Oil Purifier Ifpm31 - Man - GB

Operating and Main-
tenance Instructions
IFPM 31
FLUID PURIFIER SYSTEM
CE 2001
Version 2.2
Serial-no.: ...............
Rev.-Date: 12.04.07
INTERNORMEN Technology GmbH

Friedensstraße 41
Germany – 68804 Altlussheim
Tel. +49 (0) 6205/2094-0 E-Mail: [email protected]
Fax +49 (0) 6205/2094-40 http://www.internormen.com
IFPM 31 Operating and Maintenance Instructions
General regulations
The IFPM 31 unit has to be operated in accordance with the regulations. All other applications
are regarded as non-conventional. INTERNORMEN Technology GmbH will assume no liabi-
lity for damage caused by the non-conventional application of the system.
Before the initial operation these instructions for operation have to be read and understood by
everyone operating and working with this system.
All modifications of the system have to be approved by INTERNORMEN Technology GmbH

before being made. Arbitrary modifications without any approval can damage the system or
other equipment. INTERNORMEN Technology GmbH will assume no liability for these
damages.
Original spare parts have to be used. If spare parts or equipment is being used, which was not
approved by INTERNORMEN Technology GmbH, all warranty claims can be lost.
For damages caused by:

- disregarding these instructions
- disregarding the duty of care during transportation, installation and operation
- false repair
- lack of maintenance
INTERNORMEN Technology GmbH will assume no liability.
Changes of the system's construction reserved.
Changes of these operating and maintenance instructions without notice reserved.

Contents
1. Structure page
1.1 The machine 2
1.2 The outside 3
1.3 Electronic control unit 4
1.3.1 Hour meter 5
1.3.2 Display of maintenance interval 5
1.3.3 Water sensor 7
2. Principle of operation 8
3. Installation and operation
3.1 Installation 9
3.2 Operation 10
3.3 Notes 13
4. Failure mesages and suggestions 14
5. Maintenance
5.1 Hydraulic pump 19
5.2 Vacuum pump 19
5.3 Genral information 22
5.4 Maintenance time schedule 23
6. Drainig the machine 24
7. Checking let systems 25
8. LED seizure 26
7.1 Status of components during operation 27
9. Water sensor 29
10. Wiring diagrams 32
11. Troubleshooting 38
11.1 Overflow 39
11.2 No oil 40
11.3 Failure cligging sensor 41
11.4 Low lubricating oil 42
11.5 Motor overload hydraulic pump 43
Motor overload vacuum pump
12. Spare parts
12.1 Basic unit 44
12.2 Control unit 46
13. Diagrams 48
14. Operating diagram 51
1
1. The structure of the

INTERNORMEN FLUID PURIFIER
1.1 The machine
The purifier consists of the following basic components:
1. Heating
2. Two-port solenoid valve
3. Vacuum chamber
4. Silica-gel air filter
5. Vacuum pump
6. Hydraulic pump
7. Outlet filter
8. Return valve 11
9. Throttle valve
10. Clogging sensor
11. Demister
12. Sensors
12
10
CAUTION!!!
This machine is not for
operating water based fluids
or any kind of fuel
2
1.2 The outside
2 1 3
4
8
13
14 5 7 11 10 12 9
1. Heating
2. Two-port solenoid valve
3. Vacuum chamber
4. Silica-gel air filter
5. Vacuum pump
6. Hydraulic pump
7. Outlet
8. Electronic control unit
9. Draining outlet for the condenser
10. Inlet
11. Draining outlet of the filter
12. Draining outlet of the vacuum chamber
13. Throttle valve
14. Separator
3
1.3 Electronic control unit

Description of the control unit
Water sensor and filter

clogging indicator
Manometer Reduce set Increase set Display

temperature temperature
Emergency
STOP
Main switch Indicator for the oil level

ON / OFF of the vacuum pump
Manometer: Shows the vacuum generated in the vacuum chamber

Main switch: To switch the energy supply ON and OFF
Display: Starting, temperature setting, displaying error messages
Filter clogging indicator: Displays the contamination of the filter in %
Water sensor: Displays the saturation level of the oil in %
Oil level indicator of the vacuum pump: Optical indicator for low oil level in the
vacuum pump
Emergency STOP: complete shut down of the system (only in cases of emergencies)
4
1.3.1 Hour meter

