44-10467-0001-01.21.07.qxd (Page 1)globalindustrialsolutions.net/pdfs/KleentekNSeriesOwnersManual.pdf · • Check all valve positions before operating to prevent pump cavitation,

KLEENTEK®

ELECTROSTATIC OIL CLEANER

N-SERIES MODEL: N10/N25/N50/N100

OWNER’S MANUAL

KLEENTEK®

KNOW YOUR EQUIPMENT

READ THIS MANUAL FIRST.

Your KLEENTEK system should provide many years of trouble-free service. This manu-al will help you understand the operation of your KLEENTEK unit. It will also help youunderstand how to maintain it in order to achieve top performance. For quick future ref-erence, fill in the system and filter information in the spaces below. Should you needassistance, call the United Air Specialists, Inc. customer service number shown below. To expedite yourservice, have the following information available when contacting UAS.

UAS ORDER #:________________________________________________________________

UNIT MODEL #: _______________________________________________________________

UNIT SERIAL #: _______________________________________________________________

CARTRIDGE FILTER PART #:____________________________________________________

SYSTEM ACCESSORIES:

______________________________________________________________________________

______________________________________________________________________________

______________________________________________________________________________

INSTALLATION DATE: __________________________________________________________

UNITED AIR SPECIALISTS, INC. CUSTOMER SERVICE

1-800-252-4647

i

TABLE OF CONTENTSPage

SAFETY PRECAUTIONS........................................................................................ ii

1. INTRODUCTION TO ELECTROSTATIC OIL CLEANING................................ 1

2. APPLICATIONS ................................................................................................ 1

3. INSTALLATION PLANNING.............................................................................. 2

4. INSTALLATION ................................................................................................ 3

5. KLEENTEK CONTROLLER.............................................................................. 3

6. OPERATION .................................................................................................... 3

7. ROUTINE MAINTENANCE .............................................................................. 4

8. ALARMS .......................................................................................................... 5

9. TROUBLESHOOTING...................................................................................... 5

10. PUMP SERVICING .......................................................................................... 7

11. REPLACEMENT PARTS .................................................................................. 8

12. APPENDIXIllustration, UNIT N10................................................................................ 11Illustration, UNIT N25 .............................................................................. 12Illustration, UNIT N50 .............................................................................. 13Illustration, UNIT N100 ............................................................................ 14Wiring Diagram, N10/N25/N50 ................................................................ 15Wiring Diagram, N100 ............................................................................ 16

13. TROUBLESHOOTING CHART ...................................................................... 17

WARRANTY

ii

IMPORTANT SAFETY INSTRUCTIONS

To reduce the risk of fire, electric shock, or injury when using your oil cleaner, follow these basic precautions:

SAFETY PRECAUTIONSWe have provided many important safety messages in this manual and on your KLEENTEK® Electrostatic Oil Cleaner.Always read and obey all safety messages.

• Use two or more people to move and install your KLEENTEK® Oil Cleaner.

• The KLEENTEK® must be properly grounded.

• Disconnect power before servicing.

• Replace all access panels before operating.

• Wear protective clothing and safety glasses when handlingcollection components or servicing the oil cleaner.

• Electrical connections should only be made by qualified personnel, and be in accordance with local and nationalcodes and regulations.

• The KLEENTEK® Oil Cleaner should be serviced by qualified and trained personnel only.

• The high voltage power supply output is 12,000 volts. Usecaution when servicing.

• Do not use in explosive atmospheres.

• Use to clean approved oils only.

• Do not use to clean oils which are explosive or highly flammable.

• Keep flammable materials and vapors, such as gasoline,away from oil cleaner.

• Operate only in a safe and serviceable condition.

• Check all valve positions before operating to prevent pumpcavitation, excess tank pressure or leakage.

!

! DA N G E R

! WARNING

! WARNING

! C AU T I O N

C A U T I O N

This is the safety alert symbol.

This symbol alerts you to potential hazards that can kill or hurt you and others. All safety messages will follow thesafety alert symbol and the word “DANGER”, “WARNING”, or “CAUTION”. These words mean:

Indicates a hazardous situation which, if not avoided, will result in death orserious injury.

Indicates a potentially hazardous situation which, if not avoided, could resultin death or serious injury.

Indicates a potentially hazardous situation which, if not avoided, may resultin minor or moderate injury.

CAUTION used without the safety alert symbol indicates a potentiallyhazardous situation which, if not avoided, may result in property damage.

1

Revised 01/07 KLEENTEK®

Oil Cleaner

KLEENTEK®

1. INTRODUCTION TO ELECTROSTATIC OIL CLEANING

A. Principles of Electrostatic Oil Cleaning

1. Electrostatic oil cleaning system utilizes an electricalfield as a means to capture foreign contaminants in aliquid. This electrical field is generated by highvoltage electrodes contained within the cleaningchamber of the system. As fluid flows through thefield, particulate contaminant including the resinousproducts of oxidation are subsequently attracted tothe electrodes due to several acting laws of physics.The contaminant then becomes lodged on thedielectric media (collectors) located between theelectrodes within the cleaning chamber.

