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RelaDyne THERMOJET H-2500E Series, Инструкция по установке и эксплуатации

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THERMOJET

®

 H-2500E SERIES 

OIL PURIFIER SYSTEM 

INSTALLATION AND OPERATING MANUAL 

Doc # 

77740119 

Rev 

15 

Date 

June 2020 

Page 

1

 of 

100

 

 

 
 
 
 

ThermoJet

 H2500E Series 

Oil Purifier System 

Installation and Operating Manual 

 
 
 
 

 

 
 

 

______________________

 

5615 W Fuqua St B-201 

•

 Houston, Texas 77085  

1-713.464.6266 

•

 Fax: 713.464.9871 

 

 

 

 
 
 
 
 
 

Doc 77740119 Rev 15 

 
 

READ AND UNDERSTAND THIS OPERATING 
MANUAL BEFORE ATTEMPTING TO INSTALL, 
COMMISSION, OR USE THIS EQUIPMENT. 
FAILURE TO UNDERSTAND THESE 
INSTRUCTIONS COULD RESULT IN SERIOUS 
PERSONAL INJURY AND OR LOSS OF 
PROPERTY. 

WARNING

Содержание THERMOJET H-2500E Series

Страница 1: ...m Installation and Operating Manual ______________________ 5615 W Fuqua St B 201 Houston Texas 77085 1 713 464 6266 Fax 713 464 9871 Doc 77740119 Rev 15 READ AND UNDERSTAND THIS OPERATING MANUAL BEFOR...

Страница 2: ...____________________________________________________________ ______________________________________________________________________ ____________________________________________________________________...

Страница 3: ...Oil Piping Connections 18 Condensate Purifier Connection 20 System Exhaust Connections 21 Electrical Power Connection 22 Grounding 25 V SYSTEM START UP AND OPERATION 26 Start Up Procedures 27 Heater O...

Страница 4: ...SHOOTING 75 Trouble Shooting Guide 76 Quick Reference Troubleshooting Guide 79 Types of Product Misapplication and Misuse Not Covered By Warranty or Guarantees 80 IX PARTS LIST DRAWINGS SCHEMATICS 81...

Страница 5: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 5 of 100 I GENERAL INFORMATION...

Страница 6: ...tion For additional information contact the manufacturing office nearest you or check our website For questions regarding this publication or if you have specific questions regarding the installation...

Страница 7: ...a hazardous situation which if not avoided will result in death or serious injury WARNING This symbol is used to identify a WARNING level of hazard seriousness WARNING indicates a hazardous situation...

Страница 8: ...tion and observe all plant driving and safety regulations Do not transport equipment on public roadways using a fork truck This symbol can be used in conjunction with a SAFETY ALERT symbol with either...

Страница 9: ...N severity level This symbol is used to indicate that the reader must read and understand referenced DATA AND INFORMATION This symbol may be used in conjunction with a NOTICE or with a SAFETY ALERT sy...

Страница 10: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 10 of 100 II UNIT IDENTIFICATION AND LABELING...

Страница 11: ...ing electrical power supplies The purchaser specifies supply voltage 460 VAC 60 Hz 3 Phase 575 VAC 60 Hz 3 Phase 380 VAC 50 Hz 3 Phase 400 VAC 50 Hz 3 Phase 415 VAC 50 Hz 3 Phase 440 VAC 50 Hz 3 Phase...

Страница 12: ...ion in Hydrocarbon Processing Industry Unit for Class 1 Grps CD T3C 22 X 30 footprint Heater Type E Electric Heater Electrical Power Supply A 460 VAC 60 Hz 3 Phase D 575 VAC 60 Hz 3 Phase E 380 VAC 50...

Страница 13: ...suitable for 50 or 60 hertz AC power as stipulated by the POWER option of the ThermoJet Oil Purifier Model Code Designation Key Power Option Code A 460 VAC 60 Hz ______________ Power Option Code D 575...

Страница 14: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 14 of 100 III DESCRIPTION OF THE PRODUCT...

Страница 15: ...t as monitored by two easily read gages which are externally mounted on the panel above the access door reaches 30 PSI 2 BAR From the filter the oil passes through the heater that elevates the oil to...

Страница 16: ...ND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 16 of 100 IV INSTALLATION THIS INSTRUMENT MUST BE EARTHED WARNING If the equipment is not used in the manner described in this manual the pr...

Страница 17: ...Dimensional Drawings in the PARTS LIST DRAWINGS SCHEMATICS section of this manual for anchor bolt and equipment clearance dimensions The base mounted ThermoJet Oil Purifier is constructed with lift ri...

