Finish Thompson BE-15, 15C User Manual

BE-15/15C

Service Manual

OBSOLETE

Version 1.3

Octo ber 2005

“BE SERIES” BE-15/15C SERVICE MANUAL

Version 1.3

Introduction

This service manual and troubleshooting guide for the BE-15/15C takes the technician through an orderly routine to determine the trouble areas and/or the cause of a problem. In many cases, damaged or defective parts are the result of failures from other components. This guide’s goal is to get to the root of a problem.

Table of Contents

Safety Precautions

Getting Started

Sequence of Operation

Model Determination

Part Descriptions and Terminology

History of Design Changes

Maintenance Schedule

Minimum Requirements

Intermittent Use and Storage

Troubleshooting Chart

Service Procedures

Troubleshooting Tests and Repairs

Level Control Board Replacement

Divert Valve Repair or Replacement

Heater Band Replacement

Vacuum/circulation Pump Servicing

Location Diagrams and Parts Lists

Electrical Schematics

Safety Precautions

WARNING:

READ, UNDERSTAND, AND FOLLOW THIS SERVICE MANUAL AND THE “BE SERIES” OPERATION MANUAL COMPLETELY BEFORE INSTALLING, OPERATING, TROUBLESHOOTING, OR SERVICING A “BE” UNIT. FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.

 ELECTRICAL WIRING, TROUBLESHOOTING, OR REPAIRS SHOULD BE

PERFORMED AND CHECKED BY A QUALIFIED ELECTRICIAN.

 WEAR PROPER EYE AND SKIN PROTECTION WHEN WORKING WITH THIS

EQUIPMENT.

 DO NOT OPEN THE FILL VALVE OR DRAIN VALVE DURING OPERATION OR

WHILE HOT. ALLOW A MINIMUM OF ONE-HALF TO TWO HOURS FOR COOLING BEFORE DRAINING OR REFILLING.

WARNING:

STORE AND KEEP ALL FLAMMABLES AND COMBUSTIBLES A SAFE DISTANCE FROM THE UNIT. A MINIMUM OF 20 FEET IS REQUIRED.

WARNING:

PROCESS GLYCOL-BASED ENGINE COOLANTS ONLY. NEVER PROCESS FLAMMABLE OR COMBUSTIBLE LIQUIDS, OR ENGINE COOLANTS CONTAMINATED WITH FLAMMABLES OR COMBUSTIBLES.

WARNING:

ANTIFREEZE/COOLANTS AND REINHIBITORS ARE POISONOUS TO PEOPLE AND ANIMALS AND ARE ALSO CORROSIVE. CLEAN UP ANY SPILLS IMMEDIATELY.

Getting Started

SEQUENCE OF OPERATION:

of the operational sequence is necessary. Below is an outline of the operation:

1. FILL - The operator pours or pumps 15 gallons of waste antifreeze/coolant into the Process Tank through the Fill Funnel. A Level Control Probe senses the presence of liquid, activating a relay on the Level Control Board (a slight “click” will be heard).

2. START - The On/off Switch is depressed, energizing the Heater Band and Pump Motor.

3. WATER PROCESS - As the water is heated and vaporizes, it passes through the tubes of the Condenser. Coolant is circulated through the shell of the Condenser, reforming the vapors into a distilled water product. This distilled water product gravity drains out of the Processed Water Hose. It takes approximately an hour for the water to begin processing, and eight to ten hours to complete the water cycle.

4. GLYCOL PROCESS - When most of the water has been processed, the temperature inside the process tank will begin to rise. When this temperature reaches 280F, a switch closes, energizing the coil on the Divert Solenoid Valve. During this portion of the process, the glycol is vaporized under a vacuum (reducing it’s boiling point). The Recycled Glycol is drawn into the Pump Reservoir. The Pump Reservoir fills with the reclaimed glycol, then gravity drains out of the Processed Glycol Hose. The glycol process takes approximately four to six hours.

5. AUTO SHUTDOWN - The BE unit will automatically terminate the process when the liquid in the process tank reaches a low level (approximately 3 1/2 gallons). This low level sensor de-activates the Process On/off Switch, shutting the unit off. The entire processing cycle takes approximately 14 hours.

6. DRAIN RESIDUES - After each cycle is complete (and the residue in the tank has cooled for two hours), the residues must be drained into a collection pan. This residue is stored for future processing.

