Coffin-Ultra-sep 1000 CJ103 Manual

July 2008
Manual No. USMN1000-CJ103
INSTALLATION, OPERATION
AND MAINTENANCE MANUAL
BILGE WATER SEPARATOR
ULTRA-SEP™ MODEL US1000-CJ103
440-480V / 60 Hz / 3PH
120 VAC CONTROL
Coffin World Water Systems

Design & Manufacture of Water Treatment Systems
1732 McGaw Ave. Irvine, CA 92614 U.S.A.

WEB: cworldwater.com
TEL: (949) 222-5777
FAX: (949) 222-5770
WARRANTY
Coffin World Water Systems, LLC (CWWS) warrants the purchaser that each ULTRA-SEP®, Bilge water
Separator System, as delivered to the purchaser, shall be free from defects in material or workmanship
for a period of eighteen (18) months from date of delivery or twelve (12) months from date of
installation, whichever comes first.
All vessels and parts thereof that are claimed to be defective by the purchaser must be returned to an
authorized CWWS service depot, at the expense of the purchaser, for inspection prior to the allowance of
any credit or replacement.
This warranty does not apply to damage resulting from accident, neglect, or misuse. The foregoing
warranty is the only warranty extended by CWWS and is in lieu of all other warranties, express or
implied, or for fitness of a particular purpose.
TABLE OF CONTENTS
SECTION 1: INTRODUCTION ..................................................................................................................... Page
1.1 MANUAL DESCRIPTION............................................................................................................ 1-1
1.2 THEORY OF OPERATION ......................................................................................................... 1-2
SECTION 2: GENERAL DESCRIPTION
2.1 GENERAL SYSTEM DESCRIPTION......................................................................................... 2-1
2.2 PROCESS FLOW DESCRIPTION .............................................................................................. 2-1
2.3 SPECIFICATIONS ........................................................................................................................ 2-3
SECTION 3: INSTALLATION
3.1 UNPACKING ................................................................................................................................. 3-1
3.2 INSTALLATION............................................................................................................................ 3-1
3.2.1 SITE SELECTION AND PREPARATION .............................................................................. 3-1
3.2.2 PIPING CONNECTION ............................................................................................................. 3-1
3.3 ELECTRICAL REQUIREMENTS .............................................................................................. 3-3
SECTION 4: OPERATION INSTRUCTIONS
4.1 COMPONENT FUNCTIONAL DESCRIPTION........................................................................ 4-1
4.2 PRESTART UP .............................................................................................................................. 4-2
4.2.1 HELI-SEP FILL .......................................................................................................................... 4-3
4.2.2 SPIR-O-LATOR FILL ................................................................................................................ 4-3
4.3 INITIAL START-UP & OPERATION ........................................................................................ 4-3
4.3.1 NORMAL OPERATION (BELOW 15PPM) ........................................................................... 4-3
4.3.2 NORMAL OPERATION OIL DISCHARGE........................................................................... 4-3
4.3.3 NORMAL OPERATION (OVER 15 PPM) RECIRCULATION TO BILGE ....................... 4-4
4.4. ROUTINE SHUTDOWN PROCEDURES.................................................................................. 4-4
4.5 ALARMS......................................................................................................................................... 4-4
SECTION 5: MAINTENANCE PROCEDURES
5.1 HELI-SEP FLUSH & REMOVAL ............................................................................................... 5-1
5.2 SPIR-O-LATOR® FLUSH ............................................................................................................. 5-1
5.3 FLUSHING THE SMARTCELL (OIL CONTENT DETECTOR) ........................................... 5-2
5.4 FILTER BAG REPLACEMENT .................................................................................................. 5-3
5.5 SPIR-O-LATORS® CLEANING ................................................................................................... 5-4
5.5.1 PREPATATION FOR CLEANING .......................................................................................... 5-4
5.5.2 CLEANING PROCEDURES ..................................................................................................... 5-5
5.5.3 CLEANING DETERGENTS ...................................................................................................... 5-5
5.5.4 CHANGE OUT PROCEDURES (IF NEEDED CONSULT FACTORY FIRST) ................. 5-6
5.5.5 REDUCED RECOVERY ............................................................................................................ 5-5
5.6 SPIR-O-LATOR® PRESERVING ................................................................................................ 5-9
5.6.1 PREPARATION FOR PRESERVING ..................................................................................... 5-9
5.6.2 PRESERVING PROCEDURES ................................................................................................ 5-9
5.7 CLEANING THE OIL SENSING PROBE .................................................................................. 5-10
5.7 SEPARATOR SOLIDS & SLUDGE DUMP ............................................................................... 5-11
5.8 CLEANING THE SEPARATOR.................................................................................................. 5-12
SECTION 6: TROUBLE SHOOTING
6.1 TROUBLE SHOOTING GUIDE .................................................................................................. 6-1
SECTION 7: PARTS LIST
7.1 SPARE PARTS............................................................................................................................... 7-1
7.2 CONSUMABLE SUPPLIES ......................................................................................................... 7-1
APPENDICES
FIGURES ................................................................................................................................ Appendix ‘A’
SYSTEM MAJOR COMPONENTS .................................................................................... Appendix ‘B’
DRAWINGS ............................................................................................................................ Appendix ‘C’
CERTIFICATES .................................................................................................................... Appendix ‘D’

Section 1: Introduction
1.1 MANUAL DESCRIPTION
This instruction manual describes the function, operating procedures, maintenance and installation requirements for the
CWWS ULTRA-SEP® Bilge Water Separator.
NOTES, CAUTIONS, AND WARNINGS are included in the operating procedures. A NOTE indicates an operating
procedure or condition that is essential to highlight or which provides an explanation for a given procedure. A CAUTION
indicates an operating procedure or practice that, if not strictly observed, may result in damage to, or destruction of
equipment or degradation of the water quality. A WARNING indicates an operating procedure or practice that can result
in bodily injury or loss of life if not correctly followed. NOTES, CAUTIONS, and WARNINGS always precede the
paragraphs to which they apply. Under normal operating conditions, adherence to the procedures described in this manual
will assure trouble-free operation.
It is important that the operator of the ULTRA-SEP® System reads and fully understands this entire manual. By
understanding the functions and normal operation of each component in the system, the operator can diagnose and correct
operating problems as they develop. Please take the time to read this manual, study the process flow diagram, and
understand the system before attempting to install and operate the system.
SPIR-O-LATOR
HELI-SEP MEMBRANES
FILTER CONTROL
BOX &
MOTOR
CONTROL
CENTER
OIL CONTENT
DETECTOR
PROCESS
PUMP
FEED PUMP
1-1
Section 1: Introduction
1.2 THEORY OF OPERATION
The ULTRA-SEP® Bilge Water Separator is a dual stage bilge water separation system. The first stage utilizes a
system generated vacuum, differential specific gravity and high efficiency two stage coalescer for the removal of the
majority of free oil and dirt separation. The second stage uses a micron filtration for removal of trace solids and
small oil droplets followed by ultra-filtration to separate and remove emulsified oils, along with the remaining
minute solids and entrained air from bilge water. The system is designed for continuous and/or intermittent
operation. After the system has been started, it is capable of automatic operation.
The innovative design of the CWWS Bilge Water Separator eliminates the need for flocculants and
chemical additives to remove the emulsified oily bilge water.
Stage 1
Incoming bilge water passes through a basket strainer (customer provided) to remove oversized solid contaminants.
From there it is drawn into the first stage consisting of a well proven coalescing HELI-SEP® Oily Water Separator,
where the free oil droplets coalesce as they pass through the permanent matrix. This oil rises to the top of the vessel
and it is collected for discharge during the oil discharge cycle. The water is then drawn through a pack of oleophillic
polishing beads, which trap the remaining fine oil droplets. These oil droplets are washed out and discharged during
the oil discharge cycle.
Stage 2
Processed water from the HELI-SEP® is then directed through particulate filtration, which further reduces solids
contamination. This semi-treated water is then fed into the process pump; this pump increases the flow and pressure
to the optimum conditions for the SPIR-O-LATORS®. The Spir-O-Lators® are engineered to produce clean water in
compliance with MEPC 107 (49), and a reject stream, which is re-circulated back for re-processing.
The system has been designed to be installed as a single skid assembly or in separate modules to accommodate
various engine room layouts.
CWWS BILGE WATER SEPARATOR
OIL TO
RECOVERED
OIL TANK
MONITOR
HELISEP
FILTER
BILGE WATER SPIR-O-LATOR CLEAN

WITH WATER
EMULSION & FEED PROCESS [OVERBOARD
FREE OIL PUMP PUMP LESS THAN
15 PPM]
DRAIN RECIRCULATE
1-2
Section 2: General Description
2.1 GENERAL SYSTEM DESCRIPTION
The ULTRA-SEP® Bilge Water Separator is an ultra-filtration process designed for separating a wide variety of
chemically or mechanically emulsified bilge water solutions. At the heart of the system are the CWWS HELI-SEP®
and the CWWS SPIR-O-LATOR® (which are designed and developed specifically for bilge water and industrial
waste applications and are impervious to most chemicals). The ULTRA-SEP®’s major components are the HELI-
SEP®, Feed Pump, Bag Filter, Process Pump, the SPIR-O-LATORS® and must also include an approved MEPC 107
(49) Oil Content Detector. The system is also available with optional influent heater for enhanced cold water
operation. The ULTRA-SEP® is designed to eliminate the need for attended operation. The controls provide two
basic modes of operation; an run mode and a clean mode. The gauge displays provide operating pressures and visual
indicators of operating conditions. The ULTRA-SEP®' s components are all corrosion resistant for long service life
and are installed on one powder-coated structural steel skid which is arranged for ease of installation and servicing.
2.2 PROCESS FLOW DESCRIPTION

The bilge water to be processed is pulled from the bilge or holding tank by the Feed Pump. The water is pulled
through a customer supplied basket strainer to remove large solids. The influent then enters the separator near the
bottom of the solids sludge collecting chamber. Most of the free oil separates from the influent immediately due to
the difference in specific gravity and the reduced flow velocity inside the separator. The flow travels upward through
the separating media matrix. This path maximizes contact with the separating media to enhance coalescence of the
oil. The flow exits the top of the separating media matrix where the oil continues to flow upwards to the top of the
separator’s oil collecting chamber due to the difference in specific gravity. The influent less the majority of free oil is
then drawn downward by the Feed Pumps’ vacuum through the polishing pack. The polishing pack removes the
small oil droplets. When sufficient oil has been collected in the oil collecting chamber, the oil sensing probes located
in the top of the separator deactivate the Feed Pump and open the clean water inlet valve. Pressurized water, sea
water or fresh water, (warm water is recommended if available 37.8ºC (100ºF). maximum) enters from the bottom of
the separator and displaces the accumulated oil in the collection chamber top of the HELI-SEP® which is discharged
through the oil discharge line. After the accumulated oil has been discharged and the oil sensing probe is again
immersed in water, the separator returns to the separating mode. The semi cleaned influent less the majority of free
oils, but with some emulsified oils, exits the HELI-SEP® through the Feed Pump.
The Feed Pump pressurizes the influent for processing through the process Bag Filter before supplying the Process
Pump with a positive suction head. The Bag filter removes suspended solids and oil droplets of approximately 5
microns and larger from the flow.
This semi-cleaned influent is supplied to the Process Pump for processing by the CWWS SPIR-O-LATORS®. The
process pump increases the influent pressure and drives the emulsions across the surface of the SPIR-O-LATOR® at
a high velocity. Water, salts and detergents are forced through the SPIR-O-LATOR® by back pressure created by the
system and the systems operating pressure control valve while oils and other waste larger than or greater than twenty
thousandths (20,000) in molecular weight are rejected. The portion of the influent forced through the SPIR-O-
LATOR® is referred to as the processed water (clean water or permeate) while the remainder is referred to as the
concentrate or reject. The processed water is discharged from the system. This system is being constantly replenished
by the influent supplied by the Feed Pump. The concentrate with the rejected oils and waste is returned to inlet of the
Bag Filter, for de-oiling and polishing before being fed to the Process Pump inlet for reprocessing through the
SPIR-O-LATORS®. This reject reprocessing allows for a higher velocity flow rate across the SPIR-O-LATORS®
which maximizes the process water output by minimizing fouling because the higher velocity shears off the excess
oils and waste of the surface of the SPIR-O-LATORS®. The process flow rate is the combination of the process
water flow and the concentrate flow.
The ULTRA-SEP® is equipped with additional features and functions to maintain optimum operating conditions.
The process water, concentrate and concentrate bleed to bilge flows are factory set and can be manually checked for
verification. Liquid filled pressure gauges are provided and identified to help monitor operating conditions.
2-1
In summary, the processed water, the output of the ULTRA-SEP®, is equal to the systems emulsified influent minus
the small concentrate bleed outlet stream. The concentrated bleed is continuously discharged from the recirculation
line, where concentrated oils can be further coalesced in the bilge, or holding tank, or in the HELI-SEP® when being
reprocessed through the ULTRA-SEP®. This process allows the ULTRA-SEP® to produce one stream of processed
water that is less than 15 parts per million that can be discharged overboard per IMO Resolution MEPC.107 (49).
The system is equipped with a Certified MEPC.107 (49) oil content monitor, which continuously monitors the
processed water for oil content. If the oil content exceeds the alarm set point the water will automatically be re-
directed to re-circulate to the bilge.
2-2
2.3 SPECIFICATIONS
Type: ULTRA-SEP® system with a HELI-SEP® bilge water
separator, Bag Filter for solids, and SPIR-O-LATORS®
for enhanced waste/oil separation.
Model Number: US1000-CJ103
Capacity: 1 M3/H (4.4 GPM)
General Design Data:
Electrical Power Input: All standard voltages. Refer to Electrical Requirements

Consumption: 4.0 kW
Clean Water Supply Ranges: (Flow) 0.1 M3/h Min. 0.45 GPM Min.
(Pressure) 275-550 kPa 40-80 PSI
Temperature Ranges: (Influent) 1°C - 50°C 34°F - 122°F

(Ambient) 1°C - 50°C 34°F - 122°F
Design Data:
Influent: A solution of water contaminated with petroleum

products, soaps, and detergents.
Effluent: (Primary) Processed water, Clean Water < 20,000 molecular

weight
.
(Secondary) Waste oils and other compounds.
Operating Pressure Range: 345-690 kPa 50 - 100 PSI
Weights and Dimensional Data:
Weight-Dry: 390 kg 858 Pounds
Weight-Wet: 480 kg 1058 Pounds
Length: 1015 MM 40 Inches
Width: 1070 MM 42.25 Inches
Height: 1550 MM 61 Inches
2-3
Piping Connections:
Oily Water Inlet (From Bilge or Holding Tank): 25 MM 1”

Processed Water Outlet (To Overboard): 25 MM 1”
Recirculation (Bleed to Bilge): 25 MM 1”
Recirculation (Processed Water to Bilge): 25 MM 1”
Oil Discharge (To Slop Tank): 25 MM 1”
Clean Sea Water Inlet: 25 MM 1”
Process Filter Drain Outlet: 20 MM 3/4”
Separator Drain Outlet: 20 MM 3/4”
Control Valve Settings:
Operating Pressure Control Valve (GV2): 1.0
Product Flow Control Valve(GV3): 1.05
Concentrate Bleed Control Valve (GV4): 0.4
2-4
Section 3: Installation
3.1 UNPACKING
Carefully remove top and sides of the crating. Inspect the system for any damage that may have occurred during
shipment. Unbolt the system from the crate. Padding on fragile items should remain in place to protect fragile items
during rigging of the system into position. Once the system is securely installed, the padding on the fragile items can
be removed.
3.2 INSTALLATION
Installation in accordance with the recommendations that follow will ensure long and trouble-free operation from the
equipment. Refer to Appendix “C” for the Installation drawing for dimensional and orientation information, and to
the Piping & Instruments Drawing for piping arrangements.
3.2.1 SITE SELECTION AND PREPARATION
NOTE
Allow ample room for servicing units electrical controls, pump motor,
SPIR-O-LATORS® and other components. Reference the drawings in
Appendix “C” for required clearances.
CAUTION
BE SURE THAT THE BILGE HAS BEEN THOROUGHLY CLEANED
OF ALL DEBRIS, LIQUIDS AND CONTAMINANTS REMAINING
FROM THE SHIPS’ FABRICATION BEFORE START UP.
Securely install the system as level as possible with the interface connections positioned to permit the most direct
route to the piping connections. Eliminate as many 90 degree turns as possible. System should be fully supported and
bolted down through holes provided in skid.
3.2.2 PIPING CONNECTIONS

NOTE
The suction source should be located so as to lift the fluid the shortest
distance possible and not to exceed 7 Meters [23 Feet] vertical. Do not draw
suction from a point less than 300 Millimeters [12 inches] above the sludge
level in bottom of the bilge or holding tank. Important ascertain that all
suction lines are air-tight. THIS IS IMPORTANT: Lines that leak air will
cause erratic performance during start up, such as frequent Oil Discharges as
the OSP on the Heli-Sep will think the air is oil. Keep the horizontal run
under 30 Meters [100 Feet] and it must be the same or larger than the
ULTRA-SEP interface.
CAUTION
INSTALL A FOOT VALVE (USER SUPPLIED) AT THE SUMP OR
HOLDING TANK END OF THE SYSTEM’S INLET SUCTION LINE.
1. Connect a line to the Oily Water Inlet from the (user supplied) sump or holding tank which is to supply the
oily water to the ULTRA-SEP® for processing. Ascertain that a foot valve (user supplied) is installed at the
(user supplied) sump or holding tank end of the line. A bleed port should be provided as close to the foot
valve end of the suction line as possible for priming purposes. The source for the inlet should be in an area
that will provide the best quality solution possible to the system. Ensure that piping is capable of supplying
the inlet to the system as required by the specifications.
3-1
NOTE
The processed water vertical lift to overboard can not exceed 20 Meters [65 feet]. If
a higher head is required an optional pump maybe required.
2. Connect the Processed Water Outlet to the discharge line going overboard.
3. Connect a line to both Recirculation’s to return the re-circulates preferably to the bilge for complete
reprocessing, or to a holding tank which is acceptable, but connecting these lines right back to the system’s
Oily Water Inlet is un-acceptable and must be avoided.
4. Connect the Clean Water Inlet to a clean pressurized water source (Sea or Fresh) for flushing the HELI-
SEP®, and for flushing or filling the ULTRA-SEP®. PRESSURE MUST NOT BE LESS THAN 1.38 bar
[20 PSI] or exceed 5.5 bar [80 PSI].
5. Connect a line to the Oil Discharge to discharge the Separator’s accumulated oil to a slop tank for waste
disposal or storage.
NOTE
For Gravity Drain, the drain lines must be higher than the (user supplied)
sump or bilge into which they are to discharge.
6. Connect lines to the Drains to gravity drain the system back to the (user supplied) sump or bilge.
3-2
3.3 ELECTRICAL REQUIREMENTS
Refer to Appendix "C" for the appropriate Electrical Drawing for the system being installed. The electrical power
requirements are given on the serial plate.
WARNING
ELECTRICAL INSTALLATION AND CONNECTION TO THE MAIN
POWER SOURCE MUST BE PERFORMED BY A FULLY QUALIFIED
ELECTRICIAN IN ACCORDANCE WITH THE PERTINENT CODES
AND REGULATIONS. TURN OFF FACILITY POWER BEFORE
MAKING ANY ELECTRICAL CONNECTIONS. SYSTEM MUST BE
GROUNDED IN ACCORDANCE WITH APPLICABLE ELECTRICAL
CODES. FAILING TO FOLLOW THE PERTINENT ELECTRICAL
SAFETY REGULATIONS CAN CAUSE THE DAMAGE OF THE
SYSTEM, PERSONAL INJURY OR DEATH.
CAUTION
INSTALL A SUITABLE CIRCUIT BREAKER (USER SUPPLIED) TO
MAIN LINE CONNECTED TO THE SYSTEM. SEE WIRING DIAGRAM
DRAWING IN APPENDIX “C”.
1. Connect incoming power for the system to the main Power Disconnect Switch located in the Motor Control
Center (MCC).
CAUTION
SYSTEM SHOULD BE VENTED AND FULL OF WATER PRIOR TO
STARTUP OR ROTATION CHECK.
CAUTION
CHECK ROTATION OF SYSTEM'S PUMP/MOTORS PRIOR TO
INITIAL START-UP.
2. Prior to start-up, ascertain that the system pump/motors are rotating in the proper direction as indicated by
the rotation arrow located on each pump/motor. The information below is typical but follow the arrows.
FEED PUMP (counter clockwise) PROCESS PUMP (clockwise)
3-3
Section 4: Operating Instructions
4.1 COMPONENT FUNCTIONAL DESCRIPTION
This table describes the function of the components.
ITEM COMPONENT NAME FUNCTION

