CLP OPERATOR S MANUAL

Transcription

1 CLP OPERATOR S MANUAL clp-04 clp-7034 For technical assistance or the WATER MAZE dealer nearest you, call , or visit our website at

2 CONTENTS Introduction...4 Unpacking...4 Important Safety Information...-6 Installation Instructions...6, Installation View Check List Before Starting... Start-up...-9 Operation CLP-04/ Programming instructions, AMC, Backwash, & Recirculation Modes Valve Location & Function...1, 16 Operation Views Water Panel Installation...1 Standard ORP/pH Sensors...16 Sensor Maintenance...17 Troubleshooting - Standard ORP/pH Sensors...1 Advanced ORP/pH Sensors...19 Troubleshooting - Advanced ORP/pH Sensors...0 Digital ORP/pH Controller & PH40 Operator Interface...1 Calibration Procedures... Digital ORP/PH Controller Error Codes General Maintenance & Service... Ozone Generator... Ozone Generator Specifications...6 Ozone Generator Breakdown Exploded View & Parts List...7- CD-10 Ozone Generator Component Identification...9 CD Ozone Generator & Maintenance Dielectric Tube Removal & Re-Installation...3 Chemical Maintenance Program...33 Daily Chemical Maintenance...34 Centrifugal Pump Operation & Maintenance...3 CLP-04 Plumbing Breakdown #1 Exploded View & Parts List CLP-7034 Holding Tank Assemblies Exploded View & Parts List CLP-7034 Tank Drain & Oil Skimmer Exploded View & Parts List CLP-7034 Main Tank Exploded View & Parts List CLP-7034 Transfer Pump Exploded View & Parts List

3 CONTENTS CLP-7034 Carbon Filter Exploded View & Parts List CLP-7034 Multi-Media Filter Exploded View & Parts List CLP-7034 Flow Meter Plumbing Exploded View & Parts List CLP-7034 Ozone Pump Exploded View & Parts List...-3 CLP-7034 Filter Pump Exploded View & Parts List...4- CLP-7034 Surge Tank/Main Drain Exploded View & Parts List CLP-7034 Optional Cartridge Filter Exploded View & Parts List...-9 CLP-04 Plumbing Breakdown # Exploded View & Parts List CLP-04 Plumbing Breakdown #3 Exploded View & Parts List CLP-04 Tank & Cone Exploded View & Parts List CLP-04/7034 Water Panel Breakdown Exploded View & Parts List CLP-04 Manifold Exploded View & Parts List CLP-7034 Manifold Exploded View & Parts List CLP-04/7034 Control Panel Exploded View & Parts List Metering Pump Exploded View & Parts List...74 Jacuzzi Transfer Pump Exploded View & Parts List...7 Transfer Pump Exploded View & Parts List...76 Scot Filter & Transfer Pump Exploded View Parts List...77 Ozone Generator & Filter Pump Exploded View & Parts List...7 Filter & Ozone Pump Exploded View & Parts List...79 Little Giant Submersible Sump Pump Exploded View & Parts List Ebara Sump Pump...4 Carbon/Multi-Media Filter Exploded View & Parts List... Multi-Media & Carbon Filter Exploded View & Parts List...6 Option Cartridge Filter Exploded View & Parts List...7- DVK-7, 7-Way Valve Exploded View & Parts List...9 Troubleshooting Consumable Parts...96 CLP=7034 Maintenance Schedule...97 Warranty...99 Model Number Serial Number Date of Purchase The model and serial numbers will be found on a decal attached to the machine. You should record both serial number and date of purchase and keep in a safe place for future reference. 3

4 OPERATOR S MANUAL WATER TREATMENT SYSTEM 4 INTRODUCTION & SAFETY INFORMATION INTRODUCTION Your owner s manual has been prepared to provide you with a simple and understandable guide for equipment operation and maintenance, based on the latest product information available at the time of printing. To keep your machine in top running condition follow the specific maintenance and troubleshooting procedures given in this manual. When ordering parts please specify model and serial number. NOTE: WATER MAZE reserves the right to make changes at anytime without incurring any obligations. Owner/User Responsibility: The owner and/or user must have an understanding of the manufacturer s operating instructions and warnings before using this WATER MAZE machine. Warning information should be emphasized and understood. If the operator is not fluent in English, the manufacturer s instructions and warnings shall be read to and discussed with the operator in the operator s native language by the purchaser/owner, making sure that the operator comprehends its contents. The owner and/or user must study and maintain the manufacturers instructions for future reference. This manual should be considered a permanent part of the machine and should remain with the machine if resold. When ordering parts, please specify model and serial number. UNPACKING 1. CLP Machine Assembly. Sludge Tub 3. Sludge Tub Bag Support 4. Accessory Box 6. Operator s Manual Note any damage to machine or components for claims against the freight lines. IMPORTANT SAFETY INFORMATION WARNING CAUTION read operator s manual thoroughly prior to use. CAUTION: To reduce the risk of injury, read operating instructions carefully before using. 1. Read the owner s manual thoroughly. Failure to follow the instructions will cause a malfunction of the machine and result in death, serious injury and/or property damage. WARNING keep water spray away from electrical wiring. WARNING: Ground system before connecting to the power supply. WARNING: Wire the system for correct voltage. See Electrical section of this manual and motor nameplate. WARNING: Meet the National Electrical Code and local codes for all wiring. WARNING: Follow the wiring instructions in this manual when connecting the system to the power lines. WARNING: All wiring must be performed by a qualified electrician.. Know the system application, limitations, and potential hazards. WARNING risk of explosion: do not spray flammable liquids. WARNING: Do not use to pump concentrations of flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc. Do not use in explosive atmospheres. Pumps should only be used with liquids compatible with pump component materials. Failure to follow this warning can result in personal injury and/or property damage. 3. WARNING: Risk of electric shock. All wiring should be performed by a qualified electrician. 4. Never make adjustments on the machine while it is in operation, except for those prescribed in this manual.. The main power must be brought from the circuit breaker and wired into the electrical box on the CLP. This line must be run through conduit to protect it from damage. A power disconnect should be located next to the machine for maintenance purposes. 6. Before servicing the machine, refer to all the MSDS s on the material identified in the wastestream. You must comply with all warnings and wear all protective clothing as stated on the MSDS s. 7. Protect all electrical cords from sharp objects, hot surfaces, oil, sunlight, and chemicals. Avoid kinking the cords. Replace or repair damaged or worn cords immediately. All wiring should be run through conduit.. Inlet water temperature must not exceed F. 9. Disconnect the power before servicing this machine. If the power disconnect is out of sight, lock it in the open position and tag it to prevent unexpected application of power.