As necessary:

 RESIDUE RUN - After 12 to 15 gallons of residues have accumulated, it is processed like waste

antifreeze. Little to no water will process, and the residue run can yield up to 11 gallons of Recycled Glycol. The Process Tank is drained, and this residue should be disposed of according to local, state, and federal regulations. Under no circumstances should residues be processed a second time or mixed back into the waste antifreeze.

 MAINTENANCE - Flush the Process Tank by filling the unit with 5 to 7 gallons of clean water and

turning the unit on. Allow the unit to process the water and automatically shut down after a couple of hours. The remaining water is drained from the Process Tank. This flushing process is repeated until the drained water is somewhat clear (see maintenance schedule on page 6).

 REINHIBIT - After the process is complete, the Recycled Glycol can be mixed with processed water to

obtain the desired freeze/boil protection and reinhibited with FTI’s “BE-Series Engine Coolant Treatment” to re-make engine coolant.

To better service a BE-Series coolant reclaimer, understanding each step

MODEL DETERMINATION:

The first step is to determine the model of the unit. This depends on the type of cooling system used. There are three varietiesknowing which one you're dealing with is vital to proper troubleshooting.

1. BE-15 “Water-cooled” uses tap water (or an external cooling system) to recondense vapors.

2. BE-15C “Chiller” is the original design of BE-15C and uses a refrigeration/Freon cooling system.

3. BE-15C “Air-cooled” is the last design (and most common) and uses a fan-cooled radiator.

PART DESCRIPTIONS AND TERMINOLOGY:

Antifreeze - A cooling medium base. Composed of

ethylene glycol, corrosion inhibitors and other additives, and dye.

Aspirator - An internally tapered, plastic tubular

attachment to the Vacuum/circulation pump used to form Vacuum.

Condenser - A shell and tube heat exchanger. The

vapors pass through the tubes as cooling water circulates through the shell to recondense the vapors into a purified liquid. Part of the Distillate Piping.

Coolant - A mixture of Antifreeze and water (usually a

50/50 ratio). Used for heat removal.

Distillate Piping - The plumbing from the top of the

Process Tank to the discharge hoses.

Divert Solenoid Valve - (Divert Valve) An electrically

operated, 3-way mechanical valve used to control Vacuum and allow the Processed Water and Recycled Glycol to drain into separate containers. Part of the Distillate Piping.

Drain Valve - Where the Residue is drained from the

Process Tank after the process is complete.

Fill Funnel - Where the waste coolant is poured into the

Process Tank. On the left side of a BE unit.

Heater Band - An externally mounted resistive-type

heating element strapped to the bottom of the Process Tank.

Level Control Board - An electronic circuit board used

to control the start and end of the recycling process depending on the liquid level in the Process Tank.

Level Control Probe - A device used to detect the

presence of liquid in the Process Tank.

Processed Water - The distilled water product that is

separated from the waste coolant after the recycling process.

Process Tank - The main fifteen-gallon vessel where

the waste coolant is heated and vaporized. The Fill Funnel and Drain Valve are attached to the left of the tank.

Pump Reservoir - A five-gallon, square plastic tub that

acts as a priming and coolant reservoir for the Vacuum/circulation Pump.

Recycled Glycol - The reclaimed glycol portion from

the waste coolant that is the result of the recycling process.

Reinhibitor - A chemical package containing corrosion

inhibitors, buffers, and dyes that is added to Recycled Glycol to make Antifreeze.

Residue - The wastes from the used coolant that remain

after processing.

Residue Run - The processing of the Residue drained

from the Process Tank to extract any remaining Glycol.

TAS1 - Temperature Actuated Switch used to control

cooling water flow on water-cooled and refrigerated models. Normally open until 180°.

TAS2 - Temperature Actuated Switch used as an

overtemp sensor for the Process Tank. Normally closed until 385°.

TAS3 - Temperature Actuated Switch used to control

the Divert Solenoid Valve. Normally open until 280°.

TAS4 - Temperature Actuated Switch used as an

overtemp sensor for the Distillate Piping. Normally closed until 150° or 180°.

Vacuum - Negative pressure used to reduce the boiling

point of the Glycol for processing at a safer, lower temperature. A BE unit uses a level of -24” to -28” Hg.

Vacuum/circulation Pump - A centrifugal pump that

sets into the Pump Reservoir. This pump circulates glycol for cooling and is used to form Vacuum.

