sh 457 paration Technologies Tomorrow's Technology Today Installation and Operation Manual for Bilge Boy 2.5 gpm (0.57 m°/ hour) Oil / Water Separator 1 |GENERAL INFORMATION 2 | SYSTEM OVERVIEW Manutactured for Separation Technologies By Nelson Industries, Division of Fleetguard / Nelson Model Number: BB00311DXX (115 VAC/ 1 Phase / 50 or 60 Hz) 'BB00322DXX (230 VAC/ 1 Phase / 50 or 60 Hz) Protected by U.S.A. PATENT 4,608,160 and CANADIAN PATENT: 1,274,784 IMPORTANT: READ THIS MANUAL. FOR RECOMMENDED CLEANERS, AND PRIOR TO INSTALLATION, OPERATION, OR MAINTENANCE. Separation Technologies 402 BNA Drive, Suite 500 3 | INSTALLATION AND START-UP MAINTENANCE / 4 | TROUBLE SHOOTING Nashville, TN 37217 (800) 877-4368 5 | COMPONENT DATA 1 STL1040 Revision 1.0 Page 1 of 421.0 2.0 3.0 4.0 5.0 TABLE OF CONTENTS Section Page Number General Information 5 1.1. Purpose and Scope 1.2 Precautions Definitions 1.3 Abbreviations and Acronym List 1.4 Detergent / Cleaner Use 1.4.1 List of approved cleaners 4.8 Product Warranty 1.6 Approval Certificates System Overview 1" 2.1 General 22 Functional 2.2.1 Gravity Separator 2.2.2 Coalescer 2.2.3 Oil Removal 2.2.4 Coalescer Element and Differential Pressure Gauge 2.3 Specifications Installation and Start-up 19 3.1. Mechanical Installation 3.2 Electrical Installation 3.3. Before Start 3.4 Start-up and Operation 3.4.1 Coalescer Element Change-out 3.4.2 Remote switch operation Maintenance 27 4.1 Maintenance 4.2 Long Term Storage 4.3 Troubleshooting 4.4 Replacement Parts List Component Data 39 STL1040 Revision 1.0 Page 3 of 42LIST OF FIGURES Figure Number and Description Page Number . Bilge Boy 2.5 gpm Oil / Water Separator 12 . Gravity Separator 13 . Coalescer Housing 14 . System Flow Paths 16 . Component Identification 17 . Installation Plumbing Guide 20 . Installation Area Recommended 21 . Control Panel Circuit Board— Layout 23 |. Circuit Board Electrical Schematic 24 ‘STL1040 Revision 1.0 Page 4 of 421.0 GENERAL INFORMATION 1.1 Purpose and Scope This manual describes and explains the installation, operation, functioning, maintenance, and trouble shooting of the Separation Technologies Bilge Boy 2.5 gpm Unit, model numbers BBO031 1DXX and BBO0322DxX. 1.2 Precaution Definitions WARNIN Identifies a practice or procedure, if followed incorrectly, has the potential 10 be life threatening or cause serious bodily injury. CAUTION: Identifies a practice or procedure that the operator must observe to prevent damage or destruction of equipment, or failure to maintain water quality. NOTE: Identifies a procedure or condition that requires additional information or explanation. 1.3 Abbreviations and Acronym List AMPS = amperes Cm = centimeters P = differential pressure f= feet ft? = square feet gal = gallons GPM or gpm =gallons per minute Hr=hour ID = inside diameter Kg = kilograms kPa = kilopascal L=liters LBS or Ibs = pounds LPM = liters per minute m= meters m?= square meters m'Mhr = cubic meters per hour mm = millimeter mmiig = millimeters of mercury OD = outside diameter OWS = oilWwater soparator PSI or psi = pounds per square inch PSID or psid = pounds per square inch differential ‘SW2 = PC Board switch #2 T=terminal VAC = voltage of atternating current VDC = voltage of direct current * inches “Hg = inches of mercury STL1040 Revision 1.0 Page 5 of 421.4 Detergent / Cleaner Use CAUTION: For proper performance of the Separation Technologies Oil/ Water Separator only specified detergents and cleaners can be used. Use of other brands or types can cause high separator effluent oil concentrations. In general, detergent use must be minimized. Oil separation performance is heavily dependent on the size and chemical stability of the oil drops present in the water. Larger, less stable drops are easier to separate Certain engine degreasers and bilge cleaners can be used without causing significant adverse effects on the Bilge Boy. Most solvént cleaners containing no detergent Compounds will not affect the separator performance. These include organic solvents suct’as #2 fuel oll. Detergents, defined here as surfactant containing formulations, generally cause the drops to be smaller, more stable and more difficult to separate. The type of detergent, its concentration, and the degree of scrubbing, determine cleaning effectiveness. Unfortunately many cleaners and degreasers create smaller, stable drops that are difficuttto-separate. NOTE: Do-notee cleaners that are emulsifiers or contain high surfactant formulations. Cleaning Recommendations: 1) Use the minimal amount of cleaner with a maximum amount of water. 2) Use high pressure hot water and / or low pressure steam whenever possible. Use the recommended cleaners whenever possible. Electric parts and motors can be cleaned with appropriate solvents. Rust can be removed with acidic solvents. 3) Use the ship's motion to assist in cleaning when possible. Rinse with an excess of water after use. 4) Spray-on / wipe-off cleaners (Formula 409, Fantastic, Simple Green, Super Clean, or the equivalent) may be used ONLY if they DO NOT enter the bilge. 