CONTENTS

Sr. No.

Contents

1.

Specifications of ELC Unit

2.

Principle of Operation

3.

Construction

4.

Operation Procedure

5.

Drain Discharge

6.

Draining/Removing Cleaned Oil from the tank

7.

Application

8.

Life of Collectors

9.

Replacement of Collectors

10.

Warranty

11.

Caution for Safety

12.

Electric Circuit

13.

Standard Spares Supplied with Machine

14.

Control and Annunciator Functions

15.

Setting Parameters

16.

Error Displays or Annunciation

17

Trouble Shooting

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Page No.

11

OPERATION MANUAL

1.

SPECIFICATIONS:

ELC-8 LP / 25 A / 50 C / 100 LP

Power Consumption

200 / 200 / 450 / 550 w

Power Source

415 V AC -3 Phase / 220 V 1 Phase 50hz

Pump Capacity

8 LP

: 2 Ltrs. / Min at 1425 rpm

25 A, 25 D

: 3.5 Ltrs. / Min at 1425 rpm

50 C, 100 LP : 10 Ltrs. / Min at 1425 rpm

Specifications

ELC 8 LP

ELC 25A

ELC 50C

ELC 100LP

Dimensions (Approx) (L)

(W)
(H)

610 mm
380 mm
540 mm

805 mm
480 mm
720 mm

805 mm
480 mm
920 mm

870 mm
620 mm
940 mm

Weight (Approx)

70 kgs.

100 kgs

140 kgs

180 kgs

12

12

16

Collector (pcs/set)

2. PRINCIPLE OF OPERATION:
The ELC system uses the principle of electrostatics to collect fluid contaminants. FERROCARE
ELC's unique design permits it to take advantage of the natural charge of each contaminant.
Contaminants that have a positive charge are drawn towards the negative electrode plate and
those with a negative charge are drawn towards the positive plate. Neutral contaminants are drawn
and deposited by gradient force to the edge of the collectors where the intensity of the deformed
electric field is the strongest.
As the fluid flows freely through the system, the ELC removes contaminants - submicronic particles
even smaller than 0.01 micron, dust, dirt and products of oxidation such as tars or sludge and
varnishes. Contaminants are trapped on cellulose collectors for easy disposal. The ELC does not
affect soluble additives.
3. CONSTRUCTION:
A) The ELC consists of the electrical panel (A) and the condenser unit (B). The latter works as the
Cleaning Cell of the ELC unit.
B) The condenser (cleaning tank) is designed for pressure 1.5 kg/cm2.
The total head of oil between the oil reservoir to be cleaned and the ELC 8LP / 25A / 50C / 100LP
unit should not exceed 3 meters. In case the head exceeds 3 meters, use our D type machine.

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4. OPERATION PROCEDURE: Refer figures 1, 2, 3 & 4.

4a. STARTING AND STOPPING THE MACHINE
Before starting the machine, ensure the following:
1. Confirm that the oil temperature, moisture content are
within limits specified for the machine, i.e., below 60C,
500ppm.
2. Check the power switch (ELCB +MCB) of the ELC is off.
3.Confirm that the collectors are in place between the
electrodes, and fasten the cleaning tank cover evenly.
4. Shut the drain valve (E) and open the sample cock (D).
5.Ensure that the pump is filled with oil and suction line is
fully immersed in oil.
6. Check that the suction and discharge hoses are
connected at both ends.
7. Open flow control valve (F) in line after the pump.
8. Switch on the ELCB after ensuring proper electrical
connections.
9. Press the FWR/REV button to bring the pump to
Forward operation as shown by LED in figure below.
Fig. 4

The Control Panel face for

ELC 100LP

ELC 8LP / 25A / 50C

HV-1

mA

mA

HV-2

KV

KV

WAIT

WAIT

FWR
REV

FWR
REV

START
STOP

START
STOP

PMP FWR

PMP FWR

PMP REV

PMP REV

HV

- ELECTROSTATIC LIQUID CLEANER

FERROCARE

LV

HV

- ELECTROSTATIC LIQUID CLEANER

LV

FERROCARE

10. Press the Start button (START/STOP). Both LED ON

means Forward. Start LED ON and FWR LED OFF
means pump running reverse. Both LED OFF means
machine stopped.
11. The ELC will start and the pump will fill the tank with oil.
The float switch gets activated as the top level is reached.
The pump will automatically stop when the cleaning cell
tank is filled with oil. The pump will automatically restart
after the preset interval and cleaning will start.

