MSS Pumps for Seawater Reverse Osmosis Installation, Operation & Maintenance Manual

Transcription

1 MSS Pumps for Seawater Reverse Osmosis Installation, Operation & Maintenance Manual Models MSS-15 MSS-20 MSS-30 MSS-50 MSS-70 Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 1 of 17

2 Introduction MSS pumps are multistage centrifugal feed pumps specifically designed for brackish and seawater reverse osmosis (RO) service. This manual provides information on the installation, operation and maintenance of your MSS series pump. Proper installation and operation will help ensure extended pump life while preventing costly down time. Before installing and operating your MSS Series pump, please read this entire manual. Be sure to keep the manual in a handy place for future use. Receiving and Inspection The MSS pump was tested before shipping to ensure it meets all performance requirements. When the equipment is received, promptly 1.0 Preparation inspect the crates or boxes for damage. Report any damage to the freight company. Please save any documents that may be enclosed. Check whether all shipped items match the shipping documentation. Report any shortage to: FEDCO Tel Ternes Dr. Fax Monroe, MI techsupport@fedco-usa.com USA web: Storage The MSS pump must be protected from moisture, sand, grit, and other foreign matter. Do not remove the protective covers from the pipe connections until ready to install. For long-term storage, keep pump and all other components in its original crate away from moisture, sand or dust. Application Range The MSS pump should only be used within the following limits: Maximum fluid temperature: 120 degrees F (49 deg C)* Maximum working pressure: 1,200 psig (82 barg) Maximum inlet pressure 140 psig (9.7 barg)* Maximum particulate size: 20 micron *can be raised with optional modifications. Table of Contents 1. Installation & Operation 1.1 Installation/Alignment Piping Pump Protection Features Preparation for First Startup Startup Maintenance Schedule 8 2. Maintenance 2.1 Troubleshooting Seal Replacement Seal Replacement (HIP) Balance Disc Miscellaneous 3.1 Parts Identification Parts Return & Warranty Warranty Registration Form Overhaul Record Coupling Manual Specific application limits are provided on the nameplate of each pump. Application limits vary from model to model. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 2 of 17

3 Terminology Figure 1.1 identifies the major pump components 1.1 Installation/Alignment Feed outlet (discharge) End shell FLUID END Series shell Feed inlet Motor adapter Motor Drain line flow direction Filter Throttle nipple Precision leveling foot Bearing drain line Support bracket foot Flow switch Coupling guard Figure 1.1 Motor and Pump Installation Requirements As with all pumps, a rigid foundation for the pump-motor assembly prolongs the life of critical components, such as the pump shaft and motor bearings. Wooden foundations are NOT acceptable as they tend to deflect during operation and lose shaft alignment. Three options on how to properly install the pump-motor assembly are briefly described below. Concrete Foundation A concrete foundation provides good support and good vibration absorption. The foundation should have a mass that is 50% more than the total weight of the equipment and its perimeter should extend at least 6 inches (15 cm) on each side from the pump and motor. Make sure the concrete is completely dry and level before installing any machinery. Make sure anchor bolts are properly sized and installed. Baseplates Your pump may include an optional FEDCO baseplate which provides good mounting surfaces for motor and pump feet and allows a better alignment process. Although the baseplate is precisely manufactured, it can flex or bend and therefore requires a solid foundation such as a concrete pad or rigid steel substructure. The baseplate itself must be installed to avoid bending caused by bolting to an uneven floor or substructure, see figure 1.3. Figure 1.2 Figure 1.3 Container Installation If the pump is installed in a container, it must be mounted on a rigid steel substructure that will not distort under the weight of the equipment or from torque reaction forces when the motor is running. Anchor Bolts Anchor bolts should be installed in accordance with the bolt manufacturer s recommendations. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 3 of 17