5) Monitor the discharge water closely to determine the effect cleaning operations may have on the separator's performance. Modify the cleaning procedures appropriately. STL1040 Revision 1.0 Page 6 of 421.4.1. List of Approved Cleaners CLEANERS Spic & Span Proctor & Gambel PO Box 599 Cincinnati OH 45201 Phone: (800) 801-1767 Drew Ameroid OWS Ashland Chemical Corp 1 Drew Chemical Plaza Boonton, NJ 07005 USA Phone: (800) 526-1015 Nalco # 2865, Nalco Chemical Co. Water Gy Division 1 Nalco Center Napiervillo IL 60563 USA Phone: (800) 477-3025 NOTE: This listing does not imply that these are the only acceptable cleaners for use with the Bilge Boy system, as Separation Technologies does not sell or endorse cleaners. Other cleaners may be tried in small amounts to determine if they adversely affect the separation performance of the Bilge Boy. If they do not in the small amount, the amount of the trial. cleaner may be increased to that normally used, then assess its affects on performance. NEUTRALIZERS Household White Vinegar ® DEODERIZERS Household Ammonia (non-detergent) STL1040 Revision 1.0 Page 7 of 421.5 Product Warranty For a period of one (1) year from date of delivery, Separation Technologies, Inc. (Seller) engineered products are warranted to be free from defects in materials and workmanship when properly installed, maintained, and operated within the specified working parameters for which the equipment was designed. If the engineered product does not perform as warranted, it will be repaired or replaced, at the Seller's discretion, free of charge, including Parts and Labor. This warranty does not apply to consumable components such as Filter Elements, lamp bulbs, etc. This warranty shall not apply to product altered by anyone other than Seller or their representatives. SELLER SHALL NOT BE RESPONSIBLE OR LIABLE FOR DOWNTIME, LOSS OF INCOME, LIVING EXPENSES, OR OTHER INCIDENTAL OR CONSEQUENTIAL DAMAGES THAT MIGHT ARISE OUT OF THE USE OF THIS PROPERTY. THIS WARRANTY IS THE SOLE WARRANTY MADE BY SEPARATION TECHNOLOGIES IN REGARDS TO THIS EQUIPMENT. SEPARATION TECHNOLOGIES MAKES NO OTHER WARRANTIES, EITHER EXPRESS OR IMPLIED, OR OF MECHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. STL1040 Revision 1.0 Page 8 of 421.6 U.S. Coast Guard / |.M.O. Approval Certificate US.Department.of Transportation V2] United States Coast Guard Certificate of Approval GUARD APPROVAL NO: 162.050/1153/0 EXPIRES: OCTOBER 27, 2004 OTL POLLUTION PREVENTION EQUIPMENT SEPARATION TECHNOLOGIES ‘402 NA ORIVE SUITE 500 NASHVILLE, TN 37217-2625 Model 82 00311 OXX 0.568 cu. m/hr (2.5 gpm). 15 pom, ofl water separator. Model 88 00322 Oxx 0.568 cu. m/nr (2-5 gpm). 15 ppm, oi) water separator. This is to certity that the ofl content meter conprising the equipment listed nas been examined and tested in accordance with the raquirenents of the specifications contained in IMO resolution MEPC.60(35). This certificate is valid only for the of} content meter referred to in this sertificate. Separator manufactured by Nelson Industries, Inc. to dugs. 96506 and s2iet Coaiascer aanufactured by Nelson Industries, Inc. to dwg. aeasao, Control eauipment manufactured by Nelson Industries, Inc. to dug. 62152 Maximum throughput of system: 0.583 cu. m/nr (2.5 gem) Measured of1 contant of effluent less than 15 pom. A copy of this certificate should be carried aboard a vessel fitted with this equisment ae all times. IMO certificates of Type Approval do not expirea and are valid for equipment manufactured at any time during the period of validity of thei Certificate Test data and results attached as appendix. This certificate supersedes approval number 162.050/1125/0 dated 27 October 1994 to transer certificate from Nelson Ind. to Separation Tech. 51s TO CERTIFY THAT he ahve amed milage mia faery vse on ese Min «gop nth tps hyd pon etd on {Caste nd apo saver pen Ths spo at bl ‘cet epraen te bee wae fot cael opel pope exon. GIVEN UNDER HY HAND THIS 27TH DAY OF fORER 1999, AT HASHINGTON D.C. WM ravkolio W. MARTIN, LCOR CHIEF, SYSTEMS ENGINEERING DIVISION 8Y DIRECTION OF THE COMMANDANT, U.S.C.G. ‘ORICA «anise Copy DEPT OF TRANGP, USCG, CoNGTOONO LTH STL1040 Revision 1.0 Page 9 of 421.7 CE Maririe Mark - BVO062 Certificate CE MARINE CERTIFICATE ANTICIPATED TO BE ISSUED BY 1 APRIL 2000 STL1040 Revision 1.0 Page 10 of 422.0 SYSTEM OVERVIEW 21 General The Bilge Boy 2.5 gpm is a two-stage gravity separator / coalescer type bilge oil / water separator (see figure 1). It is designed and fabricated to effectively remove oil from bilge water The system operates at a maximum of 2.5 gpm (0.57 m°/ hr). It may be used with or without oil content monitors / alarms and remote bilge switches (see MARPOL 73 / 78 for specific requirements). This system does not require the use of chemicals or additives. Specific detergents and cleaners, at limited concentrations, may be used for engine room and bilge cleaning operations with the water that is to be processed by this equipment. 