OPERATION & MAINTENANCE MANUAL SERIES 32PT 2 HP SUBMERSIBLE CHEMICAL INDUCTION UNIT

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2 OPERATION & MAINTENANCE MANUAL SERIES 32PT 2 HP SUBMERSIBLE CHEMICAL INDUCTION UNIT --- TABLE OF CONTENTS --- SECTION 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.1 Description of Operation. Page 1 1.A.2 Identification Information... Page 1 1.A.3 Normal Operation Information.. Page 1 Pre-Startup Checks... Page 1-6 Startup Procedures. Page 7 Normal Operation... Page 8 Normal and Emergency Shutdown.. Page 9 Sequence of Operations Page 10 1.A.4 General Assembly Drawings, Sections, or Photographic Views... Page A.5 Dimensions, weight, capacity, and design conditions.. Page 13 SECTION 2: Detail Installation, Maintenance, Calibration and Repair 2.A Installation 2.A.1 Reference drawings or schematics to assemble and install. Page A.2 Equipment interfacing. Page 18 2B Safety 2.B.1 Identify all safety and tag-out procedures... Page 19 2.C Lubrication 2.C.1 Drawing referencing lubrication reservoirs or location.. Page 19 2.C.2 Lubrication Chart. Page D Statistical Information 2.D.1 Performance Pump curves/flow charts. Page 22 2.D.2 Insulation resistance Page 22 2.D.3 Performance test. Page D.4 Performance test data sheet.. Page 24 2.D.5 Operational startup testing forms. Page E Preventive Maintenance (PM) 2.E.1 CIU inspection, electrical checks and routine lubrication tasks.. Page F Troubleshooting and Corrective Maintenance 2.F.1 Troubleshooting SAVVY panel and or CIU.... Page F.2 General Motor Faults Resistance Check. Page 32 2.F.3 GAS MASTRRR Disassembly.. Page G GAS MASTRRR Parts List 2.G.1 Parts List Drawing and Part Numbers Page 37 Section 3: Equipment Data Sheets 5.A.1 Equipment Data Sheets SECTION 4: Warranty, RGA Form and Contact Information Warranty and Exchange Program Exchange Policy RGA Form Contact Information

3 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.1 Description of CIU Operation The GAS MASTRRR series 32PT submersible chemical flash mixer is non-vacuum style designed for flash mixing into wastewater. When the CIU is submerged and the motor is running the CIU receives the from the and then flash mixes the chemical in the wastewater stream. The series 32PT utilizes a USA manufactured FRANKLIN ELECTRIC submersible 316 S.S. down well motor. The motor operates at 3450 RPM. The motor is liquid filled (USP Mineral oil) and water-cooled. The axial mixing intensity is produced by a rotating propeller made of Hasteloy-C. The is metered by remote chemical metering pumps. The GAS MASTRRR series 32PT submersible chemical flash mixer is controlled and protected by a SAVVY control panel. The panel has a fused disconnect switch, starter with trip heaters, CPT, lightning arrestor, and a SYMCOM motor monitor for voltage/amperage protection of the motor. The motor monitor provides adjustable fault parameters and time-delay restarts on programmable fault conditions. 1.A.2 Identification Information The MASTRRR series 32PT submersible chemical flash mixer is installed in the Channel for flash mixing. Equipment description: GAS MASTRRR Series 32PT, 2HP, 460 VAC, 3 phase. 1.A.3 Normal Operation Information Pre-startup Checks: The series 32PT unit should be checked for proper mounting location and orientation per the engineer s specifications. The following checks should be performed before the CIU is lowered below the water. Check the mineral oil level in the motor. Check that all cables or materials are clear from the propeller area of the unit. Check that all bolts are tight and that the unit is securely in place. Check that the flexible hose and fittings are clamped and fastened securely. Check all lugs for tightness. Check supply voltage with meter for correct motor voltage. Voltage etched on motor should match the measured voltage. Note voltage should not exceed + or - 8% of rated motor voltage. Check that fuses are rated for full load amps of motor. (Full load amps etched on motor shell). Check that the SYMCOM components are in place and wired correctly. 1

4 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Pre-startup Checks: Continued Check parameters of the SYMCOM 777-LR motor monitor as indicated below. See pages 3-5 for calibration procedures if required. Check to insure proper rotation of mixing propeller. See page 6 for rotation check procedures. Rotation should be counter-clockwise when looking at the face of the mixing propeller or clockwise when looking at the top of the motor. See page 6 for reversing motor rotation. WARNING! Caution should always be used when working with AC power! Only certified electrical personnel should connect and check all connections. Always check that power is disconnected before work is done within the control enclosures. Always check with voltage meter! Never assume the disconnect is off! SETTINGS FOR THE SYMCOM 777-LR MOTOR SAVER RECOMMENDED SETTINGS FOR THE GAS MASTRRR SERIES 32PT, 2 HP, 460vac PARAMETERS SETTINGS LV 425 HV 500 VUB 005 MULT 1 OC 3.8 UC 2.5 CUB 005 TC 005 RD RD RD #RU/ADDR 001/AO1 #RF oc1 UCTD 002 GF.50 2

5 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Pre-startup Checks: Continued Check parameters of the SYMCOM 777-LR motor monitor as indicated below. See pages 3-5 for calibration procedures if required. Check to insure proper rotation of mixing propeller. See page 6 for rotation check procedures. Rotation should be counter-clockwise when looking at the face of the mixing propeller or clockwise when looking at the top of the motor. See page 6 for reversing motor rotation. WARNING! Caution should always be used when working with AC power! Only certified electrical personnel should connect and check all connections. Always check that power is disconnected before work is done within the control enclosures. Always check with voltage meter! Never assume the disconnect is off! SETTINGS FOR THE SYMCOM 777-LR MOTOR SAVER RECOMMENDED SETTINGS FOR THE GAS MASTRRR SERIES 32PT, 2 HP, vac PARAMETERS SETTINGS LV 2 HV VUB 005 MULT 1 OC. UC. CUB 005 TC 005 RD RD RD #RU/ADDR 001/AO1 #RF oc1 UCTD 002 GF. 2