Страница 18: ...tion to the ThermoJet Oil Purifier is not practical ensure that the suction height from the reservoir drain to the inlet connection of the ThermoJet is no more than 8 feet 2 4 meters above the minimum...

Страница 19: ...tice is to install a manual shut off valve if one does not already exist directly onto the reservoir connection routed to the ThermoJet inlet connection If the oil reservoir is located below the Therm...

Страница 20: ...densate Purifier Assembly CPA connection is FNPT Pipe CPA connection is to a dirty oily water drain system Condensate Purifier Connection NPT NOTICE When cleaning oil spills consult with your lubricat...

Страница 21: ...t be piped away to a location that is not occupied The ends of the vent header pipe should be such that rain animals and blowing dust and dirt cannot enter Exhaust piping must be 3 4 NPT DN20 or large...

Страница 22: ...equirements as long as the unit meets the operating conditions ThermoJet Oil Purifier is wired for the power supply stated on the nameplate It must not be re wired for any other voltage The power circ...

Страница 23: ...electrical connections should only be made by a qualified electrician A switch or circuit breaker shall be included in the building installation it shall be in close proximity to the equipment and wi...

Страница 24: ...terminals L1 L2 and L3 located in a terminal enclosure See the diagrams below for terminal location and user terminal connection identification The power connection is three phase Voltage is as speci...

Страница 25: ...of 100 35 Grounding ThermoJet Oil Purifiers must be grounded to ensure safe operation An external ground terminal is located on the left side of the terminal enclosure See diagrams below for circuit g...

Страница 26: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 26 of 100 V SYSTEM START UP AND OPERATION...

Страница 27: ...servoir to drain any free water which may have accumulated Care should be taken to avoid spills and ground contamination with the drained waste Avoid inputting free water from the serviced reservoir f...

Страница 28: ...r rotation against the directional arrow located on drive end of the motor If incorrect place the Circuit breaker in the OFF position and disconnect supply power at the source NOTICE Recycle all drain...

Страница 29: ...ndle to the ON position and again use the ON OFF Selector Switch to jog the electric motor and verify proper motor rotation Once the motor rotation is correct leave the Selector Switch in the ON posit...

Страница 30: ...ion line can escape As soon as oil flow is established close this valve to prevent any oil spills In case of oil spillage the user or other responsible body must ensure appropriate cleanup and deconta...

Страница 31: ...no oil is flowing trace the inlet piping for blockages such as a closed valve If the oil path is free from obstructions manually prime the pump and the inlet piping Ensure that the suction line dista...

Страница 32: ...rature Alarm reset button to reset the high temperature alarm and turn the Heater High Temperature alarm pilot light OFF The yellow Heater On pilot light will remain ON until the oil temperature appro...

Страница 33: ...is in the oil stream located at the heater vessel discharge This thermocouple provides the oil temperature signal to the temperature controller see above for heater ON OFF control A thermocouple is c...

Страница 34: ...the heater controller will sense the decreasing oil temperature and attempt to energize the heater However the high limit controller will prohibit the oil heater from energizing and oil temperature wi...

Страница 35: ...p discharge pressure is too low adjust PCV1 by turning adjustment screw clock wise to increase the oil pressure and c clockwise to decrease the oil pressure setting Once adjusted the filter discharge...

Страница 36: ...upply tank being serviced System pressure on the return oil circuit is maintained by a check valve set at 50 PSIG 3 4 BAR Return oil pressure can be monitored by observing the System Discharge pressur...

Страница 37: ...e to the condensate purifier assembly The excess oil is removed from the condensate and the water is properly routed to the sewer system The discharge from the Condensate Purifier Assembly may be cont...

Страница 38: ...spillage the user or other responsible body must ensure appropriate cleanup and decontamination is carried out Reference CLEANING AND DECONTAMINATION in the ROUTINE MAINTENANCE section of this manual...

Страница 39: ...tinuous operation with initial results being achieved in 8 12 passes after starting The number of initial passes necessary to clean the oil in a reservoir is contingent upon the contamination level pr...

Страница 40: ...fset the failure symptoms and lead to more serious problems before detection and corrections can be made Keeping system adjustments to a minimum is intended to make the systems more reliable and to in...

Страница 41: ...ing is between 50 to 100 PSIG 3 5 and 6 9 BAR at operating temperature depending upon size configuration of the oil return line d The temperature controller output setting gauge reading is relatively...

Страница 42: ...ressure will falls to zero To shut down the system 1 turn the selector switch form the ON to the OFF position 2 allow the system to operate until the motor turns off 3 turn the main disconnect switch...

Страница 43: ...a is clear of all hazardous or explosive gases or materials and that a HOT WORK PERMIT or other authorization to work has been issued and posted according to all facility standards and procedures Wher...