This on delay timer switches off the pump every time the float switch is operated after the machine is
started, even after a power failure or shutdown. This ensures that the contaminants from the collector,
which may have been dislodged into the oil in the ELC tank during power failure or shut down are
redeposited on the collectors before the oil flow is restarted.
4b. STOPPING THE MACHINE: Press the Stop button (START/ STOP) to stop the machine. The
LED will switch off to indicate pump stoppage.
5. DRAIN DlSCHARGE When the ELC is continuously operated for a long time, it is advisable
to discharge about 1 litre of the oil from the drain valve (E) at an interval of 50 hours. This
ensures discharge of heavy contaminants from the drain.
6. DRAINING/ REMOVING CLEANED OIL FROM THE TANK
a)
b)
c)
d)
e)
f)
g)
h)

Switch off the ELC

Put plastic oil pan under the Y type strainer of suction hose.
Unscrew the cap of the Y type strainer remove wire mesh and clean.
Replace the wire mesh after cleaning and retighten the cap of the strainer
Open air cock on the top cover of the cleaning tank (Sampling cock(D))
Open the control panel door and set internal toggle switch "ON"
Set the Forward /Reverse button (FWR/ REV) to reverse. The LED will be off.
Press the Start button. The pump will start in reverse and drain the tank.

PRECAUTION: Do not pump out all the oil, care has to be taken to switch off the pump if dirty oil
starts flowing out of the machine.
i)
The oil at the bottom should be drained into the oil pan from the drain valve.
NOTE: If final oil is required to be NAS grade 7 (ISO code16/13) and better, do not drain oil from
the cleaning tank back to the reservoir.
j)
IMPORTANT: The oil pump can only be reversed by pressing the push button inside the
panel and the FWR/REV button on the control panel together, after opening the panel.
7. APPLICATION
The Electrostatic Liquid Cleaner "ELC" unit can be used for cleaning hydraulic and lubricating
oils of the following general specifications.
Temperature - below 60 degrees C and Moisture - below 500 ppm
The ELC unit cannot be used for cleaning of:
a) Oils with moisture in excess of 500 ppm
b) Oils with detergent dispersant additives
c) Some synthetic oils
d) Conductive oils

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8. LIFE OF COLLECTORS
The life of collectors depends on the contamination level in the oil.
If contamination level is 7 to 10 mg/100 ml., a new collector set can clean about 5,000 litres
(ELC-50C) of oil. The average life of a collector is 2,000 hours.
A rough indication of collector life is as follows:
Type of ELC

ELC-8 LP

7.0-10.0mg

10-15mg

ELC-50 C
7.0-10mg

10-15mg

ELC-100LP

Contaminant
Level/ 100ml

7.0-10.0mg

Life of

800 500 2,000 1,5004,000 3,000 8000 6000 1,000 Ltrs

800 Ltrs
2,500Ltrs
2,000Ltrs 5,000 Ltrs 4,000 Ltrs 10,000 Ltrs 8,000 Ltrs
in 1,500
in 800
in 800
in 500
in 1,500
in 800
in 1,500
800
to 2,000 hrs to 1,000 hrs to 1,000 hrs to 800 hrs to 2,000 hrs to 1,000 hrs to 2,000 hrs to 1,000 hrs