The hour meter can show at any time how long the Purifier has been working
The following steps are necessary to display the meter:
- Push ENTER + ARROW RIGHT (Please note: Make sure to push the ENTER button first,
otherwise you simply raise the set temperature). You will see the working hours in the
display.
- While keeping the buttons pressed, the displayed time will not change. Internally, of course,
the hour meter is continuing to count time.
- As soon as the buttons are released, the display will switch back to the initial state.
1.3.2 Display of maintenance interval
In order to ensure that all expendable materials needed for maintenance are ordered on time,
and internal clock for the maintenance intervals is integrated in the software. By hitting the
buttons "ENTER + ARROW LEFT" the time left till the next maintenance is being displayed.
Similar to displaying the hour meter, make sure to hit the "ENTER"-button first.
5
If the maintenance interval is exceeded, pushing these buttons will display the time that has
elapsed since that point.
6
1.3.3 Water sensor
CAUTION!!!
The water sensor does not measure the total water content!
The water sensor included in the system cannot determine the total water content. It only
shows the activity of water in the oil. As long as free water is present in the system, the water
activity will be at 100%. If the water content drops below the saturation point at a given tempe-
rature, this will be indicated by the only left lit LED. Please note: an accurate measurement is
only taken during the return phase of the machine's cycle. The display of the sensor goes from
100% to 10%. 100% indicate absolutely saturated or even over-saturated oil. 10% indicate
anhydrous oil. The coloured LEDs show the current status of the fluid concerning the
endangerment caused by the water.
RED = high danger

YELLOW = mediocre danger
GREEN = little/no danger
7
2. Operation principle
The oil is drawn into the system by a vacuum, generated by the vacuum pump (5).
First it will pass through a heating (1) with an output of up to 3000 W in order to increase the
oil's temperature and therefore accelerate the purification process.
A certain predefined amount of oil will be drawn trough a two-port solenoid valve (2) into the
vacuum chamber (3). In vacuum chamber the fluid will diffuse over the dispersion material,
which will create a larger free surface. Water will vaporize due to the lowered evaporation point
in the vacuum. An air stream is introduced to the chamber through the silica-gel air filter (4)
serving two different purposes: It will function as a carrier for the water vapor from the oil and
at the same time it allows adjustments to the vacuum generated within the chamber using the
throttle valve (13). These conditions do not only help to remove free water from oil, the system
does remove all - free and emulsified- water. The air loaded with vapor will be drawn out of the
chamber by the vacuum pump. It will pass through a condenser and an oil mist separator in
order to be emitted to the atmosphere. The oil is drawn out of the chamber through a high
performance particulate filter element back into its reservoir by an hydraulic pump. This pump
was designed especially for working with vacuums.
8
3. Installation and Operation
3.1 Installation
The INTERNORMEN Fluid Purifier should be placed near the oil reservoir.
When installing the system please make sure that the machine is in a level position. If this is not
possible make sure that the vacuum pump with the oil level indicator are located at the lower
end of the system.
The oil inlet has a SAE 1 1/2" flange connection for pipes. It can be shut using an 1 1/2" ball
valve. After filtration the oil is discharged through a SAE-flange 1 1/4".
Both lines have to be connected to the oil reservoir and tightened.
Electrical power supply is connected using a 16A plug with pole separator. Before initial operati-
on please check all ball valves as followed:
- OIL OUT closed

- WATER OUT open
- IN open
CAUTION! Check the sense of rotation of both motors before

operation.
The direction of rotating can be checked as followed:

- Turn system on
- Wait for the display
The motor of the hydraulic pump will be started simply by hitting the "arrow left"-button (yes). The
right sense of rotation is marked with an arrow on the motor itself. The sense of rotation of the
vacuum pump is synchronised to that of the hydraulic pump. After the direction is checked turn
off the system immediately.
9
If the direction is wrong, the phases of the plug can be switched using a screw driver.
Apply screwdriver here

and turn right/left
3.2 Operation
Immediately before the initial operation remove the seal from the Silica-Gel breather and
completely open the choke valve of the air duct.
ADVICE In order to ensure failure-free operation of the system,

the vacuum should be set at -0.6 bar for a certain
amount of time*. Degassing will be performed which
will allow safer operation
* Benchmark: app. 4 hours for ISO VG 46 and a volume of 4.000 l.
Before the system is started the following settings will be requested in the display:
- Empty vacuum chamber:

This option will allow emptying of the vacuum chamber in order to conserve the system or
as preparation for handling of a different tank (see chapter 6). In addition to that, the rotating
direction of the motors is being determined (see chapter 3.1).
10
- Viscosity setup: This displayed request allows choosing the viscosity of the oil that is being
operated. Temperature influence has to be considered. This setting will effect the overflow
safety switch of the system. If the viscosity set wrong, malfunctions and failures can bet he
result.
The viscosity is divided in three main groups:
ISO VG 32 ISO VG 100 ISO VG 320

11
1. Check position of ball valves
2. Remove the sealing of the silica-gel air filter
3. Open throttle valve comletely
4. Turn on power supply
5. Unlock the emergency switch (if locked)
6. Follow the instructions given in the display
7. Set the vacuum
8. Set the temperature using the buttons
9. In case of an emergency use

the Emergency-Switch
12
3.3 Notes
- The buttons Temp up and Temp down allow to set the intended heating temperature. When
reaching the high point, the heating will turn of. When dropping below the set temperature,
the heating will be switched back on. Please keep in mind that the set temperature simply is a
switch-off criteria. It cannot be assured that the temperature of the fluid actually reaches that
point.
- Moist air from the vacuum pump will be led through a moisture precipator and then emitted
to the atmosphere. The level of the reservoir has to be checked daily. The fluid collected by
the condenser can be discharged using the ball valve (9). The separated water will mainly be
present as steam. So if the water content of the oil is very low, there will be hardly any water
collected in the condenser. It is not a mistake if no water is collected in the precipator. This
only indicates low water content or low temperature of the oil.
- The operator can set the vacuum in the chamber by opening and closing the choke valve (13).
The ideal vacuum and the ideal oil temperature depend on the type of fluid and its condition.
The vacuum shouldn't exceed -0.9 bars and be less than -0.6 bars.
ADVICE: The conveying volume flow depends on the following:

