Eaton 2596 Manual

Installation, Operation &
Service Manual
Model 2596
Self-Cleaning Strainer
2” to 8”
IOM 2596 2-8 Rev 0
1
Table of Contents Page No.
Introduction ……………………………………...
Receiving, Handling & Inspection ……………..
Storage ………………………………………….
Installation ………………………………………..
Start-Up ………………………………………….
Operation ………………………………………..
Normal Shut-Down ……………………………..
Emergency Shut-Down …………………………
Maintenance ……………………………………….
Internal ……………………………………………
Reducer …………………………………………..
Manual Operation of the Backwash Arm ……..
Disassembly and Parts Replacement ………..
Removal of Cover & Operating Mechanism ….
Seals Replacement……………………………….
Lower Bushing Replacement ………………….
Upper Shaft Seal Removal…...………………...
Upper Shaft Seal Replacement .……………….
Motor Replacement ……...………………………
Speed Reducer Replacement ...………………..
Trouble Shooting ………………………………..
Drawings …………………………………………
Backwash …………………..…………………….
Assembly ………………………………………….
Recommended Spare Parts …………………….
Introduction
A self-cleaning strainer is a device installed in a pipe-
line to remove dirt and other unwanted debris from
fluids. Straining is accomplished by directing the fluid
through "sized" openings in perforated straining ele-
ments. Self-cleaning strainers have integral back-
wash systems designed to isolate and clean a small
portion of the element while the remaining area contin-
ues to strain normally. During operation, fluid flow
through the strainer is continuous. A small quantity of
"clean" fluid is used to wash the element and then
carry the concentrated debris away from the strainer
through the backwash system.
Read all instructions before installation or
operation of equipment. Failure to comply
with these instructions could result in
bodily injury or property damage.
Eaton Filtration, LLC
44 Apple Street, Tinton Falls, NJ 07724
Phone: [phone] Fax: [phone]
e-mail: [email protected]
Web: www.eaton.com/filtration
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Introduction, Continued
Self-cleaning strainers are installed where continuous
removal of debris from the process fluid is required and
where fluid flow cannot be interrupted for cleaning the
straining elements. These strainers are used where
manual cleaning is not convenient or practicable for
reasons such as: the need for frequent cleaning, possi-
bility of strainer not being cleaned when required due to
remote location, variable loading rate, etc. Trapped
debris is retained inside straining element cavities.
These accumulated solids are then backwashed
through the hollow backwash arm shaft to a waste line.
Self-cleaning strainers are rated to withstand the pres-
sure of the piping system design.
Receiving, Handling and Inspection
Prior to shipment, strainers have all external machined
surfaces coated to protect against rust. All openings
are covered and the motor-reducer unit is wrapped with
plastic.
Inspect strainer after unpacking for damage incurred
during transit. Report any damage to carrier immedi-
ately. If strainer is not to be installed immediately, refer
to storage instructions.
Remove preservative with solvent wetted cloths. Exer-
cise care when using solvent.
Check to be sure the rated pressure and temperature
on the strainer nameplate is not less than the maximum
pressure and temperature of the system. The rated
pressure shown on the nameplate is the maximum
working pressure - including shock - at which the
strainer may be operated.
Check to be sure the available electrical power matches
the voltage, phase, and cycle requirements of the
strainer motor.
Remove flange and thread protectors. Check for and
remove any foreign or loose materials such as blocking,
desiccant bags, etc. that could be carried downstream
when fluid is introduced into the strainer.
Storage
Store strainers indoors in a clean, dry environment
whenever possible.
Replace all protective wrappings, flange protectors,
plugs, etc. which may have been removed during
receiving inspection.
Outdoor storage, when unavoidable, requires special
treatment described below:
Place a bag of silica gel or similar desiccant in each
pipe connection to absorb moisture
Attach to inside of flange protectors and put reminder
labels on outside.)
Reapply rust preventative to any machined surface
that became exposed due to handling or receiving
inspection.
Make sure all openings are covered. Seal flange
protectors with waterproof tape.
Wrap motor-reducer unit with plastic and secure with
tape. Permit air circulation or provide adequate des-
iccant for moisture control.
Protect the entire strainer with heavy polyethylene
wrap and seal with waterproof tape.
CAUTION: Before strainers are put into opera-
tion after storage be sure to remove all desic-
cants, protective bags, caps, plugs, etc. Inspect
gasketing and shaft seals for possible deteriora-
tion and replace as required.
Inspect oil level in reducer and check lubricant
for accumulated condensation.