6 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Pre-startup Checks: Continued Check parameters of the SYMCOM 777-LR motor monitor as indicated below. See pages 3-5 for calibration procedures if required. Check to insure proper rotation of mixing propeller. See page 6 for rotation check procedures. Rotation should be counter-clockwise when looking at the face of the mixing propeller or clockwise when looking at the top of the motor. See page 6 for reversing motor rotation. WARNING! Caution should always be used when working with AC power! Only certified electrical personnel should connect and check all connections. Always check that power is disconnected before work is done within the control enclosures. Always check with voltage meter! Never assume the disconnect is off! SETTINGS FOR THE SYMCOM 777-LR MOTOR SAVER RECOMMENDED SETTINGS FOR THE GAS MASTRRR SERIES 32PT, 2 HP, 0vac PARAMETERS SETTINGS LV HV VUB 005 MULT 1 OC. UC.5 CUB 005 TC 005 RD RD RD #RU/ADDR 001/AO1 #RF oc1 UCTD 002 GF. 0 2

7 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Pre-startup Checks: Continued Calibration programming of SymCom 777-LR Note: Some MODE SELECT positions are dual function such as #RU / ADDR position. When the MODE SELECT switch is pointed at the #RU / ADDR, you may view and program #RU and ADDR. To view the two settings rotate the DISPLAY / PROGRAM adjustment across its entire range. You will see the #RU setting when the DISPLAY / PROGRAM adjustment is between approximately 7 O Clock and 11 O Clock. You will see the ADDR setting when the DISPLAY / PROGRAM adjustment is between approximately 11 O Clock and 5 O Clock. To program #RU or ADDR, following the programming instructions above. The #RU setting will only be programmed when the DISPLAY / PROGRAM adjustment is between approximately 7 O Clock and 11 O Clock. Likewise, the ADDR setting will only be programmed when the DISPLAY / PROGRAM adjustment is between the 11 O Clock and 5 O Clock. ADDR setting should be A 1. Suggested Settings LV / HV The recommended settings for LV (low voltage) and HV (high voltage) are determined by the original motor manufacturer. Settings are to be no more than + 8% of the motors name plate voltage. Series 32P motor is nameplate rated at 460 VAC. Therefore setting is as follows: 460 VAC motors LV = 42 & HV = VUB VUB is the voltage unbalance trip point. The Nema MG1 standard recommends against operating a motor above a 5% voltage unbalance under any circumstances. Therefore, a setting of 5 is the highest setting allowed. MULT MULT is the multiplication factor for determining true current settings and represents the number of conductors passing through the main current holes marked A, B, & C on the 777-LR. Qty. 1 conductor should be passing through each hole. Therefore, a setting of 1 should be programmed. OC Represents the manufacturer s maximum service factor amperage. The OC (over current) setting is typically no more than 95% of S.F. FLA (service factor full load amperage). 2 HP, 460 VAC motor has a 4.1 S.F. FLA rating. The OC setting should not exceed 3.8 UC The UC (undercurrent) setting is typically set at 70% of S.F.FLA (service factor full load amperage). This setting will typically detect if a submersible or inline unit is running out of water. The UC setting should not exceed 2.5 3

8 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Pre-startup Checks: Continued from Page 3 Calibration programming of SymCom 777-LR CUB CUB is the current unbalance trip point. This setting must be no more than 5%. A setting of 5 or lower is advised. TC TC designates the trip class for overload protection. The trip class defines the trip delay when an overload is detected. Series 32PT submersible units require a TC setting of 010 or lower. Set at 005. RD1 RD1 is the rapid cycle timer. An RD1 setting 20 seconds will generally protect the motor from rapid successive power outages or short cycling caused by the motor controls. Set at 000. RD2 - RD2 is the restart delay after the overload relay trips on current unbalance, single phasing and overload. A setting of 1 5 minutes is recommended. SET at 002. RD3 RD3 is the restart delay after an undercurrent trip. A setting of 1-5 minutes is recommended. SET at 002. #RU #RU is the number of successive restart attempts allowed after an undercurrent fault before the underload relay requires manual reset. A setting of 1 is recommended. SET at 001. ADDR ADDR is the address setting for the RS485 communication to the RM2000 keypad display. This setting should be A01 and should not be adjusted. SET at AO1. #RF #RF is the number of successive restart attempts allowed after a current unbalance, single phasing or overload fault. The recommended setting is oc2 which will allow 2 restart attempts on over current then require manual reset. This setting should be oc1 and should not be adjusted. SET at oc1. UCTD UCTD is the undercurrent trip delay timer. This setting represents the maximum time that the model 777 will tolerate an undercurrent condition. This setting should be 2 4 seconds and should not be adjusted above 4 seconds. SET at 002 GF GF is the ground fault protection amperage threshold. This setting detects the leakage current to ground and signals an insulation breakdown in the system. The GF setting should be somewhere between 10 and 20% of the full load amperage for the HP installed. SET at.50 MODE / SELECT switch should be placed in the run position after parameters are programmed. 4