5 10. The best insurance against an accident is precaution and knowledge of the equipment. 11. WATER MAZE is not liable for modifications or use of components not purchased from WATER MAZE. 1. Personal Safety: a. Wear safety glasses and other applicable protective clothing at all times when working on the CLP. installation INSTRUCTIONS Refer to item #6 under Important Safety Information. b. Keep your work area clean, uncluttered and properly lighted. Replace all unused tools and equipment. c. Keep visitors at a safe distance from work area. d. Make the workshop safe with padlocks and master switches. 13. Running the system without water will damage the pumps and will void the warranty. 14. Release all pressure within the system before servicing any component. 1. Drain all liquids from the component before servicing. 16. Check hoses for weak or worn conditions before each use, making certain that all connections are secure. 17. Periodically inspect pump and system components. Perform routine maintenance as required. 1. Do not touch an operating motor. Modern motors are designed to operate at high temperatures. 19. Do not handle a pump or pump motor with wet hands, when standing on a wet or damp surface, or in water. 0. The pump motors are equipped with an automatic resetting thermal protector and may restart unexpectedly. Tripping is an indication of motor overloading as a result of operating the pumps at low heads (low discharge restriction), excessively high or low voltage, inadequate wiring, incorrect motor connections, or a defective motor or pump. 1. IMPORTANT NOTE: The sump pump is not a trash pump and is subject to premature failure unless sump pit baffling or additional protection is provided.. Do not stand on the bracket that supports the Electrical Box, Ozone Generator and the ORP/pH Controller or on tanks 1 or. During installation and maintenance obtain an OSHA approved ladder. 3. Keep machine from freezing. 4. Do not spray water directly at machine. INSTALLATION INSTRUCTIONS 1. Because of the nature of the equipment, it is recommended these machines be installed indoors.. Locate the CLP on a containment pad to prevent contamination. 3. Level machine by using shims that will provide ample support and will not corrode or deteriorate over time. 4. Have a qualified electrician connect the proper power supply to the electrical control box. It is recommended that a ground fault circuit interrupter be installed in the circuit breaker for the CLP. NOTE: An electrician needs to locate where the power supply will enter the electrical box and punch a hole.. Install Orp/pH probes into cone bottom tank. Remove cap and immerse probes into water. Don't let probes dry. Save cap for future need. 6. Install the angle face dump valve (page 0) on bottom of cone bottom tank. Run air hose (item 6, page 7) from angle face dump valve to air valve assembly. Follow electrical wiring diagram for air switch wires. 7. Plumb oil decanter barrel (see page?).. Run ORP/pH pump hoses from pumps to injectors. 9. Run air from air compressor to machine (See page 66). Use at least a 3 CFM air compressor with psi. 10. Drill holes for " bulkheads and install bulkheads. Connect the sludge tub assembly by placing the sludge bag support into the sludge tub. Attach the sludge bag onto the sludge inlet fitting using the screw clamp provided (see page?). 11. Attach the " flex hose to the sludge tub by screwing the hose barbs into the bulkhead connectors, then attach the " flex hose to the hose barb using a hose clamp. The return line should gravity return to the catch basin. The " inlet flex hose should connect between the cone tank discharge valve and the sludge bag inlet connector (see page?). 1. Build the inlet plumbing from the sump pump discharge port (min. 1-1/" pipe) to the CLP 1-1/" inlet line. If the pipe is to be under the concrete, use " pipe. Lower the sump pump into the sump pit. 13. Position the sump pump in the bottom of sump pit. a. Elevate on a stand or cinder blocks, 6" off the pit floor, to keep pump from sucking in rocks or other heavy material that may plug pump or plumbing. WATER TREATMENT SYSTEM OPERATOR S MANUAL

6 OPERATOR S MANUAL WATER TREATMENT SYSTEM CLP-04 INSTALLATION VIEW ph Injector Inlet Cone Bottom Tank Bag Support Sludge Tub " Flex Hose Inlet Line Oil Decanter Barrel Return Backwash Line Catch Basin Inlet Line Sump Pump Sump Pump Installation (3 Phase) Sump Pit FS1 FS FS7 Inlet Line Sump Pump Sump Pit FS1 FS Sump Pump Installtion 6

7 CLP-7034 INSTALLATION VIEW Cone Bottom Tank Inlet Sludge Tub WATER TREATMENT SYSTEM OPERATOR S MANUAL Oil Decanter Barrel " Flex Hose Inlet Line Sump Pit Return/Backwash Line Inlet Line Sump Pump Installation FS1 Sump Pit Sump Pump FS Inlet Line Sump Pump Sump Pump Installation (3 Phase) FS1 FS Catch Basin FS7 7

