Installation, Operation and Maintenance Instructions

Transcription

1 FJ-400A Installation, Operation and Maintenance Instructions Coalescers ERIEZ MAGNETICS HEADQUARTERS: 2200 ASBURY ROAD, ERIE, PA U.S.A. WORLD AUTHORITY IN SEPARATION TECHNOLOGIES

2 Introduction This manual details the proper steps for installing, operating and maintaining the Eriez HydroFlow Coalescers. Careful attention to these requirements will assure the most efficient and dependable performance of this equipment. If there are any questions or comments about the manual, please call Eriez at for Coalescer assistance. CAUTION Safety labels must be affixed to this product. Should the safety label(s) be damaged, dislodged or removed, contact Eriez for replacement ERIEZ MAGNETICS ALL RIGHTS RESERVED 2

3 Table of Contents ERIEZ hydroflow Coalescers TANK-SIDE COALESCER... 5 INSTALLATION... 5 For Air Pump Equipped Models... 6 OPERATION... 6 For Air Pump Equipped Models... 6 Skimmer Adjustment... 7 MAINTENANCE... 7 TROUBLESHOOTING... 7 For Air Pump Equipped Models... 7 PARTS LIST... 8 DRAWINGS... 9 PORTABLE COALESCER INSTALLATION Choosing the Location Installing the Unit Initial Assembly Assembly OPERATION Start-Up and Operating Procedure O operating Procedure Notes Cleaning Procedure MAINTENANCE TROUBLESHOOTING PARTS LIST - AIR POWERED UNIT PARTS LIST - ELECTRIC POWERED UNIT /8" AIR PUMP FOREWORD MAINTENANCE Valve and O-Ring Diaphragm INSPECTION Air Valve Assembly Fastener Torque Requirements SPECIFICATIONS Dimensions PARTS LIST Repair Kits - Wet End ERIEZ HydroFlow Coalescers

4 Table of Contents (continued) ERIEZ hydroflow Coalescers SELF-PRIMING ELECTRIC PUMP DESCRIPTION Pumps Units Shipped Without Motor Assembly Motor MAINTENANCE Mechanical Seal Replacement Shim Adjustment PARTS LIST PORTABLE COALESCER JR INSTALLATION Choosing the Location Installing the Unit Initial Assembly Assembly START-UP & OPERATING PROCEDURE Operating Procedure Notes Cleaning Procedure SPARE PARTS PARTS LIST MAINTENANCE /8" SPECIALTy Performance Maintenance Manual Before You Begin Valve and O-Ring Maintenance Diaphragm Maintenance Air Valve Assembly Inspection Fastener Torque Requirements Specifications Typical Installation Dimensions Performance Curve Parts List Repair Kits - Wet End

5 Tank-Side Coalescer Model E Installation 1. Connect one end of the 1/2" hose to the hose barb on top of the coalescer drum and attach the other end to the hose barb on the pump/skimmer assembly. Use the snap grip hose clamp (supplied) to make positive seal connections on both ends. (See Figure 1 for further clarification.) DO NOT CUT THE HOSE SHORTER. IF THE HOSE IS CUT SHORTER, IT WILL INCREASE THE COOLANT FLOW THROUGH THE SKIMMER AND PUMP, WHICH WILL IN TURN NOT ALLOW THE SKIMMER TOP TO FLOAT PROPERLY. 2. Connect the 1" clear hose to the 90 hose barb on the side of the coalescer drum. Use the snap grip hose clamps (supplied) to make a positive seal connection. 3. Make sure the drum inner baffle is adjusted to the same height as the drum. Center the baffle in the drum and place lid on drum so that the 1/2" bulkhead in the lid fits inside the baffle. Tighten lid. 4. Elevate the coalescer drum to a point above the machine tool sump so that clean coolant can gravity flow out of the drum through the 1" clear hose and back into the sump. (No more than 2' above the skimmer assembly.) (See Figure 2 for further clarification.) Do not allow the discharge hose to be submerged in the fluid or it will back up in the drum. 5. Measure depth of sump. Before placing pump/skimmer assembly into the sump, adjust the skimmer height so that the skimmer base is approximately 1-1/4" below the coolant level in the sump. (See Figure 2 for clarification.) NOTE 1: If the sump depth is less than 5", modification will need to be made to the skimmer. The skimmer must be trimmed so that the base and the float are short enough to fit the sump. A band saw, cut off saw or hacksaw can be used for this purpose. The length to which to trim the parts are explained in Table 1. Coalescer drum (15 gal.) Figure 1 Typical TSC Assembly/Parts Pump/skimmer assembly Figure 2 TSC Typical Set-Up 3/4" Drum spigot Coalescer drum lid 1/2" - 90 Hose barb Snap grip hose clamp 1" - 90 Hose barb 1/2" Clear hose Snap grip hose clamp Rigid stand Pump/skimmer assembly G.F.C.I. plug adaptor Clean coolant return (1/2" clear hose) Dirty coolant (1/2" clear hose) Coolant flow arrows G.F.C.I. plug adapter Rigid stand 1" Clear hose 1" Underflow piping Inner (pvc pipe) baffle Tramp oil flows to surface in drum Machine coolant sump Coalescer drum Sump level ERIEZ HydroFlow Coalescers 5