4 Assembly The pump and motor are usually shipped in separate crates. This allows easier movement of the motor and pump to the final installation location. The pump crate also contains the coupling and accessories necessary for the pump-motor installation. The coupling is already assembled therefore do not take it apart. The required tools are indicated below: Shims for Motor Leveling Alignment Pins (provided) Feeler Gauges (provided) Allen Wrench Anti-seize Compound (provided) Motor Installation Bring motor to final location on baseplate or concrete pad. Wipe motor flange face clean with a cloth to remove protective coating. Install motor feet bolts and tighten securely. Note: be aware of soft foot. Soft foot is a gap between the motor s foot and the foundation which can distort the motor frame creating stresses. Eliminate soft foot by properly shimming the motor before proceeding with the pump installation. Motor Rotation Check 1. Before pump is brought to the motor, connect power to the motor; 2. Briefly jog motor to determine direction of rotation. Correct rotation is indicated by an arrow on the pump motor adapter. Rotation is CLOCKWISE when viewing motor from fan end; 3. If rotation is incorrect, switch any two leads to the motor to change rotation. Note that changing leads to the VFD will not change rotation direction. Pump Installation and Alignment Pump alignment is much simpler than with most multistage centrifugal pumps. The precision fit between the motor face and the pump motor adapter face ensures radial alignment of the pump and motor shafts. To obtain angular alignment, the only requirement is for the pump flange and motor flange to be parallel. If these two faces are parallel, then the pump and motor shafts are aligned, see figure 1.4. The alignment process is in two steps. The first step, called initial alignment will put the pump and motor in approximate angular alignment (coupling is not installed). The second step is to install the coupling on the motor shaft and then accurately align the pump and motor shafts. There is a slight difference in how to align the pump equipped with a NEMA motor (see figure 1.5) and an IEC ( metric ) motor (see figure 1.6) because of a difference in the design of the motor flange. Figure 1.4 Must be parallel Flanges are in contact Motor adapter Permanent gap NEMA motor Motor adapter IEC (metric) motor Figure 1.5 NEMA frame Figure 1.6 IEC frame Initial alignment 1. Remove coupling guards from motor adapter. 2. Install alignment pins provided in top motor bolt holes on motor flange face. 3. Carefully slide pump toward motor leaving a small gap between motor and pump flange faces. 4. Using feeler gauges, measure the gap between motor adapter and motor at 4 different points around adapter, see figure 1.7. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 4 of 17

5 5. Adjust pump discharge end side to side and up and down by rotating the pump leveling foot nuts until the gap is uniform, meaning that the flange faces are parallel. (Figure 1.8 shows non-parallel flange faces). 6. Bolt precision leveling foot to the foundation and torque to recommended bolt manufacturer s requirement. (Do not secure the support bracket(s) until later). 7. Remove top cradle from leveling foot and slide pump away from motor to provide room to install the coupling. Final Alignment 1. Apply anti-seize compound on motor shaft and install motor key on shaft; 2. Install shaft coupling on motor shaft, install and tighten set screws; a. Note: there are no set screws on the pump coupling hub. This allows proper operation of the pump shaft. b. For more information on the coupling, consult its manual (model number is ). 3. Apply anti-seize compound on pump shaft and install pump key. Make sure radius of key sits in the radius of the shaft keyway. 4. Place pump on alignment pins (installed in initial alignment and slide toward motor. Carefully guide the pump shaft and key into the coupling hub; 5. By hand, push the pump until the flange faces are in contact or very close; 6. Using feeler gauges, check for any non-uniform gap between the flange faces. a. In the case of a NEMA motor (figure 1.5), there will always be a gap. Use appropriate feeler gauge to verify that the gap is uniform, indicating that the flange faces are parallel. 7. Adjust discharge end as necessary until gap is uniform around adapter. The gap variation should not exceed (0.53 mm) around the motor adapter face. 8. Install motor adapter bolts and tighten in a star pattern. 9. Install top cradle back to precision leveling foot. 10. Install all support bracket feet bolts and secure to foundation. 11. Install motor adapter guards. 12. Perform a last alignment check after pipes are connected and pump is primed. See section 1.4 Final Alignment Check. Figure 1.7 Figure 1.8 Improper gap 1.2 Piping Inlet Piping Vacuum/pressure gage is recommended to allow measurement of pump inlet pressure. The pump must never be throttled on the inlet side. Keep the inlet pipe free of high points which could trap air and could disrupt pump priming. After installation of the inlet piping, test for pressure integrity and air-tightness. Outlet Piping A spool piece or other removable piping should be installed at the pump outlet. During inspection of the shaft seal, the fluid end is detached from the motor shaft and motor adapter. Therefore, the pump assembly must be free to move about 12 inches away from the motor adapter in order to gain access to the mechanical seal area as in figure 1.9 (disassembly procedures described in section 2.2). Pipe elbows may be attached to the pump inlet and pump outlet connections. The inlet piece may be rotated in 90 degree increments. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 5 of 17

