Ebbco GRS-0250-B-CC User manual

INDUSTRIAL FILTRATION SYSTEMS
MODEL # GRS-0250-B-CC
OPERATION AND MAINTENANCE MANUAL
EMPLOYEES

Page 3
This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Contents:
Section 1 Introduction.
1.1 Introduction.
1.2 Sequence of Operation.
Section 2 Specification.
2.1 Utilities Requirements.
2.2 System Specifications.
Section 3 System Installation and Start-Up.
3.1 Installation Procedure.
3.2 Start Up Procedure.
Section 4 Maintenance.
4.1 Garnet Removal System Daily Check List.
4.2 Garnet Removal Pump Suction Basket.
4.3 Garnet Removal System Pump.
4.4 Garnet Removal Centrifugal Separator.
4.5 Work Tank Sweeper Package
4.6 Abrasive Bag Hopper
Section 5 Troubleshooting Guide.
5.1 System Troubleshooting.
5.2 Pump Troubleshooting.
Section 6 Spare Parts.
Section 7 General Policy & Limited Warranty.
Section 8 Product Literature & Drawings.
8.1 Pump Suction Strainer Basket.
8.2 System Pump.
8.3 Centrifugal Separator.
8.4 General Assembly.
8.5 Layout drawing.
8.6 Sweeper Package.
8.7 Electrical Schematic.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 1: Introduction
1.1 Introduction
This following technical manual provides instruction on installation and operation of the Garnet
Removal System manufactured by Ebbco Inc. With correct maintenance and system operation the Garnet
Removal System will keep garnet form building up in the waterjet cutting machines work tank and will
increasing production by eliminating down time for tank shoveling. The Garnet Removal System will
require some assembly on site. This will include sweeper package assembly and connecting the Garnet
Removal System to the waterjet cutting machines work tank. The Garnet Removal System is
manufactured using quality materials and by highly experience production staff. The Garnet Removal
System is tested in Ebbco's test department to ensure that it meets the specifications required by the
customer. The Garnet Removal System is inspected and all test data documented prior to shipment.
1.2 Sequence of operation.
This system is designed to keep garnet from building up in the cutting table. The method used to
achieve this is the use of agitation on the bottom of the tank by water pumped through eductor header
nozzles located and directed in engineered locations. The garnet thus stays in suspension due to the
agitation and is carried out of the tank by way of the heavy duty centrifugal pump. It is pumped through a
centrifugal separator, which concentrates the garnet in the fluid stream and separates it for disposal into
an abrasive bag hopper. Excess water that comes out of the separator when it purges the solids from the
collection chamber is decanted from the hopper, returning to system tank.
SYSTEM TANK
Note: This is a generic model of the layout of Ebbco’s
GRS-0250-B-CC-MC system. Your individual
components (# of eductors and their positioning, for
example) and system positioning may vary depending
on your individual needs. Please see the Parts List
(Section 6) for a list of your individual components.
Strainer Basket
Separator
Pump
Abrasive
Bag Hopper
Centrifugal
separator
Suction
line
Discharge line