B. Unit Construction

1. Unit specifications are listed in Table 1. A list of thereplacement parts for the electrostatic oil cleaningunit types is included on page 9 and 10. Should it benecessary to replace any parts on an electrostatic oilcleaning unit, the part description and part numbershould be used to identify them in the orderingprocess.

2. Illustrations can be seen in Section 11, beginning onpage 8. Important components and features havebeen labeled for ease of identification.

CleaningChamber Power

Model Capacity Flow Rate Width Length Height Weight Consumption*Number Gal/Liters gpm/lpm in/cm in/cm in/cm lb/kg watts

N10 3.3/12.5 0.5/1.9 15.75/40.0 26.9/68.3 26.75/67.9 115/52.3 640

N25 5.1/19.3 1.5/5.7 15.75/40.0 26.9/68.3 30.38/77.2 125/56.8 640

N50 9.3/35.2 2.8/10.6 15.75/40.0 27.9/70.9 33.75/85.7 165/75.0 675

N100 18.6/10.4 5.6/22.4 20.75/52.7 33.75/85.7 33.75/85.7 280/127.0 785

*N10/N25/N50 with optional heater kit requires an additional 150 watts.*N100 with optional heater ket requires an additional 300 watts.

D.C.D.C. Voltage

Model System Voltage Voltage Cut Off HV Power Quantity of CollectorNumber Volts/Phase/HZ Output Point Supplies Collectors Replacement

N10/N25/N50 115/1/60 10-12KV 3.0 KV 1 1 Cartridge 2000-4000 hrs of use

N100 115/1/60 10-12KV 3.0 KV 2 2 Cartridge 2000-4000 hrs of use

Table 1UNIT SPECIFICATIONS

2. APPLICATIONS

A. The DOC units can be used to clean any non-conductive fluid such as hydraulic or lubricating oils, provided the oil conforms to the following limitations:

1. The temperature of the oil is below 140˚F (60˚C).

2. The viscosity of the oil is below 200 cSt (926 S.U.S.).

3. The water content of the oil is below 500 ppm.

B. The DOC unit should N0T be used for the followingapplications:

1. Oils with a water content greater than 500 ppm.

2. Oils with a high level of detergent dispersant additives.

3. Oils which are conductive (such as water-based fluids).

C. Environmental Considerations

1. The N-Series Kleentek modules are designed tooperate within an ambient temperature range of 32˚Fto 120˚F (0˚C to 49˚C). Units with optional heater kitcan operate to -10˚F (-23˚C).

2. The Kleentek units should never be installed in directsunlight.

3. The Kleentek electrical components are contained in a NEMA 4 enclosure, providing a degree ofprotection from dirt, rain, snow, splashing water, etc.The Kleentek unit should never be subject to hosedirected water.

! DA N G E REXPLOSIVE HAZARD. DO NOT USE TO CLEAN OILS THAT AREEXPLOSIVE OR HIGHLY FLAMMABLE.

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Oil Cleaner

KLEENTEK®

Figure 1PREFERRED INSTALLATION DIAGRAM

3. INSTALLATION PLANNING

A. Relative Height of Units (See FIGURE 1)

1. The cleaning chamber of a standard electrostatic oilcleaning unit is designed to withstand pressure up to25 psi. The pump internal by-pass relief valve isfactory set at 25 psi. The oil cleaner should not beinstalled in a manner as to apply more than 25 psi ofback pressure from the reservoir. The unit shouldnot be more than ten feet above or below thereservoir.

B. Plumbing Requirements (See FIGURE 1)

1. Ball valves should be installed in the supply line andreturn lines from the oil reservoir to isolate theKleentek unit from the reservoir during servicing orrepair.

2. The return line should enter the oil reservoir at apoint that is always below the maximum oil level inthe reservoir. For optimum circulation of oil thereturn line should be located on the opposite side ofthe reservoir from the supply line.

! DA N G E RELECTRICAL SHOCK HAZARD. TO PREVENT ELECTRICAL SHOCKDISCONNECT OIL CLEANER FROM POWERSOURCE BEFORE SERVICING.

C. Electrical Requirements

1. The DOC units are wired for 115 volts/singlephase/60 hertz. A 10' power cord is provided forconnection. A Power On/Off Switch is provided forunit operation. The unit should be disconnected fromthe power source before servicing. The DOC unitsalso have one available ”dry” contact alerting there isan alarm condition, for connection to the machine’scontrol panel.

D. Equipment Required

1. The DOC comes complete with all necessary parts andcomponents for dedicated operation. Connections for oilsupply, return and drain are provided. Ball valves shouldbe installed on the supply and return lines in order toisolate the Kleentek unit from the reservoir duringcollector changes, servicing or repair. A suction straineris strongly recommended to be used on the supplyside of the pump to protect it from malfunction. Astrainer can be provided as an option with theoptional hose kit.

61-10048-0002

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Oil Cleaner

KLEENTEK®

4. INSTALLATION

A. Installing Collectors1. Prior to installation of collector media for the initial unit

start-up or for replacement of fully loaded media, be surethe Power Switch is in the “Off” position and suppliedpower is disconnected.