2.2 Functional 2.21 Gravity Separator The first stage of the system is the gravity separator (see figure 2). Water is drawn into the unit by suction from either the main or oil pump. The gravity separator is where most of the oil is removed from the water, and where the oil collects to be pumped to a holding tank. Large oil.drops rise to the top of the housing, duo to the lighter density of the oil.’ Smaller oil drops flow down and out at the bottom with the water. From the gravity separator outlet, the water and oil flow through the main pump and into the coalescer housing at the bottom. 2.2.2 Coalescer The coalescer is the second stage (see figure 3). The water and oil flow inside-out through the element. The oil drops are'captured by the element, while the water flows through the outlet to be discharged overboard. The oil caught in the element collects, or coalesces, with ether oil as it moves toward the outside of the element. On the Outside layer of the element the oil grows into drops. The oil drops grow until large enough to release from the element. When the drops release, they rise to the top of the coalescer housing. STLI040 Revision 1.0 Page 11 of 42,Figure 1. Bilge Boy 2.5 gpm Oil / Water Separator Revision 1.0 Page 12 of 42Gravity Separator Housing Figure 2. STL1040 Revision 1.0 Page 13 of 42Figure 3. Coalescer Housing ‘STL1040 Revision 1.0 Page 14 of 422.2.3 Oil Removal ‘The difference in pressure between the gravity separator and the coalescer housings produces flow through the 0.95 cm (0.38 inch) OD Oil Return Tubing (see figure 4). Oil collecting at the top of the coalescer housing flows through the return tubing to the inlet of the gravity separator. A metering valve controls the flow to about 0.4 LPM (0.1 gpm). Water also flows through the return tubing and helps keep the tubing free flowing. The oil retumed to the gravity separator inlet is of a drop size that will separate from the water and collect at the top of the gravity separator housing, When about 2 L (0.5 gal) of oil has collected in the gravity separator, it will cover the oil detector probe. When the oil.detector senses a 50% or higher concentration of oil, it will send a signal to the control panel. The controls stop the main pump and start the oil pump. The oil is removed from the top of the grauity separator and pumped to the ship's waste oil holding tank. After about 20 seconds the oil is removed, the pumps switch back again, and the system continues processing water through the separator. NOTE: Air in the gravity separator is detected as oil by the probe. Prolonged “dry* operation of the oil pump will cause damage to the oil pump impeller. 2.2.4 Coalescer Element and Differential Pressure Gauge - Water and oil can pass through the coalescer element. Dirt and other solid — contaminants in the oil and water get trapped. In time the dirt will clog the element to the point where it will not coalesce oil properly. This is when the element needs to be Teplaced. A differential pressure gauge measures the clogging of the element. A gauge reading of 69 kPa (10 psid) or more indicates that the element should be replaced. A red line has been added to.clearly indicate pressure above 69 kPa (10 psid). NOTE: Read the gauge only when the main pump is operating. The differential pressure gauge includes a switch that can be used to indicate when the element should be changed. The 120 VAC 4 amp (3 amp 30 VDC inductive) rated switch is pre-set to close a set of contacts at 10 psid. See the electrical section for wiring information. STLI040 Revision 1.0 Page 15 of 42‘System Flow Paths Figure 4. ‘yuey Buypioy tto pas Bnvp oinssald Fepuexoyig quowers dung urew SNISNOH ua9SSTYOO wOLveVdaS ALIAVES: ‘STL1040 Revision 1.0 Page 16 of 42Component Identification Figure 5, aBnep aunsseidg lepuaieyig juewey duing ujew 32nN|O 4272 3880 110 quewala Alen 4eagajZ0D Buyexew yaluy OU}. LUN}2y HO. SNISNOH YOLVeVdas YsOSATVOO ALIAVES: STLI040 Revision 1.0 Page 17 of 422.3 Specifications MAXIMUM FLOW RATE: 2.5 gpm (0.57 m°/ hr) SEPARATOR TYPE: Two Stage - Gravity Separator / Coalescer DIMENSIONS: 28 inch (71 cm) HEIGHT 35 inch (90.cm) — WIDTH 16 inch (41m) DEPTH INLET: 1% inch NPT QUTLETS: % inch NPT WEIGHT: — 150 Ibs (70 Kg) DRY 220 Ibs (100 Kg) WET CAPACITY: 8 Gallons (30 Liters) TOTAL 4 Gallons (15 Liters) EACH HOUSING OPERATING PRESSURES: RELIEF VALVE SET AT 15 psig (104 kPa) GRAVITY SEPARATOR: 12 inch Hg (804 mm Hg) Maximum Vacuum GRAVITY SEPARATOR HOUSING HYDROSTATIC TEST: 150 psig COALESCER ELEMENT: 10 PSID (69 kPa Differential) COALESCER HOUSING HYDROSTATIC TEST: 150 psig ELECTRICAL: Model BB00311DXX: 6 AMPS @ 115 VAC/ 1 Phase / 50 or 60 Hortz Model BB00322DXX: 3 AMPS @ 230 VAC / 1 Phase / 50 or 60 Hertz STL1040 Revision 1.0, Pago 18 of 423.0 INSTALLATION WARNING: Installation MUST be done by qualified personnel [46CFR 110.15-160}, following accepted plumbing and electrical practices. Read the complete Installation Section prior to installation. Unsuitable installation can result in improper operation, component damage, and potentially hazardous conditions. Make certain ALL Installation Steps are completed correctly. THIS PRODUCT IS NOT TO BE INSTALLED IN HAZARDOUS LOCATIONS AS DEFINED IN THE US COAST GUARD ELECTRICAL ENGINEERING REGULATIONS. WARNING: Motors can spark. Explosion & death can occur. Do not use where flammable vapors are present. -Not to be installed in hazardous locations as defined in the US Coast Guard Electrical Engineering Regulations [4SCFR 111.80-5(a)(8) to (10). 