9 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Pre-startup Checks: Continued from Page 4 Calibration programming of SymCom 777-LR The LED output display on the model 777-LR can show various system operating parameters: * Average Voltage * Average Current * L1 L2 Voltage * L1 Current (A) * L2 L3 Voltage * L2 Current (B) * L3 L1 Voltage *L3 Current (C) When the MODE SELECT switch is in the RUN position, the LED will display one of the above operating parameters. To select or change the display parameter, turn the DISPLAY / PROGRAM adjustment to the desired position as shown on its label. The multifunction display also announces system faults such as low voltage, high voltage, single phasing, voltage unbalance, current unbalance, and reverse phasing errors. Any time the MODE SELECT switch is in the RUN position, the RESET / PROGRAM button may be pushed to view the last fault which occurred. The table below shows the possible messages. Displayed Message oc SP ub uc CF GrF HI Lo rp off Meaning Tripped on Over current Tripped on Current Single Phasing Tripped on Current Unbalance Tripped on Undercurrent Tripped on Contactor Failure Tripped on Ground Fault Tripped on High Voltage Tripped on Low Voltage Incoming phases have been reversed. A stop command was issued from a remote source. 5

10 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Pre-startup Checks: Continued CHECKING AND CORRECTING ROTATION NEVER HOLD OR TOUCH THE PROPELLER WHILE CHECKING ROTATION! STAND CLEAR OF UNIT WHEN CHECKING ROTATION! NEVER RUN UNIT DRY! The series 32PT CIU propeller runs in a CCW direction when looking at the propeller face. LOOKING AT THE PROPELLER FACE PROPELLER ROTATION COUNTER CLOCKWISE CIU SIDE VIEW PROPELLER ROTATION PROPELLER ROTATION When checking rotation, bump starter momentarily (1 or 2 seconds only) with unit out of water if required. Never run unit out of water more than a few seconds! Run unit only in the direction indicated above. REVERSING MOTOR ROTATION Always turn power off and disconnect power at disconnect switch! Check power with voltage meter to verify power is off. Then rotate any two (2) motor legs (example rotate L1 and L2 motor lead wires). Verify rotation change. Always check voltage on all legs to ground and leg to leg. Amperage on all (3) legs. Note and log all readings for warranty registration. Verify trip heaters are sized or adjusted at full load amps of the motor. FL amps are etched on motor barrel. Record all readings on the start up test report located at the end of this manual. 6

11 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Startup Procedures Check to see if flex hose is connected to the GAS MASTRRR unit and the second feed port has a cap plug installed (second feed port not installed on all units). Lower unit to proper submergence depth making sure the feed hose and power cord are clear from the mixing end. Connect CL-1 hose/cord clamps while lowering unit. Connect flex hose to the chemical source piping connection. Close shut-off valve at the chemical source piping connection. Make sure unit is fully submerged and lowered to the guide rail stops. Unit should pivot to a horizontal position and the winch cable will go slack. Turn winch handle till the cable becomes tight. Turn ROA switch to Off position on SAVVY panel. Turn power disconnect switch to On position. RM-2000 display should indicate voltages on L1, L2, and L3 (see detail 1). Push Up button till amperages I1, I2, I3, and IAVG are displayed. Display will show * because motor is not running (see detail 2).. Turn ROA switch to Run position. Unit will start and amperages will be displayed on screen. Verify amperages are at or below 3.4 F.L. amps. Push Up button till CUB% and VUB% are displayed (see detail 3). Verify CUB% is below 5%. With unit running within parameters, open the shut-off valve at the chemical source piping connection and adjust feed rate at the chemical feed source. Detail 1 Detail 2 Detail 3 7

12 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Normal Operation In normal operation the control panel ROA switch should be in (A) automatic. The series 32PT unit will start and run continuous unless stopped manually or a fault condition occurs. The unit should always be submerged and never allowed to run out of water. Liquid feed applications the chemical will be controlled from an external chemical metering pump. The amperage will increase slightly as the liquid chemical feed rate increases. The voltage/amperage monitor will look at motor amperage and line voltage for fault conditions. The unit monitors and will shut down for the following fault conditions: low amperage, high amperage, low voltage, high voltage, amperage unbalance, phase loss, phase reversal, ground fault, high stator temperature, and rapid cycling. Should a fault occur (high amperage as example) the unit will immediately stop and a 1- minute time delay will count and then restart the unit. This allows fault condition to clear if it was an intermittent problem. The unit will restart after the time out period. Should the unit continue to see the high amperage condition, it will again stop and a second 1 minute time delay restart will commence. Should the fault condition not clear itself by the second restart, the unit will stop and the fault condition will be displayed. The unit will then require manual reset to start. Intermittent voltage supply problems may cause nuisance trips, which the time delay feature may save the unit from damage and then restart after the condition clears itself. The unit has time delay reaction to low amperage; the time delay interval is 1 minute. The unit will try to restart one time. Should the unit continue to see low amperage condition, it will stop and require manual reset to start. The unit has an instantaneous trip for voltage faults and will not restart until proper power is restored. The PM24 Temperature Controller monitors the CIU temperature and trips the starter out on a programmable temperature setting. Unit will not restart until motor temperature drops below programmable reset setting. The series 32PT unit may be momentarily run in hand position to check/verify propeller rotation. 8

13 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Normal Shutdown Turn chemical metering off if chemical is not required, send chemical to standby mixer, or alternate injection point. Close shut-off valve at the chemical source piping and let the unit run. Disconnect flex hose and let the unit run to evacuate remaining chemical in the flex hose. After chemical evacuation is accomplished turn OA switch to Off position and disconnect power via the disconnect lever located on the SAVVY panel. Emergency Shutdown Turn the SAVVY panel OA switch to Off position and disconnect power via the disconnect lever located on the SAVVY panel. Turn chemical metering off if chemical is not required, send chemical to standby mixer, or alternate injection point. Close shut-off valve at the chemical source piping and let the unit run. Disconnect flex hose and let the unit run to evacuate remaining chemical in the flex hose. 9

