Operation Manual Elc 100lp PLC With Ms6 Dhu

OWNERS MANUAL Page 1 of 27
OPERATION
MANUAL
ELECTROSTATIC LIQUID CLEANER (ELC)
ELC 100LP MS6 DHU
FERROCARE MACHINES PVT LTD

S.N.32/3/8, YEWLEWADI ROAD,
BEHIND ANGRAJ HOTEL, KONDHWA BUDRUKH
PUNE-411048, MAHRASHTRA
Ph. +91-9607974281/82/83
Email :- [email protected] http:// www.ferrocare.com
Helping you …... work better ….. under pressure

FERROCARE MACHINES PVT.LTD. - INDIA
CONTENTS
Sr . No CONTENTS Page No
About this manual 3

1. Introduction 4
2. Principle of Operation 5
3. Operating Conditions 5
4. Model Selection Guide 6
5. Application 6
6. Safety Instructions 7
7. Specifications of ELC Unit 9
8. Construction 9
9. Installation Procedures 10
10. Operation Procedures 11
11. Drain Discharge 12
12. Draining/Removing Cleaned Oil from the Cleaning Tank 12
13. Temporary Stoppage 13
14. Stoppage of High Voltage 13
15. Life of Collectors 14
16. Replacement of Collectors 14
17. Warranty 14
18. Control panel 15
19. DIGITAL mA/KV METER WITH RUNNING HOURS 16
19.b. Parameter setting for DI meter 17
20. Fault Annunciations 18
21. Standard Spares Supplied with Machine 19
22. Trouble Shooting 20
23. MS6 operation 23
24. Appendix – B (CKT Diagram of ELC Unit)

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

“ELECTROSTATIC LIQUID CLEANER MACHINES (ELC)”
1.0. INTRODUCTION
Thank you for purchasing the “Electrostatic Liquid Cleaner Machine “ (ELC). 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.

2.0. PRINCIPLE OF OPERATION :
Electrostatic Liquid Cleaner (ELC) machine is a mobile compact unit used for removing solid
suspended particulate contamination from hydraulic/Lubricating oils upto a level of 1 micron and
below.
The ELC system uses the principle of electrostatics to collect fluid contaminants.
FERROCARE ELC's unique design permits it to take advantage of the natural charge of each
contaminant.
Oil is made to pass through an electric field.

Contaminants that have a positive charge are drawn towards the negative electrode plate and
those with a negative charge are drawn towards the positive plate. During their movement to the
opposite electrodes the contaminants are trapped on the collector papers inserted between the
electrodes.
Neutral contaminants are drawn and deposited by gradient force to the edge of the collectors where
the intensity of the deformed electric field is the strongest.
As the fluid flows freely through the system, the ELC removes contaminants - submicronic particles
even smaller than 1 micron, dust, dirt and products of oxidation such as tars or sludge and
varnishes. Contaminants are trapped on cellulose collectors for easy disposal.
The ELC does not affect soluble additives.
3.0. OPERATING CONDITIONS :
Suitable for filtration of mineral based hydraulic and lubricating oils

Allowable moisture content in oil below 500 ppm
Maximum temperature : 600 C
Standard power source : 415 V / 3-Phase / 50 Hz

4.0. MODEL SELECTION GUIDE
The selection of Electrostatic Liquid cleaner machine model is based

a) Total oil quantity available to be maintained super clean
b) Viscosity of oil to be filtered
c) Cleanliness level of the oil to be maintained
CONVENTIONAL HYDRAULICS ( MAX. QUANTITY)

ISO VG 32 CST 46 CST 68 CST 100 CST
MODEL
ELC 8LP 2500 1700 1100 600
ELC 25A 6000 4200 2800 1500
ELC 50C 12000 8300 5600 3000
ELC 100LP 30000 20000 14000 7600
NOTE :
FOR OIL CLEANLINESS REQUIREMENT OF NAS 7 AND BETTER DERATE THE ABOVE MAX
QUANTITY BY 50%
5.0. APPLICATION
The Electrostatic Liquid Cleaner "ELC" unit can be used for cleaning hydraulic and lubricating
oils of the following general specifications.
Temperature - below 60˚C and Moisture - below 500 ppm
The ELC unit cannot be used for cleaning of:
a) Oils with moisture in excess of 500 ppm
b) Oils with detergent dispersant additives
c) Conductive oils
NOTE:
Suitable models are available for high temperature applications. Separate models are available for
synthetic oils and fire resistant fluids.
Separate models available for Flame / Explosion proof requirements.

