7
© Copyright 2017 Zoeller
®
Co. All rights reserved.
Cutter Maintenance
To remove star cutter: Heat the center
bolt to 177 °C (350 °F) to loosen Loctite
®
thread sealant.
Grind the Star Cutter and Disc seen here to a 32 microfinish. Surfaces
must be flat to within 0.025 mm (0.001") T.I.R. Gap must be between
0.178 mm (0.007") and 0.305 mm (0.012") on these parts.
1.
All power circuits must be disconnected and locked out before
any attempts are made at servicing.
The star cutter and disc can
be removed and sharpened by grinding the cutting faces. Both star
cutter and disc must be removed from the pump. Removal of these
parts can be accomplished in the field by removing pump from the
sump and positioning horizontally to access the intake of the pump. If
seals or other repairs are required, the pump must be totally removed
and serviced in a shop by a qualified pump technician or authorized
service center.
2. Thoroughly clean the star cutter and disc assembly. Tilt pump back to
the vertical position to make certain the end play has been removed.
Check and record the clearance between the star cutter and disc with
a feeler gage. The correct running clearance is between 0.178 mm
(0.007") and 0.305 mm (0.012").
3. With pump in horizontal position, heat the hex head bolt in the center
of the star cutter with a propane torch. The bolt must be heated to
177 °C (350 °F) to soften the thread lock sealer on the bolt for ease of
removal. Remove the bolt by turning in a counterclockwise rotation. It
will be necessary to use a wood block to prevent the star cutter from
turning while removing the bolt. Pull star cutter from the shaft and
remove the spacer shims located behind the star cutter.
4. Remove the six cap screws holding the disc and remove disc from
the pump.
5. The disc and star cutter can be replaced with new service parts or
resurfaced by grinding. Resurfacing is accomplished by surface grinding
both disc and star cutter to a 32 micro finish. Do not attempt grinding
in the field. Send parts to a qualified machine shop or return to the
factory for repair. The disc, star cutter and shims are a matched set.
Keep parts together. Measure disc before and after resurfacing with
micrometer and record measurements.
6. After resurfacing, the disc and star cutter must be flat within 0.025
mm (0.001"). If the disc has been surface ground, it will be necessary
to remove shims to compensate for the material removed from the
disc. As a starting point, remove shims of the same thickness as
the amount machined from the cutter disc. Final running clearance
must be between 0.178 mm (0.007") and 0.305 mm (0.012"). Be sure
pump is in vertical position and all end play has been removed before
measuring.
7. Clean bottom of pump where disc is located and replace disc and
retainer screws. Torque to 28 kg (63 in-lbs) - 30 kg (67 in-lbs). Replace
star cutter with the correct shims. Install washer and torque hex head
bolt to 23 kg (71 in-lbs) - 34 kg (75 in-lbs). apply Loctite 262 thread-
lock sealant or equal to bolt threads prior to insertion. Check running
clearance with pump in vertical position to remove end play. Clearance
must be between 0.178 mm (0.007") and 0.305 mm (0.012") to obtain
efficient grinding when pump is put back in service.
8. Check the oil in the motor housing before reinstalling. Contact the
factory if the oil has a milky appearance or burnt smell. The level
should be even with the fill plug when pump is in the upright position.
Add oil if required. Use insulating oil supplied by the factory.
FIG. 6.
Operation, continued
• Spray coat unpainted surfaces with rust inhibiting oil.
• The impeller should be rotated every six months in order to keep the seal lubricated
and not develop a permanent set.
If panel is to be stored, the following is advised:
• Store the panel inside whenever possible and leave in the shipping box.
• All openings shall be sealed.
• Store in an upright position.
• Do not stack anything on top of panel.
START-UP PROCEDURE
Before placing the equipment into operation the following should be checked:
• Clean pit.
• Electrical boxes dry and securely installed.
• Floats positioned properly.
• Discharge valves open.
• Adequate water level in basin for pump submersion.
Once the above has been verified proceed with the following checks:
• Pump power cables and control floats properly installed and voltage verified.
• Conduit connections to panel are properly sealed.
• After installing the pump into the containment area, with adequate submergence, open
the discharge valve fully. Start the unit using manual controls. If flow is appreciably
less than rated performance, pump may be air locked. To expel trapped air, jog the
unit several times, using the manual controls.
• Have a qualified electrician take voltage and current measurements with the pump
running. Record these readings in the space provided in the
“Owner’s Information”
section on page 1 of this manual for future reference.
ADJUSTMENT PROCEDURE
Pumps: No adjustments are required.
Floats: Refer to the system drawing or to the panel wiring schematic for the desired
location of each float switch setting.
Valves:
Discharge valves should be placed in the fully open position. Systems should
not be operated for extended periods of time with the discharge valves
partially closed due to damaging the valve.
SHUT-DOWN PROCEDURES
If a system is shut down for more than six months, the following is recommended:
Pumps: If pit is to remain dry, then the pump can remain in the pit. Do not run dry. If
the pit is to remain wet, the pump should be removed and stored as noted
above.
Panels: The panel should have all openings sealed to prevent moisture and dust from
entering the enclosure. Prior to restarting system, the panel should be inspected
for presence of moisture and any loose connections.
Valves:
Consult the valve/actuator supplier for information concerning these systems
components.