its own manual controls. Electrical control Panel
consist of
1. ELCB+MCB 415 V AC
Trip the electrical supply of the unit and heater in case of short circuit or overload current & leakage
current that may occur during operation.
2. OVERLOAD RELAY 1 AND 2:
To protect the motors of oil pump and vacuum pump from overload. The relay should always be kept
on manual reset mode.
3. LVDH is fitted with PLC based control panel to control and display the parameters during operation
of the LVDH machine . Ref fig 9.1
Fig.9.1. CONTROL PANEL FOR LVDH MACHINE
NOTE: The keys provided on the panel are soft touch hence care should be taken while
operating the same. Avoid pressing the keys if not required.


10 .OPERATION:
Ensure that the suction and discharge pipes are connected properly to the oil tank. The suction
should be from a point at the bottom so that water will be available for removal. If the tank is
partitioned, the suction should be from the section likely to have most moisture. A suction strainer
should be fitted at the suction hose inlet. The discharge pipe should be to a point away from the
suction.
Switch on the ELCB+MCB to start supply. 415V 50Hz, 3 phase supply in correct RYB sequence is
required. The unit is fitted with a single phase preventor so it will not start if the phase sequence does
not match.
Start the LVDH using the start /stop button, the vacuum pump will start and the display will indicate
the LVDH – operating hours. It is recommended that the vacuum pump be run for 20 minutes
before allowing oil into the unit. During this time, heater should be “Off”. The vacuum pump will
then be warmed up, and this will prevent the steam vapors from condensing and mixing with the
vacuum pump oil. This time delay is provided in the processor program hence only the vacuum pump
will start initially and the oil inlet and the heater will start only after 20 min of delay time set.
After the vacuum pump has run for 20 minutes, the inlet solenoid valve will open and the heaters will
“Come On” . The continuous scrolling display will indicate the heater temperature ‘T’ once the
heaters are on.
The condensing unit switches “ON” after a time delay of 3 mins.
11. Control Panel Display

The control panel will show following Operating hours and Oil temperature in scrolling Mode
LED indicators are provided for:

1. Heater on (Bottom right)
2. Vacuum pump On
3. Discharge Pump on (Bottom right) – this will show whether the discharge pump is running. In auto
mode the discharge pump is controlled by float switches and will switch on and off to maintain oil
level in the vacuum chamber within set limits.
4. Vacuum release – this indicator will come on when the condensate pot is filled with water and
“Auto Discharge” operates to empty out the water.
12. Chiller unit indications
1. Power On: There is a 3 mins “on delay“ timer.

2. Digital display temperature of return air after cooling the steam to water.
3. Digital display will indicate “LT 15” when set temperature is reached.
4. Thermostat cutout: The compressor switches off at limit temperature.


13.0 PROCESSOR OPERATION PASSWORD FOR MANUAL OPERATION
Access to the programming in the Processor is through password.

Procedure to be followed for the programming of the LVDH – controller.
Password Operation
The face of the processor display show 2 buttons, namely setting and arrow.
When you press the “setting” button, the display will change to “P100”
Now press the “Arrow” button and the display will increase by one point. Bring it to
“P106” and press the settings button again.
With this password, the parameters can now be displayed and changed , pump can be set to manual,
scroll time can be changed. This window for changing is open for 8 seconds. If no changes are made
in 8 seconds, password has to be re-entered.
To access a parameter, use the “SETTING” KEY. Parameters will be displayed one by one. To
change the value, press the “Arrow” UP, the parameter will increase one point.
Do not change factory settings; use this only for scroll time setting. DO NOT change any of
Caution the parameters given below. Changes if required will be made by company personnel only.
To operate discharge pump in manual mode, enter password, and follow the above procedure to
change the discharge pump setting to manual mode.


14.0 MICROPROCESSOR SET PARAMETERS
Parameter Display
The display box will show the following parameters in continuous scrolling or when the “Arrow” button
is pressed.
1. Temperature “Set” temperature. This is the temperature at which the heaters are set to cut off.
2. Operating hours. The vacuum pump oil tends to collect some of the moisture removed from the
oil begin dehydrated, and over a period of time this deteriorates the performance of the pump. The
service hours for the vacuum pump are indicated as “H 002” . The settings are from 001 to 006. Each
unit is of 250 hours (001 = 250 hours..002= 500 hours) ..the vacuum pump oil must be changed at
the 500 hours.
3.Scroll time – “ n 03” This indicates the time for which scrolling parameters (Oil temperature and
Running Hours) are displayed. This parameter can be set form 0 to 10 secounds. When set to “0” the
display will not scrol.
4. Heater on – “h on” in some cases when the oil from the system is available hot, it may not be
necessary to put on the heater, or when the equipment is being used only to “Degassify” oil, the
heater may not be required.
5 .Auto Discharge – the LVDH will discharge the water removed automatically when the condensate
pot is filled up. A float switch in the condensate pot will operate and vacuum pump will switch off. At
the same time, Vacuum release solenoid will open and vacuum will be released. The water release
solenoid will open after 30 seconds and remain open for 17 min allowing water to drain out.