- Temperature
- Set vacuum
- Viscosity of the oil
According to the chosen settings and the operated oil,
continuous pumping is ensured for both the intake and
the draw off.
13
4. Error messages
In case of the malfunction of a component, the system is shut off. One of the following failure
messages will appear in the display:
No Oil
This message will be displayed if no fluid reaches the lowest switch after a certain amount of
time. The reasons for this error could be the following:
- high viscosity
- small diameter of suction line or too long suction line
- suction height to great
- closed or not entirely opened ball valve
- contaminated solenoid valve
Measures to eliminate this error can be found in Chapter 11.2, page 40
Overflow
Is being displayed, if even though the solenoid valve is closed and the hydraulic pump is run-
ning the oil level reaches the highest sensor for a certain amount of time. The reaction time is
being determined by the viscosity chosen during the starting process.
Possible reasons for this error are:
- chosen viscosity wrong
- high vacuum
- defect hydraulic pump
- clogged pressure line
14
Measures to eliminate this error can be found in Chapter 11.1, page 39.
Filter Clogged
This message indicates a clogged particulate filter. Exchange filter and restart the system.
15
Failure Clogging
Sensor
Indicates that there is no connection between the PLC and the clogging indicator. Check wires
and connections, if necessary replace them.
No lubricating
oil in v-pump
Indicates low oil level in the vacuum pump. This can be caused by the clogging of the filter in
the vacuum pump and the loss of oil related to that. Exchange the filter, fill up oil and restart
the system.
16
Motor overload
hydraulic pump
This message will be displayed, if the switch to protect the motor of the hydraulic pump is acti-
vated. Check the power supply, all three phases must be present. If checked, open the hou-
sing of the controls and reset the motor protection switch manually.
Motor overload
vacuum pump
This message will be displayed, if the switch to protect the motor of the vacuum pump is acti-
vated. Check the power supply, all three phases must be present. If checked, open the hou-
sing of the controls and reset the motor protection switch manually.
Measures to prevent these failure messages will be described in chapter 11.5, page 43.
17
After 500 hours of operation the message shown below will be displayed. The red light will
start flashing.
Keep the system operating. It is highly recommended to follow these suggestions. When
started after maintenance procedures are completed the system will request information about
the service.
CAUTION! If maintenance is ignored the system could

break down and all warranty claims could be
lost
Pushing "YES" will reset the clock for maintenance and a new cycle will begin.
18
5. Maintenance
CAUTION! When doing any maintenance procedures the system has

to be turned off and secured from accidentally being
turned on.
5.1 Hydraulic pump
Generally hydraulic pumps do not require special maintenance. However during regular
maintenance work on the entire purifier the following points should be taken into account:
a) Examine the alignment of the clutch control, fixing bolts and connections tightness.
b) The condition of a pump depends on the volumetric efficiency. Therefore also the
deviation from the original number of revolutions should be observed while performing
maintenance. Deviations > 10% require closer investigation.
5.2 Vacuum pump
The Purifier operates with an oil lubricated