3.1 Mechanical 1) Identify all of the system components and check for possible damage or missing components. (see figure 5) Using figures 6 & 7 as guides, install the OWS using 3.8 cm (1.5 inch) 1D or larger non-collapsible hose or pipe on the inlet and 1.9 cm (0.75 inch) ID or larger non-collapsible hose or pipe at the-outlets: 2) Allow as much room as possible for solids to collect under the inlet without entering the system. Be very sure the inlet plumbing is air tight. An air leak into the plumbing may damage ar destroy the oil pump impeller. 3) _ Install a suitable strainer and’a foot valve (check valve) on the inlet piping. NOTE: It is recommended that unions be installed as close as possible-to the check valves on the water and oil discharge lines. An air leak is not as noticeable as a liquid leak. Carefully check all inlet piping. CAUTION: Both the oil & water discharge plumbing should include a vertical section at least as high as the top of the OWS. This is necessary to help prevent siphoning and provide a slight back pressure to assist sealing of the check valves. CAUTION: Some types of engine coolant rust inhibitors, anti-freezes, and Tow temperatures may cause damage to the pump impellers. STLI040 Revision 1.0 Page 19 of 42Installation Plumbing Guide Figure 6. ue Bupproy tte pesn C q | sfnug ainsgaig fenuoowia Wpwers souyHOSIC ¢waLYM STLI040 Revision 1.0 Page 20 of 42Figure 7.. Installation Area Recommendation 162m 422m 4) 0.61 m (2) above the top '0.31'm(1") beyond each end 0.91 m(3}) in front and behind ‘STL1040 Revision 1.0 Page 21 of 423.2 Electrical, WARNING: ELECTRICAL INSTALLATION AND CONNECTIONS ARE TO BE MADE ONLY BY QUALIFIED PERSONS. FOLLOW ALL APPLICABLE CODES AND PRACTICES, HAZARDOUS VOLTAGES ARE USED. DISCONNECT POWER AT S. THE SOURCE BEFORE PERFORMING ANY SERVIC! AN, vawcer 3.2.1 Oil/ Water Separator Electrical Connections: Wi pone Model.BB00311DXX: Seicrecseoe «© Connect "HOT" 115 VAC lead to T13 FOR MANUAL *HAND* OPERATION. * Connect *HOT* 115 VAC teat! from the bilge level control switch to T18 FOR REMOTE SWITCH "AUTO" OPERATION. * Connect “NEUTRAL" 115 VAC lead to T14 or T17. Connect "GROUND to T15 or T16. Model BB00322DXx: * Connect "HOT* 230 VAC lead to T13 FOR MANUAL "HAND" OPERATION. * Connect *HOT" 230 VAC lead from the bilge level control switch to T18 FOR REMOTE SWITCH AUTO" OPERATION. * Connect "NEUTRAL" 230 VAC lead to T14 or T17. * Connect “GROUND to T15 or T16. 3.2.2. Differential Pressure Gauge / Switch Connections: * The red wire.is wired to the normally closed contact. The black wire is wired to the normally open contact. The white wire is wired to the common contact. Contact rating: 4 amperes at 120 VAC (3 amp at 30 VDC) inductive. The wire leads.are 12 inches long, 18 AWG. 3.2.3. Oil Content Monitor Connections: NOTE: A remote switch (Oil Content Monitor or Bilge Alarm relay contacts) — may be connected to the control panel to stop the system when high oil concentrations are detected, Connect the normally open (overboard) relay contacts to TS & T6. When high oil levels are detected (alarm mode) and the switch contacts close, the separators alarm relay (K3) is activated. This will disconnect power to both pumps. STL1040 Revision 1.0 Page 22 of 42Figure 8... Control Panel Circuit Board - Layout 88 5 8 Gay of} | OFF O00 Oo} Lole ane = oO] poe OOO we 4 |e r ‘lol Lole ser Bozcz * Soe) Se - @ e ° a tte E Pago 23 of 42Figure 9.. Circuit Board Electrical Schematic NOTE: Fuse sizs or 965048 STL1040 Revision 1.0 Pago 24 of 423.3 Before Start-Up 1) Be sure the main switch is "OFF* with the electrical Power disconnected from the source. 2) Recheck the electrical connections and all plumbing to be sure they are correct. 3) Check Circuit Board to ensure Switch SW2 is in the center position. 4) Fill both Gravity Separator and Coalescing Housings, and all inlet plumbing with water. 5) Open the Oil Return Line Metering Valve 1 turn counter-clockwise from fully closed CAUTION: A closed Oil Return Line Metering Valve is unsuitable because oil will ill the Coalescer Housing and be discharged with the water. Open the Oil Return Line Metering Valve more when the bilge water contains mostly lube or other viscous oils. Opening the Oil Retum Line Metering Valve more than suggested 1 tum does not affect the separator performance, but it will reduce the water flow slightly. 