6 NOTE 2: Once the skimmer height is set as described, the skimmer will maintain operation even with a sump level fluctuation of plus or minus 1-1/4". NOTE 3: For sump levels less than 3-1/2", the pump cannot be directly coupled to the skimmer. In these cases, use a short piece of hose and some barbed fittings to connect the pump to the skimmer after removing the pump from the skimmer base. # hose connection assembly is available for this purpose. If the space available or the pump and skimmer do not allow the assembly to fit in the sump, using # hose connection allows the pump and skimmer to be separated and then installed in the sump. If there is not room for both the pump and skimmer assembly in the sump, use the pump by itself. Sump Level Trim Amount Skimmer Height After Trim Sump Level Range of Trimmed Skimmer 5-1/4" or +2-1/4" from initial None 4-5/8" greater level 4" 1-1/4" 3-3/8" +1 from initial level 3" 2-1/4" 2-3/8" 0" from initial level 2-3/4" 2-1/2" 1-7/8" 0" from initial level Less than 2-3/4" Cannot do N/A TABLE 1 N/A 7. Make sure filter screen is in skimmer base. 8. Set pump/skimmer assembly into sump in an area where tramp oil tends to accumulate, or at an area of convenience. The base will sit on the sump bottom keeping the pump/skimmer assembly upright. It is best to sit the skimmer as low as possible in the sump with the upper set screw installed so the upper portion of the float will still stay within the lower portion of the skimmer base. This allows the upper portion to bob up and down a small amount, which helps keep the skimmer clean of solids. 9. Plug pump power cord into a GFCI plug adapter, and then into a 110 volt electrical outlet. For Air Pump Equipped Models 1. Cut the 1/2" hose to length to fit between the pump, and the skimmer. (For Standard skimmer equipped unit follow steps 5-7 in the previous section). 2. If unit comes with triangle skimmer, attach one end on the barbed fitting on the triangle skimmer and the other end to the pump inlet 3. Place the triangle skimmer so that the screened inlet is pointing up in the sump. Make sure the fluid pickup of the skimmer is under the surface of the fluid. If it is too high, loosen the jam nut on the bottom of the pickup pipe and unscrew the pick up pipe to lower the inlet. Tighten the jam nut. 4. Adjust the air pressure regulator all the way out to start with so when the air line is connected to the regulator the pump will not start right away. Operation 1. Once pump is operational, fluid will flow through the 1/2" hose and into the coalescer drum. 2. Initially, the time to fill the drum will be 6-8 minutes. 3. Optional: Fill coalescer drum with new coolant to avoid reducing coolant level in machine tool sump. Coalescer drum holds approximately 15 gallons of coolant. 4. Once the drum is full, clean coolant will gravity flow through the underflow pipe, out the drum, and back into the machine sump. Tramp oil will float to the surface in the drum and will be contained until it is drained off. Adjust the PVC elbow that is attached to the drain spigot on the inside of the drum so the opening of the elbow is just below the fluid level in the drum while it is running. When tramp oils build up inside the drum they will automatically drain out through this elbow when the spigot is opened. The spigot valve can remain open all of the time if the elbow is adjusted correctly. Or periodically open the spigot to drain out any tramp oils. For Air Pump Equipped Models 1. Open the flow control ball valve on top of the drum all the way. Slowly increase the air pressure so the pump starts working. Air pressure should be between 25 and 30 PSI. 2. Once pump is operational, fluid will flow through the hose and into the coalescer drum. 3. Initially, the time to fill the drum will be 6-8 minutes. 4. Once the drum is full, clean coolant will gravity flow through the underflow pipe, out of the drum, and back into the machine sump. At this time adjust the ball valve on the inlet to the drum so that the flow rare is 1-1/2 GPM. Running faster than this may not allow tramp oils to settle out in the drum. Tramp oil will float to the surface in the drum and will be contained in the drum until the drain spigot on the side of the drum is opened allowing oil to be drained from the drum (Note: oil draining must be done when pump is de-energized). 6

7 Skimmer Adjustment 1. Push down on the 3/8" rod as shown at (A). 2. Pull up on the pump as shown at (B) to release assembly. 3. Push down or pull up on the pump as shown at (C), depending on if assembly needs to be raised or lowered. 4. At required level, release pump. Assembly will lock in place. 5. Set thumbscrew collars. 6. Remove pressure at (A).Maintenance Thumbscrew collar Skimmer Float A A A 1/2" Hose barb Pump Troubleshooting Problem Probable Cause Remedy 1. Pump not pumping 2. Not removing oil 3. Coolant discharges from drum before drum is completely full Electrical power disconnected Skimmer obstructed or plugged Reconnect power Remove Obstruction Pump not pumping See 1 Skimmer float stuck below Clean Skimmer surface Skimmer screen Clean screen plugged 1" clear hose is submerged upon start up Pull hose to an area above the surface. Crack drum spigot until drum is full. TABLE 2 Skimmer screen Skimmer base Thumbscrew collar 3/8" Rod (part of stand) Maintenance 1. Drain oil from the drum as required. Time intervals between drainings will depend upon tramp oil levels in the machine sump. 2. Remove drum lid once a month to check for sludge buildup in the drum. It is important to remove sludge often as bacteria will breed in the sludge. 3. Check operation of skimmer daily. Make sure the skimmer float is skimming the surface of the machine sump. 4. Check skimmer screen for plugging once a week. If it is plugged, remove screen and clean. C Stand base View A-A Skimmer Float - Closed end detail closed end up for proper operation, open end down into skimmer base. Figure 3 TSC Skimmer Adjustment B For Air Pump Equipped Models Problem Probable Cause Remedy Air turned off to the pump Turn air back on 1. Pump not pumping 2. Not removing oil 3. Coolant discharges from drum before drum is completely full Skimmer obstructed or plugged Pump chamber is plugged with solids Pump is air locked Remove obstruction Disassemble the air pump and remove solids from chambers Purge all air from hose between pump and drum Pump not pumping See 1 Skimmer float stuck below Clean Skimmer surface Skimmer screen Clean screen plugged 1" clear hose is submerged upon start up TABLE 3 Pull hose to an area above the surface. Crack drum spigot until drum is full. ERIEZ HydroFlow Coalescers 7

8 Parts List Skimmer assembly with stand # Skimmer assembly with stand and pump # Thumbscrew collar Skimmer float ( ) Skimmer Screen ( ) 1/2" Hose barb ( ) 1/4" Coupling ( ) Pump ( ) Part # Description Quantity Skimmer stand Skimmer screen Skimmer float Skimmer base Thumb screw Pump Thumb screw collar /2" NPT hose barb /4" Pipe Coupling 1 *Contact Eriez for pricing and availability on above components TABLE 4 Skimmer base ( ) Thumbscrew collar ( ) 3/8" Rod (part of stand) Stand stand ( ) Figure 4 TSC Skimmer Part Numbers 8