Collectors

10-15mg

ELC-25 A

7.0-10mg

10-15mg

9. REPLACEMENT OF COLLECTORS (Refer Fig. 2)

Unscrew all bolts of the condensor (cleaning tank) cover and remove the contaminated
corrugated type collectors (H) (dielectric media), and electrode covers. At this time, make
sure to clean electrodes before replacing with new collectors.
10. WARRANTY
a) The manufacturer shall repair all defects, except consumable parts for a period of
12 months from the date of shipment. in any event, the manufacturer shall not be
responsible for any and all damage or failure due to incorrect operation, malpractice,
mishandling and negligence.
b) In the event that the user finds any defect in the ELC, the user shall advise the details of
such defect in writing to the manufacturer. The manufacturer shall correct such defects
promptly. The manufacturer reserves the right to make final judgement on claims made by
the user.
c) In no event shall the manufacturer be liable for any and all consequential loss, damage or
expenses howsoever arising from all claims upon and all liability of the manufacturer.

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C
B
A
Fig. 5

Seal
Nut

Fig. 6

Hi-Volt
Cable

14. CONTROL AND ANNUNCIATION FUNCTIONS

HV-1

mA

mA

HV-2

KV

KV

WAIT

WAIT

FWR
REV

FWR
REV

START
STOP

START
STOP

PMP FWR

PMP FWR

PMP REV

PMP REV

HV

- ELECTROSTATIC LIQUID CLEANER

LV

FERROCARE

100LP

HV

- ELECTROSTATIC LIQUID CLEANER

LV

FERROCARE

8LP / 50C / 25A

The panel displayed indicates that High Voltage is 10.6 kV and that machine is running with pump
in forward mode for ELC 100LP (fig. on left).
The panel displayed (fig. on right) indicates that current is 0.6 mA and the machine is running with
pump in forward mode for ELC 8LP / 25A / 50C .
For 100LP - indicator for HV-1 is green and display is V for Voltage. The 100LP machine uses
TWO High Voltage transformers, hence the LEDs are divided as HV-1 and HV-2.
For other ELCs - Indicator for milliamps is green and current is 0.6 mA. Since the machines have
only one transformer, the LED lights are separate for mA and kV.
The Pump Switch LED is ON, meaning pump is running forward.
The display will scroll across four parameters, namely, mA, kV (milliampere current and Voltage
across the electrodes), temperature and running hours in sequence. Each parameter will be
displayed for the duration set in Scroll Time setting

15 a. SETTING PARAMETERS:
Pressing the "SETTING" button
will select the
next parameter
for display.

Pressing the (value)

"ARROW" button
will increment the parameter
by one point.

16 b. SAFETY SETTINGS:
There is a push button inside the panel which allows the programming functions, so that the set
parameters cannot be disturbed by anyone playing with the push buttons.
Display of different parameters can still be selected, but settings cannot be changed until the
internal switch is activated after opening the panel cover.

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The following parameters can be set or displayed:

1. Set Current: 2 to 10 mA /for 100LP/ 50C : 5mA for 25A/ 8LP

Set current : 10.0 mA

( 2 to 12 mA)

This is the set current across the electrodes. This setting is

required to protect the heart of the machine viz., High
Voltage Transformer. If the current increases there is
conduction across the electrodes i.e., they are getting
"shorted" or a short circuit path is available which would
overload the transformer.
The HVT is therefore protected by setting it to trip at this
"set current" which can be varied from 2 to 10 mA.
The current across the electrodes can increase if water is
mixed in the oil or it contains excessive metal particles.

2. Set Temperature:

Set Temp. : 60C

(30 to 65 C)

This setting is for the temperature of oil passing through

the ELC. Insulators in the ELC are made of PVC and
cannot withstand sustained high temperatures.
The SET temperature between 30 and 60 degrees, is
selected to trip the pump if hot oil is passing through the
unit. Temperatures above 50 deg C are harmful to the oil
as well as the ELC.
Note: All units are not equipped with oil temperature
sensor.

3. L. V. Setting:

LV Setting: 05
(1 to 10)

This the setting for the Low Voltage operation of the ELC.
This sets the tripping current for the transformer when ELC
is operating on low voltage of 5 KV. In the particular case
above, the ELC will trip at 2 mA (for 25 A/ 8LP, 5mA for
50C/100 LP). This setting ensures safety of the
transformer.

