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OPERATION MANUAL OF
LVDH – 3000- CU

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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 -3000-CU 8
7. Application 9
8. Procedure for Installation 9
9. Operation & Control Scheme 10
10. Operation 11
11. Control Panel display 11
12. Chiller Unit Indication 12
13. Processor Operation Password for Manual Operation 12
14. Microprocessor Set Parameters 13
15. Fault Indication 14
15.a. Resetting the LVDH 14
16. Safety Provisions 15
17. Operation Tips do’s and Don’t’s 15-16
18. Intermittent Operations 16
19. Trouble Shooting & Maintenance 17-18
20. Oil Testing 19
20.a. Inlet Oil condition 19
20.b. Sampling Procedure 19
20.c. Oil Tests 19
21 Electrical Circuit Diagram 20

Annexure II Chiller Unit Operation Manual 21-26

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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.

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OWNERS MANUAL Page 4 of 26
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.

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OWNERS MANUAL Page 5 of 26
1. INTRODUCTION
The VACCUM DEHYDRATON UNIT, MODEL LVDH–3000 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. Moisture sensor provided at the
outlet of the LVDH unit gives readout for the ppm level for moisture content in the oil at LVDH outlet.

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 (up to 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 – 3000

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.

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4. CONSTRUCTION
LVDH machine consists of four 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 50 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-134a , 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.

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SCHEMATIC DIAGRAM

Fig 1.1

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6. 0 Technical Specifications of LVDH-3000-CU

SR.NO. DESCRIPTION

1. Electrical Supply :415V ,3 PH – 50 Hz , 4 Wire

2 Oil Inlet :3/4”

Type : Gear Pump – Coupled
Nominal flow rate : 50 ltrs /min, Operating Pressure : 1 to 5
kg/sq.cm, Motor Power : 0.75 hp , 3PH

3 Discharge pump details

3.1. Type : Gear Pump – Coupled
3.2. Nominal flow rate :120 liters/min.
3.3 Operating pressure : 1 to 10 kg/sq.cm
3.4. Motor Power :3 hp , 3 Ph, Oil Outlet: 1 ½ ”, with hydraulic
hoses

4 Vacuum Chamber Capacity : 100 liters (nominal)

5. Operating vacuum : up to 750 mm of Hg@MSL

6.0 Heater Type : Low watt density heater

6.1. Heater Load: 16 KW – 415-VAC-50Hz

7 Vacuum pump model E-300

7.1. 2. Stage, Belt Driven, INDO WOOSUNG make. Model E - 300

7.2. Motor power: 0.50 hp , Flow 180lpm

7.3. 1440 RPM, 3PH

8 Condenser –Tandem Mounted Refrigeration Type Condenser

unit with proprietary
8.1. 0.5 TR Cooling unit.
9 Moisture Sensor

10 Overall Dimensions
10.1. .Length : 1590 mm
10.2. Width : 1350 mm
10.3. Height : 1500 mm
10.4. Weight of unit (approx)
10.5. Empty : 450 Kgs
11 Unit provided with: Two fixed caster wheels ,Two swivel

12 Duty conditions : Continuous

13 Paint: External -synthetic enamel Internal -Epoxy

14 Color/Shade : Kangaro Blue & Black

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NOTE :
7.1. 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 are available for higher capacity.

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 preventer 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.

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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.8.1. 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.

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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 pump 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- LVDH 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.

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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.

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14. Microprocessor Set Parameters

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 seconds. 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 “Degasify” 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.

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15. Fault Indications

Fault Indications
The following fault indications are available

Float Switch- 1 & 2 control the discharge pump in auto mode.

Float Switch - 3 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 giving full
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.
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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) FLOAT SWITCHES 1&2 –To prevent flooding of the vacuum chamber or to prevent dry running of
the discharge pump.
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.