3
Installation
Position the strainer in the line so that the fluid enters
the connection marked inlet.
CAUTION: Lift strainer with slings under the inlet
line nozzles and through the reducer mount. Con-
nect all 3 points above strainer for stability.
Be sure sufficient headroom is provided for easy re-
moval of the internal parts.
Support the strainer in the line as follows:
These strainers are provided with footpads or slotted
openings to accommodate the use of anchor bolts.
Put the strainer in place on concrete or foot mounts.
DO NOT support the strainer or the piping coming to
and from the strainer by the strainer flanges or flange
bolting.
Do not support the strainer, or the piping coming to
and from the strainer by the strainer flanges and
flange bolting.
Connect the strainer to the line. Use the same type
flange faces. For example: Do not bolt raised face
flanges to iron flat face flanges. Iron flanges must be
flat with full face gaskets.
Strainers are subject to face-to-face
variations due to shrinkage, machin-
ing and fabrication tolerances. Pre-
fabricated piping systems must allow
adjustment at the strainer connec-
tions.
Be sure flange gaskets are in place and fasteners are
tightened to correct torque values.
Attach a drain line to the bottom NPT drain connec-
tion. Install a ball, gate, or plug valve in this line.
Keep this valve closed except when necessary to
drain the strainer.
Attach the backwash line to the bottom NPT back-
wash connection. A vigorous backwash flow is neces-
sary for proper operation of the strainer. It is impor-
tant to prevent pressure loss by having a short, free-
flowing backwash line with a minimum of bends, el-
bows or vertical runs.
Install a backwash valve in the backwash line. The
valve may be manually or automatically operated.
This backwash valve is to be used only for full-on/full-
off control.
For all applications, a manually operated pinch valve
(supplied by others) to throttle backwash flow may be
installed downstream of the backwash valve. See
‘Suggested Backwash Line Installation’, Figure 3.
Prior to start up, inspect the inlet waterway for wooden
chocks that may have been provided to restrain the
backwash arm during shipping. Remove wooden
chocks if provided.
Prior to start up, rotate the backwash arm manually to
assure freedom of movement. To operate manually,
the drive pin must be removed from the top of the
shaft.
See “MANUAL OPERATION OF THE EXTERNAL
BACKWASH SYSTEM”. Use an adjustable wrench
on the flats provided on the shaft to allow at least one
complete revolution to assure freedom of movement.
CAUTION: Be sure power source matches motor
requirements. Damage may occur if improperly
connected. Motor starter should incorporate a
thermal overload device to protect the motor. In-
terlock strainer motor with process fluid service
pump where feasible. Install a fusible disconnect
or circuit breaker on the incoming power service.

