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RelaDyne ThermoJet G3500E Series Installation And Operating Manual

Oil purifier system
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Installation and Operating Manual
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.
______________________
5615 W Fuqua • Houston, Texas 77085
1-713.464.6266 • Fax: 713.464.9871
THERMOJET
OIL PURIFIER SYSTEM
INSTALLATION AND OPERATING MANUAL
ThermoJet G3500E Series
Oil Purifier System
WARNING
®
G3500E SERIES
Doc #
77740123
Rev
14
Date
June 2020
Page 1 of 104
Doc 77740123 Rev 14

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Summary of Contents for RelaDyne ThermoJet G3500E Series

  • Page 1 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 1 of 104 ThermoJet G3500E Series Oil Purifier System Installation and Operating Manual WARNING READ AND UNDERSTAND THIS OPERATING MANUAL BEFORE ATTEMPTING TO INSTALL, COMMISSION, OR USE THIS EQUIPMENT.
  • Page 2 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 2 of 104 NOTES: _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________ _______________________________________________________________________...

  • Page 3: Table Of Contents

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 3 of 104 Table of Contents I GENERAL INFORMATION ........................... 5 Manufacturer Contact Information ........................ 6 Explanation Of Graphic Symbols In The Documentation ................7 II UNIT IDENTIFICATION AND LABELING ....................
  • Page 4 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 4 of 104 Removal From Use, Disposal And Transport ..................... 74 Draining and Cleaning Procedures ......................77 VIII TROUBLE SHOOTING ..........................78 Trouble Shooting Guide ..........................

  • Page 5: I General Information

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 5 of 104 I GENERAL INFORMATION...

  • Page 6: Manufacturer Contact Information

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 6 of 104 Manufacturer Contact Information 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 and operation of ThermoJet®...

  • Page 7: Explanation Of Graphic Symbols In The Documentation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 7 of 104 Explanation Of Graphic Symbols In The Documentation The following graphic symbols are used in this publication to communicate specific detailed information necessary for the safe operation of this product.
  • Page 8 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 8 of 104 SYMBOL SYMBOL DESCRIPTION AND USE This symbol is used to warn against “CRUSHING”. The equipment should never be tipped or stood on edge. This symbol can be used in conjunction with a “SAFETY ALERT”...
  • Page 9 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 9 of 104 SYMBOL SYMBOL DESCRIPTION AND USE This symbol is used to indicate that gloves and other “PERSONAL PROTECTIVE EQUIPMENT (PPE)” should be used. This symbol may be used in conjunction with a “NOTICE”.

  • Page 10: Unit Identification And Labeling

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 10 of 104 II UNIT IDENTIFICATION AND LABELING...

  • Page 11: Thermojet ® Model G3500- Model Code Designations

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 11 of 104 ThermoJet ® Model G3500- Model Code Designations Electrical Standard: The ThermoJet ® Model G3500E Oil Purifier is designed to comply with Class 1 Groups CD/ T3C Inlet Power: The ThermoJet®...

  • Page 12: Model Code Designation Key

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 12 of 104 Model Code Designation Key ThermoJet ® Model G3500E Oil Purifier Option Description Option Code Description Degassing Application in Application Type Hydrocarbon Processing Industry G3500 Electrical Area Classification...

  • Page 13: Tag Detail For G3500E Model Oil Purifiers

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 13 of 104 Tag Detail for G3500E Model Oil Purifiers Data Ref. Description Example Model No. Per Customer. P.O. & Manufacture Job Order See ”...

  • Page 14: Description Of The Product

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 14 of 104 III DESCRIPTION OF THE PRODUCT...

  • Page 15: Principal Of Operation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 15 of 104 Principal of Operation The ThermoJet Oil Purifier works on the principal of air stripping. The use of air or nitrogen bubbled through contaminated liquids has long been used to remove contaminants.

  • Page 16: Installation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 16 of 104 IV INSTALLATION WARNING If the equipment is not used in the manner described in this manual the protection provided by the equipment may be impaired WARNING THIS INSTRUMENT MUST BE EARTHED...

  • Page 17: Receipt Inspection

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 17 of 104 Receipt Inspection Remove all shipping materials and plastic plugs. Inspect for shipping damage externally and internally (open enclosure door), and immediately report any damage found to the delivering freight company.

