Enclosure 66 - TM-55-1905-223-24-11 - Marine Sanitation Device (MSD).pdf

*TM 55-1905-223-24-11

TECHNICAL MANUAL

UNIT, INTERMEDIATE DIRECT

SUPPORT

AND INTERMEDIATE GENERAL

SUPPORT

MAINTENANCE INSTRUCTIONS

MARINE SANITATION DEVICE (MSD)

FOR

LANDING CRAFT UTILITY (LCU)

NSN 1905-01-154-1191

*Supersedes TM 55-1905-223-24-11, 17 January 1989, including all changes.

DISTRIBUTION STATEMENT A: Approved for public release, distribution is unlimited.

HEADQUARTERS, DEPARTMENT OF THE ARMY

FEBRUARY 2008

TM 55-1905-223-24-11

a

WARNING SUMMARY

The ORCA IIA Marine Sanitation Device (MSD) receives, treats, and discharges processed sewage (blackwater – B/W or graywater G/W) waste overboard (when permitted).

BLACKWATER - waste of human origin from water closets and urinals that is transported by the ship sewage system.

GRAYWATER - discarded water from deck drains, lavatories, showers, dishwashers, laundries, and garbage grinders as well as discarded water from shipboard medical facilities. Graywater does not include industrial waste, infectious waste, and/or human body waste.

Personnel must, at all times, observe all safety regulations while performing maintenance or repairs. Every practical safety feature has been incorporated into the design and manufacture of this equipment, however, personnel must be aware of the following potential hazards:

MODIFICATION HAZARD

Unauthorized modifications, alterations or installations of or to this equipment are prohibited and are in violation of AR 750-10. Any such unauthorized modifications, alterations or installations could result in death, injury or damage to the equipment.

MOVING MACHINERY HAZARDS

Be very careful when operating or working near moving machinery.

Running engines, rotating shafts and other moving machinery parts could cause personal injury or death. Before maintenance is performed on motor driven equipment, the main circuit breaker should be de-energized and labeled “OUT OF SERVICE.” Only authorized maintenance personnel should make repairs to this equipment.

GAS HAZARDS

A serious potential hazard associated with sewage systems is hydrogen sulfide (H2S). It is a colorless, flammable, toxic gas with a characteristic smell of rotten eggs at low concentrations. However the sense of smell is lost after 2-15 minutes of exposure, making it impossible to smell dangerous concentrations. The permissible exposure limit (PEL) for H2S is 10 parts of H2S for every million parts of air (commonly expressed as 10 ppm H2S).

The IDLH (Immediately Dangerous to Life or Health) limit is 100 ppm H2S. In addition when H2S burns, it produces another very toxic gas, sulfur dioxide (SO2). For additional information, refer to Naval Ships Technical Manual (NSTM) Chapter 593, POLLUTION CONTROL, S9086-T8-STM-010. When removing access covers, fresh air from a known outside source must be supplied to the surrounding area. Only after this fresh air has been supplied for proper tank ventilation should personnel open the tank. Under no circumstances should any person service a tank without a second person, capable of rendering aid, standing by. If an extended period of time for tank repair is anticipated, personnel should utilize the proper respiratory equipment.

Immediately Dangerous To Life Or Health (IDLH) is a classification assigned by the U.S. Navy Gas-Free Engineering Program (Naval Ships’ Technical Manual (NSTM) CHAPTER 074, VOLUME 3 - GAS FREE ENGINEERING S9086-CH-STM-030) to a confined space (such as sewage holding tanks or sewage system piping) in which the atmosphere meets one or more of the following conditions: flammable vapors at a concentration of 10 percent or greater of the lower explosive limit (LEL); an oxygen content of less than 19.5% or greater than 22%; the presence of toxicants above IDLH exposure limits given in Appendix G of NSTM Chapter 074, Volume 3. Entry into IDLH spaces is authorized only under emergency conditions and only the Commanding Officer can authorize opening and entry into IDLH spaces. Additional information concerning hydrogen sulfide and sewage tank entry is provided in NSTM Chapter 593, S9086-T8-STM-010 and NSTM CHAPTER 074, VOLUME 3, S9086-CH-STM-030.

b

SAFETY SUMMARY - Continued

CHEMICAL HAZARDS

The ORCA IIA MSD requires a constant supply of hypochlorite solution (common household bleach). Containers for the solution must be stored in a six inch bed of sand, located in a well ventilated, dark, and dry area. When handling containers, take extreme care to avoid hypochlorite solution contact with the skin, excessive inhalation of the vapors, or splashing in eyes. In case of an accident, flush the affected areas with water IMMEDIATELY. An Emergency Eye Wash Station must be located in the bleach storage area.

DISEASE HAZARDS

Good personal hygiene habits by those operating and servicing the MSD are imperative. Washing of hands with hot, potable water and disinfectant soap should be accomplished after coming in contact with sewage or any contaminated equipment. Personnel shall not be allowed to eat, smoke, or drink, in the MSD pump room.

Personnel with skin abrasions, punctures, or any other wounds shall not be allowed to service MSD equipment. In order to minimize the risks of health and sanitation hazards associated with the MSD, personnel shall follow sanitary and hygienic practices contained in section 4 of NSTM Chapter 593, S9086–T8–STM-010. When performing maintenance, which requires disassembly of sewage equipment or when contact with sewage is possible, personnel protective equipment (PPE) specified in section 4 of NSTM Chapter 593, S9086–T8–STM-010 shall be donned.

ELECTRICAL HAZARDS

Respect all circuits. Precautions set forth in Naval Ship’s Technical Manual (NSTM), Chapters 300, 302, 310, and 320, shall be observed with respect to electrical equipment and circuits. Special precautionary measures are essential to prevent applying power to the system/equipment at any time maintenance work is in progress.

