PHASEP MINI & JUNIOR SEPARATOR

TRAMP OIL REMOVAL SYSTEM

PARTS AND SERVICE MANUAL

© JUNE 2003 - TURBO SYSTEMS INCORPORATED PUBLICATION NO. 864510-0011

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

TURBO SYSTEMS INCORPORATED

Thank you for choosing a TURBO SYSTEMS INC. Tramp Oil Removal System. We are proud to have you
among our Turbo Systems’ Incorporated family of users.

TURBO SYSTEMS’ Tramp Oil Removal Systems simply and reliably remove tramp oil from coolant. This
patented oil removal technology will improve metal working fluid life by at least 50%. Since oil contamination is
the most common cause of metal working fluid disposal this system will reduce the need for hazardous waste
disposal. Machine efficiency is increased and operator safety is improved since these Tramp Oil Removal
Systems work with little maintenance attention and without interrupting production time. TURBO Tramp Oil
Removal Systems are available in many sizes and for various applications. For further information, contact:

Sales Department
TURBO SYSTEMS INCORPORATED
203 Turbo Drive
Kings Mountains, NC 28086

This Service Manual is intended to assist with the normal maintenance that will assure long service life of your
TURBO Tramp Oil Removal System. It is in two parts – a Service Instruction Section, followed by a Parts
Section, which includes drawings and parts lists for the basic elements of the conveyors.

NOTICE
ALL INFORMATION CONTAINED IN THIS MANUAL IS INTENDED TO BE CORRECT; HOWEVER
INFORMATION AND DATA IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT NOTICE. TURBO
SYSTEMS INC. MAKES NO WARRANTY OF ANY KIND WITH REGARD TO THIS INFORMATION OR
DATA. FURTHER, TURBO SYSTMES INC. IS NOT RESPONSIBLE FOR ANY OMISSIONS OR ERRORS
OR CONSEQUENTIAL DAMAGE CAUSED BY THE USER OF THE PRODUCT. TURBO SYSTEMS
RESERVES THE RIGHT TO MAKE MANUFACTURING CHANGES, WHICH MAY NOT BE INCLUDED IN
THIS MANUAL.

Turbo Systems Inc. supplies data necessary for the proper instruction, test, operation and maintenance of this
product. Turbo Systems Inc. retains all proprietary rights in and to the information so disclosed and such shall
not be reproduced, copied, or used in whole or in part for purposes other than those for which it is furnished.

1. TABLE OF CONTENTS
CONTENTS PAGE

Introduction & Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Instructions for Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Typical Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
How to Properly Size a PhaSep Tramp Oil Removal System . . . . . . . . . .. . . 3-4
Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installation and Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Trouble Shooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14-15
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Phasep Coalescor Service Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17-25

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

2. INSTRUCTIONS FOR ORDERING PARTS

INSTRUCTIONS FOR ORDERING PARTS

Furnish the following information on your order: Furnish exact shipping instructions:
• Model and serial no. of machine • Complete shipping address
• Catalog number and name of part • Mode of delivery
• Quantity wanted • Parcel post, truck line, etc
• Purchase order number
• Bill to address

How to find the model and serial number of your machine:

The machine model number and serial number is stamped on the machine nameplate located on the reservoir
of the unit.

TURBO SYSTEMS INCORPORATED

DIRECT YOUR ORDER TO: 203 Turbo Drive
Kings Mountains, NC 28086 U.S.A.
Telephone: (704) 739-7111 Fax: (704) 739-6039

WARRANTY
Seller warrants that within 12 months from original shipment, if its products are operated by the original specified
user: Seller will repair or replace, at its option, free of charge except freight, FOB shipping point, any parts it finds
nonconforming on these conditions:
a. on request, user promptly allows seller to inspect, and user returns all requested parts to seller’s plant,
and
b. user has operated and maintained products in accordance with seller’s maintenance and operational
literature and good business practice; and
c. products have not been misused, abused, damaged by accident or altered without seller’s written
consent; and
d. user employs trained maintenance and operating personnel; and
e. buyer meets all payment obligations;

Seller warrants products manufactured by others to the extent warranted by their original manufacturers, on
these conditions. Parts, which have expected life shorter than one year under normal usage, are excluded.
USED PRODUCTS ARE SOLD AS IS. SELLER MAKES NO WARRANTY FOR USED PRODUCTS EXCEPT
AS TO TITLE. BUYER MAY INSPECT AND TEST BEFORE SHIPMENT AND ACCEPTS USED PRODUCTS
ON THESE TERMS.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES WHETHER WRITTEN, ORAL,
OR IMPLIED, (INCLUDING ANY WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE.)