Страница 44: ...l in the ThermoJet Oil Purifier and its subassemblies may be contaminated with the substances being removed from the processed oil Ensure that the methods used to manage and dispose of these materials...

Страница 45: ...il Heater Maintenance X p n 40500060 Flange Gasket 6 Inch Auto Tune Oil Heater Controller X Check and Adjust Operating Pressures X Verify Low Oil Pressure Switch Operation X Verify Oil Heater High Tem...

Страница 46: ...ecessary this list should be expanded to include additional check points applicable to your particular installation that are important in assuring proper and continuous and safe operation Check and re...

Страница 47: ...ousing and allow the oil to drain into a suitable container Turn the locking ring on the filter housing counter clockwise using the supplied wrench that is attached to the filter housing until the hou...

Страница 48: ...he strainer Collect and properly dispose of all collected contents To remove and clean the strainer screen remove the large plug The suction screen along with the dirty oil and particulate can be remo...

Страница 49: ...oil absorption media sock if saturated This absorption media sock should remain effective for two to four weeks Periodic visual inspection is the only way to determine if sock is saturated To replace...

Страница 50: ...tube from the bottom of the filter housing Next firmly grasp the filter housing with both hands and lift upward and turn to the left Clock wise The filter housing can then be lowered away from the fi...

Страница 51: ...s open the cabinet door and locate the jet mixer The inlet air screens are located on top of the jet mixer To access the air filter screens remove the wing nuts from the top of the air breathers and l...

Страница 52: ...t oil inlet and outlet connection First drain all oil from the separation vessel and the inlet oil filter A drain plug is located in the outlet pump suction line between the separation vessel outlet a...

Страница 53: ...to the oil filter drain valve and 6 oil pressure tube to the outlet oil pressure gauge Once all tubing has been removed remove the separation vessel cover plate from the vessel The cover plate is secu...

Страница 54: ...el control valve sticks or does not operate smoothly it should be replaced Use part number 51850100 VALVE LEVEL CONTROL Once all parts are inspected and determined to be in proper working order reasse...

Страница 55: ...ssel The heater vessel drain is located on the interior of the ThermoJet H2500E cabinet Remove the closure cap from the drain valve and set aside Using a pail to gather the oil open the drain valve lo...

Страница 56: ...way of the conduit union Loosen the conduit union and separate the two halves of the fitting so that the heater bundle can be removed WARNING Use suitable transport equipment for removing the heater b...

Страница 57: ...elements Clean the heater bundle to remove any residue or contamination that may have entered the heater vessel Inspect the interior of the heater vessel and wipe clean with a lint free cloth NOTICE W...

Страница 58: ...e 58 of 100 Remove the drain tubing between the heater tube and the inlet of the jet mixer Remove the elbow at the heater vessel end and inspect the drain orifice Insure that the drain orifice is clea...

Страница 59: ...tall terminal cover Install the cap on the drain valve in the bottom of the heater vessel and insure that the drain valve is in the close position Take care to guard against pinching and crushing haza...

Страница 60: ...repaired in the field If the flame path is damaged the enclosure is to be removed from service and replaced with a new properly working enclosure Before performing this maintenance task ensure that th...

Страница 61: ...g process begins Once the auto tune process is completed the process display will cease to flash and the unit will revert to normal operation Insure that the oil temperature operates at the prescribed...

Страница 62: ...eturn oil pressure is for the purpose of insuring that the systems operating pressures are correctly adjusted For information on adjusting the inlet oil pressure refer to the section titled Adjusting...

Страница 63: ...circuit so that the oil heater is inoperable if the oil pressure drops below 135 PSI 9 3 BAR For additional information refer to the wiring diagram included in the section of this manual titled IX PA...

Страница 64: ...w pressure switch operation has been confirmed adjust the pressure control valve by turning the adjusting screw C Clockwise to set the system operating pressure to it normal operating set point of 240...

Страница 65: ...emperature alarm heater cutout setting power to the oil heater element is interrupted When this happens the oil temperature as indicated on the heater controller display will begin to decrease As the...

Страница 66: ...e the thermocouple simulator to the same screws Take care to observe proper polarity for and terminations Restart the ThermoJet by turning the main disconnect to the ON position and then switching the...

Страница 67: ...perature and attempt to energize the heater However the high limit controller will prohibit the oil heater from energizing and oil temperature will continue to fall The Heater ON pilot light will be i...

Страница 68: ...and re connect the high limit thermocouple Take care to observe proper connections for and terminations Securely re install the enclosure covers NOTICE When a Heater High Temperature alarm occurs the...

Страница 69: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 69 of 100 VII CLEANING AND DECONTAMINATION...