Disconnect power and tag the circuit to warn of a potentially dangerous situation. Use a multimeter to ensure all electrical circuits are de-energized before touching any part of the circuit. Before working on electrical system/equipment, check with multimeter to ensure that system is not energized. Circuits not known to be dead must be considered live and dangerous at all times. The voltages used to operate this equipment are high enough to cause severe injury or death. When working near electricity, do not use metal rules, flashlights, metallic pencils, or any other objects having exposed conducting material. Troubleshooting procedures frequently require that checks be made while the power is on. Use extreme care to prevent contact with live circuit parts. Touching these parts could result in electrical shock. Be sure to de-energize all equipment before connecting or disconnecting meters or test leads. When connecting a meter to terminals for measurement, use a range higher than the expected voltage.

DO NOT REPAIR OR ADJUST ALONE

Under no circumstances should repair or adjustment of energized equipment be attempted alone. The immediate presence of someone capable of rendering aid is required. Before making adjustments, be sure to protect against grounding. If possible, adjustments should be made with one hand, with the other hand free and clear of equipment. Even when power has been removed from equipment circuits, dangerous potentials may still exist due to retention of charges by capacitors. Circuits must be grounded and all capacitors discharged prior to attempting repairs.

TEST EQUIPMENT

Make certain test equipment is in good condition. If a test meter must be held, ground the case of the meter before starting measurements. Do not touch live equipment or personnel working on live equipment while holding a test meter. Some types of measuring devices should not be grounded; such devices should not be held when taking measurements.

INTERLOCKS

Interlocks are provided for safety of personnel and equipment and should be used only for the purpose intended.

They should not be battle-shorted or otherwise modified except by authorized maintenance personnel. Do not depend solely upon interlocks for protection. Whenever possible, disconnect power at power distribution source.

For Artificial Respiration, refer to FM 4-25.11.

A/(B blank)

LIST OF EFFECTIVE PAGES

NOTE: *Supersedes TM 55-1905-223-24-11, 17 January 1989, including all changes.

Date of issue for revision is: 08 February 2008.

TOTAL NUMBER OF PAGES IS 162 CONSISTING OF THE FOLLOWING:

Page *Change No. No.

Page *Change No. No.

Cover a and b i and ii 1-1 through 1-12 2-1 through 2-89/(2-90 blank) 3-1 through 3-22 4-1/(4-2 blank)

*Zero in this column indicates an original page.

A-1/(A-2 blank) B-1 through B-5/(B-6 blank) C-1 and C-2 D-1 and D-2 Glossary-1 and Glossary-2 Index-1 and Index-2

DA 2028

Metric Chart/PIN i

TECHNICAL MANUAL HEADQUARTERS

DEPARTMENT OF THE ARMY

WWASHINGTON, D.C., 08 February 2008

UNIT, INTERMEDIATE DIRECT SUPPORT AND

INTERMEDIATE GENERAL SUPPORT

MAINTENANCE INSTRUCTIONS

MARINE SANITATION DEVICE (MSD)

FOR

LANDING CRAFT UTILITY (LCU)

NSN 1905-01-154-1191

REPORTING ERRORS AND RECOMMENDING IMPROVEMENTS

You can help improve this publication. If you find any mistakes or if you know of a way to improve the procedures, please let us know. Submit your DA Form 2028 (Recommended Changes to Equipment Technical Publications) through the Internet, on the Army Electronic Product Support (AEPS) website. The Internet address is https://aeps.ria.army.mil. The DA Form 2028 is located under the Public Applications section in the AEPS Public Home Page. Fill out the form and click on SUBMIT. Using this form on the AEPS will enable us to respond quicker to your comments and better manage the DA Form 2028 program. You may also mail, fax or e-mail your letter or DA Form 2028 direct to: TACOM Life Cycle Management Command, ATTN: AMSTA-LC-LMPP/TECH PUBS, 1 Rock Island Arsenal, Rock Island, IL 61299-7630. The e-mail address is ROCK-TACOM-TECH- PUBS@conus.army.mil. The fax number is DSN 793-0726 or Commercial (309) 782-0726.

DISTRIBUTION STATEMENT A: Approved for public release; distribution is unlimited.

TABLE OF CONTENTS

PAGE

CHAPTER 1 INTRODUCTION.................................................................................................... 1-1

Section I General Information ............................................................................................... 1-1 Section II Equipment Description and Data ........................................................................... 1-2 Section III Principles of Operation........................................................................................... 1-5

CHAPTER 2 UNIT MAINTENANCE INSTRUCTIONS................................................................ 2-1

Section I Repair Parts; Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment....................................... 2-1 Section II Service Upon Receipt ............................................................................................ 2-1 Section III Unit Preventive Maintenance Checks and Services (PMCS) ................................ 2-11 Section IV Unit Maintenance Troubleshooting Procedures..................................................... 2-13 Section V Unit Maintenance Procedures................................................................................ 2-26 Section VI Preparation for Storage or Shipment ..................................................................... 2-89

CHAPTER 3 INTERMEDIATE DIRECT SUPPORT MAINTENANCE INSTRUCTIONS ............ 3-1

Section I Repair Parts, Special Tools; Test, Measurement and Diagnostic Equipment (TMDE); and Support Equipment................................ 3-1 Section II Service Upon Receipt ............................................................................................ 3-1 Section III Intermediate Direct Support Preventive Maintenance Checks and Services (PMCS)............................................................................................. 3-2 Section IV Intermediate Direct Support Troubleshooting ........................................................ 3-3 Section V Intermediate Direct Support Maintenance Procedures .......................................... 3-5 Section VI Preparation for Storage or Shipment ..................................................................... 3-22

*Supersedes TM 55-1905-223-24-11, 17 January 1989, including all changes.

ii

TABLE OF CONTENTS – Continued

PAGE

CHAPTER 4 INTERMEDIATE GENERAL SUPPORT MAINTENANCE INSTRUCTIONS ........ 4-1

APPENDIX A REFERENCES....................................................................................................... A-1

APPENDIX B MAINTENANCE ALLOCATION CHART................................................................ B-1

APPENDIX C EXPENDABLE/DURABLE SUPPLIES AND MATERIALS LIST............................ C-1

APPENDIX D TORQUE VALUES................................................................................................. D-1

GLOSSARY ABBREVIATIONS AND DEFINITIONS.................................................................. Glossary-1

ALPHABETICAL INDEX ....................................................................................................................... Index-1

1-1

CHAPTER 1

INTRODUCTION

Page

Section I. General Information ................................................................................................. 1-1

Section II. Equipment Description and Data ............................................................................. 1-2

Section III. Principles of Operation............................................................................................. 1-5

SECTION I. GENERAL INFORMATION

1-1. SScope. The scope of this manual is as follows:

a. Type of Manual. Unit, intermediate direct support, and intermediate general support maintenance instructions.

b. Model Number and Equipment Name. ORCA IIA-36 Marine Sanitation System, installed aboard the LCU

2000 Class watercraft.

c. Purpose of Equipment. The Marine Sanitation System collects, treats, and discharges sewage waste.

