Not binding progressive cavity pump, 05-24 up to 70-6l (60 pages)
Summary of Contents for Seepex Macerator 110 Series
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Not Binding Operating and Assembly Instruction Macerator This operating and assembly instruction is only for general information. Type I 110 with flush connection Issue 1 .09.2018...
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Not Binding Operating and Assembly Instruction Macerator This operating and assembly instruction is only for general information. Type I 110 with flush connection Issue 1 .09.2018...
Index Index Index Index 1 1 1 1 Safety Safety ..........................................................................................1 1 1 1 Safety Safety..............................General notes Safety and warning notes 1.2.1 Warning notes 1.2.2 Danger symbols 1.2.3 Information symbols Dangers that can be caused by the machine Qualification of the personnel Authorised people 1.5.1...
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Index Index Index Index Measures before commissioning.................... 14 Initial commissioning/repeated commissioning De-commissioning 7 7 7 7 Maintenance ............................Maintenance Maintenance Maintenance..................................................................................18 Preventative measures 7.1.1 Machine down-time Lubrication 7.2.1 Joint grease Inspection 8 8 8 8 Malfunctions, causes, rectification ......................
Safety General notes Always keep the operating and maintenance instructions close by the machine. If problems cannot be solved with reference to the operating and maintenance instructions, please contact the manufacturer. Observe the following points in addition to these operating and maintenance instructions: •...
• List item Dangers that can be caused by the machine seepex machines are built in accordance with the state of the art. Nevertheless, there is a residual risk, because the machine works with: • Mechanical movements that pose a danger •...
Avoid/limit risks by the use of collective technical protective equipment or by organisational measures at work. Safety and protective devices Prior to start-up, bolt seepex machines onto a concrete foundation so as to ensure stability. Starting and stopping devices must be clearly recognisable. Take appropriate measures to avoid defects.
Safety Designated use • Only use seepex machines if they are in perfect condition and in compliance with the oper- ating and maintenance instructions. • Do not start up the machine unless the system in which the machine is installed is in accor- dance with the provisions of the applicable guidelines and statutory regulations.
Description of macerator General description seepex macerators consist of: • Cutterhead assembly • Shear plate, rotating cutter head knives • Macerator casing drive Characteristic features • The fixed shear plate has round or long-hole openings. Mode of operation and principle of maceration •...
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Technical data Data sheet Declaration • Data sheet and declarations are commission specific documents and not part of this not binding operating and assembly instruction. Ausgabe Dokument Blatt A / 07.09.2018 1 (1) OM.TED.MACe issue document sheet...
Transport, Intermediate storage, Disposal Safety CAUTION Damage to property/injuries due to incorrect transport Slight injury or damage to property can occur Comply with the safety notes and transport notes on the packaging. Use suitable means of transport, lifting devices and tools. ...
Temporary storage/Corrosion protection If stored temporary for longer periods additional corrosion protection is necessary. Discuss required corrosion protection measures with seepex. Store in dry, closed rooms that are free of frost to protect against ambient influences. Disposal...
Heavy components that cannot be chopped (e.g. metals, stones) Damage to the cutting tools Separate components prior to entry Connect seepex heavy solid collection separator upstream Open emptying flap and remove solids. Installing the fully assembled macerator.
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Assembly / Installation seepex macerator power supply DANGER Line voltage and rated frequency. Death or serious injury will occur. Observe type plate on macerator. Note manufacturer's regulations (Chapter 13). Observe safety regulations. Pipelines 5.5.1 Inlet and outlet connection •...
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Date of installation: Assembly check carried out on: Please enter operational data: Conveying liquid: Temperature: Fuse level/motor protection or power consumption Frequency control If yes: Supplied by seepex Supplied by customer Frequency: Speed: Power consumption: ________________________________ _______________________________________ Place, date Signature / company stamp...
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Commissioning / De-commissioning Measures before commissioning Note the technical data (chapter 3.). 6.2.1 Checking pipelines Check flange screwed connections (SCH). Design: I Design: U NOTICE Ensure unrestrained flow of liquid. Breakdown and/or irreparable damage to the macerator. Open all shut-off elements prior to switching on the macerator. 6.2.2 Protective devices on the macerator DANGER Missing protective device.