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 2: System Specifications
2.1 System utilities requirements
Inlet connection : 3" steel hose barb
Outlet connection: 2 1/2" steel hose barb
Electrical: 230vac/3ph/60Hz
Full load amps: 33.0 amps
2.2 System components
Pump suction basket – PKG-98
Cast iron housing with flanged inlet and outlet connections. Internal basket is constructed of perforated
stainless steel.
System pump – PCL 2x3x10B-CC+6
Close-coupled, all iron construction, 316 stainless steel shaft sleeve, semi-open impeller.
Motor:
Electrical: 230vac/3ph/60Hz
Horse power: 10 hp
Full load amp @ 230vac: 25.6 amps
Speed: 1760 rpm
Enclosure: TEFC
Pump: PCL 3x4-10-B-CC+6
Impeller: 10“dia.
Centrifugal Separator -SDS-250-B
Carbon steel construction, designed to remove 98% of particulate from liquid, sized at 74 micron and
larger with a specific gravity of 2.6 or higher.
Maximum particle size: 3/8-inch
Maximum pressure rating: 150 psi
Pressure loss range: 4.5 to 12 psi
Electrical controller – EHOA-3
Disconnect supplied by others. Provide maximum upstream protection per NEC code 430-52 and table
430-152
Enclosure: Steel, Nema 12
Transformer: 75va primary/secondary fused
Filter pump starter module: Internal sort circuit / thermal overload.
Filter pump starter module: PKZ2 Internal sort circuit / Thermal overload.
Thermal overload yellow dial set point 230vac: 25.6 (FLA of motor)
Sort circuit red dial set point 230vac: 332.8 (13 times FLA of motor)
Pressure gauge – GRS-60-GA
Range: 0-60 psi
Face
dia: 2"
In
letsize: 1/4"NPT
Casematerial: Stainless/steel
Wetted parts: Brass

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 2: System Specifications
Vacuum gauge – GRS-V-GA
Range: -30inhg -
0psi
Face
dia: 2"
In
letsize: 1/4"NPT
Casematerial: Stainlesssteel
Wetted parts: Brass
Abrasive bag hopper – 1-CUYD-ABH
All carbon steel construction. 1 cubic yard capacity. 3" coupler on decant outlet.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 3: System Installation and Start-Up
3.1 Installation Procedure
1. Upon receipt of the system, carefully check each component against the bill of materials to ensure
that everything has been received with the system. If anything is missing or damaged, immediately
contact the freight company to file the appropriate claim.
2. Remove system from wooden 2 x 4 undercarriage using suitable materials handling equipment.
3. Install catcher tank sweeper package as shown in the sweeper layout drawing provided.
4. Install the gate valve to the suction port on the catcher tank.
5. Install the gate valve to the discharge port on the catcher tank.
6. Install hose barbs into the suction and discharge gate valves.
7. Close the suction and discharge valves.
8. Fill the catcher tank with water.
9. Position system next to waterjet machine as discussed with Ebbco Inc. Anchor system to floor as
necessary.
10. Using the black suction hose and clamps provided in the installation kit, connect the suction barb on
the catcher tank to the suction barb on the garnet removal system.
11. Using the black discharge hose and clamps provided in the installation kit, connect the discharge
barb on the catcher tank to the discharge barb on the garnet removal system.
12. Place abrasive bag hopper under purge outlet. Connect decant line to fitting provided on hopper.
13. Connect the overflow piping from the 3" port on the abrasive bag hopper to the garnet pump column.
14. Have a qualified industrial electrician connect the 3 phase electrical power to the control panel as per
electrical drawing. (230vac/3 ph/60Hz)
3.2 Start Up Procedure:
1. Check the pump suction basket for debris.
2. Open the suction and discharge valves on the catcher tank.
3. Ensure that the catcher tank is full of water.
4. Check pump for correct rotation (clockwise as viewed from the top of the motor) by bumping the HOA
switch, located on the main electrical panel.
5. The pump motor on the filtration system has been synchronized at the factory if the pump motor is
running in reverse have a qualified electrician swap over one of the in coming line powers at electrical
panel.
6. Turn the HOA switch to the HAND position.
Warning! If the filtration system dose not prime after 5 seconds, stop the system. Try three more times
and if the system still will not prime call the Ebbco service department 1-586-716-5151
7. Check separator inlet and outlet pressure gauges to ensure differential pressure is between 4 and 12
psi.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 3: System Installation and Start-Up
Warning If pressure differential is too low or is too high,
call the Ebbco service department 1-800-991-4225