1-2. Maintenance Forms, Records, and Reports. Department of the Army forms and procedures used for equipment maintenance are those prescribed by DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual.

1-3. Destruction of Army Materiel. Refer to TM 750-244-3 for instructions covering the destruction of Army materiel to prevent enemy use.

1-4. Reporting Equipment Improvement Recommendations (EIR). If your Marine Sanitation Device needs improvement, let us know. Send us an EIR. You, the user, are the only one who can tell us what you don't like about your equipment. Let us know why you don't like the design or performance. If you have Internet access, the easiest and fastest way to report problems or suggestions is to go to https://aeps.ria.army.mil/aepspublic.cfm (scroll down and choose to submit an Equipment Improvement Recommendation (EIR), a Product Quality Deficiency Report (PQDR or a Warranty Claim Action (WCA). You may also submit your information using an SF 368 (Product Quality Deficiency Report). You can send your SF 368 via e-mail, regular mail, or facsimile using the addresses/facsimile numbers specified in DA PAM 750-8, The Army Maintenance Management System (TAMMS) Users Manual. We will send you a reply.

1-5. Preparation for Storage or Shipment. Administrative storage of equipment issued to and used by Army activities will have preventive maintenance performed in accordance with the Preventive Maintenance Checks and Services (PMCS) charts before storing. When removing the equipment from administrative storage, the PMCS should be performed to assure operational readiness. Repacking of equipment for shipment or short term storage is covered in Paragraph 2-25.

1-2

SECTION II. EQUIPMENT DESCRIPTION AND DATA

1-6. Characteristics, Capabilities, and Features. A very broad view of the marine sanitation device is as follows:

a. Characteristics.

(1) Self-contained (with exception of bleach tank, commode warning light, and remote status indicator panel).

(2) Electrically operated.

(3) Automatic.

(4) Sewage processing unit.

b. Capabilities and Features.

(1) Receives, treats, and discharges processed sewage waste.

(2) Operates with salt, brackish, or fresh water.

(3) Has warning system to indicate tank full conditions.

(4) Provides sanitary service for up to 36 people.

CAUTION

Under no condition may the sewage handling capacity of the individual system be exceeded. An overload condition could cause damage to other system components.

1-7. Location and Description of Major Components. Figure 1-1 shows the location of major MSD components. The following information concerns dataplates on components in the marine sanitation system.

a. Recording Identification Data. Serial numbers and model numbers are shown on dataplates on the equipment. Since wear may cause dataplates (nameplates) or stencils on the equipment to become unreadable, serial numbers, model numbers, Control Parts List (CPL) numbers, and other appropriate data should be recorded. This information is important when servicing and when replacing or ordering parts.

b. Location of Dataplates (Nameplates).

(1) Marine Sanitation Device. The dataplate is located on the left side of the external framework on the electrical junction box (control panel assembly) end of the unit.

(2) Pumps. The dataplates on all pump units are located on the individual pump motor housings.

1-8. Equipment Data. The following is the general equipment data for the sanitation device and all associated components.

a. Sanitation Device

Model ORCA IIA-36, by Envirovac Inc.

Capacity:

Sewage 1,080 gl (4,088 L) per day Persons 36 Dimensions and Weights:

Height: 42.5 in (108 cm) Width: 18.5 in (47 cm) Length: 44 in (112 cm)

1-3

Dimensions and Weights continued:

Dry Weight: 775 lb (352 Kg) Wet Weight: 1,075 lb (448 Kg)

Allowable Pitch and Roll: 30 degrees

Allowable Hydrostatic Head: 10 ft (3 m) water

Bleach Requirement: 2.25 gl (8.5 L) per day

External Piping Connections:

Sewage Inlet: 3 in (76.2 mm) 150# ANSI Flange Connection Sewage Outlet (at discharge pump): 0.75 in (19 mm) 150# ANSI Flange Connection Vent Outlet: 1.5 in (38.1 mm) 150# ANSI Flange Connection Backwash Inlet: 0.5 in (12.7 mm) 150# ANSI Flange Connection

Electrical Connections:

Input: 110/220 VAC, 1 phase, 50/60 Hz, 30 amp Current Draw: 115/220 VAC, 3.5 kva

b. Associated Components.

Treatment Tank Capacity: 17.5 gl (66.15 L)

Sedimentation Modules:

Quantity: 3 (split tanks in series, 6 total) Capacity: 30 gl (113.5 L) (10 gl each)

Macerator:

Waste King: 1 hp, 115/230 VAC, 60 Hz

Flow Pump and Motor:

Motor:

Baldor, Model CL3503A 1.5 hp, 3,450 RPM 115/230 VAC, 60 Hz Pump: Tecumseh Model 23938 Impeller Diameter: 2.875 in (73 mm)

Bleach Tank: Capacity, 10 gl (37.9L)

Location Requirements:

Horizontal: Within 10 feet (3 m) of the unit Vertical: Minimum of 1 foot (30.5 cm) above the unit

Retention/Reduction Screen: Wire Cloth, 24/014

Sprinkler Head Pressure: 30 psi (2.1 Kg/cm2) Flow: 3.6 gpm (16.4 L/min)

Commode Warning Light 110/120 VAC

1-9. Safety, Care, and Handling. Safety precautions must be observed at all times while performing maintenance. General WARNINGS and first-aid data appear in the front of this manual. Review all safety information before starting any task. Carefully read through an entire maintenance procedure before performing any maintenance function. Make sure the task can be done safely. All WARNINGS, CAUTIONS, and NOTES are of great importance to your safety and the safety of the equipment.

