ZEROwaste HX PERC SYSTEM USER MANUAL AIR QUALITY LABORATORIES Seattle, Washington 1
IMPORTANT FILTER MAINTENANCE Refer to the description and diagram on the next pages to identify filter housings A, B and C. Replace one B-1 charcoal filter every 30 days, or sooner if the system alerts you to the presence of perc in filter A. To use filters efficiently and economically, follow this routine exactly: 1. Remove the filter cartridge from filter housing A and dispose of it in your hazardous waste drum. TIP: Make sure that the old filter washers have not stuck to the filter housing top or bottom. 2. Remove the cartridge (and its washers) from filter housing B and install it in filter housing A. 3. Place a new filter in housing B to complete the changeover. 1. Old filter A to hazardous waste drum 2. Move old filter B to A 3. Insert fresh B-1 filter in B Change the particulate filter ( C ) at least every 90 days. Dispose of the old particulate filter in your hazardous waste drum and replace it with a new particulate filter. Lubricate the O rings in the three filter housings to seal them against air leaks. Place some lubrication on the rubber O rings in all three filter housings. Use Vaseline or an equivalent-bodied lubricant. If the filters are heavily contaminated with solvent, shorten the changeover cycle period and check the dry-cleaning machine s separator. FAILURE TO FOLLOW THESE INSTRUCTIONS MAY RESULT IN ENVIRONMENTAL DAMAGE AND COULD VOID YOUR WARRANTY. 2
ZEROwaste HX system Description of water flow (see diagram next page) Waste water enters the ZEROwaste tank through the twoinch inlet with the blue cover (1) or by being directly connected to the barbed fitting on the top of the lid. When the electronic sensors (2) are in contact with water (above the reserve level of about 2 gallons), the pump (3) turns on. The pump (3) pulls water from the tank through the siphon tube (4). The water first goes into the particulate filter C, where any tiny solids are removed. From there, the water goes to filter A, where perc is removed from the solution by the B-1 filter. In filter A the water passes through the perc sensor chamber. It is then pulled through the pump and pushed through filter housing B (6), which holds a second B-1 filter. The water has now been stripped of perc and flows from filter B (6) to a tee fitting (7) in the tube. A bypass needle valve (8) in the tube regulates the rate at which cleaned water is pumped to the heat exchanger. Finally, using heat from the steam line, the heat exchanger boils off the cleaned water and discharges the steam through the ½ line from the heat exchanger to your roof. 3
ZEROwaste HX system 4
ZEROwaste HX system SYSTEM OPERATION (877) 450-8782 To start the system, turn the power switch to ON. A red OPERATE light on the Filter Guard label and a beep will indicate that the unit is powered on. A small delay is normal: there is a short delay built into the circuitry. The machine automatically senses the presence and level of water in the tank. When more than about two (2) gallons of water is present in the tank, the machine automatically begins to pump. Pumping continues until the water level goes down to the reserve level of about two (2) gallons. A red TANK FULL warning light indicates that at about six (6) gallons the water level is close to the tank s capacity. The operation of the machine is not damaged by a water level above that, but you will not receive additional warnings. Use care when the level of water in the tank is high. The capacity of the tank is eight (8) gallons. 5
FILTER GUARD ALARM SYSTEM The filter guard system tells the operator that filters need to be changed because the system has detected perc in filter A beyond the capacity of that filter to absorb it. When this condition occurs, the system s sensor detects the perc, and the filter guard system turns off the ZEROwaste HX System and alerts the operator to change the filter. A red light blinks on the control panel and an alarm sounds. The ZEROwaste HX System also will stop operating when a significant quantity of solvent in the storage tank separates from the waste water and touches the sensor. A red light and an alarm will tell the operator that there is solvent in the tank, which must be drained before the unit can operate again. See the notes below about the PERC SAFETY INTERLOCK for specific instructions about handling this situation. PERC SAFETY INTERLOCK To ensure environmental safety, the system is equipped with an electronic perc-sensing safety interlock. When about one (1) gallon of syrupy liquid perc accumulates in the bottom of the tank, the unit will cease pumping, and an alarm and red warning light will indicate PERC IN TANK. When this condition occurs, you must drain the perc from the tank before continuing. The drained-off perc can be put into the drycleaning machine for distillation and reuse. After the perc is removed, the ZEROwaste system s tank can be refilled, and pumping and operation will continue. Caution: Do not put waste water with visible quantities of perc into the machine. Pure perc can deteriorate parts of the system and will shorten filter life. If perc is visible in the waste water, it should be returned to the dry-cleaning machine for distillation. Check your 6
water separators on the dry-cleaning machine to make sure they are functioning properly. MAINTENANCE Change filters monthly. See the first page of this manual for step-by-step instructions, and the following section for additional tips. CONTACT US For technical support, filters, parts, or supplies, please visit: www.zerowastemachines.com or call: (877) 450-8782. 7
