MOLEAER XTB 25 Manual

XTB 25/50 Gen 2 Manual Rev B
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OPERATION MANUAL
MOLEAER XTB 25/50
NANOBUBBLE GENERATOR
INSTALLATION, OPERATION AND MAINTENANCE INSTRUCTIONS

XTB 25/50 Gen 2 Manual Rev B
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Table of Contents
1EQUIPMENT DRAWING.............................................................................................................- 3 -
2INTRODUCTION........................................................................................................................- 6 -
3SAFETY INSTRUCTIONS .............................................................................................................- 6 -
4DESCRIPTION OF EQUIPMENT...................................................................................................- 6 -
5PIPING –GENERAL....................................................................................................................- 7 -
6PIPING –SUCTION ....................................................................................................................- 7 -
7PIPING –DISCHARGE ................................................................................................................- 7 -
8WIRING & GROUNDING............................................................................................................- 7 -
9GAS –GENERAL........................................................................................................................- 8 -
10 GAS –CONNECTION................................................................................................................- 8 -
11 GAS –FLOW & PRESSURE........................................................................................................- 8 -
12 XTB GENERATOR OPERATION .................................................................................................- 8 -
13 PUMP MAINTENANCE.............................................................................................................- 9 -
14 PUMP DISASSEMBLY...............................................................................................................- 9 -
15 PUMP ASSEMBLY..................................................................................................................- 10 -
16 CLEANING & SANITIZING THE XTB NANOBUBBLE GENERATOR ...............................................- 10 -
17 GENERAL CHEMICAL CLEANING PROCEDURES .......................................................................- 10 -
18 GENERAL MECHANICAL CLEANING PROCEDURES...................................................................- 11 -
19 TROUBLESHOOTING .............................................................................................................- 11 -
20 PROBABLE CAUSES ...............................................................................................................- 11 -
21 PUMP WINTERIZATION.........................................................................................................- 12 -
22 LIMITED WARRANTY.............................................................................................................- 12 -
23 REVISION HISTORY ...............................................................................................................- 14 -

XTB 25/50 Gen 2 Manual Rev B
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1EQUIPMENT DRAWING
General Arrangement
Piping and Instrumentation Drawing

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Figure 1-XTB 25 P&ID Schematic

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Figure 2- XTB 50 P&ID Schematic

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2INTRODUCTION
Moleaer (Latin for “tiny air”) is a technology company that integrates nano-scale materials into proprietary technologies to
develop highly efficient and simple solutions for transferring gas into liquids. These solutions enhance the performance, and
modify the functionality, of liquids for a wide variety of applications.
Moleaer XTB Nanobubble Generators provide the most efficient solution to transfer any gas to any liquid. The XTB generators
produce trillions of nanobubbles in the 70-200 nm range providing greater than 200x the interfacial surface area compared to
fine micro bubbles. Gas is transferred into water with >90% efficiency providing maximum utilization potential. Moleaer
nanobubbles remain in suspension after saturation creating a reserve of available gas in the liquid. This low-turbulence,
nanobubble gas injection process results in the most efficient method to enhance the performance of any type of liquid.
3SAFETY INSTRUCTIONS
TO AVOID SERIOUS OR FATAL PERSONAL INJURY OR MAJOR PROPERTY DAMAGE, READ AND FOLLOW ALL SAFETY
INSTRUCTIONS IN MANUAL AND ON PUMP. THIS MANUAL IS INTENDED TO ASSIST IN THE INSTALLATION AND OPERATION OF
THIS UNIT ANDMUST BE KEPT WITH THE UNIT.
This is a SAFETY ALERT SYMBOL. When you see this symbol on the unit or in the manual, look for one of the
following signal words and be alert to the potential for personal injury or property damage.
Warns of hazards that WILL cause serious personal injury, death, or major property damage.
Warns of hazards that CAN cause serious personal injury, death, or major property damage.
NOTICE:
INDICATES SPECIAL INSTRUCTIONS WHICH ARE VERY IMPORTANT AND MUST BE FOLLOWED.
THOROUGHLY REVIEW ALL INSTRUCTIONS AND WARNINGS PRIOR TO PERFORMING ANY WORK ON THIS UNIT. MAINTAIN ALL
SAFETY DECALS.
UNIT NOT DESIGNED FOR USE WITH HAZARDOUS LIQUIDS OR FLAMMABLE GASES. THESE
FLUIDS MAY BE PRESENT IN CONTAINMENT AREAS.
4DESCRIPTION OF EQUIPMENT
OPTIONAL PUMP STYLES
Optional bearing frame-mounted or close-coupled, single and three phase, ODP, TEFC and three phase explosion proof motors,
and submersible are available. Optional mechanical seals include: Carbon/Ceramic/BUNA, Carbon/Ceramic/Viton,
Carbon/Silicon Carbide/EPR, Silicon Carbide/Silicon Carbide/EPR and Silicon Carbide/Silicon Carbide/Viton.