1-4

Figure 1-1. MSD Components.

1-5

SECTION III. PRINCIPLES OF OPERATION

1-10. General. Figure 1-2 illustrates how the sanitation device interfaces with other external components in the sewage system. For the operation of these individual system components, refer to the LCU Operator’s Manual, TM 55-1905-223-10.

1-11. System Functional Description. The following describes the sanitation system design and the sewage treatment process.

a. System Description.

(1) The Marine Sanitation Device is a self contained unit. All of the major components are located within the enclosure panels of the unit, with the exception of the bleach tank, commode warning light, and remote status indicator panel.

(2) The system is equipped with an electronic monitoring system which automatically controls the treatment of sewage, warns of any motor shutdown, and pinpoints the problem motor. It also warns of any treatment tank overload condition, thus avoiding damage to other system components or to the vessel’s electrical supply.

(3) The control system comprises one modular unit. The control panel assembly (Figure 1-3) houses the electronic monitoring circuit and an in-line circuit breaker.

b. Treatment Process. (Figure 1-4.)

(1) Blackwater and graywater from the surge tank enters the treatment tank of the MSD. The sewage is macerated and chlorinated. The macerated sewage is continuously recirculated into the treatment tank until the solids are small enough to pass through the retention/reduction screen. The retention/reduction screen is continuously backwashed to prevent solid build up and clogging/plugging. Sewage particles that passed through the screen enter the inlet of the flow pump, which pumps the sewage into the sedimentation tanks. Any agglomerated solids fall to the bottom of the sedimentation tanks and are returned via the sludge flow control valve to the treatment tank for further processing. If pressure in the discharge line builds up above 35 psig (241.5 kPa), the pressure relief valve opens to allow the return of processed sewage into the treatment tank.

(2) The processed effluent is discharged from the MSD through a spring loaded check valve. The check valve creates a back pressure to allow flow through the sludge return lines. The minimum pressure required to start opening is 5 psi (34.5 kPa). This pressure will increase as the discharge flow increases. The effluent is disinfected with a bleach solution (sodium hypochlorite and water) and chemical oxidation within the treatment tank. Disinfection is accomplished by a metering system (solenoid and needle valve) that meters an appropriate amount of bleach into the treatment tank. The bleach solution is stored in a 10 gallon tank mounted above the treatment tank.

(3) The level sensor assembly is located on the inlet side of the retention/reduction screen and consists of four electrodes (ground, low level, demand level, and high level). The level of the sewage in the treatment tank in relation to the electrodes is sensed by the microprocessor in the circuit control board assembly.

(4) When the sewage level reaches the tip of the demand electrode, an 18 minute cycle is started. If the low level electrode is uncovered after 18 minutes, the MSD stops processing sewage and goes into the standby mode. If the low level probe is covered after 18 minutes, another 18 minute cycle continues without interruption and the cycles are repeated, if necessary, until the low level probe is uncovered. If the sewage level covers the high level electrode, the HIGH LEVEL LED light on the status indicator (control panel) begins flashing. If the high level condition persists for 10 minutes, the MSD will shutdown automatically. During this automatic shutdown period, the LED light on the status indicator will remain illuminated. The MSD will not automatically restart after a power failure, the reset pushbutton must be depressed to restart the MSD system.

1-6

Figure 1-2. Marine Sanitation Device System Flow and Components Location (Sheet 1 of 2).

1-7

Figure 1-2. Marine Sanitation Device System Flow and Components Location (Sheet 2 of 2).

1-8

Figure 1-3. Marine Sanitation Device Control Panel Assembly.

1-9

1-12. Functional Description Of Components. The component descriptions are listed in the order of flow. See Figure 1-4 for location of item.

a. Treatment Tank (1). Provides space for sewage retention and treatment.

b. Retention/Reduction Screen (2). Retains larger solids in the treatment tank until they are broken down by the macerator and able to pass through and into the sedimentation modules.

c. Impact Sprinkler/Backwash Nozzles (3). Washes the retention/reduction screen to prevent clogging by solid.

d. Flow Pump (4). Moves the effluent from the treatment tank into the sedimentation tanks.

e. Sedimentation Tanks (5). Three sets of split tanks (6 total) in series for the filtration and settlement of suspended solids.

f. Level Sensor Assembly (6). Monitors the treatment tank level by sending a signal to the electrical junction box which controls pump operation. It is located inside the treatment tank.

g. Macerator Pump (7). A garbage disposal type unit for shredding treated sewage.

h. Backwash Pressure Gauge (8). Indicates the pressure on the backwash water inlet line. The gauge line located in the front of the unit is installed in the backwash water line on the underside of the unit.

i. Backwash Solenoid Valve (9). Controls the backwash water while the system is processing or is in the rest period. It is located on the underside of the unit beneath the treatment tank area.

j. Bleach Tank (10). Provides storage for the bleach solution. It is located separate from the unit and has a gravity feed for delivering the bleach through a metering valve and to the optional metering solenoid valve on the unit.

k. Metering Valve (11). Meters the required amount of bleach solution into the treatment tank for disinfection of the effluent.

l. Metering Solenoid Valve (12). Electrically operated valve controls delivery of bleach from the bleach tank to the unit. It operates only when the metering valve is open.

m. Status Indicator (13). Indicates any motor malfunction or high level of sewage.

n. Control Panel Assembly. (14). Provides location for the mode selector switch, microprocessor, electrical connections, and is the control system that continually monitors motor operation and treatment tank conditions.

o. Vent Piping (15). Vents the sanitation device to the outside air. Vent float check valves within each sedimentation tank cover prevent liquid from entering the vent piping system.

p. Surge Tank (16). Provides short term storage prior to treatment tank to prevent overflow when system is shutdown and prevent treatment tank from running low on effluent.

q. Surge Pump (17). Transfers unprocessed sewage from the surge tank to the treatment tank, controlled by level sensors.

r. Commode Warning Light (18). Activated by the tank level indicator on the surge/holding tanks. Indicates treatment tank is filled to capacity.