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

TYPICAL APPLICATIONS

Turbo Systems’ Tramp Oil Removal Systems can be utilized anywhere there are two
distinct phases of liquid (i.e. oil and water). Most commonly, the applications are
machine coolant and parts washer fluids. Turbo Systems’ Tramp Oil Removal
Systems have been utilized to remove oily wash water from parking lots, holding tanks
on large semi truck washing stations, air compressor blow down, and many other
applications.

Applying the Turbo Systems’ Tramp Oil Removal System is very straightforward. The
two easiest ways to determine whether this coalescing unit can be used to separate
two liquids are as follows below:

1. Visually inspect the liquid in the tank or sump. If there is a visible oil layer in the
system, the Turbo Systems’ Tramp Oil Removal System can be applied.

2. The second method requires that a sample of the fluid to be separated be taken.
The sample is placed in a bottle. Let the liquid rest for ten to fifteen minutes. If
there are distinctly visible phases of liquid present in the sample, the Turbo
Systems’ Tramp Oil Removal System will work well.

The Turbo Systems’ Tramp Oil Removal System is not capable of separating
chemically emulsified products. However, Turbo Systems’ Tramp Oil Removal
Systems will significantly reduce the level of mechanically emulsified oils in a
liquid. An example of a mechanical emulsion is oil that has been run through a
centrifugal pump a number of times. This type of emulsion will typically be seen as
a separate phase of liquid. Pure oil will be the top phase, mechanical emulsion as
the second phase and the base fluid as the third phase.

Successful Turbo Systems’ Tramp Oil Removal System applications include:

Machine Tool Coolants Rain Water Run-off
Mop/Wash water Retention tanks at Vehicle wash stations
Compressor Blow down Quenching tanks
Oil Spill Clean up

HOW TO PROPERLY SIZE A TURBO SYSTEMS’ TRAMP OIL REMOVAL SYSTEMS

Properly sizing the Turbo Systems’ Tramp Oil Removal System is fairly simple. As a
basic rule, the unit should produce five to seven turnovers of the entire liquid volume
in a 24-hour period. An example is below:

A customer has a 500-gallon tank. Multiply 500 by five (turnovers) and the liquid
volume we need to process is 2500 gallons. Divide 2500 gallons by 1440 (1 gallon per
minute over a 24 hour period) and the number is 1.736. This represents the size of the
coalescing unit needed to get the minimum five turnovers in 24 hours.

500 gallons X 5 turnovers = 2500 / 1440 = 1.736

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

Round up to the next highest whole number, in this case the application calls for a unit
capable of producing two gallons per minute.

If the unit cannot operate 24 hours per day, the size of the coalescing unit should be
increased to accommodate the necessary five turns per day.

If the customer operates three shifts per day, the size of the coalescing unit should be
larger to accommodate the constant influx of oily waste into the fluid. The larger size
will help eliminate the waste oil before it has an opportunity to become emulsified into
the fluid.

THEORY OF OPERATION

The TURBO SYSTEMS’ Tramp Oil Removal Systems use steel plate pack systems for a
coalescing media. When an oily liquid is brought into the coalescor, oil droplets want
to naturally rise to the surface. The actual droplet size of the oil determines how
quickly each droplet will rise in a liquid. As a general rule, larger droplets will rise
faster than smaller ones. It is these smaller droplets that the coalescor unit is
designed to collect better than competitive coalescors.

The steel plates of the plate pack system give oil a surface to make contact with. Once
contact is made, the droplet temporarily sticks to the plate surface. Our plate packs
are designed with a 45° angle to allow the oil droplets to slowly migrate up that angle
until they have reached the edge of the plate. During the journey, the oil droplets
break away from the edge of the plate and rise to the surface of the coalescing unit
where they will be skimmed off by an internal skimming tube.

Turbo Systems’ Tramp Oil Removal Systems are designed to create a Laminar flow.
This means that the flow through the coalescor is non turbulent. A non-turbulent
environment allows smaller droplets to rise more quickly. Turbo Systems’ Tramp Oil
Removal Systems also creates a very slow flow through the unit. Typically, the flow
through the coalescor is one linear foot per minute or less. This is a very important
element to the success of the coalescor. Combined with the non turbulent, laminar
flow, the very slow liner motion of the liquid, allows the coalescor to remove droplets
in the size range of 20 microns.

Once the liquid has passed through the coalescing plates, there is a retention dam
near the end of the coalescing unit. This retention dam serves to keep the coalesced
oil in the top of the coalescing unit from discharging back into the liquid from which it
came. Clean fluid flows beneath the retention dam and exits out of the coalescing unit.
The Turbo Systems’ Tramp Oil Removal Systems operate on a bypass loop allowing
for repeat flow through the plate packs. With average conditions, the liquid
discharging form the coalescing unit is 98% or higher, free of waste oil.