15. Fault Indications
Fault Indications
The following fault indications are available
FL 3 – FL 4. this means the float switch of that number is faulty.
FS 1 and FS 2 control the discharge pump in auto mode.
FS 3 is theIt high
chamber. stopslevel safety switch
the vacuum pump.which will prevent
It indicateds oil from
that the being pump
discharge sucked
is further fromfull
not giving the vacuum
discharge
running the LVDH on a barrel of the same clean oil may help to solve the problem, or service should
be called for.
V OL – indicates the vacuum pump motor is overloaded. Reset the OVerl button for vacuum pump
after it cools and restart.
1.Change the oil in the vacuum pump.
2. Check and change the belt driving the pump if necessary.
If the problem persists, call for service.
P OL – indicates that the discharge pump is overloaded. Reset the button for the
discharge pump after it cools down. Check that the heater cutoff is operating at the set temperature.
If the problem persist, call for service.
15.a )RESETTING THE LVDH MACHINE AFTER FAULT INDICATION
1) PROCEDURE TO RESET THE LVDH FOR ‘SERV’ FAULT INDICATION
When the LVDH machines stops due to service indication to reset press key to reset and
start the LVDH machine.
If the LVDH does not reset repeat the procedure.
2) PROCEDURE TO RESET THE LVDH FOR ALL OTHER FAULT MESSAGES OTHER THAN
‘SERV’
When LVDH stops due to any other fault indication other than ‘SERV’ press key to reset
and start the LVDH machine.
Note
FL 1 and FL 2 control the discharge pump in auto mode.

FL3 is the high level safety switch which will prevent oil from being sucked further from the vacuum
chamber. It stops the vacuum pump. It indicates that the discharge pump is not working to capacity.
Run the LVDH on a barrel of the same clean oil this may help to solve the problem, or service should
be called for.


16. Safety Provisions – Following are the safety provisions provided in the unit.
A) 415 V ELCB+MCBs – To trip the electrical supply of the unit under short circuit, overload current
conditions.
B). MCB – To protect control circuit and heater, in case current exceeds, due to short circuit,
overload etc.
C) OVERLOAD RELAYS – To protect the discharge pump and vacuum pump motor.
D)
theFLOAT SWITCHES
discharge pump. 1&2 –To prevent flooding of the vacuum chamber or to prevent dry running of
E) FLOAT SWITCHES 3&4 – To prevent flooding of the vacuum chamber and condensing chamber.
F) SOLENOID VALVE / NON RETURN VALVE - To provide unidirectional flow.
G) PHASE PREVENTOR / PHASE SENSOR – To prevent direction change of vacuum pump and
discharge pump.
Cooling Unit
A. Timer to prevent restart of compressor “on load”
B. Thermostat cutout to prevent frosting on steam condenser.
17. Operating Tips – Do’s and Don’ts

FL-3 is indicated on the control Panel
Fig 14.1
FL-3 means float switch 3 activated. This occurs when oil is not being evacuated from the vacuum
chamber at a sufficient rate, and oil level has gone up to the 3 rd float switch. Oil input is more than Oil
output.
1. Release Vacuum by opening ball valve for manual vacuum release on condensate pot. (Refer to
the mechanical circuit diagram fig. 1.1 item no. 6.1 )
2. Restart the discharge pump in manual mode. To restart the discharge pump on manual mode
follow the instructions as per PARA . 11 and change the discharge pump mode to manual.
This may happen sometimes because of some variation in oil flow, since the oil viscosity changes
with temperature and moisture content. Check the discharge flow physically. The discharge will
increase if vacuum is reduced. If it happens consistently, pump requires service.
Do’s
a. Run the vacuum pump for 20 min before allowing oil into the machine (with Heater “Off”).
b. Check that the oil contains moisture, with crackle tester provided with the machine. (Procedure for
crackle test is given in PARA 20 of OIL TESTING) Condensation on exposed areas of tanks is not
the correct indication that oil contains moisture.
c. Drain free water from the system before connecting LVDH. It saves energy and time.
d. Check the vacuum pump oil is clear. If it is milky, change it. Use oil of viscosity 150 cst @40 0C.
Enklo 150 recommended, or it is better to use a good engine oil, rather than continue with emulsified
oil.
e. Check the discharge and idle timings for 2-3 cycles. If idle time is more that 2-3 times discharge
timings, clean the strainers in the circuit.
f.
beCheck
withinthat
20mmfull vacuum is reachedPressure
Hg of Barometric in about at
5 minutes of starting
your location. thelevel,
At sea vacuum pump.be
it should Vacuum should
>740mm Hg.
On the Deccan plateau in South India it should be above 680mm Hg.
h. Release the vacuum when LVDH is stopped.