1. Skid Base Provides a rigid foundation for mounting system components.
2. HELI-SEP® Separator Vessel Vessel that provides the initial bulk separation of the free oils
and senses when enough oil has accumulated to be discharge
automatically to a customer supplied oil slop tank. The vessel
contains a separating media matrix, a polishing pack and the
oil sensing probe (OSP)
3. Oil Content Detector, Monitors the processed water for oil content and controls the
Bilge Alarm - OCD two processed water outlet valves: Factory Set 15 PPM.
Overboard - oil content less than 15 PPM.
Re-circulate - oil content 15 PPM and above.
4. Feed Pump (PU1) Creates a suction on the HELI-SEP® pulling in the bilge water
from Bilge or holding tank. Pressurizing the feed to the process
Bag Filter and to the Process Pump suction.
5. Process Pump (PU2) Boosts the pressure and flow for proper processing through the
SPIR-O-LATORS®.
6. Control Panel Contains the switches and indicators for activating, monitoring,
operating and stopping the system.
7. SPIR-O-LATOR® Rack Pressure housing(s) with mounting brackets for installation of
the spiral wound SPIR-O-LATORS®.
8. Low Product Pressure (PSL2) Activates warning/alarm when low SPIR-O-LATORS®
Product pressure is detected and advises cleaning is required
9. High SPIR-O-LATOR® Turns off when influent is to hot to process or during the clean
Temperature (TSH1) circulation cycle a SPIR-O-LATOR® high temperature is
detected
10. Process Filter Housing (FIL1) Contain replaceable filter, the final polishing filter for the
influent before being processed by SPIR-O-LATOR®.
Lights
11. Power Illuminates when the power switch is in on position.
12. Feed Pump (PU1) Illuminates when the Feed Pump PU1 is on.
13. Process Pump (PU2) Illuminates when the Process Pump PU2 is on.
14. Water Discharge Illuminates when SV1 Overboard solenoid is open.
15. Oil Discharge Illuminates when the OSP (oil sensing Probe) senses and SV4
opens and puts he Heli-Sep® in an Oil Discharge Mode.
IMPORTANT: the same thing will happen if it sees air
instead of oil from leaky inlet lines or strainers from the bilge.
4-1
16. Alarm • Illuminates when temperatures is over limit (TSH1).
• Illuminates when low pressure switch (PSL2) is sensed.
• Illuminates when Feed Pump (PU1) or Process Pump (PU2)
motor contactor is tripped.
• Illuminates when Oil Sensing Probe (OSP) is sensed
• Blinks when cleaning mode is complete.
ITEM COMPONENT NAME FUNCTION

Switches
17. Power switch - Controls system power to all electrical control components.
ON/OFF
18. System switch – Three position switch. Put in “RUN” for normal operation,
CLEAN/OFF/RUN “CLEAN” for cleaning and “OFF” for maintenance or shut
down.
19. Flush switch – Three position momentary switch. Flip it to “OWS” or “PIR-
OWS/OFF/SPIR-O-LATOR O-LATOR” and a three minutes HELI-SEP® or “SPIR-O-
LATOR” flush cycle will start. If it is flipped to “OWS” or
“SPIR-O-LATOR” again during the three minutes cycle the
cycle will stop.
20. Alarm switch – Momentary switch, resets all alarm condition.
RESET
4-2
Operating chart (at a glance) valve, light, pump and switch location for each function. This chart should also be
referenced when reading all the following:
PRE START UP NORMAL OPERATION MAINTENANCE
4.3.3
OPERATING CHART OVER 15 5.1 5.2 5.5.1 & 5.5.2 5.3 5.4
4.2.1 4.2.2 SPIR- 4.3.2
SECTION 4.3.1 PPM HELI-SEP SPIR-O- CLEANING SMART BAG
HELI-SEP O-LATOR OIL
OPERATING RECIRCULA FLUSH & LATOR SPIR-O- CELL FILTER
FILL FILL DISCHARGE
TION TO SLUDGE FLUSH LATOR FLUSH CLEAN
BILGE
BV1
BV2
BV3
/ / /
MANUAL VALVE
BV4
BV5
BV7
BV8 /
BV10 /
GV2
GV3 LEAVE ALL AT FACTORY SETTINGS
GV4
SV1 * * * * * * * * *
AUTOMATIC
* * * * * * * *
VALVE
SV2 *
SV3
SV4 / /
FEED PUMP
OFF ON ON OFF ON OFF ON ON/OFF OFF OFF
PUMP
(PU1)
PROCESS
PUMP (PU2) OFF ON ON ON ON OFF ON ON OFF OFF
POWER ON ON ON ON ON ON ON ON ON OFF
SYSTEM
OFF OFF RUN RUN RUN RUN RUN RUN RUN OFF
SWITCHES
CLEAN /
OFF / RUN
FLUSH
OWS / OFF / SPIR-O- SPIR-O-
OWS OFF OFF OFF OWS OFF OFF OFF
SPIR-O- LATOR LATOR
LATOR
POWER ON ON ON ON ON ON ON ON ON OFF
FEED PUMP OFF ON ON OFF ON OFF ON ON OFF OFF
PROCESS
PUMP OFF ON ON ON ON OFF ON ON OFF OFF
LIGHTS
WATER
DISCHARG ON ON ON ON ON ON ON ON ON OFF
E
OIL
DISCHARG ON ON ON ON ON ON ON ON ON OFF
E
ALARM OFF OFF OFF OFF OFF OFF OFF OFF OFF OFF
* : CONTROLLED BY SMART CELL ONLY. IF OVER 15 PPM SV2 OPEN SV1 CLOSED. IF BELOW 15 PPM SV1 OPEN / SV2
CLOSED
/ : OPEN THEN CLOSE
/ : CLOSE THEN OPEN
4-3
4.2 PRE-START UP
4.2.1 HELI-SEP FILL
1. Put all manual BV valves in the position shown on chart BV1, BV4 & BV8 are all open.
2. Turn Power Switch On.
3. Put system Switch in Off position.
4. Put Flush Switch on OWS position.
5. When air is gone and the OSP (Oil Sensing Probe) sees water, and when water bleeds out of BV2 & BV8
then close those valves.
6. Note, this will fill in 3 minute cycles only. If all the air is not gone out and the OSP (Oil Sensing Probe)
does not yet see water then put the Flush Switch in Off position and then back to OWS to repeat another
three minutes and continues until all the air is removed.
4.2.2 SPIR-O-LATOR® FILL
1. Put all manual BV valves in the position shown on the chart. BV1, BV4 & BV10 are open, all
others closed.
2. Turn Power Switch On, System Switch in Off position and Flush Switch in Spir-O-Lator® position.
3. When air is gone and water bleeds out of BV4 and BV10 then close those valves.
4. This cycle run in 3 minute increments. If all the air does not bleed out repeat cycle by putting Flush
Switch to Off the back to Spir-O-Lator® until all the air is removed.
4.3 INITIAL START-UP & OPERATION

4.3.1 NORMAL OPERATION (BELOW 15 PPM)
1. Put all manual valves in position shown on the chart BV1 is open all others are closed.
2. Turn on Power Switch, put System Switch in Run position, put Flush Switch in Off Position.
3. The system will begin producing clean water and discharging it over board.
4. Power, Feed Pump & Process Pump lights will be illuminated. The Water Discharge light will also be
illuminated if SV1 is open and the system is discharging over board.
5. Both Pump PU1 and PU2 are running.
6. All solenoid and ball valves should be in the positions shown on P&ID and also shown in the operating
chart.
4.3.2 NORMAL OPERATION OIL DISCHARGE
When Oil Sensing Probe (OSP) sees enough oil to discharge it will automatically do the following:
4-4
1. Shut off Feed Pump PU1.
2. Open SV4.
3. Close SV1 & SV3.
4. The Oil Discharge light will illuminate.
5. If this discharge runs over 5 minutes before Oil Sensing Probe (OSP) sees water the system will shut
down and illuminate the Alarm light.
6. If the Oil Sensing Probe (OSP) signals the need for 3 consecutive oil discharges within 15 minutes the
system will also shut down and illuminate the Alarm light. Note, this typically mean one of two things:
a. There is excessive oil in the bilge or
b. There is an air leak feeding the system and the Oil Sensing Probe (OSP) sees air and thinks its
water
7. When all oil is discharged to the slop tank and oil sensing probe sees clean water it will revert back to
normal operation.
8. Note, Process Pump (PU2) will continue running during this cycle.
4.3.3 NORMAL OPERATION (OVER 15 PPM) RECIRCULATION TO BILGE
When the “Oil Content Detector” (OCD) reads over 15 PPM the following happens automatically
to prevent oil from being discharge over board.
1. SV1 closes & SV2 opens.
2. The water discharge light will go out.
3. Everything else remains the same as in normal operation.
4.4 ROUTINE SHUTDOWN PROCEDURES

Prior to any system shutdown, it is recommended that the operator observes and compares the performance of the
system with the normal operation specifications and initial operation readings recorded in this manual. Doing so will
enable the operator to identify and take corrective actions to ensure a properly functioning system at all times.
CAUTION
THE SPIR-O-LATORS® SHOULD REMAIN MOIST AT ALL TIMES.

IF THE SPIR-O-LATORS® ARE ALLOWED TO TOTALLY DRY
OUT, THEY MAY BE RUINED. BY FOLLOWING THE SPIR-O-
LATORS® FLUSH PROCEDURE SEE 5.2 IN MAINTENANCE
SECTION 5. THIS WILL ASSURE THEY WILL SIT IN CLEAN
WATER DURING A SHUT DOWN. FOR PROLONGED SHUT
DOWN SEE SECTION 5.6.
4-5
4.5 ALARMS
The following chart lists the alarms, activating device, and possible cause of the alarm. A shutdown alarm must be
reset by the Alarm Reset Switch before the Ultra-Sep can be restarted.
ALARM DISPLAY ACTIVATING DEVICE POSSIBLE CAUSE

(Type of Alarm)
LOW PRODUCT PSL2 1. Improperly set flow control valves
PRESSURE Activated when the Product Pressure GV2, GV3 or GV4.
Alarm Light On drops below the PSL2 set point 2. Defective sensor.
For Factory set point check P&ID 3. Worn / Defective process pump.
4. Fouled Spir-O-Lators®.
5. Concentration in the loop or bilge
HIGH SPIR-O-LATOR® TSH1 1. High inlet temperature.
TEMPERATURE Activated when Process Temperature 2. Low product flow.
Alarm Light On exceeds the TSH1 set point. 3. Clean cycle reached set point.
For Factory set point check P&ID
HIGH OIL CONTENT ON OIL CONTENT DETECTOR 1. Large amount of detergent.
SMART CELL MONITOR Activated when oil content exceeds 2. Circulation loop high in oil
Digital Display Indicator the Smart Cell alarm 1 set point and concentration.
Blinking delay. 3. Oil Content Detector being out of the
(Warning Alarm) (See Appendix “B”, Section 7) MAIN INFORMATION SCREEN.
EXCESSIVE HIGH OIL OIL CONTENT DETECTOR 1. Spir-O-Lators® damaged.
CONTENT Activated when oil content exceeds 2. Spir-O-Lators® adapter damaged.
the Smart Cell alarm 2 set point and 3. Spir-O-Lators® inter-connector
delay, plus one minute damaged (Ultra Sep Models 5000 and
(See Appendix “B” OCD - Smart higher).
Cell) 4. Fouled Spir-O-Lators® .
5. Oil Content Detector Monitor Cell
dirty.
6. Cleaners not totally flushed out of the
system
EXCESSIVE HIGH OIL Oil Sensing Probe (OSP) 1. Oil Sensing Probe (OSP) fouled and
CONTENT needs cleaning.
• Over 5 minutes 2. Air being sucked in inlet line.
• 3 times in 15 minutes. IMPORTANT the Oil Sensing Probe
Alarm light on (OSP) will thing air is oil.
3. Excessive oil in the bilge.
4-6
Section 5: Maintenance Procedures
5.1 HELI-SEP FLUSH & SLUDGE REMOVAL
It is recommended that this procedure be performed every 24-32 hours of operation to remove excess oil build up in
the system and to remove sludge that settle in the bottom of the vessel it should also be performed prior to each
membrane cleaning.
1. Leave Power Switch on.
2. Put the System Switch in Off and allow the system to sit for 10 minutes.
3. Open valve BV3.
4. Put Flush Switch in OWS position.
5. It will flush for 3 minutes.
6. Close BV3
7. Put Flush Switch in Off position and then back to OWS position to continue flushing to slop tank for 3
more minutes.
8. Put Flush Switch back into Off position the Process Pump (PU2) will go on and system will be back in
normal operation.
5.2 SPIR-O-LATOR FLUSH

This should be performed
• Before every shutdown.
• Prior to cleaning the Spir-O-Lator®.
• After cleaning the Spir-O-Lator® to flush the cleaning detergent from the system.
1. Put System Switch in Off position.
2. Put Flush Switch in Spir-O-Lator position.
3. The System will automatically flush for 3 minutes. Feed Pump (PU1) and Process Pump (PU2) will be
running, SV4 & SV3 open, SV1 & SV2 closed for 3 minutes.
If after a cleaning the smart cell reads over 15 PPM you can repeat the flushing or put the System Switch
in Run position it will recirculate to bilge until it flushes itself clean and then return to discharge over
board when the PPM drops below 15.
5-1
5.3 FLUSHING THE SMARTCELL (OIL CONTENT DETECTOR)
1. On the OCD SMART-CELL use the DOWN and UP Keys to view the Menu options.
2. Scroll down to "Diagnostics" then press the ENTER key. The screen will change as shown:
3. Select “View disp PPM” and press ENTER. The clean water solenoid valve now is activated and clean
water is introduced to the monitor. You must then open (BV7) to allow the clean water to flow thru the
monitor and to drain. This will flush out the SMART-CELL. The display will appear as below and the
ppm reading of the clean water will be displayed. This reading should be less than 2 ppm.
4. Let the SMART-CELL flush for 30-60 seconds then close (BV7) and press the ENTER key twice to leave
the diagnostics screen, set the clean water solenoid valve back to sample and return to the operation screen
of the SMART-CELL.
5-2
5.4 FILTER BAG REPLACEMENT
Refer to the Flow Diagram Drawing in Appendix “C” for the location of the referenced valves.
WHEN TO REPLACE
The Process Bag filters require replacing when the differential pressure reaches 1 bar [15 PSID] between the inlet
and outlet of the filter housing (Use PI2 and PI3 to determine this difference). Shut down the system by turning the
power switch (1) off
REPLACEMENT PROCEDURE
When changing bags it is a good practice to flush out the housing to remove accumulated dirt and sediment. The
following procedure should be followed to change the bag filters.
1. Turn the Power Switch in Off position.
2. Open the Process Filter Drain Valve (BV5).
3. Open the Process Filter Vent Valve (BV4).
4. Loosen cover clamp bolt and remove cover clamp.
5. Remove the cover.
6. After the housing has drained, remove the filter bag.
7. Check the internal filter bag support basket for debris, remove and clean if necessary.
8. Check the condition of the cover gasket and replace if necessary.
9. If removed, re-install the cleaned support basket into the filter housing making sure basket flange is firmly
seated onto the step on the inside of the filter housing.
10. Install a new or cleaned filter bag into the support basket making sure the filter ring is firmly seated against
the top of the basket flange. Be sure that the bag is fully extended to the bottom of the basket.
11. Re-install the cover. When tightening the cover clamp, it may be necessary to light tap the clamp to have it
fully seat and seal the filter housing.
12. Close the Process Filter Drain (FIL1) Valve (BV5).
13. Refill the system as described in Spir-O-Lator® fill on section 4.2.2 before restarting. Be sure air is fully
bleed out of BV4 before closing.
5-3
5.5 SPIR-O-LATORS® CLEANING
WHEN TO CLEAN
The Coffin World Water System ULTRA-SEP® Bilge water Separator employs an automatic system flush after
shutdown of the process pump, which is a very effective means of protecting the SPIR-O-LATORS® from fouling.
However, in normal operation the SPIR-O-LATORS® can become fouled by mineral scale, biological matter and
grime. These deposits build up during operation until they cause a loss in processed water production or a loss of
processed water quality, or both. The SPIR-O-LATORS® require a cleaning when the processed water back pressure
drops to 2 Bar [30 PSI], or when processed water quality decreases noticeably.
It should be noted that the processed water output rate will vary depending on when flow rate is checked in
relationship to time from last flush. Also, flow rate will change if the inlet composition changes, the operating
pressure changes or the temperature changes. This is normal and does NOT indicate SPIR-O-LATORS® fouling.
Check all system operating parameters and make comparison with initial operating data recorded during initial
startup, or in log sheets, before attempting to clean the SPIR-O-LATORS®. If after considering all the above factors,
it is determined that the SPIR-O-LATORS® require cleaning or change out, carefully follow the steps outlined on the
following pages.
CLEANING TYPICAL (CHANGE OUT CONSULT FACTORY FIRST)

