P.O. Box 4, N-3201 Sandefjord Norway - Tel Fax

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1 Introduction and User Instructions for PURIFINER TS-5060PMH. Bypass oil purification system with preheater. The Purifiner oil filtration system for bypass installation is designed for continuous maintenance of all types of lubrication oils, hydraulic oils, turbine oils, freezer compressor oils, etc. Designed for use in pressurised hydraulic system, lubrication system or oil-lubricated propeller shaft casing system, with a back pressure on the return side ranging from 0 to 8 bar. The cotton filter removes particles in the oil down to 1 my. The evaporator removes water in the oil, including bound water, down to 100 ppm. The flow rate of the fine filter (cotton filter) is approximately 600 litres of oil per day. Low flow provides optimum cleaning of the oil. Description: Positions are indicated on the images. Pos.: 24 Pos.: 6 Pos.: 3 Pos.: 10 Stainless steel frame. All components are fitted to this frame. Oil supply. Suction piping from the oil system to be purified is fitted to the pipe coupling on the Purifiner (3/8" BSP male thread). Fixed pipework is recommended. Hose couplings approved for maritime use in engines may also be used (compressed highpressure hoses). Prefilter 60 micron. If the Purifiner is installed for cleaning very contaminated oil systems, we recommend that an extra filter is fitted, for example on the suction line upside the prefilter. The filter should be approximately 100 micron, washable and with a flow indicator. An extra prefilter reduces the consumption of Purifiner filter elements. The return to the main system is fitted to the 3/8" BSP male thread pipe coupling on the Purifiner. Fixed pipework is recommended. Hose couplings approved for maritime use in engines may also be used (compressed high-pressure hoses). 1

2 Pos.: 8 Pos.: 7 Pos.: 1 Pos.: 21 Pos.: 23 Pos.: 25 Pos.: 19 Pos.: 20 Pos.: 18 Pos.: 2 Suction and pressure pump. Manometer. The manometer displays the internal working pressure in the Purifiner unit. The pressure must be between 3 to 5 bar. Thermostatic preheater, 600 W. The factory setting is 45 C. The adjustable temperature range is between 5 to 80 C. Filter housing. The oil flows from the preheater to the bottom of the filter housing. A jet fitted at the bottom of the filter housing regulates the oil flow volume and dispersion through the cotton filter Pos. 23. The jet opening cannot be adjusted. (See text box on page 5.) Cotton filter element (fine filter). Specially designed for filtering hydraulic, gear and lubrication oils. When the cotton filter is replaced, it is important that the top cover and O-ring are fitted correctly, and that the wing nuts are tightened in a diagonal sequence to ensure an even pressure on the O-ring and filter element. Prefilter No. 3 is replaced simultaneously. Heating element (150 W). (Evaporator). Above the cotton filter element, the oil passes a diffuser plate with 8 holes, which distribute the oil flow to the evaporator unit consisting of a heating element. (See picture on page 5.) Free water or bound water (emulsion) in the oil is extracted using heat. The water turns into vapour and is extracted from the oil and drained to the outside of the Purifiner via the vapour vent Pos19 and drain hose. The oil temperature is increased by 2 to 5 C in the dispersion chamber. This results in the following maximum oil temperature: Temperature setting for preheater + 2 to 5 C. Atmospheric (no) pressure is used in the oil reservoir of the evaporator in order to gravity-feed the oil to the return tank Pos 20. Vapour vent. Water vapour generated in the evaporation chamber is evacuated via the vapour vent through a hose outside the Purifiner, either into the open or to a sump. Return tank (Expansion tank). Oil from the evaporation chamber gravity-feeds into the return tank. The return tank has automatic high and low level control, which initiates opening or closing of the solenoid valve by way of electric signals, i.e. draining or filling of the return tank. Level control. Solenoid valve. 2