8) Check all fittings, nuts, bolts, vents, afid covers for tightness. 7) Be sure the supply tank has enough water in it so that air will not be drawn into the system, 3.4 Start-Up 1) Apply power to the system and tum-the main switch to "HAND". The oil pump will Tun first for about 20 seconds. The blue indicator light on the control Panel should confirm the oil pump operation. CAUTION: If the system has air in the inlet plumbing or gravity separator, the oil pump impeller may be damaged if run dry for more than 30 seconds. 2) Alter about 20 seconds the oil pump should stop and the main pump will start. The white indicator fight will confirm the main pump operation. NOTE: If the oll pump operates initially for more than 20 seconds, or frequently when little or no oil is present, air may be entering the system. Tum the main switch to ‘OFF*. Check for air leaks and refill the gravity separator if necessary. See the trouble shooting section for testing procedures. STLI040 Revision 1.0 Page 25 of 422) 3) 4) 3.5 Changing:the Coalescer Element Tum the main switch to *OFF* and disconnect the power at the source. Open the Coalescer Housing drain plug at the bottom of the housing and drain the water into a container. NOTE: Opening the cover vent will speed draining. About 16 L (4 gallons) will drain. Remove the cover, the element nut & washer, and the rubber spacer. Remove the element by lifting it straight up. CAUTION: Be careful not to damage the 0.95 cm (0.38") OD oil return tubing inside the Coalescer Housing. 5) 6) 7) 8) 9) 10) 11) Wipe out all the oil off the inside of the housing. Install a new element (either end up). Reinstall the drain plug, spacer, washer and nut. Hand tighten the element nut. NOTE: A3 mm 0.13") space is common between the element nut and washer. Fill the housing with water. Replace the cover, tighten the cover clamp and close the cover vent. ‘8:6 Remote Switch Automatic Operation For automatic operation using a remote switch (ie: bilge lavel control switch) when connected as indicated in the "Electrical Installation” instructions, turn the main switch to the AUTO position. STL1040 Revision 1.0 Pago 26 of 424.0 MAINTENANCE 4.1 Maintenance Once every 6 months clean the oil detector probe. Change the oil coalescer element every 6 months or as indicated by the differential pressure gauge. 4.2 Long Term Storage (4 weeks or more) 1) Tum the main switch to OFF" and disconnect the power supply at the source. 2) Drain all fluids completely from the system. This includes the all plumbing to the inlet, outlet, and waste oil hotding tank. 3) Open and wipe clean both housings. 4) Remove and discard the coalescer element. 5) Open the oil retum metering valve fully (counter-clockwise) and apply slight air Pressure to the coalescer end of the oil return tubing. This will clear the tubing of oil, water and debris. WARNING: DO NOT USE EXCESSIVE AIR PRESSURE. WEAR EYE AND OTHER PERSONAL PROTECTION TO PROTECT FROM FLYING DEBRIS. 6) Loosen the pump covers and drain the pump cavity. 7) Lightly lubricate the pump impellers. This prevents damage to the impeller during the next start up. A.silicone type lubricant is recommended. 8) Replace the pump gaskets and covers, and tighten. 9) Replace the housing gaskets, covers and clamps. STL1040 Revision 1.0, Page 27 of 42ap joez jo JOs1UOD pue SsoUreY o11m eu 186} OSIe [IM esNPEDOIT SIU :3LON “spuooes 02 s! eu uopesedo duind yo 8 un enode J, 9 ©, “8, Sdais wedeH “D 46H pinous soveo;puy duind uew oyu ou Ltn PUB ‘spUddES OZ inoge 40} 14Bh PInoYS soyeorpuy duund yo enyq eu, ,CNYH, 0} YOUMS UreW eLN WIN PUB LeMOd Aiddeey “A funupeu “Kejop ewin etn eseaioep 0} esy}00I0 jod penojs aun Bulwum Aq eu Aej@p suojinjones o¢] (‘ese=10U 01 esIMyO0K (guy) moos seyewon (r7em, 84 UI 110 OU Jo ern Sey eB) “ojeyduoo spuose: ‘exe sjueusnipe pue s1S6} el) UEYM Sesny EY eoR|deLy “SuNeipdo sdwund ey NOUN K pt S Oe peyoeyo oq oF syuBil »g Annoy 109 Ot MOM [IM € BSNS ® Z ESN BUACWOL :3LON uey} e401, «NO. duind 110 __ “edo jy | esr Jo ‘puno1g 01 Hous 0} eum sedunf yLwied JOU OG :NOLLAWD "Pesny gzesn4 enowey “CG Cheon Buyew ey) Jo sfeUJWHO) eu UeDMIeg ouIM soduIN| BurDeId Aq 10}98I9P I (Aeme yyBreais ind pue qer ‘Bnjd BuneW soyJe1ep Ho etn EAOWEH “a 20IN0S OU Je JeMOd O4Y JOSULOISIP PUE AO. OF UDIIMS VIEW WNL “Y NOILOV SAILOSYHOD: asnvo a7avsoud WOLAWAS HGIND ONILOOHS 37ENOUL wb ¢z hog ebi1a ep2p 40 62 e6eg ‘Buldjd re}Uy etn Jo sseuryBp erp yoyo “Burdid yoyuy fe yoyo Anjos 480) pinby| B se e\qzeofoU se JOU &] yee] J7e UY “ION. ‘S261 10) Burquinid yey etn yoe4o 360p uonipuco ey) 11 “enoge 2, dexs yeede1 pue sence eup eDideu “worn 1SUle1 UB\YA SOBI0 JO S]UEP 20} 184SEB JOO PUE JenCO eu HEU OSIY “PIN INS 0q 0} s0]U80 OWN Ut ‘eGN} UIEIP Ho ALR 4OBUD “iI ‘Mh JOU 81H Yaldulod 5} 1 63ns oq o} 1ojexedes Aynes6 ey OUD UOLA ‘enoge y, 1eedeH “yno sawios ‘ye jor ;Susquinjd ebzeyosip 110 eu us ei} wiry pue ‘seMod Kidde} “> ideoxe ‘Buyyjou 4] spuoses o¢ s0ye WeysK: JO Ino ewo9 pINOYs JeIBM 10 11 “NYH. 01 Yous “s01eM 10 ue eoeid pur ‘Aue yoeo 0} Burquinid ey) sepun s8urequoo pezis Ajerenbepe yo94o e6yeyosIp duund yo Eyl eye Buyquinid euy yoeuucdsiq “g “eoinos ey) Je JeMod ey) JOSULODSIP PUE .140. 