MSD Model 12 M1-1.pdf

Section 8: Maintenance

SECTION 8.0: MAINTENANCE

PP

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General Inspection

Do not touch electrical connections before you first ensure that power has been disconnected. Electrical shock can cause serious or fatal injury. Only qualified personnel should attempt the installation, operation and maintenance of this equipment.

8.1: MACERATOR PUMP

Refer to the macerator pump diagram and accompanying parts list in Section 10.0 when performing the following procedures.

8.1.1: Macerator Pump Parts Replacement (General)

This unit is designed to contain sewage. Flush it thoroughly before opening. Take necessary sanitation precautions to prevent health hazards.

Table 8-1 Macerator Pump Parts Replacement Guide

STEP ACTION

1 Set the Auto Off Hand switch to OFF or press the "OFF" button

2 Open the Unit Main Circuit Breaker or electrical disconnect. Follow proper lockout/tagout procedure

3 Close the valves at the pump discharge and suction

4 Remove the motor from the pump by removing the four 3/8” hex head cap screws (3) Remove the pump from the installation

5 Remove the four 5/16” hex head cap screws (18) and remove the suction head (22)

6 Unscrew the five 5/16” hex head cap screw (14)

7 Remove the volute case (27)

8 Remove the cutter ring (23) from the volute (27)

9 Check the radial cutter (19) and axial cutter (17) for clogging. Clean these parts without removing them from the shaft unless replacement is necessary

10 If the cutters require replacement, remove the flathead screw (21), impeller washer (20), and radial cutter (19) from the shaft. Tap the radial cutter (19) with a plastic hammer if necessary to loosen it (the thread is right handed)

O&M. Rev.05 Exceltec International Corporation

Table 8-1 Macerator Pump Parts Replacement Guide (cont.)

STEP ACTION

11 Lift the axial cutter (17) off of the impeller (26) and remove the spring pin (25)

12 Unscrew the impeller (26) from the shaft in the same manner as the radial cutter (19)

13 Clean all parts thoroughly with soap and water. DO not use abrasives or caustic solutions

14 Inspect the impeller (26), spring pin (25), axial cutter (17), and radial cutter (19)

15 Thoroughly clean the machined faces of the bearing frame (12) and volute (27)

16 Apply a fresh bead of Permatex to the faces of the bearing frame (12) face. Replace the volute (27) and screws. Do not replace the cutter ring (23) yet.

17 Loosen the ¼” bearing cap socket head cap screws (34) ½ turn. Replace the cutter ring

(23) and suction head (22)

18 Perform steps 3-10 in Table 8-4, Axial Cutter Adjustment

19 Reinstall the macerator

NOTE: Replace both the mechanical seal and rotating seal together as a set (P/N 22200)

8.1.2: Macerator Pump Mechanical Seal Replacement

If the oil in the bearing chamber contains water, either the mechanical seal (28 and

30) or the O-rings (29 and 47) is leaking and requires replacement. To replace the seals or O-rings, perform the following procedure.

Table 8-2 Macerator Pump Mechanical Seal Replacement Guide

STEP ACTION

1 Remove cutters, impeller, and the pump parts as described in Table 8-1, Macerator Pump

Parts Replacement (General)

2 Remove the socket head cap screws (15) in the seal plate (11). Screw two of the screws into the tapped back holes to force the seal plate (11) from the bearing frame (12)

3 Remove the seal plate (11). Remove the stationary seal half from the seal plate (11)

4 Remove the O-ring (29), coat a new O-ring with clean pump oil, and install the new O-ring

5 Check the sleeve bearing and shaft for wear. Replace worn parts

6 Press in the new stationary seal half (30) using the correct size press sleeve. Care should be taken not to chip or scratch the seal face

7 Remove from the back of the impeller (26) and replace the rotating half of the mechanical seal (30). Use sealant included with the seal kit. Care should be taken not to chip or scratch the seal face

8.1.3: Macerator Pump Ball Bearing and Oil Seal Replacement

If the ball bearing (33) is rusted or feels rough when it is turned, replace it. Use the following steps for replacement. Perform steps 1-13 of Table 8-1 before beginning step 1 of Table 8-3.

Table 8-3 Macerator Pump Ball Bearing and Oil Seal Replacement Guide

STEP ACTION

1 Loosen the setscrew in the coupling flange (38) and slide it off of the shaft (10).

2 Remove the two socket head cap screws (34) and pull the shaft and bearing cap (8) from the bearing frame (12)

3 Remove the snap ring (9) from the bearing cap (8) and pull the bearing (33) and shaft

(1) from the bearing cap (8).

4 Clamp the shaft (1) in a vise at the largest OD Ensure that the vise jaws do not damage the shaft; use vise jaw covers if necessary.