9 Drawing # G1 ( E) Tank Side Coalescer ERIEZ HydroFlow Coalescers 9

10 Drawing # G1 ( ) Tank Side Coalescer W/ Large Submersible Pump & Stand Skimmer 10

11 Drawing # G1 ( ) Tank Side Coalescer W/ Air Pump & Stand Skimmer 11 ERIEZ HydroFlow Coalescers

12 Drawing # G1 ( ) Tank Side Coalescer With Air Pump & Triangle Skimmer 12

13 Drawing # G1 ( ) Tank Side Coalescer With Jr. Belt Skimmer 13 ERIEZ HydroFlow Coalescers

14 Portable Coalescer Installation Choosing the Location Locate the coalescer as near to the intended point of use as possible. Avoid high traffic or forklift path areas to decrease possible bumping or damage to the coalescer. For maximum performance, place the coalescer in a level location capable of supporting the flooded operating weight of the unit, allowing access for maintenance and tramp oil container. Installing the Unit Place the unit in the chosen location. Provide an oil collection container and place near the tramp oil discharge of the coalescer. Initial Assembly 1. Remove top of coalescer to access those parts packed inside the unit. 2. Replace cover on top of coalescer. Assembly 1. Close drain valve on bottom of unit. Open tramp oil discharge valve. 2. Connect clean fluid discharge hose to clean fluid outlet. Adjust the height of the clean fluid discharge line as necessary to ensure unimpeded gravity flow back to the coolant sump. Use the supplied magnetic hose holder to hold hose in place. 3. Connect tramp oil discharge hose to oil outlet. 4. Make sure a magnetic hose holder is on dirty fluid transfer hose near floating Triangle Floating Skimmer on air pump and base mounted electric pump models. 5. Base mounted electric pump and air operated dual diaphragm pump units: Connect the dirty fluid transfer hose from the Triangle Floating Skimmer assembly to the quick disconnect fitting on the inlet of the basket strainer on air pump models. On base mounted electric pump models, connect the dirty fluid transfer hose to the pump inlet. If there is no room to use the Triangle Floating Skimmer in the sump or if there are floating chips on the surface of the coolant, use the supplied Suction Screen assembly with hose and connect it to the unit as described. 6. Connect utilities for pump. See also the Pump Owner s Manual in the Appendix. For units with the air-operated pump, connect shop compressed air to the pump. For units with electric pump, plug the electric cord into a 110-volt grounded outlet. NOTE: Outlet should be GFI protected. The electric pump model is equipped with a switch, which should be turned OFF at this point. 7. Place Triangle Floating Skimmer into sump, or use the Suction Strainer where there is not enough room to use the Triangle Skimmer. 8. Remove Basket strainer bowl and fill with water or the process fluid and reinstall. 9. On air pump and electric pump models: Clamp hose holder to wall of sump. Adjust as necessary to keep Triangle Floating Skimmer in a position where it will not interfere with the machine tool or parts washer operation. NOTE: The skimmer should have the wire mesh strainer pointing up. Adjust the inlet height of the Triangle Floating Skimmer center inlet pipe so that the inlet is approximately 1/8"-1/4" below the oil layer in the sump, which will allow the collector to always collect both oil and water and enable optimum performance in the coalescer. For shallow sumps, the triangle floating skimmer can be inverted. (The wire mesh strainer pointing down, adjust the inlet pipe fitting so it is below the surface of the fluid when inverted). Adjust the skimmer inlet so you do not see a vortex of air in the middle of the inlet as that will cause foam inside the coalescer. 14

15 NOTE: If there are floating chips on the surface of the fluid, do not use any floating skimmer as the chips will clog up the skimmer and cause the unit to plug up and fail. If floating chips are a problem, disconnect the skimmer hose from the inlet and connect the supplied suction strainer to the inlet using the suction strainer's connecting hose and quick disconnect fitting. Place the strainer in the tank so the hose is submerged into the fluid. It is not meant to pull fluid from the surface of the coolant sump. Operation Start-Up and Operating Procedure 1. Check for proper utility connections and installation of all components. 2. Make sure the tank is level. 3. Prime the coalescer by filling with fresh, clean fluid to a level just below the clean fluid outlet. On base electric pump units this will help fill the pump head cavity with fluid to prime it the first time. 4. For units equipped with air-operated pump, adjust the feed air pressure to PSI which will start the pump pumping fluid. Double diaphragm air pumps are self-priming. NOTE: Air operated pumps must have a minimum of 30 PSI air pressure to operate properly. 5. For units equipped with the base mounted electric pump, place the discharge hose into the clean side of the coalescer tank. Plug the electric cord into a grounded outlet. The tank drain valve is a 3-way valve. Move the handle of the valve so that the flow pattern on the handle shows flow from the tank to the pump. This will allow fluid from the tank to backfill the pump cavity. You will see some fluid going out the Triangle Floating Skimmer when the pump cavity is full. Using the on/off switch on the unit, turn the unit on while holding the Triangle Floating Skimmer under the fluid level in the sump to allow the pump to fully prime. If the unit does not immediately begin drawing fluid, turn the pump on and off several times. When the pump is primed, place the clean discharge hose back into the machine sump. 6. For all units, allow the pump to introduce oil-laden coolant to the coalescer. 7. If the unit is portable and will be moved from machine to machine, it must be operated long enough to remove the accumulated free tramp oils. A good rule of thumb is to take the amount of coolant in the sump, divide that amount by the flow rate of the coalescer (3 GPM), and multiply that figure by 4 to 6 passes to come up with an operating time. For example, a 100 gallon sump would need to circulate through a 3 GPM coalescer for 4-6 passes or 133 to 200 minutes. 100 gallons * 4 = 133 minutes 3 gpm 100 gallons * 6 = 200 minutes 3 gpm The more tramp oils present, the longer the unit may have to run to get the free tramp oils out of the coolant. 8. Adjust the flow rate to 2-3 GPM, so the fluid does not back up into the coalescer tank. Use the 1/2" ball valve installed between the pump outlet and the coalescer tank inlet to adjust the flow. NOTE: Air pump must have a minimum 30 psi feed pressure. For optimum performance of the coalescer, do not exceed the rated flow rate of the unit. 9. Allow the unit to begin collecting tramp oil. Adjust the gray tramp oil removal pipe by moving the slot opening in the pipe using the T handle tool provided so that it is 1/8"-3/16" above the fluid level in the tank. This will allow a layer of oil to build up on the fluid, which will dewater as it rises before flowing into the oil removal pipe and out of the unit. After the unit has run for a while, this oil removal pipe can be adjusted again to provide wetter or drier oil as desired. NOTE: It is normal to have a layer of oil on top of the coolant in the coalescer tank. The thicker the layer of oil, the less coolant will be in the oil when it is discharged from the coalescer tank. Operating Procedure Notes After initial start-up, periodically monitor the coalescer s operation. When not in use, close all valves. The waste oil collection container should be routinely emptied to avoid overflow. Periodically clean accumulated solids that have settled out during processing. (See Cleaning Procedure). Remove and clean the basket strainer monthly or as needed. If unit will be idle for more than a single day, drain the unit completely to avoid bacterial growth in the stored fluid. ERIEZ HydroFlow Coalescers 15