  • Page 18: Inlet And Return Oil Piping Connections

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 18 of 104 Inlet and Return Oil Piping Connections The oil inlet and outlet connection sizes are 1” FNPT. The user suction and discharge line sizes (either schedule 40 (min) pipe or smooth I.D.
  • Page 19 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 19 of 104 To prevent the potential risk of static electricity ensure that free falling oil does not exceed 6 inches (150 mm).

  • Page 20: Nitrogen Inlet Connection

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 20 of 104 Nitrogen Inlet Connection The nitrogen supply inlet connection is 3/8” FNPT. The plant’s nitrogen supply line should be equal to or larger than the 3/8”...

  • Page 21: Condensate Purifier Connection

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 21 of 104 Condensate Purifier Connection Condensate Purifier Assembly (CPA) connection is ½” FNPT. Pipe CPA connection is to a dirty / oily water drain system.

  • Page 22: System Exhaust And Relief Valve Connections

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 22 of 104 System Exhaust and Relief Valve Connections The exhaust to flare connection is a 3/4” FNPT spring-loaded check valve rated at 1/2 PSIG. (0.04 BAR) Do not reduce the connection size.
  • Page 23 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 23 of 104 To properly vent discharge gas to the plant’s flare system, the exhaust to flare piping is connected to the 1/2 PSIG (0.04 BAR) spring loaded pressure check valve located on the vent connection of the ThermoJet Oil Purifier.

  • Page 24: Electrical Power Connection

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 24 of 104 Electrical Power Connection Supply power service is made at a terminal enclosure below the controller. The connection is 3/4” conduit 3/4”...
  • Page 25 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 25 of 104 WARNING Electrical power service must have adequate circuit protection. Use the table below for selection of proper user provided interrupt device.
  • Page 26 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 26 of 104 Access the power terminals by unscrewing the cover on the terminal enclosure. Service power to the ThermoJet Oil Purifier originates at terminals L1,-L2 and L3 located in a terminal enclosure. See the diagrams below for terminal location and user terminal connection identification.

  • Page 27: Grounding

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 27 of 104 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 ground connection location. Suitable wire size range is 1/0 - #14 STR.

  • Page 28: System Start-Up And Operation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 28 of 104 V SYSTEM START-UP AND OPERATION...

  • Page 29: Start-Up Procedures

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 29 of 104 Start-Up Procedures Before each start-up, perform a “walk-around” of the purifier installation noting if the points covered in INSTALLATION Section of this manual are correct. Ensure that the oil filter element is installed in the filter housing and that the O-ring is in good condition.
  • Page 30 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 30 of 104 NOTICE: Recycle all drained oils. NOTICE: Dispose of all contaminated cleaning materials in accordance with all environmental laws, ordinances and directives.
  • Page 31 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 31 of 104 Ensure that all sources of electrical power are disconnected before opening the controller. Failure to do so may result in serious injury or even death.
  • Page 32 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 32 of 104 Use the air bleed/sample valve on the downstream of the inlet pump so that air in the suction line can escape.
  • Page 33 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 33 of 104 NOTICE: Wear appropriate personal protective gear. When cleaning oil spills consult with your lubricating oil supplier and the lubricating oil MSDS documentation regarding safe guards and Personal Protective Equipment (PPE) requirements...

  • Page 34: Heater Operation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 34 of 104 Heater Operation: The electric heater will not energize until flow is established and all the air escapes from the heater tube and the oil pressure builds.
  • Page 35 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 35 of 104 Unscrew enclosure cover to Use UP and DOWN buttons access heater controller to adjust setting When making adjustments to the oil heater control temperature setting the system must be energized and operating.
  • Page 36 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 36 of 104 Should the vessel surface thermocouple output reach the high temperature 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.

  • Page 37: Adjusting System Pressure

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 37 of 104 Adjusting System Pressure The pressure control valve (PCV1) downstream of the Oil Heater is factory set at 16.5 BAR (240 PSIG) at the heater process temperature of 82 C (180 F).

  • Page 38: System Discharge Pressure

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 38 of 104 System Discharge Pressure No adjustments are necessary to the discharge pressure. Once the pressurized oil is processed through the ThermoJet Jet Mixer it enters the separation vessel where the air and removed water vapor is vented out of the system.

  • Page 39: Adjusting The Nitrogen Supply

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 39 of 104 Adjusting the Nitrogen Supply Prior to setting the nitrogen supply check the nitrogen supply needle valve and ensure it is the full closed position.