The system is set up to allow easy semi-automatic cleaning of the membranes in place or for easy change out if
needed. You can easily clean in place per the cleaning description that follows. We recommend that you do this until
the cleaning does not revive the membranes to with in 40 % of their original fresh water start up production, but first
exhaust all cleaning procedures as a different cleaner or two steps cleaning process may work. If none of these are
successful we recommend consulting the factory first before changing them out and returning them to the closest
cleaning center.
5.5.1 PREPARATION FOR CLEANING

The SPIR-O-LATORS® are cleaned in place. No disassembly of components is required.
1. Shut down the system according to the Routine Shutdown Procedure.
2. First run a Heli-Sep flush see section 5.1, second run a Spir-O-Lator® flush see section 5.2.
CAUTION
When mixing the cleaning solutions, wear a face mask, rubber apron and
rubber gloves.
3. After the SPIR-O-LATOR® flush has concluded, a batch of detergent should be applied. Pour the
recommended amount of cleaning detergent as given in Section 5.4.4 into the Process Filter Housing’s
(FIL1) Cleaning Canister. Open the Process Filter Drain Valve (BV5) followed by Cleaning Valve (BV6) to
allow for the cleaning detergent to be drawn into the Process Filter by vacuum.
5. Once the Cleaning Canister is emptied of detergent, immediately close the Cleaning Valve (BV6) and
Process Filter Drain Valve (BV5) as to minimize pulling any air into the Process Filter Housing (FIL1).
5-4
5.5.2 CLEANING PROCEDURES
1. Follow preparation for cleaning in Section 5.5.1. to perform a Pre Clean cycle and load a batch of cleaning
detergent.
2. Start the Cleaning cycle by opening BV4 and putting the clean/off/run switch in the clean position. During
this time, approximately 10 seconds, purge the Process Filter (FIL1) of any air accumulated during the
Preparation for Cleaning procedures by opening and closing its Vent Valve (BV4).
3. The Process Pump (PU2) will start running in a Circulation Cycle allowing the detergent to mix and flow
across the SPIR-O-LATORS® to scourer its surfaces. It will run for a minimum of 30 minutes or until the
temperature switch (TSH1) shuts the system down when the recalculating cycle heat the water to 50°C.
Note: Heating the water to between 45°C - 50°C will provide the best cleaning.
4 If after the Circulation Cycle is finished turn the clean switch off and let it soak for a minimum of 4 hours.
Over night would be best. Then do Spir-O-Lator® flush to remove detergent from the system see 5.2
5. After the flush has finished, and Spir-O-Lator cleaned water production has not fully recovered follow the
Preparation For Cleaning 5.4.1 steps 4 and 5 to inject another batch of cleaning detergent for a second and
last Circulation Cycle if needed.
EXCEPTION, if cleaning with chlorine bleach, DO NOT repeat this cycle and DO NOT soak.
6. At the end of the cleaning cycle (or when restarting after a prolonged or overnight soak) you will need to
flush out the SPIR-O-LATORS® thoroughly to remove all the cleaning detergents from the system,
otherwise on start up the smart cell will register higher PPM’s and recalculate to bilge until the detergent is
purged.
7. After cleaning, the process bag filter may need to be replaced with a new filter if the differential pressure is
over 10 PSI. (See Filter Bag Replacement 5.3)
8. The ULTRA-SEP® is now ready to operate. To restart the system after cleaning, refer to the Pre-start
procedures. If a prolonged shutdown is required, refer to the SPIR-O-LATOR® Preserving Section 5.6.
5.5.3 CLEANING DETERGENTS

There are a variety of cleaning detergents, both liquid and powder that can be used. The success of the cleaning
procedure outlined on Section 5.4.2 will be determined by how close (+/- 10%) the processed water back pressure as
shown on the gauge panel (PI5), returns to its normal operating PSI as indicated on the systems P&ID as line 6
“Spir-O-Lator Product Max” showing both pressure and flow.
The best procedures to be used will often need to be determined by experience due to bilge water characteristics,
which change from ship to ship.
The following are three of the most common types of contaminants:
NOTE
It is recommended to keep the PH of any alkaline cleaning mixture between
10 and 12. See the following PH measurement procedure.
“The PH of the solution can be checked by taking a sample from the Process
Filter (FIL1) Vent Valve (BV4) after the solution has mixed for 1 to 2 minutes
for measurement. If the PH is over 12, drain some out and add water to the
canister. Continue this until the PH gets below 12.
1. If the bilge water is fouled with fair soot, (fine carbon particles) and/or oil, and /or organics it is
recommended to use CWWS Cleaner No. 1 or No. 1A (alkaline types).
5-5
NOTE
Normally cleaning for oil (CWWS Cleaner No. 1 or No. 1A) will provide the
best performance, however a scale may gradually build up that is not
removed by this cleaning procedure. When this occurs, it will appear that
the Alkaline procedure is ineffective. An Acid cleaning is then
recommended to see if the problem is corrected. When using these acidic
compounds keep the PH levels over 2.
2. If the membrane is fouling due to the water hardness and metallic scale (rusty pipes or bilge water), it is
recommended to use CWWS Cleaner No. 2 (acid type).
NOTE
Chlorine bleach is to be strictly used only when biological fouling has
occurred and must be used in the recommended amounts (refer to table on
the following page) and NEVER allowed to soak or circulate for over ten
minutes.
3. If the membrane becomes biologically fouled, typical indications are bad odor, process water discolored to
light green, or it can be blackish. This usually means the unit has not been flushed or run for awhile and the
SPIR-O-LATORS® were allowed to soak in the bilge water. It is recommended to use a short, under 10
minutes, chlorine bleach cleaning cycle followed by a thorough flush and then followed by an alkaline
cleaning.
Also reference our Spare Parts List (7-1) for cleaners available:
NOTE
Other cleaners such as Drew Chemicals “Fresh” or “LAC” can be used to
clean the SPIR-O-LATORS for the short term. But their performance may
not be optimal and may decrease membrane life and void the warranty.
RECOMMENDED CWWS
PART GOOD FOR: TYPE:
CLEANERS NUMBER:
CWWS MCLN6732 SOOT/OILS/

5 GALLON ALKALINE
CLEANER NO. 1 PAIL
ORGANICS
CWWS MCLN5511 SOOT/OILS/

5 GALLON ALKALINE
CLEANER NO. 1A PAIL
ORGANICS/BIOLOGICALS
CWWS MCLN7147 HARDNESS /

5 GALLON ACID
CLEANER NO. 2 PAIL
METALIC SCALE
NOTE
As indicated in cleaning procedures, paragraph 5.4, cleaning should take
place when the processed water back pressure drops to 1.7 Bar [25 PSI]
(Reference Pressure Gauge PI5). The time between cleanings will vary
based on how the Bilge is set up, Bilge Management Practices, and the
characteristics of the Bilge Water.
5-6
RECOMMENDED QTY TO BE USED PER CLEANING CYCLE (IN QUARTS)
MODEL CLEANER 1 & 1A / CLEANER 2 / CHOLRINE BLEACH
250 ½ ½ ½
500 ½ ½ ½
1000 ¾ ¾ ¾
2000 1½ 1½ 1½
3000 1½ 1½ 1½
5000 3 3 3
7500 4½ 4½ 4½
10000 6 6 6
TYPICAL SPIR-O-LATOR
P&ID PRODUCTION FLOW CURVE
Line 6
Max flow Clean Point
rating 30 PSI
Time between cleanings

varies depending on bilge
5.5.4 CHANGE OUT PROCEDURES (ONLY IF NEEDED, CONSULT FACTORY FIRST)

The SPIR-O-LATORS® can be easily changed out and those that have fouled beyond the point that in-place cleaning
will not return them to 40% of their Max. flow rate given on line 6 of the P & ID (See Drawings Appendix “C”), can
be returned for special cleaning. Prior to removing, Review Section 5.4.5 thoroughly to be sure all in place
cleaning has been tried and then consult the factory for details.
1. Flush the Spir-O-Lator® (see 5.2) for system for 9-12 minutes before changing out. Then follow that with
the Preserving Procedure (5.6.2) before changing out.
NOTE
®
Refer to the SPIR-O-LATOR Housing Assembly drawing located in
Appendix “C”, for detailed assembly procedures.
2. Remove each complete fouled SPIR-O-LATOR® using the quick disconnects and replace with complete
new or cleaned SPIR-O-LATOR® from your stock.
3. Replace Process Filter (FIL1) if required before restarting the unit (See Filter Bag Replacement 5.3)
4. Restart the system per the Initial Start Up Procedure.
5. Pack the wet preserved fouled SPIR-O-LATOR® in the plastic bag the replacement came out of. Seal the
bag tight, then place in the individual SPIR-O-LATOR® box.
6. Obtain a RMA (Return Material Authorization) from CWWS for the special cleaning. When cleaned they
will be returned to you for the next cycle.
5-7
5.5.5 REDUCED RECOVERY:

If the cleaner you are using as outlined in Section 5.4.4 has worked for a period of time but you notice the
SPIR-O-LATORS® are “not” recovering as before, a contaminant that your cleaner is not addressing may have
caused a gradual scale build up and a different cleaner or a two step cleaning procedure may correct the problem.
We suggest trying the following procedures. If these do not improve the recovery, consult the factory for further
options.
NOTE
If you do see improvement, but not enough. Repeat the cycle extending the
circulation and soak times.
1. FIRST: Try a different cleaner following the normal cleaning procedure. For example, if you have been using
cleaner No. 1, try cleaner No. 1A, if this does not work then try No. 2. If you still have no success, try the
chlorine for Bio-Fouling as outlined in Section 5.4.4 Step 3, and as stated above, if you see improvement repeat
the cycle lengthening circulation and soak times.
2. SECOND: We have found the following two step procedure to be effective in some cases:
Step 1: Do a normal cleaning with cleaner No. 1, extending the cleaning circulation time (5.4.2 Step 3)
to 1 ½ hours. Then extend the final soak (5.4.2 Step 7) for a minimum of 1 hour. Be sure to flush
thoroughly when complete.
Step 2: Repeat the cleaning procedure again using cleaner No. 1A. Also repeat the 1 ½ hour cleaning
circulation time (5.4.2 Step 3)
NOTE
This will heat the solution to about 40°C
Then extend the final soak to overnight , or for a minimum of 4 hours. Follow with a through flushing.
CAUTION
Use the proper amounts of chemicals as outlined in section 5.5.3
and error on the (+) side.
5-8
5.6 SPIR-O-LATOR® PRESERVING
PROLONG SHUTDOWN
The interior of the SPIR-O-LATORS®, being dark and moist, is an excellent breeding ground for microorganisms.
During prolonged shutdowns or storage periods of three (3) or more weeks, the SPIR-O-LATORS® should be
disinfected and sterilized by filling the system with a preserving solution. Preserving the SPIR-O-LATORS® will
save them from premature fouling or early failure by preventing bacteria from forming while the system is shut down
for extended periods of time. If not clean, the membranes should be cleaned before preserving. Refer to Flow
Diagram drawing in Appendix "C" for the location of the referenced valve callouts shown in parenthesis. Refer to
Figure 3, The Control Panel, for the location of the electrical switches and displays.
5.6.1 PREPARATION FOR PRESERVING.

No disassembly of components is required.
1. FIRST: Do a normal cleaning as outlined in Section 5.4.
2. SECOND: Then prepare the SPIR-O-LATORS® per the Preparation for Cleaning procedures 5.4.1 except
on step 5 replace the cleaning detergent with the preserving solution as outlined below.
CAUTION
When adding the preserving solution, wear a face mask, rubber apron and
rubber gloves.
PRESERVATIVE MIXING
Model Teaspoons of Chlorine Mixed in pints of water
US250/500 1 2
US1000 1 1
US2000 2 2
US3000 3 3
US5000 4 4
US7500 6 6
US10000 8 8
5.6.2 PRESERVING PROCEDURES

1. Follow the preparation for Preserving as stated above.
2. Start the Preserving Cycle (same as cleaning cycle). During initial start up, approximately 10 seconds, purge
the Process Filter (FIL1) of any air accumulated during the Preparation for Preserving procedures by
opening and closing its Vent Valve (BV4).
2. After the 10 seconds, the Process Pump (PU2) will run in a Circulation Cycle allowing the preservative to
mix and flow across the SPIR-O-LATORS®. Allow the Circulation Cycle to operate for approximately 5 –
10 minutes to fully penetrate the SPIR-O-LATOR surfaces.
3. After the preservative has been circulated, stop the preserving operation by putting the Clean/Off/Clean
Switch to Off position.
5-9
4. After a prolong shutdown, restart the system by first using the Manual Operation Procedures. Following the
pre-start procedures, see 4.2.1, 4.2.2
5.7 CLEANING THE OIL SENSING PROBE

If the system’s oil discharge function is constantly being activated, the Separator’s Oil Sensing Probe may require a
cleaning or the inlet lines developed an air leak.
1. Disconnect the wires and remove the Probe holder.
2. Clean off the Oil Sensing Probes.

a. Emery cloth or wet sand paper may be required to clean metal portions of Probe prongs.
NOTE
When replacing the Oil Sensing Probe ensure that the threads are properly
aligned. Do not over tighten.
3. Replace Oil Sensing Probe and reconnect.
5-10
Section 6: Troubleshooting
6.1 TROUBLE SHOOTING GUIDE BILGE WATER SEPARATOR
WARNING
TURN OFF FACILITY ELECTRICAL POWER WHEN PERFORMING

ELECTRICAL CHECKS, UNLESS ELECTRICAL POWER IS
SPECIFICALLY REQUIRED FOR PARTICULAR ELECTRICAL
CHECK. ELECTRICAL SHOCK, SERIOUS PERSONAL INJURY, AND
EQUIPMENT DAMAGE MAY RESULT BY ACCIDENTALLY
TOUCHING LIVE ELECTRICAL CIRCUITS.
SYMPTOMS PROBABLE CAUSE CORRECTIVE ACTION
System inoperative when Facility power not ON. Turn on facility power.
Power Switch is turned to On.
Circuit breaker on facility input power Reset circuit breaker.

line tripped.
Power Switch defective. Repair or replace switch.
Power Disconnect Switch defective. Repair or replace switch.
Defective Relay(s). Replace relay(s).
Blown Line Fuse Replace fuse.
Rapid cycling between operation Air leak in system or inlet lines. Hydrostatically test suction piping and
and oil discharge. vessel then repair as necessary.
Note: 3 Oil Discharges in 15
minutes will put the system in
alarm condition
Defective Probe Amp. Relay 5CR1. Replace relay.
Defective Oil Sensing Probe. Replace probe.
Positive head feeding system over 5 PSI Correct Feed
Discharging excessive water to the Air leak in incoming lines Fix leak
slop tank
Dirty Oil Sensing Probe. Clean probe.
Defective Probe Amplifier Relay. Replace relay.
Manual OWS Flush switch stuck on. Check Switch.
6-1
Section 6: Troubleshooting
SYMPTOMS PROBABLE CAUSE CORRECTIVE ACTION
No oil discharge. Clean water inlet line is not pressurized with Ascertain that clean water inlet line
water. is pressurized.
RV1 pressure regulator closed or defective Set or replace
Defective Clean Water Inlet Valve SV4. Repair or replace Valve.
Defective Probe Amplifier Relay. 5CR1 Replace relay.
PU1Pump Motor will not start. Separator in Oil Discharge Mode. Check for pump run light or oil
discharge run light.
System in Clean Mode. Check Switch position
Thermal Overloads tripped. Reset
Failure to Pump Air leak in suction. Disassemble pump and replace

impeller.
Impeller is worn or damaged. Check suction and discharge lines.
Clogged suction or discharge lines. Reduce height or distance between

pump and bilge or holding tank.
Excessive suction lift. Hydrostatically test suction piping

and repair leak.
Noisy pump operation Starved suction. Check obstruction in suction

pumping.
Air leak in suction. Hydrostatically test suction piping

and repair leak.
Excessive suction lift. Maximum recommended suction is

6 meters [19.6 ft] vertical lift. For
Feed Pump
Suction line too small. Use larger suction line.
Loose mounting bolts. Tighten mounting bolts.
6-2
Section 7: Parts List
7.1 SPARE PARTS

The following list of repair parts is recommended for 1 year of operation.
QTY DESCRIPTION CWWS PART #

1 Heli-Sep OWS 500 Cover Seal O-Ring HCON0054
4 Process Filter (FIL1) Cover Seal O-Ring ORGN8000
1 Feed Pump (PU1) Impeller PJIB9190
1 Feed Pump (PU1) Seal Kit PKJM9190
(Cover O-Ring & Pump Casing Seals)
1 Process Pump (PU2) Seal Kit PKGN3656S
(Mechanical Seal & Pump Casing Seals)
3 Solenoid Valve Repair Kit, ½” VRKD0800
2 Solenoid Valve Coil, - 120VAC VCLD0040
1 Oil Sensing Probe OSPB0074
2 Pressure Gauge, 2.5 Dia. Liquid Filled GALK0463
¼”MNPT, 0-100 PSI (Scale also in BAR/100kPa)
2 Pressure Gauge, 2.5 Dia. Liquid Filled GALK0464
¼”MNPT, 0-160 PSI (Scale also in BAR/100kPa)
1 Combination Vacuum / PSI Gauge, 2.5 Dia. Liquid Filled GALK0424
¼” MNPT, 30 HG – 0- 60 PSI (Scale also in BAR/100kPa)
4 Fuse, Type GMA 250 Volt, 0.75 Amp FGMA0075
4 Fuse, Type GMA 250 Volt, 1.5 Amp FGMA0150
1 Relay, Probe Amplifier, 120 VAC REPA0041
1 Relay, Control SPDT, 120 VAC REGP0042
SEE Oil Content Detector Manual Spare Parts List for Oil Content Detector Spares
7.2 CONSUMABLE SUPPLIES

The following list of consumable supplies are needed for operation. Quantities will vary according to
makeup of bilge and usage of the system.
2 SPIR-O-LATOR® Cleaner Alkaline (5 gal.) MCLN6732

®
3 SPIR-O-LATOR Preservative (1 kg each) ASMS0000
8 Process Filter, S8 5 Micron Bag Filter FBGB0568
7-1
APPENDIX 'A'
Figures
FIGURE NO. DESCRIPTION
1 ULTRA-SEP
ISO
2 ULTRA-SEP
ISO
3 ULTRA-SEP
Control Box
APPENDIX 'B'
Major Components
NO. DESCRIPTION
1 Membrane Housings
2 Membrane Elements
3 Process Pump
4 Feed Pump
5 Process Filter
6 Pressure Switches
7 OCD – Smart Cell
8 System Valves
9 Pressure Gauges
7-1
8
1. Membrane Housings
7-1
10
4” SPIR-O-LATOR HOUSING: 1 - ELEMENT – MHUP1440
Design Pressure 600 PSI