14 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.3 Normal Operation Information Sequence of Operations Startup Check to see if flex hose is connected to the GAS MASTRRR unit and the second feed port has a cap plug installed (second feed port not installed on all units). Lower unit to proper submergence depth making sure the feed hose and power cord are clear from the mixing end. Connect flex hose & power cord with zip ties while lowering unit. Connect flex hose to the chemical source piping connection. Close shut-off valve at the chemical source piping connection. Make sure unit is fully submerged and lowered to the guide rail stops. Unit should pivot to a horizontal position and the winch cable will go slack. Turn winch handle till the cable becomes tight. Turn OA switch to Off position on SAVVY panel. Turn power disconnect switch to On position. RM-2000 display should indicate voltages on L1, L2, and L3 (see detail 1). Push Up button till amperages I1, I2, I3, and IAVG are displayed. Display will show * because motor is not running (see detail 2).. Turn OA switch to position. Unit will start and amperages will be displayed on screen. Verify amperages are at or below 3.4 F.L. amps. Push Up button till CUB% and VUB% are displayed (see detail 3). Verify CUB% is below 5%. With unit running within parameters, open the shut-off valve at the chemical source piping connection and adjust feed rate at the chemical feed source. Sequence of Operations - Shutdown Turn chemical metering pump off if chemical is not required, send chemical to standby mixer, or alternate injection point. Close shut-off valve at the chemical source piping and let the unit run. Disconnect flex hose and let the unit run to evacuate remaining chemical in the flex hose. After chemical evacuation is accomplished turn OA switch to Off position and disconnect power via the disconnect lever located on the SAVVY panel. 10

15 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.4 General assembly drawings, sections, or photographic views PRESSURE EQUALIZATION DIAPHRAGM ASSEMBLY SELF-ALIGNING "KINGSBURY" THRUST BEARINGS LIQUID FILL RESERVOIR MINERAL OIL FILLED HERMETICALLY SEALED WINDINGS WITH SELF HEALING "ANTI-TRACK" RESIN SYSTEM 316 STAINLESS STEEL MOTOR SHELL TITANIUM SPLINED SHAFT BUILT-IN LIGHTNING ARRESTORS (1 PHASE) STAINLESS STEEL "WATER BLOC" LEAD ASSEMBLY TITANIUM HOUSED SILICON CARBIDE SEAL 4 WIRE SUBMERSIBLE CABLE TITANIUM SHAFT 11

16 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.4 General assembly drawings, sections, or photographic views 12

17 Section 1: General Information for Operation and Maintenance 1.A General Instructions 1.A.5 Dimensions, weight, capacity, and design conditions The GAS MASTRRR series 32PT submersible design allows liquid chemicals to be non-vacuum flash mixed directly into a water channel with superior velocity gradient mixing intensity. The direct through feed system allows the liquid chemical to be induced upstream of the propeller and provides a high rate axial dispersion of the chemical mixture into the wastewater channel. Optional Titanium External Feed Pipe assembly should be used for aggressive or heavy scaling chemicals. It utilizes a rugged and reliable U.S.A. manufactured submersible motor of 316 stainless steel construction. It has a Titanium housing and Hasteloy-C propeller for long-term duty in harsh submerged environments. The motor is liquid filled, water cooled, and 460 VAC 3 phase service for feed rates up to 10 GPM liquid chemical and axial dispersion rate of 725 GPM. 13

18 2.A Installation 2.A.1 Reference drawings or schematics to assemble and install 14

19 2.A Installation 2.A.1 Reference drawings or schematics to assemble and install 15

20 2.A Installation 2.A.1 Reference drawings or schematics to assemble and install 16

21 2.A Installation 2.A.1 Reference drawings or schematics to assemble and install 17

22 2.A Installation 2.A.2 Equipment Interfacing 18

23 2.B Safety 2.B.1 Identify all safety and tag-out procedures 2.B.1 NEVER Identify HOLD all OR safety TOUCH and THE tag-out PROPELLER procedures WHILE CHECKING ROTATION! STAND CLEAR OF UNIT WHEN CHECKING ROTATION! NEVER RUN UNIT DRY! WARNING! Always lower the unit completely below the water surface. Never run unit out of water. Verify ROA is in the OFF position and turn power disconnect switch to OFF before raising the CIU. WARNING! Caution should always be used when working with AC power! Only certified electrical personnel should connect and check all connections. Always check that power is disconnected before work is done within the control enclosures. Always check with voltage meter! Never assume the disconnect is off! 2.C Lubrication 2.C.1 Drawing referencing lubrication reservoirs or locations 19

24 2.C Lubrication 2.C.2 Lubrication chart The Series 32PT is the only equipment that requires maintenance inspection for lubrication. This mineral oil filled upper reservoir provides the internal lubrication of the Franklin Electric motor thrust bearings, hermetically sealed stator and lower seal assembly. The lubricant used from the factory is a NSF approved white mineral oil. 100% Pure White Mineral Oil Clear, stainless, odorless, tasteless H1 Lubricant NSF / USDA Registered FDA 21 CFR Alternate mineral oil can be used. Off the shelf bottles of mineral oil available at any drug store such as CVS or Walgreens. The lubricant used from the factory is a NSF approved white mineral oil manufactured by: CLEARCO PRODUCTS CO., INC. 3430G PROGRESS DRIVE BENSALEM, PA Tel: (800) Fax: (215) info@clearcoproducts.com WebAddress: Typical maintenance requires less than a few ounces to be added. If unit is drained and refilled the amount required would be 4 quarts. CLEARCO PRODUCTS CO., INC. data sheet on next page 21 20