Start-Up
Check the reducer for lubricant. Reducers are
shipped filled with oil. Before operating, the breather
plug must be installed in the top of the reducer (should
be placed in the uppermost side). See “Maintenance
Reducer” section.
Open reducer vent that has been plugged to prevent
lubricant loss during shipment.
Energize strainer motor and/or controls.
Open vent on strainer cover.
Slowly fill the strainer with fluid. Close strainer vent
when fluid begins to overflow the vent.
CAUTION:
The strainer must be filled with the working fluid
for operation to lubricate all bushings. Do not op-
erate strainer dry.
NOTE: Good operating practice dictates that the op-
erator observe the strainer carefully for several weeks
to determine the best operating mode, that is, continu-
ous or intermittent backwash. Refer to “Self-Cleaning
Strainer Control Panel Instructions” provided with
such equipment.
Operation
Operate the strainer in the continuous mode only,
unless controls for intermittent operation have been
provided and energized.
Normally the vent and drain valve are left in the closed
position. Approximately once each week, open the
drain valve for two to three minutes to remove any
settled debris on the strainer bottom. Note amount of
debris discharged. Frequency of this operation is de-
pendent upon the type and amount of trapped solids
in the liquid.
Take daily readings of the pressure drop across the
strainer to ensure proper operation.
CAUTION: Total pressure drop in excess of 10
psig is a warning signal requiring investigation
and corrective action. Permanent damage may
result if operated in excess of 15 psig.
Start-Up...Continued
If the differential pressure exceeds 10 psid:
Check strainer to verify rotation of the backwash arm.
If the shaft (visible at top of strainer) is rotating then
arm is rotating (refer to Trouble Shooting Section).
Check backwash line for restrictions. Valves in this
line should be opened fully, except for high pressure
or mesh screen applications in which case the back-
wash control and/or throttling valve should be adjusted
to a flow rate which produces thorough cleaning.
Position drain valve fully open for 2 to 3 minutes to
clear strainer of accumulated debris.
Increase the duration of the backwash cycle by adjust-
ing the timer in the control panel.
Should the pressure drop still remain above normal
with the backwash operating, close the outlet valve
and open the backwash valve fully for several min-
utes. If the pressure drop is not normal upon resum-
ing flow through the unit, the strainer should be shut-
down and internally examined.
Normal Shut-Down
Backwash the strainer for at least six minutes to clean
the strainer element.
Close the inlet/outlet flow valves. Then slowly open
the bottom drain valve and the vent on the strainer
cover.
De-energize strainer motor and/or controls.
Follow standard maintenance procedures contained
herein. Do not allow the straining elements to dry
while full of debris.
Emergency Shut-Down
To quickly shut-down the system, close the inlet and
outlet flow valves.
Fully open all vents and drains. Proceed with cau-
tion as the strainer may be under full pressure.
De-energize strainer motor and/or controls.
Follow standard maintenance procedures as soon as
possible.
4

Maintenance—Internals
At scheduled intervals, the strainer cover should be
removed for internal inspection (refer to “Normal
Shut-Down” procedures).
Follow “Removal of Cover and Operating Mechanism
Assembly” procedures.
Inspect assembly for damage or wear due to normal
operation.
Examine straining element and check for mechanical
damage or blinding. Refer to Disassembly and Re-
placement Parts Procedures.
Clean straining element thoroughly. Cleaning may be
accomplished by scrubbing the straining element with
a bristle brush or spraying with a high pressure hose.
If necessary the straining element may be steam
cleaned.
Maintenance—Reducer
The oil in a new reducer should be drained at
the end of two weeks or 100 hours of operation,
whichever comes first, and the case thoroughly
flushed with a light flushing oil. The original oil can
be used for refilling if it has been filtered; otherwise
new oil must be used.
After the initial maintenance in Item 1 above,
it is recommended to change the reducer oil every
2500 hours of operation or every six months
(whichever comes first) for units operating under nor-
mal conditions. If the unit is operating in extremely
dirty or high temperature environments, the oil should
be changed more often.
The unit should be filled when not running to
the center of the oil sight gauge or the oil level plug
with Mobil 600W cylinder oil or equivalent AGMA 7 or
7EP lubricant when the ambient temperature does
not exceed 90оF.
For units operating in ambient temperatures
normally between 80оF – 125оF, Mobil 600W super
cylinder oil or equivalent AGMA 8 or 8EP lubricant is
recommended. Please refer to gear reducer manu-
facturer’s instruction operation manual.
Manual Operation of the Backwash Arm
.The Strainer is furnished with a drive pin that when
removed allows manual operation.
De-energize the power supply to the strainer motor.
Remove the drive pin.
The drive shaft is now disconnected from the reducer
and may be rotated manually.
Manually open the backwash control valve (manual
cleaning only).
Place a wrench on the flats at the top of the backwash
arm/shaft. Rotate the shaft at 1-1/2 turns per minute
and long enough to get the required low pressure
drop. Direction of rotation is clockwise.
CAUTION: Do not use excessive force on the
backwash arm. Disconnecting the shaft from the
reducer also disconnects the shaft from the pro-
tection of the motor overloads. If excessive resis-
tance is met, the cover must be removed and the
source of blockage cleared away.
To return the strainer to normal operation, first close
the backwash control valve.
Replace the drive pin.
Energize the power supply to the strainer drive motor.
The strainer is now ready for operation.
Disassembly and Parts Replacement Proce-
dures
The strainer cover assembly may be removed and
disassembled without removing the body from the
process piping. This permits examination or replace-
ment of any internal part.. Refer to this manual and
the included assembly drawings for the location of
parts.
CAUTION: Do not perform any maintenance on
this strainer until normal shut down procedures
have been performed
Removal of Cover and Operating Mechanism
Assembly
Complete “NORMAL SHUT-DOWN” procedure.
Disconnect power source and remove fuses in the
control panel.
5