Don’ts
a) Do not allow free water into the LVDH.
b) Do not open parts other than strainers.
c) Do not use the LVDH for degasifying aggressive gases like Ammonia.
d) Do not use heater while degasifying oil.
e) Do not repeatedly restart the cooling unit in case of fault indication.
The vacuum distillation unit model LVDH-100 cannot be used for the following:
a. Water based fluids.
b. Oils with volatile additives.
18. INTERMITTENT OPERATION
18a. Temporary Stoppage:

1. Switch off main supply from ELCB.
2. Close the oil inlet valve.
3. Release the vacuum by opening the ball valve for manual vacuum release on condensate pot
(Refer fig 1.1 of schematic diagram item no. 6.1), and then open the Manual water drain ball
valve (Refer fig 1.1 of schematic diagram item no. 6.1) to drain out condensed water.
4. Close both valves after release 0f vacuum and condensed fluid.
18b. Shutting Down the Unit:

a. Follow the procedure 6a for temporary stoppage
b. Position a tray below the strainer of the inlet hose.
c. Drain oil from vacuum chamber by operating discharge pump on manual.
d. Close the inlet valve of the unit.
e. Close the outlet valve of the unit.
f. Open the strainer cap and remove strainer basket and clean.
g. Put back the strainer basket and tighten the strainer cap.
h. Disconnect suction and delivery hoses and drain all the oil from the hoses to the tank.
i. Cover the inlet and outlet ports of quick release coupling ends with suitable rubber or polymer
caps.
j. Drain the condensate pot and water from filters and heating chamber drains.


19. Trouble Shooting & Maintenance
1. Does not start – Check phase sequence

2. Try to start the heater “Off”. If it starts, one or both heaters are defective and should be replaced.
3. Vacuum level low – Vacuum pump service vacuum pump, check oil level and top up if necessary.
3a. Leakage from quick release coupling – Fix properly the inlet and release coupling outlet hose
connection.
3b. Solenoid Valve – Check the valve
4. Oil temperature low
a) Heater operation. Check supply.
b) Check heater condition for continuity and insulation resistance and replace if burnt.
5) OL – indicates the vacuum pump motor is overloaded. Reset the over load button for vacuum
pump after it cools and restart.
Change oil in the vacuum pump.
Check and change the belt driving the pump if necessary.
If the problem persists, call for service.
P OL – indicates that the discharge pump is overloaded. Reset the button for the discharge pump
after it cools down. Check that the heater cutoff is operating at the set temperature. If the problem
persists, call for service
2. Maintenance Schedule of Unit:

It is recommended that proper records of the unit be maintained and updated periodically. Format for
the log should to be maintained in given below.
All
andthe irregularities
properly recorded in and
operation, any
intimated to malfunction, failure
the authorized of components
personnel etc. must
for any needed be immediately
corrective action.
LOG SHEET FOR LVDH PERFORMANCE AND MAINTENANCE
HR VACUUM
MOISTURE
DATE METER VACUUM TEMP. PUMP OIL REMARK
IN OIL
READ CHANGE
3. TIPS FOR SMOOTH OPERATION

a. VALVES: Check all values for , smooth operation and leak tightness.
b. VACUUM PUMP: i) Check oil daily
ii)
c. Change
The unitoilshould
after every 500 hours
achieve of operation.
full vacuum in 4-5 minutes, and the vacuum pressure should not
drop after standing idle for 2 hours. This test should be done monthly. Call for service if the
unit does not pass this test.