8 OPERATOR S MANUAL WATER TREATMENT SYSTEM b. Position the pump away from incoming water to help prevent cavitation. c. Tie a rope or chain to the pump handle and bring out of the top of the pit for ease of pump removal. Do not lift pump by power cords or plumbing. Have a union installed on plumbing at the top of the pit. Position union so it can easily be reached and opened for pump removal. 14. The High Level Control Float FS1 (black, normally open) is the upper float which controls the upper limits of the sump. It prevents the sump from flooding by opening SV1, the rain water solenoid valve. Float tether length must be a minimum of " long. Position the upper most point of float a few inches below top of pit. The Fresh Water Make-up Float FS (grey, normally closed) controls the lower limits of the sump. It prevents the sump from running dry by opening SV, the fresh water solenoid valve. Turn-on point for the Fresh Water Make-up Float must be at least " above the suction inlet of sump pump. The further the water must travel before reaching the sump, the higher the float must be placed above the suction intake. On three phase units, a third float is needed to protect the sump pump from the possibility of running dry. Position the Low Water Protector Float #7 (black, normally open) 6" above the suction inlet of sump pump. Single phase sump pumps have a float built into them. Floats must travel their complete arc without: Water going over the top of the pit. Touching sidewalls or bottom. The pit running out of water. Interfering with electrical wiring, plumbing, bottom or sidewalls of sump, or any object. Attach the floats to the PVC line on the sump pump. Check to assure the floats can operate freely. (See Installation View.) 1. Run the electrical cords from the sump pump and floats to the electrical junction boxes near the inlet line and attach wires. If the sump pump and floats are located farther then 0 feet from the electrical junction boxes, then have an electrician install water tight junction boxes with conduit and proper sized wire to extend the electrical connections. 16. Connect the fresh water line (3/4" GHM garden hose not provided) to the Fresh Water Inlet port on the water panel (see Water Panel Illustration). 17. Connect the Outlet to Pressure Washers to your pressure washer by using a /" garden hose (not provided). Valve #7 behind the water panel should remain closed until start-up. You may need a 1" line to obtain a higher flow. If you are going a great distance or using a lot of elbows, you may not get full flow. Start-up INSTRUCTIONS not sealed. 1. Connect the Rain Water Overflow to the sewer or storage (line not provided). Valve # behind the water panel should remain halfway open. Caution: Discharge Permits are required and must be obtained before any treated water is discharged. 19. Connect a hose to Rinse Water outlet if it is to be used. Make sure valve #6 behind the water panel stays closed until rinse water is needed (hose not provided). NOTE: The use of rinse water in a closed loop system will overfill the system and will lead to an overflow situation causing the rainwater overflow valve to open. 0. Run the "Return/Backwash" line back to the collection pit or first pit where the water will be collected (refer to pages 7-9). This is very important so that there is no stagnant water when recycling and also to give more setting for the backwash water. If not done properly, it could void warranty. Run at least a " line if above ground and 3" if below ground. The sludge tub and oil decanter barrel are plumbed together and run to the return line. Any back pressure could overflow the sludge tub and/or oil decanter barrel. A separate return line for the sludge tub and oil decantor barrel may be needed, the sludge tub can be elevated or a check valve can be installed. Check List Before Starting: Yes No 1. Is inlet line connected from the sump pump to the inlet of the machine?. Is the voltage correct? 3. Is the return line connected? 4. Is the Fresh Water Make-up hose connected?. Is the Outlet to Pressure Washer hose connected. 6. Is the Rainwater Overflow connected? Start-Up: Make sure that the CLP is level. Turn on the Fresh Water Makeup hose. After checking for proper power supply voltage, turn on the circuit breaker to the CLP Machine. Note: Make sure all switches are turned OFF. Fill the sump pit with water, and check that the water level does not drop, which would indicate the pit is