Removal of Cover and Operating Mechanism
Assembly...Continued
Disconnect electrical connections to the motor.
Match mark the body girth flange with the cover girth
flange.
Loosen and remove all studs and nuts from the cover
assembly.
Using slings under the gear reducer that attach above
the whole strainer cover assembly, gently lift the cover
assembly straight up.
Place the cover assembly on an elevated SECURE
surface with wooden blocks that has enough room the
loosen the bolts securing the bottom Cenpeller plate
to the cover.
Loosen and remove the four bolts securing the bottom
Cenpeller plate to the cover.
Carefully lift the cover assembly straight up until it
clears the top of the straining element. This will leave
the backwash arm/shaft attached to the cover assem-
bly.
Place the cover assembly on a SECURE surface.
Take precautions to prevent tipping over and or falling
of the cover assembly.
The straining element with Cenpeller support will be
left on the secure surface. This will allow removal of
the straining element. The straining element may now
be inspected and replaced as necessary. Note: the
top element o-ring is now available for inspection.
To remove the backwash arm/shaft, position the cover
assembly in an upright position. Make sure that there
is ample support under the backwash arm/shaft.
Make note of the relative position of the shaft and the
reducer top. Remove the drive pin from the top of the
backwash arm/shaft.
Using slings under the gear reducer that attach above
the whole strainer cover assembly, gently lift the cover
assembly straight up. This allows the backwash arm/
shaft to slide out of the gear reducer and the top seal.
Note: You must be positioned to support the back-
wash arm/shaft as it will be unsupported as it clears
the reducer and seal.
Other components to be inspected at this time include
the lower bushing, inner and outer internal seals in the
body and body O-ring. To reassemble, reverse the
above steps as applicable.
Body O-Ring, Inner and Outer Internal Seals
Replacement
First, complete “Normal Shut Down” procedure.
Disconnect power to the strainer motor, and discon-
nect the motor leads.
See "Removal of Cover Assembly and Straining Ele-
ment" Instruction Steps 1 through 7.
Inspect body O-Ring, inner and outer internal seals
and replace as necessary.
Replace Cover Assembly by reversing steps referred
to in “Removal of Cover Assembly and Straining Ele-
ment” above.
Lower Bushing Replacement
First, complete “Normal Shut Down” procedure.
Disconnect power to the strainer motor, and discon-
nect the motor leads.
See "Removal of Cover Assembly and Straining Ele-
ment" instructions Steps 1 through 11.
Inspect the lower bushing on the backwash arm/shaft
for signs of wear. If wear is excessive, remove and
replace the bearing.
NOTE: This is a composite material and is force fit on
the backwash arm. The nature of this material is to
relax and therefore become loose. The bushing
should be changed if there is a very loose fit. Exces-
sive or eccentric wear will then occur on the backwash
arm. To remove a tight fitting damaged bushing, care-
fully cut apart and slide off the arm.
To replace the lower bushing, press fit the bushing
"inside" diameter over the "bushing" surface of the
backwash arm. Approximately 200 pounds of force
will be required.
Replace Cover Assembly by reversing the Instruction
in “Removal of Cover Assembly, Straining Element &
Backwash Arm/Shaft”.
6