0) YOWMS UIE WN, “y : “worsts eu, 20148 jOUUBO se JEU) 08 ‘aje1edo 0} 19}0M Jo BLUNIOA UeIoHINS B eABY ISN eBIIG OULL “31ON 740) Pinoys s0}B0IpUI enjq ey) eqoud so}O@IEp jI0 eu SeyaEEL Jone] BLY LOUAA, sorezedes AyAe46 ety Wo.) 1078 64) UIBIP ‘UO JOFEAIPUI SHUM SUN LIM “ah jod sitn ysed 166 youu NOK 4 sonquisip 800] ano 10 seGojouyse | uoHIesEdes fed “suoposuUoD SSoULEI ‘Suuim oun pue | esng Hoey ‘enoge ,y, mo}jo} ueddey Jou seop sity duind urew ey ey) uous pue ‘spuoses oz inoge 4 duund jo eniq eu “.GNYH. Of yams UTeW BU) nous JO}Bo|pUL DUE JeMod Aiddeoy “yo 1en09 oy) onBey “J0}eM Y soyeredes Aynes6 oy jt "8 @sny BZ esNy now I< goo G "80iN0S OU We JeMOd eYp JOBUUODSIP PUP . JO, 0} YOUN UNeYY LUN No Ayney 284) U} Yo OU J0 on Sey of Spuodses Oz uey) a0 wNOn dwnd 110 NOIWOV SALLOSHHOO asnvo s1avaoud WOLdWAS HIND ONLLOOHS 31ENOUL WE ¢°z hog aba ebFane Ou 19 HOE OT WO fees yeys ou Ul yee] se Ue esneo UEO duind ey) Jo weWUBYESIN, “AnosuI09 porTEIsuIEL Uueeq sel | eunsue 0} eu ‘Jo}OUs ey) WOH} penowe: Ueeq sey duind 110 eU) H “H, ‘s¥20| 1 e1q)ssod 10} Aynjoxe0 Bujquunjd @Bse42sIp 110 PUE JIU} By YOBYD “eAOge Woy 09 @ EF Sdais pue ‘a deis ‘e# esneD reeded ‘ioreredes Aynes8 lp Ul $12 101012 | “D “swiojgoud enyen yoeyo eouesinu enjose: Kew [Buds (Isd 2-1) eat p4-Z] eafen oeyo edh} pepeo| Buds Y “ALON ‘enTeA yoeus ull eBsEYO8Ip No OMY couIdeLS “4 82 'L'9 soinfy ees “joo1109 5] uoNEHeIsU) oY) 12M euNsUE 014984 “a “soreredes Aynei6 etn jo do} ey) seu oq pinous fone! eu Yer reup oun Bulppe sey “ovesedes AyAB1B 84) o1U| Y9EQ pedNod og UBD TEU junowe ey elon, “eBejids enpun ino\yM Penowes eq 0 J8ACO BLA MOHE IM SIL “JENCD 04 Burrow! e10jeq iovevedes Auabi6 oun wos (WUId 1) 7.$°0 INoge AlUO UIeIC :310N ‘e1e\ynewios Buyquunyd eByeyosp yo oun uy S| Yee} etn “dor eu UI St se 0u 40 ‘Jono Joje1edes AynwiB uy enQUIE! PUE ,4O, 0} YOUMS UW OY NL °C “penduse Ajeye/duioo s} ue Aiddns ey e10}0q 0 LOWS UU eu) win, Ue) Aiddns ey} LOI} eu] LONONS Buy JeIU OY sTe Mole JOU OG :ALON, 1 ‘Aiddns ou) 10 ‘uo sewoo Joveojpuy duing yo eu nun e118 weysKs oy) 167 “ejesedo pnoys dund uyew euy ueLy Ue spuoges OZ Inoge 40} 1UBh Pinoys Joyeorpul duund j10 eniq GUL. ".GNWrY. 04 YOUNS UJeW eLy Luny pu 1emod AiddeeH “OD -euyy eB1euDsy jo ety Brjd pise g esny enowey “a “eaunos o4} 18 10Mod OU }ELUOOSID PUB AID. O1 YOUNIS LIB WNL “Y “Buyquinig eBreyosiq IO ul 4ee7 AV (sevem ‘941 Ut 10 ou 40 oma Sey spuoses 0z uey} S10; »NOn dung 10 NOILOV 3AILDSHHOO 3SNVO F1aVaOud WOLdWAS HGIND ONILOOHS 31ENOwL wWdB ¢°z Aog e618 ey2p 10 Le ebeg “ObByDEIG 10] BURT SDTEWDSIp TO BU HOOYS OS|e PUR SEBLID 10]TaTETU und eu} yo8yo '(2ch4 01-40 sd ¢'L-) BH YoU) € UeWy Sse} Spee! eGneD wnNdeA OLN“ ‘SuoneyuM UoReIEIsU YN ¥e4D “| ‘9620019 10 suonolnses 104 Buyquinyd yeyuy eum yoouD “3 'spuoces o¢ 10} weysfs eu) eye16do AIUD :NOLLNWO JOU Seop uo}eH SU Ui “(Ba Op- 40 Bisd g-) BH youl s} eoge 40 UUMS Urew eu LIN pure seMod eu) AIddeey “@ (1, 2:n614) syuy pepuouusooes ey mol Jore1edes eu) 10 peio) Je speas eBne6 winnoea et “SONVH, “Buydnoo {UOu! B/E 64) UI eGNeG wnnoeA e eoeId PUB JerEM WJM JojeLedes AyABIB OU IL} “O “Yeno9 sojezedes Aynei6 ou JeIUe9 8uN UI JUEA LAN YOU! B/E SsBIq ey exoWeY “g “eosnos ey) ye 1emod A YOOUUODSIP PUP 140. OF YOUMS VIEW WNL “y (quewe)3 Je0seje09 etn BujBueYD, pue s98nBD eunssedg lenue16}1q ¥ JUSWIEIS 18959/200, UO suojToes 64) ees) “ebpULED conideu ‘(229 £'0) pisd of speeoxe ebe5 | “S625 punsseig fenuEieyig HooUD “y quewerg JEN PeBGNIg FenueWy si4p Ul suONEYWT BuIquinig MeMey _“y. uone}/e}suUy /Buiquinig 1e1400u syed pebewep 40 85840019 104 Suquinyd woysks 641 Pur ‘sojou! ‘seyfeduy duund eyeudordde ey) yoeyo ‘uoHeD9} s0U6 2 AHO] E18 SION “D ‘quiod 8141 puoeq Buiquinid eu (duind soo) MO}y Waysig MoT Ul UonoU|sed 40 e6ex00/q & eq ysnWU e16y) ‘sUOHeDO] @SU) JO YIO" Je poo6 18 “elqissod Buiquinig eu uy Se SOnTeA yOoU UI 0} B80)9 SE ‘BBLEYOSIP 10 puE J61eN eUN YIOg JO} MoM ONL YOEUD -y | _ONOUISEY JO e6EYOOIg NOMOV SALLOSYYOO 3ShV9 S1avaoud WOLdWAS AGIND ONLLOOHS 31ENOUL wd6 gz fog 26); epSBI WHOL 5407, :penjve Loyoas ey) Jed se euy uInjo1 yo ey Ino LEAD ‘sissied weIgord et foie and ‘61M UBEFO AJUO YIM SO;NUIL 8} Bujsno} 48088200) SMO otn exeiedg “(esuj00}0-163unN09 Buyeyoui uinyes yo exp uodo soyeredes Ayneld 10 uj exouses ‘[rehe} (,Z) Wo UBL) e101 8] Bulsnoy se0seleco aut 0} peuunjel Jou SI “juewsor|dey juewe|3, einpesoid ou) BuymoIio) Ajinjareo jueWe|® OY) iSules pure @NOWOY “Y 40088/209 J981/00U, (-aaueysisse 10} Jomnquasip je90] anos WJ29) “ennoeJep S| Zy ABIEH °O (osn 7 : Jeuee|gjueBie\eq ees osiy) ‘UOHISOd 48189 GUY U! S} ZAMS YOUMS JEU eANSUB 0} HEYD “g lo wm