6 Design piping with spool piece for easy pump installation Remove top cradle to slide pump forward pump O.K. to use elbows at inlet and outlet Mechanical seal access Temporary Support Figure Piping Alignment Do not force any misaligned pipes to connect to the pump discharge or inlet, as shown in figure All pipe connections must be aligned appropriately as shown in figure Properly support all pipes to avoid placing strains on the pump. Figure 1.10 Incorrect pipe alignment. Figure 1.11 Correct pipe alignment. 1.3 Pump Protection Features For maximum reliability and life, the MSS pump series are equipped with two (2) features designed to protect the FEDCO water-lubricated thrust bearing from damage - a flow switch (figure 1.12) and a bearing line filter (figure 1.13). The key to these protection features is that they will help maintain flow through the bearing drain line by blocking debris that can plug the line (the filter) and a flow which will activate the user s pump shutdown control if the bearing drain flow becomes too low. Figure 1.12 Flow switch The flow switch provides means to shut down the pump if flow through the bearing drain line is too low for safe operation. The decrease or loss of flow indicates blockage in the bearing drain assembly, which could lead to pump failure. The switch must be wired to the plant s control system per the below specifications and must activate a shutdown of the pump s motor. The pump can operate no more than a couple minutes with a blocked bearing drain line. The programming of the control should have a delay long enough at start-up to allow the pump to reach normal operating conditions. If the delay is not programmed, the switch will give false alarms and the pump and motor will not be able to start. Switch Specifications and Ratings: Switch: SPST,10VA Electrical Connection: No. 24 AWG, 24 to 26 Polymeric Leads Electrical Rating: 120VAC Contact Rating: 10W Switch Voltage (DC or AC Peak): 200 Max. Switch Current (DC or AC): 0.4A Max. Carry Current (DC or AC): 0.4A Max. Break Down Voltage: 230 VDC Min. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 6 of 17

7 Wiring: normally preset for open Installation: 10 X pipe diameter upstream and downstream of sensor Flow Switch Trip If the flow switch causes a pump shutdown, the root cause can be several factors including debris in the feed stream such as sand that has plugged the bearing drain line. Please take the following steps: 1. Remove the filter housing cap and remove sintered element. a. Clean sintered element under running water. b. Wipe clean filter housing. c. Reassemble filter. 2. Remove throttle nipple off the bearing drain line. a. Clean throttle nipple under running water. b. Reassemble throttle nipple. To start the unit again, follow the start-up procedure from section 1.5 of this manual. If a second shut down occurs, in addition to the above steps, check the balance disc (see 2.4 Balance Disc Maintenance section): a. If the balance disc is in good condition, clean it and reuse it; otherwise, replace. b. Reassemble balance disc. Figure 1.13 Bearing Drain Line Filter The bearing filter is located just upstream of the throttle nipple indicated in figure 1.1. This filter helps prevent the narrow passage in the throttle nipple from becoming blocked. Figure 1.13 shows a detailed view of the filter and how to remove and clean the filter element. IMPORTANT- Never Operate the Pump Dry 1.4 Preparation for First Startup The pump will be seriously damaged if operated dry even for one second. The pump must be filled with water prior to starting the motor even if only to check direction of motor rotation. IMPORTANT- Never Operate the Pump Without Adequate Flow Since pump operation generates heat within the pump, a flow of fluid through the pump must be maintained to remove that heat. Pump flow should be at least 20% of the design flow rate to eliminate potential damage. Motor Startup and Rotation Direction The wiring diagram located on the motor name plate, electrical junction, junction box cover, or wiring tag should be used to correctly wire the motor according to the voltage available. Be sure to follow all manufacturer's instructions on motor lubrication. Before applying power, prime the pump. This means that water must fill all pipes and air must be vented for all high points in the piping and from tanks, filters, etc. Apply power for ONE SECOND MAXIMUM to check direction of motor shaft rotation. The direction of rotation for 3 phase motors may be reversed by interchanging any two leads. Note that changing the leads to the VFD (if used) will not change direction of motor rotation. High Inlet Pressure Option The discharge flow from the highpressure seal carrier will increase as the inlet pressure to the pump increases. The maximum flow will depend on the MSS model and inlet pressure. Please measure the drain flow and record below for future reference. If, in the future, the drain flow increases by about 40%, then routine maintenance should be performed as explained later in this manual. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 7 of 17