25 2.C Lubrication 2.C.2 Lubrication chart 21

26 2.D Statistical Information 2.D.1 Performance Pump curves/flow charts The Series 32PT operates at a constant speed of 3450 RPM. The propeller is a fixed size of 4.0 OD and produces an axial dispersion of 725 GPM. Motor amperage at this fixed rate will be at or under 3.4 amps (F.L. amps). Amperage will vary dependant on supply voltage of 460 VAC, 3 phase. Any voltages under 460 VAC or above 460 VAC will cause a slight increase amperage. 2.D.2 Insulation resistance VOLTS Line to Line Resistance (Ohms) Line to Ground Resistance w/power cord (Ohms/MegOhm) 2 HP Ohms New Motor 2,000,000 Ohms/2.0 MegOhm Motor in good condition 500,000 Ohms/ MegOhm Insulation damage Less than 500,000 Ohms/Less than.50 MegOhm 2.D.3 Performance test CIU Inspection and Performance Testing Procedure - This procedure is designed to assure the quality of inspection and operational testing of GAS MASTRRR series 32PT submersible chemical induction units (CIUs). Inspection and testing procedures are designed to meet the applicable sections of: Inspection Procedures prior to testing - This procedure is designed to check the assembly process prior to testing. 316 S.S. materials are inspected for sharp edges or burrs. Removal of sharp edges or burrs may be done by wire brush or grinding to achieve a smooth edge or surface. CIUs are inspected for proper oil fill level. Fill with mineral oil if required leaving a ½ air gap below the oil fill port. CIUs are inspected for oil leaks. Inspect oil fill plug for Teflon tape and tightness. Inspect propeller area for oil residual. CIUs are inspected for propeller alignment and binding. Rotate propeller by hand for ease of rotation and fill if any binding is present. If binding is present remove propeller and check for causes. Loosen cone and realign if required. Install propeller on shaft and recheck for binding. CIU power cords are inspected for proper length and signs of cable damage. Log motor serial number and nameplate data on Factory Test Report. Installation Procedures for testing- This procedure is designed as a guide line for the installation and testing of CIUs prior to shipment. CIUs are to be mounted to a slide rail bracket in a vertical direction. Power cords are to be bound and pulled out of the propeller area. Install flex hose for GPM liquid feed to unit. Mount the slide bracket on the guide rail and submerge to the proper depth. CIU motors must be completely submerged when running. Make sure all hoses and cords are bond and clear of the propeller area. 22

27 2.D Statistical Information 2.D.3 Performance test - Continued from page 22 CIU Inspection and Performance Testing Procedure Installation Procedures for testing - Continued from page 22 Check control panel for proper voltage prior to installing motor leads to starter. Check nameplate motor voltage to insure unit is tested at correct voltage. Set starter trip heaters to full load amps of motor. Program SYMCOM motor monitor for name plate motor data. Shut off control panel power and install motor leads to starter. Bump motor momentarily to check motor rotation. If rotation is backwards shut of control panel power and rotate L1 and L2 motor leads. Turn on power and check rotation. Apply GPM flow to unit. Adjust GPM to desired flow rate if applicable. With rotation correct start unit and check voltage and amperage via the RM-2000 keypad and hand held voltage/amperage meter. Motor should operate at or below rated input amperage. Unit should not operate above full load motor amperage. If readings are below full load amperage let the CIU run for 5 to 10 minutes to heat up stator. Motor amperages will decrease slightly as motor heats up. Log voltage between each power leg as indicated on the Factory Test Report. RM-2000 display will provide voltages and average in real time mode. Log amperage for each power leg as indicated on the Factory Test Report. RM-2000 display will provide amperages and average in real time mode. Log voltage and amperage unbalance % s. RM-2000 display will provide amperage and voltage unbalance in real time mode. Inspect unit operation for mixing intensity. Log in comments. Inspect unit operation for vibration or noise. Log in comments. If CIU operates with in parameters shut off control panel power and remove motor leads. Install ohm meter between motor leads and log ohm readings as required on Factory Test Report. Remove unit and clean for shipment. Log all required data and sign the Factory Test Report. 2.D.4 Performance test data sheet Located on page 24 23

28 2.D Statistical Information 2.D.4 Performance test data sheet - Continued from page 23 Power Cord Length: 25 feet Size: 12g Conductor: 4 24

29 2.D Statistical Information 2.D.5 Operational startup testing forms Warning! This report must be completed for each CIU installed and started. Copy this report form and use for each CIU. All forms must be returned to THE MASTRRR COMPANY completed within 30 days of start-up. Failure to report and follow the installation and start-up guidelines set forth in this manual will void all warranty for the CIU. Start-up Date: Equipment Original Ship Date: Project: City/State: Individuals Present at Start-up Start-up Technician: Phone: Owner: Phone: Engineer: Phone: Contractor: Phone: Representative: Phone: Equipment Model #: Serial #: Motor HP: Motor Voltage: Phase: Equipment Condition: Mounting Orientation: Vertical Horizontal Pivoting CIU Submergence Depth: Feet Style: Through Feed Pipe Size Inches PVC Flex Hose Diameter: Inches External Feed Pipe Size Inches Hose Length: Feet Supply Chemical: Supply Pipe Size: Inches Distance (from chemical source to application point): Feet Valves Installed: 25

30 2.D Statistical Information 2.D.5 Operational startup testing forms Continued from page 25 Warning! This report must be completed for each CIU installed and started. Copy this report form and use for each CIU. All forms must be returned to THE MASTRRR COMPANY completed within 30 days of start-up. Failure to report and follow the installation and start-up guidelines set forth in this manual will void all warranty for the CIU. Serial #: SAVVY Control Panel: Yes No SYMCOM Installed: Yes No Surge Arrester Installed: Yes No Starter Manufacturer: Size: MCP: setting amps Voltage Readings to Motor Operating: L1 L2: L1 Grnd: L2 L3: L2 Grnd L3 L1: L3 Grnd: Percentage Unbalance: % (Use RM-2000 display Real Time Mode for % data) Ground Wire Size: Gauge Ground Source: Amperage Readings: (with maximum vacuum draw or full liquid chemical GPM federate) L1: amps L2: amps L3: amps Percentage Unbalance: % (Use RM-2000 display Real Time Mode for % data) Electrical Comments: 26