1-13. Hardware Interface. The MSD hardware interface details the interconnection and flow through the system. See Figure 1-5 for functional block diagram.

1-14. Software Interface. The MSD software interface shows the interconnection and signal flow through the system. See Figure 1-6 for software functional block diagram.

1-10

Figure 1-4. Functional Block Diagram/Interface.

1-11

Figure 1-5. Hardware Functional Block Diagram.

1-12

Figure 1-6. Software Functional Block Diagram.

2-1

CHAPTER 2

UNIT MAINTENANCE INSTRUCTIONS

Page Section I Repair Parts, Special Tools; Test, Measurement, and Diagnostic Equipment (TMDE); and Support Equipment ..................................................2-1

Section II Service Upon Receipt ........................................................................................................2-1

Section III Unit Preventive Maintenance Checks and Services (PMCS) ............................................2-11

Section IV Unit Maintenance Troubleshooting ....................................................................................2-13

Section V Unit Maintenance Procedures............................................................................................2-26

Section VI Preparation for Storage or Shipment .................................................................................2-89

SECTION I. REPAIR PARTS, SPECIAL TOOLS; TEST, MEASUREMENT,

AND DIAGNOSTIC EQUIPMENT (TMDE); AND SUPPORT EQUIPMENT

2-1. Common Tools and Equipment. For authorized common tools and equipment, refer to the Modified Table of Organization and Equipment (MTOE), CTA 50-970, Expendable/Durable Items (Except: Medical, Class V, Repair Parts, and Heraldic Items), CTA 50-909, Field and Garrison Furnishings and Equipment or CTA 8-100, Army Medical Department Expendable/Durable Items, as applicable to your unit.

2-2. Special Tools, TMDE, and Support Equipment. Special tools; test, measurement, and diagnostic equipment; and support equipment requirements are listed and illustrated in the Repair Parts and Special Tools List (RPSTL), TM 55-1905-223-24P. These items are also listed in the Maintenance Allocation Chart (MAC), Appendix B of this manual.

2-3. Repair Parts. Repair parts are listed and illustrated in the Repair Parts and Special Tools List (RPSTL), TM 55-1905-223-24P.

SECTION II. SERVICE UPON RECEIPT

2-4. Checking Unpacked Equipment.

a. Inspect the equipment for damage incurred during shipment. If the equipment has been damaged, report the damage in accordance with the instructions of DA PAM 750-8.

b. Check the equipment against the packing slip to see if the shipment is complete. Report all discrepancies in accordance with the instructions of DA PAM 750-8.

c. Check to see whether the equipment has been modified.

d. Remove and replace protective caps, plugs, inserts, wrappings, and tape when inspection/inventory is completed. Inspect piping openings for damage. Wipe off dirt, grease, or protective films at time of installation.

e. Remove chocks from resilient mounted components.

2-5. Deprocessing Unpacked Equipment. After receipt and inspection of unpacked equipment, make sure that all packing materials, temporary braces, masking tape, etc., are removed from the material before installation.

2-6. Preliminary Servicing and Adjustment. To ensure that the sanitation unit will be adequately inspected, serviced, and operationally tested before it is subjected to normal everyday use, the following procedures are required to be performed.

2-2

a. Device Installation Checks.

WARNING

Turn electrical power OFF to the MSD system to avoid personal injury.

Lockout/Tagout according to vessel SOP.

(1) Mechanical Installation Check. Check pump, motor, macerator, and connections to make certain components are securely mounted, bolts tight, and so forth.

(2) Piping Installation Check. Before startup, check that the following connections are plumbed and fittings secured (Figure 1-2):

(a) Sewage Inlet Flange Connection.

(b) Sewage Discharge Flange Connection.

(c) Backwash Feed Flange Connection.

(d) Vent Piping Flange Connection.

(e) Bleach Tank Tubing Connections.

NOTE

Perform a general check on all visible Poly Vinyl Chloride (PVC) piping and hose connections. Ensure that all connections are tight and hose clamps tightened.

(3) Electrical Installation Check. Before starting, check the following wiring (refer to Figure 2-3):

(a) Make visual check of control panel connections. If any unterminated wires are found, review drawing 19207 LCU2K-00593-01 and reinstall.

(b) Check the main power line.

(c) Make certain that fuses are installed.

(d) Ensure that all POWER switches (circuit breakers) are in the OFF position.

b. Operation.

Personnel should not operate the device unless they are familiar with the procedures contained in this manual.

(1) Controls And Indicators. Controls and indicators used during device operation are listed in Table 2-1 and their location shown in Figure 2-1.

(2) Control Station Indicator. The EOS has an ORCA IIA Control Station Indicator and provides indications as listed in Table 2-3 and shown in Figure 2-2.

The green POWER ON indicator remains illuminated continuously during normal operation. When any status indicator is illuminated continuously, a problem exists (Table 2-2).

c. Initial Start-Up Procedure. Ensure device installation check procedures, Paragraph 2-6.a., have been accomplished. Proceed as follows:

2-3

Ensure that the vessel’s primary circuit breaker and the control panel circuit breaker are in the OPEN (OFF) position at the start of these procedures.

Toxic and flammable vapors are generated in the sewage system. Provide ventilation from outside source before removing treatment tank covers. Avoid open flames and prolonged breathing of fumes.

(1) Fill bleach tank with 10 gallons (38 liters) of bleach. Check all connections for leaks. Tighten as necessary.

(2) Open all sewage inlet, vent and discharge lines to the MSD.

(3) Align gray water and black water diverter valves to overboard or holding tank. Align valves to surge tank and macerator for transfer to treatment tank.

(4) Manually fill MSD treatment tank with water until level stabilizes at approximately mid level in the treatment tank.