2. To install a collector cartridge in the electrostatic oil clean-ing unit, close the isolation valves in the supply and returnlines. If the Kleentek oil cleaner has pumped oil see“Draining the Cleaning Chamber” in section 6D.

3. To install a collector cartridge, first unscrew (counterclock-wise) clamp and remove chamber lid. Once the lid is off,loosen and remove the wing nut and slide the triangularinsulator plate off of the center post. The existing filtershould slide up and off of the center post.

4. Place a collector cartridge over the center post with themetal tabs facing down and slide it into the cleaning cham-ber. The metal tabs on the outside of the cartridge shouldmake contact with the cleaning chamber wall and themetal tab in the center of the cartridge should make con-tact with the center post. One cartridge is needed perchange out. (Note: N-100 Requires [2] filters per collec-tor.)Make sure the triangular insulator plate is in the bottomof the chamber with the ridges facing upward.

5. Check to ensure that the o-ring gasket which provides theseal between the cleaning chamber cover and the cleaningchamber is in the top flange within the cleaning chamber.

6. Replace the cleaning chamber cover and press down light-ly until the cover has a snug fit with the cleaning chamber.

7. Replace the cleaning chamber clamp and tighten theclamp until securely fastened.

8. Close air vent valve on cover.

5. KLEENTEK CONTROLLERThe controller is Nema 4, internally fused (10A SB) and has abuilt-in overload for the pump motor.

A. Controller Pushbuttons and LED's1. START – press to start filling, cleaning or draining oil; Start

LED illuminated when Kleentek is enabled.2. STOP – press to stop filling, cleaning or draining oil; Stop

LED illuminated when all processes are stopped.3. FWD – press to change pump direction to forward; FWD

LED illuminated when pump running in forward direction.4. REV – press to change pump direction to drain tanks; REV

LED illuminated when pump is running in the reverse direction.

5. ALARM RESET – press to clear alarm conditions aftercorrecting cause of alarm; Alarm Reset LED illuminatedwhen alarm conditions are active.

6. UP – press UP repeatedly to scroll up through screens todisplay current conditions. After 10 seconds the display willreturn to the default screen

7. DOWN – press DOWN repeatedly to reverse, scrollingdown through screens to display current conditions. After10 seconds the display will return to the default screen.

6. OPERATION

A. Power UP1. Confirm that the oil to be cleaned conforms with limits

stated in Section 2.2. Ensure that the collector media is properly installed as

described in Section 4A.3. Close drain and sample valve on the cleaning chamber.4. Ensure that supply and return lines are open to machine

reservoir.5. Plug in the 115VAC 6. Turn the power selector switch located on top of the

enclosure to the ON position. The power selector switchilluminates signifying operation. If the light does not illumi-nate consult the troubleshooting chart. The controller willpower up, all LEDs will flash ON, the controller configura-tion and firmware revision are displayed for 10 secondsand then the current condition is displayed.

7. To fill the tanks follow the filling instructions.

B. Filling1. Open air bleed valve(s) on the top of the tank.2. Press the START pushbutton. The display reads [TANK

FILLING / IN PROGRESS... ], the LED above START illu-minates, the LED above FWD illuminates, the pump runs.

3. After several minutes the tank(s) will be full. The pump willstop. There may be a delay. When the float switche(s) detecta full tank then the following may be displayed if all tank(s)are not equally full: [TANK FILLING/15 SECOND PAUSE].The pump may run again briefly to top off the tank(s).

4. When the tank(s) is full then the pump will stop for 3 min-utes. The high voltage is enabled and the display readsHV = 11.9KVDC / PUMP START – 3.0 MIN. The timer willcount backwards showing the remaining minutes until thepump will start.

5. Close the air bleed valves at the top of the chamber(s).6. After the 3 minute delay the pump will restart and the

Kleentek will be cleaning oil (see cleaning).7. If the tank does not fill after a period of time then the

Alarm pilot light will flash, the Alarm contact will close, theLED above Alarm Reset will illuminate and the display willread [ TANK NOT FILLING / TIMEOUT ALARM ]. Consultthe troubleshooting chart.


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Oil Cleaner

KLEENTEK®

7. ROUTINE MAINTENANCEALWAYS disconnect the unit from the 115 VAC supplypower source before servicing.

A. Maintenance Scheduling

The following schedule is for hydraulic oil with moderatecontamination. If heavily contaminated oil is to becleaned, the amount of time between maintenanceoperations will be less. It should be noted, theseschedules are not absolute. The time for themaintenance procedures will vary from one application to the next.

* Dependent upon application, collector life could beextended up to one year. However, collectors must bechanged at least once every year!

Table 2MAINTENANCE TABLE

B. Replacing Collectors and Cleaning the CleaningChamber

It will be necessary to change collectors when changingto a different type of oil as well as when they are dirty.At this time, the inside of the cleaning chamber shouldbe cleaned as well. The cleaning procedure is asfollows:

1. Drain the cleaning chambers per instructions in 6D.

2. Remove the cleaning chamber covers.

3. Remove the contaminated collector cartridges.

4. Clean the inside of the cleaning chambers withkerosene. Wipe down the inside of cleaningchambers with lint free cloths until they are free ofany contaminants or kerosene.