8 Pressure Switches A pressure switch should be installed at the pump inlet to prevent pump operation if the feed pressure to the pump is below about 10 psig. Upstream Filtration The pump must be protected from debris in the feed water such as sand, gravel, welding slag, etc. A 20 micron or better filter must be located upstream of the pump inlet to protect the pump from accidental release of sand or gravel from any multimedia filters that may be used. Final Alignment Check Please double check alignment just before initial operation as the attached pipes or the added weight of water in the system pipes and vessels can distort the foundation, especially if in a container. It is easy to recheck the alignment of the pump and motor. 1. Loosen all motor flange bolts by about one (1) turn. 2. Using the feeler gauge measure any gap that may form between the motor face and the flange. The gap may be zero or very small. If the maximum variation from the largest gap to the smallest gap around the flange is smaller than indicated in table 1.1 then alignment is OK. 3. If the gap variation is greater than the maximum allowable, please realign the pump per the procedure defined in the pump installation section. Note that misaligned piping can often cause misalignment. IMPORTANT - The switch must be programmed with a delay at pump start to allow sufficient time for pump to reach normal flow and pressure! 1.5 Startup Flange Gap Tolerances Non-uniform gap good 0.021" 0.53mm acceptable 0.032" 0.81mm Table Figure 1.14 Before starting the pump, please verify that the following have been checked. Check list: 1. Coupling set screws tightened 2. Motor Adapter guard installed 3. All anchor bolts tightened 4. All pipe couplings tightened 5. Motor rotation determined 6. Motor greased as required 7. Inlet pressure indicator checked 8. Inlet pressure switch checked 9. Outlet pressure indicator checked 10. Piping filled with water, and bled of air In addition to the above check list, verify that the flow switch has been properly wired into the motor starting circuit and that there is a sufficient delay in responding to the flow switch to allow the pump to achieve the design flow and pressure. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 8 of 17

9 Pump Start-up 1. Start low pressure booster pump and vent air from tanks, high spots, etc. 2. Verify that there are no leaks in the piping. 3. Start MSS pump. 4. Check for leaks. 5. Check for unusual noise or vibration. 6. Adjust system valves and controls as needed to obtain the desired operating condition. 1.6 Maintenance Schedule By following the schedule of preventive maintenance presented below, the MSS pump will deliver years of trouble-free performance. One (1) day after commissioning 1. Recheck pump alignment (see section 1.4 Final Alignment Check above). 2. Clean the filter element, rinse filter housing then reinstall the filter. If there is significant debris, please identify the source of the debris and correct. Most often, it is sand from the multimedia filter. 3. Visually inspect coupling and tighten the coupling bolts to the specified torque if necessary (see table 1 of the coupling manual. Coupling model is ). Six (6) months after commissioning 1. Inspect pump alignment (see section 1.4 Final Alignment Check above). 2. Clean the filter element, rinse filter housing then reinstall the filter. 3. Visually inspect coupling and tighten the coupling bolts to the specified torque if necessary (see table 1 of the coupling manual. Coupling model is ). Twelve (12) months after commissioning 1. Inspect pump alignment (see section 1.4 Final Alignment Check above). 2. Clean the filter element, rinse filter housing then reinstall (replace filter element if necessary). 3. Inspect pump coupling: torsional backlash and tightening torque (refer to the coupling manual for more details. Coupling model is ). 4. Replace mechanical seal if early signs of failure are noticed. 5. Inspect and replace, if necessary, balance disc (see section 2.4). a. Note: If balance disc requires replacement, change mechanical seal as well. Annually 1. Inspect pump alignment (see section 1.4 Final Alignment Check above). 2. Clean the filter element, rinse filter housing then reinstall (replace filter element if necessary). 3. Inspect pump coupling: torsional backlash and tightening torque (refer to the coupling manual for more details. Coupling model is ). 4. Replace mechanical seal if early signs of failure are noticed. 5. Inspect and replace, if necessary, balance disc (see section 2.4). a. Note: If balance disc requires replacement, change mechanical seal as well. Five (5) Years 1. Annual maintenance per above. 2. Disassemble fluid end for detailed inspection (refer to FEDCO Inspection/Overhaul Manual). Note: Follow manufacturer's recommendations for motor maintenance. 2.1 Troubleshooting If the pump appears not to be operating normally, please use the following checklist to help identify the potential problem. Note that most problems are not related to the pump. Also, contact FEDCO technical support by (techsupport@fedco-usa.com), telephone or FAX. They will give you easy, Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 9 of 17