6.0. SAFETY INSTRUCTIONS
CAUTION
a) ELC is a high voltage electric equipment and special attention should be paid to its
operation.
b) In no event should the electric panel of the ELC be opened without and before turning off all
Electric switches. It is strongly advised that only qualified electrical engineers check or
Touch electric parts.
c) All machines have earth connections ending at the Supply plug. Please make sure that your
plug in socket has proper earthing. Earthing is an essential safety feature.
CAUTION
d) When the ELC is hooked up as shown in fig 1 it is especially requested to pay attention to
valve operation. Please ensure valves (5.1 / 5.3, 5.2, 5.4, 5.5, 5.6, 5.7 & 5.8) are open before
operation.
e) If the pump is operated at the "normal" position with the valves shut , the high pressure will
built up in the ELC will damage the equipment
f) If the pump is operated at the 'reverse' position with the valves shut , the pressure will damage the
pump oil seal resulting in oil leakage
FIG 2
CAUTION
f) High voltage intake probe is made of PVC (Ref fig 2). Please tighten carefully. Do not keep the
HV probe loose.

If the unit falls during transportation or moving may cause serious accident. Do not go near a load
that is being lifted.
There is possibility that unit may catch fire. Do not install the unit near fire or other potentially
explosive atmosphere.
Breakage of pipe may cause oil to flow out. Consider this & other factors when selecting pipe material
during installation.
To prevent electric shock machines must be properly grounded.
Be sure to turn off the power to the unit before servicing or inspection.
7.0. SPECIFICATIONS: ELC- 100 LP +MS6+DHU
Power Source 415V, 3 - Phase 50Hz
Specifications ELC 100LP

Dimensions (Approx) (L) 1400 mm
(W) 1400 mm
(H) 1000 mm
Weight (Approx) 300 kgs.
Collector (pcs/set) 16
Heater Capacity (Kw) 6
Power consumption 750 watts
InletPump Capacity ( LPM)/ Hp 20 / 0.75
In Put Supply 3 Phase / 415v / 50Hz
Inlet / Outlet Connection ¾ “ BSP end fittings
Finish Powder coat
8.0. CONSTRUCTION:
A) The ELC consists of the electrical panel (A) and the condenser unit (B). The latter works as the
Cleaning Cell of the ELC unit.
B) The shell (cleaning tank) is MS fabricated and designed to withstand 1.5 kg/cm2, operating
pressure.
C) The heating chamber is MS fabricated with 2nos. heaters to withstand 1.5kg/cm sq., operating
pressure.
D) The MS6 unit is SS fabricated with 6 nos. high power magnetic candles to withstand 1.5kg/cm sq.,
operating pressure.
E) The depth filters protect heavier particles to enter to ELC machine and absorb some amount of
moisture content.

The total head of oil between the oil reservoir to be cleaned and the ELC 100LP unit should not
exceed 5 meters.
9.0. PROCEDURE AND FLOW CHART FOR INSTALLATION
 Inlet to the unit should be connected from the bottom of the oil tank
 Outlet from the unit to be given from the top of the oil tank
 Ensure that a valve is provided at the inlet point of the unit, so as to isolate the inlet flow during
shut down or servicing of unit.
 Check the pump rotation direction before starting the unit.
 Ensure that inlet valves are opened when ELC with MS6 & DH machine is put in to operation.
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.
WARNING Make sure that the unit or parent equipment should be properly grounded .
Connect the equipment to 3 phase power supply. 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.

10.0 OPERATION PROCEDURE (Refer Fig. 1 , 2 ,3 & 4)
1. Confirm that the oil temperature, moisture content are

within limits specified for the machine, i.e., below 90˚ C,
500ppm.
2. Check the power switch (ELCB +MCB) of the ELC is off.
3.Place the covers on the electrode plates and collectors in

between the electrodes. Refer Fig.2, and fasten the cleaning
tank cover evenly.
4. Connect hose (with Y-type strainer) to the pump suction

joint (C fig 3) and insert the other end of the hose into the
reservoir of oil to be cleaned.
4. Shut the drain valve and open the sample cock to release
air from the tank.
5. Ensure that the pump is filled with oil and suction line is
fully immersed in oil.
6.Check that the suction and discharge hoses are

connected at both ends.
7. Open flow control valve in line after the pump.
8. Switch on the ELCB and pump switch to normal mode .