Heavy components that cannot be chopped (e.g. metals, stones) Damage to the cutting tools Separate components prior to entry. Connect seepex heavy solid collection separator upstream Open emptying flap and remove solids. 6.3.2 Avoid macerator dry running NOTICE High temperature between knife and shear plate.
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Note dismounting / reassembly (Chapter 9). 6.4.4 Storing/Protecting the macerator from corrosion NOTICE Damage to property from missing corrosion protection. Damage to property may occur from corrosion. Discuss suitable corrosion protection measures with seepex. – Keep commission no. of macerator ready. Ausgabe Dokument Blatt D / 06.03.2013...
Maintenance Preventive measures The maintenance personnel must have these operating instructions, follow them and also require corresponding qualifications. DANGER Dangerous voltage. Death or serious injury can occur. Note safety regulations. Disconnect motor from all sources of energy. Secure electrical connections against restarting. 7.1.1 Macerator standstill NOTICE Macerator standstill.
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Disorders, causes, remedy See the macerator's technical data (Chapter 3) for its application. Operational malfunction Causes Remedy Friction between shear Set cutter clearance. plate/headstock too Put lubricant (liquid soap) large. between shear plate/ knives. Wrong or faulty shear Deburr and clean contact plate surfaces on bearing hous- ing.
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Disassembly / Re-assembly Table of contents: Drive Shaft (102) Disassembly Reassembly After disassembly of the lock nut (106) and locking Lubrication plate (107) the drive shaft (102) will be pressed out of the bearing housing (100). The sectional drawing "Headstock Assembly" and parts list can be taken from Point 9.
Disassembly / Re-assembly Adjust the bearing with lock nut (106) without clearance / pre-clamping and lock it with a new Headstock (905) locking plate (107). Fill the external bearing area A and B with grease 1) . 2.5.1 Adjustment of the distance between knives A - Slip ring (380), fitting discs (112) with a total Shaft Sealing (SEA) thickness of 3 mm (dimension "P"), headstock...
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Disassembly / Re-assembly 2.5.2 Headstock (906), split ring (903) - Re-assembly Lubrication of Headstock Assembly Continue assembly as illustrated and observe The lubrication of the bearing depends on design, particularly: range and size. See document OM.MAI.__, Fill the shaft sealing (SEA) at area "L" with grease Point 7.2.1.3.
Dismantling / Reassembly Macerator Dismantling / Reassembly Range: Size: 9.1.1 Prepare macerator for dismantling DANGER Dangerous voltage. Death or serious injury can occur. Note safety regulations. Disconnect motor from all sources of energy. Secure electrical connections against restarting. WARNING Tilting or falling macerator. Death or serious injury can occur Attach cutter casing (500) to secure the macerator.
Dismantling / Reassembly 9.1.3 Dismantling 9.1.3.1 Macerator - dismantling Alternative A Remove screw fitting (SCH) on pipelines (FLA). Remove pipelines (FLA). Remove screw fitting (SCH) on macerator feet. Observe de-commissioning instructions (→ chapter 6.4). Alternative B Remove screw fitting (SCH) on pipelines (FLA).
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Dismantling / Reassembly 9.1.3.3 Cutterhead assembly (SDE) - dismantling Remove screw fitting (506, 507). Remove drive casing (200) with cutter- head assembly (SDE). Remove O-ring (501). Remove lubrication nipple (128). Remove screw fitting (124, 125, 250, 251). Remove cover plate (120), seal (122) and lip seal (126) from drive casing (200).
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Dismantling / Reassembly Insert O-ring (501) in cutter casing (500). Insert drive casing (200) with cutterhead assembly (SDE) in the cutter casing (500). Mount drive casing (200) with screw fitting (506, 507). 9.1.4.2 Assembling the drive (ANT) Push on distance ring (153) and coupling (149) to limit stop.
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Dismantling / Reassembly Alternative B Insert macerator between pipelines (FLA). Mount screw fitting (SCH) on pipelines (FLA). Mount screw fitting (SCH) on macerator feet. Assemble flushing connection (SSÜ). Ausgabe Dokument Blatt E / 07.03.2013 OM.MAI.11e 5 (5) issue document sheet...