10 step by step instructions on how to proceed. Most field problems can be easily solved by the customer very quickly and with little or no cost using FEDCO and telephone assistance. However, FEDCO can dispatch a technician if the problem remains. Low Flow or Low Pressure Restriction in inlet or outlet pipes Check pump inlet pressure - if too low, this can cause loss of pressure and flow; Verify valve position of all control valves is at proper settings make sure throttle valve is fully open (if used). Incorrect pump speed/direction Check VFD setting for proper speed setting (if used); Verify power supply is at expected frequency (50 or 6o Hz); Check motor direction of rotation. Air leaks (if vacuum on pump inlet) Check inlet piping joints; Check pump shaft mechanical seal a failing seal can allow air to enter the pump. Pump cavitation Check inlet pressure during pump operation cavitation can often be heard as a rough, unsteady noise; Check flow rate excessive flow reduces discharge pressure and increases cavitation potential. Air in casing Air in casing will cause low discharge pressure. Restart pump several times to flush the air out. Internal damage Remove discharge housing and cavity cover and inspect balance disc. Look for heavy wear (grooves) and take measurement as explained in figure 2.5. If further investigation is required, please contact FEDCO. Pump Vibration or Unusual Noise Operating conditions Pump cavitation (see above); Flow rate is excessive; Flow rate is less than minimum specified. Misalignment Check alignment as described in section 1.4 Final Alignment Check. Excessive Motor Load - motor runs hot or shuts off Check supply voltage, voltage imbalance between legs; Check ambient air temperature when motor is running; Check motor wiring; Check fuses (loss of phase). Check flow rate and VFD frequency settings Leakage Pipe Joints Disassemble pipe coupling joints, check for damaged gasket or debris in gasket area. Pump Shell Damaged O-rings replace O-rings. Shaft Damaged mechanical seal replace mechanical seal. Pump does not start or shuts down quickly Flow switch 1. Check programmed delay: might not be enough time delay for pump to develop flow in bearing drain line; 2. Bearing drain line filter may be blocked proceed with filter inspection procedure (see section 1.3 Flow Switch Trip) Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 10 of 17