rotary vane vacuum pump
Checking the oil level
If the oil level is below the MAX-mark on the oil sight glass, more oil has to be added. This is
accomplished by filling in the oil through the oil fill plug, until the level reaches the MAX-mark on
the oil sight glass.
Low oil level is also indicated by the additional red light on the control unit. Is the oil level too low
the Purifier will shut down automatically and the failure message "Low lubricating oil" will
appear in the display. Refilling is necessary.
19
Changing oil
The first oil change has to be performed after 100 hours of operation. Further oil changes and oil
change intervals depend on operating conditions. After 500 hours of operation maintenance is
suggested in the display (see chapter 4). The maximum operating time of an oil filling under ideal
conditions is 2000 hours. However an oil change should be performed at least every six months.
If there is considerable large contamination it could be necessary to change the oil more fre-
quently. When exchanging the oil the Purifier has to be turned off and the warm pump has to be
ventilated in order to reach atmospheric pressure. Drain the old oil through the oil drain plug.
When oil stops running, close the plug and start up the pump again for a few seconds. Reopen
the oil drain plug and discharge the remaining oil. Refasten the oil drain plug. Fill with fresh oil
through the oil fill plug. Used oil is to be disposed according to the valid environmental laws.
Oil types
Fully synthetic oils according to DIN 51506, lubricating group VC have to be used. The oil
volume is approximately 0.4 litres. We suggest the BP Enersyn RC S 68 oil
Monitoring and exchanging the exhaust filter
If oil mist escapes from the separator during operation the exhaust filter has to be replaced. For
that purpose remove the exhaust cover and the filter spring. The exhaust filter can be extracted
with the help of the attached wire strap. When installing new exhaust filters always use new
sealings as well.
Exchange of the gas ballast valve
If the filter of the gas ballast valve is clogged, the entire gas ballast valve unit at the cylinder cover
must be unscrewed and replaced by a new one.
Cleaning the inlet flange
To clean the inlet flange screen, disconnect the four screws and remove the inlet flange. Take
out the screen and clean with blast air.
Cleaning the fan cover
The fan cover should be inspected regularly for dirt. Clogging of this fan cover prevents cool air
form being drawn into the pump, which may lead to overheating of the vacuum pump.
20
Operating principle of the pump
The pump operates based on the principle of rotary slide valves. An eccentrically pivoted rotor
(2) rotates in the cylinder. The centrifugal force of this rotation will press the vanes (3) against
the walls of the cylinder. These vanes divide the sickle shaped space between the cylinder and
the rotor in chambers. The combination of these chambers with the suction line will drawn in the
gas. Further rotation will compress it and finally exhaust it over the oil separator.
Oil is frequently injected to this compression space by the pressure difference. This oil will be
emitted to the separator with the air. It will be separated from the exhaust air by gravity and the
air filter (7). Oil will collect at the bottom of the separator from where it will be reinjected to the
compression space (circular lubrication).
The exhaust air (free of oil mist) is being emitted to the atmosphere over the exhaust cover (6).
21
5.3 General maintenance
Please also check the following when performing maintenance:
1. Use the Emergency stop switch in order to check its functionality and eliminate eventual
blockings. If the emergency stop switch does not turn off the system operation has to be
delayed until the cause of this malfunction is found and eliminated.
2. Check the functionality of the overload relays of both motors. If the function is disturbed,
the relay should be replaced.
3. Clean the hoods of the motors during maintenance in order to prevent overheating.
4. Check the functionality of the upper level sensor as followed:

- look for the checkpoint at the sensor (see picture below)
- touch this marking with a magnet (check both sides) when the system is switched on
but not running
- Green and red LEDs have to light up
If the red LED does not light up, the sensor has to be replaced.
22
5.4 Maintenance time schedule
Checking/Draining the separator daily
Checking oil level of vacuum pump weekly
- Clean electric motors

- Change oil of vacuum pump
- Replace the filter element of the vacuum pump
- Replace breather after 500 hours of operation
- Check the functionality of the highest sensor (see page 18)
- Check functionality of the Emergency-Stop
- Check excess current
- Check system for leaks
- Retighten connecting screws

- Check all cable for signs of aging
semi-annually
- Change filter element (or is clogged)
- Clean the outside of the unit
- Calibrate the water sensor

annually
- Check the unit for corrosion
23
6. Draining the system
When draining the system, if -for example- a different oil is supposed to be purified, the
following steps have to be performed:
- Shut suction line using the ball valve
- Turn off the system and restart it
- The display will show the following
- The hydraulic pump will discharge oil from the vacuum chamber for as long as you keep the
"YES" button pressed.
- Release the button as soon as all oil is being discharged from the chamber (different sound
of the pump and more vibrations indicate this).
- Re-perform this procedure after approximately 30-60 minutes in order to also drain the oil
from the dispersion material.
- Disconnect suction line
- For collecting the oil from the heating place a tank or a bucket underneath the inlet and
slowly open the ball valve.
CAUTION! A filter element can only be used for cleaning one fluid
type! If the system is being used to purify different
types of oil please use new elements for every type of
oil!
24
7. Checking let systems
If the unit is let for service reasons or if it is reactivated after a longer shut down period, these
following checkpoints should be checked:
Clean the unit and look for damages on the outside
Check the content of the vacuum chamber and the heater, if necessary drain those
Check the oil level of the vacuum pump. If contamination with alien/external oil is suspected,
replace both the oil and the filter element in the vacuum pump.
Provide the unit with power and check the functionality of the motors
Check the functionality of the emergency stop
Remove the water sensor and clean it
Exchange the filter element

Check the condition of the air breather, determine the saturation of the silica pellets and
exchange them if necessary.
Check the oil mist separator, drain it or replace it if damaged.
25
8. LED seizure
The digital inputs of the PLC are used as followed:
Input no. Function

1 lower Sensor (min.)
2 middle Sensor (max)
3 upper Sensor (Overcharge lock)
4 signal "filter clogged"
5 Oil level indicator for the vacuum pump
6 Motor protector hydraulic pump
7 Motor protector vacuum pump
The thermometer is connected to the analogue input no. 1

The contamination indicator is connected to the analogue input no. 2
The different components of the system are being controlled by the following digital outputs of
the PLC:
Output no. Function