31 2.D Statistical Information 2.D.5 Operational startup testing forms Continued from page 26 Has the equipment been installed in the location specified by the engineer? Yes No Has the equipment and wiring been installed with quality workmanship? Yes No Has the electrical equipment, voltage and amperage been checked? Yes No Has the mineral oil level been checked? Yes No Has the rotation been checked? Yes No Is the power cable been securely strapped away from the propeller area? Yes No Is the CIU submerged to an approved depth? (must be fully submerged at all times) Yes No Has the owner/operators/maintenance personnel been instructed on submersible requirements and/or raising the CIU while running? Yes No Has the owner/operators/maintenance personnel been instructed on all Operational, shutdown, startup and storage requirements of the CIU? Yes No Have O&M manuals been approved and delivered? Yes No Have all personnel been trained and instructed on the guidelines of this manual? Yes No Installation or startup comments: I hereby certify that the CIU and associated equipment has been installed to the guidelines set forth in the Installation & Operations manual as published by THE MASTRRR COMPANY. The CIU has performed in accordance with the specifications and is in excellent working order. I have also read and understand the maintenance and safety guidelines as explained in the Installation & Operations manual. MASTRRR COMPANY or Representative Owner or their Representative Date: Date: 27

32 2.E Preventive Maintenance (PM) 2.E.1 CIU inspection, electrical checks and routine lubrication tasks Preventive Maintenance (PM) should be performed at 3-month intervals. All Preventive Maintenance (PM) can be performed by general maintenance personnel. One person can perform Preventive Maintenance (PM) in less than 30 minutes. WARNING! Follow shutdown procedures on page 9 before raising CIU for inspection or maintenance. Always turn unit off and shut off disconnect switch before raising unit above the water surface. Never run unit out of water! Gloves should be worn when handling CIU. CIU inspection Check that all cables or materials are clear from the propeller area of the unit. Check that all bolts are tight and the unit is securely in place. Check that the flexible hose and fitting are clamped and fastened securely. Check all lugs for tightness. Electrical checks WARNING! Caution should always be used when working with AC power! Only certified electrical personnel should connect and check all connections. Always check that power is disconnected before work is done within the control enclosures. Always check with voltage meter! Never assume disconnect is off! At 3-month intervals or sooner check voltage leg to leg, then legs to ground. Check supply voltage via RM-2000 display in Real Time Mode or manually with voltmeter for correct motor voltage. If checking manually with voltmeter, check voltage on terminals 1L1, 3L2 and 5L3 located on the top of starter. See detail below. Voltage etched on s.s. motor (460 VAC) should match the measured voltage. Voltage should not exceed + or 8% of rated motor voltage. Log readings on maintenance inspection form located at the end of this manual. Make copies for future inspection reports. Maintenance records are required for all returned units for warranty consideration. 28

33 2.E Preventive Maintenance (PM) 2.E.1 CIU inspection, electrical checks and routine lubrication tasks Routine lubrication tasks Continued from page 28 WARNING! Follow shutdown procedures on page 9 before raising CIU for inspection or maintenance. Always turn unit off and shut off disconnect switch before raising unit above the water surface. Never run unit out of water! Raise to inspect for material that may have collected around the lower propeller area. Check unit for liquid oil fill level. See detail below. Remove the ¼ S.S. liquid fill plug and inspect the mineral oil fill level. Add mineral oil as required. Do not fill to top! Leave a ½ air gap for expansion. Remember to replace ¼ S.S. plug. 29

34 2.F Troubleshooting and Corrective Maintenance 2.F.1 Troubleshooting SAVVY panel and or CIU *Note: Before shutting off main power to the control panel or disconnect switch at the control panel, open door and log fault conditions via fault history mode. Log information. Fault Alarm Checking Procedure Corrective Action SP Voltage HI or LO oc uc CF Using voltmeter check lugs 1L1, 3L2, and 5L3 at the top of the starter for correct volts on each leg. Check Leg to Leg, & Leg to Grnd. Power must be + or 8% of rated voltage. Using voltmeter check lugs 1L1, 3L2, and 5L3 at the top of the starter for correct volts on each leg. Check Leg to Leg, & Leg to Grnd. Power must be + or 8% of rated voltage. Using voltmeter check lugs 1L1, 3L2, and 5L3 at the top of the starter for correct volts on each leg. Check Leg to Leg, & Leg to Grnd. Power must be + or 8% of rated voltage. Shut off power and raise unit for inspection. Check propeller area for material wedged between cone and propeller. Rotate propeller by hand to see if rotation is free or binding. If free spins then check oil level of motor, and meg motor leads for shorts to ground. See meg test information on page 36 of this manual. Check to see that unit is fully submerged. Using voltmeter check lugs 1L1, 3L2, and 5L3 at the top of the starter for correct volts on each leg. Check Leg to Leg, & Leg to Grnd. Power must be + or 8% of rated voltage. Shut off power and raise unit for inspection. Check propeller area for material wear between cone and propeller. Rotate propeller to see if it free spins on shaft. Check for impact marks on propeller. During severe impact with solid object the internal shaft coupling will act as a shear pin Contactor Failure Do not try to restart unit. Raise CIU and check power cord for cuts or abrasion. Check for loose lugs back to Power source. Contact power company if voltage is incorrect. Contact power company if voltage is incorrect. Contact power company if voltage is incorrect. Clear material if any. If locked and will not turn, contact factory. If no oil, flush motor and refill with oil. If meg test shows short, contact factory. Contact power company if voltage is incorrect. Replace cone and/or propeller. Contact factory. Replace cut or damaged power cord. 30