(5) Open backwash gate valve. Check pressure gauge to ensure 40 ± 5 psi (275.8 +/- 34.5 kPa) backwash pressure.

(6) Place MODE switch on control panel to CONT position.

(7) Place POWER switch to ON position only long enough to observe flow pump rotation.

(8) Flow pump shaft rotation must be clockwise as viewed from the motor end of the pump. Observe arrow rotation on the pump casing/frame. If rotation is not correct, reverse power leads to system.

(9) Repeat step (6) above to ensure correct rotation.

(10) Place MODE switch on control panel to AUTO position.

(11) Push RESET pushbutton.

(12) Flush clean toilet continuously until surge tank fills and MSD starts. Wait 10 seconds between flushes. The MSD will start automatically and process sewage for 18 minutes. After the 18 minute cycle, the system will stop. If the MSD continues past 18 minutes, refer to Section IV, Unit Maintenance Troubleshooting.

(13) Initially open the metering valve 1/4 turn. The metering valve will require further adjustment when sewage is processed.

(14) The MSD is now ready for operation.

Final adjustments are made by sampling the effluent from the discharge to get the required level of residual chlorine.

d. Normal Operation. To normally operate the MSD, proceed as follows (Figure 1-2):

(1) Align Marine Sanitation Device Supply and Discharge Piping System as follows:

(a) Open SW-14, SUPPLY TO MSD.

(b) Fill Bleach Tank.

(c) Open SEWAGE INLET VALVE PL-11.

2-4

(d) Ensure, BLACKWATER DIVERTER valve PL-1 and GRAYWATER DIVERTER valve PL-2 are aligned to flow to MSD.

(e) Open PL-4, OVBD DISCH and PL-3, MSD-OVBD DISCH.

(2) Place MODE switch to AUTO position.

(3) Place POWER switch to ON position.

(4) Push LOW VOLTAGE RESET pushbutton switch.

In the event of power failure, the MSD does not reset automatically. LOW VOLT- AGE RESET must be made after any power interruption or intentional shutdown.

(5) Device will now operate automatically in 18 minute cycles as required. See Figure 1-4 for Functional Block Diagram/Interface.

If any status LED indicator (red) is on continuously, a problem exists. Refer to Section IV, Unit Maintenance Troubleshooting. Refer to Table 2-1 for light status/system condition and Table 2-2 for Status Indicator Reference.

(6) POWER ON LED indicator is continuously illuminated.

The CONT mode of operation should be used only in an emergency condition since the automatic control of the MSD is bypassed. Constant operator attention is required during the CONT operation of the MSD.

e. Emergency Operation. In the event of a microprocessor failure, sewage can be treated with the MSD in the continuous mode, for short periods of time.

(1) Place MODE switch to CONT position.

(2) Place POWER circuit breaker to ON position.

f. Shutdown/Storage Procedure. If for any reason, the MSD is to be out of use for an extended period of time, proceed as follows:

Ensure compliance with Federal and international laws prior to overboard discharge of untreated sewage.

(1) Allow all effluent to be discharged from the MSD IAW local directives.

(2) Fill treatment tank with clean water and allow entire MSD to flush once.

(3) When the MSD completes discharge of the rinse water and shuts down, place MODE SWITCH to

OFF position.

(4) Close sewage inlet (PL-11 and PL-3) and seawater supply to MSD (SW-14).

(5) Close bleach tank isolation valve.

(6) Place ships power switch to OFF position.

(7) Refer to Paragraph 2-6.g. to drain the MSD.

2-5

Table 2-1. Controls and Indicators

ITEM NO.

CONTROL/INDICATOR Figure 2-1 FUNCTION

POWER Switch 1 Controls power application to MSD and protects (Circuit Breaker) the system.

MODE Switch 2 Places device in automatic operation (normal) AUTO - - - CONT mode or in continuous mode.

LOW VOLTAGE RESET 3 Resets system after power interruption and Pushbutton Switch when macerator, flow pump, or backwash requires a reset.

POWER ON LED Indicator 4 Illuminates when power is applied via circuit (green) breaker. Remains illuminated as long as power is applied.

MACERATOR LED Indicator 5 Indicates macerator pump failure if it stays illum- (red) inated.

FLOW LED Indicator 6 Indicates flow pump failure if it stays illuminated.

(red)

BACKWASH LED Indicator 7 Indicates absence of backwash water pressure if (red) LED stays illuminated.

HIGH LEVEL LED Indicator 8 Flashing light indicates high level and that (red) system is trying to clear condition. Device will shutdown if light is flashing for 10 minutes or more. After 10 minutes, the light stays illum-inated.

COMMODE WARNING Light 9 Indicates treatment tank is filled to capacity.

(red).

Table 2-2. Status Indicator Reference

LIGHT STATUS SYSTEM CONDITION

POWER ON light illuminated; all other lights off System on, processing sewage.

POWER ON light illuminated; MACERATOR light continuously illuminated

Macerator pump failure - high current condition.

POWER ON light illuminated, FLOW light continuously illuminated

Flow pump failure - high current condition.

POWER ON light illuminated; BACKWASH light continuously illuminated

Backwash pressure too low or nonexistent.

POWER ON light illuminated; HIGH LEVEL light continuously flashing

Indicates high level and that system is trying to clear condition.

POWER ON light illuminated; HIGH LEVEL light continuously illuminated

High level in treatment tank - automatic shutdown after 10 minutes.

Table 2-3. EOS Control Station Indicator

CONTROL/INDICATOR Figure 2-2 FUNCTION

ORCA IIA CONTROL STATION 1

INDICATOR (amber)

Indicator OFF No Power to ORCA

Indicator ON (Steady) ORCA Operational

Indicator FLASHING ORCA Requires Attention

2-6

Figure 2-1. Controls and Indicators.

2-7

Figure 2-2. EOS Control Station Indication.

2-8

Figure 2-3. Typical Shipboard Electrical Connections.

2-9

g. Drain MSD Procedure. Drain MSD for prolonged storage and where there is a possibility of freezing.