Upper Shaft Seal Removal
First, complete “Normal Shut Down” procedure.
Disconnect power to the strainer motor and discon-
nect the motor leads.
Disconnect power and remove fuses in the control
panel.
Disconnect electrical connections to the motor.
Upper Shaft Seal Removal.. Continued
Make note of the relative position of the backwash
arm/shaft and the reducer top. Remove the drive pin
from the top of the backwash arm/shaft.
Remove the four (4) bolts holding the speed reducer
and motor to the cover assembly.
Carefully lift the reducer and motor straight up until it
clears the top of the backwash arm/ shaft.
Remove Screws (B) from the Housing (A) & slide
Housing (A) over the backwash arm/shaft. See Fig-
ure 1
The Upper Bushing (D) and the two (2) Quad-Rings
(C) can be inspected and replaced as needed. See
Figure 1.
Figure 1
Upper Shaft Seal Replacement
Refer to Figure 1.
Slide Gland Gasket (F) down the backwash arm/shaft
to the Packing Block (machined area around the top
central hole of the cover).
Slide O-Ring (E) down the backwash arm/shaft to the
Gland Gasket (F).
Slide Upper Bushing (D) over the backwash arm/shaft
to the Upper O-Ring (E).
Lubricate the two (2) Quad-Rings (C) with a light film
of Process Compatible Lubricant and insert each into
the Housing (A).
Upper Shaft Seal Replacement..Continued
Slide Housing (A) over the backwash arm/shaft, until
the Housing (A) rests on the Packing Block and over
the Upper Bushing (D).
Align holes in Housing (A) and Gland Gasket (F) to
the Packing Block.
Insert the Screws (B) into Housing (A) going through
the Gland Gasket (F) and into Packing Block and
screw until tight.
Replace the gear reducer and motor using Instruction
Steps 8 through 13 in “ SPEED REDUCER RE-
PLACEMENT”.
7

8
Motor Replacement
First, complete “Normal Shut Down” procedure.
Disconnect power source and remove fuses in the
control panel and motor leads.
Remove bolts holding the motor to the reducer and
the key from the motor output shaft.
CAUTION: Do not Allow the Motor to Drop Or For
It To Rest On The Shaft.
Install the key on the new motor output shaft. Install
the new motor on the reducer and secure with motor
mounting cap screws.
Reconnect the power leads to the motor.
Replace fuses and reconnect power source.
Speed Reducer Replacement
First, complete “Normal Shut Down” procedure.
Disconnect power and remove fuses in the control
panel.
Disconnect electrical connections to the motor.
Remove bolts holding the motor to the reducer and
place the motor on a secure surface.
Remove the key from the motor output shaft.
CAUTION: Do not Allow the Motor to Drop Or For
It To Rest On The Shaft.
Speed Reducer Replacement..Continued
Make note of the relative position of the shaft and the
reducer top. Remove the drive pin from the top of the
backwash arm/shaft.
Remove the four (4) bolts holding the speed reducer
to the cover assembly.
Carefully lift the reducer straight up until it clears the
top of the drive shaft.
Position the new reducer in relative position as in Step
5 above. Secure with bolts.
Install the drive pin.
Install the motor key on the motor output shaft. Install
the motor on the reducer and secure with motor
mounting cap screws.
Check lubricant levels in the reducer and check the
vent.
Reconnect the power leads to the motor.
Replace fuses and reconnect power source.

9
Trouble Shooting
High Differential Pressure due to high solids
loading in process fluid:
Increase length of backwash cycle or backwash
continuously.
Backwash Arm not rotating, Motor overloads
tripped:
Obstruction between straining element and back-
wash arm.
Misalignment of backwash arm.
Bearing failure.
High Differential Pressure due to piping:
Shorten backwash piping by eliminating elbows,
vertical pipe runs and restrictions due to valves,
fittings, etc. By removing pipe friction loses, system
pressure losses are reduced.
Trouble Shooting, Continued
Backwash Arm not rotating, Motor and/or reducer
failure:
Incorrect voltage applied to strainer motor.
Overload heaters in motor starter improperly sized.
Lubricant level in reducer too low, reducer vent
plugged, or no lubricant.
Control Problems:
Blown fuses.
Incorrect voltage applied to control panel and/or
valves, switches, etc.
Incorrect wiring between control panel and valves,
switches, alarms, etc.
Differential pressure switch improperly adjusted.
Insufficient air pressure applied to pneumatically oper-
ated backwash valves

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Suggested Backwash Line Installation
Figure 2