  • Page 40: System Vent Operation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 40 of 104 System Vent Operation No adjustment is necessary for operation of the vent system discharge. Once the nitrogen supply begins flowing into the separation tank and is vented into the facility flare header.
  • Page 41 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 41 of 104 The discharge from the Condensate Purifier Assembly may be contaminated with the substances being removed from the processed oil. Ensure that the methods used to manage and dispose of these materials are in compliance with all governing authorities and plant policies and procedures.

  • Page 42: Monitoring Normal Operation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 42 of 104 Monitoring Normal Operation Although the ThermoJet G3500E may be used to clean lubricants in batch operations, it is most commonly installed to clean oil in a single dedicated reservoir.

  • Page 43: List Of Gases Removed By Thermojet G-3700E Series

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 43 of 104 List of Gases Removed By ThermoJet G-3700E Series Ammonia Dimethylpentane Methyl Butane Benzene Dimethylpropane Methylcyclopropane Butadiene Ethane Methylcyclopentane Butane Ethylene Methylpentane Butene...
  • Page 44 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 44 of 104 WARNING When collecting oil from the sample valve, the oil will be hot and under pressure. NOTICE: Wear appropriate personal protective gear when collecting oil samples.

  • Page 45: Dailey Thermojet Oil Purifier System Operational Checks

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 45 of 104 Dailey ThermoJet Oil Purifier System Operational Checks The following operating checks should be made daily; a) The normal inlet Pump Discharge pressure gauge reading is between 210 to 240 PSIG (14.5 and 16.5 BAR) at operating temperature.

  • Page 46: System Shutdown

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 46 of 104 System Shutdown ThermoJet Oil Purifiers are equipped with a timing relay which delays cessation of oil flow for 2 minutes after the power selector switch has been transferred from the ON to the OFF position.

  • Page 47: Routine Maintenance

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 47 of 104 VI ROUTINE MAINTENANCE NOTICE: Only a qualified person should make replacement of spare parts. WARNING Before performing maintenance tasks ensure that the area 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...

  • Page 48: Maintenance Checks

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 48 of 104 Maintenance Checks To insure proper system operation the following maintenance procedures should be performed according to the schedule indicated below. If the any interim abnormal operating condition is observed on a shorter than indicated interval, maintenance actions should be executed as those conditions are observed.
  • Page 49 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 49 of 104 WARNING Contents in this system are under pressure while operating. Surfaces and contents may be HOT. Once the system has been shut down allow sufficient time for cooling before servicing this equipment.

  • Page 50: General Inspection

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 50 of 104 General Inspection Prior to performing routine maintenance task a general inspection should be made for the overall operating condition of the ThermoJet Oil Purifier and system. A list of items to be checked is provided below. When necessary, 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.

  • Page 51: Oil Filter Maintenance

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 51 of 104 Oil Filter Maintenance Check the inlet pump discharge and filter discharge pressure gauges for the pressure loss between the two readings.

  • Page 52: Y-Strainer Maintenance

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 52 of 104 Y-Strainer Maintenance To check and clean the suction screen in the Y Strainer, first shut down the ThermoJet. See the section titled Shut Down Procedures on how to turn the ThermoJet Oil Purifier OFF.

  • Page 53: Condensate Purifier Assembly Maintenance

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 53 of 104 Condensate Purifier Assembly Maintenance Maintaining and replacing the oil absorption media in the Condensate Purifier Assembly (CPA) can be done while the ThermoJet is operating.

  • Page 54: Separation Vessel Maintenance

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 54 of 104 Separation Vessel Maintenance The ThermoJet Oil Purifier must be shut down before performing separation vessel. This maintenance operation involves removing the separation inspection cover plate and cleaning the interior of the separation vessel.
  • Page 55 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 55 of 104 There are six stainless steel tubes that are connected to the separation vessel clean out cover that restrict immediate access that must first be removed. These are 1) oil outlet tube to the oil outlet connection 2) oil supply tube from the outlet pump 3) oil pressure relief tube from the outlet pump pressure limiting valve 4) oil supply tube between the inlet pump and in oil filter 5) the drain tube connected to the oil filter drain valve and 6) oil pressure tube to the outlet oil pressure gauge...
  • Page 56 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 56 of 104 Once the cover plate and level control valve has been removed inspect the interior of the separation reservoir and clean using a lint free rag. See the sections of this manual titled Cleaning and Decontamination and Removal from Use, Disposal and Transport for additional information.