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.
17. Operating Tips – Do’s and Don’ts

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 VM4 recommended oil. 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. Check that full vacuum is reached in about 5 minutes of starting the vacuum pump. Vacuum should
be within 20mm Hg of Barometric Pressure at your location. At sea level, it should be >740mm Hg.
On the Deccan plateau in South India it should be above 680mm Hg.
h. Release the vacuum when LVDH is stopped.

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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-900 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.

15b. 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.

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19. Trouble Shooting & Maintenance

Sr.No PROBLEM CHECK SOLUTION

1. ELCB+MCB is ON, 1) Single Phase Preventer 1) Change the phase sequence
but No Indication On 2) Power Supply At Input of 2) Switch on the power supply
Processor ELCB 3) Replace if faulty ( out of ELCB is
3)Out Put Supply From Elcb 415v)
4) Fuse No1 4) Replace if faulty ( check the
5) Lvt Output continuity )
6) Display LVT (0 -13v) Input 5) Replace if faulty (out put of lvt is
and Output Supply. 0-230v)
7) Processor 6) Replace if faulty ( out out of lvt is
0-13v)
7) Replace if faulty
2 ELCB + MCB trips 1)ELCB+MCB 1) Replace if faulty
immediately 2) Heater 2) Replace if faulty ( check the
3) Vacuum pump and continuity )
Discharge pump motor 3) Replace if faulty (check the
winding. winding)
4) LVT primary winding short 4) Replace if faulty ( check the
and grounded winding)
5)VPC, DPC and HC contactor 5) Replace if faulty ( check the
contactor coil )
3 ELCB+MCB not trip Push the test button on Replace if faulty
after short circuit. ELCB+MCB
4 Vacuum pump is ON 1) Vacuum pump oil level. 1) Oil level is low, top up the oil.
but pressure not 2) Vacuum pump belt 2) Observed in damage condition ,
building up. 3) Vacuum pressure leakage. replace.
3) Check and rectify the leakage.
5 Vacuum pressure is 1) Suction line. 1) if inlet valve is closed, then open
ok but oil is not 2) Y- strainer it.
sucking. 3) Line filter 2) if clogged , clean it
4) Inlet solenoid valve 3) if clogged, clean it
4) Replaced if faulty(check the coil )
6 Discharge Pump Is 1) Outlet line 1) If outlet valve is closed, then
ON but oil is not 2) NRV open it.
Discharging 3) Discharge pump. 2) Replace if faulty (check whether
it is jam or stuck )
3) Replace if faulty

7 Heater is ON but 1) Heater MCB 1) Replace if faulty

temp not rising up 2) Heater contactor 2) Replace if faulty
3) Temperature sensor 3) Replace if faulty
4) Heater 4) Replace if faulty

8 Fuse - 1 blows 1) LVT secondary winding 1) Replace if faulty

repeatedly 2) Contactors coil short 2) Replace if faulty
3) Solenoid valve coil short 3) Replace if faulty

9 Display showing ''V- 1) Check input 3ph power 1) Do the proper supply.
OL '' indication supply. 2) Reset if disturb, or replace if

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2) OLR setting faulty
3) Vacuum pump oil level 3) If level is low, top up the oil.
4) Vacuum pump belt 4) Replace if damaged
5) Vacuum pump 5) If it is jam, do the flushing with
6) Vacuum pump motor diesel.
6) Replace if faulty
10 Display showing ''D- 1) Check input 3ph power 1) Do the proper supply.
OL'' indication supply. 2) Reset if disturbed, or replace if
2) OLR setting faulty.
3) Discharge pump and motor. 3) Replace if faulty.
11 Display showing ''FL- 1) Check discharge outlet line. 1) If outlet valve is closed, then
3'' indication. 2) NRV open it.
(This may happen 3) Discharge pump 2) Replace if found faulty
sometimes because 4) Float – 1 ,2 & 3. 3) Replace if faulty
of some variation in 4) Replace if faulty.
oil flow, since the oil ( check the continuity )
viscosity changes
1.Release Vacuum
by opening ball valve
for manual vacuum
release on
condensate pot.
2. Restart the
discharge pump in
manual mode. Reset
the FL-3 indication,
again put the
discharge pump in
auto mode. if
problem still occur
again follow the side
procedure )

12 Display showing It indicates to do the replace 1). press setting button & switch off
“serv” indication the vacuum pump oil after & on ELCB+MCB,
flushing.
13 Display showing “set” 1). Temperature sensor. 1). Replace if faulty.
indication.