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
4.1 Garnet Removal System Daily Check List
Warning Always disconnect power and relive pressure from the system before performing any
maintenance on this filtration system.
Caution Always follow correct lock out procedures when working on this filtration system.
Warning Failure to keep suction above −10 in/hg could result in catastrophic pump failure.
1. Make sure suction basket is serviced (empty).
2. Open all gate valves.
3. Start filtration system.
4. Check suction basket pressure gauge. At start up this should read approximately −3 in.hg – service
basket before the suction vacuum gauge reads −10 in.hg.
5. Check inlet and outlet gauges on top of separator. These pressure readings should be approximately
35 psi on the inlet gauge and approximately 26 psi on the outlet gauge. Separator must run between
4 and 12 psid.
Warning This garnet removal separator must run between these pressure differentials. If the system does
not maintain the proper differential pressure it will affect the garnet removals performance and can cause
premature pump maintenance/failure.
6. Service hopper as needed.
7. In front of the eductors there will be no garnet accumulation, however there maybe some quite areas
in the tank where garnet may collect. The garnet "pile" should not be allowed to exceed 6" in height.
Monthly checking of garnet build up on the tank bottom is advised, using a stick tap on the tank
bottom in various locations. Any garnet accumulation will show up on the stick and it can be easily
removed.
If there are any questionsregarding this system please call the Ebbco Service Department at
1-800-991-4225

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
The system will require the following items to be maintained on a scheduled basis.
Warning Always disconnect power and relive pressure from the system before performing any
maintenance on this filtration system.
Caution Always follow correct lock out procedures when working on this filtration system.
4.2 Pump Suction Basket
The vacuum gauge located on the pump suction basket should be monitored every time the system is
started and then after every 8 hours of operation to ensure that the suction does not exceed −10 in/hg.
The pump suction basket should be removed and emptied every 8 hours of operation. It is important to
check the condition of the gasket on basket’s lid, make sure it is free of dirt and is firmly in place before
turning the system back on.
Ebbco recommends that a preventive maintenance schedule be implemented for this component.
Note: The vacuum gauge must read −3 in.hg – service basket at −10 in.hg.
4.3 System Pump
The centrifugal pump has been tested and greased at the factory; therefore lubrication is not necessary
for a period of approximately six to eight months. Remember that over greasing will cause the bearing to
run hot, so grease bearings sparingly when it is necessary. Ebbco recommends the use of sri # 2
chevron ball bearing grease.
Applications were there is a high abrasion the pump may have to be inspected quarterly for wear on
impeller and impeller housing.
It is recommended that a routine maintenance schedule be set up and followed for the best service of the
pump. A periodic comparison of existing operating conditions and data against data taken when pump
was initially started may indicate a problem developing and allow for a planned maintenance check before
a breakdown occurs.
4.4 Centrifugal Separator
There is no scheduled maintenance on the separator itself.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
4.5 Work Tank Sweeper Package
To ensure that the garnet removal system works
at the designed performance the work tank
sweeper package must be visually inspected
every 12 months. If the sweeper package is
damaged (broken eductor or piping, blocked
suction) there will be a noticeable change in
system performance. This may manifest itself as
a separator inlet pressure drop, a low differential
across the separator or a high vacuum gauge
reading. If any of these condition occur and are
not corrected the system pump and other
components will become damaged.
Once the work tank has drained of water:
•Check for damaged of broken piping and eductors.
•Check for any garnet build up in front of any eductor.
•Check for any material that may be wedged between the eductor nozzle and the horn.
Ebbco Inc can provide an experience service technician to service the tank sweeper package and inspect
the complete system. Please call Ebbco for pricing and to schedule a service technician.
4.6 Abrasive bag hopper
The hopper should be visually inspected to be aware of solids level, service when full.
Horn Nozzle