Guys JOIRM aBseussiq (voyses Bujooyseignoy oyoeds euy e8g) ‘uopounyew sojoeeq 10 “y | S| J0VeIedeg AUAEID EYL | Ul UOWJEUGDUCD “peBfind ewosag seq Je15 B2q eu) UeYM eyeoypul O} eBNeB wNNOEA e EISUI “O 10 payena|ya . "Boxe eoepns 40 (.4 2) 54 Z'0 Jo wnluju e sey pur ‘uo.oIW ¢ Ye pared SI Feu euO Jo9Ios ‘posh 5} JOM Seq, uy Bnid Ajyoinb jj Jey Spros einjdeo oy Aog eBj1 ey; e10Jeq 104) edAy BEQ a “quowera 89807¢00 yj BuiBueyo, pur ,ebnen ensses -p juouie|g 18080209, uo SuoRIes 201M ‘oui 90g ‘Bulpee: e6neg ensseig 10 ey) e10u pur s0Predes oy) ereiedO_“Y ul peo" spiios UBIH, NOILOV SALLOSUHOD asnvo s1avaoud WOLdWAS ACIND DNILOOHS 31ENOUL was ¢°z Aog e611 ep2p 10 E¢ e6eg ((pasojo yoms sioBuEO ON *6") [ey] ABjes WHET YI yoRYD 'smte}s Ayrenb seem ebzeyosIp 10} wuEe J0 JOyUOUI etn YO0UD “90uN0S eu) 12 J8MOd eY) JOBUUOOSIP PUB .a140, O} YOIIME UW WNL pelenioy Abjey Wely yaHmg ure eoeidou Ile ao oc Ayne4 YoUMs ueW. “woyoeuuos 200d 10 811m 8800] & 10} p120q yNov!o PUB YOUUMS UIE e4Y WON PU 0} SEMI BLA YORU (01 8 6 seinby eas) “39019 JBUIULeY Bu Te Uo}I2eULOD Jood 10 exym 8500) © 10} BULA BujWOOU) etn ¥oeUE) ‘2008 oY) 18 JOMOd OUI JeUUODSIP PUR ,4-I0, 0} YOUMS UEW win S ww onoeuuog BuLIy Jog “soyesedes seyem / 10 yp Jo jeuEd JosjUOS @4y 0} Jemed ¥eUD ‘20un08 JeMtod etn 90D “8030S eu 18 JeMOd OLY JOBUUOOSIP DUE .-14O, 0} YOUME UIEW WNL 80INOg BY Ye JeMOg ON “G eng 10 en 60e/d8 JO/PUE YOOUD {821N0S 8U 18 1OMOd YL TOSULOOSI UE JO, OF VOWS UTE wun I< ile i wuedo, ¢ esng 10 » sn GNOx 81 Yous UIEWY) eyeiado JON S80q Wa}sis NOILOV SAILOSHHOD 3SNVS S7avEoud WOLAWAS AdIND ONILOOHS 371SNOUL WB ¢'z hog ablIg ey“yeu 10I0W 10 pur soyedust ‘eieaugn ‘pex9o| | Alex) sejej0s sojeduu eunsue pue s8A09 Jenedul] dwng enowers pey907 WEUS 10,0 /_sej}eduy} dunes BuIqUINIc VEIN UI SHEET AY 40} AEUD dn -4eig 0} sou s61eM 16 1n-exe Bussno}| se0seTe09 pue soTeredeg finer WOM NSU" Aug Buluuny dung wSN3dOn asn4 Udy - SUWLL yous sayesadQ 40}0W dung NO, Sou OTe cwuerake exp Bupsayees juedo, | eNO. Saure7 zoreo|pUIy 010)0q exnyeiedwey wOo4 0} J000 0} OW OLY MOITE PUB JO, OF UgIIMS UTBW ei WNL “y | PECHEAC fEUUELLL JOON wasieda iON “dund jo eu 10) ¢ esr. pus duund uew eYt 10} Z BSN HOeUD “a $009 1010) dung *@01NOS ey Je JoMod ey JOBUUODSIP PU 140. O} YDNMS UU ey WNL“ wuedo, esn4 “so0p xoq jo11U00 ‘4p uo eyeid Budnoo ety ou! 4o2q y90Ig YeWUOD eLY SseId PUE ging eM) EdRKdeH “a nq e1p sseo0e pue 0019 yeIUCD (.4d0, Sduse7 soyeorpu) uf esveje: 0} qe} Gupjooy ey Aud Apue6 ‘ienyp MelOs ‘epeIa WBIENS EWS B LIM “O 400p joued jonuos ey ued “g sayes0do Jojo; dwing ‘e0unos ayy ye omod @un 198uUOOSIP PUB JO, 0} UOIIMS UW OUP WNL “Y yne peuing due, “uonsenb u} J07eOIpUI BUY 0} #2019 feUIUNE euY LUBY) BULA eM HOU “a ‘canes ou 7 ioniod ey eUUCOSIP pue Jo, UpIMS UW eM wn “y| __BUlslNp @S00| 10 Jog NOILOV SAILOAHHOD asnvo a18veoud WOLdWAS AGIND ONILOOHS 31sNOUL wdé s‘z Aog e6i1a evep jo ge e6ed ‘uoysenb eney Nok J 1O\NqUISIP {200} INO JoeIUOD “hyoeu109 Peieuuoo exe LEH B PL H ‘EL # SUIM esNs eq 0} oNeWEYDS BULIM etp 4OeYD “P1204 yNDH}O Jeued jox1409 eu oF Ajyedosd peyoeuuod s) sseuseY eum BUY SoWINESE 1501 SILL !SLON “uojesedo jeuou yim Suinujuoo e10}0q € BZ Sesny eoeide1 pue ‘Bnjd BuyeU eu oouUcdes ‘eum sedun| en enOWOL} “+ ‘2030S eu JB JeMod }OeUUODSIP PUB .H:IO, 01 YOHIMS Jomod UEW OLY WIN “| “uoWe1edo /eUOU UI SB YOWMS PUB UOROUN} pINoYs syYyBI| JoTeOIpUL duind ety pue sovoeyep jo ein ssed-Aq 0} jeuBls aA zi etA sMoyE By JeduN| ou, “a “GONVH,) Uo Yous ujeU by) win} pue JeMod eo\sey “3, “Bujeredo wo1} sduind ou ueneid 0} € Z Sasny enoweY “G 'sin990 Punois e j! uedo jm | en ‘puNoAB 0} YoUS 0} eum edwin] OMY MO}Te 10U OG "NOI “uo jo seded 10 e1 yews y ‘Enid Sunew oi jo sjeujue) .g, PUB , +, olN SSO10e nf @ yoeuu0g “O 10 ey) wou, Bnjd Guyeus ssowey eum elg oouUoDSI “a 18 18MOd 198UUODSIP PU ,4.10, 01 YOWNE LIEW WIN] “y 1uoo pue sseUeY e11m Bunse} J04 10}99}6p 110 SseC-Aq OL orbs sojpeuueg enn aod so1omIec No 618 ASAL AULINDEID TOULNOD / SSANYVH SHIM /3d0Ud HOLOSiaq 110 HIND ONILOOHS 31ENOUL WB ¢°z og abyIg ey4.4 Replacement Parts List ST ‘OLD NELSON DESCRIPTION PART NUMBER PART NUMBER 'BBOO311DxXX ‘965044 Bilge Boy 2.5 gpm 115VAC/ 1Phase / 50 or 60 Hz (BBOOS22DXX 965048 Bilge Boy 2.5 gpm 230VAC/ 1Phase /50 or 60 Hz: 391950588 99036K Recommended Spare Parts Kit (consists of one (1) each of the following: Q56732, 59330, 059329, 062021, 262018, 062017, Q62178, 059213, 88580C, 058403, & 0229039) 391950688 ‘99004K Purp Kit (consists of one (1) each of the following: Q56732, 59330, 059329)_ 391950788 "05672 or 98953A_| ‘Pump Impeller [391950888 (059330 Pump Shaft Seal - Nitrile '391950988 (59329, Pump Cover Gasket ‘391951088 062021 or 99961A | 7amp Fuse 391951188 [62018 or 99958A_| 6 amp Fuse. 991951288 [262017 or 99957A_| % amp Fuse 397951388, ‘Gb2i78 Pump Ingleator Lamp — Pre 1997 Production Units 391951488 59213 | Pump Adapter O-Ring 391951588 '88580C Coalescer Filer Element ‘391951688 (058403 Housing Cover Gasket ‘391951788 0229039 Pump Indicator Lamp ~ 1997 and after Production Units i 391851688 Oi52883, Bilge Alarm Mounting Bracket 391951988, (228036 ‘230 Volt AC Oil Pump indicator Assembly 391952088. (0229037, 290_Volt AC Main Pump Indicator Assembly 391952188 (0229040, Mode Selector Switch 391952288 (0229048 115 Volt AC Main Pump indicator Assembly 391952388 (0229049 15 Volt AC Oil Pump Indicator Assembly 991952488 0229051 ~ [415 VAG 7/230 VAG Conversion Kit 301952568, "0229201 or 99963A_| Oil Detector Assembly 391952688 | 061919 Control Panel PC Board 391952788 062125, Pump Head (No Motor) 391952888 "G62i71 oF 99970A | Pump Motor (No Pump Head) 391952988 (069730 ir Chieck Valve. 