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

INSTALLATION AND MAINTENANCE

COOLANT TANK PREPARATION

If the wash solution or coolant in your equipment is heavily loaded with dirt and oil the sumps
should be drained, cleaned and recharged with fresh solution or coolant.

NOTE: In the above case, you may elect to fill the separator with clean coolant and begin
processing. Many times this is acceptable although the overall processing time will be
lengthened.

SEPARATOR TANK LOCATION AND OPERATION

The discharge height of the separator must be high enough to insure unimpeded gravity flow
back to the tank of your equipment.

Easy access to the separator cover, pump control, separator sump and oil skimmers should
be provided.

Locate the unit on a level surface. The separator must be level to insure maximum
performance. Charge the separator with clean coolant or wash water. The tank is correctly
filled when fluid starts to flow out the “FLUID OUTLET” port.

SET-UP PROCEDURE
1. Remove the tramp oil removal system from the packaged skid or box and inspect the
unit to insure there is no damage.
2. Lift the lid of the tramp oil reservoir and remove any loose parts (skimmer, hoses,
manuals, etc.) that are packaged inside the unit when shipped. Do not remove the
plate pack modules.
3. Position the tramp oil removal system near the tool tank from which the tramp oil will
be pumped. Level the unit using the four leveling bolts provided at the base of the
tramp oil removal system. Note that this unit must be leveled from both front to back
and side to side to insure proper operation.
4. Connect the corrugated suction hose to the hose fitting located on the strainer filter,
which is on the unit. “Do not cut the hose at this time.”
5. Locate an area on the tank that tramp oil will be pumped from and mount the hose
stabilizer assembly. This assembly is magnet is can be attached to the tank easily. It
is provide simply to keep the suction hose in place so the float sits level in the coolant.
6. Once the hose stabilizer assembly is properly positioned, cut the corrugated suction
hose to provide the proper length from the filter to the hose stabilizer. Secure the
hose clamps to make sure no air can be suctioned at the fitting connections. If the
hose connection and fittings leak the unit will not properly operate.
7. Find the area on the tank that has the least amount of turbulence. Typically an area
partitioned by baffles from any coolant pumps is ideal as long as floating tramp oil can
freely flow into this area. Position the float assembly in this area. Cut the remaining
corrugated suction hose to length from the float assembly to the fitting on the hose
stabilizer assembly. Make sure the hose is not kinked or twisted before tightening the
hose clamps. Insure the float assembly is positioned level in the liquid to be pumped
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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL
into the tramp oil removal system, otherwise the unit will not operate properly. If the
float assembly is positioned under a tank cover, insure that the top of the floating balls
never come into contact with the bottom of the tank covers. If they do, the unit will
only suction clean liquid and not skim the tramp oil, which floats on top of the liquid.
Also insure that the coolant level in the tank will never be so low that the balls come
into contact with the bottom of the tank. In this case no liquid from the tank can be
pumped.
8. Connect the clear 1” I.D. drain hose the barbed fitting on the unit, which is labeled
“fluid outlet” and route it from the tramp oil removal system back into the tank from
which the tramp oil is being suctioned.
9. Once all of the hoses have been installed check the drain valve on the tramp oil
removal system and insure that the drain valve is in the “closed” position.
10. Connect the customer supplied air supply hose to the quick connection fitting located
on the pneumatic regulator assembly. If the customer’s female quick connection fitting
is not compatible with the male quick connection fitting provide on the tramp oil
removal system, please change the quick connection fitting on the regulator to be
compatible with the customer’s female quick connection fitting.
11. Check the leveling of the tramp oil removal system once again to insure that it properly
leveled. The unit is now ready to be filled and operated.

Pump Operation Air Diaphragm Pump

FOR CPS-MINI ¾ GPM FLOW RATE
The All Flow ½” pump is capable of operating at a maximum flow of 14 gallons per minute.
The pump should not be operated at more than 1 gallon per minute due to potential overflow
of the mini coalescor. The CPS-MINI is designed for optimal efficiency at ¾ gallon per
minute flow rate.

To achieve the ¾ gallon per minute flow rate, the steps below must be followed.

Step 1.
Set the Air regulator to 40 psi. This can be done by adjusting the yellow knob on top of the
filter regulator assembly. (Warning!) The knob is a lock down style. It may be necessary to
pull up on the knob before turning. Failure to do so could cause damage.

Step 2.
To maximize your coalescor, the pump should not cycle more than 63 beats per minute. The
beats per minute can be adjusted with the flow control valve located between the filter
regulator and the pump. Any faster rate will minimize the unit’s efficiency and could cause a
potential overflow. If at 40 psi the pump fails to begin operating, simply adjust the needle
valve slightly higher until the pump begins to cycle. Reduce the flow back down to allow the
56-63 cycles per minute flow rate to insure proper operation.