Waste Coolant - The dirty antifreeze/coolant before the

recycling process.

Water Solenoid Valve - An electrically operated, 2-way

mechanical valve used to control water flow on water-cooled models.

HISTORY OF DESIGN CHANGES:

Take special note of the serial number of the unit. This number can be found on a nameplate located on the left side panel (a five digit sequence number, a letter corresponding to a month, then the year built). It is vital to know the design vintage of your “BE” unit. Older units used 120 VAC controls while later design units use 240 VAC controls. Replacement parts and voltage readings will differ between the two designs. Following is a brief overview of the update history for these units:

Date

Code

E91 External Level Control Probe E91 F91

J91

350 Temp Switch removed 180 Temp Switch (TAS1) added

150 Temp Switch (TAS4) added

K91 “Chiller” system eliminated

F92 240 VAC control system

J92 Stainless steel pins in Divert

Solenoid Valve

K92

Changed 410 Temp Switch (TAS2)

J93 Changed Level Control Board

L93 Changed Condenser

I94 Changed Divert Temp Switch

(TAS3)

L95

Change 150 Temp Switch (TAS4) to 180°.

E96 Added a support bracket for the

condenser.

K96 Changed Condenser

Design Change or Modification

Description of Change

or Noteworthy Information

Previous units had the probe mounted in the top of the Process Tank. The probe was relocated into piping next to Fill Funnel. Safety shutdown system was omitted eliminating a snap switch, relay, and reset switch. This was added to turn on the water flow or compressor once the tank reached 180. This helped to prevent excessive condensation on the piping inside the cabinet. TAS1. This temp sensor was added to the distillate piping near the divert valve to shut the unit down in the event of improper cooling. TAS4. The refrigeration cooling system was replaced by the air-cooled radiator. Most of the earlier built “Chiller” systems have been refitted with an air-cooled system. The original 120 VAC controls were changed to 240 VAC. Components changed were the on/off switch, contactor, level control board, and coils for solenoid valves. Original valve used plastic pins that melted if the unit overheated. The stainless steel variety is more reliable.

The tank overtemp switch was changed to an auto-reset 385 snap switch. The 410 version was a manual reset switch. TAS2.

Changed from a “Series 16” to a “Series 26” board. The all copper “Champ” condenser was replaced with a

CuNi “Sendure”. More corrosion resistant. Original type used soldered connections for the wires, and had a metal casing. The new version is ceramic and uses push-on connectors. The 280 temp rating is unchanged. TAS3. The distillate piping overtemp switch has been changed to a 180 version, allowing units in warmer climates to operate a little warmer. A bracket was hung from the top panel and bolted to the divert valve to help prevent condenser breakage.

Changed to an all-braised construction condenser capable of handling higher temperatures.

Maintenance Schedule

MINIMUM MAINTENANCE REQUIREMENTS:

Regular maintenance and upkeep is the key to preventing problems with “BE Series” equipment. Keeping the Process Tank clean is the single-most important preventive maintenance requirement. Avoid the processing of heavily contaminated used coolant and do not process coolants containing oil, transmission fluid, or gasoline. When antifreeze/coolant is spilled or splashed, clean it up immediately.

Antifreeze/coolant is poisonous, and will corrode the paint and cabinet of the BE unit.

CAUTION:

Wear proper eye and skin protection when working with this equipment.

CAUTION:

Do not open the fill valve or drain valve during operation or while hot.

Allow a minimum of one-half to two hours for cooling before draining or refilling.

Every cycle:

 DRAIN RESIDUES - Evacuate all residues from the process tank before attempting a waste coolant run.

If less than 3 1/2 gallons of residue drains, perform a cleaning cycle (see “FLUSH” procedure in the “Weekly” section of the “Maintenance Schedule”). Failure to do so will result in damage to the BE unit.

Weekly or every five (5) waste coolant runs:

 FLUSH - Perform the following flush cycle in order to maintain quality product and to prevent a build-up

of material on the inside of the Process tank. Failure to do so will result in damage to the BE unit. This is especially important after a residue run.

1. By gravity draining, remove as much residue as possible from the Process Tank.

2. Fill the Process Tank with 5 to 7 gallons of clear water.

3. Depress the On/off Switch to the ON position and allow the unit to run until it automatically shuts off.

This usually takes 2 to 3 hours.