Confirm pump suction in normal position. The power and
pump lamps will switch on, The H.V. lamp will remain off at
this stage, even though it has been switched on.
Close Sample Cock .
FIG 3 9) Switch on the high voltage switch to 'Hi' position

10) The pump will automatically switch off when the cleaning
cell tank is filled with oil. The high voltage lamp will then
switch ON after 10 minutes time delay. The pump will
automatically re-start after the preset interval.
(The machine has on delay timer which switches off the
pump for a set delay period every time there is a power
failure or shutdown). This ensures that in case of an
unplanned shutdown, the contaminants deposited on the
collectors, which may have been dislodged into the oil in the
ELC Tank, are re deposited on the collectors, before the oil
flow is re-started.
12) Switch ON heater switch and set the desired
temperature.

11.0. DRAIN DlSCHARGE : When the ELC is continuously operated for a long time, it is advisable to
drain about 1 litre of the oil from the drain valve at an interval of 1500 hours. This ensures
discharge of heavy contaminants from the drain.
12.0. DRAINING / REMOVING CLEANED OIL FROM THE CLEANING TANK

Procedure for discharge of cleaned oil from the ELC machine:
a) Put plastic oil pan under the Y-type strainer of suction hose.
b) Set pump switch to 'off'.
c) Unscrew the cap of Y-type strainer, remove wire mesh and clean.
d) Re-place wire mesh after cleaning and re-tighten cap of strainer. This will prevent
back flushing of dirt from strainer
e) Open air cock on the top cover of the cleaning tank. Alternatively, connect discharge hose
to pump suction .
f) Set the pump switch to reverse. The cleaned oil will be pumped back to the oil tank
(reservoir) of the hydraulic machinery.
PRECAUTION: Care has to be taken to ensure that the pump is switched off as soon as
dirty /contaminated oil starts flowing out of the machine. Do not drain for more than 3 minutes.
g) After pumping out the cleaned oil, switch off power and discharge oil from the drain into the
oil pan.
NOTE: Do not perform this operation if oil of NAS grade 7 or ISO Code 16/13 purity and
better, is required.

13.0. TEMPORARY STOPPAGE
a) If the ELC has to be temporarily stopped,
1) Switch off pump
2) Switch off high voltage - it is important to switch off high voltage after switching off the
pump, or contaminants will be discharged into system.
3) Switch off ELCB
b) To restart,
1) Switch on ELCB
2) Switch on high voltage - before switching on pump, or contaminants will be discharged
into the system.
3) Switch on pump .The pump will restart automatically after the set interval. Refer para 6(l)
14.0. STOPPAGE OF HIGH VOLTAGE

a) When electric current exceeds 5mA for ELC 8 LP / 25 A or 10mA for 50 C / 100 LP in the
condensor (cleaning tank), the high voltage and pump lights will be automatically turned off
and the warning red/alarm light will come on.
b) When the alarm lamp is lit, turn off pump and high voltage switch. This switches off the alarm light.
c) Switch on the high-voltage. If the high voltage system trips immediately with HOL or LOL indication
- replace collectors.
NOTE: If the HVT trips with H-oL or L – oL indication within 5 hours of operation with new collectors:
1) Check for water or moisture in the oil
WARNING:
When restarting the ELC unit, follow the procedure described in para 9
Temporary Stoppage
.
2) Metallic sludge on electrode holder (Discharge all oil and empty the condenser (cleaning cell).
Remove electrodes and wipe off the surface of electrodes (I) and (J) and the edges of the
electrode holder.
If the cause of stoppage is due to metallic sludge, this cleaning Procedure will eliminate the
problem).

15.0. LIFE OF COLLECTORS
The life of collectors depends on the contamination level in the oil.
If contamination level is 7 to 10 mg/100 ml., a new collector set can clean about 5,000 liters
(ELC-100LP) of oil. The average life of a collector is 1,000 hours.
A rough indication of collector life is as follows: continuous patch test to be taken every week.
** Life of collector depending on contamination level in oil.
16.0 REPLACEMENT OF COLLECTORS (Refer Fig. 5)
FIG . 6
Unscrew all bolts of the condensor (cleaning tank) cover and remove the contaminated corrugated
type collectors (H) (dielectric media), and electrode covers. At this time, make sure to clean
electrodes before replacing with new collectors.
17.0. WARRANTY
a) The manufacturer shall repair all defects, except consumable parts for a period of 12 months from
the date of shipment. in any event, the manufacturer shall not be responsible for any and all damage
or failure due to incorrect operation, malpractice, mishandling and negligence.
b) In the event that the user finds any defect in the ELC, the user shall advise the details of such
defect in writing to the manufacturer. The manufacturer shall correct such defects promptly. The
manufacturer reserves the right to make final judgment on claims made by the user.
c) In no event shall the manufacturer be liable for any and all consequential loss, damage or
expenses howsoever arising from all claims upon and all liability of the manufacturer.