9 Turn the sump pump switch to the ON position. The sump pump lamp will illuminate if sump pump is operating. (Note: the pump has an internally operated float for low water on single phase only. The sump pump should fill the cone bottom tank with water. FS3 in tank 1 will shut off the sump in the up position). Adjust the flow of water into the CLP using valve #1 by reading the indicator marks on the inlet flow meter. Set flow -4 GPM above demand. Turn "ON" the Ozone Generator timer inside the electrical control panel by pulling out the pins on the face of the timer and rotating the timer to those pins to activate the ozone generator as needed to control bacteria. Each pin pulled will activate the ozone generator for one half hour. After the testing is complete, rotate the timer to the correct time. Turn the filter pump switch to the ON position. Tank # should fill and FS will turn off the filter pump when in the up position. The filter pump lamp will illuminate when pump is in operation. Adjust valve #10 so that the filter flow meter has the same or GPM lower flow rate than the inlet GPM flow rate. Turn the transfer pump switch to the ON position. The pump should pressurize and shut off. NOTE: When the pump is put into operation the pressure switch may need to be adjusted. See inside cover of pressure switch for adjustment instructions. The HP pump is set at 0 PSI ON and 40 PSI OFF. The transfer pump lamp will illuminate when pump is operating. Turn the ozone pump switch to the ON position. Check to ensure the oil skimmer is adjusted properly. Adjust if needed by screwing the funnel up or down, or angling the pipe to allow a small amount of water to free flow. If oil starts to build up on top of the cone tank, adjust the skimmer to allow increased flow. NOTE: Only adjust the oil skimmer when the sump pump is running. Place the ORP/pH probes in the bracket inside the CLP tank. Remove the liquid filled cap on the end of the probes and place them in the bracket. Make sure the tank is full of water and the probes are kept wet. Run the connector through the hole in the tank wall near the bracket and attach the connectors to the controller. The connector with the white tag near it is the ORP and is connected to the top stud on the controller. The other is the ph and is connected to the bottom stud on the controller. Look over entire machine for leaks. The machine was hydrostatically tested at the factory but may have been damaged in shipment. operating instructions Program the AMC controller (see page 13, CLP- 7034). Turn the ozone generator ON/OFF switch ON (see page 33). Set ozone generator for proper air flow (see page 16). Turn ORP/pH controller switch on (see page ). Turn ORP/pH feed pumps on. Adjust valves per instructions on pages 16 and 1. Check Multi-Function timer (see page?) is set for seconds (CLP-7034). OPERATION: clp-04/7034 The CLP-04/7034 are a fully automatic, self-contained wash water recycling system suitable for treating wastewater generated from cleaning machinery and equipment. They are designed to separate free oil/greases and dirt. At the heart of the automated system is an automatic maintenance controller (AMC). The AMC provides the benefits of reliability and versatility to control numerous functions. The AMC controls pump operations, machine mode light display, filter status, backwash requirements, recirculation and sludge dumping. Filter Mode In a typical operation, wastewater is gravity fed from a wash pad catch basin to a sump pit (preventing large solids from entering the sump pump). Water resides in the sump pump pit until Tank #1 requires water. On Tank #1's demand, wastewater is pumped into the cone bottom tank. In the cone bottom tank the following occurs: Wastewater exits the tank by passing through a series of corrugated coalescing cones. These cones slow the flow of water (velocity drop) allowing the separation and settling of solids. Solids settle to the bottom of the tank and are later automatically removed (see automatic sludge dump). The coalescing cones oil attracting properties, combined with the incline angle, maximizes free oil/water separation. Free oils are skimmed from the surface and discharged to a 6 gallon oil decanter for further separation. To control odor and kill bacteria, an ozone pump recirculates ozonated water through the upper section of the cone bottom tank. Water is gravity fed from the 600 gallon tank to Tank #1 and remains there until Tank # requires water. When water is consumed from Tank # (by pressure washer, recirculation or sewer discharge) the filter pump circulates water from Tank #1 through the filters to Tank #. Flow rates through the filters can be adjusted up to 30 WATER TREATMENT SYSTEM OPERATOR S MANUAL 9

10 OPERATOR S MANUAL WATER TREATMENT SYSTEM gallons per minute (GPM). For best results the flow rate should be set to the lowest GPM that still allows the entire system to operate correctly (the lower flow rate increases wastewater/filter contact time and reduces the filters solids loading). Water remains in Tank # until it is either discharged to the sewer (check your local regulations for limits in your area), reused by the pressure washer or used for recirculation of the pits and filters (see recirculation mode). In the event an excess amount of water enters the system (through rinse water or rain water) water is automatically discharged from Tank # through the rain water overflow solenoid valve to either the sewer or to a holding tank. If the system's water level becomes too low (i.e. evaporation, vehicle carry off), a fresh water make-up solenoid valve feeds fresh water to Tank # until proper levels are maintained. Filters To ensure optimum filter performance and life, the multi-media and carbon filters must periodically be backwashed (see automatic backwash mode). The multi-media filter consists of a blend of sand, garnet, gravel and anthracite. The media blend is efficient in screening out solids to -30 microns. During the recirculation mode, the constant flow through the media filter provides a final polish to the water. The carbon filter consists of degassed, virgin activated carbon. Carbon removes, through absorption, pesticides, solvents, benzene, diesel fuels, acetone and other hydrocarbons as well as low levels of heavy metals. operating instructions The CLP-7034 also has the optional cartridge filter kit (P/N 30-7; 0 microns, P/N 30-79; microns) available for greater filtering down to 0 or microns, using two 0 sq. ft. elements. The CLP-04 also has the optional cartridge filter kit (P/N ; 0 microns, P/N ; microns) Automatic Backwash Mode Backwashing the media filters is required to rejuvenate the filter media. Backwashing removes collected materials and disperses the media to eliminate any channeling. During normal operation of the CLP-04/7034, the multi-media filter, carbon filter or both may become impacted with filtered solids, resulting in pressure head loss through the filters and in poor overall performance. The CLP-04/7034 will backwash everyday if it needs to or not. When you program the AMC, per the instructions on pages 13-14, the multi-media will start backwashing at midnight for 30 minutes. The CLP will then recover the water level in Tank #1 and then backwash the carbon filter. The operator cannot use the pressure washer at that time, so it is important that the program imitates your schedule. If it doesn't, call factory for assistance in reprogramming your controller. To backwash, the affected filter is isolated and the flow is reversed via air actuated three way valves. A slip stream solenoid is activated to allow proper water flow (30 GPM for multi-media valve 0, 1-0 GPM for carbon valve 1) and water is pumped from Tank #1 through the filter by the filter pump. This process continues for 30 minutes and the resulting backwash outflow is returned to the wash pad catch basin. Once backwashing of the first filter is completed the second filter will then be backwashed. At no time will both filters be backwashed at the same time. Program Schedule Sheet The Program Schedule Sheet shows descriptions of Modes, Programs and Recommended Settings: 10 PROGRAM A Auto Backwash 7-days/ week MODE DESCRIPTION MODE RUN TIME 1 Media Backwash 30 minutes Tank 1 Recovery 1 minutes 3 Carbon Backwash 30 minutes 4 System Recirculation hours Filter Recirculation 1 hour 6 Auto Purge 1 minute Program Start Times 1:00 AM OFF OFF OFF 1 3 4