391953088 71156 Differential Pressure Gauge 397953188 ‘Q7a4o2 1/8" Female NPT Gauge Fitting 391953388 (078396. "34 Male NPT Fube Fitting = "91953488 ‘25605 “% Formed Tube (Gravity Separator Housing to Main je Pump) 391953685 78357 ‘3 Female NPT Tube Fitting 391953788, 69284 4 Hose to" NPT Fitting STL1040 Revision 1.0 Page 36 of 424.4 Replacement Parts List (continued) ST ‘OLD NELSON DESCRIPTION PART NUMBER. PART NUMBER 991953888 (55040 Decal Sat (inlet, Outlet, Drain) 391953988 (68864 3 NPT Elbow 1391954088. (969288 Pressure Relist Valve 391954188. (Q25606 "34° Formed Tube _(Main Pump to Coalescer Housing) 391954986. (061935 ‘Control Panel Box Assembly 391954488 (043745 ‘Namepiate 391954588. (968867 34” NPT x 7- long Nipple 391954688 (Q69512 34° NPT Check Valve (391954788 (032304 ‘Oil Retum Line Assembly 391954888 978395 1/8" NPT Male Connector 391954988, (68865, 34° x He x 3/8” NPT Reducing Tee. 391955088. (969231 34° NPT Close Nipple. 391965188 (049753 Decal Set (Water, Oil, Main, Pump, Element) 991955288 Q4i176 Service Manual 391955388 (059398 (0.88 OD x 0.5010 Gasket STLI040 Revision 1.0 Page 37 of 42STL1040 Revision 1.0 Page 38 of 42,5.0 COMPONENT DATA PUMP AND MOTOR SPARE PARTS KEY DESCRIPTION MFGR MFGR PART ‘ST PART # NUMBER NUMBER 4_[Screw, End Cover Plate 91002-0090 NIA 2 [End Cover 11833-0000 NIA 3 _| Gasket *** 9156-0000 391950988 4 impeller *** Jabsco {9200-0003 391950788 5 "| Seal ** 1040-0000 391950888 6_| Body 9154-0000 NA’ 7_| Screw, Pump to Motor 98019-0020 N/A 8 | Motor Leeson NWA 391952888 N/A [Pump Head Assembly Jabsco 9130-0003 391952788 NOTE: *** Means included in Pump Spare Parts Kit (ST P/N: 391950688) STL1040 Revision 1.0 Page 39 of 42MOTOR: May be configured for: 1/4 Hp, 115 VAC, single phase, 60 Hertz, 1725 R.P.M., 50°C Ambient 4/4 Hp, 230.VAC, single phase, 50 Hertz, 1425 R.P.M., 50'C Ambient Continuous duty, clockwise rotation, non-ventilated, 4 amp max (115 VAC) 3 amp max (230VAC). Draw, 416 SS shaft, automatic thermal overload, split phase capacitor starting, sealed ball bearings, special urethane coating of all internal components, water drain holes, shaft seal to resist fluid penetration PUMP: Service Instructions: A. DISASSEMBLY 1. Remove the-end cover screws, end cover and gasket. 2. Withdraw the impeller by pulling it straight out from pump body. (Install a new impeller and replace the cover, gasket and screws, or continue if replacement of the shaft seal is required.) 3. Remeve the-screws that attach the pump bady to the motor. NOTE: The pump is mounted “upside down" when reading the cover. 4. Disconnect the pump from the separator plumbing and-loosen the motor mounting bolts. NOTE: When servicing the MAIN PUMP loosen but DO NOT REMOVE the tubes attached to the bottom of the gravity separator housing or the coalescer housing. This wilkassist the alignment and re-assembly. 5. Tap the pump body lightly between the ports to loosen it, and then pull it straight away from the motor to remove it. 6. Press the seal out of the seal cavity of the pump body, noting the direction of the lip. STL1040 Revision 1.0 Pago 40 of 42B. ASSEMBLY 1. Press the new seal into the seal cavity of the pump body with the lip in the same direction as when removing the damaged one. (The lip should face the impeller bore of the pump.) NOTE: The retainer supplied with the replacement seal is not normally required in the bronze body pump assemblies. 2. Lubricate the lip of theseal and the motor shaft, preferably with a silicone type grease. : 3. Reattach the pump body to the motor. NOTE: The pump should be mounted "upside down" when reading the cover. 4. Reconnect the separator plumbing to the pump. CAUTION: The brass Swagelok (compression) tube fittings have a fine thread and are easily cross thread. Take extra care when aligning and reassembling them. 4, Tighten the motor mounting bolts. 5. Align the flat of the impeller drive hole with the flat of the motor shaft and gently push the impeller into the pump body with a clockwise twisting motion. Compressing the impeller blades together will assist the assembly process. NOTE: Do not damage the impeller blades on the edge of the cavity. 6. Reassemble the cover, new gasket and cover screws to the pump body. STL1040, Revision 1.0 Page 41 of 42STL1040 Revision 1.0 Page 42 of 42