35 2.F Troubleshooting and Corrective Maintenance 2.F.1 Troubleshooting SAVVY panel and or CIU Continued from page 30 *Note: Before shutting off main power to the control panel or disconnect switch at the control panel, open door and log fault conditions via fault history mode. Log information. Problem Checking Procedure Corrective Action Fuses blown or circuit breaker tripped Check fuses for recommended size and check for loose, dirty or corroded connections in fuse receptacle. Check for tripped circuit breaker. If circuit breaker immediately trips on restart shut off power, raise unit and check power cord for cuts or abrasion. Meg motor leads for shorts to ground. See meg test information on page 32 of this manual. Replace with proper fuse or reset circuit breaker. If meg test shows short, contact factory. Locked Unit Locked rotor conditions can result from material wedged between shaft and cone. Unit run without oil in motor. Power related problems: voltages, unbalanced, phase loss, or surges swell hermetically sealed stator. Amp readings will be 3 to 6 times higher than normal. Inspect unit and remove material. Contact factory for RGA #. Cut or Bad Power Cord Inspect cord for cuts or abrasions. Meg motor leads for shorts to ground. Meg motor to check for damage. See meg test information on page 32 of this manual. Replace power cord with factory cord. Contact factory for cord or if motor is damaged. SAVVY Panel or SYMCOM Malfunction Push reset button on the 777-LR monitor or turn power off and on by shutting off the disconnect switch and then back on. This will reset 777-LR monitor. Check for pending faults on RM-2000 display. Do not restart if any pending voltage or CF fault is displayed. If no pending faults, try to restart unit. Contact factory if power or SYMCOM reset fails. High Temperature SOLO alarm Check to see if motor is fully submerged. Check for correct voltage or voltage unbalance. Allow time for the motor to cool. Contact power company if voltage is incorrect. 31

36 2.F.2 General Motor Faults Resistance Check *Note: Turn HOA off and shut off disconnect switch to avoid damage to meter or electrical shock hazard. Disconnect all motor leads from SAVVY panel or starter. How to Measure Ohm Values Between Leads and Ground (Insulation Resistance) Connect one ohmmeter lead to any one of the motor leads and the other ohmmeter lead to ground. Set the scale lever to R x 100K and zero balance the ohmmeter. What is to be done The Results What It Means Measure resistance from any motor Ohms per table below for line to If the ohm value is normal, the cable lead to ground (Insulation ground resistance. >.500 Megohms. motor windings are not grounded resistance). and the cable insulation is not damaged. How to Measure Resistance between Leads (Winding Resistance) If the ohm value is below normal, either The windings are grounded or the cable Insulation is damaged. Check the cable For cuts or abrasions. Connect one ohmmeter leads to any two of the motor leads. Set the scale lever to R x 1 for values under 10 ohms. For values over 10 ohms, set the scale lever for R x 10. Zero balance the ohmmeter. What is to be done The Results What It Means Ohms per table below for line to line resistance. Measure winding resistance (Resistance between leads). If the ohm values are normal, the motor windings are neither shorted nor open. If the ohm value is less than normal the motor is shorted. If the ohm value is greater than normal, the winding or cable is open, or there is a poor cable junction or terminal connection. VOLTS Line to Line Resistance (Ohms) Line to Ground Resistance w/power cord (Ohms/MegOhm) 2 HP Ohms New Motor 2,000,000 Ohms/2.0 MegOhm Motor in good condition 500,000 Ohms/ MegOhm Ohms Insulation damage Less than 500,000 Ohms/Less than Ohms MegOhm 32

37 2.F.3 GAS MASTRRR Disassembly The GAS MASTRRR series 32PT is a sealed unit. The general maintenance or field repair should be limited to removal of the propeller or cone for cleaning of debris, chemical scale buildup, or for upgrades in design. Removal or replacement of power cord assembly during the warranty should only be performed by THE MASTRRR COMPANY or authorized repair representatives unless permission is given in writing. See power cord removal and installation details below and on page 38. Disassembly of a GAS MASTRRR series 32PT motor should only be performed by THE MASTRRR COMPANY or its authorized repair representatives. Motors under warranty should be returned freight prepaid (with maintenance reports) to THE MASTRRR COMPANY for warranty consideration and service. Warning! Sending the motor to a local electric motor repair shop is at the risk of the owner. Any work or disassembly performed on a GAS MASTRRR series 32PT during the warranty period by someone other than THE MASTRRR COMPANY or authorized representative, will void any and all warranty in its entirety. Power Cord Removal and Installation Warning! Removal of the power cord assembly during the warranty period is at the risk of the owner. Any work or disassembly performed on a GAS MASTRRR series 32PT power cord during the warranty period by someone other than THE MASTRRR COMPANY or authorized representative, will void any and all warranty in its entirety, unless permission is given in writing. Cables damaged while in operation should be replaced with a new power cord assembly. Splicing submersible cables should be made with commercially available potting or heat shrink slicing kits for emergency use only. Notification should be made to THE MASTRRR COMPANY of any power cord damages or repairs. Units sent in for warranty consideration should have the power cord intact. Do not cut the power cord at the motor to reduce weight. Power cords that have been cut off below 10 (feet) will jeopardize warranty consideration. With written permission the power cord assemblies may be removed or replaced in the field. Series 32PT submersible power cords seal by tightening the jam nut, which compresses the rubber bushing, insert against the end of the motor stator. Properly assembled power leads are a permanent and reliable seal for submerged duty in water or wastewater applications. Since the rubber bushing insert is tightly compressed and takes shape matching the exact cavity of each individual motor, reusing a power cord after removal from a motor is not recommended. Permanent change in the rubber shape and resulting bushing damage, which occur during removal or re-assembly, make reuse a risk in same or any other motor. The following page describes the proper procedures for removal and installation of power cord assemblies in Series 32PT submersible motors. Continued on page 34 33