(1) Perform Paragraph 2-6.h. steps 1 through 7.

(2) Place a suitable container under each drain plug to catch waste water.

(3) Remove the drain plug at the Macerator discharge elbow.

(4) Remove the drain plug at the Flow Pump housing.

(5) Remove the drain plug for the sludge return line, located on the unit foundation, below the Flow

Pump motor.

(6) Drain the overboard discharge line and the backwash water supply line, loosen the bolts at the connection flanges and pry them loose until all liquid is drained.

If the zinc anode requires replacement, perform item 10 of Table 2-4 at the completion of draining the MSD.

(7) Ensure there is no liquid in the backwash supply line between the Solenoid Valve and the sprinkler head or nozzles, remove the low pressure switch line (at the switch end) and let it drain. Reconnect low pressure switch line when draining is complete.

(8) Empty the chlorine tank and disposed of chlorine IAW regulations.

h. Flushing MSD System. This procedure addresses the biologically safe way to flush out hazards and make working on the MSD system much safer. The hazard warnings and cautions should still be adhered to regardless of how safe the system might be.

To flush the MSD, proceed as follows:

(1) Place the POWER circuit breaker for the sewage transfer pump to the OFF position.

(2) Place the MSD Control Panel circuit breaker to the OFF position.

(3) Remove the treatment tank inspection cover.

(4) Fill the treatment tank with fresh water to the top float switch level, replace the treatment tank inspection cover, but do not bolt.

Do not operate the MSD with just the backwash pump and the chlorinator when the treatment tank is empty, unless you are securing it for immediate repairs/maintenance and placing it back in service after repairs are complete.

Doing so will create a hyper-chlorinated mix which may be corrosive to the Macerator and the Flow Pump.

(a) If fresh water is not available to fill the treatment tank use the backwash pump to rinse treatment tank.

1. Turn off the Chlorine Metering Valve.

2. Place the MSD Control Panel circuit breaker to the ON position and the MODE switch in the CONT position.

2-10

3. Ensure that backwash water is flowing into the treatment tank, by looking through the clear inspection cover. If no clear cover is installed, do so by observing the pressure gauge. The gauge pressure will fluctuate as the solenoid valve opens/closes.

If the unit is allowed to run totally dry damage, to the flow pump impeller and mechanical seal is imminent.

4. If pump cavitation is heard or after 15 minutes secure the system and inspect flow pump to ensure the mechanical seal is cool to the touch.

5. Repeat steps 1 through 4 until systems backwash pump have been allowed to operate for a total of 30 minutes.

6. Place the MSD MODE switch and Control Panel circuit breaker to the OFF position.

7. Ensure the treatment tank is empty. Proceed to Step (8) below.

(5) Place the MSD Control Panel circuit breaker to the ON position and the MODE switch in the CONT position until the treatment tank is empty.

(6) Repeat steps 3, 4 & 5 two times.

(7) As soon as the unit is empty for a third time, place the MSD Control Panel circuit breaker to the OFF position.

(8) Perform repairs or maintenance IAW applicable repair procedure.

(9) Install treatment tank inspection cover and tighten bolts removed in step 3.

2-11

SECTION III. UNIT PREVENTIVE MAINTENANCE CHECKS AND SERVICES (PMCS)

2-7. EExplanation of PMCS Table. PMCS is designed to keep the equipment in good working condition. This is accomplished by performing certain tests, inspections, and services. Table 2-4 lists items to be serviced and the procedures needed to accomplish the PMCS. The “Interval” column tells you when to perform a check or service.

If needed, PMCS may be performed more frequently than the indicated interval. The “Procedures” column tells you how to perform the required checks and services. If your equipment does not perform as required, see Table 2-5, Troubleshooting and Table 3-2, Intermediate Direct Support Troubleshooting. Report any malfunctions or failures on a Equipment Inspection and Maintenance Worksheet. In the “TM” Number column on the DA Form 2404/5988E, record the appropriate Item Number from the PMCS table.

The column labeled "Equipment is Not Ready/Available If:" of the PMCS Table 2-4 is not intended to imply the condition of the vessel. This column only indicates the condition of the equipment.

T ab le

-4

P re ve nt iv e

M ai nt en an ce

C he ck s an d

S er vi ce s

D

D ai ly

W

W ee kl y M

M on th

Q

Q ua rt er

S

S em ia nn ua lly

A

A nn ua l

In te rv al

Ite m

N o.

M

Q

S

Ite m s

T o

B e

In sp ec te d/ S er vi ce d

P ro ce du re s E qu ip m en t I s

N ot R ea dy

A va ila bl e

If:

R

N

IN

G

U se e xt re m e ca ut io n w he n ch ec ki ng e ne rg iz ed c irc ui ts to av oi d el ec tr oc ut io n.

A lw ay s en su re a ffe ct ed c irc ui ts h av e be en s ec ur ed , l oc ke d ou t a nd ta gg ed o ut

P er fo rm in g m ai nt en an ce w ith c irc ui ts e ne rg iz ed m ay r es ul t i n de at h or in ju ry to p er so nn el o r eq ui pm en t d am ag e.

E le ct ric al c on ne ct io ns C he ck a ll el ec tr ic al c on ne ct io ns fo r tig ht ne ss : C on tr ol

P an el A ss em bl y, C ab le E qu ip m en t R ou tin g

A ss em bl y, F lo w P um p an d

S ol en oi d, a nd M ac er at or

P ar ag ra ph

2-am ag ed o r de fe ct iv e pa rt s pr ev en t o pe ra tio n

P an el s ar e no t s ec ur el y m ou nt ed o r ar e da m ag ed w hi ch c ou ld af fe ct o pe ra tio n.

F w p um p dj us t f lo w p um p im pe lle r

(P ar ag ra ph

-1 9)

Im pe lle r is d am ag ed or d ef ec tiv e.