5 Use a spanner wrench to unscrew (right hand thread) the lock nut (35) from the shaft (1).

6 Use a bearing puller to remove the bearing (33).

7 Remove the shaft from the vice and press on a new bearing. It is important to press only on the inner race. If a bearing press is not available, use a sleeve and a hammer to tap on the inner race and install the bearing.

8 If the oil seal (36) has been leaking, pry the old seal out. Clean the seal pocket. Coat the OD of a new seal with Permatex. Press the new seal into place in the seal pocket of the bearing cap (8).

9 Replace the bearing cap O-ring if it is defective. Lubricate the O-ring (32) before installation.

10 Completely reassemble the macerator pump and fill it with new oil.

11 Turn the pump shaft by hand from the motor end. Check for roughness or binding during rotation. Adjust cutter blades if necessary (see Table 8-4).

12 After reinstallation of the pump, run the pump for a few seconds. Ensure that all parts run smoothly and are correctly adjusted. Ensure that the direction of rotation as viewed from the suction end of the pump is counterclockwise.

8.1.4: Macerator Pump Axial Cutter Adjustment

Perform the following steps to adjust the clearance between the axial cutter (19) and the cutter ring (23).

Table 8-4 Macerator Pump Axial Cutter Adjustment Guide

STEP ACTION

1 Turn the Auto Off Hand switch to OFF or press the "OFF" button

2 Open the Unit Main Circuit Breaker of electrical disconnect. Follow proper lockout/tagout procedure.

3 Loosen the jam nuts (7) on the setscrews (6) that are located on top of the bearing cap (8).

4 Loosen the setscrews (6).

5 Tighten the socket head cap screws (34) evenly until the axial cutter (17) just drags on the cutter ring (23) when the shaft (10) is turned by hand. Be careful not to damage the cutter ring.

6 Back off the cap screws (34) 1/8 turn.

7 Tighten the setscrews (6) evenly.

8 Tighten the jam nuts (7) on the setscrews (6).

9 Turn the shaft (1) by had to determine if there is any drag that is caused by interference. If drag exists, repeat the above steps and back off the cap screws another 1/8 turn.

10 Completely reassemble the macerator pump and fill it with new oil.

11 Close unit main circuit breaker and operate the pump momentarily in HAND position to check for proper operation.

Note; Be sure that all cap screws (34) are tightened or loosened the same amount and that the setscrews (6) are tight against the bearing frame (12). The setscrews (6) increase the c learance and the cap screws (34) decrease the clearance.

8.1.5: Seawater Y-Strainer Maintenance

The seawater "Y" type strainer screen should be cleaned every 30 operational days or more frequently as conditions require. Follow the procedure below.

1. Turn HAND-OFF-AUTO switch to the OFF position or press the "OFF" button.

2. Close the seawater supply valve and the cell feed valve.

3. Unscrew and remove the "Y" strainer screen and flush with water.

4. Re-assemble the strainer, open the seawater supply valve, and the cell feed valve. Check for leaks.

5. Turn the HAND-OFF-AUTO switch to the AUTO position or press the "AUTO" button to return to the normal operation.

8.2: RECTIFIER FIRING BOARD

Exceltec recommends that the firing board be returned to the factory for repair.

When a failure is suspected, see the firing board troubleshooting guide. Replace the

PCB and check the system for proper operation. If the system operates properly after replacing the board, return the faulty board to Exceltec for repair and return, otherwise return the old board to the system and continue to troubleshoot.

Rectifier Firing Board Replacement

Voltage required to operate this equipment can cause injury or death. Prior to working on the equipment, place all switches and circuit breakers in their open (off) position and tag them “DANGER, SHOCK HAZARD.”

Table 8-5 Rectifier Firing Board Replacement Guide

STEP ACTION

1 Open Unit Main Circuit Breaker or disconnect using proper lockout/ tagout procedures 2 Remove electrical connections from PCB 3 Replace PCB with a known good spare 4 Replace electrical connections and restore power to system 5 Verify bookcell current and voltage are within the normal limits

8.3: BOOKCELL

8.3.1: Bookcell Drain for Inspection and Cleaning

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Daily backflushing should be effective in controlling solids buildup in the Bookcell but is not as effective against scale deposits. These deposits, which form on the terminal cathode and the cathode sides of the bipolar electrodes must be removed by hand.

For this reason, the Bookcell must be opened, inspected, and cleaned periodically during normal operation. The purpose of inspection and cleaning is to remove seawater mineral deposits from the electrodes and to ensure they remain firmly attached in the Bookcell. Cleaning and inspection must be performed every 7 to 14 days, depending on seawater conditions and hydraulic loading.