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5PIPING –GENERAL
Piping should be no smaller than the pump connection size and kept as short as possible, avoiding unnecessary fittings to
minimize friction losses. All piping MUST be independently supported and MUST NOT place any piping loads on the pump or
generator.
NOTICE: DO NOT FORCE PIPING INTO PLACE AT PUMP SUCTION AND DISCHARGE CONNECTIONS.
ALL PIPE JOINTS MUST BE AIR-TIGHT
6PIPING –SUCTION
Short and direct suction piping is recommended. For suction lifts over 10' (3 m) and liquid temperatures over 120º F (49º C),
consult pump performance curve for net positive suction head required (NPSH R).
If a pipe size larger than pump suction is required, an eccentric pipe reducer, with the straight side up, MUST be installed at the
pump suction.
If pump is installed below the liquid source, install a full flow isolation valve in the suction for pump inspection and maintenance.
NOTICE: DO NOT USE THE ISOLATION VALVE TO THROTTLE PUMP. THIS MAY CAUSE LOSS OF PRIME, EXCESSIVE
TEMPERATURES AND DAMAGE TO PUMP, VOIDING WARRANTY.
If the pump is installed above the liquid source, the following MUST be provided:
•To avoid air pockets, no part of the piping should be above the pump suction connection.
•Slope piping upward from liquid source.
•Use a foot valve or check valve ONLY if necessary, for priming or to hold prime during intermittent duty.
•The suction strainer or suction bell MUST be at least 3 times the suction pipe diameter area.
•Ensure that the size and minimum submergence over suction inlet is sufficient to prevent air from entering
through a suction vortex.
NOTICE: LEAVING AIR VALVE OPEN WHEN PUMP IS NOT OPERATIONAL MAY CAUSE LOSS OF PRIME.
7PIPING –DISCHARGE
Install a check valve suitable to handle the flow, liquids, and to prevent backflow. After the check valve, install an appropriately
sized gate valve to be used to regulate the pump capacity, pump inspection, and for maintenance. When required, the pipe
increaser should be installed between the check valve and the pump discharge.
Pump discharge should ideally be positioned at least 2 feet below fluid surface.
8WIRING & GROUNDING
Install ground and wire according to local and National Electrical Code requirements
Install an all-leg disconnect switch near the pump.
Disconnect and lockout electrical power before installing or servicing pump.