  • Page 57: Oil Heater Maintenance

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 57 of 104 Oil Heater Maintenance The ThermoJet Oil Purifier must be shut down before performing oil heater maintenance. The oil heater is located on the right side of the unit.
  • Page 58 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 58 of 104 Once electrical power has been removed and locked out from the unit, open the electrical terminal enclosures for the oil heater and disconnect the power wires from the terminals. Remove the cap from the first conduit elbow adjacent to the heater enclosure and pull all of the conductors through the conduit so that they are out of the way of the conduit union.
  • Page 59 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 59 of 104 NOTICE: When removing the oil heater bundle from the heater vessel, the end of the vessel will be open. Care should be taken to avoid, minimize and control oil spills.
  • Page 60 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 60 of 104 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.
  • Page 61 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 61 of 104 Once inspection and cleaning is complete reinstall the tube fitting with drain orifice and the drain tubing from the bottom of the heart tube and the jet mixer With a new flange gasket, use the flange studs and nuts to install the heater bundle into the heater vessel.

  • Page 62: Auto Tune Oil Heater Controller

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 62 of 104 Auto Tune Oil Heater Controller The ThermoJet Oil Purifier must be running and operating normally in order to perform this maintenance task.
  • Page 63 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 63 of 104 ↩ ⏬ With the controller set point set to the normal operating temperature (82°C / 180° F) press until - - - - appears on the display.

  • Page 64: Check And Adjust Operating Pressures

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 64 of 104 Check and Adjust Operating Pressures The ThermoJet Oil Purifier must be running and operating normally in order to perform this maintenance task.

  • Page 65: Verify Low Oil Pressure Switch Operation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 65 of 104 Verify Low Oil Pressure Switch Operation The ThermoJet Oil Purifier must be running and operating normally in order to perform this maintenance task.
  • Page 66 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 66 of 104 Lock nut Use the adjust the screw to change the oil pressure setting Monitor oil pressure at the oil filter inlet pressure gauge while adjusting the pressure control valve (PCV)

  • Page 67: Verify Oil Heater High Temperature Cutout Operation

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 67 of 104 Verify Oil Heater High Temperature Cutout Operation To perform this maintenance task, the ThermoJet Oil Purifier must be running and operating normally. This maintenance task is performed to ensure safe operation should a high temperature condition occur.
  • Page 68 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 68 of 104 This maintenance task requires that a thermocouple simulator be connected to the terminal connectors of the thermocouple. NOTICE: Thermocouple simulators should be provide an output signal for a type J thermocouple up to 150°C (300°F) minimum.
  • Page 69 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 69 of 104 NOTICE: The Heater High Temperature alarm is set to disable the oil heater as temperature increases above 135°C ±2°C (275°F ±4°F).
  • Page 70 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 70 of 104 NOTICE: When a Heater High Temperature alarm occurs the red pilot light will illuminate. The alarm pilot light will remain illuminated and the oil heater will not be operable until the Heater High Temperature reset button is depressed.

  • Page 71: Cleaning And Decontamination

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 71 of 104 VII CLEANING AND DECONTAMINATION...

  • Page 72: Cleaning And Decontamination

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 72 of 104 Cleaning and Decontamination Oil spills may be wiped up using paper, cloth or other absorbent media. Clean reservoir and cabinet surfaces with mild soap and water.
  • Page 73 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 73 of 104 NOTICE: When cleaning oil spills consult with your lubricating oil supplier and the lubricating oil MSDS documentation regarding safe guards and Personal Protective Equipment (PPE) requirements NOTICE:...

  • Page 74: Removal From Use, Disposal And Transport

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 74 of 104 Removal From Use, Disposal And Transport When properly maintained, the ThermoJet Oil Purifier equipment is designed to provide many years of continuous service.
  • Page 75 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 75 of 104 • Disconnect all electrical supply wiring. For power wiring connection locations reference the INSTALATION section of this manual. Ensure that all previously connected sources of electrical power are disconnected before opening the AC power enclosures and attempting to disconnect electrical wiring...
  • Page 76 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 76 of 104 Do not tip or stand equipment on edge WARNING Use suitable transport equipment for lifting and setting the equipment into place. Ensure that the equipment is secured prior to and during lifting and transport.

  • Page 77: Draining And Cleaning Procedures

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 77 of 104 Draining and Cleaning Procedures Draining and cleaning procedures must be practiced if the ThermoJet is being used to remove water contaminant in different type of oil and from different reservoirs.

  • Page 78: Trouble Shooting

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 78 of 104 VIII TROUBLE SHOOTING...