16 Cleaning Procedure Initially, inspect unit weekly to determine how quickly solids accumulate in your application. The frequency of cleaning your coalescer depends upon individual plant conditions. Re-examine the cleaning frequency of unit with any changes in the plant that could affect coolant condition or coalescer operation. 1. Shut Down Shut off pump to stop feed to unit. Close all operating valves. Disconnect the utilities. 2. Drain Fluid Slowly open the drain valve. Collect any sediment in a container for disposal. Position another container under the drain valve and empty the fluid from the unit. Reuse the drained coolant only if it is not contaminated with bacteria or has not become rancid. Troubleshooting 3. Clean Tank Remove the media packs from the unit by removing the weighted bracket that holds the media packs and lifting out the packs. Clean media packs by washing with a pressure washer, or simply running through a parts washer. Thoroughly clean the tank removing any accumulated oil or solids from the tank walls and bottom. Check oil removal pipe for solids build up. Flush if needed. Dispose of cleaning fluid properly. 4. Reassemble Close the drain valve. Reinstall the media packs. Check all hose connections, fittings and valves for leaks. Tighten as required. Re-prime the coalescer with new fluid or with the old fluid if in good condition. Follow Start-up and Operating Procedure. Adjust unit for proper oil removal. Maintenance Refer to the Owner s Manual for maintenance of the transfer pump. A periodic check of the units overall condition is recommended. Problem Possible Cause Solution 1. Tramp oil in clean effluent. 2. Coolant in tramp oil effluent. 3. No oil being removed. 4. Unit overflowing. 5. No flow through unit. a. Sudden increase in amount of tramp oil in sump. b. Oil has become chemically emulsified. Oil removal pipe opening is set too close to the fluid level. No tramp oil in system. Outlet flow restricted. a. Check for oil leaks into sump. b. Contact your coolant supplier for sample analysis and corrective actions. Adjust pipe so slot is 1/8" - 3/16" above liquid level. Stop using unit until tramp oil is present. Check hose, clean or repair as needed. a. Basket strainer is plugged. a. Check basket strainer; clean screen b. Is coolant in a pit? b. Base mounted electric pump can only pull 10' total head. c. Pump is not working. c. Check electric pump for dirt. d. Check pump to see if it lost prime. e. Check air pump feed pressure (minimum pressure is 30 PSI) f. Check air pump, check balls, seats or diaphragms. Table 1 16

17 Air Powered Unit Parts List - Portable Coalescer Figure 1 Unit overview 17 ERIEZ HydroFlow Coalescers

18 Air Powered Unit Parts List - Portable Coalescer Item Number Part Number Quantity Required Part Description Filter Cube Lid Gasket 5 H Valve Ball 3/4" Pushlock Fitting Caster Rigid Caster Swivel Caster Swivel with Brake Strainer Discharge Hose for Tramp Oil Hose Fitting Pump Double Diaph Air 3/ Pipe PVC 1/4 15 H Valve Ball 1/2" Quick Disconnect Adapter Quick Disconnect Adapter Skimmer Hose Pump Hose Pushlock Elbow Fitting Hose Holder Regulator Air Pinch Clamp Quick Disconnect Adapter 26 H Valve Ball Fitting Barbed Corr. Hose, End of Skimmer Oil Removal Assembly 30 FJ IOM Hose Clamp Clamp T-Bolt Dixon STBC Suction Strainer Assembly Triangle Skimmer Assembly Hose Clamp Hose 1 1/4"ID TABLE 2 Air powered unit - PARTS list 18

19 Electric Powered Unit Parts List - Portable Coalescer figure 2 unit overview 19 ERIEZ HydroFlow Coalescers

20 Electric Powered Unit Parts List - Portable Coalescer Item Number Part Number Quantity Required Part Description Filter Cube Rubber Foam Adhesive Pipe Union 1/2 Orifice (Blank) Drain Pushlock Fitting Caster Rigid Caster Swivel Caster Swivel with Brake Hose 1 1/4"ID Hose Oil Discharge Oil Discharge Barb Fitting Pump Pipe Elbow PVC Male QD Adapter Vinyl Skimmer Hose Fitting Barbed Hose Clamp Pinch 19 H Drain Ball Valve Skimmer Hose Barb Fitting Corrugated Hose Oil Removal Assembly Coolant Discharge Clamp Suction Strainer Assembly Triangle Skimmer Assembly Pump Ball Valve On/Off Toggle Switch Pump Tubing Pump Tubing Tank Powercord Extension Strainer Poly T-Line 1/2" 39 H Valve Ball 3/4" Pipe PVC 1/4 TABLE 3 Electric Powered Unit - Parts List 20