11 Recirculation Mode The purpose for recirculating the water through the pit system and the filters is to minimize odor, kill bacteria and provide high quality polished water. Once each day the CLP will enter a recirculation mode. This mode consists of two separate stages. Stage 1: The transfer pump sends water from Tank # through the return line to the wash pad catch basin. To prevent odor and kill bacteria, the return water is ozonated via a mazzi injector. Stage : Water is recirculated through the filter pack. The transfer pump circulates water from Tank # through a mazzi injector to Tank #1. From Tank #1 the filter pump circulates water through the filters to Tank #. Automatic Sludge Dump During normal operation, the settling properties of the solids will result in sludge build-up inside the cone bottom tank cone. This sludge must be periodically removed. This is accomplished once each day by an automated sludge dump system. To dump sludge, an air activated dump valve opens while simultaneously a water solenoid activates (to stir-up any impacted material in the bottom of the cone bottom tank) to allow sludge to flow to the sludge collection bag. To reduce excess water in the sludge bag, the water solenoid is only activated for a few seconds. Once the dump valve closes, the sludge bag is allowed to de-water and excess water is returned, via gravity feed, to the wash pad catch basin. If at any time, the user needs an additonal sludge dump, a manual switch enables the automatic sludge dump cycle. Programming the AMC (Automatic Maintenance Controller; 04, 7034) The AMC Controller needs to be programmed on site. The reason for this is when power is cut to the unit the program is lost. There is a 9V battery inside the AMC Controller (pull down on bottom cover of the AMC) that will power the controller and hold the program for approximately 7 hours. The 9V battery will take care of intermittent power loss but will not hold program from factory to site during shipping. Before programming, connect battery inside AMC. Replace battery yearly. programming instructions. To set current hour, press +/ON or -/OFF button. 3. Press the NEXT button. 4. To set current minute, press +/ON or -/OFF button.. Press the NEXT button. 6. To set current day, press +/ON or -/OFF button until current day is flashing. 7. Return dial to the AUTO/ON position. Programming Backwash & Recirculation Modes The backwash and recirculation program requires (3) basic instructions to operate automatically: A. Operation Days (Usually 7-days a week). B. Start Time (Usually at night when washing is not being performed). C. Mode Run Times (length of backwash and recirculation times) A. Setting/Editing Program Operation Days 1. Turn control dial to SET PROGRAM OPERATION DAYS.. Set program switch to program A. (See Program Schedule Sheet for program descriptions). 3. Press +/ON or -/OFF button until CAL (calendar) is flashing. 4. Press the NEXT button to see program operation days. SU (Sunday) will begin flashing.. To select the day (flashing), press the +/ON button. To remove a day, press the -/OFF button. 6. Repeat step until all operation days are selected. 7. Return dial to the AUTO/ON position. B. Setting/Editing Program Start Time 1. Turn control dial to SET PROGRAM START TIME.. Set program switch to program A. (See Program Schedule Sheet for program descriptions). 3. Press +/ON or -/OFF button until program start time number 1 is flashing (upper left corner of display). 4. Press the NEXT button.. To set the hour, press +/ON or -/OFF button. 6. Press the NEXT button. 7. To set the minute, press +/ON or -/OFF button. Note: Programs, 3, 4 should read OFF.. Return dial to the AUTO/ON position. WATER TREATMENT SYSTEM OPERATOR S MANUAL Setting/Editing Current Time and Day 1. Turn control dial to SET TIME & DAY position. 11

12 OPERATOR S MANUAL WATER TREATMENT SYSTEM 1 C. Setting Editing Mode Run Times 1. Turn control dial to SET MODE RUN TIMES.. Set program switch to program A (see Program Schedule Sheet for program descriptions). 3. Mode number 1 will begin flashing (lower left corner of display). 4. Press the NEXT button. Mode number will stop flashing and timer display or "OFF" will begin flashing.. To set run time, press +/ON or -/OFF button. Note: To remove (skip) a mode, press the +/ON and -/OFF buttons at the same time. OFF should be displayed. (Refer to Program schedule sheet previous page, e.g. Program A, Mode 1 is 30 minutes). 6. Press the NEXT button. The next mode number will begin flashing. 7. Repeat steps 4-6 until all run times have been set for modes Return dial to the AUTO/ON position. RUNNING PROGRAMS Auto Backwash (Program A) - Used for Daily Operations 1. Set program switch to Program A.. Turn control dial to AUTO/ON position. Program will cycle through modes 1-6 when start time is reached. Mode number and program letter will flash to indicate status. Display will show time remaining in that mode. 3. CLP-04/7034 will return to filter mode when mode 6 (filter recirculation mode) is complete. Manual Start If you want to manually start the program, depress the "manual start" button on the AMC controller times. The program will now start and will go through the program at the programmed times. If you want to speed up the process and go to the next mode, depress the "next" button on the AMC controller and the program will move to the next mode. Valve Location & Function: It is extremely important to know the location and function of the valves on the CLP. Improper positioning of the valves can cause overflow or damage which could result in time consuming clean-up and repairs. Study the section on Valve Location and Function. Valve 1 - Flow Control Valve This valve controls the amount of water allowed into the CLP from the sump pump. Adjust -4 gpm valve instructions above your demand on the system (See Pages 17, 19, 0). Valves & 3 - Ozone Pump Should be open at all times (See pages 19, 4, 44). NOTE: Only to be closed when removing or replacing the ozone pump. Valve 4 - Oil Skimming Bucket Valve should be closed except when draining off oil (See pages 17, 1, 49). Valve - Tank Valve This valve should be open at all times except when removing air valve for repair (see pages 17-19). Valve 6 - Rinse Water Control Valve This valve is opened only when rinse water is needed (See pages 66, 6). Valve 7 - Outlet to Pressure Washer Valve (See pages4, 0, ). After start-up, this valve is left fully open all of the time. Controls water to the pressure washer (See pages 66, 6). Valve - Rain Water Overflow Valve Left open partially. When SV#1 opens, water is allowed to discharge while still providing water for the pressure washer (See pages 66, 6). Valve 9 - Recycle Flow Control Valve This valve is used to control the volume of water going back to the collection pit for recycling through the system when the PLC or AMC activates the solenoid, SV3, for recycling the system. Open partially to match filter flow meter allowing a smooth flow without cycling transfer pump as much as possible (See pages 46, 4, 0). Valve 10 - Filter Flow Control Valve This valve controls the amount of water allowed to flow through the filters. Adjust to the same or gpm below valve #1 (See pages 4, 44, 46). Valve 11 & 1 - Filter Control Valve When set on Filter, this valve allows water to pass through the filter. When set on Backwash, the water passes through the filter in reverse, then passes back to the catch basin. The air valves control these valves (See pages 17-19). Valve 13 Should be open at all times. Allows pressurized water to flush sediment from the cone tank (See pages 17-19). Valve 14 This valve should be open at all times to allow pressurized water to flush out the sludge hose