5. Allow chambers to dry.

C. Cleaning

1. Press the START pushbutton. The LED aboveSTART illuminates, The high voltage power is ON,The display reads [ HV = 11.9KVDC / PUMP START– 3.0 MIN ] Timer will count backwards showing theremaining time until the pump will start. The displaywill rotate between showing the HV reading for allavailable tanks.

2. After 3 minute delay, the pump starts, the FWD LEDilluminates, the display reads [ HV1 = 11.9KVDC /CLEANING OIL ].

3. The Kleentek unit is now pumping and cleaning oil

4. To stop the Kleentek unit press STOP. The pumpstops, the STOP LED illuminates, the display reads [KLEENTEK OFF / ].

D. Draining

1. Press the STOP pushbutton. The LED aboveSTOP illuminates.

2. Close the isolation valve in the return line.

3. Press START, the START LED illuminates.

4. Press REV immediately. Wait a few seconds thenthe pump runs in reverse, the REV LED illuminatesand the display reads [ TANK DRAINING / INPROGRESS...].

5. Open the air bleed valves at the top of the chamberlid(s). Remove the brass plug from the clear tubing.This allows all the oil to be pumped from the cleaningchambers without creating a vacuum in the cleaningchamber(s).

6. Wait several minutes until the Kleentek automaticallystops. The tanks are empty. The display reads [POWER DOWN AND / CHANGE COLLECTOR ]. Noother functions including scrolling UP and DOWN will beavailable until the controller is powered down using thePOWER selector switch on top of the enclosure.

7. Turn the power selector switch to OFF. Selectorswitch is not illuminated. The tanks are now empty,the Kleentek is OFF and the collectors may now bereplaced.

8. Remove the lid from the tank(s) and then removefilter hold-down and filter.

9. The remaining inch of sediment and oil can bedrained via the bottom drain valve, located behindthe access panel below the electrical enclosure.

10. It is advisable to clean the cleaning chamber(s)thoroughly before further use. See cleaningprocedure in section 7B.

! C AU T I O NFIRE HAZARDTO REDUCE THE RISK OF FIRE PROPERLY DISPOSE OF OIL AND KEROSENE SOAKED CLOTHS.

DOC-UNITS

1st Collector 2,000 hrsCartridge Replacement of operation

Replacing *Every 180 days, orCollector Cartridges 4000 hours operation

Rinsing Cleaning When changingChamber with Kerosene collector


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Oil Cleaner

KLEENTEK®

6. Install the new collector cartridges per instructions in 4A.

7. Replace the cleaning chamber cover(s) and close theair vent on the chamber cover(s).

8. Turn power switch “ON.”

9. Reset Timer by pressing the Alarm Reset pushbutton10 times.

8. ALARMSEach component that can effect Kleentek operation haspossible alarm conditions. While an alarm condition isactive, the LED above Alarm Reset will be illuminated,the red pilot light on top of the enclosure will flash andthe alarm contact will close. The following are possiblealarm displays.

A. CHANGE COLLECTOR / 4000 HR ALARM

1. Press alarm reset to clear the alarm. The onlyoperation allowed after this alarm is draining thetanks. If cleaning is restarted then the alarm willoccur again.

2. Drain the Kleentek using the drain procedure.

3. Replace the collector(s)

4. Reset the hour counter4.1. Press UP once4.2. Display TIMER = 4000 HOURS / IN USE =

166 DAYS4.3. Press Alarm Reset 10 times within 30 seconds4.4. Display PRESS DOWN TO RESET. / OTHER

KEYS TO CANCEL4.5. Press down4.6. Display TIMER = 0 HOURS / IN USE =

166 DAYS4.7. The timer is now reset. Refill the Kleentek unit

using the fill procedure.

B. ALARM CODES

1. HV1 = 2.8KVDC / HV FAILURE ALARMHV2 = 11.8KVDC / HV FAILURE ALARMThe voltage for the tank 1 HV power pack hasdropped below 3KVDC. If the Kleentek unit only hasone tank then the HV for that tank has failed.Correct the condition (consult troubleshooting guide)and press alarm reset to clear the alarm. The samealarm could be displayed for other HV supplies. Ifthe displayed voltage = 0.0KVDC then check that thecable from the tank to the power pack is connectedcorrectly.

2. PUMP MOTOR ALARM / OVERCURRENT – 6.5 AThe motor current is too high. Correct the conditioncausing the overcurrent condition and press alarmreset to clear the alarm.

3. PUMP MOTOR ALARM / UNDERCURRENT – 0.0 AThe motor current is nonexistent. Correct thecondition causing the undercurrent condition,probably the motor connector is disconnected andpress alarm reset to clear the alarm.

4. TANK NOT FULL / ALARMScroll UP/DWN to this screen: TANK 1 / NOT FULLThe float switch for the tank noted is not sensing theoil level. Press Alarm Reset to clear alarm. Fill thetanks to correct.