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Electrical supply MUST match pump’s nameplate specifications. Incorrect voltage can cause fire, damage
to the motor and voids warranty .
Motors equipped with automatic thermal protection open the motor’s electrical circuit when a thermal
overload exists. This can cause the pump to start unexpectedly and without warning. Use only stranded
copper wire to motor and ground. The ground wire MUST be at a least as large as the wire to the motor.
Wires should be color coded for ease of maintenance.
FAILURE TO PERMANENTLY GROUND THE PUMP, MOTOR AND CONTROLS BEFORE CONNECTING TO ELECTRICAL
POWER CAN CAUSE SHOCK, BURNS OR DEATH.
NOTICE: UNIT ROTATION IS CLOCKWISE, WHEN VIEWED FROM THE MOTOR END. INCORRECT ROTATION MAY CAUSE
DAMAGE TO THE PUMP AND VOIDS THE WARRANTY.
9GAS –GENERAL
Moleaer XTB Generators can produce gas nanobubbles using a variety of compressed feed gases. The gas should be free of oil,
moisture and particulate. If conditioning of the gas is required, install filtration to remove contaminants and a dryer to
remove moisture. If high-purity oxygen is used, ensure lines and fittings are oxygen-clean. At all times, follow state and federal
and OSHA regulations.
10 GAS –CONNECTION
Moleaer XTB Generators come with a standard ¼” male industrial connector. Connect the compressed gas supply hose to unit,
with a ¼” female quick coupler. If another connector is desired, remove the industrial air connector from the face plate, and
replace it with any other connector having a 1/4” NPT thread.
11 GAS –FLOW & PRESSURE
Gas flow rates can be adjusted depending on application and desired effect. The XTB generators are designed to deliver a
spectrum of nano and / or micro bubbles to meet the requirements of the process or application. Low gas flow rates produce
more nanobubbles and have a higher gas transfer efficiency whereas higher gas flow rates produce both nano and microbubbles
that have a lower gas transfer efficiency but higher mass transfer rate. Refer to the specification table for suggested gas flow
rates for the different size units.
GAS PRESSURE FEEDING THE XTB GENERATOR SHOULD BE A MINIMUM OF 100 PSI OR 6.9 BAR. INCREASING OR DECREASING
GAS FLOW RATES WILL ALTER THE PRESSURE REFLECTED ON THE XTB GAS PRESSURE GAUGE. DO NOT EXCEED 125 PSI (8.6 BAR)
IN GAS PRESSURE. EXCESSIVE GAS PRESSURE MAY COMPROMISE SEALS INSIDE THE GENERATOR AND RESULT IN A SUDDEN DROP
IN PRESSURE. IF THIS OCCURS, CLOSE THE GAS FLOW METER COMPLETELY, REDUCE THE GAS PRESSURE FEEDING THE
GENERATOR, AND THEN SLOWLY REOPEN THE VALVE AGAIN TO THE DESIRED GAS FLOW SET POINT.
When pump is not running, turn off gas feed to prevent losing pump prime.
12 XTB GENERATOR OPERATION
Open intake and discharge valves to flood piping to prime the pump.
NOTICE: PUMP MUST BE FULLY PRIMED BEFORE OPERATION.

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OPERATION AT OR NEAR ZERO FLOW CAN CAUSE EXTREME HEAT, PERSONAL INJURY OR PROPERTY DAMAGE.
Turn on the pump starter switch and run pump at normal operating conditions and check the piping for visible leaks. If necessary,
adjust the pipe supports.
NOTICE: NORMAL OPERATING PRESSURE RANGE ON THE PUMP IS BETWEEN 13-25 PSIG.
CHECK PUMP FLOW RATES WITH A FLOW METER. RATES SHOULD BE +/- 10% OF THE SYSTEM’S DESIGNED FLOW. PUMP FLOW
RATES LOWER THAN THE SYSTEM SPECIFICATIONS WILL RESULT IN LARGER BUBBLES AND LOWER OXYGEN TRANSFER
EFFICIENCIES –IT IS NOT RECOMMENDED 
Set gas flow to desired level using the middle of the floating ball as the index point.
13 PUMP MAINTENANCE
Motors have permanently lubricated bearings. No lubrication is possible or necessary. Follow the motor manufacturer’s
recommendations for maintenance.
PUMP DISASSEMBLY
FAILURE TO DISCONNECT AND LOCKOUT ELECTRICAL POWER BEFORE ATTEMPTING ANY MAINTENANCE
CAN CAUSE SHOCK, BURNS OR DEATH.
CASING MAY CONTAIN HAZARDOUS FLUIDS THAT CAN CAUSE PERSONAL INJURY OR PROPERTY DAMAGE.
Containing pumpage as required, remove pump casing vent and drain plugs. Remove and discard the respective plug O-rings.
Drain and flush system, as required. Remove the four motor bolts from the motor base or foundation. Remove the eight casing
cap screws, then using the slots provided about the casing, pry the back pull-out assembly from the casing.
Remove and discard the casing O-ring and the internal casing O-ring.
NOTICE: IMPELLER COMPRESSES THE MECHANICAL SEAL SPRING –BE PREPARED FOR THE IMPELLER TO SPRING FROM SHAFT
WHEN IMPELLER IS REMOVED.
Remove the end cap from the motor, exposing a slot in the end of the motor shaft. While holding the shaft from rotation with a
screwdriver, remove the impeller locknut (if present) by turning it COUNTERCLOCKWISE.
Remove impeller by turning counterclockwise when looking at the front of the pump. Protect hand with rag or glove. Apply
localized heat for 1-2 minutes or to an approximate temperature of 250º C. Disassemble while hot. Heating will decrease the
break-loose torque of the Loctite 243 and allow for easy removal.
EXCESSIVE HEATING MAY CAUSE DAMAGE TO THE SEAL. SEAL REPLACEMENT IS RECOMMENDED IF PUMP
IS DISASSEMBLED OR REPAIRED.
Using two pry bars, 180º apart, CAREFULLY separate the seal housing from the motor adapter. The mechanical seal rotary
assembly will slide from the motor shaft with the seal housing. CAREFULLY push out the mechanical seal stationary seat from the
seal housing. Inspect and wipe clean the stationary seat bore. Replace as necessary. DISCARD the mechanical seal assembly. If
necessary, remove the four motor hex bolts and CAREFULLY slide the motor adapter from the shaft.