21 3/8" Air Pump Foreword Flush and neutralize the pump to be certain all corrosive or hazardous materials are removed prior to any maintenance. This procedure should always be followed when performing maintenance, transporting used pumps or returning pumps for factory service. Maintenance Valve and O-Ring 1. Remove the nuts (3) and washers (4) from the bolts (23) in manifolds. Remove the manifolds (20), (11). Two of the four max pass valves and back-ups (13, 14) are located inside of the bottom of the outer chambers (16). Gently remove and inspect for excessive wear, pitting or other signs of degradation. Inspect manifold o-ring (12) as well and replace if necessary. 2. The other two max-pass valves are located inside of the bottom of the discharge manifold (20). Repeat the procedure for inspection of discharge valves, back-ups and o-rings. (Some pumps such as those built with PTFE have ball valves in place of the max pass valves. Repeat the procedure inspect valve seat (28), balls (29), ball cage (27) and o-ring (12)). 3. When re-assembling the max-pass pump, the sleeve (15) should be assembled into the valve cavity first, followed by the max-pass valve (13), the valve backup (14) and finally the o-ring (12). For pumps with balls valves, the cage (27) should be assembled into the valve cavity first, followed by the ball (29), valve seat (28), and finally the o-ring (12). Lightly tighten all external fasteners when assembling, torquing them to their requirements after pump is completely assembled. NOTE: When using pumps built with PTFE o-rings, always replace with new PTFE o-rings, since the original o-rings may not reseal the pump. Diaphragm 4. To inspect diaphragms, remove the nuts (7) from the carriage bolts (8) on the band clamps (16) surrounding the outer pump chambers (16). If replacement is necessary due to abrasion or rupture, unscrew the outer diaphragm plates (17). Only models that have PTFE elastomers will have both a PTFE overlay (18) that faces the outer pump chamber and an o-ring (25) on the air side of pump. (NOTE: Pumps that do not contain PTFE will not have o-ring (25) they are built with diaphragms (19) only.) 5. To inspect the diaphragm rod s lip seals, remove diaphragm rod and carefully pick out the lip seals from inside the intermediate (22). Replace if necessary. Be sure to reinsert the lip seals with open cup facing the inside of the pump. Make sure that the rod guide is facing the air valve assembly and slide the diaphragm rod back into intermediate. 6. Take one diaphragm and with the curved side of the inner diaphragm plate facing the diaphragm, assemble onto the outer diaphragm plate stud. Screw the assembly into the end of the diaphragm rod. Repeat for the other side. Torque the outer diaphragm plates to requirements. 7. Position outer diaphragm chambers onto the intermediate, making sure that the witness line of the intermediate matches with the parting line of the chamber. 8. When positioning band clamps, use soapy water or a compatible lubricating spray on the inside of the band clamps to aid assembly. Tap with a mallet on the outside of the clamp to help position it while tightening the fasteners. The band clamp fasteners are stainless steel. To prevent galling, apply an anti-seize compound to the thread. Tighten to final torque requirements. 9. Position the manifolds, making sure of their orientation in relation to the air valve for your application. Also, make sure that the manifold o-rings do not shift from their grooves during reassembly. Tighten all external fasteners to final torque requirements after the pump is completely assembled. ERIEZ HydroFlow Coalescers 21

22 Inspection - 3 /8" Air Pump Air Valve Assembly CAUTION Only one side of the mechanism has a hard-stop. Shifting the mechanism past its operating position can cause the spring to pop free and internal components to come loose. Use caution when shifting the mechanism manually. 10. If there has been a diaphragm rupture and fluid has entered the air side of the pump, the complete air system should be inspected. Remove the air valve assembly (2) by unscrewing the six long hex-head air valve assembly screws (9). Figure Clean or replace the air valve assembly if there is excessive wear, dirt build-up or chemical attack. Inspect for proper shifting of the spring mechanism by manually pushing the metal spring retainer from one side to the other. 12. To reinstall the air valve, first shift the spring mechanism to the side with the hard-stop. Next, prop the spring retainer into a more neutral position by inserting a 7/64" or 3mm hex key as shown between the hard-stop and the spring retainer. 13. With the rod guide (1) positioned such that the opened end is facing the air valve assembly opening, slide the air valve assembly in place so that the forks slide into the rod guide. Once the fork of the spring retainer is in the rod guide, pull the hex key free and push the air valve assembly fully into place. Finally, reinsert and tighten the air valve assembly screws to the torque listed on the specs sheet. Figure 2 Fastener Torque Requirements NOTE: When reassembling, loosely tighten all external fasteners adjusting and aligning. Then gradually, in an alternating fashion, tighten to the torque requirements listed below. Air valve assembly screws-12 in-lbs (1.35 NM) Band clamps-13.3 ft-lbs (18.8 NM) Manifold bolts-10 in-lbs (1.13 NM) Outer diaphragm plates-40 in-lbs (4.5 NM) U.S. Patent Number Figure 3 22

23 Specifications - 3 /8" Air Pump Dimensions Dimensions in inches and (mm). NOTE: Air inlet is on the side with stainless steel insert. The air valve assembly is on the opposite side of the pump. figure 4 typical INSTALLATIon Figure 5 Capacity Max temp Max air pressure Min air pressure Dry lift Weight Max solids Air supply Fluid inlet/ discharge Adjustable 0-9 GPM (34.0 LPM) PVDF models F (93 C) Other models F (66 C) 120 psi (8.2 bar) 20 si (1.3 bar) Models w/ptfe balls - 10' (3m) Models w/max-pass valves - 17' (5.2m) PVDF models - 5 lbs (2.3 kg) Other models lbs (1.7 kg) Models w/max-pass valves - 1/4" (6.4m) Inlet - 1/4" NPS female (BSP or NPT compatible) Outlet - 3/8" NPS female (BSP or NPT compatible) 3/8" NPS female (BPS or NPT compatible) TABLE 1 Figure 6 TABLE 2 Performance curve (based on water-flooded suction) ERIEZ HydroFlow Coalescers 23