Tools and Materials Required

• Standard hand tools

• Torque wrench

• Voltmeter or test lamp

• Nonmetallic flat scraper

• Nonmetallic nylon bristle brush

• Shop rags

• Catch tray

● Voltages required to operate this equipment are hazardous. Before servicing, place all switches and circuit breakers in the open (off) position and tag: DANGER, SHOCK HAZARD. Use a voltmeter or other suitable instrument to verify that circuits are de-energized

● The cell contains sewage. Backflush thoroughly before opening.

Take necessary sanitation precautions to prevent health hazards.

Table 8-7 Drain, Inspect, and Clean the Bookcell

STEP ACTION

1. Perform the bookcell backflush procedure described in section 6.5

2. Open the Unit Main Circuit Breaker

3. Close the Bookcell feed valve (valve between the macerator and the Bookcell)

4. Close the Seawater supply valve. (1/2” or ¾” valve to the Y-strainer)

5.

The Bookcell may now be opened and inspected, cleaned, or repaired as required.

REFERENCE: Section 8.3.2 Bookcell Cleaning and Electrode Replacement, for further instructions on bookcell maintenance

6. When the bookcell has been closed and all cover bolts correctly torqued, the bookcell may be put back into service

7. Open Bookcell feed valve and open Seawater valve

8. Energize the Unit Main Circuit Breaker, and press the RESET button

9. Turn the Auto-Off-Hand switch to AUTO or press the "AUTO" button

10.

When the Unit starts, verify that the Bookcell current and voltage is correct. (see Table 10-6) Unit will not start unless the level in tankV-1 is above the ON level switch. (LSH) Check the Bookcell and associated piping for leaks.

8.3.2: Bookcell Cleaning and Electrode Replacement

The electrodes can be cleaned when the bookcell is open for periodic inspection.

Occasionally, electrode replacement will also be necessary. For reference, see the bookcell assembly drawings in Section 10.0.

NOTE

The coating on the anodes is relatively soft and can be damaged. DO NOT attempt to clean anodes with a metal scraper or wire brush, this will damage the anodes.

Table 8-8 Bookcell Cleaning and Electrode Replacement

STEP ACTION

1 Once the Bookcell has been drained and the power turned off, the Bookcell may be opened.

2 Install a catch tray or garbage bag under the Bookcell to be opened.

3 Loosen and pull back the Bookcell cover bolts using a ½” socket and hand wrench. The bolts are retained in the Bookcell door. Do not remove the bolts completely.

4 Open the Bookcell and inspect the electrodes in the chamber formed by the Door, and Base of the Bookcell.

5 The electrodes should not be eroded on the edges or pitted. They should be firmly attached and mounted flush in the Bookcell.

6 Bi-polar electrodes should be coated black on one half and bare metal on the other half.

The terminal anodes should be totally coated black and the terminal cathodes should be shiny bare metal.

7 Use a soft brush and water. (NO METAL BRUSHES OR SCRUBBING PADS) to clean the seawater deposits from the electrodes. The deposits should be soft and come off easily.

8 If any of the electrodes are not firmly attached or have lifted, they should be removed, cleaned, and reinstalled. Prior to reinstallation, a 1/8” bead of high quality silicone caulk shall be run around the perimeter and screw holes on the backside of the plate.

9 The electrode should be installed firmly and allowed to cure before being put back into service.

10 When the Bookcell is ready to be closed, wipe the body O-rings and the center seals clean, then lubricate them with silicone grease. Also lubricate the threads of the cover bolts with thread lubricant. Lift and push the Bookcell door so that the alignment pins match their respective holes.

Table 8-8 Bookcell Cleaning and Electrode Replacement (cont.)

STEP ACTION

11 Start one bolt at the top to retain the Bookcell parts in place. Beginning at the bottom and working upward, torque the bolts in pairs to 10 lb-ft. Do not overtighten bolts or the Bookcell body will be damaged.

12 When the cover bolts have been tightened, the Unit valves can be aligned to put the Bookcell back into service.

8.3.3: Storing Valves

If valves are to be stored for extended periods:

• Keep valve inlets covered.

• Keep valves in the closed position.

8.3.4: Ball Valve Adjustment and Repair

The PVC ball valves are designed with an adjustment feature. If the valves show signs of initial leakage due to normal wear, the ball valve seat tension may be adjusted with hand tools. Remove the valve body from the piping. Use a valve wrench or a large pair of needle nose pliers to tighten the seat against the ball. The adjustable seat is on the downstream side of the valve (see the flow arrow).

Inserting a tool into two of the four notches and turning the seat can tighten the seat.

Care should be taken not to over-tighten the seat. This will make the valve difficult or impossible to operate. It can also cause damage due to increased seat wear and breakage of the valve stem from over-torque.