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Replace the motor assembly and deflector, as required. Disassembly is complete.
PUMP ASSEMBLY
If removed, replace the motor shaft deflector. Install the motor adapter, with the drain opening DOWN, using the four hex bolts.
Torque bolts to 168 lbs. in. (19 N m). Slide the seal housing assembly onto the motor shaft, seating it fully and squarely against
the motor adapter.
Using a quality grade O-ring lubricant, lubricate the outer elastomer of the mechanical seal stationary seat. Fully and squarely
install the stationary seat into the seal housing. With a clean, lint-free cloth, CAREFULLY wipe off excess lubricant or debris. DO
NOT damage the seat face.
Using a quality grade O-ring lubricant, lubricate the inner elastomer of the mechanical seal rotary assembly. Fully and squarely
install the rotary assembly against the stationary seat.
To install impeller, clean shaft and impeller thoroughly with denatured alcohol and a wire brush to remove cured Loctite from
threads. Wait for parts to dry and then apply Loctite 7649 primer to threads on shaft and impeller. Allow 3-5 minutes for primer
to dry. Apply 3 drops of Loctite 243 medium strength thread-locker to shaft threads and 2 drops on impeller threads. Tighten
impeller to a torque value of 144 lbs. in. (16 N m).
Using a quality grade O-ring lubricant, lubricate and install a new casing O-ring and internal O-ring (1SN only). Slide the back pull-
out assembly into the pump casing and secure using the eight casing cap screws. Torque the cap screws to 70 lbs. in. (8 N m),
using a cross pattern sequence to assure the casing is pulled down evenly. With new O-rings installed, install the casing vent and
drain plugs, tightening securely. Assembly is complete.
14 CLEANING & SANITIZING THE XTB NANOBUBBLE GENERATOR
In normal operation, the internal elements of the XTB generator can become fouled by mineral scale, biological matter, colloidal
particles and insoluble organic constituents. Deposits can build up on the surfaces during operation until they cause diminished
operation. Best practices include routine preventative cleaning with acid and alkali chemicals. In some instances, if large solids
are allowed to pass into the generator, blockages can occur.
15 GENERAL CHEMICAL CLEANING PROCEDURES
1. Prepare the cleaning solution
2. Introduce the cleaning solution
3. Recycle
4. Soak
5. Conduct high-flow pumping
6. Flush out
7. Restart
SAFETY PRECAUTIONS
•Maximum temperature 100o C or 212oF
•pH tolerance range 2-14
•Each cleaning situation is different; therefore, specific cleaning recommendations are dependent on the type of foulant.
Consult the general cleaning instructions for information that is common to all types of cleaning such as suggested
equipment, pH and temperature limits, and recommended flow rates; then apply the specific recommendation as
needed.