FOR CPS-JR 1.5 GPM FLOW RATE

The All Flow ½ inch pump is capable of operating at a maximum flow of 14 gallons per
minute. The pump should not be operated at more than 1.5 gallons per minute due to
potential overflow of the Junior coalescor. The CPS-JUNIOR is designed for optimal
efficiency at 1 ½ gallon per minute flow rate. To achieve the 1 ½ gallon per minute flow rate,
the steps below must be followed.
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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

Step 1.
Set the Air regulator to 40 psi. This can be done by adjusting the yellow knob on top of the
filter regulator assembly. (Warning!) The knob is a lock down style. It may be necessary to
pull up on the knob before turning. Failure to do so could cause damage.

Step 3.
To maximize your coalescor, the pump should not cycle more than 80 beats per minute. Any
faster rate will minimize the unit’s efficiency and could cause a potential overflow. (It may be
necessary to run the pump faster to get the initial prime. If at 40 psi the pump fails to begin
operating, simply adjust the needle valve until the pump begins to cycle. Reduce the cycles
per minute to no higher than 80 cycles per minute to insure proper unit operation.

Evaluating Oil Levels in the PhaSep Coalescor

It is not uncommon to notice two to three different phases of liquid in the separation tank
Generally, a one to one and one half inch level of oil should be kept on the surface to prevent
any coolant from being skimmed off into the oil holding tank.

The sketch below is characteristic of what can occur in the separation tank.
The oil level should be approximately 1” deep. The cream layer is normally ½ of the depth of
the oil layer.

Waste oil should be removed from the unit on a regular basis to avoid an excessive build up.
If an intermediate layer (reverse emulsion) is evident, this should be removed regularly as
well. To avoid coolant or cleaning solution loss, always maintain a minimum of 1/4 of inch
waste oil on the surface of the coalescor.

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

Separator Clean Out Procedure

Turn off the pump.

Drain off the waste oil.

Once all of the oil has been removed from the surface of the separator lower the discharge
hose and allow the liquid level to return to the level of the overflow weir.

Drain the remaining liquid from the separator. Using the ”TANK DRAIN” port, first drain off
the solids that have collected on the bottom of the unit, then drain the remaining clean
coolant. The clean liquid should be saved for reuse if possible. Do not mix any dirt or
particulate on the bottom of the separator with the clean liquid.

Remove the separator plates from the tank and wash with fresh water or a steam hose. In
the case of carbon steel plates, these should be placed back in coolant before surface rusting
occurs.

Remove all solids and any oil from the sides and bottom of the separator tank, and
thoroughly clean the tank prior to reinstalling the plate packs. Plates should be installed in up
flow sequence with the incline of the plate pack positioned as shown in the diagram on page
5.

Recharge the tank with the clean liquid removed. Turn on the system and allow the
separator tank to refill. Adjust the slotted pipe skimmer to the desired height and replace the
tank cover. Check all hose connections, fittings and gaskets for leaks and tighten if required.

Additional Maintenance Requirements:

A daily check of the floating skimmer is recommended to insure that the skimmer inlet is not
blocked by floating solids.

A periodic check of the unit flow rate is recommended. This unit is designed for a flow rate
indicated on the page 7 of the manual, depend upon the separator model. A simple check
can be performed by allowing the discharge hose to flow into a container of a known volume
while timing the process. The discharge flow rate should fill the container in an amount of
time that equates to the prescribed gallons/minute.

FLOTATION ADJUSTMENTS
If your unit is equipped with a Stainless Steel Vortex float, there is no adjustment of the float.
You only need to make sure the float is in an upright and level position with the triangular
opening of the float box pointed upwards. The straight hose fitting should be below liquid
level.
To maximize your float potential, tighten the gray corrugated hose with a hose clamp around
the straight fitting. A hose clamp should have been provided for this purpose and should be
securely tightened so that no air leakage occurs at the hose and fitting connection.