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 5: Troubleshooting Guide
5.1 System Troubleshooting
Warning Always disconnect power and relive pressure from the system before performing any
maintenance on this filtration system.
Caution Always follow correct lock out procedures when working on this filtration system.
1. Pump will not start
a. Check the electrical hookup for proper direction and power requirements.
Warning do not operate the pump without the inner basket inside the strainer
2. No flow/no pressure
a. Check the electrical hookup for proper direction and power requirements. The pump’s motor
should run clockwise looking down from the top.
b. Check fuses in step-down transformer. Replace as necessary.
c. Check the motor for any foreign objects.
3. Decreasing flow and pressure during operation
a. Check the pump protection strainer for fouling. If plugged, remove the contaminants. Caution:
do not operate the pump without the inner basket inside the strainer.
4. Low flow/low pressure (10 psi or less)
a. Check the rotation of the pump motor. It should be running in the direction noted in 1.a.
b. Check the pump protection strainer for fouling.
5. No flow/maximum pressure (pegged gauges)
a. Check the separator’s purge area for blockage.
6. No transfer of solids/correct separator pressure/correct separator flow
Check for blockage in purge area.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 5: Troubleshooting Guide
5.2 System Pump
For troubleshooting pumps, read symptom describing problem, consult keyed causes and correct those
that apply. Caution: be sure unit’s power is disconnected before attempting any work on pump or motor.
SYMPTOM KEY NUMBERS FOR CAUSES
A Pump does not deliver liquid 1,2,3,4,6,10,12,14,15,20,21
B Pump delivers too little flow 2,3,4,5,6,7,10,11,12,13,15,18,20,21,27,28
C Delivery pressure too low 5,12,13,14,15,18,20,27,28
D Pump loses prime after starting 2,3,5,6,7,10
E Pump needs too much power 13,15,16,17,18,21,22,24,25,27
F Seal leaks 22,24,29,30
G Pump vibrates or is noisy 2,3,4,10,19,21,22,23,24,25,26,28,29,30,31,
32,33,34
H Motor bearings have short life 22,24,25,26,29,30
I Pump overheats and/or seizes 1,4,19,20,22,25,26,29,30
CAUSES
1 Pump not primed 18 Viscosity of liquid different than design
2 Pump or suction pipe not completely full of
liquid 19 Pump operating at very low capacity
3 Suction lift too high 20 Parallel operation of pumps unsuited for such
operation
4 Pump cavitating, increase suction pressure 21 Foreign matter in impeller
5 Excessive amount of air/gas in liquid 22 Misalignment of pump or piping
6 Air pockets in suction pipe 23 Foundations not rigid
7 Air leakage in suction pipe 24 Shaft bent
25 Rotating part rubbing on stationary part
26 Bearings worn
10 Suction pipe not sufficiently submerged 27 Wear ring worn
11 Impeller, suction or trap partially or
completely plugged 28 Impeller damaged
12 Speed too low 29 Shaft running off center due to worn bearings
or misalignment
13 Voltage wrong or too low 30 Impeller out of balance resulting in vibration
14 Wrong direction of rotation 31 Excessive grease in bearing causing high
bearing temperature
15 System head too high for pump design 32 Lack of lubrication
16 System head too low for system design 33 Dirt in bearings
17 Specific gravity of liquid different than
design 34 Rust in bearings due to water getting into motor

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 6: Parts List
REC.
ON
SITE
QTY
REQ. DELIVERY TIME COMPONENT DESCRIPTION LOCATION OF PART ON SYSTEM PART NUMBER
N/A 1 2-4 weeks Centrifugal separator On separator support
frame.
SDS-0250-B
N/A 1 2-4 weeks Complete pump On pump base. PCL2x3-10-B-CC+6
1 1 2-4 weeks Pump impeller Inside pump impeller
housing.
PCL2x3-10-B-CC+6-
IMP.10”
1 1 Stock
2-5 days
Pump case gaskets Inside pump impeller
housing.
61115
1 1 Stock
2-5 days
Pump strainer basket's
internal basket
Inside pump suction
strainer.
PKG-98-IB-SS
1 1 Stock
2-5 days
Pump strainer basket's lid
gasket
On suction basket lid. U9-46
2 2 Stock
2-5 days
0-60 psi liquid filled pressure
gauge
Separator inlet/outlet. GRS-60-GA
1 1 Stock
2-5 days
Vacuum gauge -30 in/mg
0PSI
On side of pump
suction strainer basket.
GRS-V-GA
N/A 1 Stock
2-5 days
Abrasive bag hopper bag In abrasive bag hopper. GRS-ABH-B
12 12 Stock
2-5 days
3/8" poly eductor End of clean discharge
in system tank.
0MP