13 Control Panel Bracket Tank #1 clp-04 operation view Optional Cartridge Filter Orp/pH Probes Valve 300 Gallon Cone Bottom Tank Junction Box Valve 1 WATER TREATMENT SYSTEM OPERATOR S MANUAL 3-Way Ball Valve Assembly Sludge Tub Valve 1 Tank # Valve 11 Valve 1 Multi Media Filter Valve 4 Valve Flow Meter Valve 13 Carbon Filter Oil Decanter Barrel Inlet Line Sump Pump Sump Pump Installation (3 Phase) Sump Pit FS1 FS FS7 Inlet Line Sump Pump Sump Pit FS1 FS Sump Pump Installation 13

14 OPERATOR S MANUAL WATER TREATMENT SYSTEM Cartridge Filter (Optional) clp-7034 operation view Control Panel Bracket 600 Gallon Cone Bottom Tank Tank # Tank #1 Sludge Tub Flow Meter 3-Way Ball Valve Assembly Valve 11 Valve 1 Valve 4 Valve Valve 14 Oil Decanter Barrel Valve 13 Carbon Filter Multi-Media Filter Junction Box 14

15 water panel installation WATER TREATMENT SYSTEM OPERATOR S MANUAL SV1 To Sewer or Storage SV To Pressure Washer To Fresh Water Line 1

16 OPERATOR S MANUAL WATER TREATMENT SYSTEM 16 Valve 1 (034 only) STANDARD orp/ph controller This valve should be open at all times except when repairing filter pump (See page 46). Valve 16 Should be open at all times. Allows fresh water into tank when SV# opens. Valve should be fully open (See pages 66, 6). Valve 17 In the recirculation mode, this valve is used to control the volume of water going to tank #1 when the PLC or AMC opens SV#4. Open partially to match filter flow meter allowing a smooth flow without cycling transfer pump as much as possible (See pages 46, 4, 0). Valve 1 (034 only) Should be open at all times. Allows water to recirculate through tank #1 or collection pit (See page 46). Valve 0 Should be open partially to control the amount of water flow to backwash the multi-media filter when the PLC or AMC opens SV#7. Set for 30 gpm (See pages 4, 44, 46). Valve 1 Should be open partially to control the amount of water flow to the backwash carbon filter when the PLC or AMC opens air solenoid valves. Set for 1 gpm (See pages 4, 6, ). standard orp/ph digital controller - model 0 feed alarm water maze 0 orp safety timer setpoint ph calibration orp / ph digital controller ph OFF MANUAL AUTO OFF MANUAL AUTO low limit high limit 4V 0/60Hz a manufactured by santa barbara control systems - santa barbara california usa feed alarm programmed in the controller will determine if outputs from the controller are sent to the feed pumps. If sanitizer or ph adjust are needed, the output will turn the corresponding feed pump on. This will inject the required sanitizer or ph until programmed levels are reached and feed pump will stop. If ORP or ph adjustment is needed the ozone pump will also turn on. The chemical is injected at the outlet of the ozone pump. If ORP is needed the controller also turns on the ozone generator. All will run until setpoint levels are reached. Acid/Base Jumper Because most systems are dealing with a high ph situation, the controller is factory set for acid feed. If you require a base feed, turn power off to entire system, open plastic door on controller, remove four screws on display board, carefully pull backboard, and turn over. Reposition the JP14 Jumper to the base position. Return board and door to original position. Start-Up Turn switch on right side of controller to the "ON" position. On power up the controller will display "109" and then "ACD" for acid feed or "BSE" for base feed depending on your requirements. Feed Mode The feed mode for the ph and sanitizer can be set to "OFF", Manual or Automatic. Set to Automatic. To select the desired feed mode, press [ORP] or [ph] until the corresponding LED indicator light is illuminated. There is a short delay before activation. Note: Holding the switch for more than seconds resets the setpoint and calibration for [ORP] or [ph] to original factory values. ORP Control Setpoint The ORP setpoint is factory set at 0 mv, which is recommended to maintain water quality by killing germs and bacteria. There is no need for ORP calibration. The sanitizing concentration required to generate a desired ORP value varies with ph and overall water quality, particularly Total Dissolved Solids (TDS) concentration and organic load. To change the ORP control setpoint: Press [SETPOINT], Press [ORP]: the display flashes, Operation Use the [UP] and [DOWN] arrows to adjust the The Oxidation Reduction Potential (ORP) and ph of the ORP value, water stream are controlled automatically by the digital Press [SETPOINT] again to save the new value. controller. The controller receives input from the ORP sensor on the activity of the sanitizer and input from the ph sensor on the ph level of the waste stream. The level of ORP and ph being sensed, and the requested levels