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

TYPICAL SCHEMATIC WITH PNEUMATIC PUMP

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

PUMP MAINTENANCE PROCEDURES

CHECK VALVE AND O-RING MAINTENANCE

1. Flush and neutralize the pump to be certain all-corrosive or hazardous materials are
removed prior to any maintenance. This procedure should always be followed when
returning pumps for factory service.
2. Remove the nuts (19) and washers (10) from the four long pumping cap screws (35).
Suction check valve seats and check balls (26, 27) are located inside of the bottom of
the outer chamber (28). Gently remove and inspect for excessive wear, pitting or
other signs of degradation. Inspect valve seat o-rings (38). Replace if necessary.
Discharge check valves are located inside of the bottom of the discharge elbows (28).
Repeat procedure for inspection of discharge check valves.
3. To inspect the manifold o-rings remove the eight sets of nuts, washers and bolts (10,
19, 20) from each manifold assembly and replace if necessary. Then reassemble and
lightly tighten fasteners. Tighten all external fasteners to final torque requirements
after pump is completely assembled. The check ball should fit into the curved portion
of the valve seat and be facing upward when reinserted into the valve seat location.
NOTE: When using pumps built with Teflon o-rings always replace with new
Teflon o-rings, since the original o-rings will not reseal the pump.

DIAPHRAGM AND PILOT SLEEVE ASSEMBLY MAINTENANCE

1. To inspect diaphragms, remove the band clamps (16) from the outer pumping
chambers (28). If replacement is necessary due to abrasion or rupture, unscrew the
outer diaphragm plates (29). Models that are built with Teflon elastomers will have a
Teflon overlay (30) that faces the outer pumping chamber and a back-up diaphragm
(31) on the airside of the pump. Pumps without Teflon will contain only the back-up
diaphragms.
2. If there has been a diaphragm rupture and corrosive or viscous fluid has entered the
airside of the pump the complete air system should be inspected. After removing the
diaphragm plate (33), the pilot sleeve assembly (14, 49, 42, 45-47) and the diaphragm
rod assembly (13, 15) may be removed by removing the retaining plates (41) (you may
only need to remove one retaining plate) and pushing the entire unit out through the
bore in the intermediate (34). The diaphragm rod assembly must be unscrewed to
remove the pilot sleeve.
NOTE: To aid in reassembly use a non-synthetic, petroleum based lubricating
grease without EP additives. Carleton-Stuart MagnaLube G is recommended.
3. Clean or replace any components that have excessive wear, dirt build-up or chemical
attack. Lube all components prior to reassembling. Reassemble pilot sleeve spacers,
o-rings and lip seals (40) within bore of intermediate. Make sure that the open side of
the lip seals is facing outward toward the diaphragms. Also make sure that the end
pilot spacers (14) are at the end of either side of the pilot sleeve assembly and all
inner spacers (47) are separated by o-rings. Next carefully insert the diaphragm rod
assembly with the pilot sleeve inside the assembly in the bore. Reattach retaining
plates. Do not over tighten self-tapping screws (24)

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4. Take one diaphragm and invert (reverse the natural bow of the material) and with the
curved side of the inner diaphragm plate facing the diaphragm assembled onto the
outer diaphragm plate stud and then screw the assembly into the diaphragm rod.
Push the diaphragm rod to the opposite side of the intermediate and add the opposite
diaphragm assembly. Tighten the outer diaphragm plate to70 in-lbs of torque.
NOTE: Inverting the first diaphragm aids reassembly.
5. Position the outer diaphragm chambers onto intermediate making sure that the
witness lines are matching.
NOTE: If the air valve has been removed, proper orientation of the air system
with fluid chambers must be observed. The top of the intermediate has a single
vertical air passage slot on the air valve mounting face while the outer chamber
check ball cavity should be pointing downward.
6. When positioning band clamps, use soapy water or a compatible lubricating spray on
the inside of the band clamps to aid assembly. Tap with a mallet on the outside of the
clamp to help position the clamp while tightening the fasteners. The band clamp
fasteners are stainless steel. To prevent galling always apply an anti-seize compound
to the thread. Tighten all external fasteners to final torque requirement after the pump
is completely assembled.
7. Position the reassembled manifolds making sure of the proper orientation in relation to
the air valve for your application. Also make sure that the valve seat o-rings do not
shift from their grooves during reassembly. Flat washers should be placed under the
head of each cap screw and nut. Tighten all external fasteners to final torque
requirement after the pump is completely assembled.

EXTERNAL FASTENER TORQUE REQUIREMENTS

NOTE: When reassembling loosely tighten all external fasteners adjusting and
Aligning and gradually, in an alternating fashion, tighten to torque requirements
listed below:

BAND CLAMPS: 13.3 ft-lbs

MANIFOLD BOLTS: 20 in-lbs
OUTER CHAMBER CAP SCREWS: 20 in-lbs

AIR VALVE MAINTENANCE

1. To evaluate the air valve components, remove the four cap screws (11), washers,
(25, 10) and nuts from the air valve body (7). The valve plate (5) and shuttle (6) may
be inspected by removing them from their location in the slot in the back of the air
valve. Inspect for scratches or surface irregularities. Replace if necessary. To
remove the plug (1) at the bottom of the air valve, point the bottom of the air valve
safely away from any people, direct compressed air through one of the lower holes in
the back of the air valve body and the plug will shoot out. Next push the air valve
spool (2) out of the air valve body. Gently reach in and pull the lip seals (43) out of
the inside bore of the air valve body. Check for cracks, splitting or scratches. Clean
components if replacement is not necessary. Inspect the plug o-ring (44) for any
damage and replace if necessary and reinsert in the o-ring groove.