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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 the irregularities in operation, any malfunction, failure of components etc. must be immediately
and properly recorded and intimated to the authorized personnel for any needed 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) Change oil after every 500 hours of operation.

c. The unit should achieve 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 condenser is of robust, maintenance-free design. It is a refrigerated type cooling unit, with its
own protection and hermetically sealed compressor. It is designed to handle large moisture removal
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 : 30-35 liters per minute average
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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: By heating oil sample on a spoon an audible crackling or popping and
momentary frothing will indicate that there is water in the oil.Refer to fig 20.1.

SPOON
N

Fig : 20.1 Crackling test

B.LABORATORY TEST: By Karl Fischer Titration Method.

C.MOISTURE SENSOR: ON-Line Moisture sensor can be fitted on discharge of fluid and supplied an
additional display unit, fitted on front panel of the unit.

Fig 20.2 MOISTURE SENSOR

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OPERATION MANUAL FOR CHILLER UNIT.

1.INTRODUCTION :

The water chiller comprises of four major parts- an evaporator, a condenser, a compressor and
metering system. The main function of a water chiller is to remove heat from the drink or from the
atmosphere in particular area and this it does by sucking up the heat by making use of refrigerant. This
refrigerant is a chemical having heat absorbent properties. The heat is then carried by the refrigerant to the
condenser from where it is released into the atmosphere in the form of vapor, air or water cooled heat
exchanger. Many times you can also see cooling towers in conjunction with the heat exchanger. These are
used in water chiller when the cooling need exceeds the normal limit. After the refrigerant has carried the
heat to the condenser it returns back in compressed form to extract more heat. This process helps in
regulation of large amount of heat thereby reducing the temperature.
2. PRINCIPLE OF WORKING :

Water Chiller manufactured by us simply works on the principle of Vapor Compression Refrigeration
Cycle. It is described briefly as below :-

The vapor-compression uses a circulating liquid refrigerant as the medium which absorbs and removes
heat from the space to be cooled and subsequently rejects that heat elsewhere. Figure 1 depicts a typical,
single-stage vapor-compression system. All such systems have four components: a compressor, a condenser
a Thermal expansion valve (also called a throttle valve), and an evaporator. Circulating refrigerant enters the
compressor in the thermodynamic state known as a saturated vapor and is compressed to a higher pressure,
resulting in a higher temperature as well. The hot, compressed vapor is then in the thermodynamic state
known as a superheated vapor and it is at a temperature and pressure at which it can be condensed with
typically available cooling water or cooling air. That hot vapor is routed through a condenser where it is cooled
and condensed into a liquid by flowing through a coil or tubes with cool water or cool air flowing across the coil
or tubes. This is where the circulating refrigerant rejects heat from the system and the rejected heat is carried
away by either the water or the air (whichever may be the case).
The condensed liquid refrigerant, in the thermodynamic state known as a saturated liquid, is next
routed through an expansion valve where it undergoes an abrupt reduction in pressure. That pressure
reduction results in the adiabatic flash evaporation of a part of the liquid refrigerant. The auto-refrigeration
effect of the adiabatic flash evaporation lowers the temperature of the liquid and vapor refrigerant mixture to
where it is colder than the temperature of the enclosed space to be refrigerated.
The cold mixture is then routed through the coil or tubes in the evaporator. A fan circulates the warm
air in the enclosed space across the coil or tubes carrying the cold refrigerant liquid and vapor mixture. That
warm air evaporates the liquid part of the cold refrigerant mixture. At the same time, the circulating air is
cooled and thus lowers the temperature of the enclosed space to the desired temperature. The evaporator is
where the circulating refrigerant absorbs and removes heat which is subsequently rejected in the condenser
and transferred elsewhere by the water or air used in the condenser. To complete the refrigeration cycle, the
refrigerant vapor from the evaporator is again a saturated vapor and is routed back into the compressor.
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3. SPECIFICATIONS OF SYSTEM :-