Страница 70: ...hermoJet Oil Purifier cabinet and reservoir may be wiped down with cloth rags or recyclable paper wipes or towels that are able to absorb oil and remove any accumulation of dust In case of oil spillag...

Страница 71: ...with your lubricating oil supplier and the lubricating oil MSDS documentation regarding safe guards and Personal Protective Equipment PPE requirements NOTICE Dispose of all contaminated cleaning mater...

Страница 72: ...ling facility or disassembly for recycling the following steps should be performed All oil must be drained from the separation tank the oil heater tube the oil filer housing and interconnecting piping...

Страница 73: ...ry Ensure that all previously connected sources of electrical power are disconnected before opening the AC power enclosures and attempting to disconnect electrical wiring Do not tip or stand equipment...

Страница 74: ...r housing and allow the oil to drain into a suitable container 4 To drain the heater vessel open the drain valve and drain the oil into a suitable container 5 Remove the oil filter element and install...

Страница 75: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 75 of 100 VIII TROUBLE SHOOTING...

Страница 76: ...inlet line sizes are as specified in Section III of this manual G Verify that suction lift does not exceed 8 feet 2 4 meters H Verify that oil viscosity does not exceed 3 000 SSU I If the pump is noi...

Страница 77: ...of accomplishing this might be to remove the thermocouple that is in the ThermoJet and attempt to read ambient condition or a known temperature Then verify that the temperature reading being displayed...

Страница 78: ...m 30 PSIG 2 bar differential If filter discharge pressure range is too low with a clean filter reset pressure relief safety valve PRV1 by turning off machine for 15 seconds and allow the pop off valve...

Страница 79: ...used Contact customer service for technical assistance if frequent filter loading occurs Clean Y strainer screen Attempt to remove contaminants not designed for air stripping such as heavy hydrocarbon...

Страница 80: ...ing to purify motor oils 6 Presence of contaminants which attack Viton seals 7 High differential pressure on oil filter 8 Operating without oil filter element or inlet Y strainer element 9 Operating w...

Страница 81: ...testing should only be made by a qualified electrician Before removing the cover to the controller contact appropriate operating personnel and obtain all required hot work permits Ensure that the are...

Страница 82: ...Doc 77740119 Rev 15 Date June 2020 Page 82 of 100 Maintenance Spare Parts List Part Number Description Quantity 1910 3006 Oil Filter Element 6 Microns 1 4052 0235 Filter Housing O Ring Viton 1 1920 1...

Страница 83: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 83 of 100 Process and Instrument Diagram...

Страница 84: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 84 of 100 PID Symbol Legend and Customer Connection Chart...

Страница 85: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 85 of 100 Electrical Wiring Diagram...

Страница 86: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 86 of 100 Transformer Wiring 575VAC 460VAC 440VAC 115VAC 110VAC...

Страница 87: ...haracteristics Item Part Number Quan Description 1 30571032 1 TRIP BLOCK 8 32 AMPS 2 77750215 R13 3 Time Delay Fuse Class CC 600V 6 Amp 3 30180010 2 Time Delay Fuse Class CC 600V 1 Amp 4 30180021 1 Ti...

Страница 88: ...se Class CC 600V 1 Amp 11 77750215 R13 3 Time Delay Fuse Class CC 600V 6 Amp 12 30180021 1 Time Delay Fuse 13i32 X 1 1i2 _ 250V 2 Amp 13 30201014 1 Ground Lug 14 30571000 1 Basic Switching Device 15 3...

Страница 89: ...45TC EXP Proof 1 1 2 HP 1 1 2 HP 230 460VAC 60HZ 1750RPM 190 220 380 440VAC 3 PHASE 50HZ 1400 RPM note 1 2 3 4 5 MOTOR ELECTRIC 1 1 2HP NEMA 7 145TC 1 1 2 HP 575VAC 3 PHASE 60HZ 1750RPM note 6 38 7778...

Страница 90: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 90 of 100 General Arrangement Drawings Front View w Door Opened...

Страница 91: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 91 of 100 Left Side View...

Страница 92: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 92 of 100 Top View Rear View...

Страница 93: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 93 of 100 Controller...

Страница 94: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 94 of 100 Dimensional Outline Drawings Front View...

Страница 95: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 95 of 100 Left Side View...

Страница 96: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 96 of 100 Rear View...

Страница 97: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 97 of 100 Right Side View...

Страница 98: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 98 of 100 Top View...

Страница 99: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 99 of 100 Bottom View Anchor bolt spacing...

Страница 100: ...THERMOJET H 2500E SERIES OIL PURIFIER SYSTEM INSTALLATION AND OPERATING MANUAL Doc 77740119 Rev 15 Date June 2020 Page 100 of 100...

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