5. TANK NOT FILLING / TIMEOUT ALARMThe tank float switch has not detected oil afterseveral minutes of filling. Check for the cause as towhy the tanks are not filling, correct and press alarmreset to clear the alarm.

6. TANK NOT DRAINING / TIMEOUT ALARMThe tank float switch has not opened within 1 minuteof draining. Check for the cause, as to why the tanksare not draining, correct and press alarm reset toclear the alarm.

7. LID POSITION ALARM / CORRECT TO CLEAN OILScroll UP/DWN to this screen: LID 1 / NOT INPOSITIONThe proximity sensor for the lid noted is not sensingthe lid. Close lid so that the proximity sensor detectsthe lid. Press Alarm Reset to clear alarm condition.

8. HV ERROR SERVICE / REQUIRED. POWER DOWNHV supply voltage is detected when there should benone. This is a fatal error for the controller. Powerdown the Kleentek unit and contact UAS.

9. MOTOR ERROR SERVICE / REQUIRED. POWERDOWNMotor current is detected when there should benone. This is a fatal error for the controller. Powerdown the Kleentek unit and contact UAS.

9.TROUBLESHOOTING (See Chart on pages 17)

ALWAYS disconnect the unit from the 115 VAC powersource before servicing.

A. Loss of High Voltage

When the electrical voltage in the cleaning chamberfalls below 3.0 KV, the power to the HV power supplywill be interrupted. The alarm contact will also be open.The minimum voltage is 3.0 KV for all units. Shouldthis occur, the unit can be reset by the following:

1. Turn the Power Switch “OFF,” then “ON.”

2. If the high voltage is cut off again within 10 secondsand the alarm signal is received, turn ”OFF” thePower Switch.

3. Test the moisture content in the oil. This can be done in one of two ways. The first way involvesobtaining a small sample of oil from the drain valveand examining it under a 50X microscope. If severalround spots can be observed, this is confirmation ofa moisture content greater than 500 ppm. Thesecond method involves heating a metal teaspoonusing a gas flame or lighter and then placing asample of oil on the heated spoon. If bubbles beginto appear in the oil then the moisture content isgreater than 500 ppm. If the moisture content isgreater than 500 ppm, the oil must be pre-treated toremove the water from the oil.

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Oil Cleaner

KLEENTEK®

11. Once the reading is taken, turn ”OFF” all power andrestore the DOC unit to its normal operating config-uration by replacing collector cartridge, cleaningchamber cover and pump/motor wires. Be sure themetal tabs on the cartridge are facing down and aremaking contact with the center post and the clean-ing chamber wall.

12. The voltage output should be 10-12KV. If a valuesubstantially less than 10KV is attained, contact theKLEENTEK representative.

D. Pump Problems - What to Look For1.No Oil is Delivered.

a. Suction lift too high for vapor pressures of liquidpumped. While pump will develop as high as 27inches of vacuum, it is good engineering practiceto reduce the vacuum to a minimum.

b. Bad leaks in suction line or port passages can bedetected by submerging pressure line from dis-charge side of pump into a pail of oil, where theair will be seen in the form of bubbles.

c. Pump shaft not rotating.Coupling defective - tongue and groove or gearnot engaged.

2. Capacity is too Low.a. Suction lift too high.b. Air leaks in suction line.c. Suction line is too small.

Can be detected by installing a vacuum gaugedirectly at the pump suction. The maximum vacu-um at the pump suction should never exceed 15inches of mercury. It is necessary to keep below15 inches, not because of the inability of the pumpto handle a higher vacuum, but primarily becauseof the vaporization that is liable to take place at ahigher vacuum. Vaporization caused by highervacuums will generally result in capacity drop-off.

d. Pump speed too slow.e. Strainer too small or obstructed.f. Suction pipe or port not immersed in the liquid

deep enough.g. Piping improperly installed, permitting air pocket to

form in pump.h. Increased clearances or wear in the pump will

sometimes cause the pump to deliver an insuffi-cient supply of liquid.

3. Pump Works Spasmodically.a. Suction lift too high.b. Air or vapor in liquid.c. Coupling slipping on pump shaft.

4. Pump Wastes Power.a. Pressure is too high.b. Liquid more viscous than desired.c. Suction or discharge lines obstructed.d. Mechanical defects.

1) End thrust on pump shaft. (Pump is notdesigned to take end thrust toward the pumpcover and extreme care must be taken toprevent thrust in this direction).

B. Alarm After Collector Change

If the alarm signals within 5 hours of operation with thenew collectors, check the following:

Test the moisture content in the oil. This can be donein one of two ways. The first way involves obtaining asmall sample of oil from the drain valve and examiningit under a 50X power microscope. If several roundspots can be observed, this is confirmation of amoisture content greater than 500 ppm. The secondmethod involves heating a metal teaspoon using a gasflame or lighter and then placing a sample of oil on theheated spoon. If bubbles begin to appear in the oilthen the moisture content is greater than 500 ppm. Ifthe moisture content is greater than 500 ppm, the oilmust be pre-treated to remove the water from the oil.