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

NOTE: Make sure that the open side of the two lip seals face each other when
reassembling the air valve. Lube all components with suggested maintenance
grease as an aid in reassembly.
2. Reinsert the air valve spool inside of the air valve body. Place the shuttle on the
middle rib of the air valve spool, through the square slot in back of the air valve. If
using the original valve plate, lubricate the side of the plate that was facing the shuttle
(or if new valve plate is used lubricate the lapped and polished side of the plate) and
place the lubricated side next to the shuttle in the slot. Press the valve plug into the
air valve body, chamfered end first.
3. Check that the gaskets (3, 4) are not cracked. If damaged, replace.
4. After gaskets are pressed back into position, align air valve onto intermediate and
reinsert the four cap screws with lock washers and flat washers. Apply 60 in-lbs of
torque to fasteners.

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TRAMP OIL REMOVAL SYSTEM TROUBLE SHOOTING GUIDE

The following chart will show some problems, their probable causes and possible solutions.
PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION
(1) Air is applied to the (a): In-line filter strainer is clogged or Clean in-line filter strainer and all suctions hoses of
pump but the pump supply hose(s) is blocked. chips or debris.
is not starting:
(b): Insure the suction skimmer float is Properly seat the suction skimmer float into the
seated properly in the coolant or fluid coolant or fluid. It should be seated so the ball floats
to be pumped. are level and fluid is being suctioned into the vortex.
(c): Pump diaphragm(s) is damaged. Disassemble pump and inspect the diaphragm for
damage. Replace if necessary.
(d). Air pressure is not sufficient to Check air pressure to insure it is at least 20 PSI (1.3
operate the pump. Bar).
(2) Pump is pumping (a). Suction line has a leak. Check all suction line connections for leakage.
but not priming:
(b). Check valve has excessive wear. Inspect check valves for wear or debris.
(c). Suction lift specification may be Check pump suction lift specifications.
exceeded.
(d) Fluid is too viscous for suction line If fluid is viscous use a larger suction line
size.
(e) Skimmer Float is not properly seated Properly position float in the fluid so that it is level.
in the fluid.
(3) Coolant leakage (a) Pump fasteners are too loose. Retorque all pump fasteners to specified torque
onto the floor: requirements.
(b) Worn or damaged pump o-rings. Replace o-rings.
(c) Pump diaphragm is damaged. Inspect pump diaphragms for rupture.
(4) Too low of flow (a) Air pressure or capacity is insufficient. Insure proper air pressure and air capacity at the air
rate: valve.
(b) Suction line has a leak. Check for leaks in suction lines and repair if
necessary.
(c). Suction line is obstructed) Check for obstructions in suction line. If necessary
clear these lines before resuming operation
(d). Fluid is too viscous for suction line If fuild is viscous use a larger suction line.
size.
(e) Check fluid temperature and viscosity. Viscosity of fluid may have increased if temperature
is lower.
(5) Air in discharge (a) Suction line has a leak. Check for leaks in suction lines and repair if
lines: necessary.
(b). Pump diaphragm is damaged. Inspect pump diaphragms for rupture and repair if
necessary.
(6) Erratic Cycling: (a). Pump check valve seats are dirty. Inspect pump check valve seats for debris. Clean if
necessary.
(b). Fluid line are obstructed. Inspect fluid lines for debris. Clean if necessary.
(c). Automatic valves are malfunctioning. Automatic valves must be properly functioning.
Repair if necessary.
(d). Viscosity of fluid is changing. Viscosity of product may be changing. Determine
cause and correct problem.

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

PROBLEM POSSIBLE CAUSE POSSIBLE SOLUTION

(7) Premature (a). Fluid has abrasive materials which If the fluid is abrasive, slow down the pump or
destruction of are pumped through the system. increase the size of the pump.
pump wetted
components.
(b). Inadequate filtration upstream from Filter fluid for sharp objects.
the pump.
(c). Pump components are incompatible Make sure fluid is compatible with wetted materials.
with the fluid being pumped.
(8): Excessive clean (a). Tramp oil tank reservoir is not level. Level tramp oil reservoir.
coolant is in the
tramp oil reservoir.
(9): Excessive tramp (a) Tramp oil tank reservoir is not level. Level Tramp oil reseroir.
oil is be drained
back into the
discharge hose.
(b) Pump is operating too fast. Adjust air pressure and needle valve to insure
proper air supply pressure and pump strokes per
minute per set up procedures.
(c). Plate packs are dirty or damaged. Inspect plate packs in repair or clean if necessary.