4. Cleaning of Strainers:
When the oil flow to the vacuum chamber is very low or zero (which can be seen from the long time
elapsed for filling of vacuum chamber i.e. more than half an hour), the indications are that the suction
strainer or line strainer is choked and requires cleaning. Clean manually and reinstall.
5. MAINTEANANCE OF CONDENSOR
The
own condenser
protection andis ofhermetically
robust, maintenance-free design.
sealed compressor. It isIt designed
is a refrigerated type
to handle cooling
large unit,removal
moisture with its
rates, During operation, the cooling unit fan should be checked by placing a band over the discharge
grille. If the cooling unit is running, and indicator does not show Lt, the fan should also be running.
6. Loading and Unloading:

a. The unit is provided with four caster wheels which make the mobility of the unit easy and
convenient.
B Four lifting points are provided on the top of the unit.
20. OIL TESTING
20.a. Inlet Oil Condition:

a. Temperature: About 50 0C
b. Max. free moisture content : 3%
c. Solid contents : Less than 0.5% by weight
d. Oil Flow : 15 liters per minute average.
20.b. Sampling Procedure:

Mark the sample bottles with following details:
a. Type of oil and quantity.
b. Wet oil label.
c. Provide sample bottles with labels e.g. initial after 1 hour of dehydration, 2 hours, 3 hours, etc.
Do not forget to properly seal and place the sample bottles in a secure place till they are
analyzed.
Important Note:
a. Any improper sampling procedure or wrong labeling will lead to wrong and erroneous oil analysis.
b. Minimum quantity of oil for each analysis should be at least 250 cc.


20.c. Oil Tests:
FOLLOWING ARE THE TESTS PERFORMED FOR EVALUATION OF MOISTURE CONTENT IN

THE HYDRAULIC OIL.
Whenever free water is present in the oil it will be generally hazy or cloudy. A simple crackle test
provides a qualitative on the spot confirmation.
A.CRACKLE TEST: will

momentary frothing By indicate
heating that
oil there
sample on a in
is water spoon an audible
the oil.Refer to figcrackling or popping
20.1. Heater and
with spoon
provided along with the LVDH machine.
SPOON
Fig : 20.1 Crackling test
B.LABORATORY TEST: By Karl Fischer Titration Method.
C.MOISTURE SENSOR: Moisture sensor supplied along with the equipment give direct readout of
the saturated moisture content in ppm. Refer fig 20.2 for moisture sensor.
Fig 20.2 MOISTURE SENSOR


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Annex II
OPERATION MANUAL FOR CHILLER UNIT.
PRINCIPLE OF OPERATION:
The steam condensor is designed to extract heat continuously from the steam to which it is attached in order
to condense the steam.
The unit consists of Mechanical Refrigeration System, utilizing refrigerant R-22 a condenser, drier.
Steam from the machine is drawn into the top inlet of Copper submerged type heat exchanger with the help of
vacuum pump provided in the LVDH machine. Steam will get cooled after passing through Copper submerged
type heat exchanger & condense into free water which will be collected in the condensate pot.
Refrigerant Circuit as follows:

Compressed refrigerant R 22 coming from compressor, passes through condenser, filter drier & the capillary
tube at which point it enters the copper evaporator coil to bottom, running counter flow to the steam & leaving the
heat exchanger at the top and then to the compressor.
The Operation of the Temperature controller is as follows:

When temperature controller calls for refrigeration because of rising steam temperature as it comes from the
machine, it starts the condenser fan and compressor motor after time delay.
BILL OF MATERIAL
1. Compressor : Emerson Climate Control Technology

2. Condensor Coil : 11” X 10” X 3 Row Copper tube Aluminum
Fins
3. Drier : Copper Strainer
4. Expansion Device : Capillary Tube
5. Cooling Coil : Submerge deep type
6. Condensor Fan Motor : Axial flow fan
7. Temperature Controller : Make: Subzero
Electrical Part with Compressor Model
Compressor Model
Item KCJ 467 HAG KCN 463 HAG KCE 443 HAE
Relay KARP5641 LT85002 LT85002
Start Capacitor 80-100 Mfd 80-100 Mfd 40-60 Mfd
Running N. A. 15 Mfd 10 Mfd

Capacitor
Overload MRA 12024112 KAT0463/B2 KAT0072/K3
Protector Or Or
KAT0733/02 KAT0159/B2


SOME HINTS THAT WILL PREVENT SERVICE CALLS:

1. Problem – Steam Condensor (i.e. condensor fan motor) is working but cooling effect is not there.
Possible Cause – (checks to be made)
1. Check the steam connections (I.e. steam inlet & outlet) are not interchanged.
2. Check the Temperature controller setting.
3. Check the MCB provided on electrical control, if MCB trip reset it.
4. As per the wiring diagram, check the connections. If there is loose contact repairs the same.
5. In case of leakage or breakage of copper tube, follow the procedure given under gas charging.
6. Even after above checks, cooling effect is not there then contact us.
HOW TO CLEAN CONDENSOR COIL:
1. Remove the front cover of chiller unit by removing necessary screws.