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed written
permission of Ebbco Inc. or its subsidiaries.
Section 7: General Policy & Limited Warranty
It is Ebbco's policy to ship and charge for replacement parts upon notification of a problem.
Warranty will be determined upon inspection of said part after it is returned to Ebbco, freight pre-paid. A
returned goods claim form will be sent with replacement part and must be returned with defective part.
Ebbco Inc. shall not be liable for incidental and consequential losses and damages under this expressed
warranty, any applicable implied warranty, or claims for negligence.
All products manufactured and marketed by Ebbco are warranted to be free of defects in
materials and workmanship for a period up to one year for date of delivery or 2080 hours of operation,
whichever comes first.
Equipment such as pumps, pump bodies, separators, etc. will carry one-year manufacturer
warranty. Pump seals: Ninety day limited warranty.
This limited warranty does not cover any products, damages or injuries resulting from misuse,
neglect, normal expected wear, chemical-caused corrosion, improper installation or operation contrary to
Ebbco's recommendations. Nor does it cover equipment which has been modified, tampered with or
altered without authorization.
No other extended liabilities are stated or implied and this warranty in no way covers incidental or
consequential damages, injuries or cost resulting from any such defected product.

Product Profile
HEAVY DUTY SUCTION STRAINER BASKET
MODEL # PKG98 & PKG51
THIS IS A PROPRIETARY
DOCUMENT OF EBBCO, INC.
PRODUCT FEATURES
THE HEAVY DUTY SUCTION STRAINER
BASKET IS USED AS THE FRONT LINE PUMP
PROTECTION. EBBCO INC SUCTION
STRAINER BASKET HAS A RUGGED ONE
PIECE CAST IRON BODY WITH A CAST IRON
LID. BASKET MATERIAL AS STANDARD ON
THE PKG-51 IS ABS AND STAINLESS STEEL
GR303 ON THE PKG-98. A STAINLESS STEEL
BASKET IS PROVIDED AS AN OPTION FOR
THE PKG-51.
A
LL LID GASKET MATERIAL IS BUNA-NITRILE
A
S STANDARD WITH EPDM AND VITON AS
OPTIONS.
•RUGGED CAST IRON HOUSING.
•PKG-98 STAINLESS STEEL PERFORATED
BASKET.
•PKG-51 ABS INTERNAL PERFORATED
BASKET. OPTIONAL STAINLESS STEEL.
•BUNA-NITRILE LID GASKET.
MODEL PKG51
MODEL PKG98
STAINLESS
STEEL BASKET

Specifications
HEAVY DUTY SUCTION STRAINER BASKET
MODEL # PKG98 & PKG51
PKG-51 PKG-98
RECOMMENDED
MAX FLOW RATE GPM 150 GPM 300 GPM
MAX TEMP 180°F 180°F
MAX PRESSURE
LOSS PSI PSI
INLET 2" NPT 3" NPT
OUTLET SQ. FLANGE SQ. FLANGE
MATERIALS OF
CONSTRUCTION
BODY CAST IRON CAST IRON
LID CAST IRON CAST IRON
O-RING BUNA-N BUNA-N
BASKET ABS (OR SS) SS
SPARE PARTS
O-RING U9-46 U9-171
FLANGE
GASKET C20-19 C20-19
LOCK HANDLE C154-18D C154-18D
LID C3-30 C3-105
ABS BASKET C108-11P N/A
SS BASKET C108-11SS 16401-0030