1 Hydraulic pump
2 Vacuum pump
3 Heating
4 Solenoid valve
6 Signal light for low oil level in the vacuum pump
These digital input and output signals can be either ON (LED is light) or OFF (LED is dark). For
further explanation of the different states: X means there is a signal (LED is flashing) and O
means that there is no signal (LED is not flashing)
26
8.1 Status of components during cperation
During the operation of the system, the actual status of components can be observed using the
LEDs of the PLC controls.
Initial state of the system, which means that the main switch is turned on but the system is not
working yet
Input no. State Output no. State
1 X 1 O
2 X 2 O
3 X 3 O
4 X 4 O
5 X
6 X 6 O
7 X
Initial start of the system:
1 X 1 O
2 X 2 X
3 X 3 O
4 X 4 X
5 X
6 X 6 O
7 X
Normal mode:
1 O 1 X
2 O(X)* 2 X
3 X 3 O(X)**
4 X 4 X
5 X
6 X 6 O
7 X
27
Overflow safety.
1 O 1 X
2 O 2 X
3 O 3 O
4 X 4 O
5 X
6 X 6 O
7 X
Off-carriage of the hydraulic pump after message ”Overflow”
1 O 1 X
2 O 2 O
3 O 3 O
4 X 4 O
5 X
6 X 6 O
7 X
* The switch state of the sensor depends on settings and the time of observation
** The switch state of the heating (Outlet 3) depends on the intended and the actual
temperature
To prevent the oil for overheating the heater will be switched off, if the solenoid valve is closed.
28
9. Water sensor
The integrated Water sensor measures the relative humidity of the fluid, as opposed to the
total water determination (free and emulsified water in the fluid) by the Karl-Fischer-method.
As a result of the measurement the fluid's saturation level with water is indicated in percent.
A connection to the ppm (mg/kg) water content determined by the Karl - Fischer- method can
be made for values between 0% and 99%. For this purpose it is necessary to know the
characteristic curve of the saturation level and the temperature of the fluid.
The indication 100% means total saturation of the fluid and therefore the presence of
dangerous free water in the fluid.
Technical data for the water sensor:
Measuring range: 0......100% r.H.

Tolerance ( MR 5.....95% at 10 .....40°C ): ± 2%
Additional error: 0,1% /K
Ambient temperature: - 20°C......+ 80°C
Output signal: 4.....20 mA
Operating voltage: 12.....30 V
Acceptable ohmic resistance at 24V DC: 600 Ohm
Pressure resistance: 10 bar
Max. flow rate: 2 m/s
CAUTION! Ammonia, bases or the like can cause the

destruction of the sensor.
29
Output signal in mA Characteristic curve of the sensor
Water content in %
To clean the sensor it is necessary to empty

the Purifier entirely. This means that there
has to be no oil in the vacuum chamber
(see chapter 6).
Then loosen the cable from the sensor (bolt-
ed joint) and unscrew the sensor from the
chamber using a SW 32 wrench.
The protective cap of the sensor itself can
also be unscrewed. Please proceed with
extreme caution in order to protect it.
The sensor itself can be cleaned in isopro-
panol or in an ultrasonic bath.
ISOP
R O PA N O L
30
After the cleaning procedure is completed place the protective cap at its original position.
Put the entire sensor back in the chamber and tighten it carefully using the SW 32.
Reconnect the cable and restart the Purifier.
The integrated sensor was calibrated prior to delivery with several different saline solutions.
The recalibration of the sensor should be performed annually.
This can take place in external laboratories, which have saline solutions with the proper
saturation level, or the sensor can be send to INTERNORMEN Technology GmbH.
Connection of the WSPS 03
+ 1 1 - X1: 9
- 2 2 - X1: 5
Plug Connector
31
10. Wiring diagrams
IFPM 31
0 1 2 3 4 5 6 7 8 9 10 11 12
A/B/C A/B/C A/B/C A=400V

-Tr1 B=480V
0 +24V C=208V
1
-F10
2,5A 2
1 3 5 1 3 5 1 5
11 12
1 1 1
-K1 -K2 -K3
/3.2 /3.4 /3.6 -S2
-F1 -F2 -F3 2 4 6 2 4 6 2 6
16A 216A 216A 2 13 14
-X2 -X1
L1+
95
97
95
97
1 3 5 1 3 5 /2.0
L1-
-F5 -F6 /2.0
1 3 5 2 4 6 2 4 6
96
98
96
98
-S1
/4.10
/3.2
/4.9
/3.4
2 4 6
-X1 -X2
1 5
PE
N
-VD
-K4
/3.8
2 6
Operating and Maintenance Instructions

PE U V W PE U V W
M M 1 2
3 3 -1MV
-H1
1,5 kW
YD
-M1 -M2
0,75 kW 0,55 kW
-X0 Hydraulic pump Vacuum pump
400V=>2,7A 400V=>1,5A
1,5 kW
-H2
L1 L2 L3 N PE 480V=>2,8A 480V=>1,5A
200V=>4,7A 200V=>2,6A
30.08.2007 Schoepp Datum 11.04.2007 INTERNORMEN Technology GmbH IFP-31 Kunde: Anlage IFP-31
Friedensstraße 41 Tel.: +49-(0)6205- 2094-0 Projekt:
Bearb. Sch p p Ort
68804Altlußheim Fax: +49-(0)6205-2 094-40 IFP-31 ANr.
32
www.internormen.com [email protected] Blatt-Nr. 1