Factory Test Pressure 660
Burst Pressure 1800 PSI
Operating pH Range 3-11

Cleaning pH Range
(less than 30 minutes) 2-12
Minimum Operating Temp. 20°F

Maximum Operating Temp. 125°F
The SPIR-O-LATOR HOUSING is designed for continuous use for membrane

filtration elements to purify waters at any positive pressure up to 600 PSI.
The SPIR-O-LATOR HOUSING has been designed to meet the standards of the
American Society of Mechanical Engineers (ASME), Boiler and Pressure Vessel
Code, Section X. At an additional cost, vessels can be inspected during
fabrication by an ASME Authorized Inspector and Code stamped.
L ±.06
Shell L S Empty Weight

Length inch Span lb
Code (mm) in (mm) (kg)
49.1 28 15
S -1
(1247) (711) (7)
14
2. Membrane Elements
7-1
12
SPIR-O-LATOR
CWWS P/N: MUFO0449 Nominal Pore size: 0.01
TYPE: Ultrafilic, Hydrophilic Typical Operating Pressure: 5 bar (70 P.S.I.)
Dimensions: 4" x 40" Max. Pressure Drop Recommended: 0.7 bar (10 P.S.I.)
O il / W ater S eparation
T he s eparation of oil and water by ultrafiltration (U F) is a well-proven technology, but its wide
s pread utilization for was tewater m inim ization or recycling applications has been lim ited by three
com m on problem s :
1. fouling from "free" oil which overflows from upstream pretreatment

2. fouling from "free" oil which de-emulsifies as the feed is concentrated
3. fouling and decomposition of the membrane from accidental
contamination of the waste stream by aggressive solvents
T he S pir-O-Lator m em brane by CW W S is a technologically

s uperior U ltraFilic m em brane elem ent that will res is t thes e
recurring obs tacles . S pir-O-Lator elem ents are not fouled
by “ free” oils or degraded by s olvents (Figure 1).
How the Spir-O-Lator Works

"Free Oil"
Coats Most
Membranes Asymmetric
Membrane
Pore Spir-O-Lator
Pressure
Pushes Water
"Fouling Free" Technology
Surfactant
Through Molecule
Membrane S pir-O-Lator m em branes are m ade
Water of a chem ically m odified polyacrylonitrile
Molecules (PAN ) polymer. To avoid fouling by "free " oils,
And Alkalinity
Builders the S pir-O-Lator element has been engineered
Surfactant to be extremely hydrophilic (water attracting)
Oil Coated Micelle as com pared to conventional m em branes
With Surfactant
which are oleophilic (oil attracting).
Membrane The improvement in membrane hydrophilicity
Direction of Flow
is quantified by measuring water-membrane-
Figure 1 air contact angles for the various m em brane
types (Figure 2). A s m aller contact angle
correlates with a m ore
hydrophilic s urface and les s
fouling by "free" oils and
highly concentrated oil
em uls ions .
S pir-O-Lator m em branes are

des igned to have as ym m etric
pore m orphology (Figure 3).
Spir-O-Lator
T his pore s tructure creates a
s urface filter with its s m alles t
opening at the outer skin of the
m em brane ("A" s haped rather
than "V "s haped). Oil and dirt
m olecules are rejected at the
s urface rather than being
irrevers ibly entrapped in the
depths of the pore.
Membranes Morphology
ULTRAFILTRATION GREY ZONE FIL
TRATION MICROFILTRATION
Anisotropic ('A ' Shaped) Membrex's New Anisotropic Isotropic and 'V' Shaped Pores
Pore Performs Surface Filtration Grey Zone Membrane Designed to Entrap Contaminants
Small pore Oil/dirt Larger pore Oil/dirt Pore opening Oil & dirt
with open rejected at with open rejected at become imbedded
substructure the surface substructure the surface in the pore &
substructure
Molecular Filtration Ultrafilter With Larger Pores Particle Filtration
Waste Applications Aqueous Cleaner Recycling Solids Separations

❚ Ideal for oil removal ❚ Ideal for recycling cleaners ❚ High initial flow rate
❚ Virtually no oil passage ❚ Cleaner passes through pore ❚ Solids clog pores
❚ Too small for recycling ❚ Most oil is held back ❚ Permanent fouling
❚ Easy to clean ❚ Easy to clean ❚ Oil passage high
❚ Hard to clean
Figure 3
Chemical Resistance
& Performance Versatility Membrane Chemical Compatibility
T he chem ical s tability of the U ltraFilic m em brane
CHEMICAL TYPE ULTRAFILIC PVDF PS
m aterial is key to the S pir-O-Lator's success
in the environm ental m arket (Figure 4). It not Aliphatic Hydrocarbons
(e.g., Hexane)
only is com patible with m os t hydrocarbons ,
acids and polar organic solvents used in m any Aromatic Hydrocarbons
(e.g., Xylene)
industrial plants, the U ltraFilic m em branes can
operate at tem peratures to 194 F (90 C) and are Halogenated Hydrocarbons
(e.g., 1,1,1 richloroethane)
T
stable in the pH range of 2 to 10. T his versatility
elim inates the need to neutralize the was te Polar Organic Solvents
(e.g., Acetone, MEK)
stream prior to filtration and m akes it possible
to recycle m os t aqueous cleaners on-line at Acids
their operating tem peratures .
Base
EXCELLENT GOOD POOR
Figure 4
Spir-O-Lator Element Design

oluti on
Perforated Central ube
T Feed S
ate
Perme
ntra te
Conc e
Permeate Collection Material

Membrane
Feed Channel Spacer
Outer Wrap
Spir-O-Lator
UltraFilic Membranes
3. Feed Pump
(PU1)
7-1
14
Model 11810-Series
Model 11810-Series
SELF-PRIMING PUMPS
FEATURES
Body: Bronze Construction
Impeller: Nitrile Compounds
Shaft: Stainless Steel Sleeve over Motor Shaft
Wearplate: Replaceable
Shaft Seal: Lip Type
Ports: 3/4" (19mm) Garden Hose
External Thread and
1/2" NPT Internal
Motor: 1/3 HP, 115V AC 60 HZ, 1725 RPM,
Single Phase, Capacitor Type,
Open Drip Proof or Totally Enclosed
Fan Cooled, Handle and 8' Cord with
3 prong grounded plug on
ODP motor only
Weight: 20 lb (9.1 kg) with ODP Motor
25 lb (11.4 kg) with TEFC Motor
VARIATIONS AVAILABLE
MODEL NO. DESCRIPTION FOOD, BEVERAGE, & DAIRY: Circulate cooling water,
11810-0003 Nitrile Impeller, ODP Motor defrost refrigeration coils, fill drums, wash down
11810-0013 Nitrile Impeller TEFC Motor equipment and floors, and utility pump.
HOME: Fill and empty tubs and pools, empty
! WARNING basements, cesspools, water systems, water lawns and
Explosion hazard. Motor can spark. gardens, remove water from low areas, and recharge
Explosion & death can occur. Do not use water softeners.
where flammable vapors are present. PLUMBING: Empty clogged sumps, drains, sinks and
tubs, and pump out water closets.
APPLICATIONS FARM: Fill tractor tires, fill water tanks, pump out silo
pits, liquid manures, transfer oil, and flush and clean
MARINE: Bait tank circulation, transfer oil, wash down, animal pens.
and utility dock pumps.
CONTRACTORS: Remove water from excavations, sup-
INDUSTRIAL: Circulate coolant on machine tools, ply water to mortar boxes and cement mixing, and wash-
industrial filling systems, utility shop pump, transfer gum down equipment.
arabic, transfer distilled water, recharge water softeners,
ice water recirculation, hydrostatic pressure testing,
vacuum pump, and aspirating pump.
OPERATING INSTRUCTIONS ASSEMBLY
1. INSTALLATION: Pump may be mounted in any 1. Install slinger and position 1⁄4" from motor boss.
position without loss of efficiency; however, it is 2. Press seal into seal bore with lip facing toward the
suggested that the pump head be down if vertical impeller bore. Apply grease to back of seal lip.
mounting is desired. The rotation of the motor shaft
determines the location of the pump’s intake and dis- 3. Install wearplate, aligning slot with dowel pin.
charge ports. Refer to Dimensional Drawing. Right 4. Apply sealant to top of cam and cam screw threads.
hand port, looking at pump end cover, is Install cam with cam screw.
inlet port.
5. Install body on motor. Tighten nut at clamp. Do not
2. DRIVE: Direct. over tighten or binding of shaft will result.
3. SELF-PRIMING: Pump will produce a suction lift 6. Lubricate impeller bore with water pump grease.
approaching 10 feet (3m) when dry and a lift up to
22 feet (6.7m) when primed. Be sure suction lines 7. Lubricate shaft OD with grease, align drive ding in
are airtight or pump will not self-prime. extended impeller insert with flat on shaft and install
impeller.
4. RUNNING DRY: Unit depends on liquid pumped for
lubrication. Do not run dry for more than 30 seconds. 8. Install gasket, end cover and end cover screws.
Lack of liquid will damage the impeller TO EQUIP WITH VACUUM SWITCH (4732-0000)
5. PRESSURES: For continuous operation, pressure 1. Install switch in tapped hole on top of inlet port.
should not exceed 20 psi (1.4 kg/sq cm). (Seal threads prior to assembly.)
6. TEMPERATURES: Nitrile impeller recommended 2. Connect switch to motor. See diagram.
for liquid temperatures of 50° to 180°F (10° to 82°C).
3. Plug into 115V AC outlet and hold down restart lever
7. FREEZING WEATHER: Drain unit by loosening the on switch until the pump primes.
end cover.
SPECIAL ATTENTION
8. NOTICE: Do not pump solvents, thinners, highly
1. Constant vibration of the restart lever indicates:
concentrated or organic acids. Damage to pump
may result. If corrosive fluids must be handled, pump (A) An air leak. This will usually show up when the
life will be prolonged if pump is flushed with water pump is first started. All suction lines should be
after each use or after each work day. checked for loose connections.
9. GASKET: Use standard pump part. A thicker gasket (B) A worn impeller. Impeller should be replaced.
will reduce priming ability. A thinner gasket will cause 2. Intermittent stopping and starting indicates that the
impeller to bind. Standard thickness 0.010". unit is operating against excessive discharge
10. SPARE PARTS: A Jabsco Service Kit should be pressure.
kept on hand to service all but the most badly worn
11810-Series pump.
VACUUM SWITCH WIRING DIAGRAM
SERVICE INSTRUCTIONS
DISASSEMBLY
1. Remove end cover screws, gasket and end cover.
2. Grasp impeller hub with water pump pliers and
withdraw from body.
3. Loosen cam screw and remove cam. Clean off
sealant. Remove wearplate with screwdriver or
hooked wire.
4. Loosen nut at body clamp. Remove body from motor
shaft.
5. Press put seal from motor mounting end of body
towards impeller bore.
6. Remove slinger from shaft.
NOTE: Inspect all parts for wear or damage and replace
if necessary.
EXPLODED VIEW
PARTS LIST
6590-Series
Key Description Qty. Part No.
1 Screw (End Cover) 6 91002-0020
2 End Cover 1 11830-0000
3 *Gasket 1 3298-0000
4 Neoprene Impeller 1 5929-0001
*Nitrile Impeller 5929-0003
5 Cam 1 490-0001
6 Wearplate 1 2235-0000
7 *Seal (Shaft) 1 92700-0420
8 Screw (Cam) 1 91003-0010
9 Body 1 11814-0000
10 Motor (ODP) 1 18739-0000
Motor (TEFC) 18753-0014
11 Nut 1 9110-0030
12 Bolt 1 91095-0090
13 Slinger (O-Ring) 1 92000-0230
14 Plug (for vacuum 1 92650-0070
switch hole)
4732-0000 - Vacuum Switch Kit:
Automatic shut off for use when pump is left unattended.
* Parts contained in Service Kit.
SERVICE KITS REPLACEMENT PUMP HEADS COMPLETE

Pump Model Service Kit Pump Model Pump Head
Number Number Number Number
11810-0001 90105-0001 11810-0003 11818-0003
11810-0011 Neoprene Impeller 11810-0013 Nitrile Impeller
11810-0003 90105-0003
11810-0013 Nitrile Impeller
Kits consist of: Impeller, seal and gasket.
DIMENSIONAL DRAWING
Inches (Millimeters)
HEAD CAPACITY TABLE

Total Head Capacity
psi kg/sq cm Feet Meters GPM LPM
4.3 0.3 10 3 9.6 36.3
8.7 0.6 20 6 8.1 30.7
13.0 0.9 30 9 6.8 25.7
17.3 1.2 40 12 4.4 16.7
NOTE: Tables show approximate performance for new pump with nitrile impeller
pumping water.
www.jabsco.com
THE PRODUCTS DESCRIBED HEREIN ARE

SUBJECT TO THE JABSCO ONE YEAR LIMITED
WARRANTY, WHICH IS AVAILABLE FOR YOUR
INSPECTION UPON REQUEST.
U.S.A. UNITED KINGDOM CANADA JAPAN GERMANY ITALY

Jabsco Jabsco Fluid Products Canada NHK Jabsco Company Ltd. Jabsco GmbH Jabsco Marine Italia
Cape Ann Industrial Park Bingley Road, Hoddesdon 55 Royal Road 3-21-10, Shin-Yokohama Oststrasse 28 Via Tommaseo, 6
Gloucester, MA 01930 Hertfordshire EN11 OBU Guelph, Ontario N1H 1T1 Kohoku-Ku, Yokohama, 222 22840 Norderstedt 20059 Vimercate, Milano
Tel: 978.281.0440 Tel: +44 (0) 1992 450145 Tel: 519 821.1900 Tel: 045.475.8906 Tel: +49-40-53 53 73 -0 Tel: +39 039 685 2323
Fax: 978.283.2619 Fax: +44 (0) 1992 467132 Fax: 519 821.2569 Fax: 045.475.8908 Fax: +49-40-53 53 73 -11 Fax: +39 039 666 307
Copyright 2005, ITT Industries Printed in U.S.A. All Rights Reserved Form: 43000-0068 Rev. B 09/2005
4. Process Pump
(PU2)
7-1
14
Installation,
Operation and
Model
Maintenance 3656/3756
Instructions
Table of Contents
SUBJECT PAGE
Safety Instructions .......................................................... 2
Description and Specifications ........................................ 2
Engineering Data ........................................................... 2
Installation .................................................................... 2
Location .................................................................... 2
Close-Coupled Units .................................................. 2
Frame-Mounted Units ................................................ 3
SAE Engine Driven Pumps .......................................... 3
Coupling Alignment ....................................................... 3
Frame-Mounted Units Only ........................................ 3
Piping ............................................................................ 4
Suction ...................................................................... 4
Owner’s Information Discharge ................................................................... 4
Wiring and Grounding ................................................... 4
Rotation ........................................................................ 4
Operation ...................................................................... 4
Model Number:
Maintenance .................................................................. 5
Serial Number: Disassembly ................................................................... 5
Dealer: Reassembly .................................................................... 6
Packed Box Instructions ................................................. 6
Dealer’s Phone No.
Trouble Shooting ........................................................... 7
Date of Purchase: Installation Date: Repair Parts ................................................................... 8
SAFETY INSTRUCTIONS Engineering Data
TO AVOID SERIOUS OR FATAL PERSONAL INJURY Maximum Liquid Temperature:
OR MAJOR PROPERTY DAMAGE, READ AND 212° F (100° C) – standard seal or packing
FOLLOW ALL SAFETY INSTRUCTIONS IN THE 250° F (120° C) – Optional high temp. seal
MANUAL AND ON THE PUMP. Maximum Working Pressure (table 1):
– NPT connections, 200 PSI (1379 kPa)
This is a SAFETY ALERT SYMBOL. – 125# ANSI flanged connections, 175 PSI (1207 kPa)
When you see this symbol on the pump or Maximum Suction Pressure: 100 PSI (689.5 kPa)
in the manual, look for one of the following Starts per Hour: 20, evenly distributed
signal words and be alert to the potential for
personal injury or property damage. Group Size Suction Discharge
11⁄2 x 2-6 (H) 2" NPT 11⁄2" NPT
DANGER Warns of hazards that WILL cause serious 1 x 2-7 2" NPT 1" NPT
personal injury, death or major property 21⁄2 x 3-7 3" NPT 21⁄2" NPT
damage. S
3 x 4-7 4" Flange 3" Flange
WARNING Warns of hazards that CAN cause serious 1 x 2-8 2" NPT 1" NPT
personal injury, death or major property 11⁄2 x 2-8 2" NPT 11⁄2" NPT
damage. 2 x 2-5 2" NPT 2" NPT
LH 21⁄2 x 21⁄2-5 21⁄2" NPT 21⁄2" NPT
CAUTION Warns of hazards that CAN cause personal 3 x 3-5 3" NPT 3" NPT
injury or property damage. 21⁄2 x 3-8 3" NPT 21⁄2" NPT
NOTICE: INDICATES SPECIAL INSTRUCTIONS 3 x 4-8 4" Flange 3" Flange
WHICH ARE VERY IMPORTANT AND 4 x 5-8 5" Flange 4" Flange
MUST BE FOLLOWED. 11⁄2 x 2-10 2" NPT 11⁄2" NPT
21⁄2 x 3-10 3" Flange 21⁄2" Flange
THIS MANUAL IS INTENDED TO ASSIST IN THE M
INSTALLATION AND OPERATION OF THIS UNIT. 4 x 6-10 6" Flange 4" Flange
THOROUGHLY REVIEW ALL INSTRUCTIONS AND 21⁄2 x 3-13 3" Flange 21⁄2 " Flange
WARNINGS PRIOR TO PERFORMING ANY WORK 3 x 4-13 4" Flange 3" Flange
ON THIS PUMP. 4 x 6-13 6" Flange 4" Flange
MAINTAIN ALL SAFETY DECALS.
L 8 x 10-13 10" Flange 8" Flange
NOTICE: INSPECT UNIT FOR DAMAGE AND 4 x 6-16 6" Flange 4" Flange
REPORT ALL DAMAGE TO CARRIER
IMMEDIATELY. Installation
WARNING UNIT NOT DESIGNED FOR USE LOCATION
WITH HAZARDOUS LIQUIDS OR • Locate the pump as near liquid source as practical; below
FLAMMABLE GASES. level of liquid for automatic repriming capability.
• Allow adequate space for servicing and ventilation. Protect
the unit from weather and water damage due to rain,
flooding or freezing temperatures.
Hazardous fluids
can cause fire,
burns or death.
• Protect the pump and piping from freezing temperatures.
• Allow adequate space around the unit for service and
DESCRIPTION and SPECIFICATIONS ventilation.
CLOSE-COUPLED UNITS
The series 3656/3756 are single stage, end suction, centrifugal
pumps for general liquid transfer, booster applications, • Units may be installed horizontally, inclined or vertically with
irrigation and general service pumping. Pumps are available in the motor above the pump.
three different materials of construction: all iron, bronze-fitted • The motor feet MUST be bolted to a substantial surface
and all bronze (“S” group only). (horizontal or vertical) that is capable of complete and rigid
Pump impellers are fully enclosed, key driven and held in support for the pump and motor. For L-Group pumps, the
position by an impeller bolt and washer. Casings are full volute motor adapter feet must also be bolted to the supportive
in design with replaceable wear rings. surface.
Dependant on the pump size, the suction and discharge • For vertical operation, the motor should be fitted with a drip
connections will be threaded or flanged. Shafts are protected cover or otherwise protected against liquid entering the
with stainless steel shaft sleeves. motor (rain, spray, condensation, etc.)
Close-coupled units have NEMA standard JM or JP motors NOTICE: DO NOT INSTALL WITH MOTOR
with C-face mounting and key driven shaft extension. SAE BELOW PUMP. ANY LEAKAGE OR
drive units bolt directly to the engine flywheel housing for SAE CONDENSATION WILL AFFECT
sizes 1, 2, 3, 4 or 5. Optional elastomer element couplings are THE MOTOR.
available for 61⁄2, 71⁄2, 8, 10, 111⁄2 and 14 inch flywheels. Frame
mounted units can be coupled to motors through a spacer
coupling, or belt driven.
2
FRAME-MOUNTED UNITS • For L-Group pumps it is recommended that the pump is
• A flat substantial foundation surface MUST be provided to supported beneath the two feet cast into the motor adapter
avoid distortion and/or strain when tightening the (108). These feet must be bolted to the support.
foundation bolts. A rubber mounting is acceptable to reduce • Begin the assembly of the pump to the engine by thoroughly
noise or excessive vibration. cleaning the engine flywheel and flywheel housing.
• Tighten motor hold-down bolts BEFORE connecting piping • For Goulds Pumps optional couplings – Ensure that the
to pump. coupling hub set screw is backed out enough to ensure
clearance for the shaft key during assembly. Mount the
(1⁄4”) Grout hole Base
Finished grouting coupling assembly to the engine flywheel using the bolts
provided torqued as follows in a crossing sequence:
(1⁄2 to 3⁄4”)
Grout
61⁄2" or 71⁄2" Flywheel – 11 lbs.-ft. (15 N. m)
Allowance
for leveling
Leveling wedges or shims – left in place
8", 10" or 111⁄2" Flywheel – 20 lbs.-ft. (27 N. m)
Top of foundation – 14" Flywheel – 50 lbs.-ft. (68 N. m)
clean and wet down
(For other couplings follow manufacturers
Wood
frame Sleeve
recommended installation procedure.)
• Place the pump shaft key into the pump shaft (122) and align
the shaft to the coupling. Slide the pump into the coupling
Washer until the engine adapter ring (340) contacts the engine
Lug flywheel housing.
• Mount the pump to the engine using the bolts and lock-
Figure 1 washers provided, torqued as follows in a crossing sequence:
• Baseplate MUST be grouted to a foundation with solid SAE #2, #3, #4, #5 – 20 lbs.-ft. (27 N. m)
footing. Refer to Figure 1. SAE #1 – 50 lbs.-ft. (68 N. m)
• Place unit in position on wedges located at four points, two • Install coupling guards (501N).
below approximate center of driver and two below • Bolt motor adapter (108) to the rigid support described
approximate center of pump. Adjust wedges to level unit. above.
Level or plumb suction and discharge connections.
Coupling Alignment
• Make sure bedplate is not distorted and final coupling
alignment can be made within the limits of movement of WARNING FAILURE TO DISCONNECT AND
motor and by shimming, if necessary. LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING ANY
• Tighten foundation bolts finger tight and build dam around
MAINTENANCE CAN CAUSE
foundation. Pour grout under bedplate making sure the areas
SEVERE PERSONAL INJURY.
under the pump and motor feet are filled solid. Allow grout
to harden 48 hours before fully tightening foundation bolts.
Hazardous machinery
• Tighten pump and motor hold-down bolts before aligning can cause personal
injury or death.
shaft or connecting the piping to pump.
• Allow grout to harden for 48 hours before tightening 4 FRAME-MOUNTED UNITS ONLY
foundation bolts. • Alignment MUST be checked prior to running. See Figure 2.
SAE – Engine Driven Pumps Parallel
The SAE engine drive bearing frame is designed to bolt directly