3 Pos.: 26 Pos.: 5 Pos.: 11 Pos.: 14 Pos.: 15 Pos.: 16 Pos.: 13 Overflow switch or safety device. Will shut down the pump in the event that the level control Pos 18 or solenoid valve Pos 2 fail. Monitoring of the Purifiner operation is controlled by circuit boards fitted in the control box. The Purifiner is started and shut down using the green start/stop button. Red "Overload" lamp. If this lamp is lit, the engine protection has been tripped. This means that the engine protection must be reset. Open the control box and push the reset button. See Troubleshooting Form. Red "No Oil" lamp. This lamp lights up when the return tank, Pos 20, is out of oil. This means that the fine filter Pos 23 is clogged and must be replaced. The "No Oil" indication has a fixed time delay of 50 minutes during start-up in order to avoid false alarms. This means that it may take some time before the return tank, Pos 20, is filled when starting up. If relevant, check for other potential sources of errors. See Troubleshooting Form. Red "Full Tank" lamp. This lamp lights up when the return tank, Pos 20, is filled with oil and the Purifiner shuts down automatically due to the back pressure in the return line to the oil system exceeding 8 bar. Reduce the back pressure in the oil system and start the Purifiner using the following procedure: The procedure for draining the return tank, Pos 20, as well to start the Purifiner is as follows: The return tank must be drained of oil before starting the Purifiner. Push and hold in the green button Pos 12 on the left side of the control box Pos 5 while simultaneously pushing in the start button Pos 11 to start up. Release the start button, but continue pushing the green pushbutton Pos. 12 until the return tank Pos 20 has been emptied. While the return tank Pos 20 is being drained, the red lamp Pos 16 will light up. It will remain lit until the return tank Pos 20 has been emptied. Release the green button Pos 12 and the Purifiner will resume normal operation. Explanation: Green button Pos 12 overrides the automatic control of the solenoid valve Pos 2, which forces it open to drain the return tank Pos 20 using the pump. See Troubleshooting Form. Hour Counter. Indicates the number of hours that the Purifiner has been in operation. Record the number of hours when replacing the filter in order to determine the filter replacement interval. This may be helpful when assessing the increasing purity of the oil. 3

4 Fuses: In the control box Pos 5, the circuit board is protected by a 1.6-A fuse in the fuse holder next to the contactor. Two RFI suppression capacitors are fitted to shield the circuit board, one above the relay in the control box and one in the solenoid valve Pos 2. Summary: It may take from 20 to 40 min. from start-up until the oil starts to flow from the fine filter Pos 23 depending on oil temperature and viscosity. It is possible to monitor the flow through the filter by checking the intervals for filling the return tank, Pos 20. in the sight glass Pos 22 on the return tank. The return tank Pos 20 has an oil capacity of 1.8 litres. If it takes four minutes between each filling (see sight glass), 27 litres of clean oil flow back to the oil system per hour. The intervals may vary depending on oil type and viscosity. However, be aware that the flow will decrease as the fine filter Pos 23 gets clogged with contaminants from the oil. The indicator lamp, Pos 15 Red "No Oil" lamp, will indicate when the fine filter must be replaced. Consumption of filter elements. The consumption of filter elements will vary depending on the type of oil system being filtered and the content of contaminants. It was mentioned earlier that in the event of very contaminated oil systems, it is important to replace the filter often during the initial stages of the filtering process. This is especially important when the cleaning of a system is started after the oil system already has been in operation for some years without extra filtering. Experience indicates that 6 to 8 filters will be used during the initial cleaning period, which may last a couple of months. After this period, the oil will be clean and the consumption will be reduced to approximately 4 filters per year, but this depends on how much contamination the oil system is exposed to. It is important to obtain oil samples before the initial start-up of the Purifiner oil purification plant. After start-up, it is important to check the oil with several oil samples. We recommend an oil sample every other month to ensure that the oil is clean. Clean oil is good for the engine! Oil samples: Through our cooperation with the oil lab Cotax AS, Larvik in Norway, we offer analysis of oil samples at fixed low prices. The oil samples are analysed based on the following standards: Water - ASTM D Acid value - ASTM D 664. Viscosity - ASTM D 445. The oil analyses may also be expanded to include analysis of the following: 21 wear metals, additives on ICP, flash point and base number for engine oil as well as a particle count. We also provide consultancy services through our partner Cotax AS. The Purifiner oil maintenance plant may be used anywhere, for example: Propeller shaft casing systems. Propeller thrusters (side propellers, directional propellers, POD propellers, water jet propellers, etc.). 4

5 Steering gears. Hydraulic systems with or without a central oil tank for hydraulic oil. Gear boxes. Gas turbines or steam turbines. Freezer and refrigeration compressors. Auxiliary engines. When the oil is pure and of an acceptable quality, we recommend taking 4 to 6 oil samples for testing per year in order to ensure good quality and operating conditions. We are happy to answer any questions regarding oil purification. The picture shows the Purifiner installed above the propeller shaft at the inner shaft seal for cleaning the casing oil. A jet is fitted in the bottom of the filter housing to regulate the volume and diffusion of the oil flow through the cotton filter Pos 23. The jet opening cannot be adjusted. 5