2. Clean the condensor coil with the help of compressed air.
3. Care should be taken to avoid damage to copper tubing fins to avoid refrigeration leakage.
4. Refit the FRONT cover after cleaning operation.
CONDENSOR FAN MOTOR:

Condensor fan motor requires no maintenance. All bearings, shafts etc., are lubricated
REFRIGERANT LOSS:
The condenser has been thoroughly tested before leaving the factory. Transportation damages require
repairs & recharging of the system. This work work should be performed by qualified persons only, generally
available in any reputable air conditioning repair & service company.
Before recharging make sure that there are no leaks & that the system has been properly evacuated by deep
vaccum.
GAS CHARGING PROCEDURE FOR CHILLER UNIT :
Connect process valve to process lines provided in the system. Pressurize the system with dry Nitrogen to
200 PSI (maximum). Do not use carbon dioxide, air or any other gas. Check the joints with soap solution. If
leakage is ovserved, repair & recheck.
Release nitrogen pressure & connect the system to vaccum pump. Evacuate for at least six hours. Vaccum
of 50 microns (0.5 mm to 11 g.) must be achieved. During evacuation, heat the components (condensor,
compressor) by infrared heating unit. While heating care must be taken so that insulation will not melt. After
evacuation, charge operation

during the charging the systemwith
withsteam
Refrigerant – R22 Qty. 650 gms. It is necessary to run the steam condensor
circulation.


MAINTENANCE
Compressor:
Compressor requires no maintenance. It is well lubricated and hermetically sealed.
If the refrigerant is lost, recharging valves are provided on the suction sides of the compressor for
recharging and /be

with. They must or attended
checking.toUnder notrained
only by circumstances
persons. the
Therefrigerant lines torefrigerant
system contains be lossened, removed
gases or tempered
under pressure.
Inlet Filter:
Proper maintenance of the inlet air filter, will assure stable operation of your steam condensor. If filter
maintenance is delayed or ignored, the maximum ambient temperature under which the unit is designed to
operate will be decreased.
As the compressor operating temperature increases above normal due to clogged inlet air filter or plugged
condenser coil, the compressor will stop operating due to actuation of the thermal overload cutout switch. As soon
as the compressor temperature has dropped within the switch cut-in-setting, the compressor will restart
automatically. The above condition will continue to happen until the filter has been cleaned or replaced.
It is recommended that power to the chiller unit be interrupted intentionally when abnormally high
compressor operating temperature causes automatic shut down of the unit. The shut down is symptomatic of
clogged or dirty filters, thus causing reduction in cooling airflow across the surface of the compressor & condenser
coil. Continued operation under this condition, can and will damage or shorten compressor life. The Steam
condensor features an easily removable inlet filter to facilitate necessary cleaning. There should be no reason to
neglect this necessary maintenance.
HOW TO REMOVE, CLEAN OR INSTALL NEW FILTER:

1) Remove the screws of front grill.
2) Clean it with the help of compressed air and refit front grill..
It is impossible to recommend a filter cleaning interval, due to vide variation of air quality conditions and
operating duty cycle of the steam condensor. Amount of air borne dust/dirt particles are different in every location.
It is recommended that when fine layer of dust or lint is visible on the surface of the filter, it should be cleaned
with
1) low pressure air
2) Water washed
3) Dried with low pressure air.
Do not run the Steam Condensor for extended period of time with the inlet filter removed. Particles of dust &
lint etc., can plug the fins of condenser coil.
Condensor Coil:
Proper maintenance of condenser coil will ensure stable operation of the chiller unit. If the condenser
maintenance is delayed or ignored, maximum ambient temperature under which unit is designed to operate will
be decreased.