4. Allow the BE unit to cool for at least 1/2 to 2 hours.

5. Place a drain pan (suitable for hot liquid) under the Drain Pipe Assembly and open the Drain Valve.

NOTE: If the drained water is heavy with particulate matter or brown to black in color, the cleaning

process must be repeated until the water begins to drain somewhat clear. Failure to do so can damage the BE unit.

 CHECK LIQUID LEVELS - Verify that the liquid in the Pump Reservoir is filled to the proper level. If

low, top off with Pump Primer, Recycled Glycol, or clear water until the reservoir overflows out of the Recycled Glycol hose.

Semi-annually:

 HEAT EXCHANGER - Clean the finned-tube surfaces of the radiator by blowing compressed air through

the fins from the inside to the outside.

 LEVEL PROBE - Remove the Level Control Probe (disconnect the white wire and unthread the probe

with a spark-plug socket). Wipe the probe’s metal rod with a shop rag to remove any build-up of residues. Take care not to bend the rod. Reinstall the probe; making sure that the rod does not make contact with the inside of the pipe.

 PUMP RESERVOIR - Drain and clean the Pump Reservoir (there is a petcock on the bottom of the

reservoir). Wipe off any oily residues from the tank surfaces and pump. Flush the radiator by forcing water through its upper hose (attach a garden hose to the loose/open hose inside the Pump Reservoir). Re-fill with Pump Primer or Recycled Glycol. Water can be used as a primer, but will result in slightly diluted Recycled Glycol for the next batch.

 PROCESS TANK - Perform a “detergent flush” of the Process Tank to help remove oily deposits.

Dissolve a non-sudsing detergent into 5 to 7 gallons of water (2 cups of automatic dishwasher detergent



such as Cascade

can be used). Pour this detergent solution into the Process Tank and allow the unit to run until it automatically shuts off (this usually takes 2 to 3 hours). Drain the remaining liquid, and rinse out the Process Tank with clean water.

 PRESSURE RELIEF VALVE - The Pressure Relief Valve is mounted to the top of the Process Tank.

Check for proper operation by lifting its lever. If the lever will not lift, replace the valve.

INTERMITTENT USE AND STORAGE:

Take additional precautions if the BE unit is used intermittently (less than once per week) or is placed in storage (more than one month). Residues left in mechanical components can become “sticky”, liquid levels can evaporate, and metal parts can corrode. Perform the following maintenance to help prevent problems with intermittent use and storage:

Intermittent use:

 DRAIN RESIDUES - Do not allow the residues to sit in the Process Tank for any length of time. Drain

according to the “Maintenance Schedule” section of this manual.

 FLUSH - Flush out any residual residues and clean the Distillate Piping by performing a flush according

to the “Maintenance Schedule” section of this manual.

Before restarting with intermittent use:

 CHECK LIQUID LEVELS - Verify that the liquid in the Pump Reservoir is filled to the proper level. If

low, top off with Pump Primer, Recycled Glycol, or clear water until the reservoir overflows out of the Recycled Glycol hose.

Storing the BE unit:

 PREPARE THE COOLING SYSTEM - Drain and clean the Pump Reservoir per the instructions in the

“Maintenance Schedule” section of this manual. Re-fill the Pump Reservoir with a 50/50 mix of water and new antifreeze or recycled antifreeze that contains reinhibitor. This will help to protect the radiator and piping from corrosion (the antifreeze will be circulated through the cooling system during the next step). Replace the cover to the Pump Reservoir.

 CLEAN THE PROCESS TANK - Drain all residues. Perform a “detergent flush” of the Process Tank per

the instructions in the “Maintenance Schedule” section of this manual.

 DISCONNECT POWER - Turn off the electrical power (at the main circuit breaker) for the BE unit. If

other equipment is connected to the same circuit, disconnect the wiring to the BE unit.

Before restarting after storage:

 RECONNECT POWER - Return the electrical power supply to the BE unit.

 HEAT EXCHANGER - Clean the finned-tube surfaces of the heat-exchangers by blowing compressed air

through the fins from the inside to the outside.

 PREPARE THE COOLING SYSTEM - Drain the antifreeze from the Pump Reservoir. Refill the

reservoir with Pump Primer, Recycled Glycol, or clear water until the reservoir overflows out of the Recycled Glycol hose. The antifreeze is removed so that the newly Recycled Glycol does not become too rich in inhibitors once the reinhibitor package is added. Replace the cover to the Pump Reservoir.