24 Parts List - 3 /8" Air Pump FIGURE 7 3/8" SPECIALTy performance plastic - unit overview 24

25 Parts List - 3 /8" Air Pump Item Number Part Number Part Description Table 3 3/8" SPECIALTy performance plastic - Parts list ERIEZ HydroFlow Coalescers 25 Qty Per Pump Models Material Rod guide 1 All Acetal Air valve assembly 1 All Various Hex nut (1/4" x 20) 4 All SS Flat washer 8 All SS Diaphragm rod 1 All SS Clamp (complete with fasteners) 2 All SS Hex nut (5/16" x 18) 4 All SS Carriage bolt (5/16" x 1-1/2") 4 All SS #8 x 1-3/4" Phillips pan 6 All SS Pipe plug, 3/8" NPT 2 Suction manifold 1 O-ring, check valve 4 Max-Pass valve 4 Max-Pass valve backup 4 Max-Pass sleeve 4 Outer chamber 2 Outer diaphragm plate Diaphragm Diaphragm 2 Discharge manifold 1 PB, PT, PE, PV CB, CT, CV KT, KE, KV PB, PT, PE, PV CB, CT, CV KT, KE, KV PB, CB PT, CT, KT PE, KE PV, CV, KV PB, CB PE, KE PV, CV, KV PB, PE, PV CB, CV KE, KV PB, PE, PV CB, CV KE, KV PB, PT, PE, PV CB, CT, CV KT, KE, KV PB, PT, PE, PV CB, CT, CV KT, KE, KV PT, CT, KT PV, CV, KV PB, CB, KB PE, KE PB, PT, PE, PV CB, CT, CV KT, KE, KV Polypro Nylon PVDF Polypro Cond. Nylon PVDF Nitrile PTFE EPDM Viton Geolast EPDM Viton Polypro Cond.Nylon PVDF Polypro Nylon PVDF Polypro Cond.Nylon PVDF Polypro Cond.Nylon PVDF PTFE Geolast Santoprene Polypro Cond. Nylon PVDF Inner diaphragm plate 2 All PS Intermediate 1 All Polypro Cap screw 4 All SS

26 Parts List - 3 /8" Air Pump, cont. Item Number Part Number Part Description Qty Per Pump Models Material Muffler 1 All Special O-ring, diaphragm 2 PT, CT, KT PV, CV, KV Nitrile Lip seal 2 All Nitrile Ball cage Check balls are standard in PT, KT, and CT pumps optional for other pumps Valve seat Check balls are standard in PT, KT, and CT pumps optional for other pumps Ball Check balls are standard in PT, KT, and CT pumps optional for other pumps Repair Kits - Wet End Models CT, KT & PT include items 12, 18, 25, 28 & 29 Models PV, CV & KV include items 12, 13, 14, 19 & 25 Models PB, BC, PE & KE include items 12, 13, 14 & 19 To order a wet end repair kit, add KIT to the pump model. e.g. PB-038 KIT NOTES: 1. SS = Stainless Steel, PS = Plated Steel 4 PT, CT, KT 4 PT, CT, KT Polypro Cond. Nylon PVDF Polypro SS PVDF 4 PT, CT, KT PTFE 2. Stock models (except PT, KT and CT models) are built with Max-Pass Valves and use items 13, 14, and PT, KT and CT pumps are not built with Max-Pass valves. These pumps have a stock Check Ball configuration. 26

27 Self-Priming Electric Pump Description These self-priming (to 15' lift) (to 10' lift on aluminum models) are designed for general purpose liquid transfer. Pumps include a semi-open clog resistant impeller. Handle liquids from 40 to 180 F (4 to 82 C) with Buna N seals and 40 to 200 F (4 to 93 C) with Viton seals. Some units will handle liquid with up to 1.65 specific gravity. For use with non-flammable, non-abrasive liquids compatible with pump component materials. Pumps Motorized units are direct coupled to a 3450 RPM motor. Single phase pump motors have automatic reset thermal protection. All models are manual mode and require field wiring; no controls are supplied. Check motor wiring before putting unit into operation (see motor nameplate for specific wiring diagram). Units Shipped Without Motor Some models are not equipped with motors. They are suitable for mounting to 3450 RPM, NEMA 56J face threaded shaft motors with counterclockwise rotation (looking at motor shaft). To find available horsepower of motor, multiply rated horsepower by service factor. This number must be equal to or greater than that required by pump. Assembly Motor (For units shipped without motor only) 1. If any parts are missing or damaged, do not attempt to assemble or operate pump until replacement parts are obtained and properly installed. 2. Verify that motor conforms to ALL standards specified in Description. 3. Place motor in vertical position with shaft end up. Set adapter (Ref. No. 4) on top of motor. 4. See Shaft Seal Replacement and follow steps to complete assembly. Maintenance WARNING Make certain that the power source is disconnected before attempting to service or disassembly any components! If the power disconnect is out of sight, lock it in the open position and tag to prevent application of power. Mechanical Seal Replacement Refer to Figures 1, 2 and 3. IMPORTANT: Always replace both the seal seat (Ref. No. 5) and the seal head (Ref. No. 6) to insure proper mating of mechanical seal components! figure 1 Mechanical Seal figure 2 Models 2856, 2857, 285A, 285M, 285B, 285C, 285D, 285J, 285K, 285P ERIEZ HydroFlow Coalescers 27