8.3.5: Ball Valve Replacement

The MSD unit is shipped from the factory with the valves socket glue welded into the piping. The valves are designed to be repaired in-place, but if removal of the valve ends is required, consult a qualified PVC piping technician. To install a replacement valve, follow these steps:

Table 8-9 Ball Valve Replacement

STEP ACTION

1 Loosen the union nuts that attach to the piping connections.

2 Slide the union nuts onto their respective pipes.

3 Put a small amount of tension on the pipes in order to open the connection just slightly between the valve and end connectors.

4 Remove the valve.

5 Put a new valve in the place of the old valve.

6 Remove the tension on the pipes.

7 Slide the union nuts back into place and tighten them.

8.3.6: Draining Filter Regulator

Every 24 hours of operation, open the drain cock on the bottom of the unit to blow down accumulated water and oil.

Section 10.3 Tables and Diagrams

SECTION 10.3: MACERATOR PUMP

This section includes a diagram of the macerator pump and the parts assemble list for this MSD unit.

O&M. Rev. 05 Exceltec International Corporation

Figure 10-3 Macerator Pump Diagram (Rev. 4)

Table 10-10 Macerator Pump Parts

Fig.

Index

Name

Qty Ass’y

EXCELTEC

PART#

1 Shaft Key 1 22201

2 Coupling Flange, 5/8” 1 22202

3 3/8-16 x 1” SS Hex Head Cap Screw 4 N/A

4-5 Not Used

6 ¼”-28 x ¾” Set Screw (Hex) 4 22206

7 ¼”-28 Hex Nut 4 22207

8 Bearing Cap 1 22208

9 Retaining Ring 1 22209

10 Shaft 1 22210

11 Seal Plate (Replaces 22211, ALL except Rev. 4)

(Replaces 22211, ALL except Rev. 3)

1 22251

22267

12 Bearing Frame (replaces 22212 ALL) Note 2 1 22266

13 Gasket 1 22265

14 5/16”-18 x 1 ½” Hex Head Cap Screw 6 22214

15 ¼”-20 x ½” Socket Head Cap Screw 3 22215

16 Not Used

17 Axial Cutter 1 22217

18 5/16”-18 x 1” Hex Head Cap Screw 4 22218

19 Radial Cutter 1 22219

20 Impeller Washer 1 22220

21 ¼”-20 x 5/8” Flat Head Screw 1 22221

22 Suction Head 1 22222

23 Cutter Ring 1 22223

24 O-Ring 1 22224

25 Spring Pin 1 22225

26 Impeller, 17-4 (replaces 22226 ALL) 1 22253

27 Volute (Replaces 22227 ALL except Rev. 3)

(Rev. 3)

1 22268

22252

28 Not Used

29 O-Ring 1 22229

30 Mechanical Seal Kit (Seal Head and Seal Seat) 1 22200-2

Table 10-10 Macerator Pump Parts (cont.)

Fig.

Index

Name Qty

Ass’y

EXCELTEC

PART#

31 ¼” NPT Hex Head Plug 4 22231

32 O-Ring, Bearing Cap 1 22232

33 Ball Bearing *Obsolete* See 48

34 ¼”-20 x 1” Socket Head Cap Screw 2 22234

35 Bearing Locknut 1 22235

36 Oil Seal 1 22236

37 Discharge Nozzle 1 22237

38 Coupling Flange, 7/8” 1 22238

39 Coupling Sleeve 1 22239

40-42 Not Used

43 Bushing, Shaft 1 22243

44 Sight Glass, Oil Cavity, Brass (SCP 1000) 1 22244

45 ¾” NPT Brass Plug (SCP-1000) 2 22245

46 Vent Breather 1 22246

47 O-ring, Shaft (Part of seal kit 22200) 1 22247

48 Ball Bearing (Horizontal & Vertical Mount Replaces 22233 ALL)

1 22248

49 Discharge Nozzle O-Ring 1 22249

50 Rebuild Kit 1 22250-2

51-53 Not Used

54 Seal Flush Nozzle (Not Shown) (Rev.3 ONLY)

1 22254

55-58 Not Used

59 Motor, Electric, 2 HP

Motor, Electric, 1HP

1 21460

21430

60 Oil, Macerator, 1 Qt. 1 22260

61 Gauge, Oil Level (Vertical Mount Only) 1 22261 & 22262

Note 1: All parts listed are interchangeable with all models of macerator pumps sold by Exceltec except where noted..

Note 2: If Bearing Frame #22212 (integral discharge nozzle) is replaced with Bearing Frame # 22266 (removable discharge nozzle), then the Volute # 22253 and the Discharge nozzle # 22237 must also be replaced.

Note 1: Internal Sleeve Bushing tool #22263 and Mechanical Seal tool #22264 are required when replacing the Mechanical Seal.

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Remove electrical connections from PCB

OmnipureHorMacPump(Section 10.3)