MODEL NWC 1000

TYPE AIR COOLED

DIMENSION OF UNIT L 660 X W 400 X H 730 MM

CAPACITY 1000 WATTS

MEDIUM TO BE COOLED Water

TEMPERATURE CONTROLLER SETTING 15 Deg Cent

SUPPLY VOLTAGE 3 Ph, 415V, 50 Hz.

CONTROL VOLTAGE 230 volt

GAS (REFRIGERANT) / Qty R-134a / 600 gms

ELECTRICAL CIRCUIT DIAGRAM NUMBER NCS/ELECT/11/10/11

PIPING CONNECTION:-

STEAM INLET 3/4 ” BSP

STEAM OUTLET 3/4 ” BSP

WATER DRAIN ½ ” BSP

4. GENERAL CAUTIONS:
DURING INSTALLATION:

Install the Water Chilling Unit in the following locations:

1. On a solid, level floor.
2. Away from direct sunlight and heat.
3. Where there is good ventilation and little humidity.
4. Where the discharged air will not be drawn in again.
5. A place convenient for piping and wiring.
6. Where there is little dust, dirt, powder, oil, mist etc.

Leave the proper amount of service space. So the suction from the front and discharge from the top will
proceed smoothly and so that maintenance and inspection are simplified.

Range of use : The Water Chilling Unit has limits regarding to room temp 35 deg cent and water
temperature 40 deg cent.

This Water Chilling Unit can not be used for following types of fluid because it is
designed to cool water unless otherwise specified.
a) Fire-resistant hydraulic oil, hydraulic oils of phosphoric ester, hydrocarbon oils, glycol hydraulic oils and
straight cutting oils.
b) Liquid chemicals and foods.
c) Acetic water.
Do not disturb the setting of temperature controller.
Do not disturb H.P. & L.P. setting

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WATER TANK:

Be careful with the partitions, piping layout etc. in the tank so that the hot water
Returning from the machine is uniformly mixed with the cool water of the Water
Chilling Unit. Further , keep the lowest water level inside water tank over the
Water outlet in order to prevent air mixing with the water.

ELECTRICAL WIRING :
Connect the wiring as per circuit diagram and ensure that all the motors are rotating in the marked direction.

5. GENERAL OPERATING PROCEDURE OF WATER CHILLER

a) HOW TO START WATER CHILLING UNIT:

Fill the water tank up to max level.

2. Connect electrical supply. (Check incoming voltage 1 Ph, 230 Volt, 50 hz )
3. Connect steam process line connection.
4. Make the main MCB for power ‘ON’ at inside electrical panel.
5. Check the incoming power supply on electrical control panel
6. After starting of selector switch, compressor will start automatically after on delay timer of
three minutes.
7. Monitor the temperature on temperature controller.
8. Check the Suction pressure on gauge it required 35 to 50 psig & Standing Pressure
( When Compressor is Off ) – 90 to 110 psig
7.STANDARD SETTING

SR NO DESRIPTION OF COMPONENT SETTING

01 LP Switch 30 PSIG
Diff :- 15 PSIG

02 HP Switch 300 PSIG

02 Temp Controller 15 Deg Cent (Pl ref Appx A)

04 Suction Pressure 35 to 50 PSIG

05 Discharge Pressure Below 250 PSIG

06 Standing Pressure 90 to 110 PSIG

Temp Controller Ideal Setting :-

SUBZERO (EF-7510P) Appx ‘A’
Para. Description Setting

Set Temp 15
P1 To set Heating or Cooling function. 0
P2 Max High Temp limit & alarm 50
P3 Min Low Temp limit & alarm 10
P4 To set Differential Temp ( Hysterics) 2
P5 Probe calibration 0
P6 Time Delay (relay restart after cutoff) 03

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MESSAGE DESCRIPTION :-
SUBZERO (EF-7510P) Appx ‘B’
Message Description

Ht Temperature above the maximum limit of the set point.