Z c A no de ith th e sy st em s hu td ow n an d dr ai ne d

(P ar ag ra ph s

2- 6.

g.

a nd

-6 .h r em ov e an d ch ec k th e zi nc a no de p lu g th e tr ea tm en t t an k, if th e zi nc a no de is le ss th an ch ng

, r ep la ce b ot h th e zi nc a no de in th e tr ea tm en t a nd se di m en ta tio n ta nk s.

P er fo rm p ro ce du re o f P ar ag ra ph to m ov e flo w p um p, to a llo w s uf fic ie nt c le ar an ce fo r zi nc a no de r em ov al fr om s ed im en ta tio n ta nk

Le ss th en lo ng

C la ss

II

I l ea ka ge

2-12

2-13

SECTION IV. UNIT MAINTENANCE TROUBLESHOOTING

2-8. Troubleshooting. Both a symptom index and a troubleshooting table are provided. The symptom index will help you locate the information you need for troubleshooting. See Figures 2-4 and 2-5 as aids in troubleshooting the electrical portion of the MSD system. Refer to Section V for unit maintenance procedures.

Utilize a multimeter to perform continuity checks on switches, solenoids, and electrical wiring.

SYMPTOM INDEX

Troubleshooting Procedure (Table 2-5)

BLEACH

No bleach being supplied to the treatment tank.

COMMODE

Commode warning lights activated by the tank level indicator on the surge/holding tanks.

CONTROL SYSTEM

High level status light stays illuminated continuously and MSD shuts down.

BACKWASH status light stays illuminated continuously and system shuts down.

MACERATOR status light stays illuminated continuously.

FLOW PUMP status light stays illuminated continuously.

POWER ON light does not illuminate when POWER DISCONNECT SWITCH is placed to ON and LOW VOLTAGE RESET push button is pressed. All other status lights do not illuminate.

One status indicator light does not illuminate other indicators illuminate properly.

Any status indicator fault light stays illuminated continuously and system does not shutdown.

Control System stops. High Level Warning Light Illuminated; Power On Light Illuminated. (Remote Status Indicator)

MODE SWITCH

Device operates properly in AUTO mode but does not operate when MODE switch is placed in CONT position.

Device operates properly in CONT mode but does not operate when MODE switch is placed in AUTO position.

Item 10

Item 11

Item 1

Item 2

Item 3

Item 4

Item 5

Item 6

Item 9

Item 12

Item 7

Item 8

Table 2-5 lists the common fault conditions that may be found during operation or maintenance of the equipment.

Look for causes and do corrective actions in the order listed. This manual cannot list every symptom that may show up, and it cannot list all the possible causes and corrective actions. If a symptom is not listed, or if it keeps up after you have performed the corrective actions, notify your supervisor.

2-14

Table 2-5. Troubleshooting

Malfunction Test or Inspection Corrective Action

During all troubleshooting, it is assumed vessel external power source is operating correctly and all applicable valves are open.

1. High level status light stays illuminated continuously and MSD shuts down.

STEP 1. Plugged screen and/or defective impact sprinkler/backwash nozzle.

Remove and clean screen (Paragraph 2-15) and/or replace impact sprinkler/backwash nozzle (Paragraph

2-21).

STEP 2. Plugged discharge line or discharge line valve is in closed position.

Clear overboard discharge line or open discharge line valve.

STEP 3. High level electrode is shorted.

Remove level sensor assembly (Paragraph 2-17). Check for continuity between leads of electrodes in level sensor assembly (TB3, terminals 10 through 15, Figure 2-5, Sheet 1): Each lead should be isolated.

STEP 4. Flow pump operating at reduced capacity.

Inspect and test (Paragraph 2-19).

The CONT mode of operation should be used only in an emergency condition since the automatic control of the MSD is bypassed. Constant operator attention is required during the CONT operation of the MSD.

STEP 5. Excessive demand on system.

Change MSD Selector Switch from AUTO to CONT (2, Figure 2-1) until demand is reduced.

STEP 6. Commode stuck in flush mode.

Check commodes for over usage or stuck flush valve, repair as required.

STEP 7. Improper transfer pump flow rate.

Change transfer pump to a lower flow rate.

2. BACKWASH status light stays illuminated continuously and system shuts down.

For information regarding the backwash pressure regulator and wye type strainer refer to TM 55-1905-223-10 and TM 55-1905-223-24-18-1.

STEP 1. No backwash water being supplied to the unit (proper reading on the backwash gauge).

Check to see if auxiliary seawater pump is on line and properly aligned. Start auxiliary seawater pump and verify proper alignment.

STEP 2. Lack of backwash water pressure.

Verify that water is being supplied to MSD. Check/clean backwash supply strainer.

STEP 3. Defective impact sprinkler/backwash nozzle.

Replace impact sprinkler/backwash nozzle (Paragraph 2-21).

2-15

Table 2-5. Troubleshooting - CONT

Malfunction Test or Inspection

STEP 4. Check for loose connection or broken wiring to the backwash solenoid valve.

Check connection and wiring to the solenoid valve and correct as necessary (Paragraph 2-13).

STEP 5. Defective backwash solenoid valve.

Replace backwash solenoid valve (Paragraph 2-21).

STEP 6. Defective backwash pressure switch.

Replace backwash pressure switch (Paragraph 2-12).

STEP 7. Gate valve closed.

Open gate valve.

System shall continuously be checked for leaks. If leaks exist, shutdown system (if not automatically shutdown), place circuit breaker to “OFF.” Replace and/or repair PVC piping, joints, hoses, etc., to return the system to a leak proof condition.

3. MACERATOR status light stays illuminated continuously.

STEP 1. Macerator malfunction.

Refer to Table 3-1 for macerator troubleshooting.

STEP 2. Macerator motor hums, but macerator does not operate.

Jammed grind element. Clear jam (Paragraph 2-18).

4. FLOW PUMP status light stays illuminated continuously.

STEP 1. Flow pump malfunction, impeller, bearings, plugged inlet, broken mount or bent shaft.

Remove and repair flow pump. Disassemble and replace defective component(s) (Paragraph 2-19).

5. POWER ON light does not illuminate when POWER DISCONNECT SWITCH is placed to ON and LOW

VOL…