11 2.2 Shaft Seal Replacement (standard) When to Replace the Mechanical Shaft Seal The mechanical seal should be inspected if leakage appears around the shaft opening in the inlet housing. Note that some leakage may occur for about 60 seconds after pump start-up. If the leakage continues longer than 60 seconds, then proceed with the seal replacement. IMPORTANT- Power to motor must be disconnected before maintenance!!! Prepare for seal removal: 1. Drain piping and pump. 2. Disconnect inlet and outlet piping. 3. Loosen two coupling set screws. 4. Remove anchor bolts on the shell support bracket(s). 5. Remove four (4) inlet housing bolts. 6. Slide fluid end at least 12 inches away from motor adapter, support inlet end with blocks (see figure 1.9). 7. Remove shaft bushing from inlet. IMPORTANT - Do not allow pump shaft to bend as fluid end is removed from motor adapter With the end of the pump shaft exposed: 1. Lubricate end of shaft to ease mechanical shaft seal removal - soapy water works well. 2. Remove inlet retaining ring (stationary) from inlet groove. 3. Through big inlet opening, push mechanical shaft seal, washers and shaft retaining ring (rotating) down the shaft and remove. 4. Inspect the inlet seal bore and shaft area for damage. Wipe with a clean rag. Mechanical Seal Installation: 1. Lubricate the shaft again for easy seal installation. 2. Install new shaft retaining ring in shaft groove. Slide shaft washer against retaining ring. 3. Slide the new rotating seal followed by the stationary seal onto shaft. 4. Slide inlet washer onto shaft and push entire seal assembly until it compresses against shaft retaining ring. 5. Install inlet retaining ring into inlet groove and make sure it s secure. See Figure 2.1 and 2.2 for properly installed shaft seal. 6. Install shaft bushing in motor adapter seat. 7. Slide fluid end toward motor and attach inlet to motor adapter. Tighten the four (4) inlet bolts. 8. Follow pump installation and alignment procedures in section 1.1 before starting the pump. Shaft Bushing Figure 2.1 Inlet Mechanical Seal Assembly Shaft Collar Assembly Inlet Retaining Ring Shaft Washer (Stationary) Inlet Washer Stationary Seal (Sits in inlet) O-Ring Rotating Seal (Sits compressed on shaft) Shaft Retaining Ring (Rotating) Figure 2.2 Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 11 of 17

12 2.3 Shaft Seal Replacement (Optional High Inlet Pressure Design) When to Replace the Graphite Shaft Sleeve If there is a 40% increase in the discharge from the high pressure seal carrier, the clearance in the graphite shaft sleeve has enlarged allowing excess flow. This can cause seal damage and should be replaced as soon as possible. Follow the procedure below to replace the sleeve. When to Replace the Mechanical Shaft Seal The mechanical seal should be inspected if leakage appears around the shaft opening in the inlet housing. Note that some leakage may occur for about 60 seconds after pump start-up. If the leakage continues longer than 60 seconds then proceed with the seal replacement procedure. Prepare for seal removal 1. Drain piping and pump. 2. Disconnect inlet and outlet piping. 3. Loosen coupling set screw. 4. Remove anchor bolts on the shell support bracket(s). 5. Remove four (4) inlet housing studs. 6. Slide fluid end at least 12 inches away from motor adapter, support inlet end and high pressure seal carrier with blocking (see Figure 1.9). IMPORTANT - Do not allow pump shaft to bend as fluid end is removed from motor adapter With the end of the pump shaft exposed: 1. Remove the four (4) studs that attached the high pressure seal carrier. 2. Slide the seal carrier away from the fluid end. a. Note: the entire mechanical seal shaft assembly will slide out with the seal carrier 3. Remove mechanical shaft seal assembly from the seal carrier. 4. Remove graphite shaft sleeve, see Figure Inspect the seal bore and shaft area for damage. Wipe with a clean rag. 6. Slide shaft sleeve inside inlet. Make sure it lines up with the carrier s anti-roll pin in the seal carrier. 7. Install new shaft retaining ring (rotating). 8. Attach seal carrier to fluid end. 9. Slide shaft washer against retaining ring. Push the new rotating seal onto the shaft until seated against the shaft washer. 10. Install the new stationary seal, inlet washer and inlet retaining ring (stationary) into the high pressure seal bore. 11. Install four (4) inlet/seal block studs and tighten into motor adapter. 12. Follow pump installation and alignment procedures in section 1.1 before starting the pump. Figure 2.3 Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 12 of 17