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Additional flushing or circulation pipe of the shaft seal in medium not necessary. • Flushing pipe is possible in certain circumstances and following consultation with seepex. Adjust shaft seal It is absolutely vital to adjust at the application site in a manner appropriate for the operating conditions.
Dismantling / Reassembly 9.4.6 Dismantling mechanical seal Use bolts (351) as forcing-off bolts, (detail – Two additional threaded holes made in housing (333). Push shaft seal (SEA) out of cutter casing (SDE) using forcing-off bolts (351). Dismantle mechanical seal (330). 9.4.7 Reassembly of mechanical seal Shaft seals are high-quality precision parts.
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Dismantling / Reassembly 9.4.8 Flush connection for shaft seal NOTICE Irreparable damage due to overheating/penetration of the product. Material damage can occur. Connect flush connection before commissioning. Flushing medium: water Flushing pressure (Dp): 0.5 bar above the pressure in the bearing housing Flushing volume (QSp): [bar] 50 100 150 200 250 300 350 400...
Stückliste Parts List Liste des pièces Macerator Typ 110 I Macerator Typ 110 I Macerator Typ 110 I Schneideinheit headstock assembly unité de coupage Schnittzeichnung Nr. sectional drawing No. plan no. 075-007A2 075-007A2 075-007A2 Benennung denomination désignation Stck. Pos. Stck. / Pos. Qty.
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Stückliste Parts List Liste des pièces Macerator Typ 110 I Macerator Typ 110 I Macerator Typ 110 I Schneideinheit headstock assembly unité de coupage Schnittzeichnung Nr. sectional drawing No. plan no. 075-007A2 075-007A2 075-007A2 Benennung denomination désignation Stck. Pos. Stck. / Pos. Qty.
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Spare parts 10.1 Spare parts list 10.2 Sectional drawing and parts list Ausgabe Dokument Blatt B / 29.03.2011 OM.SZG.02e 1 (1) issue document sheet...
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Contact: ............Commission: Type: Tel.: .............._________________________ _______________________ Fax: ............... E-mail: ............Customer service: Germany Tel +492041.996-231 Delivery address: seepex GmbH Fax +492041.996-431 ............... Postfach 10 15 64 Rest of Europe Tel +492041.996-224 ............... D-46215 Bottrop Fax +492041.996-424 ............... service@seepex.com Outside Europe Tel +492041.996-120...
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Spare parts Version for copying Quantity Component Material Comment Set of gaskets O-ring / gasket according to data sheet (chapter 3.1) Lip seal Lip seal O-ring Mechanical seal / stationary according to data sheet (chapter 3.1) seat unit O-ring O-ring O-ring O-ring Felt ring...
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Tel.: ..............__________________________ Fax: ............... E-mail: ............Customer service: Germany Tel +492041.996-231 Delivery address: Fax +492041.996-431 ............... seepex GmbH Postfach 10 15 64 Rest of Europe Tel +492041.996-224 ............... D-46215 Bottrop Fax +492041.996-424 ............... service@seepex.com Outside Europe Tel +492041.996-120 ...............
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Zugehörige Unterlagen 12.1 Zusatzeinrichtungen/Technische Information • Zusatzeinrichtungen und technische Informationen sind kommissions- spezifische Dokumente und nicht Bestandteil dieser unverbindlichen Betriebs- und Montageanleitung. Ausgabe Dokument Blatt 1 (1) A / 29.06.2017 OM.ZUG.XXd issue document sheet...
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Anhang 13.1 Herstellerunterlagen / Zulieferer • Hersteller- und Zuliefererunterlagen sind kommissionsspezifische Dokumente und nicht Bestandteil dieser unverbindlichen Betriebs- und Montageanleitung. Ausgabe Dokument Blatt A / 29.06.2017 OM.MDS.XXd 1 (1) issue document sheet...
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Fax +34.91.6409371 info.es@seepex.com Russia China India SEEPEX Ltd. Ugreshskaya SEEPEX Inc. SEEPEX Pumps (Shanghai) Co., Ltd. SEEPEX India Pvt. Ltd. Str. 2 Bldg. 23 511 Speedway Drive Xuanzhong Rd. 399, Building 13 Office No. 305. Enon Nanhui Industrial Area...