Gepr. Version
Zustand nderung Datum Name Norm Urspr. Ers. f r Ers. durch Hauptkreis /main circuit Bl von Anz 1/7
IFPM 31
0 1 2 3 4 5 6 7 8 9 10 11 12
/1.11
L1+ L1+
/3.0
/1.11
L1- L1-
/3.0
-X2 -X1 -X1 -X2
X10 0V 24V X31 24V 1 2 3 4 5 6 7 8 X61 DIR STEP 0V
POWER OUTPUT SM
X12 X11
-JT
NANO-B
-Ds
DK 422 LCD PC
INPUT COUNTER IN ANALOG OUT

X21 X41
1 2 3 4 5 6 7 8 A B 0V X62 0V 1 2 3 4 0V OUT 0V X51
11.04.2007 Schöpp Datum 11.01.2007 INTERNORMEN Technology GmbH Anlage IFP-31

Friedensstraße 41 Tel.: +49-(0)6205- 2094-0 Projekt: IFP-31 Kunde:
Bearb. schoepp Ort
68804 Altlußheim Fax: +49-(0)6205-2 094-40 IFP-31 ANr.
Gepr. www.internormen.com [email protected] Blatt-Nr. 2
33
Version
Zustand Änderung Datum Name Norm Urspr. Ers. für Ers. durch SPS / PLC NANO-B Bl von Anz 2/7
IFPM 31
0 1 2 3 4 5 6 7 8 9 10 11 12
Digitalausgänge NANO-B
digital output NANO-B
-X31
1 2 3 4 6
h-pumpe v-pumpe heater m-valve alarm
95 95
-F5 -F6
/1.3 /1.5
96 96
A1 A1 A1 A1 X1
-K1 -K2 -K3 -K4 -La
A2 A2 A2 A2 X2
-X2 -X2
/2.12
L1+ L1+
/4.0
/2.12
L1- L1-
/4.0
1 2 1 2 1 2 1 2
/1.3 /1.5 /1.7 /1.10
3 4 3 4 5 6 5 6
/1.3 /1.5 /1.7 /1.10
5 6 5 6
/1.3 /1.5
13.04.2007 Schöpp Datum 09.01.2007 INTERNORMEN Technology GmbH Anlage IFP-31

Friedensstraße 41 Tel.: +49-(0)6205- 2094-0 Projekt: IFP-31 Kunde:
Bearb. Schöpp Ort
68804 Altlußheim Fax: +49-(0)6205-2 094-40 IFP-31 ANr.
34
Gepr. www.internormen.com [email protected] Blatt-Nr. 3
Version
Zustand Änderung Datum Name Norm Urspr. Ers. für Ers. durch SPS-Ausgänge /PLC outputs Bl von Anz 3/7
IFPM 31
0 1 2 3 4 5 6 7 8 9 10 11 12
-FTL1 -FTL2 -FTL3 -S10

oil-min oil-mid oil-max low oil v-pimp
1 3 2 1 3 2 1 3 2 1 3 2
-X3 -X3 -X3 -X3

-X2 1 -X2 2 -X2 3 4
-X1 -X1 -X1 -X1
/3.12
L1+ L1+
/5.0
/3.12
L1- L1-
/5.0
-X1
/5.7
97 97
signal VS1
-F5 -F6
/1.3 /1.5
98 98
-X21
oil-min oil-mid oil-max filter-clogged low-oil v-pump failure M1 failure M2
1 2 3 4 5 6 7

Digitaleingänge NANO-B
digital input NANO-B
11.04.2007 Sch p p Datum 11.01.2007 INTERNORMEN Technology GmbH IFP-31 Kunde: Anlage IFP-31
Bearb. schoepp Ort
IFP-31
35
68804Altlußheim
www.internormen.com
Fax: +49-(0)6205-2
[email protected]
094-40 ANr. Blatt-Nr. 4
Gepr. Version
Zustand nderung Datum Name Norm Urspr. Ers. f r Ers. durch SPS-Eing n ge / PLCinputs Bl von Anz 4/7
IFPM 31
0 1 2 3 4 5 6 7 8 9 10 11 12
-CP -WSPS03
-VS
PT100
1 PE 2
-X3 -X3 -X3

6 7 5
-X2 -X3
9
-X1 -X1
/4.12
L1+ L1+
/4.12
L1- L1-
-X2 -X1 -X2 -X1
/4.6
-C2
+
1
+ 1
signal VS1
1
-C1 -R1
2 2
-X41
Temperature
1 1 2 3 4 5 6 7 8 9 10 11 12 1 2 3 4 5 6 7 8 9 10 11 12
-WFD1 clogging sensor -WFD1 water sensor

bottom strip top strip

Analogeingänge NANO-B Kontakte WFD01
analog input NANO-B contacts WFD 01
26.02.2009 Koenig Datum 11.01.2007 INTERNORMEN Technology GmbH IFP-31 Kunde: Anlage IFP-31
Bearb. schoepp Ort
36