13 2.4 Balance Disc Inspection/Replacement When to Inspect The pump balance disc may be inspected at intervals of approximately 8,000 hours of operating time (approximately annually) or when the flow switch has triggered a pump shutdown. Refer to figure 2.4 to see the location of the balance disc in the pump (also see part identification drawing, section 3.1). IMPORTANT Power to motor must be disconnected before maintenance!!! Preparing for Inspection 1. Drain piping and pump and disconnect outlet piping; 2. Disconnect one end of the thrust bearing drain line; 3. Remove through nipple from the discharge housing (save O-ring); 4. Loosen flange bolts on end shell flange; 5. Remove retention clips on discharge housing by unscrewing cap screws (3) (use 3/16 Allen wrench); 6. Remove shell retaining ring - a flat head screwdriver can help pry the snap ring out of the groove. 7. Remove discharge housing from end shell. Figure 2.4 Balance Disc Inspection 1. Remove bearing cavity cover (be sure to save the O-ring); 2. Lock motor coupling with a strap (chain) wrench so pump shaft can t move; 3. Remove hex head nut, lock washer and washer; 4. Slide balance disc off pump shaft (note the O-ring); 5. Check balance disc for wear in the seal area. See Figure 2.5; a. up to 0.020" (0.508 mm) of wear is acceptable. 6. Inspect the bearing area on the bearing holder for grooves, wear, etc; 7. Replace worn parts as needed. Reassembly Replace balance disc (with O-ring). Install balance disc washer, lock washer and nut; a. torque the nut to 50 ft-lbs. Install bearing cavity cover with O-ring; Install the discharge housing and the discharge housing retaining ring; Install retention clips and tighten down cap screws. Firmly tighten flange bolts in star pattern to obtain metal-to-metal contact - tighten to 45 ft-lbs. Reconnect bearing drain line. Be sure that through nipple is clear of obstructions. Reconnect inlet and outlet piping. Remove strap wrench from motor coupling, install coupling guard; Fill piping with water and purge air. Follow normal start-up procedures. Figure 2.5 Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 13 of 17 NOTE! 1. Minimum allowable thickness = ( mm). 2. Use average of 4 measurements spaced around circumference.

14 PARTS IDENTIFICATION DRAWING Inlet Motor MSS DISCHARGE ASSEMBLY & THRUST BEARING Motor adapter Inlet O-ring Inlet ring Series shell Series spacer Series flange O-ring End shell Leveling foot craddle Discharge ring Discharge housing Bearing holder Balance disc O-ring Discharge housing O-ring Lock washer Balance disc Balance disc key Nut Cavity cover O-ring Washers Shaft bushing Starting impeller housing Leveling foot craddle End spacer Cavity Cover O-ring Through nipple Discharge housing retaining ring Flow Switch Shell support bracket Support bracket foot Throttle nipple Filter Floor Diffuser housing STAGE DETAIL PRECISION LEVELING FOOT Impeller COUPLING ASSEMBLY MECHANICAL SEAL ASSEMBLY SPLIT COLLAR DETAIL Diffuser bearing (Buna N) Motor key Set screw Collar Sleeve Pump shaft coupling key Stationary seal Rotating seal Shaft (Rotating) Retaining Ring Split Collar Stage Spacer Shaft Inlet (Stationary) Washer Inlet (Stationary) Retaining Ring Shaft (Rotating) Washer Motor shaft Pump shaft Snap Ring Last Revised: March, ; MSS-V2.0; J.S.

15 Motor PARTS IDENTIFICATION DRAWING Motor adapter Inlet Inlet O-ring Inlet ring Series shell MSS Series spacer Series flange O-ring Leveling foot craddle End shell Discharge ring Discharge housing DISCHARGE ASSEMBLY & THRUST BEARING Bearing holder Balance disc O-ring Discharge housing O-ring Lock washer Balance disc Balance disc key Nut Cavity cover O-ring Washers Shaft bushing Shell support bracket Leveling foot craddle End spacer Cavity Cover O-ring Through nipple Discharge housing retaining ring Flow Switch Shell support bracket foot Throttle nipple Filter PRECISION LEVELING FOOT STAGE DETAIL Impeller bowl Diffuser housing Motor key COUPLING ASSEMBLY Set screw MECHANICAL SEAL ASSEMBLY SPLIT COLLAR DETAIL Collar Sleeve Diffuser bearing (Buna N) Stage spacer Pump shaft coupling key Stationary seal Rotating seal Shaft (Rotating) Retaining Ring Split Collar Impeller Shaft Inlet (Stationary) Washer Motor shaft Pump shaft Inlet (Stationary) Retaining Ring Shaft (Rotating) Washer Snap Ring Last Revised: March, ; MSS-V2.0; J.S.