C. Testing - High Voltage

If the DOC unit is not removing contaminants from theoil or is functioning below the designed standard levelof operation, this could be due to a lack of high voltagein the cleaning chamber. In this case, the voltage beinggenerated in the cleaning chamber will need to betested. To test the voltage in the cleaning chamber,proceed with the following instructions:

1. Attain a high voltage probe. It is recommended touse a digital multi-meter and 40KV high voltageprobe or equivalent.

2. Drain the DOC unit per instructions in Section 6D.

3. Ensure that flow is stopped and Power Switches are“OFF”.

4. Remove the cleaning chamber cover.

5. Remove the collector cartridge.

6. Disconnect the electrical connector leading to thepump/motor.

7. Replace cleaning chamber cover fastener (bandclamp) to provide signal to Proximity Switch.

8. Be sure that no one is touching anything within thecleaning chamber and turn the Power Switch “ON.”

9. The center post is the means by which high voltageis transmitted to the cleaning chamber cartridge. Inorder to attain a voltage reading from the centerpost, it will require two people to perform the nextstep. One person, with an insulated tool, must defeatFloat Switch located inside the cleaning chambersBe careful! The high voltage is now ON in thecleaning chamber. The cleaning chamber isgrounded and there will be no danger unless thecenter post is contacted.

10. The ground clip from HV probe must be connectedto the grounded tank. Using the high-voltage probe,the second person will contact the center post andattain a voltage output reading.

! WARNINGELECTROSTATIC SHOCK HAZARD. USE EXTREME CARE WHEN TESTING FOR HIGH VOLTAGE.

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KLEENTEK®

! CAUTIONPINCH HAZARDDISCONNECT UNIT FROM POWER SOURCEBEFORE SERVICING

2) Driving shaft and pump shaft misaligned.3) The pump may be binding due to insufficient

end clearance.4) Pump shaft bent.5) Misalignment within pump due to strains built

up by piping or installation.5. Pump is Noisy.

a. Machine or part of it is acting as sounding board.b. Misalignment of couplings. Coupling set up too

close to pump.d. Vibration of pump.

1) Bent Shaft.2) Worn pump.

e. Air leaks into suction side of pump.f. Suction lift so high that an air pocket forms within liquid.

6. Handle With Care.If it becomes necessary to remove pump from yourequipment to return to the manufacturer, plugsshould be inserted in the ports to prevent foreignmaterial from getting into the moving parts. Pumpsare precision-built and should be given everyreasonable care.

10. PUMP SERVICINGA. Disassembly of Seal

The seal assembly of the pump may be changedwithout disassembly of the rest of the pump.1. Place the pump in vise, shaft facing up, so that

one jaw grips across the two ports. Do not tightenexcessively as pump housing may be distorted.

2. Inspect shaft at key-way, flat or drive tang. Anyburrs will interfere with removal of housing plugbearing assembly.

3. Remove housing plug with face type spanner wrench.4. Remove the seal from shaft. The rubber boot

will be bonded to the shaft, so it is necessary topush down on the seal to break this bond.Grasp the metal outer shell with any suitabledevice and pull the seal assembly upwards.The spring and washer should also be removed.

5. The pump assemblies have a snap ring on theshaft to back up the seal assembly. Do notremove this snap ring unless you arecompletely disassembling the pump. A step onthe shaft is used as the seal back up.

6. Remove stationary seal face from housing plugby pressing out from opposite side.

7. If damaged, remove the 0-ring from outsidediameter (O.D.) of housing plug.

B. Disassembly of Pump1. Seal assembly must be removed before

disassembly of pump. Also remove snap ring onshaft.

2. Mark cover and body of the pump for properreassembly. Remove cap screws, cover, idlerand rotor from housing.

C. Inspection1. Check pump housing, rotor, idler gear, idler pin

and crescent for wear, chipped or broken teeth.2. Housing bore and rotor O.D. may be checked for

wear by positioning rotor in the housing andcheck for clearance in the bearing. The shaftmust turn freely without any detectable side play.Any side play will require replacement of thehousing, rotor or both. If both housing and rotorrequire replacing, it is economically advisable toreplace the pump.

D. Assembly of PumpThe following must be carefully followed whenpump is reassembled:1. Clean all parts thoroughly using great care to

eliminate all dirt.2. Install rotor in pump body.3. Apply gasket to cover. Use new gasket if old one

is damaged.4. Place idler gear on pin in cover assembly.5. Place cover assembly with gear on pump. (Align

matching marks for proper location.)6. Install cover cap screws. Pull down gradually

and alternate from a screw on one side to oneon the opposite side. Torque to 7-10 ft. lbs.

7. Install snap ring on shaft.E. Assembly of Seal

1. Clean all parts thoroughly using great care toeliminate all dirt.

2. Oil shaft with suitable lubricating oil.3. Oil inside of new rotary seal assembly.4. Press stationary face into housing plug. Lapped

surface must be up. Protect this lapped surfaceby covering it with a piece of paper when pressingdown on face. Use your fingers for this operation.

5. Place new 0-ring on O.D. of housing plug, ifrequired, and lubricate with oil.

6. Lubricate carbon face liberally with lube oil.7. Reassemble housing plug into position over the

pump shaft. Do not nick seal face by hittingpump shaft. Tighten the housing plug withspanner wrench. Rotating seal will automaticallybe positioned by this operation.