Lt Temperature below the minimum limit of the set point.

PP Probe short circuit, circuit open or without probe.

On/Off Comp. Relay on/off

On/Off Keyboard locked/unlocked

Flashing Time delay in progress

8. CAUTIONS DURING OPERATION :

1) Never run without water in the tank .

2) There is a built- in delay timer and Water Chilling Unit will not start again immediately after it has been
tripped. This is normal and does not indicate any problem with cooling unit.

3) The Water Chilling Unit should not be used to start cooling when the water temperature is high more than
50 deg cent. Start the cooling unit simultaneously with the machine and control water temperature
automatically with temperature controller. If the coolingunit is started when the water temperature is high, built
in relay compressor is activated to stop operation.

4) The temperature controller adjusts water temperature at the cooling unit inlet.

9. MAINTENANCE INSTRUCTIONS :

In the interest of safety, turn off the operation switch and the main power source when doing any checking or
servicing.

COOLING UNIT CABINET:

1. Wipe the cabinet surface with a dry cloth. If it is very dirty, use a quality soap or Neutral detergent. Do not
spray water directly on the cabinet.
2. Do not use a brush, polishing powder, acid or solvents such as benzene, hot water etc. because they will
damage the paint.

WATER TANK:
Keep the water mixed with coolant inside the water tank at the proper level to prevent sucking in of air etc.
Always keep the water in the tank clean.

CONDENSER CLEANING :

If the Air cooled Chilling Unit is operated without the cleaning of condenser, the the dirt , dist & oily
particles will accumulate in between the gaps of condenser fins & affect on the condensation of refrigerant
causing a breakdown in terms of high pressure. In order to avoid such type of breakdown, periodically clean
the condenser by cleaning blower.

FOR A PROLONGED LAYOFF:

1. Be careful that dust, dirt, water etc do not get into the interior of the Water Chilling Unit.
2. Turn off the operation switch and main power.
3. Be careful that water dust and dirt do not build up on the surface of the Water Chilling Unit.

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10. BILL OF MATERIAL:

REFRIGERATION CIRCUIT:

1 COMPRESSOR Qty -01 Make Emerson

Model KCE 444 HAG

1 Ph, 230V, 50 Hz
2 Condenser Coil Qty-01 Make BRAC
Model Fins Type

3 Filter Drier Qty-01 Make Dry All

Model EK 30 5S
4 Expansion Device Qty-01 Make Capillary Tube

5 Cooling Coil Qty-01 Make BRAC

Copper Tube Submerge Type
6 Water Tank Qty-01 Make Sharda S S

7 Level Gauge Qty-01 Make ‘ S’ Instuments

8 Hand Valve Qty-06 Make Castle

Model 1/4”
9 Suction Pressure Qty-01 Make Wika
Gauge
Model -30 to 300 PSIG
10 Drain Valve Qty-01 Make Hi-Tech

Model ½ “ BSP

ELECTRICAL CIRCUIT

Sr. Description Make & Model Qty

No.
1) MCB 1 PN 06 AMPS (For Control) SIEMENS (C6) 1 NO
230/415 V,50 HZ
2) TEMP CONTROLLER SUBZERO (EF-7569 P) 1 NO
08 AMPS
3) LP/HP SWITCH Danfoss 1 NO
15 – 100 PSIG LP
90 – 450 PSIG HP
4) Condenser Fan BRAC (8” Axial) 1 NO
2850 RPM, 220/240V AC

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