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

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5. Scroll time parameter:

The display scrolls across parameters i.e., it displays 4 set
parameters one by one. It will display, turn by turn mA , KV,
temp., and running hours.
In this case each parameter will be displayed for
5 seconds, and then the next one will be displayed for
3 seconds. If the scroll time is set to zero, then the selected
parameter will not be continuously displayed. Other
parameters will have to be manually selected for display
using the "SETTING" button.

Scroll Time 03
(0 to 10)

6. Service life setting:

SErv - Service
If Op. Hrs. = 1, then 250 Hrs.
Controller Trip on "SERV"
Recommended Settings:
50C . . . . . . . . 06 hrs.
100LP . . . . . . 06 hrs.
25A . . . . . . . . 05 hrs.
8LP . . . . . . . . 03 hrs.

The collectors which hold contaminants removed from oil

being cleaned, have a specific service life. This means
that the collectors should be changed after a specified
running hours.
Each unit on this setting is 250 hours. When the set
running hours are completed the unit will display "SErv",
meaning that the service life is completed. The collectors
should be removed, examined, and if necessary replaced
(Service life is 1000 hrs. for 25A, 1500 hrs. for 50C &
2000 hrs. for 100LP)
The setting is based on a unit of 250 hours. Therefore
H006 as shown above means 1500 hours service life.
H004 would mean 1000 hours. H008 means 2000 hours.
Setable parameters should be distributed from the factory
setting except when necessary and by people trained for
instrument calibration.

7. Auto Restart Pump:

If the pump trips on overload, "P_ol ", it can be restarted
automatically if " Ar" is set to "Y".

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16. ERROR DISPLAYS OR ANNUNCIATION:

LS - Limit Switch

FS - Float Switch

This error display means that the ELC tank cover is open.
When properly secured the cover operates a limit switch
and switches off this error message.
Trouble Shooting:
! Put back the top cover, if not in place and tighten all the
bolts securely.
! Check that the limit switch is OK.
There is a float switch which does not allow the
electrodes to be charged. If not totally immersed in oil.
When the float switch is activated, the motor will trip for
a five minute interval and restart. It will now run
continuously. This interruption is provided so that
contaminants from previous operation do not flow out
with the new oil, and are redeposited on the collectors. if
the pump does not start, or the float switch is faulty, then
also this error signal will appear. This error means that
there is insufficient oil in the tank. One reason is that oil
is not available to the pump. This alarm will come due to
Hi-volt fuse blown out.
Trouble Shooting:
! Check that the oil pump is running.
! Check if oil is available and the suction hose is properly

immersed in the oil.

! Check "Y strainer" to ensure there is no blockage.
! Check float switch operation manually.

This indicates that overload relay of the pump motor has

operated. The preset here is Auto. The pump will start
automatically on cooling. A manual setting is possible.
PoL - Pump over load

Trouble Shooting:
! Check that there is no obstruction to the discharge.
! Check the pump / motor are aligned and secured to the

foundation.
! Check the pump motor windings electrically.
! Check capacitor overload relay and contactors.

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This indicates that the tripping current of the HVT is

reached in "Hi" mode.
H-oL - Current Over Load
in "Hi" mode

Trouble Shooting:
! Check whether there is moisture in the oil.
! Check if oil contains an excess of metal particles

If low switch over is "y" the machine will now switch to low
and if the current exceeds even the low setting the
machine will trip.
This indicates that the tripping current of the HVT is
reached in "Lo" mode.
L-oL - Current Over Load
in "Lo" mode

Trouble Shooting:
! Check whether there is moisture in the oil.
! Check if oil contains an excess of metal particles.
Temperature overload :
This indicates that the temperature of the oil flowing
through the machine is too high and the machine will stop.

ot - Temp Over Load

10

Trouble Shooting:
! Check the setting is not too low.
! Check the oil cooler in the equipment.
! Heavy moisture in oil.