to the flywheel housing for engines with an SAE no. 1, 2, 3, 4
or 5 mount. The pump shaft extension is sized for use with
couplings bolted directly to the flywheel. Goulds Pumps
optional couplings are sized for 61⁄2", 71⁄2", 8", 10", and 14" Angular
flywheels. Although other flywheel mount couplings may be
used, it is recommended that the Goulds Pumps coupling be
used to ensure long and trouble-free operation from your Figure 2
Goulds Pump. • Tighten all hold-down bolts before checking alignment.
INSTALLATION • If realignment is necessary, always move the motor. Shim
• The pump may be installed horizontally, with the discharge as required.
rotated to any position allowed by the casing bolt pattern • Parallel misalignment, shafts with axis parallel but not
(371). It is recommended that the discharge be located concentric. Place dial indicator on one hub and rotate this
horizontally, above the suction. hub 360° while taking readings on the outside diameter of
the other hub. Parallel alignment is achieved when reading is
• The casing must be supported on all pumps by a rigid
0.005" (0.127 mm) TIR, or less.
support which is anchored to the unit base or foundation.
• Angular misalignment, shaft with axis concentric but not
• For M-Group pumps it is recommended that this support is parallel. Place dial indicator on one hub and rotate this hub
bolted to the motor adapter ring using 2 or more of the 360° while taking readings on the face of the other hub.
casing bolts (371). It is likely that longer bolts will be Angular alignment is achieved when reading is 0,005"
required for the additional support thickness. Use SAE grade (0.127 mm) TIR, or less.
5 bolts, torqued as indicated in this manual.
3
• Final alignment is achieved when parallel and angular PIPING – DISCHARGE
requirements are satisfied with motor hold-down bolts tight. • Install a check valve suitable to handle the flow, liquids and
NOTICE: ALWAYS RECHECK BOTH ALIGNMENTS to prevent backflow. After the check valve, install an
AFTER MAKING ANY MECHANICAL appropriately sized gate valve to be used to regulate the
ADJUSTMENTS. pump capacity, pump inspection and for maintenance.
• When required, pipe increaser should be installed between
Piping the check valve and the pump discharge.
• Piping should be no smaller than pump’s discharge and
suction connections and kept as short as possible, avoiding Wiring and Grounding
unnecessary fittings to minimize friction losses. See Table 1. Install, ground and wire according to
WARNING
• All piping MUST be independently supported and MUST local and National Electrical Code
NOT place any piping loads on the pump Requirements.
NOTICE: DO NOT FORCE PIPING INTO PLACE Install an all leg electrical power
AT PUMP SUCTION AND DISCHARGE disconnect switch near the pump.
CONNECTIONS. Disconnect and lockout electrical
• All pipe joints MUST be airtight. Hazardous voltage power before installing or servicing
can shock, burn or
PIPING – SUCTION cause death. the pump.
Electrical supply MUST match
• For suction lifts over 10 ft. (3 m) and liquid temperatures pump’s nameplate specifications.
over 120° F (49° C), consult pump performance curve for
Incorrect voltage can cause fire,
net positive suction head required (NPSHR).
damage motor and void the warranty.
• If a pipe size larger than pump suction is required, an Motors without built-in protection MUST be provided
eccentric pipe reducer, with the straight side up, MUST be
with contactors and thermal overloads for single phase
installed at the pump suction.
motors, or starters with heaters for three phase motors.
• If pump is installed below the liquid source, install a gate See motor nameplate.
valve in the suction for pump inspection and maintenance.
• Use only copper wire to motor and ground. The ground
NOTICE: DO NOT USE THE GATE VALVE TO wire MUST be at least as large as the wire to the motor.
THROTTLE PUMP. THIS MAY CAUSE LOSS Wires should be color coded for ease of maintenance.
OF PRIME, EXCESSIVE TEMPERATURES
• Follow motor manufacturer’s wiring diagram on the motor
AND DAMAGE TO PUMP, VOIDING
nameplate or terminal cover carefully.
WARRANTY.
• If the pump is installed above the liquid source, the following WARNING FAILURE TO PERMANENTLY
MUST be provided: GROUND THE PUMP, MOTOR AND
Hazardous CONTROLS BEFORE CONNECTING
• To avoid air pockets, no part of the piping should be above voltage
the pump suction connection. TO ELECTRICAL POWER CAN CAUSE
SHOCK, BURNS OR DEATH.
• Slope the piping upward from liquid source.
• Use a foot valve or check valve ONLY if necessary for Rotation
priming or to hold prime during intermittent duty.
NOTICE: INCORRECT ROTATION MAY CAUSE
• The suction strainer or suction bell MUST be at least DAMAGE TO THE PUMP AND VOIDS
3 times the suction pipe diameter area. THE WARRANTY.
• Insure that the size and minimum submergence over
• Correct rotation is right-hand, CLOCKWISE when viewed
suction inlet is sufficient to prevent air from entering pump from the motor end. For frame mounted units, switch power
through a suction vortex. See Figures 3 through 6.
on and off quickly to observe rotation. On close coupled
units, remove motor end plug or cover to observe rotation.
H min. H min. • To reverse three phase motor rotation, interchange any two
D D
power supply leads.
Operation
Figure 3 Figure 4 WARNING DO NOT OPERATE FRAME
H
16 MOUNTED OR SAE UNITS WITHOUT
15
14 SAFETY GUARDS IN PLACE OR
H = Min. Submergence in feet
13
12 SEVERE PERSONAL INJURY MAY
11
10 RESULT.
9
8
3.0D 7
6 Hazardous machinery
min. 5 can cause personal
4 injury or death.
1.5D 3
H min. 2
min.
1
D min. 1 2 3 4 5 6 7 8 9 10111213141516 V
D 2 D
V = Velocity in feet per second
= GPM x 0.321 GPM x 0.4085
Area D2
Figure 5 Figure 6
4
WARNING SPLASHING OR IMMERSING OPEN FRAME-MOUNTED UNITS
DRIP PROOF MOTORS IN FLUID CAN • Model 3756 S-group has greased for life bearings.
CAUSE FIRE, SHOCK, BURNS OR No regreasing is possible or necessary.
DEATH.
• Model 3756 M or L-group bearing frame and SAE drive
bearing frame should be regreased every 2,000 hours or at a
three month interval, whichever occurs first. Use a #2
Hazardous voltage
can shock, burn or
sodium or lithium based grease. Fill until grease comes out of
cause death. relief fittings, or lip seals, then wipe off excess.
• Follow motor or engine and coupling manufacturer’s
WARNING OPERATION AT OR NEAR ZERO lubrication instructions.
FLOW CAN CAUSE EXTREME HEAT,
PERSONAL INJURY OR PROPERTY • Recheck alignment.
DAMAGE. SEASONAL SERVICE
• To REMOVE pump from service, remove drain plug and
drain all unprotected piping.
Extreme heat can • To RETURN pump to service, replace drain plug using
cause personal injury
or property damage. Teflon™ tape or equivalent on male threads.
• Reconnect suction line if removed, examine union and repair
NOTICE: NO NOT RUN PUMP DRY OR SEAL
if necessary.
DAMAGE WILL RESULT.
• Refer to OPERATION section of manual.
• After stabilizing the system at normal operating conditions,
check the piping. If necessary, adjust the pipe supports.
Disassembly
• On frame-mounted units, coupling alignment may have
changed due to the temperature differential between pump • Follow ALL warnings and instructions in the
and motor. Recheck alignment following procedures and “MAINTENANCE” section of this manual.
hazard warnings in “COUPLING ALIGNMENT” section • Close-coupled units: Remove motor hold-down bolts.
of this manual. • Frame-mounted units: Remove coupling guard, spacer,
coupling and frame hold-down bolts.
Maintenance LIQUID END
WARNING FAILURE TO DISCONNECT AND 1. Remove casing bolts (371).
LOCKOUT ELECTRICAL POWER
BEFORE ATTEMPTING ANY 2. Remove back pull-out assembly from casing (100).
MAINTENANCE CAN CAUSE SHOCK, 3. Remove casing wear ring (103) if excessively worn.
BURNS OR DEATH. NOTICE: DO NOT INSERT SCREWDRIVER BETWEEN
IMPELLER VANES TO PREVENT ROTATION.
Hazardous voltage 4. On close-coupled units, remove motor end plug or cover
can shock, burn or
cause death. to expose screwdriver slot or flats on end of motor shaft.
FAILURE TO RELIEVE SYSTEM 5. While restraining shaft with an appropriate tool (close-
CAUTION coupled units) or with a strap wrench (frame-mounted
PRESSURE AND DRAIN SYSTEM
BEFORE ATTEMPTING ANY units) remove impeller bolt (198). Impeller bolt may need
MAINTENANCE CAN CAUSE to be heated with torch to remove. Discard.
PROPERTY DAMAGE, PERSONAL NOTICE: EXERCISE CAUTION WHEN HANDLING
INJURY OR DEATH. HOT IMPELLER BOLT.
Hazardous pressure
can cause personal 6. Remove impeller washer (199). Discard.
injury or property
damage. 7. Insert two pry bars, 180° apart, between impeller (101) and
seal housing (184). CAREFULLY pry off impeller.
WARNING IF PIPING HAZARDOUS OR TOXIC 8. Remove impeller key (178).
FLUIDS, SYSTEM MUST BE FLUSHED
PRIOR TO PERFORMING SERVICE. 9. Remove seal housing bolts (370B) and seal housing (184)
pulling with it the mechanical seal assembly. Discard seal
assembly and seal housing o-ring (513). For packed box
pumps see “PACKED BOX INSTRUCTIONS”.
10. Remove adapter bolts (370) and adapter (108).
Hazardous fluids can
cause personal injury
or property damage. 11. Inspect shaft sleeve (126). If badly scored, remove by
heating with torch. Discard.
CLOSE-COUPLED UNITS NOTICE: EXERCISE CARE IN HANDLING HOT
• Bearings are located in and are part of the motor. For SHAFT SLEEVE.
lubrication information, refer to motor manufacturer’s
instructions.
5
12. Push out the mechanical seal stationary seat from the 8. Fully and squarely install the rotary assembly of seal
seal housing. Discard. against the stationary seat.
13. On units equipped, remove seal housing wear ring (203) NOTICE: REPLACE IMPELLER BOLT AND WASHER
if excessively worn. WHENEVER IMPELLER IS REMOVED.
DISASSEMBLY OF BEARING FRAME OR 9. Install impeller key in shaft keyway. Mount impeller on
SAE BEARING FRAME shaft and push until it bottoms. Hold in place.
1. Remove deflector (123) from shaft. 10. Install new impeller washer.
2. Remove bearing cover (134). 11. Apply LOCTITE® #262 or equivalent, to new impeller bolt
3. Remove shaft assembly from frame. threads and tighten to:
4. Remove lip seals (138, 139) from bearing frame (228) and
3
⁄8"-16 bolts 20 lbs.-ft. (27 N. m)
bearing cover (134) if worn. Discard..
1
⁄2"-13 bolts 38 lbs.-ft. (51 N. m)
5. Remove retaining ring (361). 12. Replace casing wear ring, if removed.
6. Use bearing puller or arbor press to remove ball 13. Replace casing bolts and tighten, in a crossing sequence,
bearings (112, 168). to torque values indicated below:
3
⁄8"-16 bolts (bronze casing) 25 lbs.-ft. (34 N. m)
Reassembly 3
⁄8"-16 bolts (cast iron casing) 37 lbs.-ft. (50 N. m)
1
• All parts should be cleaned before assembly. 3
NOTICE: O-RING SHOULD BE REPLACED AFTER ANY 14. Check reassembled unit for binding by rotating shaft with
DISASSEMBLY OF UNIT. appropriate tool from motor end.
BEARING FRAME 15. If rubbing exists, loosen casing bolts and proceed with
1. Replace lip seals if removed. tightening sequence again.
2. Replace ball bearings if loose, rough or noisy when rotated. 16. Replace motor hold-down bolts and motor end plug or
3. Check shaft (122) for runout. Maximum permissible is cover on close-coupled units.
0.002" (0.05 mm) TIR. 17. Replace coupling, spacer, coupling guard and frame
4. Refer to the “MAINTENANCE” section of this manual hold-down bolts on frame-mounted units.
for M-group bearing frame regreasing instructions. NOTICE: ALWAYS RECHECK BOTH ALIGNMENTS
LIQUID END AFTER MAKING ANY ADJUSTMENTS.
1. Inspect shaft removing any debris or burrs. 18. Refer to the “COUPLING ALIGNMENT” section of
this manual to realign shaft.
2. Treat shaft with LOCQUIC® Primer “T”, or equivalent,
following manufacturer’s instructions carefully. 19. Assembly is complete.
3. When replacing shaft sleeve, spray new shaft sleeve’s bore Packed Box
with LOCQUIC® Primer “T”, or equivalent. Let parts dry
and then apply LOCTITE® #262 on the same surfaces. 1. Make sure stuffing box is free of foreign materials and
Slide new sleeve over shaft with a twisting motion, wipe clean before beginning packing of packed box. Refer to
off excess. Let cure according to instructions. Sectional Assembly in the repair parts section.
NOTICE: MECHANICAL SEAL MUST BE REPLACED 2. Take special care during installation of packing rings
WHENEVER SEAL HAS BEEN REMOVED. because they are die-formed. To install, twist the ring
FOLLOW SEAL MANUFACTURER’S sideways just enough to fit it around the shaft sleeve.
INSTRUCTIONS CAREFULLY. FOR PACKED DO NOT ATTEMPT TO PULL RINGS STRAIGHT
BOX PUMPS SEE “PACKED BOX OUT. See Figure 7.
INSTRUCTIONS”. CORRECT WRONG
4. Replace seal housing wear ring, if removed.