17 ph Calibration To calibrate the ph, use a reliable, fresh test kit (Phenol Red). Note the value of the ph and compare it to the display value. To change the ph calibration: press [CALIBRATION], Press [ph]: the display flashes, Use the [UP] and [DOWN] arrows to adjust the ph value, Press the [CALIBRATION] again to save the new value. ph Control Setpoint The ph setpoint is preset at 6.. To change the ph control setpoint: Press [SETPOINT], Press [ph]: the display flashes, Use the [UP] and [DOWN] arrows to adjust the ph value, Press [SETPOINT] again to save the new value. Out-of-Range Alarms The out-of-range alarms are factory set at 40 to 60 mv for ORP and 6. to 7. for ph. If the ORP is below the low limit, the red LED alarm flashes but the sanitizer feed continues. If the ph limits are exceeded, the red LED alarm flashes and the ph feeder continues. To change an alarm limit: Press [LOW LIMIT] or [HIGH LIMIT], Press [ORP] or [ph]; the display flashes, Use the [UP] and [down] arrows to adjust the value, press [LOW LIMIT] or [HIGH LIMIT] again. CAUTION: Increasing the out-of-range limits may cause overfeeding of chemicals. orp and ph sensor maintenance The controller is virtually maintenance free. The enclosure and front panel can be cleaned with a soft cloth moistened with a mild soap and water solution or a glass cleaner. Do not use abrasives or harsh chemicals. Sensor Cleaning/Testing The sensor tips must be kept clean and free from chemical deposits and contamination to function properly. After saturation in the waste stream, the sensors may need to be cleaned on a weekly or monthly basis depending on the water quality and other facility-specific charac- sensor maintenance teristics. Slow response and inconsistent readings are indications that the sensors are in need of cleaning. To clean a sensor, carefully remove it from the compression fitting or holding bracket. Clean the tip of the sensor with a mild liquid detergent (Joy, etc) solution. Rinse with fresh water and soak the sensor in a mild acid solution for five minutes. Rinse with fresh water and reinstall the sensor. To check sensor for proper operation place a small amount of white vinegar, muriatic or hydrochloric acid into a cup and place sensor probe into solution. For the ph sensor, the needle should drop. For the ORP sensor, the needle should rise. NOTE: Only clean one sensor at a time. Sensors must stay in some kind of liquid at all times. Sensor Replacement For preventative maintenance it is also recommended to replace the sensors on an annual basis or as performance diminishes. Sensor Storage Extended exposure to atmospheric conditions will cause the sensor tips to dry out. Always remove and properly store the sensors if they are to be winterized or inactive. Store the sensors with the original cap provided, making sure that each cap is filled with clean water. If the storage containers have been misplaced, store the sensors individually in small glasses or plastic containers with clean water covering the sensor tips. Terminal Block Wiring B W G B W G ORP R W B Power Rotary Flowswitch B=black, W=white, G=green, R=red Dry-Contact Alarm B W G ph WATER TREATMENT SYSTEM OPERATOR S MANUAL 17

18 WATER TREATMENT SYSTEM Troubleshooting Guide TROUbleshooting - orp/ph sensors All controllers are manufactured to the highest quality standards and thoroughly tested before leaving the factory. State-of-the-art designs and fabrication technology should ensure years for trouble-free operation. problem no lights are on with power on illogical ph and orp value displays orp feeder does not activate ph feeder does not activate solution Check for power going to controller. Check for damaged power connector. Check internal fuse (1A slow blo) marked F3 on control board. The sensor cable connections may be reversed. Verify that the sensor cables are properly connected to their respective BNC connectors on the controller unit. Make sure the AUTO feed light for ORP is on. Check the ORP setpoint. Check ORP relay fuse (A slow blow) marked F on control board. Verify that the acid/base feed jumper JP14 on the control board is properly set. Make sure the AUTO feed light for ph is on. Check the ph relay fuse (A slow blow) marked F on control board. ph requires frequent calibration inconsistant or slow ph or orp readings Clean or replace the sensor as outlined in the maintenance section. Verify that the sensor cables are properly connected to their respective BNC connectors and the controller unit. Clean or replace the sensor as outlined in the maintenance section. Replace the sensors if needed. chemical feeder runs continuously Make sure the AUTO feed mode is selected. Verify that the chemical feeders are properly connected to their respective connectors or controller unit. 1