38 2.F.3 GAS MASTRRR Disassembly - Power Cord Removal and Installation Removal of the Power Cord Assembly All warnings should be read and understood before removal of the power cord assembly from any GAS MASTRRR series 32PT submersible unit. Warnings are listed on page 33. Turn power off to the unit before raising, and disconnect power cord leads from the SAVVY control panel or starter. Loosen the jam nut with a wrench and slide the nut up the cord a few inches. Pull the cord from the stator housing. The cord may be difficult to remove and no tools should (pliers) be used which may damage the cord or potting material within the 316 S.S. outer sleeve. Installation of the Power Cord Assembly All warnings should be read and understood before removal of the power cord assembly from any GAS MASTRRR series 32PT submersible unit. Warnings are listed on page 33. Make sure the power cord bushing and the connector hole in the motor stator are clean and dry. A small amount of silicon grease is permissible, but all dirt particles or moisture should be removed. Meg the motor stator windings using a 1,000-volt DC megger. A good motor should measure at least 50 megohms between connector pins in the connector hole and the motor shell. Follow the megger s instructions and log the value after the value stops changing. Make sure the cord assembly is free from damage, dirt or moisture, and that the entire rubber-bushing surface is lightly greased with Dow 7 or equivalent insulative grease. Do not attempt to insert an ungreased cord assembly in the connector hole, which may cause bushing damage or an unreliable seal. When inserting the stainless steel jam nut, prelubricate the jam nut threads with Dow 7 or equivalent insulative grease, or nonconductive Teflon thread lubricant to prevent galling. Insert by hand into the connector hole with the rounded key on the rubber bushing metal sleeve aligning in the matching motor key slot. The bushing must be inserted straight into the hold far enough that the jam nut can be started by fingers into the threads. Slightly move the cord back and forth sideways during entry to release air and ease in installation. Do not rush and force a jammed bushing into the motor. Remove any jammed assembly and inspect for cause. Tighten the jam nut to a torque of foot pounds. The jam nut face should be within a range of zero to not more than.060 inch from the motor face. A greater gap indicates the bushing is not properly seated in the connector hole. With the motor and connect submerged the megohms from any lead to the water or motor frame should still be 50 megohms or higher. A low megohm reading after lead assembly or sudden drop in it during installation indicates a damaged cord or improperly assembled connector. Unit should be rechecked before use. 34

39 2.F.3 GAS MASTRRR Disassembly Propeller and Cone Removal and Installation All warnings should be read and understood before removal of the propeller and cone assembly from any GAS MASTRRR series 32PT submersible unit. Warnings are listed on page 33. Turn power off to the unit before raising, and working on the unit. Lay the unit on its side in a flat area. Do not lay unit over grating. Bolts and or washers may be dropped. Propeller Removal Remove the Tivar plug located in the center face of the propeller (see detailed picture below). Push plug on one side with screwdriver. Tilt plug and remove with fingers or pliers. Socket head shaft bolt will be exposed. This bolt holds the propeller to the shaft. Use 1/4 Allen wrench and loosen bolt. Always wear protective gloves when removing propeller. Propellers are tightly pressed on the splined shafts. Do not rush and damage the propeller. Care should be taken when using pliers or any other tools to pull on the propeller. Check to find spacer washer on end of shaft or inside of propeller. Cone Removal Locate and remove qty. 4 socket head bolts with ¼ Allen wrench. Bolts are located at the end of the stainless steel motor flange. The cone may then be removed. Replace or clean cone as required. To remount the cone, follow above in reverse. USE 1/4 ALLEN WRENCH ON SOCKET HEAD BOLTS. REMOVE TIVAR PLUG. USE 1/4 ALLEN WRENCH ON SOCKET HEAD SHAFT BOLT. Propeller Installation The propeller should be installed with care. Make sure spacer washer is in place on the shaft or inside the hub of the propeller. Lube internal o-ring on the inside hub of the propeller with silicone grease. The carbon wiper on the top of the propeller should be in place and clean. Push propeller over shaft and align with the splines on the shaft. Press firmly to seat the propeller. Tighten shaft bolt into shaft. Make sure bolt is not cross-threaded. Propeller should tighten and sink inside cone. There should be no gap between back of propeller and seat. Rotate propeller to insure free spin with no binding. Replace Tivar plug into hole to seal and protect shaft bolt. See page 36 for exploded view drawing. 35

40 2.F.3 GAS MASTRRR Disassembly SERIES 32PT 2 HP MOTOR 3/8 SOCKET HEAD BOLTS QTY. 4 36

41 2.G GAS MASTRRR Parts List 2.G.1 Parts List Drawing and Part Numbers Parts Detail, Number and Quantity #1 STAINLESS STEEL MOTOR : 460 THREE PHASE 2 HP PT# Qty. 1 #2 POWER CORD (4 WIRE - 12 G.) 2 HP PT#412-2 Qty. 1 #3 SILICON CARBIDE SEAL ASSEMBLY PT# Qty. 1 #3a CARBON CERAMIC SEAL ASSEMBLY "LOWER" PT#1001-2L Qty. 1 #4 CONE BOLT (SOCKET HEAD) PT# Qty. 4 #5 CONE (TITANIUM) 2 HP PT# T Qty. 1 #6 SHAFT BOLT (SOCKET HEAD) PT# Qty. 1 #7 PROPELLER (HASTELOY-C) 2 HP PT# 1031-PR-HC Qty. 1 #1 STAINLESS STEEL MOTOR: 230 THREE PAHSE 2 HP PT# #1 STAINLESS STEEL MOTOR: 200 THREE PAHSE 2 HP PT#

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