16 3.2 Parts Return and Warranty Please contact FEDCO before returning any equipment. You must have a Return Authorization Number (RAN) issued by FEDCO before we can accept any parts. All returned parts must be shipped prepaid to FEDCO with the RAN clearly marked on the package. We need this number to ensure proper handling of the returned parts and supply of new parts, if needed. Repair by FEDCO on equipment that is out-of-warranty will be warranted for three (3) months. Ask FEDCO for details of the repair warranty. Parts will be replaced in accordance with the FEDCO warranty. Use the following address to return parts: ATTN: Field Service Department FEDCO 800 Ternes Drive Monroe, MI USA Additional contact information: Tel Fax techsupport@fedco-usa.com Web site: How to Return Parts to FEDCO 1. Provide FEDCO with the following information: Serial number of unit. Description of why parts are being returned. 2. FEDCO will provide a Return Authorization Number. 3. Pack the unit in the original shipping crate or other suitable crate and clearly mark the Return Authorization Number on the outside of the crate. 4. Send unit, freight prepaid, to FEDCO at the above address. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 14 of 17

17 MSS Pump Warranty Fluid Equipment Development Company, LLC, (FEDCO), warrants its MSS feed pump to be free from defects in design, materials or workmanship for a period of 18 months from shipment or 12 months from the date of installation of the product, whichever occurs first, when said product is operated in accordance with written instructions and is installed properly. If the MSS pump is altered or repaired without prior approval of FEDCO, all warranties are void. All equipment provided by FEDCO, including pump motors, must be installed on a rigid, steel support structure and base capable of handling full loads during operation. Failure to do so will void warranty. All equipment must be installed such that there are no pipe stresses on FEDCO equipment. Failure to do so will void warranty. If the MSS pump is not installed and aligned as per FEDCO Installation and Operation Manual, any subsequent damage to the pump and/or motor will be excluded from the warranty If any defects or malperformance occur during the warranty period, FEDCO's sole obligation shall be limited to alteration, repair or replacement at FEDCO's expense, F.O.B. factory, of any parts or equipment, which upon return to FEDCO and upon FEDCO's examination prove to be defective. All parts returned for warranty service must be shipped prepaid and include FEDCO's return authorization number. Equipment and accessories not manufactured by FEDCO are warranted only to the extent of and by the original manufacturer's warranty. FEDCO shall not be liable for damage or wear to equipment caused by abnormal conditions, excessive temperatures, and vibration or caused by corrosives, abrasives or foreign objects. The foregoing warranty is exclusive and in lieu of all other warranties, whether expressed or implied, including any warranty of merchantability or fitness for any particular purpose. In no event shall FEDCO be liable for liable for consequential or incidental damages. Register the warranty at the time of installation by completing the Warranty Registration Form of section 3.3 and sending it to FEDCO. Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 15 of 17

18 3.3 Warranty Registration Form THIS FORM MUST BE COMPLETED AND RETURNED TO FEDCO TO ACTIVATE YOUR WARRANTY COVERAGE. FEDCO will send confirmation of start of warranty coverage Please FAX this page to FEDCO to register your warranty. FAX to: (USA) or ATTN: Technical Support Initial Installation Model #: Serial #: Installation Date: Startup Date: VFD frequency (Hz) if used Voltage and Hz of power supply Feed Flow: Suction Pressure to Pump: Discharge Pressure: Drain flow rate (high inlet pressure option only): Comments: Installed by: Telephone: Fax: Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 16 of 17

19 3.3 Overhaul Record Overhaul Date: Operating Hours: Reason for Overhaul: Operating Data Prior to Overhaul: Feed Flow: Suction Pressure to Pump: Discharge Pressure: Operating Data After Overhaul: Feed Flow: Suction Pressure to Pump: Discharge Pressure: GENERAL NOTES: Overhauled by: Telephone: Fax: Copyright 2009 Fluid Equipment Development Company Version MSS 2.0 Last revised: 04/2009 Page 17 of 17

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