18.0. CONTROL PANEL

ELC 100LP
1) Power Lamp
2) Pump Lamp (Nor)
3) Pump Lamp (Rev)
4) Digital Indicator Circuit Board
5) Input Transformer for Digital Meter
6) H.V. Switch
7) Pump Switch
8) Fuse-F1
9) Delay Timer
10) MR2-Contactor Alarm Relay
11) MR1-Contactor Float Relay for Hi & low volt
12) MS1-Contactor for Forward mode
13) MS2-Contactor for Rev mode
14) Over Load Relay for Forward & Rev mode
15) Fuse-F2 for Hi-volt
16) Connector

19.014.0. CONTROL AND ANNUNCIATION FUNCTIONS
FIG .7
The panel displayed indicates that High Voltage is 10.6 kV and that machine is running with pump
in forward mode for ELC 100LP .
For 100LP - indicator for HV-1

1 is green and display is V for Voltage. The 100LP machine uses
TWO High Voltage transformers, hence the LEDs are divided as HV HV-1 and HV-2.
2.
For other ELCs - Indicator for milliamps is green and current is 0.6 mA. Since the machines have
only one transformer, the LED lights are separate for mAand kV.
The Pump Switch LED is ON, meaning pump is running forward.
The display will scroll across four parameters, namely, mA, kV (milliampere current and Voltage
across the electrodes),
lectrodes), temperature and running hours in sequence. Each parameter will be
displayed for the duration set in Scroll Time setting
15.0 PROCESSOR OPERATION & PASSWORD FOR CHANGING THE SETTINGS.
The parameter settings are password protected. To access to the program through password follow
the procedure as given below.
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”

Once the display shows press o enter the processor programming.
With this password, the parameters can now be displayed and changed, pump can be set to manual,
and 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.
Caution – Do not change factory settings; use this only for scroll time setting. DO NOT change any of
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.
20.0. PARAMETER SETTINGS FOR MICROPROCESSOR :
Followings parameters can be set and displayed in the microprocessor.
1. Set Current: 2 to 10 mA/for 100LP

This is the set current across the electrodes. This setting is
required to protect the heart of the machine viz.,High Voltage
Transformer.
If the current increases here is conduction across the
electrodes i.e., they are getting "shorted" or a short circuit path
Set current : 10.0 mA is available which would overload the transformer
(2 to 12 mA ) The HVT is therefore protected by setting it to trip at this "set
current" which can be varied from 2 to10mA
The current across the electrodes can increase if water is

mixed in the oil or it contains excessive metal particles
2. Set Temperature:
This setting is for the temperature of oil passing through the
ELC. Insulators in the ELC are made of PVC and cannot
withstand sustained high temperatures.
The SET temperature between 30 and 60 degrees, is selected
to trip the pump if hot oil is passing through the unit.
Set Temp : 60ºC Temperatures above 600 C are harmful to the oil as well as
(30 to 65º C) the ELC.
Note: All units are not equipped with oil temperature sensor.
3. L. V. Setting:
This is the setting for the Low Voltage operation of the ELC.
This sets the tripping current for the transformer when ELC is
operating on low voltage of 5 KV.
In the particular case above, the ELC will trip at 2 mA for 25 A/
8LP and 5mA for 50C/100 LP.
LV Setting :05 This setting ensures safety of the transformer.

4. L.V. Skip:
This sets the "Low" mode of the HVT.
If this parameter is set to "n" the transformer will change to
"Low" mode after the current set for Hi mode i.e., 10 mA is
exceeded (with a delay of 1 sec.)
If the current exceeds the "Low" (5 mA) also, the machine will
trip.
If this parameter is set to "y", the machine will trip directly

when "High" current is exceeded.
5. Scroll time parameter:
The display scrolls across parameters i.e., it displays 4 set

parameters one by one. It will display, turn by turn mA, kV,
temp., and running hours.
In this case each parameter will be displayed for 3 seconds,
and then the next one will be displayed. If the scroll time is set
Scroll Time 03 to zero, then the selected parameter will not be continuously
(0 – 10) displayed. Other parameters will have to be manually selected
for display using the "SETTING" button.
6. Service life setting:
The collectors which hold contaminants removed from oil