19 advanced digital orp/ph controller & maintenance advanced DIGITAL ORP/pH CONTROLLER Operations The digital ORP/pH controller is used to automatically control the oxidation reduction potential (ORP) and ph of the CLP system. The controller is used with a sensor that is installed in the 300/600 gallon tank. The sensor analyzes the water and operating like a miniature battery it generates a small electronic signal which is amplified and analyzed by the controller for display on the controller screen and for activation of the chemical feeders, the ozone generator and the ozone (mix) pump. The sensor reads the acidity of the water. The ideal ph range is 6. to 7.. Below 6., the water is increasingly acidic. This causes corrosion of the equipment (pump, filter, plumbing, etc.). Above 7., the water is too alkaline. This causes cloudiness and scaling. In addition, high ph values reduce the activity of the sanitizer. The sensor also reads the OXIDATION-REDUCTION POTENTIAL (ORP or Redox) of the sanitizer for possible chlorine or bromine and ozone. ORP which is measured in millivolts (mv) provides a superior index of bacteriological water quality because it monitors the activity of the sanitizer rather than just its quantity as with conventional PPM (parts per million) test kits (60 mv = 1 ppm). We have preset the controller to maintain a ph level of 6. and an ORP level of 0 millivolts (mv). ph Control Because most soaps that are used in the cleaning process are of a high ph level, we will normally have to adjust the ph level down. WATER MAZE recommends using Aluminum Sulfate as it has a low ph for ph adjustment and is also helpful as a flocculent to settle out solids. If you do use an acidic type cleaner the controller will have to be adjusted for that application. Call the factory for instructions. When the ph level goes above 6. the S1 contact light on the controller will light up, the ph pump will turn on and the ozone (mix) pump will turn on until the ph level returns to 6.. ORP (Sanitizer) Control The purpose for the sanitizer is to control bacteria and odor. WATER MAZE does this with ozone and a sanitizer supplied by the customer, usually chlorine. When the millivolts go below 0, the S contact light will turn on and the ozone generator and ozone (mix) pump will turn on. If the millivolts continue to drop below 00, the S4 contact light on the controller will turn on and in addition to the ozone already running, will turn on the sanitizer pump to inject sanitizer until millivolts reach 00 again. When the millivolts hit 0 the ozone generator will shut down. MAINTENANCE Maintenance Process for ORP/pH Probes 1. Inspect cable for cuts or evidence of cable being crimped.. Use a cotton swab, not a brush and clean the probe using any mild detergent such as dishwasher liquid. Don't use an ammonia based product. 3. Rinse 4. Dip in muriatic acid for seconds.. Rinse 6. Let probe regroup in clear water for an hour before returning it to system. Many probes last several years, but the average life span is to 3 years with regular maintenance. Periodic Maintenance for the EXA PH40 Converter The PH40 transmitter requires very little periodic maintenance. The housing is sealed to IP6 (NEMA 4X) standards, and remains closed in normal operation. Users are required only to make sure the front window is kept clean in order to permit a clear view of the display and allow proper operation of the push-buttons. If the window becomes soiled, clean it using a soft damp cloth or soft tissue. To deal with more stubborn stains, a neutral chemical may be used. NOTE: Never use harsh chemicals or solvents. In the event that the window becomes heavily stained or scratched, replace the window. When you must open the front cover make sure that the seals are clean and correctly fitted when the unit is reassembled in order to maintain the housing's weatherproof integrity against water and water vapor. The ph measurement uses high impedance sensors and may otherwise be prone to problems caused by exposure of the circuitry to condensation. The EXA instrument contains a lithium cell to support the clock function when the power is switched off. The cell needs to be replaced at year intervals (or when discharged). Contact your nearest WATER MAZE service center for spare parts and instructions. WATER TREATMENT SYSTEM OPERATOR S MANUAL 19

20 OPERATOR S MANUAL WATER TREATMENT SYSTEM Periodic Maintenance for the Sensor System The sensor system must be kept clean to function well. This may require regular cleaning of the electrode. (The effect of a dirty electrode will be to slow the system response and perhaps corrupt the measuring loop entirely.) The frequency of cleaning and the method of cleaning will depend entirely on the process. In a heavy oil and dirt load, the probe may have to be cleaned weekly; with low dirt and oil load you may only have to clean the probe monthly. Calibration of Sensor System The periodic recalibration of the sensor system is necessary to ensure best accuracy. This takes into account the aging of the sensors, and the nonrecoverable changes that take place. These processes are slow, however. If frequent recalibration is needed, it is usually because the cleaning process is not effective, the calibration is not well executed or the ph readings are temperature dependent. Monthly calibrations should be sufficient for most applications. If a film remains on the ph sensor, then measuring errors can be interpreted as a need for recalibration. Because these changes are reversible with correct cleaning, make sure the cleaning is done before recalibrating the system. metering pump The slow shift of asymmetry potential could signal a poisoning of the reference electrode system by the process. The decrease of slope equals a decrease of sensitivity of the glass electrode or can show a coating buildup at the electrode. The EXA PH40 makes a distinction among diagnostic findings. All errors are signaled by the FAIL area in the display. Only faults in the measuring circuits activate the FAIL contact switching. See a detailed table of error codes with possible causes and remedies on pages 9 and 30. VSP0 METERING PUMP #-39 (Variable Speed Peristaltic) TECHNICAL INFORMATION Materials: Feed Rate: Pump Head... Polycarbonate Pump Head Tubing...Special Synthetic Rubber Strainer and Injection Point Fitting...PVC.6-0 GPD Tubing Size: 7/16" O.D. x 1/4" I.D. Dimensions: Hgt. = ", Wdt. = 6-1/4", Dpt. = 7" 0 TROUBLESHOOTING The EXA PH40 is a microprocessor-based analyzer that performs continuous self-diagnostics to verify that it is working correctly. Error messages resulting from faults in the microprocessor systems itself are few. In addition, the EXA PH40 also checks the electrodes to establish whether they are still functioning within specified limits. The transmitter checks the glass-electrode impedance for a low value to determine if it is broken or cracked, and for a high impedance to check for internal breakage or disconnection. The reference system is prone to more faults than the glass electrode in general. The unit measures the impedance value and compares it to the programmed value in memory to determine acceptance during testing. A high impedance signals pollution or poisoning of the reference electrode diaphragm. Also, the EXA PH40 checks the electrodes during calibration to determine if the reaction time is suitable for ph measurement. A specially timed check can be activated following each cleaning cycle. After calibration, the unit checks the calculated asymmetry potential and the slope to determine if they are still within limits specified by the software. Standard Accessories Provided with Pump: Head Tubing Injecting Fitting with Check Valve Strainer Polyethylene Tubing (1/4" O.D. x 1') Tubing Sleeve (for strainer connection) Electrical Rating: 4V.3 Amps 0/60 Hz Maximum System Pressure: PSI (maximum allowable at injection fitting)