Reserve Systems Inc. Note on this pumping unit: The ROS20-24 pumping unit is a direct replacement for the R2000K, R2000CK, DF2000 (58E-61-00010), except it does not contain the normal LED readout on any of these models. Monitoring can be by the LED capsule on the pump top, or simultaneously with an additional LED capsule, or the same external cable can have the capsule removed and the wires fed to data retrieval. Additionally, the unit has the option of using a M20 threaded float (NC) to advise it is time to add oil to the tank at a predetermined level within. This is a prototype pumping unit, and for this reason the wires are pre- installed for both the tank and the second LED capsule- to show routing. RED and white/ to purple in pump, no polarity. If the second capsule is not wanted it can be removed by just clipping the wires under the pump LED capsule feeding the external cable. Replace its strain relief connector with the 4 NPT plug. Also, if the float is not wanted to read tank level, it can similarly be removed by clipping the cable wires within. If this is done the purple leads must be connected together electrically and crimped or the unit will think the tank level is low. The normal out of oil “tank” signal will still work with the float removed. If the float is removed replace its strain relief connector with the 1/2 NPT plug. In using the signals for data retrieval, the manual gives the pin out of the wires. You have the option of unit powered LED, pump/check oil level led, tank empty LED and sample oil LED. Any or all. Ifa single alarm signal is preferred the pump, tank and sample LED’s can be wired to the same output. They are switched independently by relays and have a 150 ma. 5ydc. output. Reserve Systems Inc. 4040 Manly Road Rosamond, CA 93560 USA Telephone: 661-256-2275 Toll Free: 888-482-8042 Fax: 661-256-4979 “E:mal: reserve systems@mindspring.comModel ROS20-A-24 Self monitoring oil makeup and service extension pumping unit. R OS ™ Reserve Oil Supply Systems We make systems for engine oil makeup and long oil changes. Reserve Systems Inc. 4040 Manly Rd. Rosamond, Calif. 93560 661 256 2275 reserve.systems@mindspring.comThe RSO20A-24 is a level makeup system pump that self monitors its operation, verifying maintenance of the engine oil level and servicing of a reserve tank and the suitability of the engine oil for use. The Reserve Oil Supply system is an engine crankcase oil level control system that can increase time between oil change intervals. The level pump exchanges oil between the engine and reserve tank, ina novel method that simultaneously adjusts oil levels up or down as needed to maintain an exact running oil level. Oil exchange increases the quantity of engine oil proportional with the volume increase of the reserve tank over just the engine volume alone, and oil changes are proportionally lengthened. The system accommodates severe engine tilts and changes in power load and warm up times, and extreme temperature applications from hot to arctic climates. The new self monitoring pump reduces the need for attention to the system and increases engine security.3.. Combined Pump 4. Air removed from the engine by Operation As the system pump #1 is returned to the engine regulates proper cil level, the through the airrelief valve andthe —_§, The closure cap allows sealed return pump #2 will fil ol to return hose. operation. Tanks may be vented the tip of the engine adapter & without impairing operation. any excess oil above this point will be returned to the reservoir. The oil level is maintained at this (running) oll level & the fluid withdrawal by 6. Monitor Alarm Outputs pump #1 alternates between (alarms continue until power oll & air. circuits are shut down) “The alternate flow of oil & air Alarms read on LED capsule on is used to monitor the pump Aievent pump cover operation “Pump” -only air or only oil oun 1 through pump #1 for 3 hours, RETURN TO indicating low or high oi level, respectively, which will shut i down pump & activate alarm, | “Sample Oil". water or fuel detected in oil. Activate alarm after 3 hours ENGINE 2.Mechanical Operation —_ruxrancon The return pump #2 also LEVEL a runs continuously while the engine is running, & returns oil from the reservoir to the engine at % the rate of : withdrawal from the ware wioranat | engine by pump #1. The - oO *Optional add oil fo tank, same oil level rises unt it LED as "tank empty’, Teaches the tp ofthe sumer ae 7S tin a ch can be pt engine adapter. in tank upper half to remind the refill of tank before empty. Not shown, “Tank Empty”. only air through pump #2 for 3 hours, indicating low reservoir oil level, activating alarm, Monitor data can be taken by cable (not shown) to a second LED capsule or for data processing 1. Mechanical Operation The withdrawal pump #7 runs continuously when the engine is running & pumps any fluid, air or oil, above the tp ofthe engine adapter & delivers it to the reservoir : f (excess oil is pumped down until air Picture View ROS20-A-24VDC tered) is encountered). (Follow the Numbers)* Threaded port on capsule body is for communication cable. Monitor signals: * Monitor Alarm LED capsule. internal pump connections can be hooked up parallel to power a second LED capsule or data processing. Green Light: Unit is powered, and the processor has an active program. Pump: The pump has pumped only air or only oil for 3 hours. Pump shuts down and signal is maintained until the unit is de-powered When repowered the LED will be off. Tank. The pump has pumped only air from the tank, or no flow, for three hours. The pump operation is not affected. When repowered the LED will be off. An optional float switch can be added to the tank to warn the operator to add oil. Its output is on the same “tank” LED, but its operation will not shut off the pump. Sample oil. This LED indicates that water or fuel contamination is detected. The Pump continues operation, and the signal is held until the unit is depowered.Oil