Gepr. Version
Zustand nderung Datum Name Norm Urspr. Ers. f r Ers. durch WFD / Analog-IN Bl von Anz 5/7
IFPM 31
0 1 2 3 4 5 6 7 8 9 10 11 12
X21/1
X21/2
X21/3
X21/5
X41/1
bs-10
X10/+24V
X31/+24V
ts-11
bs-1
bs-2
X10/0V
X41/0V
ts-10
ts-1
ts-2
Anschlu§bezeichnung
A2
97
2
-L
+L
5
1
Ziel Connection No.
Destination
WFD1
WFD1
WFD1
WFD1
WFD1
WFD1
WFD1
Kennzeichnung
Designation
L1 S1
L2 S1
L3 S1
S2
K4
S2
K4
F5
F5
JT
JT
JT
JT
JT
JT
JT
JT
JT
PE
+24V
N
9
1
0V
Klemmen-Nr. / Terminal-No.
X0
X3
X2
X1
Laschenverbindung / Link
FTL1
FTL2
FTL3
S10
WSPS
WSPS
WSPS
CP
CP
FTL1
FTL2
FTL3
FTL1
FTL2
FTL3
VS
VS
VS
S10
La1
Anschlu§bezeichnung
Terminal strip
Terminal strip
Terminal strip
Terminal strip
Anscli§leiste
Anscli§leiste
Anscli§leiste
Anscli§leiste
Connection No.
Ziel
Destination
Kennzeichnung
Designation
PE
X2
2
3

26.02.2009 Koenig Datum 12.01.2007 INTERNORMEN Technology GmbH IFP-31 Kunde: Anlage IFP-31
Bearb. schoepp Ort
37

Gepr. Version
Zustand nderung Datum Name Norm Urspr. Ers. f r Ers. durch Klemmbelegung / terminal strips Bl von Anz 6/7
11. Troubleshooting
ERROR CAUSE REMEDY

1. Malfunction of the middle sensor
Display 2. Malfunction of the upper sensor
see page 39
”Overflow” 3. Extreme foaming
4. Loose connection to the PLC-controls
1. Blocked suction line
2. Clogged solenoid valve
Display
3. Viscosity too high/Pipe too long see page 40
”No oil”
4. Malfunction of the lower sensor
1. Plug removed
Display 2. Loose cables on the WFD 01
”Failure clogging 3. Cable break see page 41
sensor” 4. Malfunction VS1
Exchange filter element

Display
1. Filter element clogged (Element description-
”Filter clogged”
see type plate)
1. low oil level on the vacuum pump

Display
2. Swimmers stuck see page 42
”Low lubricating oil”
Display 1. Check the supply voltage

“Motor overload 2. Check the availability of all 3 phases see page 43
hydraulic pump” 3. Check the fuses
Display 1. Check the supply voltage

“Motor overload 2. Check the availability of all 3 phases see page 43
vacuum pump” 3.Check the fuses
Change polarity with the

Wrong direction of the 1. Wrong polarity of the three-phase
plug using the
motor rotation power system
separators
38
11.1 Overflow
prompt
"overflow"
check
viscosity
no
O.K. ?
yes
check
the outlet
no
O.K. ?
yes
check upper remedy

sensor malfunction
no
replace sensor O.K. ?
yes
reduce vacuum
restart
the unit
39
11.2 No Oil
prompt
"No Oil"
check
inlet
no
O.K. ?
yes
check remedy
magnetic valve malfunction
no
clean the valve O.K. ?
yes
check
lower sensor
replace no
O.K. ?
sensor
yes
check the
viscosity/ inlet
hose length
restart the
unit
40
11.3 Failure clogging sensor
prompt
"Failure clogging
sensor"
check plugs
no
O.K.?
yes
check the remedy

WFD01 malfunction
contacts
remedy no
O.K. ?
malfunction
yes
exchange
connecting cable
exchange clogging no
O.K.?
indicator
yes
restart the
unit
41
11.4 Low lubricating oil
prompt
"low lubricating oil"
check the
oil level in
vacuum pump
no
O.K. ?
yes
check the
floating body refill oil
of the indicator
remedy no
O.K ?
malfunction
yes
check the
connection to
PLC
no
reconnect O.K. ?
yes
restart the
unit
42
11.5 Motor overload hydraulic pump

Motor overload vacuum pump
Display
"Motor overload
hydraulic pump"
or
"Motor overload
vacuum pump"
check
voltage
no
OK?
yes
check if all 3
phases are
available
remedy no
OK?
malfunction
yes
check remedy
the fuse malfunction
exchange no
OK?
fuse
yes
reset the
motorprotector
manually
restart
the unit
43
12. Spare parts
12.1 Overview machine base unit
WSPS 03
44
No. Quantity Description Article number
1 1 Ball valve 1 1/2'' 322022