28 Self-Priming Electric Pump, cont. NOTE: It is not necessary to remove piping from pump casing. The motor and impeller assembly are removed from back of casing. 1. Unthread cap screws (Ref. No. 3) and remove pump casing (Ref. No. 10) from adapter (Ref. No. 4). 2. The motor used with this pump is a 56J frame. It has a threaded shaft; impeller is screwed directly onto shaft. To unscrew the impeller (Ref. No. 9), turn counterclockwise (CCW) facing impeller. NOTE: A screwdriver slot or two flats for use with an open end 7/16" wrench are provided at the rear of the motor shaft (remove bearing cap for access). To hold the motor shaft from turning, either insert a large screwdriver blade into the slot or usw a 7/16" wrench across the flats. Before removing impeller, remove impeller nut (Ref. No. 13) and impeller seal washer (Ref. No. 14) (where applicable). 3. Remove the adapter from the motor mounting face. The seal head (Ref. No. 6) and impeller shims (Ref. No. 8) will come loose at this time. IMPORTANT: Retain impeller shims for use when reassembling unit. 4. Push seal seat (Ref. No. 5) from the adapter recess with a screwdriver. 5. Clean the adapter recess before inserting a new seal seat. 6. Carefully wipe the ceramic surface of the new seal seat with a clean cloth. 7. Wet the rubber portion of he seal seat with a light coating of soapy water. 8. Press the new seal seat squarely into the cavity in the adapter. If the seal seat does not press squarely into the cavity, it can be adjusted into place by pushing on it with a piece of cardboard between the pipe and seal seat to avoid scratching the seal seat. (This is a lapped surface and must be handled very carefully). 9. After the seal seat is in place, insure that it is clean and has not been marred. 10. Using a clean cloth, wipe the shaft and make certain that it is perfectly clean. 11. Secure the adapter (Ref. No. 4) on the motor mounting face. Carefully guide motor shaft through the seal seat. 12. Apply a light coating of soapy water to the inside rubber portion of seal head (Ref. No. 6) and slide onto the shaft (with the sealing face first) so that the rubber portion is just up over the shaft shoulder. 13. Replace any impeller shims which may have been removed in disassembly (See Shim Adjustment ). 14. Screw the impeller (Ref. No. 9) back in place, tightening until it is against the shaft shoulder. NOTE: After impeller clearance has been set (See Shim Adjustment ), place a new impeller seal washer onto exposed shaft. Screw impeller nut onto shaft and tighten (where applicable). 15. Remount the pump casing (Ref. No. 10) on the adapter (Ref. No. 4). (See Shim Adjustment if motor or impeller was replaced). IMPORTANT: Always inspect the O-ring gasket (Ref. No. 7) for cracks or cuts when unit is disassembled; replace if damaged. Shim Adjustment When installing a replacement impeller (Ref. No. 9) or motor (Ref. No. 1), it may be necessary to adjust the number of shims (Ref. No. 8) to insure proper running clearance between the impeller and the casing. Proceed as follows: NOTE: A proper running clearance is less than For impeller replacement, add one (1) shim in addition to the one (1) removed originally. 2. For motor replacement, add two (2) shims in addition to the shims removed during disassembly. 3. Reassemble the pump using Mechanical Seal Replacement for reference. IMPORTANT: Insure that the casing is snugly in place and check the shaft to make sure it is turning freely (use the screwdriver slot in the motor to turn the shaft). If it turns freely, check to inure that the casing cover and casing are fitted metal to metal where they meet on the outside. If they are not metal to metal, tighten the fasteners (Ref. No. 3) and recheck the shaft for free turning. Tighten carefully turning the shaft while tightening so that the motor bearings are not damaged in the event that too many shims were installed. If the shaft seizes before fasteners are completely tight, disassemble the pump and remove one (1) shim and repeat reassembly. 28

29 Parts List - Electric Pump Item Number 1 Part Descr & 285F & 285G & 285H-95 Model Numbers & 285J & 285K & 285E M-95 & 285P-95 Motor (ODP) Motor (TEFC) Fastener * * * * * * * 4 4 Adapter & 6 7 Shaft seal assy. (Buna N) Shaft seal assy (Viton) O-ring (Buna N) O-ring (Viton) Shim package (1 of ea.) 0.010" " 0.030" 9 Impeller Casing /2" NPT Drain plug * * * * * * * 1 12 Fastener * * * * * * * 4 13 Impeller nut Impeller seal washer (*) Standard hardware item, available locally (-) Not applicable ( ) Not shown Figure 3 Qty 29 ERIEZ HydroFlow Coalescers

30 Parts List - Electric Pump, cont. Item Number 1 Part Description Model Number & 285F-95 Motor (ODP) Motor (TEFC) Slinger washer Handle Fastener * 4 5 Adapter & Shaft seal assy. (Buna N) Shaft seal assy. (Viton) optional O-ring (Buna N) O-ring (Viton) optional Shim package (1 of ea.) 0.010", 0.020", 0.030" Qty Impeller Casing /2" NPT Drain plug * 1 13 Fastener * 4 14 Foot Impeller nut * 1 16 Impeller seal washer * 1 (*) Standard hardware item, available locally (-) Not applicable ( ) Not shown Figure 4 30