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17. TROUBLE SHOOTING

NO.

PROBLEM

CHECK

SOLUTIONS

1.

ELC B + MCB is "ON"

But (power light off).
Machine does not
Switch on.

1. Power supply from socket

2. fuse no. 1 (central fuse)
3. Loose connections at source

1. Switch "ON" power supply

2. Replace if fused.
3. Tighten properly

2.

ELC B + MCB
trips earth leakage

1. Motor connection loose

2. Winding insulation low
3. Motor Capacior leakage to
the body.
4. MS1, MS2, OLR power contact
short circuit
5. Loose connection at plug point
phase and neutral or phase to
phase wire touch or phase to
earth

1. Rectify
2. Overhaul motor
3. Replace if faulty

1. Use the test button of ELCB

+ MCB to trip it

1. Replace ELCB if faulty

3.

ELC B + MCB is not

Tripping

4.

Motor does not operate 1. Overload relay not working

(oil tank empty) and it
Indicates (P-OL)
2. Input supply
3. Loose contact of power supply
line
4. Motor + pump alignment
5. Pump jam
6. Centrifugal switch
7. Motor connection and winding
and capacitor leakage

4. Replace if faulty
5. Tighten properly

1. Push reset and turn to "Auto"

Replace if faulty.
2. Ensure input power supply
3. Tighten properly

8. Contactor contacts (power)

4. Readjust properly
5. Open and clean the
Rotor, and strainer mesh
6. Replace if faulty
7. Replace if capacitor
faulty rectify connection
8. Replace if faulty

5.

Excessive pump noise

1. Flow control valve is closed

2. Y-strainer

1. Open valve
2. Clean if choked

6.

Pump does not draw

oil

1. Pump suction by placing hand

on suction port
2. If no pump suction

1. If suction is good check

suction hose is dipped in oil
2. a) Overhaul and clean
the relief valve
b) Replace the pump

7.

Oil leakage from pump

1. Check the oil seal

2. Loose bolts

1. Replace if necessary
2. Tighten properly

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11

NO. PROBLEM

CHECK

SOLUTIONS

8.

1. Thermal OLR

1. Set current with required

motor name plate ratings
2. Open and clean mesh
3. Re-adjust properly
4. Repair if necessary
5. Ensure power supply of
correct voltage
6. Tighten properly and
replace if faulty

Motor trips frequently

when machine is in
operation and it
Indicates (P_OL)

2. Y- strainer
3. Motor pump alignment
4. Motor winding weak
5. Power supply voltage (230/415)
6. Loose contact of contactor
power contact and OLR

9.

Fuse-1 blows
repeatedly.

10.

Indicates H-OL and

1. More moisture in oil check with
L-OL and / or HVT fuse
CC kit.
blows repeatedly.
2. Open top cover and check if
SS electrodes are correctly
placed In the slot
3. Collector heavily contaminated

1. Replace collector and start

the machine after moisture is
removed from the oil
2. Ensure electrodes placed
properly
3. Replace, if necessary

11.

ON PLC indicates 'ot'

1. Oil temperature & setting.

2. Open the top cover and check
electrodes are correctly placed
in the slot
3. Check moisture in oil
4. Transformer earthing cable
loose.

1. It should not exceed 60C

2. Place correctly, if not.

1. The oil has high detergents

(HLDP)

1. It takes about 10 times

longer to clean than
ordinary oil
2. Viscous oil takes longer
to clean
3. Use larger ELC

12.

1. MS1 or MS2 motor contactor coil Replace if faulty

open
2. Timer
Replace if faulty

HV' led is 'ON' and the

MA' reading is below
5 mA, oil is not being
Cleaned

2. Check if viscosity is high

3. Should be below 500 ppm

4. Connect properly

3. Contamination ingression rate

is high
4. Oil oxidation if oil has been
4. Drain out about 10% oil
used for many years or
oil from the oil reservoir.
generation of oxidation matter is
Top up with the new oil
high.
or add.
5. Collector is contaminated.
5. Replace with new
collector.

12

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