quality sensor. The oil quality sensor is mounted inside an oil accumulator, which is usually screwed into the outlet of the engine withdrawal pump #1. The sensor chip has a water accumulator and a fuel sensor fuse. Water detection is delayed for 3 hours to exclude alarm generations when water is put in the engine by routine oil makeup, so that the alarm response is specifically to leaking cooling systems. Response levels are approximate 2% water in oil. Fuel detection is automatic when the fuel dissolves the chemical fuse, which occurs when fuel exceeds about 2% fuel in oil for 2 hours. After detecting fuel, the inexpensive sensor chip needs to be replaced. Right: Accumulator and oil sensor head. Oil accumulator must point downward to trap oil sample. Below: JIC sealed oil accumulator and oil sensing head and field replaceable sensor chip. The oil quality sensor is a product of VSI Oil Corporation. Palo Alto Calif. For further information on this and other related oll quality monitoring capabilities contact VSI Oil directly. 5IN-8-8 strainer assembly: Itis intended that the R)S20 unit should have these oil filters at each pump inlet. Almost half of all Reserve pump problems are related to pumping contamination. The strainer assembly can be cleaned by dis-assembling at the #20 SAE ORB bushing. The internal strainer is a slip fit into this bushing and can be fully replaced or cleaned. A magnet at the end of the strainer should have metal particles removed before reassembly. End ports are % NPT to match the % NPT ports on the ROS20-24 pump. As a special the strainer assembly can be ported with an SAE#10 ORB thread. Consult with the factory for this option. 4a" NPT. -}-——____—-2271n 20.032 ——_____+ 1.8750in j* Al ++ 0.6260in - cn RESERVE SYSTEMS MATERIAL Weight Inline Strainer Assembly Strainer: 303 $3 ‘Assembly: 1.160 ibs. [Bushing: Zine Plated Bushing: Zine ‘Assembly: 0.720 Ks. Body: 606176 a BHGRS wv ‘Aturninur Nes Magnet: Ceramic eA ea War ares [oe IMODEL ROS20-A-24, SELF MONITORING OIL LEVEL PUMP ASSEMBLY FOR HIGH HP ENGINES RESERVE SYSTEMS Operating specifications 24VDC. dual function level pump: Electrical Data: Internal electronics isolated from frame. Pumps are solenoid driven piston type. Operating nominal voltage, voltage range: 2AVDC., 2010 38ved. Peak Current, inductive, 180 Ms. Max,.amps 0.84/27 de Average rated current, amps. n Enclosure ipss ‘Mechanical data: Overall dimensions (XW! sv") Mounting hole 30 176 X 148 mm (11.8 6.9 X tensions 138X 95 mm (5, ar) Hydraulic felectrie thread size YO NPT 4ea/ % NPS Sea. ‘Component weight 115kg 255 Ibs.) Max. ambient air temperature 110 C @30F) Min. ambient air temperature 10 min.* Rated flow, pump #1, pressures to 130 KPa.,-28C and above 36.8 Libr. (9.74 GPH) Rated min. flow, pump #1 pressures to 130 kPa, -35C 10Lihe. @.64GPH) Rated flow, pump 2, pressures to 413 kPa, -28C and above 7.8 Uwe (1.98 GPH) Rated flow, pump 2, pressures to 413 kPa, 35C 35 Lit. (0.92. GPH) Lift, self priming, height of lifts are altitude dependent. ‘380mavhig./ 18 in, hg, Oiltype Varies, Max. il viscosity ‘no min. at start up* May engine oil temperature 135C Min. oil temperature 40" ‘Alarm response levels, optional quality se Water, 2% approximately Pucl, 2% approximately Pai ‘Acrylic powder, natural yellow Other standard requirements: ‘The pump is sold with a strainer/flter for use in the inet lines of| ‘each pump, PN IN-8-8, Oil sensor assembly part of total pump assembly. Pump hydraulic ports “NPT. Electrical ports ¥4 NPS. * Pump operation wil take time to establish as temperatures approach 10, the point at which ol oes solid state, but operation ofthe system isnt limited to this temperature Reserve Systems Inc. 4040 Manly Road Rosamond, CA 93560 U.S.A. Telephone: 661-256-2275 Toll Free: 888-482-8042 Fax: 661-256-4979 E-mail: reserve.systems@mindspring.comWhat to do when there is an alarm signal Note: As the pump will turn off with pump errors for 3 hours, do not remove a non running pump until the system has been checked. Checking a unit is as simple as checking the running pump inlets for vacuum and the pump outlets for flow. #2 pump flow appears as a slow drizzle. Suction can be felt by placing a finger over the pump inlet fittings. Suction on the #2 side takes longer to develop. After an alarm and the pump shuts down, the LED will light until depowered, and the alarm will be off when repowered. Asa rule, an engine in which the oil level is being maintained and a tank showing consistent oil consumption indicates a system that operates correctly. An alarm being generated for any reason is an early warning to check the engine. If there is a pump alarm or a tank alarm, do not ignore it. At first Opportunity: Check both the engine and the tank for oil. If the engine oil level is not at a safe range than the unit can be electrically shut off and the engine serviced and run without the system until it can be diagnosed. 1. Ifthe engine is low: Either the engine is using oil faster than the system can replace it, or the pump has no flow to the engine, or the tank is empty. 2. If the engine oil level is high and the tank is not overfilled: Than the withdrawal pump might have lost suction either by mechanical or electronic problem, dirt in the pump, or by a hose leak. Suction can be tested with a hand over the withdrawal pump inlet. 3. If the engine oil level and the tank are overfilled, then oil is being added to the engine instead of the tank and is being transferred back to the tank by the pump until the tank is overfilled. In normal operation all oil additions should be to the engine only. An exception is if the engine is “making oil” by water or fuel contamination. If there is a “sample” alarm than sample oil. Fuel dilution will cause a permanent inexpensive and replaceable sensing chip. Water can work itself out of the oil slowly if the fault is not an engine that is losing coolant. The sensor can detect these conditions days before otherwise they would be found,