31 Portable Coalescer Jr Installation Choosing the Location Locate the coalescer as near to the intended point of use as possible. Avoid high traffic or forklift path areas to decrease possible bumping or damage to the coalescer. For maximum performance, place the coalescer in a level location capable of supporting the flooded, operating weight of the unit, allowing access for maintenance and tramp oil container. Installing the Unit Place the unit in the chosen location. Provide an oil collection container and place near the tramp oil discharge of the coalescer. Initial Assembly 1. Remove top of coalescer to access those parts packed inside the unit. 2. Replace cover on top of coalescer. Assembly 1. Close drain valve on bottom of unit, open tramp oil discharge valve. 2. Connect 3/4" clean fluid discharge hose to clean fluid outlet using pipe dope or Teflon tape. 3. Place the discharge hose to the machine sump, adjust the height of the clean fluid discharge hose as necessary to ensure unimpeded gravity flow back to the coolant sump, use the supplied magnetic hose holder to keep the hose in place. Do not allow the end of the hose to be submerged in the fluid. Start-Up & Operating Procedure 1. Check for proper utility connections and installation of all components. See assembly procedures and schematic. 2. Make sure the tank is level. Use the adjustable leveling legs or casters. 3. Prime the coalescer by filling with fresh, clean fluid to a level just below the clean fluid outlet. The Coalescer tank holds approximately 13 gallons. 4. Measure depth of sump. Before placing skimmer assembly into the sump, adjust the skimmer height so that the skimmer base is approximately 1-1/4" below the coolant level in the sump. Note 1: If the sump depth is less than 5", modification will need to be made to the skimmer. The skimmer must be trimmed so that the base and the float are short enough to fit the sump. A band saw, cut off saw or hacksaw can be used for this purpose. The length to which to trim the parts is explained in Table 1. Note 2: Once the skimmer height is set as described, the skimmer will maintain operation even with a sump level fluctuation of plus or minus 1-1/4". Sump Level 5-1/4" or greater Trim Amount Skimmer Height After Trim None 4-5/8" Sump Level Range of Trimmed Skimmer +2-1/4" from initial level 4" 1-1/4" 3-3/8" +1 from initial level 3" 2-1/4" 2-3/8" 0" from initial level 2-3/4" 2-1/2" 1-7/8" 0" from initial level Less than 2-3/4" Cannot do N/A N/A Table 1 4. Connect the dirty fluid transfer hose from the skimmer to the inlet of the basket strainer using the supplied clamp. 5. Attach a shop compressed air line to the air pressure regulator/filter on unit. ERIEZ HydroFlow Coalescers 31

32 5. Make sure filter screen is in skimmer base. 6. Set skimmer assembly into sump in an area where tramp oil tends to accumulate, or at an area of convenience. The base will sit on the sump bottom keeping the skimmer assembly upright. It is best to sit the skimmer as low as possible in the sump with the upper set screw installed so the upper portion of the float will still stay within the lower portion of the skimmer base. This allows the upper portion to bob up and down a small amount, which help keep the skimmer clean of solids. 7. Turn the unit on by turning on the air supply and adjusting the air pressure to PSI. The pump will self-prime to 10'. Once the pump has been turned on, it will take a few moments for dirty coolant to start to enter the tank. The coolant will likely have air mixed with it, which will bubble in the coalescer tank. This is normal and helps push the tramp oils towards the tramp oil outlet. 8. Allow the unit to begin collecting tramp oil. Adjust the tramp oil removal pipe elbow so that the opening is 1/16"-1/8" above the fluid level in the tank. This will allow a layer of oil to build up on the fluid, which will dewater as it rises before flowing into the oil removal pipe and out of the unit. After the unit has run for a while, this oil removal pipe elbow can be adjusted again to provide wetter or drier oil as desired. NOTE: IT IS NORMAL AND DESIRABLE FOR A LAYER OF OIL TO BE ON TOP OF THE COOLANT IN THE COALESCER TANK. The thicker the layer of oil, the less coolant will be in the oil when it finally is discharged from the coalescer. 9. If the unit will be portable and will be moved from machine to machine, it must be operated long enough to remove the accumulated free tramp oils. A good rule of thumb is to take the amount of coolant in the sump, divide that amount by the flow rate of the Coalescer (1 GPM), and multiply that figure by 4 to 6 passes, to come up with an operating time. For example, a 50-gallon sump would need to circulate through a 1 GPM Coalescer for 4-6 passes or 200 to 300 minutes. The more tramp oils present, the longer the unit may have to run to get the free tramp oils out of the coolant. NOTE: THIS UNIT WILL ONLY REMOVE FREE TRAMP OILS THAT WILL FLOAT, IT WILL NOT REMOVE CHEMICALLY EMULSIFIED TRAMP OILS THAT DO NOT FLOAT. Operating Procedure Notes: After initial start up, periodically monitor the coalescer s operation. When not is use, close all valves. The waste oil collection container should be routinely emptied to avoid overflow. Periodically clean accumulated solids that have settled out during processing (see Cleaning Procedure). Remove and clean the basket strainer monthly or as needed. If unit will be idle for more than a single day, drain the unit completely to avoid bacterial growth in the stored fluid. 32

33 Cleaning Procedure: Initially, inspect unit weekly to determine how quickly solids accumulate in your application. The frequency of cleaning your COALESCER JR depends upon individual plant conditions. Re-examine the cleaning frequency of unit with any changes in the plant that could affect coolant condition or coalescer operation. 1. SHUT DOWN Shut off pump to stop feed to unit. Close all operating valves. Disconnect the utilities. 2. DRAIN FLUID Slowly open the drain valve Collect any sediment in a container for disposal. Position another container under the drain valve and empty the fluid from the unit Reuse the drained coolant only if it is not contaminated with bacteria or has not become rancid. 3. CLEAN TANK Remove the tramp oil discharge elbow and valve assembly. Remove the Media pack from the unit lifting it up by the wire tie end in the pack. Clean Media pack by washing with a pressure washer, or simply running through a parts washer. Thoroughly clean the tank removing any accumulated oil or solids from the tank walls and bottom. Check oil removal pipe for solids build up, flush if needed. Dispose of cleaning fluid properly. 4. REASSEMBLE Close the drain valve. Reinstall the Media pack, reinstall the tramp oil drain valve and elbow assembly, make sure there is a gasket on each side of the tank wall. Check all hose connections, fittings and valves for leaks. Tighten as required. Re-prime the coalescer with new fluid or with the old fluid if in good condition. Follow Start up and Operating Procedure; adjust unit for proper oil removal. ERIEZ HydroFlow Coalescers 33