being cleaned, have a specific service life. This means that
the collectors should be changed after a specified running
hours. Each unit
SErv - Service on this setting is 250 hours.When the set running hours are
If Op. Hrs = 1,then 250 Hrs completed the unit will display "SErv", meaning that the
Controller Trip on “SERV” service life is completed. The collectors should be removed,
Recommended Settings: examined, and if necessary replaced
50C …………… 06 Hrs (Service life is 1000 hrs. for 25A, 1500 hrs. for 50C & 2000
100LP…………..06 Hrs. hrs. for 100LP)
25A ………. 05 hrs
8 LP ………. 03 hrs
The setting is based on a unit of 250 hours. Therefore H006

as shown above means 1500 hours service life. H004 means
1000 hours & H008 means 2000 hours. Setable parameters
should not be disturbed from the factory setting except when
necessary and by people trained for instrument calibration.

7. Auto Restart Pump:
If the pump trips on overload, "P_ol ", it can be restarted

automatically if " Ar" is set to "Y".
21.0. ERROR DISPLAYS OR ANNUNCIATION:
1.0 LIMIT SWITCH – LS
This error display means that the ELC tank cover is open.
When properly secured the cover operates a limit switch and
switches off this error message
Trouble Shooting:
LS – Limit Switch  Put back the top cover, if not in place and tighten all the
bolts securely.
 Check that the limit switch is OK.
2 . FLOAT SWITCH – FS There is a float switch which does not allow the electrodes to
be charged, If not totally immersed in oil. When the float
switch is activated, the motor will trip for a five minute interval
and restart. It will now run continuously. This interruption is
provided so that contaminants from previous operation do not
FS – Float Switch flow out with the new oil, and are redeposited on the
collectors. if the pump does not start, or the float switch is
faulty, then also this error signal will appear. This error means
that there is insufficient oil in the tank. One reason is that oil is
not available to the pump. This alarm will come due to
Hi-volt fuse blown out.
Trouble Shooting:-
 Check that the oil pump is running.
 Check if oil is available and the suction hose is
properly immersed in the oil.
 Check "Y strainer" to ensure there is no blockage.
 Check float switch operation manually.
3 .PUMP OVER LOAD – POL

This indicates that overload relay of the pump motor has
operated. The preset here is Auto. The pump will start
automatically on cooling. Manual setting is possible.
Trouble Shooting:
POL – Pump over load  Check that there is no obstruction to the discharge.
 Check the pump / motor are aligned and secured to the
foundation.
 Check the pump motor windings electrically.
 Check capacitor leakage overload relay tripped and
contactors.

4 .CURRENT OVER LOAD IN HI MODE – H-oL
This indicates that the tripping current of the HVT is reached

in "Hi" mode.
Trouble Shooting:
 Check whether there is moisture in the oil.
H-ol – Current Over Load In  Check if oil contains an excess of metal particles
“Hi” mode If low mode ( Lt ) is "y" the machine will now switch to
low and if the current exceeds even the low setting
the machine will trip.
5 .CURRENT OVERLOAD IN LOW MODE – L-OL
This indicates that the tripping current of the HVT is reached in

"Lo" mode.
Trouble Shooting:-
L-ol – Current Over Load In  Check whether there is moisture in the oil.
“Lo” mode  Check if oil contains an excess of metal particles.
6 .TEMPERATURE OVER LOAD - OT
Temperature overload : This indicates that the temperature of

the oil flowing through the machine is too high and the
machine will stop.
Ot – Temp Over Load Trouble Shooting:-

 Check the setting is not too low; it should be 60 deg C
 Check the oil cooler in the equipment.
 Heavy moisture in oil.
7 .DIFFERENTIAL PRESSURE TRIP – dPt
Machine is equipped with an additional "DH" filter attachment

for special applications, where sometimes small quantities of
moisture may be detected in the oil. The "DH" filter attachment
has a pressure switch, set at a differential pressure ∆p of 1.5
kg/cm . When the DP switch trips, the processor will stop and
show this display - (Differential Pressure Trip)
Trouble Shooting:
 Switch off the machine and change the filter element. If
on restarting, the pressure again rises immediately,
check that the outlet flow is not blocked.
22.0. STANDARD SPARES SUPPLIED WITH MACHINE

a) Collectors .........................................Two sets

b) Suction Hose ....................................1 No. 5 meters with Y Strainer
c) Delivery Hose .................................. 1 No. 5 meters
d) Rings Spanner for Top Cover ...........1 No.
e) 'O' Ring for top cover ........................1 pc
f) 'O' Ring for PVC Probe..................... 1 pc.
g) Gasket for PVC Probe....................... 1 No.