8. If pump is equipped with ball bearing, pressbearing onto shaft. Press on bearing inner racewith suitable sleeve. Do not hammer intoposition or press on bearing outer race.

9. Check pump for free rotation by turning shaftwith suitable wrench. There will be a definiteresistance to turning because of the seal load.The pump must turn freely without binding.

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11. REPLACEMENT PARTSTo order parts, contact your local KleentekRepresentative or UAS directly:

United Air Specialists, Inc.4440 Creek Road

Cincinnati, OH 45242Attn: Kleentek Customer Service Dept.

1-800-252-4647www.kleentek.com

Figure 2PUMP CUTAWAY DIAGRAM

The following information is required for prompt service:

1. Unit Model Number (See I.D. Label on side of tank)

2. Unit Serial Number (See I.D. Label on side of tank)

3. Part Number (Refer to Replacement Parts List on page 9)

When returning a defective part under warranty, youmust call UAS for a return authorization number (RMA).This number should appear on the package beingreturned. With this control number, we can ensureprompt service. You can also return defective parts toyour local Kleentek Representative.

1. HOUSING2. HOUSING BUSHING3. COVER4. IDLER PIN5. COVER GASKET6. ROTOR

7. RETAINING RING8. SEAL ASSEMBLY9. “O” RING10. IDLER11. HOUSING PLUG12. COVER BOLTS

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N10/N25/N50 GENERAL PARTS LISTITEM NO. PART NO. UNIT TYPE PART DESCRIPTION

1 02-10576-0004 N10 High Voltage Intake Assembly02-10576-0004 N25 High Voltage Intake Assembly02-10576-0003 N50 High Voltage Intake Assembly

2 20-10061-SSL2G N10/N25/N50 Power Switch3 21-1250 N10/N25/N50 High Voltage Power Supply4 22-10011-0001 N10/N25/N50 MTR, 1/4HP, 115/1/60, TEFC, 1725RPM (less pump)5 25-10003-0001 N10/N25/N50 Control Interface6 37-10001-0002 N10 O Ring for Chamber Cover

37-10001-0002 N25 O Ring for Chamber Cover37-10001-0003 N50 O Ring for Chamber Cover

7 46-10001-0010 N10 Pump Assembly (0.4 GPM) (less motor)46-10001-0025 N25 Pump Assembly (1.5 GPM) (less motor)46-10001-0050 N50 Pump Assembly (2.8 GPM) (less motor)

8 46-10002-10 N10 Pump/Motor Assembly (0.4 GPM)46-10002-25 N25 Pump/Motor Assembly (1.5 GPM)46-10002-50 N50 Pump/Motor Assembly (2.8 GPM)

9 60-0198 N10 Collector, Supporter/Insulator60-0198 N25 Collector, Supporter/Insulator60-0477 N50 Collector, Supporter/Insulator

10 60-0215 N10 Cleaning Chamber Cover Fastener60-0215 N25 Cleaning Chamber Cover Fastener60-0424 N50 Cleaning Chamber Cover Fastener

11 60-0472 N10 Collector Cartridge Element60-0473 N25 Collector Cartridge Element60-0474 N50 Collector Cartridge Element

12 20-10119-PLR N10/N25/N50 Pilot LightOPTIONS

* 37-10001-001 N10/N25/N50 O-Ring for Intake Fitting* 02-10723-0001 N10/N25/N50 High Voltage Cable Assembly

ITEMS NOT SHOWNNot Shown 20-2864 N10/N25/N50 Proximity SwitchNot Shown 60-0045 N10/N25/N50 Float SwitchNot Shown 20-10145-10 N10/N25/N50 Fuse

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KLEENTEK®

N100 GENERAL PARTS LISTITEM NO. PART NO. PART DESCRIPTION

1 02-10576-0003 High Voltage Intake Assembly2 20-10119-PLR Pilot Light3 20-10061-SSL2G Power Switch4 21-1250 High Voltage Power Supply5 22-10011-0001 MTR, 1/3HP, 115/1/60, TEFC, 1725RPM (less pump)6 25-10003-0001 Control Interface7 37-10001-0003 O Ring for Chamber Cover8 46-10001-0100 Pump Assembly (5.5 GPM) (less motor)9 46-10003-100 Pump/Motor Assembly (5.5 GPM)10 60-0477 Collector, Supporter/Insulator11 60-0424 Cleaning Chamber Cover Fastener12 60-0474 Collector Cartridge Element

OPTIONS* 37-10001-0001 O-Ring for Intake Fitting* 02-10723-0001 High Voltage Cable Assembly

ITEMS NOT SHOWNNOT SHOWN 20-2864 Proximity SwitchNOT SHOWN 60-0045 Float SwitchNOT SHOWN 20-10145-10 Fuse

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Appendix 1UNIT N10

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Appendix 2UNIT N25

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KLEENTEK®

Appendix 3UNIT N50

KLEENTEK®14


Oil Cleaner

Appendix 4UNIT N100

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Appendix 5N10/N25/N50 Wiring Diagram

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KLEENTEK®

Appendix 6N100 Wiring Diagram

No Power To Unit

Unit & Control BoardOn/Off Switch

Main Power Source

On/Off Switch

Power Source

Make sure switch is in the “On” position.