Temperature Controller Manual
Para. Description
To set the set point of the controller
How to set other parameters
P1 To set Heating or Cooling function.
P2 Max High Temp limit & alarm
P3
P4 Min Low
To set Temp limitTemp
Differential & alarm
( Hysterics)
P5 Probe calibration
P6 Time Delay (relay restart after cutoff)
P7 Defrost duration
P8 Defrost frequency
LP Keypad lock
Al Alarm-to activate buzzer
E1 Relay status on probe failure
FS Restore factory defaults
EP End programming & Keypad functions
Operating messages
Wiring diagrams
Panel cutout & dimensions
Ideal set point for your requirement

1) P1 - 0
2) P2- 35
3) P3-15
4) P4-2
5) P5-0
6) P6-3
Message Description Parameter

Ht Temperature above the maximum limit of the set point. P2
Lt Temperature below the minimum limit of the set point. P3
PP Probe short circuit, circuit open or without probe, or
temperature > 99 Degree Celsius or < -50 Degree Celsius.
On/Off Comp. Relay on/off SP, P4
Flashing Alarm (Ht, Lt or PP) AL
On/Off Keyboard locked/unlocked LP
On Defrosting in progress P7, P8
Flashing Time delay in progress P6
Set Point of Temperature Controller Manual
P1 0
P2 45
P3 12
P4 3
P5 0
P6 3
P1 1


Trouble Shooting Chart
Sr No Condition Cause Remedy

1. Unit Not Starting No power supply MCB Trip Check incoming supply voltage Reset
MCB
2. Fan is on but temperature Compressor trip or loose connection 1)Check unit AMPS (Reqiured 3.5
not maintained In electrical wiring Amps if compressor on)
3. Fan & Compressor is on but Air Filter chocked Clean Air Filter and condenser by air
temperature not maintaining
Check gas pressure on Gauge. It
Gas leakage requires 125 to 150 PSIG (If unit is in
OFF Condition) & 30 to 50 PSIG (If
unit is in ON condition)
4. Unit not maintaining Compressor not working First of all confirm that compressor is
Temperature even gas on by measuring current. It requires
pressure is OK (150 PSIG in to shown 4.0 Amps. If shown 2.5
OFF condition) Amps then there are chances of gas
leakage or compressor mechanical
breakdown
5. MCB Trip When Unit Start Fan Motor burn out Check fan motor ground test
Compressor burn out Check compressor motor resistance

& ground test
Short Circuit Check electrical wiring short circuit
6. Unit working but not Low water level in tank Check water level in level gauge.
7. removing water from

Gauge showing Oil
150 PSIG Refrigeration system chocked Fill
Callwater in proper
refrigeration level
technician and
pressure in Off condition check gas strainer or capillary to be
and 0 PSIG in on condition replace both part and recharge the
and not maintaining system
temperature
Healthy System:
1. Full load current: 4.0 Amps
2. Only Fan Motor Connect: 0.24 Amps
3. Gas Pressure in unit OFF condition – 125 to 150 PSIG
4. Gas pressure in unit ON condition – 45 to 60 PSIG


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Sr. No. Contents Page No

Annexure II Chiller Unit Operation Manual 22-26

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About This Manual

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impurities which are excavated via a condenser, to the atmosphere.

2. WATER CONTAMINATION AND ITS HARMFUL EFFECTS ON OIL

Water in oil can be:

Advantages of Vacuum Dehydration Unit are:

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The schematic flow chart (refer fig 1.1) is self – explanatory.

4 a. Heating Chamber Description:

4 c. Refrigerated Type Condensing Apparatus

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6. 0 Technical Specifications of LVDH-100-CU-EL

1 ELECTRICAL SUPPLY 415 V, 3PH – 50Hz, 4 W IRE

2 CONTROAL PANEL PLC CONTROL

A TYPE MEG-50 MONOBLOCK

B NOMINAL FLOW RATE 50Ltrs /min

C OPERATING PRESSURE 1 TO 10 Kg/sq.cm.

D MOTOR POWER 1 hp, 1440RPM , 3PH

7 HEATER TYPE LOW WATT DENSITY HEATER

9 VACUUM PUMP DETAILS

A CAPACITY 180 Ltrs/min

B DRIVE BELT DRIVEN

A EMPTY 425 Kgs

12 UNIT PROVIDED WITH TWO FIXED CASTOR WHEELS, TWO SWIVELL

13 DUTY CONDITIONS CONTINUOUS

14 COLOUR SHADE CRIMSON & BLACK

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NOTE : USE ONLY VM 4 GRADE OIL FOR VACUUM PUMP

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Make sure that the unit is properly grounded .