23. ELECTRIC ClRCUIT

24.0. TROUBLE SHOOTING
22.1. PUMP TROUBLE
a) Pump Cavitation:
1) If the pump is excessively noisy, check flow control valve (F) (refer Fig.3) in line after
pump is fully open.
2) If noise persists, overhaul Y-type strainer and clean if necessary.
b) Check Electric Fuse: Replace the fuse if necessary. Fuse holder is located on the front
switch board panel. Use correct rating fuse. Refer CKT diagram attached.
c) Overload Relay (OLR):

The OLR relay is preset on Auto. In case of overload, the relay will re-set automatically on cooling.
The OLR also has a manual function which may be used at the users' discretion .If the pump does
not run
after resetting the breaker (overhaul and clean the rotor and roller of the pump) check the pump for
clogging,
or alignment for coupled pumps.
The motor may be faulty.
S. No PROBLEM CHECK SOLUTION

1 ELCB+ MCB is on but 1) output supply from elcb+mcb 1) Replace if faulty.
Power light off 2) Power supply. 2) Switch on power supply.
3) fuse no. 1 3) Replace if fused.
4) Indicating socket & bulb. 4) Replace if faulty.
5) Lvt output supply. 5) replace if faulty
2 2 elcb + mcb trips 1) elcb+mcb 1) Replace if faulty
Immediately 2) motor connection and 2) Rectify if faulty.
Windings. 3) Replace if faulty.
3) l. V. Transformer primary 4) Replace if faulty.
Winding short & grounded. 5) Replace if faulty.
4) Motor capacitors leakage.
5) ms1, ms2, orl power contact
3 Elcb + mcb not Short circuit. 1) Replace if faulty.
1) push the test elcb + mcb
4 Tripping 1) Thermal overload relay. Short circuit.
Motor does not 2) selector switch element & 1) Push reset and turns to auto.
Operate Contactor coil. 2) Replace if faulty.
3) centrifugal switch of motor 3) Replace if faulty.
4) loose contact from power 4) Correct.
Supply line. 5) ensure input power supply
5) Input supply. 6) Replace / repair.
6) Pump jam. 7) Replace motor.
7) Motor connection & winding.
5 Excessive pump noise 1) Flow control valve. 1) Open valve.
2) Motor pump alignment. 2) Readjust.