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

TRAMP OIL REMOVAL SYSTEM MAINTENANCE SCHEDULE

The following chart shows a suggested maintenance schedule for the conveyor to insure proper operation and
longevity.

Time Frame Procedure Problem Resolution

Daily Inspect skimmer to insure Skimmer not If necessary, reposition float,
it is floating level in the positioned correctly reroute hose or clamp hose to
fluid. in fluid. insure it does not move.
Daily Lift lid and inspect tramp Tramp oil reservoir Drain off and discard excess tramp
oil build up. full of tramp oil. oil, which has accumulated in the
tramp oil collection reservoir.
Weekly Inspect tramp oil tank to Too much clean Re-level unit if necessary.
insure it is leveled properly coolant in the tramp
and has not been moved oil reservoir or too
out of position. much tramp oil
returned to the
clean sump.
Weekly Inspect filter element to No or low pump Remove the filter element; discard
insure it is not clogged. flow. contaminants and clean element
before reinstalling. Suggested
weekly frequency may vary
depending upon customer’s
application.
Monthly Inspect hoses to insure No or low pump Remove obstructions as
there are no blockages flow. necessary.
from the float to the
discharge line.
Monthly Inspect pump for proper Coolant leakage or Refer to pump maintenance
operation to insure even erratic pump flow section of this manual for repairs if
and consistent flow and rate. necessary.
check for any signs of seal
leakage.
Monthly Inspect hoses to insure Foaming occurs or Replace damaged hoses, properly
they are in good condition, the system does position hoses, tighten fittings and
properly positioned and not operate hose clamps as necessary.
that all pipe fittings and effectively.
hose clamps are securely
tightened.
Every 3 months Inspect plate packs to System is not Repair plate packs if necessary
insure they are in good separating tramp oil and gently wash to remove any
condition and are not effectively. accumulated sediment build-up.
covered with a build-up of
sediment and thick tramp
oil.
Every 6 months Inspect tramp oil tank for Tramp oil tank Drain all tramp oil out of tramp oil
accumulated sludge and capacity is reduced reservoir, empty all fluids and
grime. or system is not clean the accumulated sediment
effective. and oil from the tramp oil tank and
plate packs. Frequency may vary
depending upon customer’s
application.

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© June 2003 - Turbo Systems Incorporated
TRAMP OIL SYSTEM

ITEM CATALOG PART NAME ITEM CATALOG PART NAME

NO. NO. NO. NO.

1 80A-100 Drain Valve Assembly 7 80A-700 Tramp Oil Reservoir

2 80A-200 Tri Vortex Skimmer Assembly 8 80A-1 Hose, 1” I.D. Drain (7190-2606)
3 80A-300 Hose Stabilizer Assembly 9 80A-27 Hose, Suction (7190-2500)
4 80A-400 Regulator Assembly 10 65A-106 Clamp, Hose (9874-1020)
5 80A-500 Strainer Filter Assembly 11 80A-2 Knob, Handle (9880-1022) Note: (Specify if
6 80A-600 Pump Assembly (8820-1001) Mounting Screw is required.)

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

TRAMP OIL RESERVOIR

ITEM CATALOG PART NAME ITEM CATALOG PART NAME

NO. NO. NO. NO.
1 80A-3 Closed Nipple, ½”(8870-1004) 4 80A-6 Hose Barb, 1” (9871-1386)
2 80A-4 Ball Valve, ½” (9872-1053) 5 65A-106 Hose Clamp (9874-1023)
3 80A-5 90° Elbow, Brass (9871-2315) 7 80A-7 Plate Pack Modules (6280-6080)

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

TRAMP OIL SYSTEM (PNEUMATIC PUMP)

ITEM CATALOG PART NAME ITEM CATALOG PART NAME

NO. NO. NO. NO.
1 80A-8 Pump, Pneumatic (9869-1159) 6 80A-12 Push Lock Fitting, ¼
2 80A-9 Hose Barb, 5/8 (9871-2314) 7 80A-13 Flex Hose
3 80A-5 Hose Barb, 90° Elbow (9871- 8 80A-14 Screw, HHC M6 X 25
2315) 9 80A-15 Nut, Hex M6
4 80A-10 Hose Clamp (9874-1020) 10 80A-16 Washer, Lock M6
5 80A-11 Hose, 5/8 ID (7190-2460)