Make sure power source is turned on.

Pump is Inoperative

Pump Motor Alarm/Overcurrent

Pump Motor Alarm/Undercurrent

Pump/Motor Drawing Too MuchCurrent

Motor Failure

Check for blockages, closed valves orhigh pressure drop in the supply line.

Once fixed, press the alarm reset button.

Check the motor wiring. If everything iscorrect, the motor may need replaced.

Pump is Operative ButNot Pumping Oil

Ensure the supply and reliefValves are Fully Open

Pump is in Bypass Mode Throughthe Internal Relief Valve.

Suction Hose Not Below Oil Level.

Suction Port

Relief is Open Due to contaminant

Pump Drive Coupling is Worn

Check for blockages, closed valves orhigh pressure drop in the supply line.

Open the valves.

Overhaul and clean the internal relief valve.

Replace the pump drive-coupling.

High Voltage FailureAlarm

Collector

High Voltage Cable Connection

High Voltage Electrode in Tank

High Voltage Power Supply

The Collector is Wet

The Oil Has a Water ContentExceeding 500ppm

The Oil or Particulate in Oil isExceedingly Conductive

High Voltage Power SupplyHas Failed

Remove and dry collector or replace.

Remove the source of the moisture in the oilor remove the moisture.

Make sure your oil conforms to standardslisted in Section 2B.

Replace the power supply.

Oil Leaking From Unit

Pump Seal

Tank Lid O-Ring

Supply and Return Oil Fittings

High Voltage Assembly

Worn of Damaged Pump Seal

Tank Lid Not Properly Clamped,O-Ring is Missing or Damaged

Fittings Are Loose

The HV Assembly Oil Seal is Broken

Replace Seal

Re-tighten lid or replace o-ring

Tighten or replace fittings as needed

Re-tighten electrode with screw driver orretaining nut with wrench.

Oil is Not BeingSufficiently Cleaned

Check Oil

Check Ingression ofContamination

Check Oil Oxidation, If Oil HasBeen in Service for Several Years

Check the High Voltage at the PowerSupply with a High Voltage Probe

The Oil Has a High Detergent Level(HLP) or the Viscosity of the Oil is High.

The Ingression Rate is High.

The Production Rate ofContaminate is High.

HV Power Supply is Disconnectedor Not Providing sufficient Voltage.

Replace Seal

Detergent oils typically take 10 times longer to clean than ordinary oil(HLP). An electric heater can be used to reduce the viscosity of the oil.

Use a larger size collector.

Check HV connection(s) or replacepower supply.

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TROUBLESHOOTING CHARTSections 8 & 9 of this manual also provide information and assistance concerning troubleshooting your Kleentek System.

FAILURE CHECKPOINT(S) POSSIBLE CAUSES RECOMMENDED SOLUTIONS

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©2005 United Air SpecialistsPart No. 44-10467-000101/07

United Air Specialists, Inc. reserves the right to change

design or specifications without notice.

4440 Creek Road • Cincinnati, Ohio 45242 USANational Phone: 1-800-252-4647

Telephone: (513) 891-0400 • Fax: (513) 891-4882http://www.uasinc.com

UNITED AIR SPECIALISTS, INC.LIMITED WARRANTY

UAS warrants to the original purchaser that all equipment will be free from defects in materials andworkmanship for one year from the date of shipment from UAS (three years for Smokeeter® andVisionAir™ models other than CC and DC series) and that major structural components on SFC and MCBseries will be free from defects in materials and workmanship for ten years from the date of shipment fromUAS. This warranty applies only if equipment is properly installed, maintained, and operated under normalconditions and does not apply to damage caused by corrosion, abrasion, abnormal use or misuse,misapplication, or normal wear and tear. This warranty will be void with respect to equipment that is subjectto unauthorized repairs or modifications. UAS makes no warranty as to goods manufactured or supplied byothers. This warranty is subject to any limitations in UAS’ quotation and may not be modified except by awritten instrument signed by the President or Vice President of Sales of UAS.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHERWRITTEN, ORAL OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OFMERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE OR NONINFRINGEMENT.

As Purchaser's exclusive remedy for any defects in the equipment, UAS will exchange or repair anydefective parts during the warranty period, provided such parts are returned, prepaid, to UAS' factory. Theobligation of UAS is limited to furnishing replacement parts F.O.B. UAS' factory or making repairs at UAS'factory of any parts that are determined, upon inspection by UAS, to be defective. In no event will UAS beresponsible for labor or transportation charges for the removal, reshipment or reinstallation of the parts.

IN NO EVENT WILL UAS BE RESPONSIBLE FOR ANY SPECIAL OR CONSEQUENTIALDAMAGES.

Documents

44-10467-0001-01.21.07.qxd (Page 1)globalindustrialsolutions.net/pdfs/KleentekNSeriesOwnersManual.pdf · • Check all valve positions before operating to prevent pump cavitation,