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Not Binding Operating and Assembly Instruction Macerator This operating and assembly instruction is only for general information. Type I 110 with flush connection Issue 1 .09.2018...
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Index Index Index Index 1 1 1 1 Safety Safety ..........................................................................................1 1 1 1 Safety Safety..............................General notes Safety and warning notes 1.2.1 Warning notes 1.2.2 Danger symbols 1.2.3 Information symbols Dangers that can be caused by the machine Qualification of the personnel Authorised people 1.5.1...
Index Index Index Index Measures before commissioning.................... 14 Initial commissioning/repeated commissioning De-commissioning 7 7 7 7 Maintenance ............................Maintenance Maintenance Maintenance..................................................................................18 Preventative measures 7.1.1 Machine down-time Lubrication 7.2.1 Joint grease Inspection 8 8 8 8 Malfunctions, causes, rectification ......................
Page 62
Safety General notes Always keep the operating and maintenance instructions close by the machine. If problems cannot be solved with reference to the operating and maintenance instructions, please contact the manufacturer. Observe the following points in addition to these operating and maintenance instructions: •...
Page 63
• List item Dangers that can be caused by the machine seepex machines are built in accordance with the state of the art. Nevertheless, there is a residual risk, because the machine works with: • Mechanical movements that pose a danger •...
Page 64
Avoid/limit risks by the use of collective technical protective equipment or by organisational measures at work. Safety and protective devices Prior to start-up, bolt seepex machines onto a concrete foundation so as to ensure stability. Starting and stopping devices must be clearly recognisable. Take appropriate measures to avoid defects.
Page 65
Safety Designated use • Only use seepex machines if they are in perfect condition and in compliance with the oper- ating and maintenance instructions. • Do not start up the machine unless the system in which the machine is installed is in accor- dance with the provisions of the applicable guidelines and statutory regulations.
Page 66
Description of macerator General description seepex macerators consist of: • Cutterhead assembly • Shear plate, rotating cutter head knives • Macerator casing drive Characteristic features • The fixed shear plate has round or long-hole openings. Mode of operation and principle of maceration •...
Page 68
Technical data Data sheet Declaration • Data sheet and declarations are commission specific documents and not part of this not binding operating and assembly instruction. Ausgabe Dokument Blatt A / 07.09.2018 1 (1) OM.TED.MACe issue document sheet...
Page 70
Transport, Intermediate storage, Disposal Safety CAUTION Damage to property/injuries due to incorrect transport Slight injury or damage to property can occur Comply with the safety notes and transport notes on the packaging. Use suitable means of transport, lifting devices and tools. ...
Page 71
Temporary storage/Corrosion protection If stored temporary for longer periods additional corrosion protection is necessary. Discuss required corrosion protection measures with seepex. Store in dry, closed rooms that are free of frost to protect against ambient influences. Disposal...
Page 72
Heavy components that cannot be chopped (e.g. metals, stones) Damage to the cutting tools Separate components prior to entry Connect seepex heavy solid collection separator upstream Open emptying flap and remove solids. Installing the fully assembled macerator.
Page 73
Assembly / Installation seepex macerator power supply DANGER Line voltage and rated frequency. Death or serious injury will occur. Observe type plate on macerator. Note manufacturer's regulations (Chapter 13). Observe safety regulations. Pipelines 5.5.1 Inlet and outlet connection •...
Page 74
Date of installation: Assembly check carried out on: Please enter operational data: Conveying liquid: Temperature: Fuse level/motor protection or power consumption Frequency control If yes: Supplied by seepex Supplied by customer Frequency: Speed: Power consumption: ________________________________ _______________________________________ Place, date Signature / company stamp...
Page 76
Commissioning / De-commissioning Measures before commissioning Note the technical data (chapter 3.). 6.2.1 Checking pipelines Check flange screwed connections (SCH). Design: I Design: U NOTICE Ensure unrestrained flow of liquid. Breakdown and/or irreparable damage to the macerator. Open all shut-off elements prior to switching on the macerator. 6.2.2 Protective devices on the macerator DANGER Missing protective device.