Troubleshooting Chart

This troubleshooting section will list a Problem with the Possible Causes. The Possible Causes will be in the recommended order that the items should be checked. “Troubleshooting Tests and Repairs” are outlined in the “Service Procedures” section of this manual. NOTE: Some of the troubleshooting tips will not be accurate for units D91 or older.

Problem Possible Causes

Unit will not turn on. 1. No or improper electrical power.

2. Level control system not satisfied.

3. Safety overtemp sensor(s) activated.

4. On/off Switch is defective.

5. Level Control Board’s relay not closing.

Premature Shutdown. 6. Electrical power outage.

7. Distillate Piping has overheated from improper cooling.

8. TAS4 is too sensitive.

9. Process Tank overheating.

10. TAS2 is too sensitive.

11. Intermittent ground on Process Tank. All 11 gallons of distillate go into the Processed Water drum. All 11 gallons of distillate go into the Recycled Glycol drum.

Less than 3 1/2 gallons of Residue drains after processing.

Unit keeps running after the On/off Switch is OFF.

Unit runs longer than 24 hours with nothing or little produced (unit doesn’t shut down).

Circuit Breaker at power main keeps tripping. Low vacuum readings after divert (less than

-24” Hg.)

Pressure Relief Valve keeps discharging. 32. Stuck/faulty Divert Solenoid Valve.

Discolored Recycled Glycol. 35. No problem. This can be normal.

12. Loose wire on TAS3 or TAS3 is defective.

13. Divert Solenoid Valve is stuck or faulty.

14. Wires/terminals on TAS3 are touching or TAS3 is

defective.

15. Divert Solenoid Valve is stuck or faulty.

16. Clogged Drain Valve.

17. Level Control Probe is shorted to ground.

18. Level Control Board failure.

19. Improper electrical hook-up.

20. Contactor stuck in engaged position.

21. Faulty On/off Switch.

22. Contactor not engaging or defective.

23. Loose or shorted wire.

24. Heater Band failure.

25. Wiring short to ground.

26. Heater Band is defective.

27. Pump Reservoir is low.

28. Debris in Aspirator.

29. Vacuum hose leaking or deteriorated.

30. Faulty Vacuum Gage.

31. Stuck/faulty Divert Solenoid Valve.

33. Debris in, weak, or improper Pressure Relief Valve.

34. Clog in Distillate Piping.

36. Oil in Waste Coolant feed.

37. Residue build-up in Process Tank.

38. Unit running with low vacuum after divert.

Service Procedures

IMPORTANT: If performing troubleshooting procedures and an electrical component is found to be defective, it is important to find out what caused the component(s) to fail. Most electrical failures occur as a result of other defective components, power fluctuations, or a wire “grounding out”. The only wires in the

entire electrical circuitry of the BE unit that should be grounded are wires #21 and #22 from the Level Control Board. Any other problems or electrical shorts to ground must be eliminated, or damage to

electrical components will reoccur.

Parts are dependent upon serial number of your unit. Be careful to order and replace the correct part. Consult the “Parts List and Location Diagrams” for specifics on part numbers and component locations. Electrical parts are voltage sensitive. Always check that the same voltage components are being replaced. Installing the improper voltage of a part can be difficult to troubleshoot when problems continue to occur.

Read and follow the “Safety Precautions” section of this manual before proceeding.

TOOLS REQUIRED: Volt/ohm meter (VOM), screwdriver set, crimping pliers, wire cutter/stripper, jumper wires (a 16 gauge or larger wire with alligator clips on each end), various wrenches (crescent, pipe, hex, allen, etc.) A temperature probe or thermometer can be helpful.

TROUBLESHOOTING TESTS AND REPAIRS:

Unit will not turn on Premature Shutdown All 11 gallons of distillate go into the Processed Water drum All 11 gallons of distillate go into the Recycled Glycol drum Less than 3 1/2 gallons of Residue drains after processing Unit keeps running after the On/off Switch is OFF Unit runs longer than 24 hours with nothing or little produced Circuit Breaker at power main keeps tripping Low vacuum readings after divert (less than -24” Hg.) Pressure Relief Valve keeps discharging Discolored Recycled Glycol

11 14 19 20 21 23 24 25 26 28 29

PROBLEM: UNIT WILL NOT TURN ON.

Possible Cause 1: No or Improper Electrical Power.

WARNING:

Electrical shock hazard present.

Electrical servicing should be performed by a qualified electrician.

Check main circuit breaker. If tripped, verify correct wiring and electrical supply to the BE unit.

 F92 and newer units require a 3-wire (L1, L2, and Ground) 240 VAC, single-phase electrical supply.

No neutral wire should be used or connected to the terminal strip in the BE’s circuit box.

 E92 or older units require a 4-wire (L1, L2, Neutral, and Ground) 240 VAC, single-phase electrical

supply. If a neutral wire is not available, connect the Ground to the “G” and the “N” position of the terminal strip in the BE’s circuit box.

If the wiring to the unit is as above and correct, refer to the “Problem: Circuit breaker keeps tripping” in the “Troubleshooting Tests and Repairs” section of this manual.

Possible Cause 2: Level control system not satisfied.

Verify that there is more than 3 1/2 gallons of liquid in the Process Tank. Verify by attempting to pour additional coolant into the Process Tank.

Check the red LED on the Level Control Board (located in the lower right corner of the BE’s circuit box). When liquid touches the Level Probe, it grounds the probe and lights the LED on the Level Control Board.

 If the LED is lit, proceed to Possible Cause 3.

 If the LED is not lit, and it is verified that there is more than 3 1/2 gallons of liquid in the Process

Tank, the unit is not sensing the liquid.

Check the Level Probe and its wiring. Touch the probe’s wire (#21) to the probe’s pipe. If the LED lights,

remove the probe and check for a clog in the pipe that would prevent liquid from reaching the probe. Also check continuity between the probe’s wire terminal and the probe’s rod. If there is no continuity, the Level Probe is defective and must be replaced.

If the LED still does not light, check the Process Tank’s ground wire connection. This wire is attached to the Process Tank with a screw (behind the small access panel in the tank’s insulation). This connection can become corroded and not allow the Level Control to function. Remove the screw, file the metal clean, and re-attach the wire with a new screw and new crimp connector.

If the screw is too corroded to remove, drill and tap a new hole for the ground into the same metal slab, next to the old screw.

CAUTION:

Do not drill a hole into or through the Process Tank. Drill into the welded metal slab only. Maximum drill depth is 1/4”.

If the LED on the Level Control Board still does not light, place a jumper wire between wire #21 and wire #22 on the Level Control Board. If the LED lights, then replace wire #21 from the Level Control Board to the Level Probe. If the LED does not light, the board is defective and must be replaced.

Possible Cause 3: Safety overtemp sensor(s) activated.

CAUTION:

Disconnect electrical power to the BE unit before performing tests

on the Temperature Actuated Switches.

Check TAS2. This is a “normally closed” switch threaded into the front of the Process Tank behind the access panel in the insulation. It is a 1/2” diameter white ceramic sensor with a brass hex base and two wires (#1L1 and #25 for units K91 or newer, #11 and #12 for E91 or older) connected to it.

 If there is continuity between the two terminals of TAS2, proceed to “Check TAS4”.

 If there is not continuity between the two terminals of TAS2, the sensor has tripped.

Remove the switch and attempt to reset. Take care not to twist off its stud or to drop the sensor.

Units J92 and earlier had a switch rated for 410F. This will be indicated by “L410” written on the sensor. This sensor should reset at 32F (place it in the freezer for a while). If the sensor will not reset, then replace TAS2 with the latest version (385F).

Units K92 and newer use a switch rated for 385F. This will be indicated by “L385” written on the sensor. This sensor should reset at 285F. If the Process Tank is cool, and this sensor has not reset, then replace TAS2.

If TAS2 has tripped, this indicates that the Process Tank is overheating. This can occur if there is a residue build-up in the tank, or the Level Control System does not turn off the unit with 3 1/2 gallons of liquid left in the Process Tank. Perform a “detergent flush” and check the Level Control System.

Check TAS4 (units J91 or newer). This is a “normally closed” switch threaded into the Distillate Piping between the Condenser and Divert Solenoid Valve. It is a 1/2” diameter white ceramic sensor with a brass hex base and two wires (#10 and #25) connected to it (it may be covered with a black plastic sheath).

 If there is continuity between the two terminals of TAS4, proceed to Possible Cause 4 & 5.

 If there is not continuity between the two terminals of TAS4, the sensor has tripped.

Remove the switch and attempt to reset. Take care not to twist off its stud or to drop the sensor.

TAS4 is a switch rated for 150F. This will be indicated by “L150” written on the sensor. This sensor should reset at 100F. If the piping is cool, and this sensor has not reset, then replace TAS4 with the latest version (180F).

If TAS4 has tripped, this indicates that the Distillate Piping has overheated. This can occur if the operator attempts to fill the Process Tank when the BE unit is still hot. The uncooled steam created can trip TAS4 and prevent the unit from turning on. If the unit is cool, TAS4 should have reset.

Possible Cause 4 & 5: On/off Switch is defective and/or

Level Control Board’s relay not closing.

There is a small relay mounted to the Level Control Board. The terminals for this relay’s output are located on the lower right corner of the board and labeled “NO”, “COM”, and “NC”. Whenever the board’s red LED is lit, the contacts between “NC” and “COM” should close and energize the coil on the On/off Switch. This can be checked by measuring for voltage at the On/off Switch.

WARNING:

Electrical shock hazard present.

Be careful when performing voltage measurements on live electrical circuits.

If TAS2 and TAS4 have checked OK, measure for voltage at the On/off Switch. For units E91 through E92, there should be 120V between wires #10 and #24. For units F92 or newer, there should be 240V between wires #26 and 1L2.

 If there is proper voltage at the on/off switch, and all other tests have passed, the On/off Switch is

defective and must be replaced.

 If there is not proper voltage at the On/off Switch, disconnect power to the BE unit and temporarily

bypass the Level Control Board. The board is bypassed by connecting a jumper wire between the wires connected to the “NO” and “COM” terminals. Restore electrical power. If the unit turns on, the Level Control Board must be replaced.

 If the BE unit still will not turn on, then the On/off Switch and Level Control Board are defective and

must both be replaced.

If the On/off Switch or Level Control Board are defective, check all electrical connections for shorts to ground. See the “Important” note in the beginning of this “Service Procedure” section.

PROBLEM: PREMATURE SHUTDOWN. Possible Cause 1: Electrical power outage.

If power to the unit is interrupted (even for a second), the unit will shut off. The cycle can be restarted by pressing the On/off Switch ON (the unit may have to cool before it will restart).

Possible Cause 2: Distillate Piping has overheated from improper cooling.

CAUTION:

Disconnect electrical power to the BE unit before performing tests

on any of the Temperature Actuated Switches.

Check TAS4 (units J91 or newer). This is a “normally closed” switch threaded into the piping between the Condenser and Divert Solenoid Valve. It is a 1/2” diameter white ceramic sensor with a brass hex base and two wires (#10 and #25) connected to it (it may be covered with a black plastic sheath). This switch opens if the Distillate Piping reaches 150 to 180F.

 If TAS4 is closed, then proceed to Possible Cause 4.

 If TAS4 is open (while unit is still hot), then check for problems in the cooling system. Proceed to

the section for your model (refer to the “Model Determination” section of this manual if unsure).

Cooling system problems with a BE-15 Water-cooled:

1. No, low, or improper water flow. The BE-15 requires a minimum cooling water flow rate of 1/2 gallons per minute. Water temp cannot exceed 80F. Verify that water is turned on to this flow rate. Warmer climates will require a higher flow rate, usually about 1 gallon per minute.

Also check for scale or mineral deposits at the water inlet and outlet connections on the left side of the BE

unit and at the Condenser’s water connections. Use a commercially available cleansing solution to remove any deposits. If the build-up is severe, the Condenser may require replacement.

2. Water Control System is faulty. Verify the water supply to the unit. A Water Solenoid Valve controls water flow through the Condenser.

 For units E91 or older, water should flow as soon as the unit is turned on. If it does not, disassemble

and clean the Water Solenoid Valve, or simply replace the valve.

 For units F91 or newer, the Water Solenoid Valve is controlled by TAS1. When the tank reaches

180F, the sensor closes, energizing a coil to open the Water Solenoid Valve and allow the water to flow. This usually takes about one hour. TAS1 is located on the top of the Process Tank (it is a 1/2” diameter white ceramic sensor with a brass hex base and two wires #13 and #15 or #13 and #19 connected to it) is a “normally open” switch.

Place a jumper wire across TAS1. If the Process Tank is over 180, and the water begins to flow, replace

TAS1. If water still does not flow, attempt to disassemble and clean the Water Solenoid Valve, or simply replace the valve.

1. Vacuum/circulation Pump motor is not coming on.

 For units E91 or older, the motor is supposed to run as soon as the unit is turned on.