3) Suction strainer. 3) Clean.
6 Pump does not 1) Pump suction by placing 1)if suction is good, check
Draw oil hand on suction port. Suction hose is immersed in oil
2) if no pump suction 2)clean strainer
3) Oil seal. 3) replace if leaky
4) prime some oil into suction
4) others 5) open valve
LINE 5) flow control valve
8 Oil leakage from 1) Check ‘o’ ring. 1) Replace if necessary.
Hose coupling
In / out
9 Motor trips 1) Thermal overload relay. 1) Set current setting.
Frequently when 2) Y - strainer. 2) Open & clean mesh.
Machine is in 3) Motor pump alignment. 3) Re-adjust.
Operation 4) Motor winding weak. 4) Replace motor.
5) low volt and over volt (voltage 5) Ensure power supply.
Fluctuation)
10 H.v. lamp and 1) Float switch. 1) Replace if faulty.
H.v.t. do not 2) Limit switch. 2) ensure operation ‘no’ to ‘nc’.
Switch ‘on’ 3) Mr1 contactor coil. 3) Replace if faulty.
But motor ‘on’ 4) selector switch contact 4) replace if faulty
elements 5) ensure phase sequence
5) motor direction
11 Hv volt ‘on’ 1) Timer coil open. 1) Replace.
But motor off 2) Timer contact ‘no’. 2) Change the spare contact.
12 Fuse - 1 blows 1) Lvt secondary winding short. 1) Replace.
Repeatedly 2) Mr1 contactor coil short. 2) Replace if faulty.
3) ms1 / ms2 contactor coil 3) Replace if faulty.
Short. 4) replace if necessary
4) timer coil
13 Fuse 2 to h.v.t 1) Timer coil short. 1) Replace if faulty.
Blows 2) Hour meter coil short. 2) Replace if faulty.
Repeatedly 3) open top cover and check if 3) ensure electrodes are
Ss electrodes are correctly Installed in the Slots provided.
Installed in the slot. 4) Replace collector.
4) High moisture.
14 Mr3 relay not tripping Call for service.
meter reading 11 to 25
ma
15 Mr3 relay of 25 a / Call for service.
8 lp not tripping
Meter reading 5 ma
16 Hv trips and alarm 1) check oil for moisture 1) If yes, change oil or
Comes on although Using checking kit. dehydrate using LV. machine
Collector is 2) check collector for 2) collectors are wet,
Replaced Moisture. Replace with dry collectors.
3) If the oil is conductive. 3) Elc not recommended.
4) the oil temperature is higher 4) oil temperature should not
0than 60 c. 0exceed 60 c.
5) f1, f2, f3 are ok, but tripping 5) replace if deformed or
Continues. Cracked.
Check insulation plate / probe. 6) ensure proper placement
6) s.s plate not installed
Properly in the slot
17 Hv lamp is on and 1) The oil has high detergents 1) It takes about 10 times
The ma / kv meter (hlpp). longer to clean than ordinary
Reading is below 5 ma. 2) Contamination ingression rate oil.
Oil is not being is high (if the contamination 2) Use larger elc.
Cleaned. level after one year use is over
10 mg/100 ml).
18 Digital display 1) Check if machine has tripped 1) if the machine is working
Is blank for any reason. normally, and display is blank
The display circuit is not
2)elc tank is empty Getting supply from its
3) hi-volt fuse Transformer. Red - Yellow-Red
Wires at left hand corner
Coming to display circuit Board
from the transformer Should
show (13v-0-13v - ac).
2) Ensure oil is filled up in tank
3) If blown, replace.
19 Display shows odd The display is to be reset -
Characters press the para button and while
keeping It pressed, switch the
Machine "off" and "on".
The display will return to
Normal.

MAINTENANCE OF MS6 MAGNET STRAINER:-
Some of the lubricating oil systems , such as a gear box lubrication need only ‘targeted’ cleaning,
because contaminants in the oil are quite specific, also the need is to remove specific size of
contamination, not all sizes.
The main types of contamination encountered are ferrous wear particles and small amount of dust
and traces of water. Ferrous particles along with moisture can result in increase in the TAN number of
the lubricating oil causing ‘Gear Pitting’ problems. It is therefore necessary to remove the ferrous
particles from the oil up to a fine level to ensure proper cleanliness level of oil thereby improving the
efficiency of the system in totality.
Ferrocare Machines Pvt. Ltd. Has introduced its new ranges of Combines MS6 + . unit trolley to take
care of these special requirements for the lubricating oils.
We already have a depth type coalescer filter for removal of moisture and particles up to 25 microns,
which is sufficient for gear box. Magnetic Strainer MS6 is coupled with this depth type filter. These two
units are available on a single trolley to remove wear particles, dust and moisture from the lubricating
oils
Combined M6
The magnet strainer unit MS6 has been specially constructed with superior materials, for applications
where fluids pick up magnetic particles in small quantities. This is most suitable for
1. Cleaning fluids.
2. Run in oils.
3. Low volume machines for finishing small components.
Magnet Strainer M6:-
The unit can hold a lot of contamination. It has high power magnets spaced closely to trap all the
contaminants in the flow. The cleaning interval should be about once a week.
Ferrocare has thus used a combination of sensible and simple technology to enhance the critical
features of both processes to provide maximum value benefit to the customer.

2.0. TECHNICAL SPECIFICATIONS
CONSTRUCTION:
Magnet Strainer:-
1. All SS Construction.
2. Six magnet candles 25 x 500 mm.
3. Overall dimension 200mm dia x 650mm height.
4. Removable Top.
5. Removable Cap for Magnet withdrawal.
6. 3/4” inlet (bottom) and 1” outlet.
7. Drain 3/8”.
8. Interconnecting R1 rubber hose with end fittings.
3.0. SAFETY INSTRUCTIONS
IMPORTANT – notes on High Powered Magnets:-
1. When working on the magnetic separator, electronic wrist watches should be removed.
2. Electronically sensitive objects such as meters, calculators, cards with electronically
readable strips, pens etc., should not be brought with in 300 mm of the magnet.
3. Persons with pacemakers are advised not to venture close to the magnet.
4. Persons wearing magnetic bands, steel kadas, should remove them when working with the
Magnetic Separator.
5. Magnet should be handled carefully. These are powerful cartridges, which are difficult
to pull apart.
4.0. Operation:-
1. The top cover (toggle clamps s) should be properly secured.