5. For mechanical seal pumps, stationary seal seat may be
dipped in water to ease installation. Place stationary seal
seat squarely into seal housing bore. Cover the polished
face of the seat with a thin piece of cardboard or paper
towel. Press seat firmly into bore using a round piece of
plastic or wood that disperses the force over the entire Figure 7
seal face.
6. Place adapter, concave face pointing up, over motor
shaft and lower it onto the motor.
7. Replace seal housing o-ring. This o-ring may be lubricated
with water or glycerin to ease in installation. Install seal
housing on adapter. Exercise care in that the motor shaft
does not dislodge or damage seal seat.
6
3. Install the two piece Teflon lantern ring supplied as shown Trouble Shooting Guide
in figure 8. Note: two pieces make one ring. Notches on
ring must face each other, but alignment is not necessary. WARNING DISCONNECT AND LOCKOUT
ELECTRICAL POWER BEFORE
ATTEMPTING ANY MAINTENANCE.
FAILURE TO DO SO CAN CAUSE A
SHOCK, BURN OR DEATH.
Hazardous voltage
can shock, burn or
cause death.
SYMPTOM
MOTOR NOT RUNNING
Teflon Lantern Ring See Probable Cause – 1 through 5
Figure 8 LITTLE OR NO LIQUID DELIVERED
4. Install the packing rings and lantern ring in the following See Probable Cause – 6 through 13
sequence to pack the packed box. Install two rings of EXCESSIVE POWER CONSUMPTION
packing, then the lantern ring, followed by the final three See Probable Cause – 3, 13, 14, 15
rings of packing. Install each ring separately and firmly EXCESSIVE NOISE and VIBRATION
seat. The use of a wooden split bushing is recommended See Probable Cause – 3, 6, 7, 10, 12, 14, 16, 17
to accomplish this. See Figure 9. Use gland to jack the
bushing and ring into the box. Stagger joints in each ring PROBABLE CAUSE
90°. Make sure the flush tap in the packed box lines up 1. Motor thermal protector tripped
with the center of the lantern ring. Any extra rings are 2. Open circuit breaker or blown fuse
spares. 3. Impeller binding
4. Motor improperly wired
5. Defective motor
WOODEN “SPLIT BUSHING” 6. Pump is not primed, air or gases in pumpage
7. Discharge, suction plugged or valve closed
8. Incorrect rotation (3 phase only)
9. Low voltage or phase loss
GLAND 10. Impeller worn or plugged
11. System head too high
12. NPSHA too low – Excessive Suction lift or losses
STUFFING 13. Incorrect impeller diameter
BOX SHAFT
14. Discharge head too low – excessive flow rate
15. Fluid viscosity, specific gravity too high
Figure 9 16. Worn bearing
17. Pump, motor or piping loose
5. Tighten gland nuts evenly, but not tight. When the pump
is started, slowly tighten the gland nuts until the leak rate
is between 40 and 60 drops per minute. A grease lubricant
can be used when the pumpage contains abrasive particles
or for a suction lift condition.
REMOVAL OF PACKED BOX
• Follow these steps to remove the packing from the
packed box.
1. Remove gland assembly.
2. With a “packing hook” remove packing.
3. Insert a wire hook into the ring on the outer edge to
remove the lantern ring.
4. Clean the packed box.
7
Repair Parts Series 3656/3756
4 6 7 8 2 5 9 10 3 11
13
3
10 17 18
12 1 14
19
20
21
Packed Box Arrangement
LIQUID END COMPONENTS POWER END COMPONENTS (shown on next page)

Item No. Description Material Item No. Description Material
1 Casing 112 Ball bearing (outboard)
Steel
2 Impeller 122 Pump shaft
Cast iron or bronze
3 Adapter 123 V-ring, deflector BUNA-N
4 Wear ring (casing) 134 Bearing cover Cast iron
5* Wear ring (seal housing) Cast iron or bronze 138 Lip seal (outboard)
BUNA-N
6 Impeller bolt 139 Lip seal (inboard)
AISI Type 300
7 Impeller washer stainless steel 168 Ball bearing (inboard)
8 Impeller key 193 Grease fitting (except S-Group) Steel
9 Seal housing o-ring BUNA-N 327C Screw (cover to adapter) (SAE only)
10 Mechanical seal See chart 340 Adapter/engine (SAE only) Cast iron
AISI Type 300 361 Retaining ring
11 Shaft sleeve stainless steel 370C Hex head cap screw (frame to cover)
12 Drain plug – 1⁄4 or 3⁄8 NPT Steel or brass Hex head cap screw (adapter to frame) Steel
13 Hex head cap screw (casing to adapter) 371C (SAE only)
14 Hex head cap screw (adapter to motor/frame) Steel 399 Key, coupling
15 Hex head cap screw (Adapter to seal housing) 501N Cover/adapter (SAE only) Galvanized steel
16 Lantern ring Teflon™
17 Packing, 5 rings Teflon™ impregnated
18 Gland AISI 316SS
19 Shaft sleeve
AISI Type 300
20 Gland stud stainless steel
21 Gland nut
* Item #5 supplied on S-group model 21⁄2 x 3-7 (71⁄2, 10 and 15 HP) and
M-group (except 3 x 4-10).
8
Performance Curves – 60 Hz, 3500 RPM
Curvas de desempeño – 60 Hz, 3500 RPM
These curves show the performance of the 3656 and 3756 at 3500 RPM and Estas curvas ilustran el desempeño de los modelos 3656 y 3756 operando a
1750 RPM, 60 Hz, and at 2900 RPM and 1450 RPM, 50 Hz. Standard impeller 3500 RPM y 1750 RPM en 60 Hz, y a 2900 RPM y 1450 RPM en 50 Hz. Se
trims are shown. muestran los diámetros de impulsor estándar.
Model 3656/3756 S-Group 3500 RPM NOTE: Not recommended for operation beyond Optional Impeller
printed H-Q curve. Impulsor optativo
9 BF / Size (Tamaño) 1 x 2 – 8 ODP & TEFC NOTA: No se recomienda la operación más allá de la
Imp. Dwg. 120-67 curva impresa de H-Q (carga-capacidad). Ordering Code Dia.
METERS FEET
METROS PIES Código de pedido Diá.
100 A 8 1⁄16"
NPSHR-FT (PIES) 3' 4' B 75⁄8"
90 300 25 30 35 40 6'
C 7 5⁄16
45
D 7
80 A 81/16'' DIA. 50
E 61⁄2
250 10'
B 7 /8''
5
TOTAL DYNAMIC HEAD (CARGA DINÁMICA TOTAL)
F 63⁄16
70 50 % EFF
G 53⁄8
C 7 /16''
5
H 51⁄8
60 200
D 7''
NOTE: Pump will pass a
50 10 sphere to 3⁄16" diameter.
E 61/2'' HP
150 NOTA: La bomba dejará
F 63/16''
40 7.5
HP pasar una esfera de hasta 3⁄16
de pulgada de diámetro.
G 5 /8''
3
5H
30 100 P
H 51/8''
20 3H
P
50 2H
P
10
0 0
0 10 20 30 40 50 60 70 80 90 100 110 120 U.S. GPM
0 5 15 20 25 m3⁄hr
CAPACITY (CAPACIDAD)
CWWS PN: PMGI271305 - 5 HP - Impeller D - 7"

16
5. Process Filter
(FIL1)
7-1
14
M O D E L L C O - 6 A N D 8 1 2 5 P S I B A G F I L T E R S
Model LCO Bag

Filter Housings
Low cost filter housings for
flow rates to 100 gpm*
These high-capacity bag filters are low in

cost and offer more dirt holding capacity.
These housings are made from carbon
steel or stainless steel. They use a newly
designed clamp cover that is easily
removed, reducing time spent on cleaning
and bag replacement. Housings also utilize
our Unistyle design offering you the option
of a side or bottom outlet. There is a
1-1/2-inch or 2-inch inlet and outlet on
the side, with a 1-1/2-inch or 2-inch
plugged drain at the bottom of the
housing. The outlet can easily be changed
to the bottom by merely moving the plug
from the drain to the side outlet.
Features
• Permanently piped housings are
opened without special tools
• Quick opening cover
• Carbon or stainless steel housings
• Large area bag and basket for greater
dirt-holding capacity
• O-ring seals: Buna N, EPR and Viton®
• Adjustable-height tripod legs
• 125 psi rated housing
Pipe size: 1-1/2"
• Basket material is compatible with housing 4.0
• Bag surface area is 5.6 square feet (LCO8), 3.0
and 2.0 square feet (LCO6) 2.5
• Uses number 12 size bags (LCO8), and 2.0
number 8 size bags (LCO6) 1.5
Pressure drop ( P) , psi
Pipe size: 2"

• 2-inch NPT ports (LCO8), and 1.0
1-1/2-inch ports (LCO6) .80
.60
.50
.40
.30
.25
.20
.15
.10
150
100
80
60
50
40
30
25
20
15
10
*Based on housing only. Fluid viscosity, filter bag used, and ex- Flow, gpm
pected dirt loading should be considered when sizing a filter.
17
14
6. Pressure Switches
(PSL2)
7-1
18
Installation And Maintenance Instructions Pressure/ Vacuum Switches
Pressure Switches
Series 96200, 96201, 96210, 96211
Vacuum Switches CWWS P/N: SWAP0411 2.5 - 15 PSI
Series 96220, 96221
Description CWWS P/N: SWAP0413 8.5 - 50 PSI
These switches are miniature size pressure/vacuum switches
having factory set or field-adjustable set-points, fixed deadbands
(differentials), and have piston or diaphragm piston sensors.
The switches are designed to provide long life and maintain
excellent set-point accuracy despite environmental conditions. Wiring
Materials wetted by the process fluid include pressure
connections of brass or stainless steel and internal elastomers Wiring must comply with local and national electric codes.
of Buna-N and Teflon as standard. Caution: Electrical rating must be within range stated on the
switch nameplate. Failure to stay within the rating
Caution: Do not use these switches for hazardous of the switch may result in damage to, or premature
or corrosive service, and do not use for oxygen
failure of, the electrical contacts.
service without proper degreasing and proper
preparation. Check nameplates on switch for Standard switch rating: 5 amps, 250 VAC/28 VDC
maximum proof (overpressure) pressure or SPDT
vacuum limits.
Standard free leads color code:
Installation Pressure switch Vacuum switch
purple = COMMON purple = COMMON
Caution: This switch should be installed by a trained red = NO red = NC
service person. A media filter should be in the blue = NC blue = NO
system to protect the switch.
Mounting: Switch may be mounted in any position. Optional termination:
Piping: Support adequate piping and mount the pressure -T1: 1/4" male quick connect terminals. C, NO, NC markings
switch to avoid excessive shock or vibration. To are on the switch.
minimize the effect of vibration on switch, mount
perpendicular to vibration. Apply pipe compound -T2: DIN 43650 type. Use 5 to 8 mm O.D. cable size. After
sparingly to male pipe threads only. Avoid pipe the cable hook-up, tighten the gland squeeze nut to
strain on switch by properly supporting and ensure firm environmental seal.
aligning piping. Pressure switch Vacuum switch
Tamper Field-adjustable models with a “T” prefix have position 1 = C position 1 = C
Resistant two set screws to lock-in the set-point position 2 = NC position 2 = NO
Option: adjustment sleeve. Use a 5/64 allen wrench. position 3 = NO position 3 = NC
Overtightening will result in switch damage. position 4 = NOT USED position 4 = NOT USED
Set-point adjustment for field-adjustable models -T4: 1/2" NPT male conduit connection with free leads.
-T5: 1/2" NPT female conduit connection with free leads.
For pressure switch (96201 and 96211 models):
Connect applicable conduit to the switch (plastic conduit
1. After connecting swi tch, turn adjustment sleeve clockwise is recommended). Generally, handtight is adequate for
to increase the set-point and counter-clockwise to decrease a conduit enclosure. Caution: use conduit hex only when
the set-point. The switch can be set either on “increasing tightening. Do no t exceed 80 lb in tightening or bending
pressure” mode or “decreasing pressure” mode. torque. Failure to follow this instruction may result in
2. For exact pressure set ting, cycle pressure swi tch and switch damage.
make fine adjustments with sleeve.
Testing of the switch
For vacuum swi tch (96221 model):
Testing of the switch may be done before or af ter final
1. After connecting swi tch, turn adjustment sleeve counter- installat ion. If bench tested, the switch should be re-tested
clockwise to increase the set-point and clockwise to
when installed in the final application. Be sure switch can be
decrease the set-point. The swi tch can be set either on
“increasing vacuum” mode or “decreasing vacuum” mode. tested without affecting other equipment. Check nameplates
for electrical rating and circui try (normally closed or normally
2. For exact vacuum setting, cycle vacuum switch and make
open) of switch. Cycle switch a few times to check operation.
fine adjustments with sleeve.
Troubleshooting OPTIONAL ELECTRICAL TERMINATIONS
Warning : Disconnect electrical power supply to swi tch
before removal or inspection.
Important: The switch is not field-repairable. In case of
damage, replace entire swi tch. NO
Causes of improper operation: C NC
1. Incorrect electrical connection: check leads to swi tch. Be
sure they are properly connected. See “Wiring” section for
circuitry color code.
2. Faulty control circuit: check electrical power supply to switch
Check for loose or blown fuses, open-circuited or grounded
wires, loose connections at switch.
3. Incorrect pressure: check pressure in system.
Pressure/vacuum must be within range specified on
-T1 SUFFIX -T2 SUFFIX
nameplate.
4. External leakage: replace pressure/vacuum switch.
5. Excessive vibration or surges: check for pressure fluctuations
in system. Check switch mounting and be sure there is no
excessive vibration.
If the operation of the pressure/vacuum switch cannot be
corrected by the above means, consult factory or authorized
factory representative.
For service or ordering information

Consult factory or authorized factory representative. Specify
full catalog number (with any optional modifications) and
factory set-point.
Warranty -T4 SUFFIX -T5 SUFFIX
All products of the company are sold and all services are offered
subject to the company's standard conditions of sale.
STANDARD MODELS OTHER OPTIONS
SET SCREW
(5/64 ALLEN WRENCH)
DO NOT OVERTIGHTEN
FREE LEADS
STANDARD
PREFIX "T"
SET-POINT TAMPER RESISTANT
ADJUSTMENT ADJUSTMENT SLEEVE
SLEEVE
1 1/4 HEX
(APPLY WRENCH
HERE ONLY)
PRESSURE
PORT
1/4 NPT
MALE
FACTORY SET FIELD-ADJUSTABLE -P1 SUFFIX
MODEL MODEL 7/16-20UNF MALE
96200, 96210, 96201, 96211, PRESSURE PORT
96220 SERIES 96221 SERIES WITH O-RING
7. Oil Content Detector
(OCD)
7-1
20
SMART CELL - BILGE - Instruction Manual
Doc. 109080 Rev. B 10.01.05
109080
INSTRUCTION MANUAL
BILGE OIL ALARM
CWWS
1732 Mc Gaw Avenue
Irvine, California, 92614
TELEPHONE: 949-222-5777 FAX: 949-222-5770
WEB: http://www.cworldwater.com
Doc. 109080 Rev. B 10.01.05
Section 1
Introduction
1.1 Important Notes 2
1.2 SMART CELL - BILGE Overview 2
1.3 Specification Listing 3
Section 2
Installation
2.1 Construction details 5
2.2 Mounting 6
2.3 Pipe work and Connections 7
2.4 Electrical Connections 8
Section 3
Commissioning
3.1 Piping 11
3.2 Electrical 11
3.3 Functional testing 11
Section 4
Operating Instructions
4.1 Getting Started 11
4.2 Clean Water Calibration 13
4.3 Set Alarm Points 14
4.4 Set Alarm Delays 15
4.5 Set Analogue out 16
4.6 View IMO Data 16
4.7 Diagnostics & Clean Water Flushing 17
Section 5
Maintenance and Spares
5.1 Maintenance (weekly) 19
5.2 Maintenance (Yearly) 19
5.3 Spares 19
Section 6
Trouble Shooting & Contact
6.1 Trouble Shooting Guide 20
6.2 Tech Support registration 21
Annexe
Certificates
EC MED Certificates 22/23
CWWS Page 1 of 23
Doc. 109080 Rev. B 10.01.05
Section 1
Introduction
1.1 Important Notes
§ All National or local codes of practice or regulations must be observed and, where
applicable, are deemed to take precedence over any directive or information
contained in this manual.
§ This equipment must be installed and operated in strict accordance with the instructions
contained in this manual. Failure to do so will impair the protection provided.
§ Installation and retro fitting of parts listed in Section 5.4 must be undertaken by a
competent and suitably skilled person.
§ Servicing, other than replacement of spares, must be undertaken by an CWWS

approved service centre.
§ The equipment must be provided with a sound electrical earth connection.
§ The unit must be isolated from the electrical supply before any maintenance of the
equipment is attempted.
§ Hazardous voltages are present within the monitor enclosure and solenoid valve
assembly.
§ It is essential that maintenance is carried out as described in Section 5. Failure to do

this will impair the functionality of the equipment and could lead to permanent
damage to the monitor.
§ The SMART CELL enclosure must not be opened. If opened a cell breach error will be
displayed on the screen (this error cannot be reset) and the “VOID” tamper proof labels
on either side of the enclosure lid will be destroyed.
1.2 SMART CELL - BILGE Overview

The SMART CELL - BILGE Monitor has been designed specifically for use in conjunction with
15ppm oily-water separator units. It has a specification and performance which meets the
requirements of the International Maritime Organisation specifications for Bilge Alarm Units
contained in Resolution MEPC 107 (49).
Analysis of the oily water sample is undertaken by a unique detector array arrangement. A
narrow beam of light is emitted across a glass cell tube which the oily water sample passes
through. Light scattered and transmitted is detected across the array and passed through
a complex oil content calculation algorithm. The resulting oil content is then displayed on
the LCD screen.
Two oil alarm relays and a 0-20mA / 4-20mA output are provided to control the overboard
discharge and to view / record oil content levels remotely.
To meet the new requirements of MEPC 107(49) an on board flash memory, Real time
clock, dual switch input and clean water / sample selection valve are fitted. These are
described in more detail in the operating instructions (Section 4).
CWWS Page 2 of 23
Doc. 109080 Rev. B 10.01.05
1.3 Specification Listing
Measurement
Oil types: Fuel Oil, Diesel and Mixture C (IMO defined)
Clean water calibration: +/- 2ppm of factory set values
Oil range: 0 - 30 ppm (trend to 40) all types
Resolution: 0.1 ppm
Accuracy oil + solids : +/- 5ppm up to 30 ppm
Solids discrimination: 100ppm Iron Oxide in 10 ppm Diesel
Response time: < 5 sec (oil reading)
Alarms
Oil alarm 1 setpoint: 1 – 15 ppm user adjustable
Oil alarm 2 setpoint: 1 - 15 ppm user adjustable
Oil alarm 1 delay: 0 – 5 seconds user adjustable (For Overboard Valve)
Oil alarm 2 delay: 0 – 600 seconds user adjustable in 10 sec increments
(For Annunciation only)

Alarm hysterisis: 0.5 ppm
Alarm contacts: 2 SP Alarm Relays 10A @ 250VAC (NC in alarm)
User Interface
LCD display: 4 x 16 alphanumeric back lit LCD display
Control: 3 button keypad
Input / Output
Analogue output: Loop powered 4-20mA / 0 - 20mA 24V
Communications: RS232 - output
Cable terminals: Accept cores of 2.5mm² (HV) and 1.5mm² (LV)
Cable glands: 4 x to accept cable diameters 10 – 12mm dia.
Switch inputs: 2 x switch inputs for separator & flow status
Data Storage and Retrieval