2 2 Heating band 326503
3 1 Solenoid valve 322006
4 app.33 litre Dispersion material 324983
5 3 Oil level sensors 324841
6 1 Watch glass 323237
7 1 Water sensor 326211
8 1 Temperature sensor 323099
9 1 Complete hydraulic pump 322003
10 1 Return valve 322805
11 1 Filter element see type plate
12 1 Clogging indicator 323148
13 1 Vacuum pump with motor 322004
13a 1 Exhaust filter 323882
13b 0.5 litre Oil for vacuum pump 324989
14 1 Water separator 323451
15 1 Throttle valve 322463
16 1 Silica-gel air filter complete 322734
16a 1 Filter element breather filter 322768
16b 1 Replacement gel 323371
45
12.2 Overview control unit
1 4 2 3 10
5
6
12
8
9
2 1 11
4
10
46
No. Quantity Description Article number
1 1 LCD-Display 321919
2 1 Display for water and contamination sensor 323555
3 1 Manometer 322005
4 1 Lamp 321977
5 1 PLC-controls 321918
6 3 16A fuse 321982
7 1 2,5A fuse 324671
8 4 Contactor 321979
9 2 Motor protector 321980
10 1 Main switch 321925
11 1 Emergency switch 321926
12 1 Transformer 322519
47
13. Diagrams
Heat output
16000
14000
12000
10000
8000
Output [W]
6000
4000
2000
0
200 250 300 350 400 450 500
Voltage [V]
48
Purification of different oil types
Oil Type Trans-

HLP CLP HF-E former
Parameter oil
suggested approx. approx. approx. max.

temperature 60°C 70°C 50°C 40°C
suggested
- 0,7 bar - 0,6 bar - 0,7 bar - 0,9 bar
vacuum
49
Parameters with an influence on the velocity of purification
Oil temperature Strong increase
Vacuum Increase
Initial water content Increase
Additives in the Oil Decrease
Suggested placement for inlet and outlet of your systems reservoir
D p I
50
14. Operation diagram

START
request "service"
time after last yes prompt service yes reset

service >500 h "service completed clock
no no
drain
viscosity
setup
initialisation
FILTER HEATER SENSORS SERVICE
V-pump ON
magnet valve
OPEN no time after last
no
no no T>Tset-D T service >500 h
U>Umax U>Umin
no
yes
yes yes yes
Sensor 1 yes yes prompt
heater OFF time>10min
ON "NO OIL"
prompt prompt
"clogged filter" "Failure clogging sensor" prompt
"change oil v-pump"
"change breather
no
no
T<Tset+D T
V-pump OFF
H-pump OFF yes
Sensor 2
heater OFF
ON
magnet valve
yes
close
no
yes
magnet
valve close H-pump
ON
yes
no
no
Sensor 3 no magnet valve

heater ON time>tges
ON CLOSE
yes yes
prompt
"Overflow"
V-pump OFF
H-pump ON
heater OFF
magnet valve close
no yes
time>2 min
V-pump OFF
H-pump OFF
heater OFF
magnet valve
close
prompt
"Reset Failure with enter"
yes no
Enter
pressed
51

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Operating and Main-

INTERNORMEN Technology GmbH

All modifications of the system have to be approved by INTERNORMEN Technology GmbH

For damages caused by:

Changes of the system's construction reserved.

Changes of these operating and maintenance instructions without notice reserved.

1. The structure of the

1.1 The machine

The purifier consists of the following basic components:

1.2 The outside

1.3 Electronic control unit

Water sensor and filter

Manometer Reduce set Increase set Display

Main switch Indicator for the oil level

Manometer: Shows the vacuum generated in the vacuum chamber

1.3.1 Hour meter

The following steps are necessary to display the meter:

1.3.2 Display of maintenance interval

1.3.3 Water sensor

RED = high danger

3. Installation and Operation

- OIL OUT closed

CAUTION! Check the sense of rotation of both motors before

The direction of rotating can be checked as followed:

Apply screwdriver here

ADVICE In order to ensure failure-free operation of the system,

* Benchmark: app. 4 hours for ISO VG 46 and a volume of 4.000 l.

- Empty vacuum chamber:

The viscosity is divided in three main groups:

ISO VG 32 ISO VG 100 ISO VG 320

1. Check position of ball valves

2. Remove the sealing of the silica-gel air filter

3. Open throttle valve comletely

4. Turn on power supply

5. Unlock the emergency switch (if locked)

6. Follow the instructions given in the display

7. Set the vacuum

8. Set the temperature using the buttons

9. In case of an emergency use

ADVICE: The conveying volume flow depends on the following:

Measures to eliminate this error can be found in Chapter 11.2, page 40

CAUTION! If maintenance is ignored the system could

CAUTION! When doing any maintenance procedures the system has

5.1 Hydraulic pump

5.2 Vacuum pump

The Purifier operates with an oil lubricated

Checking the oil level

Monitoring and exchanging the exhaust filter

Exchange of the gas ballast valve

Cleaning the inlet flange

Cleaning the fan cover

Operating principle of the pump

5.3 General maintenance

Please also check the following when performing maintenance:

4. Check the functionality of the upper level sensor as followed:

5.4 Maintenance time schedule

Checking/Draining the separator daily

Checking oil level of vacuum pump weekly

- Clean electric motors