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

STRAINER FILTER ASSEMBLY

ITEM CATALOG PART NAME ITEM CATALOG PART NAME

NO. NO. NO. NO.
1 80A-9 Hose Barb, 5/8 (9871-2314) 4 80A-19 Jam Nut (9850-1039)
2 80A-17 Strainer Filter (9873-1110) 5 80A-5 Hose Barb 90° Elbow (9871-2315)
3 80A-18 Bushing Reducer (8871-1386) 6 80A-18 Bushing Reducer (8871-1386)

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

HOSE STABILIZER ASSEMBLY

ITEM CATALOG PART NAME ITEM CATALOG PART NAME

NO. NO. NO. NO.
1 *80A-20 Bracket, Stabilizer (3280-0714) 4 80A-23 Nut, 5/16-18 (8850-1005)
2 *80A-21 Coupling, Full ½” (9871-1228) 5 80A-24 Magnet (9888-1421)
3 *80A-22 Screw, HHC 5/16-18 X 3/4 6 80A-25 Barbed Fitting, 5/8 (9871-1089)
(8820-1018)

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

TRI VORTEC SKIMMER ASSEMBLY

ITEM CATALOG PART NAME ITEM CATALOG PART NAME

NO. NO. NO. NO.
1 *80A-26 Skimmer Body (4280-4483) 5 *80A-29 Ball Float (9872-1065)
2 *80A-27 Hose, Suction (7190-2500) 6 *65A-106 Hose Clamp (9874-1020) (Not
3 *80A-28 Screw, ¼-20X1/4 (9826-3019) Shown)
4 *80A-25 Adapter Fitting (9871-1089) 7 80A-200 Tri Vortex Skimmer Assembly
(*Includes All Above Items)

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© June 2003 - Turbo Systems Incorporated
REGULATOR ASSEMBLY

ITEM CATALOG PART NAME ITEM CATALOG PART NAME

NO. NO. NO. NO.

3 80A-30 Air Regulator (9873-1037) 7 80A-34 Connector, Air Hose (9874-1025)

4 80A-31 Pressure Gauge (9873-1038) 8 80A-35 Air Valve
5 80A-32 Nipple, ¼ X ¼ (8870-1036) 9 80A-36 Pipe Plug, ¼
6 80A-33 Street Elbow, ¼ (8871-1119) 10 80A-37 Close Nipple, ¼

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 ITEM CATALOG PART NAME ITEM CATALOG PART NAME
NO. NO. NO. NO.

© June 2003 - Turbo Systems Incorporated

1 80B-1 Air Valve End Plug 26 80B-23 Valve Seat
2 80B-2 Air Valve Spool 27 80B-24 Ball
3 80B-3 Gasket, Inner 28 80B-25 Outer Chamber
4 80B-4 Gasket, Outer 29 80B-26 Outer Diaphragm Plate
5 80B-5 Valve Plate 30 80B-27 Overlay
6 80B-6 Shuttle 31 80B-28 Diaphragm
7 80B-7 Air Valve Body 32 80B-29 Diaphragm Manifold
8 80B-8 Lock Nut, ¼-20 33 80B-30 Inner Diaphragm Plate
10 80B-9 Washer, Flat 34 80B-31 Intermediate
11 80B-10 Screw, Cap ¼ X 4 ½ 35 80B-32 Cap Screw, ¼ X 7”
12 80B-11 Air Flow Control Valve 36 80B-33 Muffler Plate
13 80B-12 Diaphragm Rod (Short) 37 80B-34 Muffler
14 80B-13 End Spacer, Pilot Sleeve 38 80B-35 O-Ring, Valve Seat
15 80B-14 Diaphragm Rod (Long) 39 80B-36 Gasket, Muffler Plate
16 80B-15 Clamp Set (Complete with Fasteners) 40 80B-37 Lip Seal, Diaphragm Rod
17 80B-16 Nut, Hex 5/16-18 41 80B-38 Retaining Plate
18 80B-17 Carriage Bolt, 5/16-8 X 1 ½ 42 80B-39 O-Ring, End Spacer
19 80B-18 Nut, Hex ¼-20 43 80B-40 Lip Seal, Air Valve
21 80B-19 Manifold Plug 44 80B-41 O-Ring, Valve Plug
23 80B-20 Suction Manifold 45 80B-42 Pilot Sleeve
24 80B-21 Screw, #6 X 1/2 46 80B-43 O-Ring, Pilot Sleeve
PNEUMATIC PUMP PARTS LIST

25 80B-22 Lock Washer 47 80B-44 Inner Spacer, Pilot Sleeve

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PHASEP MINI & JUNIOR SEPARATOR TRAMP OIL REMOVAL SYSTEM - PARTS AND SERVICE MANUAL

PNEUMATIC PUMP ASSEMBLY

© June 2003 - Turbo Systems Incorporated Publication No. 864510-0011