2. The unit would have to be vented initially.
3. Run the unit in a fluid stream. It is suitable for use up to 20 LPM and 2 bar pressure.
For Cleaning:-
1. Drain the unit by opening drain.

2. Remove the top cover.
3. Remove the magnet carrier assembly, and put it in a bucket of cleaning fluid (Diesel,
Kerosene).
Note:
Do not use the MAC filter element when the system is used with water based coolants.

4. Remove the magnets one by one, and place them gently on a flat surface (not a steel table)
with a small wooden or non ferrous block between 2 magnets to ensure they do not stick to
each other.
5. Rinse the now empty carrier assembly and wipe dry with lint free cloth.
6. Replace the carrier assembly in the housing without magnets.
7. Replace the magnet cartridges one by one.
8. Close the top cover.
Cleaning Procedure of MS6 candles –
Remove each candle, all the deposits will fall off into the tray, by gravity. Wipe clean, if required.
** This has to clean every fortnight.
Operation of DH Unit:-
The unit runs a filter, and a pressure gauge, and a setting to trip at a dP of 2 kg/cm2. When it
reaches this setting, the filter element needs to be changed.
The filter element also needs to be changed after any incident of water/moisture ingress in the oil.
After it is expressed to water / moisture, it will be choked with moisture, and will not filter particles.
4.1. Starting and Stopping the Machine
Before starting the machine, ensure the following:
 Confirm that the elements and magnet candles are in place, and fasten the tank covers evenly.
 Shut the drain valves and open the sample cock .
 Ensure that pump is filled with oil and suction line is fully immersed in oil.
 Check the suction and discharge delivery hoses are connected properly at both ends.
 Switch ON Selector switch to run the pump in "Forward" operation.
 The unit will start and the pump will fill the housings with oil.
 Stopping the machine Switch off selector switch to stop the machine.
4.2. Draining/ Removing cleaned oil from the tank
a. Switch off the unit

b. Open air cock on the top cover of the Filter housing (Sampling cock)
c. Drain oil from the bottom of the drain valve.


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OWNERS MANUAL Page 1 of 27

FERROCARE MACHINES PVT LTD

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About this manual 3

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About This Manual

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Instructions and Operation Manual for

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2.0. PRINCIPLE OF OPERATION :

Oil is made to pass through an electric field.

The ELC does not affect soluble additives.

3.0. OPERATING CONDITIONS :

Suitable for filtration of mineral based hydraulic and lubricating oils

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4.0. MODEL SELECTION GUIDE

The selection of Electrostatic Liquid cleaner machine model is based

CONVENTIONAL HYDRAULICS ( MAX. QUANTITY)

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6.0. SAFETY INSTRUCTIONS

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To prevent electric shock machines must be properly grounded.

7.0. SPECIFICATIONS: ELC- 100 LP +MS6+DHU

Power Source 415V, 3 - Phase 50Hz

Specifications ELC 100LP

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9.0. PROCEDURE AND FLOW CHART FOR INSTALLATION

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1. Confirm that the oil temperature, moisture content are

3.Place the covers on the electrode plates and collectors in

4. Connect hose (with Y-type strainer) to the pump suction

6.Check that the suction and discharge hoses are

7. Open flow control valve in line after the pump.

8. Switch on the ELCB and pump switch to normal mode .

FIG 3 9) Switch on the high voltage switch to 'Hi' position

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12.0. DRAINING / REMOVING CLEANED OIL FROM THE CLEANING TANK

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14.0. STOPPAGE OF HIGH VOLTAGE

1) Check for water or moisture in the oil

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16.0 REPLACEMENT OF COLLECTORS (Refer Fig. 5)

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18.0. CONTROL PANEL

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19.014.0. CONTROL AND ANNUNCIATION FUNCTIONS

For 100LP - indicator for HV-1

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

15.0 PROCESSOR OPERATION & PASSWORD FOR CHANGING THE SETTINGS.

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Once the display shows press o enter the processor programming.

20.0. PARAMETER SETTINGS FOR MICROPROCESSOR :

Followings parameters can be set and displayed in the microprocessor.

1. Set Current: 2 to 10 mA/for 100LP

The current across the electrodes can increase if water is

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If this parameter is set to "y", the machine will trip directly

5. Scroll time parameter: