Finish Thompson BE-55C User Manual

COOLANT RECYCLING SYSTEM

BE-55C

Instruction Manual

For unit

Serial # number

0660A96

or newer

Version

July

2014

BE-55C Instruction Manual

~ Introduction ~

Congratulations on your purchase of the BE-55C Coolant Recycling System. The BE-55C is designed to recycle used ethylene or propylene glycol-based engine coolants utilizing vacuum distillation technology (the same process used in the manufacture of new anti-freeze). The recycled product meets or exceeds original equipment specifications. The process is completely automatic, requiring minimal operator involvement. When properly operated and maintained, the BE-55C can provide years of trouble-free service and reduce new antifreeze purchases and waste disposal. Recycling is also good for the environment.

~ Table of Contents ~

RECORD YOUR SERIAL NUMBER HERE: ________________________________

Safety Precautions 2 Parts Description and Terminology 3 Start-Up and Installation 4 Supplied Parts and Accessories 4 Choosing a Location 4 Fill and Drain Assembly 5 Pressure Relief Valve 5 Air Connections 5 Electrical Connections 6 Priming the Circulation Pump 6 Sequence of Operations 7 Operating the BE-55C 8-9 Reinhibitor Information 10 Maintenance Schedule 11 Trouble Shooting Guide 14 - 34 Specifications 35 Common Spare Parts 35 Parts Location Diagram 36 Hose Layout Diagram 37 Electrical Schematic 38 Warranty 39

~ Safety Precautions ~

WARNING: READ THIS MANUAL COMPLETELY BEFORE

INSTALLING AND OPERATING THIS UNIT. FAILURE TO FOLLOW THESE PRECAUTIONS CAN RESULT IN SERIOUS INJURY OR DEATH.

 A QUALIFIED ELECTRICIAN SHOULD PERFORM ELECTRICAL WIRING.  WEAR PROPER EYE AND SKIN PROTECTION WHEN OPERATING THIS

EQUIPMENT.

 DO NOT OPEN THE FILL VALVE OR DRAIN VALVE WHILE THE UNIT IS

PROCESSING.

 ALLOW A MINIMUM OF TWO HOURS TO COOL BEFORE DRAINING OR

RE-FILLING.

WARNING: PROCESS GLYCOL-BASED ENGINE COOLANTS

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

WARNING: STORE AND KEEP ALL FLAMMABLES AND

COMBUSTIBLES A SAFE DISTANCE FROM THE UNIT. A MINIMUM OF 20 FEET IS REQUIRED.

~ Part Descriptions and Terminology ~

Antifreeze - A cooling medium base composed of ethylene glycol or propylene glycol, corrosion inhibitors and other additives, and dye. Aspirator - An internally tapered, plastic tubular attachment to the Vacuum/circulation pump used to create 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 in engines. 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. Inhibitor – Finish Thompson’s Premium Inhibitor restores critical corrosion protection agents to

Recycled Glycol allowing it to meet or exceed new antifreeze standards. Level Control Boards – Electronic circuit boards used to control the automatic fill and automatic cycle completion functions of the unit.

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. Process Tank - The main 55-gallon vessel where the waste coolant is heated and vaporized. Pump Reservoir - A five-gallon, square plastic tub that acts as a priming and coolant reservoir for the

Vacuum/circulation Pump.

Recycled Glycol - The distilled glycol product that is separated from the waste coolant. Residue - The wastes from the used coolant that remain after processing. 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 180°. Vacuum - Negative pressure used to reduce the boiling point of the Glycol for processing at a safer, lower temperature. Vacuum/circulation Pump – A centrifugal pump located in the pump reservoir. It is used to circulate fluid through the unit’s cooling system and is connected to the Aspirator to create vacuum. Waste Coolant - The dirty antifreeze/coolant before the recycling process.

~ Installation & Start-up ~

SUPPLIED PARTS AND ACCESSORIES: The BE-55C comes equipped with most everything required for operation. A box of parts is located

inside the cabinet. Reinhibitor is required and is available in 5-gallon or 55-gallon containers. Optional pump primer is also available to initially fill the pump reservoir. The user must supply their own receiving and storage drums, electrical wiring, air hose to the unit, and piping for the pressure relief system. Processed Glycol and Processed Water drums should be plastic or coated steel to prevent corrosion. Residue drum must be metal to withstand heat.

CHOOSING A LOCATION:

Locate the BE-55C in a cool, ventilated area. The unit is not weatherproof, must be installed in a sheltered area and protected from freezing. The maximum allowable ambient temperature for operation is 100F (38ºC). The unit produces approximately 42,000 BTU’s per hour of heat. Adequate ventilation must be provided to insure that the ambient temperature does not exceed 100ºF (38ºC).

Make sure there is sufficient space behind the unit (12 inches minimum) to allow proper air circulation through the heat exchangers. Space for two drums is required on both sides of the BE-55C. Also verify that there are no flammables or combustibles used or stored within 20 feet of the unit (see Safety Precautions section of this manual). It’s a good idea to keep the BE-55C mounted to it’s shipping skid in the event that the unit needs to be moved or transported to a different location.

WASTE COOLANT

DRUM

TOP VIEW

INSTALL

12 INCHES MINIMUM

FROM WALL

BE-55C

DO NOT USE

OR STORE

FLAMMABLES OR

COMBUSTIBLES WITHIN

20 FEET OF UNIT

WALL

PROCESSED

WATER DRUM

PROCESSED

GLYCOL DRUM

FILL & DRAIN ASSEMBLY:

Remove the plugs from the Fill Port and the Drain Port on the left side of the BE-55C. Assemble and install the Fill Pipe Assembly onto the Fill Port and the Drain Pipe Assembly onto the Drain Port.

The Drain Pipe Assembly consists of two parts. Thread the part with the tee onto the nipple of the drain port, and the second part (with the flare fitting) into the top of the tee. Turn the parts as necessary to allow the valves to operate freely.

Use plumber’s Teflon tape and a pipe wrench to ensure tight, leak-free connections. Refer to the “Parts Location Diagram” for the piping configurations.

PRESSURE RELIEF VALVE: Screw the pressure relief valve onto the connection on

the back of the cabinet. Use piping capable of handling temperatures up to 400F. This piping should be routed into a receiving container capable of holding 5

AIR CONNECTION

gallons of hot liquid (e.g., a 5 gallon metal pail with a bung opening in the lid).

AIR CONNECTIONS:

Connect a filtered air supply to the BE-55C via the 1/4-

INST ALL PRESSURE RELIEF VALVE HERE

inch FNPT connector located on the rear panel of the unit. Maximum allowable inlet pressure is 125 psi. An internal regulator is installed to reduce the air supply to 10 psi. Air is used for the Drain Assist feature for the Process Tank.

CUSTOMER

SUPPLIED

CUSTOMER

1”NPT x 3 1/2’

SUPPLIED

PIPING AND

5-GALLON

BUCKET

FILL PORT

NOTE: Do not change factory setting on internal regulator.

DRAIN PORT

BE-55C Installation and

eration

LEFT SIDE VIEW

ELECTRICAL CONNECTIONS: The BE-55C requires a 208-240 volt, 3 phase, 60 Hz (special 50 Hz units are available) and 40-amp

electrical service with ground. Process times are longer at voltages less than 240V (up to 25% longer when incoming voltage is 208V). Electrical connections should be performed by a qualified electrician and in accordance with local codes. A minimum of 10 gauge copper wire must be used.

1. Remove the front panel of the BE-55C. Remove the cover from the circuit box.

2. Run the wiring through the grommetted hole in the rear panel of the unit and into the BE-55C’s circuit box. Bring the wire into the Circuit Box and secure the wire with the strain relief.

3. Connect the wiring to the upper terminal block connections labeled “L1”, “L2”, “L3”, and “G”. Be certain that the connections are correct and solidly attached to the terminal block.

NOTE: The BE-55C’s circuitry incorporates a “phase control relay” (orange colored device in circuit box) that will not allow the unit to operate if the field connections are incorrect. This prevents the three phase motors from rotating in the wrong direction.

INCOMING POWER

If “phase control relay” light is not lit, switch any two incoming power wires to correct phasing.

L1 L2 L3 G

PRIMING THE CIRCULATION PUMP:

1. Locate and remove the square access panel in the top of the BE-55C.

2. Remove the lid from the Pump Reservoir tank, and fill with 5 gallons of FTI pump primer. Be careful not to splash when pouring. Ensure that the liquid level in the pump reservoir is maintained at all times.

3. Replace the Pump Reservoir lid and access panel cover when finished.

NOTE: If a Start-up Kit was not purchased, water can be substituted for the FTI Pump Primer but will result in slightly diluted Processed Coolant for the first run.

~ Sequence of Operation ~

The BE-55C requires minimal operator involvement. Once the unit is filled with waste coolant and started, the unit can operate virtually unattended until the process is complete. Following is the normal sequence of operation for a waste coolant run in the BE-55C.

 FILL - The Fill Hose is inserted into a 55-gallon waste coolant drum. A Fill Switch on the BE-55C

starts a vacuum pump. As a vacuum is formed in the process tank, the Fill Valve is opened to draw in the waste coolant. When the drum is emptied, the operator switches the Fill Switch off. An overfill sensor prevents more than 55 gallons from entering the tank.

 WATER PROCESS - The BE-55C Process On/off Switch is depressed, starting the heaters and the

heat-exchanger circulating pump. As the water is heated and vaporizes, it passes through a condenser and reforms into a distilled water product. This distilled water product gravity drains into the processed water receiving drum.

 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 divert solenoid valve and creating a vacuum. At this point, the upper heaters de-energize and remain off for the remainder of the cycle. During this portion of the process, the glycol is vaporized under a vacuum (reducing its boiling point).

 AUTO SHUTDOWN - The BE-55C will automatically terminate the process when the liquid in the

process tank reaches a low level (approximately 5-7 gallons). This low level sensor de-activates the Process On/off Switch, shutting the unit off.

 DRAIN ASSIST - After the cycle is complete, and the residue in the tank has cooled for two to three

hours, the residues must be drained into a residue collection container. The Drain Assist Switch is depressed (activating the air supply solenoid) and the Drain Valve is opened until the residues stop flowing.

 REINHIBIT - After the process is complete, the Processed Glycol can be mixed with Processed

Water or low mineral content tap water to obtain the desired freeze/boil protection and reinhibited with FTI’s “BE-Series Engine Coolant Treatment” to re-make engine coolant.

 MAINTENANCE - As recommended by this manual, periodic flushing and fluid level checks should

be performed as outlined to insure proper operation and continued quality of recycled product.

~ Operating the BE-55C ~

CAUTION: ALWAYS WEAR SAFETY GOGGLES, PROTECTIVE CLOTHING, AND GLOVES

WHEN OPERATING THIS UNIT.

1. Position your two collection drums to the right of the BE-55C and insert the unit’s hoses into the drums. Take care to not allow the level of the processed liquid to cover these hoses to prevent over-pressure or liquid from being drawn back into the process tank.

2. Insert the clear, braided Fill Hose into your waste coolant drum.

3. Close both the Fill Valve and the Drain Valve.

4. Depress the Fill Switch. The vacuum will begin to register on the Vacuum Gage. When the

vacuum reaches -10” to - 15” Hg., open the Fill Valve to allow the waste coolant to be drawn into the process

VACUUM GAUGE

PROCESS

OFF

FILL

OFF

DRAIN ASSIST

OFF ON

5. Depress the Process Switch to the ON position. The switch’s light will illuminate, the cycle begins, and will now function automatically. When the process is complete (usually less than 20 hours), the Process Switch will move to the OFF position, and the light will go out.

NOTE: If the Fill Switch illuminates during the process while it is in the OFF position, the distillate overtemp switch has activated. This indicates that the unit is in a cool-down mode. The process will resume when the distillate temperature cools. See “TAS4 keeps tripping due to cooling system problems” on page 22.

tank. The Fill Switch will automatically disengage when approximately 55 gallons is drawn into the tank. Close the Fill Valve. If less than 55 gallons is to be processed, manually disengage the Fill Switch when the waste coolant drum is empty and close the Fill Valve.

NOTE: Do not over-fill the process tank. Fill only from a 55-gallon drum. Processing batches less than 55 gallons can result in inconsistent yields.

NOTE: The BE-55C is not designed to process motor oils. Every attempt must be made to prevent oil and debris from entering the Process Tank. Failure to do so will result in poor quality product and could damage the BE-55C.

6. The Processed Water and Processed Glycol are now ready for mixing and reinhibiting (refer to the Adding Reinhibitors/Freeze Point Check instructions at the end of the manual). The Processed Glycol normally contains approximately 10-20% water.

7. Allow the BE-55C to cool for at least two to three hours. NOTE: Warm residues flow easier than cold residues, allowing the tank to be more completely

drained of residue.

8. Use the Drain Assist to remove the residues from the process tank to a waste container.

CAUTION: LIQUID DRAINED FROM THE PROCESS TANK CAN REMAIN VERY HOT FOR

MANY HOURS. USE EXTREME CARE WHEN DRAINING.

Place the Black Drain Hose into a metal waste container. Depress the Drain Assist Switch and carefully open the Drain Valve. Air will begin to push the residue into your waste container. When residue no longer is flowing, and only air is coming out of the hose, close the Drain Valve and push the Drain Assist Switch to the “off” position. Open the manual drain valve and allow any remaining liquid to flow into a catch pan, and then close the valve.

NOTE: Use only the special high temperature Black Drain Hose on the air assisted residue drain. Other hose types may burst due to high temperature.

9. Dispose of residue properly in accordance with Federal, State and Local regulations.

10. Perform maintenance as outlined in the “Maintenance Schedule” section of this manual. NOTE: Residue must be drained after every run. Failure to do so will result in poor quality product

and will damage the BE-55C. NOTE: If less than 5 gallons of residue is drained, or the material is the consistency of tar, a

cleaning cycle must be performed before attempting another waste coolant cycle (refer to the “Maintenance Schedule” section of this manual).

NOTE: Never re-run residue or mix residue with waste coolant to re-run. Doing so will result in poor quality product and will damage the BE-55C.

Finish Thompson Premium Inhibitor Blending Instructions

Finish Thompson’s Premium Inhibitor is a fully formulated antifreeze inhibitor package designed to restore critical corrosion protection agents to glycol recycled with BE Series distillation systems. When properly inhibited, the recycled glycol meets and exceeds various performance specifications including ASTM D-3306, D-4985, D-6210 and TMC RP-329.

This one part formula is easy to use and economical. Because it works on all engine types, it eliminates the need to have more than one formula for automotive and heavy-duty engines. In addition, it can be used on either ethylene or propylene glycol.

When used with diesel engines, no pre-charge dose of supplemental coolant additives is required (normal SCA maintenance is required).

Blending Instructions:

Use only ethylene or propylene glycol recycled using the BE Series distillation process. Glycol must be between 50º and 100º Fahrenheit (10º and 38º Celsius) to be properly inhibited. Begin mixing the glycol and slowly pour 2 ½ fluid ounces of Finish Thompson Premium Inhibitor for every gallon of concentrated glycol produced by the BE Series distillation system. Continue to mix for approximately fifteen minutes to ensure complete blending. If a 50/50 mixture of glycol and water is desired, add the appropriate amount of low mineral content or distilled water until the freeze point is –34º F (-37ºC). Use a high quality device such as a refractometer to verify freeze point.

Note: Glycol produced by the BE Series distillation process can contain 10-20% water, do not mix 50% water with the distilled glycol.

Store Finish Thompson Premium Inhibitor above 40º Fahrenheit (5º Celsius) Use part number J104016 to reorder additional five-gallon pails of inhibitor If you have any questions concerning Finish Thompson Premium Inhibitor, contact FTI sales by

telephone at 814-455-4478, by fax at 814-455-8518 or by e-mail at fti@finishthompson.com

~ Maintenance Schedule ~

CAUTION: ALWAYS WEAR SAFETY GOGGLES, PROTECTIVE CLOTHING, AND GLOVES

WHEN WORKING ON OR WITH THIS UNIT.

CAUTION: NEVER WORK ON OR WITH THIS UNIT WHILE IT IS HOT. ALLOW A MINIMUM

OF TWO HOURS COOL-DOWN TIME.

EVERY CYCLE:

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

run. If less than 5 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-55C.

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-55C. For best results, perform a “detergent flush” to help remove oily deposits.

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

2. Fill the Process Tank with 25 gallons of clear water (follow the filling procedure outlined in the “Operating the BE-55C” section of this manual). To perform a “detergent flush”, dissolve 4-6 cups of non-sudsing automatic dishwasher detergent such as Cascade



in the 25 gallons of clear water

before filling the process tank.

3. Depress the Process Switch to the ON position and allow the unit to run for two hours. Then turn the unit off.

NOTE: Do not allow this cycle to run longer than two hours for the cleaning process. Doing so can damage the BE-55C.

4. Allow the BE-55C to cool for at least 1/2 hour.

5. Place the Black Drain Hose into a metal waste container. Depress the Drain Assist Switch and carefully open the Drain Valve. Air will begin to push the residues into your waste container. When residue no longer is flowing, and only air is coming out of the hose, close the Drain Valve and push the Drain Assist Switch to the “off” position. Open the manual drain valve and allow any remaining liquid to flow into a catch pan, and then close the 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 will damage the BE-55C.

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

(refer to “Priming the Circulation Pump” section of this manual). If low, top off with clear water or processed glycol.

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