Calibration data storage: Stored onboard microcontroller in Smart Cell
IMO required data: Stored in Control enclosure (SMART CELL may be
changed with data remaining on board)
IMO required data retrieval: Via LCD display or RS 232 communication link
CWWS Page 3 of 23
Doc. 109080 Rev. B 10.01.05
Environmental & Sample

Ambient humidity: 90%RH Max @ 55°C
Ambient temperature: 0°C - +60°C
Sample / clean water temperature: +1°C - +60°C
Sample / clean water flow rate: 0.5 - 4.0 litres / min
Sample / clean water pressure: 0.1 bar - 10 bar
Sample / clean water select: 3 way universal solenoid valve
Sample pipe fittings: ¼ inch BSPP
Inclination 25° in any plane from normal mounting
System and Supply

Supply voltage: 115 or 230V AC, 50 – 60Hz (24VAC available)
Supply voltage Consumption: < 50 VA including solenoid valve
Supply voltage tolerance: +/- 15%
Other supply tolerance: +/- 10%
Projected life: > 50,000 hrs
Protection class: IP 65
Approvals: EU MED (GL)
Construction and other Criteria.
Security: Protection of all calibration dependent items plus
software lock
Manual clean: Fitted as standard
Weight: 3.2 Kg
CWWS Page 4 of 23
Doc. 109080 Rev. B 10.01.05
Section 2
Installation
2.1 Construction Details
The SMART CELL - BILGE Monitor is split into two logical modules. The display / control
module (2) (left) contains the membrane keypad, LCD display and the Smart Bilge Control
PCB. Contained on this PCB are all the control and data storage associated electronics in
addition to all the customer terminations which can be accessed via the cable glands(5).
This PCB links a 5 volt supply and RS485 communications to the Cell electronics via a 4 wire
interface cable.
The SMART CELL (1), contains the optoelectronics and mechanics used in the calculation of
the sample oil content. UNDER NO CIRCUMSTANCE IS THIS ENCLOSURE TO BE OPENED.
Sample (7) and clean water (8) lines are connected to the solenoid valve to allow
automatic selection of clean water for clean water calibration and diagnostics.
Sample/Clean water is exhausted from the monitor via the outlet (6) after passing through
the measuring sensor. A manual cell clean unit (3) is provided which must be used in
accordance with the maintenance requirements in Section 5. The throttle (9) can be used
to increase or decrease the back pressure in the cell. This is especially useful if air is present in
the sample.
Fig 2.1
Construction details
FIXING HOLES
FOR M6 3 1 SMART - MEASURING CELL
TYPICAL 4 POSNS 6
2 SMART - DISPLAY/CONTROL MODULE
3 MANUAL CLEAN
WARNING - HAZARDOUS VOLTAGE INSIDE ! !
4 3 WAY SOLENOID VALVE
THROTTLE ADJ 9
SMART - BILGE
RTE
RTE
5 CABLE GLANDS IP68 RATED

CALIBRATION VOID
CALIBRATION VOID
FOR CABLE Ø10 - 14

WARNING
WARNING
2 SMART - CELL
6 SAMPLE OUPUT CONNECTION
289
CUSTOMER FITTING 1/4" BSPP REQD

RTE
RTE
1 7 SAMPLE INPUT CONNECTION

205.0
235.0

8 CLEAN WATER INPUT CONNECTION
9 THROTTLE
5
4 WEIGHT:- 3.2 Kg
7 8
275.0
148.5
295.0
CWWS Page 5 of 23
Doc. 109080 Rev. B 10.01.05
2.2 Mounting Details

The SMART CELL - BILGE monitor should be located on or in close proximity to the oily-water
separator to minimise response delays. Under no circumstances should the distance
between the monitor and the separator exceed a distance that would result in a response
time of more than 20 seconds and breaching IMO regulations.
Mounting Note: if the monitor is sold with Bilge Water Separator, It is pre-installed.
Mount the SMART CELL - BILGE by means of 4 x M6 bolts on to a rigid vertical surface and
preferably with the display panel of the monitor at operator eye level.
Fig 2.2
Mounting Details
FIXING HOLES
FOR M6
TYPICAL 4 POSNS
DO NOT OPEN
WARNING - HAZARDOUS VOLTAGE INSIDE ! NO SERVICEABLE PARTS INSIDE !
THROTTLE ADJ
SMART - BILGE
RTE
RTE
CALIBRATION VOID
CALIBRATION VOID
WARNING
WARNING
SMART - CELL
RTE
RTE
205.0
275.0
CWWS Page 6 of 23
Doc. 109080 Rev. B 10.01.05
2.3 Pipe Work and Connections

Fig 2.3 Shows all pipe fittings required for Sample In, Clean Water In and Sample Out.
Note: If the monitor is sold with Bilge Water Separator, the system is pre-wired and
pre-piped.
Fig 2.3
Pipe Fittings
ANTI SIPHON TUBE
2 Metre
Minimium
3 200mm
SAMPLE OUT Min
10mm PIPING
DO NOT OPEN
WARNING - HAZARDOUS VOLTAGE INSIDE ! NO SERVICEABLE PARTS INSIDE !
THROTTLE ADJ
SMART - BILGE
SMART - CELL
SAMPLE IN CLEAN WATER IN
1 2
DRAIN
ENSURE LEVEL
IS CLEAR OF
BILGE WATER
Item No. Description

1 Sample Inlet 1/4 inch BSPP fitting
2 Clean Water Inlet 1/4 inch BSPP fitting
3 Sample Outlet 1/4 inch BSPP fitting
CWWS Page 7 of 23
Doc. 109080 Rev. B 10.01.05
2.4 Electrical Connections
WARNING: Hazardous voltages are present In the control enclosure – Ensure

equipment is isolated before proceeding.
Please read the following points before attempting any electrical work.
§ Ensure all cabling is volt free and isolated.

§ This unit must be connected to the mains supply via a suitably rated double pole (3mm
contact gap), 2 Amp fused, isolator unless such fusing/isolation is provided by
associated equipment. Isolator should be clearly marked as to function.
§ Cable gland entries can accept cables from 10 to 12 mm diameter and terminal blocks
will accept cable cores of 2.5mm2 (mains / Alarm contacts ) and 1.5 mm2 ( terminals
less than 48 V ) . Cables carrying hazardous voltages must be at least 0.5 mm2 csa.
§ When terminating mains cabling at monitor and electrical source, the earth conductor
must be made longer than the live and neutral conductors.
User terminations are located by removing the lid from the SMART Display/Control module
via the four screws. A protection plate is situated above the terminals which must be
removed via 4 M3 screws.
Fig 2.4.1
User Terminations
CONNECTION TO CONNECTION TO CONNECTION TO

DISPLAY MEMBRANE SMART CELL
INTERNAL INTERNAL INTERNAL
1 1J14 KEYPAD 1
J13
J15 SMART-CELL
1
J12
JTAG
Tx 1
J11 RS232
J8 RS232 CONNECTION
0-20mA - Rx
4-20mA 4-20mA 1
ANALOGUE J6 J9 CUSTOMER VOLT FREE SWITCH
OUTPUT + SW1
1 INPUTS - SEPARATOR ON/OFF STATUS
1 1
IO PORT J7 CUSTOMER VOLT FREE SWITCH
SW2
INPUTS - BACKFLUSH/OTHER
JP1 TO BE LINKED
JP1
IF 24VAC IS REQUIRED
J1 J2 J3 J4 J5
L 1 2 3 1 2 3
FUSE F1 E N L E N L E N
SUPPLY IN SAMPLE-CLEAN
250V 1.25A ANTI SURGE
~
ALARM 1 ALARM 2
SMARTBILGE PCB
CUSTOMER OUTPUT
INPUT TO SOLENOID
230-110 VAC VALVE
OR 24VAC CONNECTION
50 - 60 Hz
NORMALLY CLOSED
IN ALARM MODE
OUTPUTS FOR
CUSTOMER
CWWS Page 8 of 23
Doc. 109080 Rev. B 10.01.05
Table 2.4.2
User Terminal Connections
Terminal Terminal description Terminal block description Max ratings

J1 - L Live in 24/115/230 V AC
Customer Supply Mains input
J1 - E Earth 250V AC, 40 VA max.
from suitably rated Isolator
J1 - N Neutral in 24/115/230 V AC
J2 - L Live 24/115/230 V AC
Open Terminal. Note:
J2 - E Earth for optional features not 250V AC , 500mA.
used with this application.
J2 - N Neutral 24/115/230 V AC
J3 - L Live 24/115/230 V AC
Sample clean control. Note:
J3 - E Earth wiring to this terminal is not to 250V AC, 500mA.
be altered.
J3 - N Neutral 24/115/230 V AC
J4 - 1 Normally closed contact Alarm 1 relay contacts,

normally closed in power down
J4 - 2 contact 250V AC/DC, 10A.
and alarm active states.
J4 - 3 Normally open contact
(Overboard Valve Control)
J5 - 1 Normally closed contact Alarm 2 relay contacts,
normally closed in power down
J5 - 2 contact 250V AC/DC, 10A.
and alarm active states.
J5 - 3 Normally open contact
(Alarm Annunciation Only)
J7 - 1 5V DC from PCB
Separator Status Switch Input 1 5V DC 20mA
J7 - 2 Switch In
J8 - 1 +24V DC 4-20mA Connection

24V DC 20mA
J8 - 2 0V 0-20mA Connection
J9 - 1 5V DC from PCB
Back-flush Switch Input 2 5V DC 20mA
J9 - 2 Switch In
J11 - 1 Tx
J11 - 2 GND RS232 Connection +/-12V DC 10mA
J11 - 3 Rx
Precise wiring details will vary dependant upon the control system to be employed but
Alarm relay 1must be used for control of the overboard discharge valve and Alarm relay 2
for alarm annunciation only.
CWWS Page 9 of 23
Doc. 109080 Rev. B 10.01.05
Section 3
Commissioning
3.1 Piping
§ Check all piping for leaks and rectify where appropriate

§ Ensure all piping and fittings conform to specifications set in Section 2.3.
3.2 Electrical
§ Check that correctly rated isolator is connected to the mains input (see Section 2.4.).
§ Check the SMART CELL - BILGE is correctly earthed.
§ Check all cabling conforms to specifications set out in Table 2.4.
3.3 Functional testing

§ Follow section 4 to start up and run clean water calibration.
§ Follow section 6 for trouble shooting should any errors/spurious readings result.
CWWS Page 10 of 23
Doc. 109080 Rev. B 10.01.05
Section 4
Operating instructions
4.1 Getting Started

The SMART CELL - BILGE is controlled and set up by the user interface on the Display/Control
Module. Use the diagram in Fig 4.1.1 to become familiar with the controls,
Fig 4.1.1
User interface
4 x 16 Alphanumeric LCD
Display
Red user interface Keys

ENTER, UP and DOWN
CWWS Page 11 of 23
Doc. 109080 Rev. B 10.01.05
On power up the user will be presented with a screen as shown in Fig 4.1.2.
§ At the top of the display the user will see the oil concentration in Parts Per Million (PPM).
§ The status of the two oil alarms will be displayed.
§ The date and time is displayed. (time is set to GMT / UTC ).
§ If either of the alarm set points is passed the LCD backlight will flash.
Fig 4.1.2
Screen Shot - Main Information Screen
Shows Oil
Concentration in
PPM
Alarm 1 state Date & Time

Alarm 2 state Display
To interrogate the SMART CELL - BILGE Monitor settings the user can press any of the Interface
Keys to bring up the Menu Options Screen as shown in Fig 4.1.3
Fig 4.1.3
Screen Shot - Menu Screen Options
Use the DOWN and UP Keys to view all the

Menu options. Press ENTER on any option
to select or on Escape to return to main
information screen.
CWWS Page 12 of 23
Doc. 109080 Rev. B 10.01.05
4.2 Clean Water Calibration
A clean water calibration can be performed to account for differences in clean water
between the factory calibrated clean water and the ships own clean water supply. On
activation of the clean water calibration the clean water / sample solenoid will select
clean water. The SMART CELL - BILGE will then average the clean water reading over the
period of 30 seconds after which a further 10 seconds will lapse for the user to verify the
calibration in monitor mode before the solenoid selects sample once more.
To set the clean water calibration enter the Menu screen as shown in Fig. 4.1.3 and scroll
down until the cursor reaches "Clean wtr cal" then press the ENTER key. The screen will
change as shown in Fig 4.2.2.
Fig 4.2.2
Screen Shot - Menu Screen Options
The screen will display for 30 seconds after

which, it will return to that shown in Fig 4.1.3.
The solenoid will select clean water for a
further 10 seconds so that the clean water
reading can be verified.
CWWS Page 13 of 23
Doc. 109080 Rev. B 10.01.05
4.3 Set Alarm Points

The SMART CELL - BILGE Monitor has two independent oil alarm contacts for user termination.
These can be set by the user to operate when the displayed Oil content reaches the required
Parts per Million (PPM) settings.
Note: The alarms have a 0.5 ppm hysteresis included to prevent relay chatter. e.g if an
alarm is set at 15 ppm and the oil concentration exceeds 15 ppm, the alarm will be
activated. The alarm will not deactivate until the oil concentration drops below 14.5 ppm.
To set the required Alarm points enter the Menu screen as shown in Fig. 4.1.3 and scroll
down until the cursor reaches "Set alrm point" then press the ENTER key. The screen will
Fig 4.3.1
Screen Shot - Alarm Set Options
Move the cursor to Alarm 1 set by

pressing the DOWN key and then press
ENTER. This will bring up the screen as
shown in Fig 4.3.2.
Note: Alarm 1 MUST be used for control

of the overboard discharge valve.
Fig 4.3.2
Screen Shot - Alarm PPM Value
The PPM value can now be set. The

range is between 1 & 15. Use the UP or
DOWN key to select the required value.
Once the required value has been
selected press the ENTER key. This will
bring the screen back to Fig 4.3.1.
Repeat this operation to set the value
for alarm 2.
Press the ENTER key 3 times to return to
the main information screen as shown in
Fig 4.1.2.
CWWS Page 14 of 23
Doc. 109080 Rev. B 10.01.05
4.4 Set Alarm Delays

Once the alarm points have been set as described in Section 4.3, the alarm delay values
can be entered. The alarm delay can be used so that if the oil concentration rises above
the oil alarm set point for a period exceeding the alarm delay value the alarm relay will
activate and only de-activate once the Oil Concentration has fallen below the Alarm Set
Point.
Note: The main information display screen will show if an oil alarm is less or more than the
current oil reading regardless of the alarm delay.
To set the required alarm delays go the menu screen as shown in Fig. 4.1.3 and scroll down
until the "Set alrm delay" then press the ENTER key. The screen will change as shown in Fig
4.4.1
Fig 4.4.1
Screen Shot - Alarm Delay Options
Move the cursor to delay 1 Set by

pressing the DOWN key and then press
ENTER. This will bring up the screen as
shown in Fig 4.4.2.
Fig 4.4.2
Screen Shot - Alarm Set Delay Value
Alarm delay 1 value can now be set

between 0 & 5 Seconds. Use the UP or
DOWN key to select the required value.
Once the required value has been
selected press the ENTER key, this will
bring the screen back to Fig 4.4.1.
Repeat this operation to set the value for
delay 2 (range between 0 & 600 Seconds
in 10 second increments).
Press the ENTER key 3 times to return to
the main information screen as shown in
Fig 4.1.2.
CWWS Page 15 of 23
Doc. 109080 Rev. B 10.01.05
4.5 Set Analogue Out

The analogue signal output can be set to either 0 – 20 mA or 4 - 20 mA and is scaled from 0
to 30 ppm calculated oil concentration. To set the required analogue signal output go to
the menu screen as shown in Fig. 4.1.3 and scroll down until the "Set analog out" then press
the ENTER key. The screen will change as shown in Fig 4.5.1.
Fig 4.5.1
Screen Shot - Analogue Output Options
Move the cursor using the UP or DOWN key

to select required option. Press the ENTER
key twice to return to the main
information screen as shown in Fig 4.1.2.
4.6 View IMO Data

It is required that the date, time, bilge alarm status and separator status is to be recorded a
for any change in alarm status or separator status and stored for a minimum of 18 months.
This data is recorded within the Smart Control / Display enclosure, allowing replacement of
the SMART CELL - BILGE whilst ensuring the data remains on board.
The separator status is recorded via the SW1 and SW2 inputs. The following configuration is
used.
SW1 Separator ON/OFF status.
SW2 Separator Back-flush (If fitted)
Note. SW2 will select clean water and activate alarms permanently when closed. To be
connected to Separator backflush control circuit via a potential free contact.
The configuration of the switches must be recorded on board and date stamped.
To view or download the IMO required data go to the Menu screen as shown in Fig. 4.1.3
and move the curser down until "View IMO data" then press the ENTER key. The screen will
Fig 4.6.1
Screen Shot - View IMO Data
Move the cursor to either View IMO

data or Dump IMO data by pressing
the DOWN key and then press ENTER.
This will bring up a screen as shown in
Fig 4.6.2 or Fig 4.6.3.
CWWS Page 16 of 23
Doc. 109080 Rev. B 10.01.05
Fig 4.6.2
Screen Shot - IMO Data
This screen displays one IMO record

at a time. Each record shows the
oil content, Alarm status, switch
input status and time/date of the
record. The users can scroll through
the records by pressing the UP and
DOWN keys. When inspection is
complete the ENTER key will exit the
user
Fig 4.6.3
Screen Shot - Dump IMO Data
By selecting the dump IMO data

command, the complete IMO
required data history is copied and
down loaded to the RS232 port.
This can be captured by purchasing
a Smart Bilge download cable
with instructions from CWWS, see
Section 5.4. The download data
screen will remain displayed until
download is complete.
NOTE: Dump IMO data command will NOT erase any data
4.7 Diagnostics & Clean Water Flushing

To view the diagnostics go to the menu screen as shown in Fig. 4.1.3 and scroll down until
the "Diagnostics" then press the ENTER key. The screen will change as shown in Fig 4.7.1
Fig 4.7.1
Screen Shot - Diagnostics
Move the cursor to either View

detectors or View disp PPM by
pressing the DOWN key and then
press ENTER. This will bring up a
screen as shown in Fig 4.7.2 or Fig
4.7.3.
CWWS Page 17 of 23
Doc. 109080 Rev. B 10.01.05
Fig 4.7.2
Screen Shot – View detectors
Once in view detectors, the solenoid

valve will select clean water and the
screen will display the current signals
present for clean water. Pressing
the ENTER key will leave the
diagnostics screen and set the valve
back to sample.
Fig 4.7.3
Screen Shot – View disp PPM
Once in “view disp PPM”, the

solenoid valve will select clean
water and the screen will display the
current calculated ppm for clean
water. Pressing the ENTER key will
leave the diagnostics screen and set
the valve back to sample.
Clean Water Flushing

During “View disp PPM”, the clean water valve is activated and clean water is allowed to
flow through the monitor. The display will appear as per Fig. 4.7.3 and the ppm reading of
the clean water will be displayed. This reading should be less than 2 ppm.
CWWS Page 18 of 23
Doc. 109080 Rev. B 10.01.05
Section 5
Maintenance and Spares
5.1 Weekly Maintenance
§ Manual Clean Cell Unit, plunge and release 10 times
durring clean water flush Section 4.7
§ Carry out “Clean Water Calibration” as per Section 4.2

§ Confirm Unit reads 0 ppm by following Section 4.7
5.2 Yearly Maintenance
§ At yearly intervals (or where necessary) the wiper ring on the manual clean assembly
should be replaced. This can be ordered from CWWS directly as part no. SBWR9039 .
§ Every IOPP survey, Cell Should be verified/re-calibrated by an CWWS approved service

centre (contact CWWS for an approved list) or a replacement calibrated cell can be
requested from CWWS (see below).
5.3 Spares
When ordering spares, it is important to supply details of the type of monitor, ser ial number
of monitor, part number of each spare required, its description and any other relevant
information.
RECOMMENDED ON-BOARD SPARES
Item Qty Part Number
Cell wiper ring 1 SBWR9039

Fuse 1.25A 1 SBFU9167
OTHER SPARES
Item Qty Part Number
Smart Cell 1 SBSC9171

Smart Bilge PCB Assy (115 + 230) 1 SBBA9019
Membrane overlay 1 SBMO9030
LCD display module 1 SBDM9068
Smart Bilge Download Cable 1 SBDC9165
Solenoid valve (230V) 1 SBSV9059
Solenoid valve (115V) 1 SBSV9060
CWWS Page 19 of 23
Doc. 109080 Rev. B 10.01.05
Section 6
Trouble Shooting Guide
6.1 Trouble Shooting Guide

Table 6.1
Trouble shooting guide
Symptoms Possible Cause Corrective Action

Monitor is switched on and Power is Isolated Check Isolator
the LCD screen is blank
Failure of mains fuse. Check fuse (F1). See fig 2.4.1.
Loose ribbon cable Check all ribbon cable connectors

connection. are firmly inserted.
LCD display Module is Contact CWWS for a replacement

damaged. LCD module (Section 5.4)
Monitor stays in alarm or Dirty measuring cell. Clean cell and perform Clean
reading is inaccurate. water calibration. Section 5.1
Or Excessive Contaminates Correct cause of contaminants

present in sample e.g. rust and run clean water calibration.
Display shows SYS ERROR, bacteria, emulsified oils,
Detector 0 – 7 Is under / detergents, discoloration of
over range. water.
Sample flow blocked or Remove blockage or restriction.