  • Page 79: Trouble Shooting Guide

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 79 of 104 Trouble Shooting Guide The following information is designed for identifying potential problems and possible solutions on the ThermoJet Oil Purifier. For complete operating instructions, parts list, electrical schematics and component locations refer to other sections of this manual PROBLEM SOLUTION...
  • Page 80 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 80 of 104 Temperature Low Oil Temperature Control A. Verify that the “heater on” light is illuminated. Problems B. Verify the unit is connected to the correct power supply. Verify that the temperature controller is set at the desired operating temperature.
  • Page 81 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 81 of 104 A. Check that all inlet line connections are tight and properly sealed. Excessive noise/vibration B. Ensure that the suction connection in the reservoir is not adjacent to or near to any oil return connection which could cause oil foaming.

  • Page 82: Quick Reference Troubleshooting Guide

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 82 of 104 Quick Reference Troubleshooting Guide DON’T Drain free water from the bottom of reservoir Operate with inadequate oil flow caused by suction line too small, elevated sections of suction piping, excessively high viscosity, excessive suction lift or suction line restrictions...

  • Page 83: Types Of Product Misapplication And Misuse Not Covered By Warranty Or Guarantees

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 83 of 104 Types of Product Misapplication and Misuse Not Covered By Warranty or Guarantees 1. Prolonged operation with air bubbles in the oil flow which causes pump cavitation and/or relief valve chatter.

  • Page 84: Parts List / Drawings / Schematics

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 84 of 104 IX PARTS LIST / DRAWINGS / SCHEMATICS WARNING EXPLOSION HAZARD – Substitution of components may impair suitability for Class 1 Groups CD NOTICE: All electrical checks and circuit testing should only be made by a qualified electrician.

  • Page 85: Maintenance Spare Parts List

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 85 of 104 Maintenance Spare Parts List Part Number Description Quantity 1910-3006 Oil Filter Element 6 Microns 4052-0235 Filter Housing O-Ring, Viton 1920-1002 Oil Absorption Media Sock...

  • Page 86: Process And Instrument Diagram

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 86 of 104 Process and Instrument Diagram...

  • Page 87: Pid Symbol Legend And Customer Connection Chart

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 87 of 104 PID Symbol Legend and Customer Connection Chart SYMBOL LEGEND OIL PIPING OIL TUBING OIL LEVEL CONTROL VALVE CHECK VALVE PRESSURE CONTROL VALVE PRESS.

  • Page 88: Electrical Wiring Diagram

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 88 of 104 Electrical Wiring Diagram...

  • Page 89: Transformer Wiring

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 89 of 104 Transformer Wiring 460VAC 440VAC 115VAC 110VAC 575VAC...

  • Page 90: Fuse Ratings And Characteristics

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 90 of 104 Fuse Ratings and Characteristics Item Part Number Quan Description 30571032 TRIP BLOCK, 8-32 AMPS 77750215 Time Delay Fuse, Class CC - 600V - 6 Amp <R13>...

  • Page 91: Bill Of Materials

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 91 of 104 Bill Of Materials Item Part Number Quan Description 02000001 Double Spur gear Pump 03501000 Jet Mixer 15000300 Pressure Gauge, 0-300 PSI 19103006 Filter Element, 6 Micron 19201002...
  • Page 92 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 92 of 104 Item Part Number Quan Description 40511031 Gasket, Oil Level Control Plate - VITON 40520235 O-ring, Oil Filter - VITON Item Not Used 49002075 Y-Strainer...
  • Page 93 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 93 of 104 Item Part Number Quan Description 77700227 Needle Valve, ¼ NPT 51001175 Relief Valve, ¾ NPT 52001075 Check Valve, ¾ NPT 03501010 O-ring, Viton , Inlet Supply –...

  • Page 94: General Arrangement Drawings

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 94 of 104 General Arrangement Drawings Front View w/ Door Opened...
  • Page 95 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 95 of 104 Left Side View Top View...
  • Page 96 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 96 of 104 Rear View Controller...

  • Page 97: Dimensional Outline Drawings

    Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 97 of 104 Dimensional Outline Drawings...
  • Page 98 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 98 of 104 Front View...
  • Page 99 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 99 of 104 Left Side View...
  • Page 100 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 100 of 104 Rear View...
  • Page 101 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 101 of 104 Right Side View...
  • Page 102 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 102 of 104 Top View...
  • Page 103 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 103 of 104 Bottom View Anchor bolt spacing...
  • Page 104 Doc # 77740123 ® THERMOJET G3500E SERIES OIL PURIFIER SYSTEM Date June 2020 INSTALLATION AND OPERATING MANUAL Page 104 of 104...

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