Page 77
Heavy components that cannot be chopped (e.g. metals, stones) Damage to the cutting tools Separate components prior to entry. Connect seepex heavy solid collection separator upstream Open emptying flap and remove solids. 6.3.2 Avoid macerator dry running NOTICE High temperature between knife and shear plate.
Page 78
Note dismounting / reassembly (Chapter 9). 6.4.4 Storing/Protecting the macerator from corrosion NOTICE Damage to property from missing corrosion protection. Damage to property may occur from corrosion. Discuss suitable corrosion protection measures with seepex. – Keep commission no. of macerator ready. Ausgabe Dokument Blatt D / 06.03.2013...
Page 80
Maintenance Preventive measures The maintenance personnel must have these operating instructions, follow them and also require corresponding qualifications. DANGER Dangerous voltage. Death or serious injury can occur. Note safety regulations. Disconnect motor from all sources of energy. Secure electrical connections against restarting. 7.1.1 Macerator standstill NOTICE Macerator standstill.
Page 82
Disorders, causes, remedy See the macerator's technical data (Chapter 3) for its application. Operational malfunction Causes Remedy Friction between shear Set cutter clearance. plate/headstock too Put lubricant (liquid soap) large. between shear plate/ knives. Wrong or faulty shear Deburr and clean contact plate surfaces on bearing hous- ing.
Page 84
Dismantling / Reassembly 9.1.10 Macerator cutting unit dismantling/reassembly Macerators with flexible coupling Range: I and U Size: 9.1.10.1 Dismantling Dismantling headstock (905) Remove screw fitting (142, 143). Remove conical unit (909), headstock (905), felt ring (910) and fitting discs (112) from bearing housing (100).
Dismantling / Reassembly Remove taper roller bearing (104) from bearing housing (100). 9.1.10.2 Reassembly Remove burrs and edges. Clean bearing housing (100). Clean drive shaft (102). Check lip seal (127) for damage and replace if necessary. Preparing bearing housing (100) for assembly ...
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Dismantling / Reassembly Fill outer areas of bearing A and B with grease. – Refer to maintenance document (chapter 7.0) for grease filling grade. Installing shaft seal (SEA) Insert shaft seal (SEA). – Follow instructions in shaft seal dismantling/reassembly document (chapter 9.4).
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Dismantling / Reassembly Mount reduced fitting disc set (112), head- stock (905) and conical unit (909) with screw fitting (142) on drive shaft (102). Check dimension "M" between cutter in headstock (905) and shear plate (900). – Use feeler gauge (WF). ...
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Dismantling / Reassembly Macerator Dismantling / Reassembly Range: Size: 9.1.1 Prepare macerator for dismantling DANGER Dangerous voltage. Death or serious injury can occur. Note safety regulations. Disconnect motor from all sources of energy. Secure electrical connections against restarting. WARNING Tilting or falling macerator. Death or serious injury can occur Attach cutter casing (500) to secure the macerator.
Page 89
Dismantling / Reassembly 9.1.3 Dismantling 9.1.3.1 Macerator - dismantling Alternative A Remove screw fitting (SCH) on pipelines (FLA). Remove pipelines (FLA). Remove screw fitting (SCH) on macerator feet. Observe de-commissioning instructions (→ chapter 6.4). Alternative B Remove screw fitting (SCH) on pipelines (FLA).
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Dismantling / Reassembly 9.1.3.3 Cutterhead assembly (SDE) - dismantling Remove screw fitting (506, 507). Remove drive casing (200) with cutter- head assembly (SDE). Remove O-ring (501). Remove lubrication nipple (128). Remove screw fitting (124, 125, 250, 251). Remove cover plate (120), seal (122) and lip seal (126) from drive casing (200).
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Dismantling / Reassembly Insert O-ring (501) in cutter casing (500). Insert drive casing (200) with cutterhead assembly (SDE) in the cutter casing (500). Mount drive casing (200) with screw fitting (506, 507). 9.1.4.2 Assembling the drive (ANT) Push on distance ring (153) and coupling (149) to limit stop.