Or restricted.
Display shows SYS ERROR,

Air bubbles are present in Turn throttle clockwise until air is
Oil content Is under / over
the Sample. removed from sample (taking
range.
care not to exceed the maximum
operating pressure.
Manual Clean has become Remove Manual clean unit and

stuck in the down position. clean with a detergent. Check
Wiper ring on the end of the piston
and replace if necessary.
Sample / Clean water Remove Solenoid valve and clean

selection solenoid has a thoroughly.
blockage.
If problems persist Contact CWWS
for a replacement
Solenoid valve (Section 5.4).
CWWS Page 20 of 23
Doc. 109080 Rev. B 10.01.05
Display shows SYS ERROR, Current Ambient Move equipment to an area

Temperature Is under / over temperature inside the Cell with ambient temp between
range. is not within 0 - 60°C. 0 - 60°C.
Display shows SYS ERROR, RS 485 communications Ensure 4-pin plug is tightly
Communications failure cable is loose / not inserted into J15. Fig 2.4.1
connected
Cell Electronics Fault. Contact CWWS for replacement

Cell (Section 5.4).
Display shows SYS ERROR, Smart Bilge electronics Contact CWWS for replacement
RTC – I2C failure failure. Smart Bilge PCB (Section 5.4).
Display shows SYS ERROR, Measuring Cell has been Contact CWWS for replacement
Cell breach contact CWWS opened. measuring cell (Section 5.4).
CWWS Page 21 of 23
Doc. 109080 Rev. B 10.01.05
CWWS Page 22 of 23
Doc. 109080 Rev. B 10.01.05
CWWS Page 23 of 23
14
8. System Valves
22
7-1
SOLENOID VALVES
(SV1-SV4)
The following procedure is for disassembly and reassembly of the solenoid valves. An exploded view is
provided for clarification. (See illustration B1 for ½” thru 1” Solenoid Valves and illustration B2 for 1
½” Solenoid Valves on the following pages.)
For ordering valves, see serial plate for control voltage:
½” NPT 120 VAC - CWWS Part No. VSDB0840

220 VAC - CWWS Part No. VSDB0850
¾” NPT 120 VAC - CWWS Part No. VSDB1240

1” NPT 120 VAC - CWWS Part No. VSDB1640

1 ½” NPT 120 VAC - CWWS Part No. VSDB2440

1. Drain water from the system and turn off electrical power to the system.
2. Pull up on coil and remove. If coil stem is separate item than valve cover, unscrew to remove
core cover, core “O”-ring, core and core spring.
3. Unscrew valve cover and remove cover screws, and cover. If coil stem is integral to valve
cover, remove core and core spring along with cover.
4. Remove exposed diaphragm spring (1 ½” valve only), diaphragm, and all body “O”-rings when
applicable.
NOTE
Refer to the spare parts list, page 7-1, when ordering replacement
parts for the solenoid valves.
5. All parts are now accessible for cleaning or replacement. Replace worn or damaged parts with
complete Spare Parts Kit for best results.
6. Reassemble in reverse order of disassembly, paying careful attention to the exploded view provided
for placement of all parts.
7. After maintenance, operate valve a few times to be sure of proper opening and closing.
24
Solenoid Valves: ½” thru 1”
The items marked with * are included in the valve repair kit.
COIL
COVER SCREWS
COVER
* CORE & CORE SPRING
* DIAPHRAGM
BODY
Illustration B1
Exploded View ½” thru 1”
Solenoid Valves
7-1
Solenoid Valves: 1 ½”
The items marked with * are included in the valve repair kit.
COIL
CORE COVER SCREWS
CORE COVER
* CORE / CORE SPRING
* CORE COVER O-RING
COVER BOLTS
COVER
* ORIFICE O-RING & GASKET
* SPRING
* DIAPRAGHM
* SERVO SYSTEM O-RINGS
BODY
Illustration B2
Exploded View 1 ½”
Solenoid Valves
26
SWING CHECK VALVES
(CV1-CV8)
Swing Check Valve 2” NPT CWWS Part No. VSCB3200

Swing Check Valve 1 1/2” NPT CWWS Part No. VSCB2400
Swing Check Valve 1” NPT CWWS Part No. VSCB1600
Swing Check Valve 1/2” NPT CWWS Part No. VSCB0800
Swing Check Valve 1/4” NPT CWWS Part No. VSCB0400
GLOBE VALVES
(GV1-GV4)
Globe Valve 2” NPT CWWS Part No. VCTB3200

Globe Valve 1 1/2” NPT CWWS Part No. VCTB2400
Globe Valve 1” NPT CWWS Part No. VCTB1600
Globe Valve 1/2” NPT CWWS Part No. VCTB0800
Globe Valves
Adjustable with Locks
MODEL
!! !#
! "
# $
" #$%$& " #'%#( " )$ " )' " *) " ($ " '$
$'
#
#'
)
)'
*
*'
(
!
" ## $ % & %
$ # '&
(( ) ##
*## $ % +, -
!"
#" $
#
( %& '. %
BALL VALVES
(BV1-BV8)
The Drain Valves and the Sample Valves are provided to manually drain and sample the contents of the
separator vessel. The standard valves used to perform these functions are typical brass ball valves.
(See illustration below).
Drain Valve (2) 1” NPT CWWS Part No. VBLB1600

Separator Sample Valve (1) 1/2” NPT CWWS Part No. VBLB0800
Sample Valve (5) 1/4” NPT CWWS Part No. VBLB0400
Typical Ball Valve

CWWS P/N: VRLB0800 - 1/2"
CWWS P/N: VRLB1200 - 3/4"
Series 530C 2
Calibrated Pressure Relief Valves 7
6
Sizes: 1/2" or 3/4" (15 or 20mm)
5
Series 530C Calibrated Pressure Relief Valves are spring operated
bronze valves designed for use only as protection from the build up 4
of excessive pressure in systems containing water, oil or air. Series
530C valves incorporate a calibrated adjustment feature for setting 3
the valve to the relief pressure required. These valves are ideally
suited for bypass thermal expansion relief. 1
Model 530C
Features
Materials
• Calibrated adjustment feature for setting valve to relief pressure
required 1. Body Bronze
• Adjustable range 50 – 175psi (3.45 – 12.06 bars) 2. Bonnet Brass
• All bronze construction 3. Disc Holder Brass
• All stainless steel springs 4. Disc Buna-N
• Buna-N disc on machined body seat 5. Adjustable Spring Stainless Steel
• Inlet (bottom), male NPT threaded 6. O-ring Buna-N
• Outlet (side), female NPT threaded 7. Spring Washer Brass
Pressure – Temperature
Capacity (530C)
psi bars
Maximum Temperature: 180° F (82° C) 300 20.7
Maximum Operating Pressure: 300psi (20.67 bars) 275 18.9
250 17.2
Spring Ranges 225 15.5
Inlet Pressure
3/4"
1 2
/ " or 3/4" (15 or 20mm): 50 – 175psi (3.45 – 12.06 bars) 200 13.8
(20mm)
1 2
/ " (15mm): 100 – 300psi (6.89 – 20.67 bars) 175 12.1
1/2"
150 10.3
Application Note: The Watts Series 530C are not ASME approved (15mm)
125 8.6
safety relief valves and should not be used in system application
100 6.9
with this requirement.
75 5.2
50 3.4
25 1.7
0 5 10 15 20 25 30 35 40 gpm
19 38 57 76 95 114 133 152 lpm
X = Set Point Flow
MODEL SIZE (DN) DIMENSIONS WEIGHT

Height Width
in. mm in. mm in. mm lbs. gm.
530C 12
⁄ or 3⁄4 15 or 20 3 76 15⁄8 41 .63 286
9. PRESSURE GAUGES
(PI1-PI5)
7-1
28
GAUGES
Model 40
Industrial Gauges
(Dual Scale)
STANDARD RANGES
Standard gauge scales - Dual.
Outer scale is PSI.
Inner scale is metric (kPa & bar.)
STANDARD DIAL RANGES AVAILABILITY GRADUATION
PSI bar. 11/2” 2” 21/2” 4” Major Minor

0-30” VAC -1 bar ✔ ✔ ✔ ✔ 5 .5
30”-0-15 psi -1-0-1 bar ✔ ✔ ✔ ✔ 5 .5
30”-0-30 psi -1-0-2 bar ✔ ✔ ✔ ✔ 10 1
30”-0-60 psi -1-0-4 bar ✔ ✔ ✔ ✔ 10 1
30”-0-100 psi -1-0-7 bar ✔ ✔ ✔ ✔ 20 2
30”-0-150 psi -1-0-10 bar ✔ ✔ ✔ ✔ 20 2
1 /2 , 2 , 2 /2 , or 4 Case
1 ” ” 1 ” ” 30”-0-200 psi
30”-0-300 psi
-1-0-14 bar
-1-0-20 bar
✔
✔
✔
✔
✔
✔
✔
✔
50
50
5
5
Center Back or Bottom Mount 0-15 psi 0-1 bar ✔ ✔ ✔ ✔ 2 .2

0-30 psi 0-2 bar ✔ ✔ ✔ ✔ 5 .5
These gauges are designed for use 0-60 psi 0-4 bar ✔ ✔ ✔ ✔ 10 1
with any medium not corrosive to 0-100 psi 0-7 bar ✔ ✔ ✔ ✔ 20 2
brass or bronze. Liquid-filled gauges 0-160 psi 0-11 bar ✔ ✔ ✔ ✔ 20 2
are recommended for reducing shock 0-200 psi 0-14 bar ✔ ✔ ✔ ✔ 50 5
caused by pressure fluctuations or 0-300 psi 0-20 bar ✔ ✔ ✔ ✔ 50 5
vibration. 0-400 psi 0-27 bar ✔ ✔ ✔ ✔ 100 10

0-600 psi 0-40 bar ✔ ✔ ✔ ✔ 100 10
0-1000 psi 0-70 bar ✔ ✔ ✔ ✔ 200 20
0-1500 psi 0-100 bar ✔ ✔ ✔ ✔ 200 20
FEATURES 0-2000 psi 0-140 bar ✔ ✔ ✔ ✔ 500 50
0-3000 psi 0-200 bar ✔ ✔ ✔ ✔ 500 50
MOVEMENT: Brass 0-5000 psi 0-315 bar ✔ ✔ ✔ ✔ 1000 100

0-6000 psi 0-400 bar ✔ ✔ 1000 100
BOURDON TUBE: C-Shaped in phosphor bronze up to 0-10000 psi 0-700 bar ✔ ✔ 2000 200
600 psi and Helical in phosphor
bronze above 600 psi
POINTER: Black enameled aluminum
DIAL: White aluminum
WINDOW: Polycarbonate - Temperature com-
pensating
CASE MATERIAL 304 Stainless steel
CONNECTION Brass
MATERIAL
CONNECTION 1/8” MNPT on 11/2” size. 1/4” MNPT
SIZE on 2”, 21/2” and 4” sizes.
ACCURACY ASME/ANSI B40.1 Grade A (2-1-2%)
GAUGES
CASE STYLES AND DIMENSIONS
BOTTOM MOUNT
B A SIZE A B C D E
Style 1
1-1/2” 1.735” 1.075” 1.5” 1.575” n/a

D
2” 2.102” 1.075” 1.734” 1.970” n/a
C
2-1/2” 2.620” 1.165” 2.270” 2.470” n/a
4” 4.200” 1.265” 2.734” 3.969” n/a
SIZE A B C D E
BACK MOUNT
B A
Style 2
1-1/2” 1.780” 0.900” 1.600” 1.614" n/a

D 2” 2.211” 1.090” 2.045” 2.030” n/a
2-1/2” 2.620” 1.165” 2.270” 2.470” n/a
C
4” 4.200” 1.265” 2.734” 3.969” n/a
SIZE A B C D E
FRONT FLANGE
A
C
Style 3
1-1/2” 1.735” 1.075” 1.734” 1.575” 1.859”

D 2” 2.102” 1.075” 1.880” 1.970” 2.281”
2-1/2” 2.620” 1.165” 2.270” 2.470” 2.281”
B
E
4” 4.200” 1.265” 2.734” 3.969” 5.297”
SIZE A B C D E
PANEL MOUNT
A C
Style 4
1-1/2” 1.735” 1.075” 1.625” 1.575” 1.797”

D
2” 2.102” 1.075” 1.880” 1.970” 2.219”
B
2-1/2” 2.620” 1.165” 2.270 2.470” 1.109”
E
4” 4.200” 1.265” 2.734” 3.969” 5.203”
APPENDIX 'C'
Drawings
DRAWING NO. REV. DRAWING TITLE
J103-US1000-C - INSTALLATION
J103-US1001-C - GENERAL LAYOUT
US1015-C - CONTROL PANEL / MCC ASSEMBLY
US536-C - SPIR-O-LATOR HOUSING ASSEMBLY
US540-C A WIRING DIAGRAM / SCHEMATIC
US550-C B PROCESS FLOW DIAGRAM
J103-US1051-C - PIPING & INSTRUMENTATION DIAGRAM

APPENDIX 'D'
Certificates

Coffin-Ultra-sep 1000 CJ103 Manual

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Coffin-Ultra-sep 1000 CJ103 Manual

Uploaded by

Copyright:

Available Formats

July 2008

Manual No. USMN1000-CJ103

Coffin World Water Systems

1732 McGaw Ave. Irvine, CA 92614 U.S.A.

FIGURES ................................................................................................................................ Appendix ‘A’

SYSTEM MAJOR COMPONENTS .................................................................................... Appendix ‘B’

DRAWINGS ............................................................................................................................ Appendix ‘C’

CERTIFICATES .................................................................................................................... Appendix ‘D’

CWWS BILGE WATER SEPARATOR

BILGE WATER SPIR-O-LATOR CLEAN

2.2 PROCESS FLOW DESCRIPTION

Model Number: US1000-CJ103

Capacity: 1 M3/H (4.4 GPM)

General Design Data:

Electrical Power Input: All standard voltages. Refer to Electrical Requirements

Temperature Ranges: (Influent) 1°C - 50°C 34°F - 122°F

Influent: A solution of water contaminated with petroleum

Effluent: (Primary) Processed water, Clean Water < 20,000 molecular

Operating Pressure Range: 345-690 kPa 50 - 100 PSI

Weights and Dimensional Data:

Weight-Dry: 390 kg 858 Pounds

Weight-Wet: 480 kg 1058 Pounds

Length: 1015 MM 40 Inches

Width: 1070 MM 42.25 Inches

Height: 1550 MM 61 Inches

Oily Water Inlet (From Bilge or Holding Tank): 25 MM 1”

Control Valve Settings:

Operating Pressure Control Valve (GV2): 1.0

Product Flow Control Valve(GV3): 1.05

Concentrate Bleed Control Valve (GV4): 0.4

3.2.1 SITE SELECTION AND PREPARATION

3.2.2 PIPING CONNECTIONS

FEED PUMP (counter clockwise) PROCESS PUMP (clockwise)

ITEM COMPONENT NAME FUNCTION

14. Water Discharge Illuminates when SV1 Overboard solenoid is open.

ITEM COMPONENT NAME FUNCTION

/ : CLOSE THEN OPEN

2. Turn Power Switch On.

3. Put system Switch in Off position.

4. Put Flush Switch on OWS position.

4.2.2 SPIR-O-LATOR® FILL

4.3 INITIAL START-UP & OPERATION

5. Both Pump PU1 and PU2 are running.

4.3.2 NORMAL OPERATION OIL DISCHARGE

3. Close SV1 & SV3.

4. The Oil Discharge light will illuminate.

4.3.3 NORMAL OPERATION (OVER 15 PPM) RECIRCULATION TO BILGE

1. SV1 closes & SV2 opens.

2. The water discharge light will go out.

3. Everything else remains the same as in normal operation.

4.4 ROUTINE SHUTDOWN PROCEDURES

THE SPIR-O-LATORS® SHOULD REMAIN MOIST AT ALL TIMES.

ALARM DISPLAY ACTIVATING DEVICE POSSIBLE CAUSE

1. Leave Power Switch on.

3. Open valve BV3.

4. Put Flush Switch in OWS position.

5. It will flush for 3 minutes.

5.2 SPIR-O-LATOR FLUSH

• Before every shutdown.

• Prior to cleaning the Spir-O-Lator®.

1. Put System Switch in Off position.

2. Put Flush Switch in Spir-O-Lator position.

1. Turn the Power Switch in Off position.