 For units F91 to E92, the motor is supposed to run after the Process Tank reaches 180 and TAS1

has closed (usually about one hour after starting the unit).

Check the pump motor’s contactor in the unit’s circuit box (upper right contactor). There should be 240

volts at wires #8 and #9 when the contactor is engaged. If the contactor is not engaged, verify there is 120 volts to the coil (wires #18 and #19). If so, the coil is defective, and the contactor needs replaced. If there is no power to the coil, TAS1 has not closed.

If the pump motor’s contactor is functioning, determine whether the pump motor is defective. Attempt to

turn the motor’s fan with a screwdriver’s blade. If the fan won’t turn, the motor’s bearings may have seized. Replace the motor or have it rebuilt. Refer to the “Vacuum/circulation Pump Servicing” section of this manual.

 For units F92 or newer, the motor is supposed to run as soon as the unit is turned on.

Check the contactor in the unit’s circuit box. There should be 240 volts at wires #8 and #9 when the

contactor is engaged. If the contactor is not engaged, verify there is 240 volts to the coil (wires #13 and #18). If so, the coil is defective, and the contactor needs replaced. A defective contactor would also prevent the unit from heating.

If the pump motor’s contactor is functioning, determine whether the pump motor is defective. Attempt to

Cooling system problems with a BE-15C Chiller:

1. Pump Reservoir is low. This is the most common cause. The reservoir only needs to be about 1/2” low to cause poor coolant circulation through the Condenser. Top off the reservoir until it overflows from the Processed Glycol Hose.

2. Unit installed in too warm of an area. If the ambient temp around the BE unit gets above 100F, then the unit can overheat. Verify good, cool ventilation in the installation area.

3. Freon is low or leaking. Locate the sight glass on the compressor. Determine whether there is moisture in the system by the color indicator. Also check for air bubbles passing through the sight glass while the unit is running. The “Chiller” should maintain the liquid in the Pump Reservoir to a temperature no higher than 110°. If signs of trouble exist, have a qualified HVAC technician service the compressor. This unit requires four pounds of R-22 Freon.

4. Cooling control system may be faulty (units F91 through I91). The TAS1 temperature sensor is located on the top of the Process Tank (It is a 1/2” diameter white ceramic sensor with a brass hex base and two wires #13 and #19 connected to it) is a “normally open” switch. When the tank reaches 180F, the sensor closes, energizing the coil on the Chiller/pump contactor. This allows the cooling water to flow through the Condenser.

Hint: If the pump’s motor turns on, TAS1 is operating OK.

 Place a jumper wire across TAS1. If the Process Tank is over 180, and the Chiller and pump

motor start, replace TAS1.

 If the Chiller and pump motor do not start after jumping TAS1, check for a faulty contactor in the

unit’s circuit box. The contactor is the upper right component. Determine whether the coil is open (check for resistance between wires # 18 and #19) or if the contacts are bad. Replace the contactor if necessary.

Cooling system problems with a BE-15C “Air Cooled”:

2. Unit installed in too warm of an area. If the ambient temp around the BE unit gets above 100F, then the unit can overheat. Verify good, cool ventilation in the installation area. Avoid installations in small enclosed rooms or near space heaters and heated parts washers.

3. Improper air circulation. Clean the finned-tube surfaces of the Radiator by blowing compressed air through the fins from the inside to the outside. Clean the fins with a degreaser if necessary. Also verify that the rear of the unit is installed a minimum of one foot from a wall. Also be sure that objects are not stacked around the rear of the Radiator (that will impede air circulation).

4. Radiator blocked internally from debris or scale. One hint that the Radiator is restricted would be if the air blown through by the fan does not feel warm (after the machine has been running for a while). Perform a flush of the Pump Reservoir and Radiator as outlined in the “Maintenance - Semiannually” section. If the low flow or blockage persists, perform a Radiator flush using a commercially available flushing solution. Also, worn, kinked, or deteriorated hoses can restrict flow. Replace any suspect hoses with standard 1/2” automotive heater hose.

5. Vacuum/circulation pump not circulating the liquid properly. While the unit is off, tilt the motor and pump out of the Pump Reservoir. There is supposed to be a gray elbow attached to the pump’s discharge. The Aspirator is attached to this elbow, as well as a hose. Verify that the elbow has not come loose from the pump, and that the hose is attached to the elbow as well and not kinked or worn. Replace any suspect or worn hoses.

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