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Dismantling / Reassembly Alternative B Insert macerator between pipelines (FLA). Mount screw fitting (SCH) on pipelines (FLA). Mount screw fitting (SCH) on macerator feet. Assemble flushing connection (SSÜ). Ausgabe Dokument Blatt E / 07.03.2013 OM.MAI.11e 5 (5) issue document sheet...
Page 94
Additional flushing or circulation pipes are not required where shaft sealing lies in medium. • Flushing pipes may be possible under special circumstances and after speaking to seepex. Adjust shaft seal It is absolutely vital to adjust at the application site in a manner appropriate for the operating conditions.
Page 95
Dismantling/reassembly 9.4.6 Dismantling of the mechanical seal Use bolts (351) as forcing-off bolts, (detail – Two additional threaded holes made in housing (333). Push shaft seal (SEA) out of cutting unit housing (SDE) using forcing-off bolts. Dismantling mechanical seal (330). 9.4.7 Reassembly of mechanical seal Shaft sealings are high-quality precision parts.
Stückliste Parts List Liste des pièces Macerator Typ 110 I macerator type 110 I dilacérateur type 110 I Schneideinheit headstock assembly unité de coupage Schnittzeichnung Nr. sectional drawing No. plan no. 075-002A2 075-002A2 075-002A2 Benennung denomination désignation Stck. Pos. Stck. / Pos. Qty.
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Stückliste Parts List Liste des pièces Macerator Typ 110 I macerator type 110 I dilacérateur type 110 I Schneideinheit headstock assembly unité de coupage Schnittzeichnung Nr. sectional drawing No. plan no. 075-002A2 075-002A2 075-002A2 Benennung denomination désignation Stck. Pos. Stck. / Pos. Qty.
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Spare parts 10.1 Spare parts list 10.2 Sectional drawing and parts list Ausgabe Dokument Blatt B / 29.03.2011 OM.SZG.02e 1 (1) issue document sheet...
Page 102
Contact: ............Commission: Type: Tel.: .............._________________________ _______________________ Fax: ............... E-mail: ............Customer service: Germany Tel +492041.996-231 Delivery address: seepex GmbH Fax +492041.996-431 ............... Postfach 10 15 64 Rest of Europe Tel +492041.996-224 ............... D-46215 Bottrop Fax +492041.996-424 ............... service@seepex.com Outside Europe Tel +492041.996-120...
Page 103
Spare parts Version for copying Quantity Component Material Comment Set of gaskets O-ring / gasket according to data sheet (chapter 3.1) Lip seal Lip seal O-ring Mechanical seal / stationary according to data sheet (chapter 3.1) seat unit O-ring O-ring O-ring O-ring Felt ring...
Page 104
Tel.: ..............__________________________ Fax: ............... E-mail: ............Customer service: Germany Tel +492041.996-231 Delivery address: Fax +492041.996-431 ............... seepex GmbH Postfach 10 15 64 Rest of Europe Tel +492041.996-224 ............... D-46215 Bottrop Fax +492041.996-424 ............... service@seepex.com Outside Europe Tel +492041.996-120 ...............
Page 106
Zugehörige Unterlagen 12.1 Zusatzeinrichtungen/Technische Information • Zusatzeinrichtungen und technische Informationen sind kommissions- spezifische Dokumente und nicht Bestandteil dieser unverbindlichen Betriebs- und Montageanleitung. Ausgabe Dokument Blatt 1 (1) A / 29.06.2017 OM.ZUG.XXd issue document sheet...
Page 108
Anhang 13.1 Herstellerunterlagen / Zulieferer • Hersteller- und Zuliefererunterlagen sind kommissionsspezifische Dokumente und nicht Bestandteil dieser unverbindlichen Betriebs- und Montageanleitung. Ausgabe Dokument Blatt A / 29.06.2017 OM.MDS.XXd 1 (1) issue document sheet...
Page 111
Fax +34.91.6409371 info.es@seepex.com Russia China India SEEPEX Ltd. Ugreshskaya SEEPEX Inc. SEEPEX Pumps (Shanghai) Co., Ltd. SEEPEX India Pvt. Ltd. Str. 2 Bldg. 23 511 Speedway Drive Xuanzhong Rd. 399, Building 13 Office No. 305. Enon Nanhui Industrial Area...
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