ADDITIONAL TIPS FOR YOUR ZEROwaste HX system 1. CHANGE B-1 FILTER A AT LEAST EVERY MONTH Even though the machine has a perc sensor built into filter A, under certain circumstances a few drops of perc could still travel beyond filter A before the alarm sounds and stops the machine from pumping. If that happens, those few drops will be caught by the B filter. (This is why the second B-1 filter is included in the design.) However, those few drops will eventually shorten the life of the peristaltic pump tube. If and when deterioration of the tube leads to the tube hardening, the pump will not pull water through the tube. If this occurs, replace the pump tube. 2. CLEANING AND TROUBLESHOOTING THE MACHINE By changing your filters frequently and keeping the probes clean (see the monthly checklist at the end of this manual for instructions) you will extend the life of the machine. If the machine stops pumping water, the problem will usually be one of the following: a problem with the pump itself; pump tubing that has lost flexibility; an air leak; a blockage; or a filter that needs to be replaced. To troubleshoot, follow these instructions: a. If the level of water in the machine is above the minimum and the pump is not turning, then either the control system has shut the machine down or there is a problem with the pump itself. Your service people can test the pump by connecting it to 115- volt power outside of the machine. If the pump does not work when separately powered, it will need to be replaced. b. If the pump is working properly, test the pump tubing (the cream-colored tubing that goes into and comes out of the pump housing). To test the tubing, disconnect the clear tubing attached to the cream-colored tubing on the left side of the 8
pump from filter housing A. Then put the clear tubing into a glass of water and observe whether the pump removes water from the glass. If the pump is turning but not removing water, then the cream-colored tubing has been damaged and will need to be replaced. c. Several things could be allowing air to leak into the pumping system. Make sure that no extra or old top or bottom filter washers have been left in the A or B filter housings. Then check to make sure that the O rings in all three housings have been lubricated, and have not deteriorated or been damaged. Finally, inspect the three housings and the clear tubing for any cracks or damage that could allow air to enter the pumping system. d. If water is still not flowing through the machine, look for sources of blockage in all three filters. In each case, test for blockages with the glass of water test introduced in step b above. The following will show evidence of blockages in tubing, filter housings, or filters that you will need to resolve if you detect them. i. First, apply the test using the clear tubing that runs from the particulate filter to the A filter. Disconnect the tubing from the particulate filter, put it in the glass of water, and turn the machine on. (Remember that the water in the tank needs to be above the minimum.) ii. Second, pull the clear tubing out of the tank, put it into the glass of water, and apply the test. 3. INSTALLING THE HEAT EXCHANGER Start with the notes at the end of this manual. The following offers additions to what you will find there. Because the tubing from the ZEROwaste HX SYSTEM is made of 9
plastic, it could melt if it were to come close to lines or steam from your boiler. We suggest that you connect a six (6) foot length of ½ copper tube to the heat exchanger and then connect the plastic tubing and the copper with a fitting that you can obtain from any hardware store. This way the plastic tube will get warm but not hot enough to melt. The plastic tube should also extend a few feet above the copper tube. This will allow the water to drop easily into the heat exchanger and not siphon back. We recommend that you mount the heat exchanger so that there is a slight slope down from the Waste Water In port. A ½ height difference will work. This will cause the waste water to run down as it flashes off. When attaching the copper tube to the Waste Water Steam Out port, try to keep the straightest line possible to the exit point. Angles and turns cause restrictions that will decrease the efficiency of the heat exchanger. A severe restriction could cause the device to malfunction, which could cause personal injury. Insulate the Waste Water Steam Out ½ copper tube with a hightemperature insulating material for the first ten (10) feet. Polyurethane foam, the most common insulation material, will not tolerate this heat. After ten (10) feet, insulate with any insulation for the rest of the run. It is wise to insulate this line so that the steam doesn t condense and drip back to the heat exchanger. You will lose some of the efficiency of the unit if this happens. 4. ODORS While the water that arrives at the heat exchanger will be free of perc, it may still contain impurities that can bring odors. Because the moisture originated from the clothes -- which may carry fatty acids, urine, vegetable juice, wine, milk, etc. -- turning this mixture into steam can produce odors. This is why we always recommend that you 10
run the heat exchanger only after adding the Steam Out line to your roof. Pipe the Steam Out line to the outside of the building. You could use an unused pipe on your roof or even run the line up the boiler stack housing If you are still having problems, please call us: (877) 450-8782. 11
ZEROwaste HX SYSTEM Monthly Maintenance Checklist Initials: Date: [ ] REPLACE B-1 FILTER A. Replace and discard filter A. Place the spent filter in your hazardous waste drum. Make sure that the old filter washers have not stuck to the filter housing top or bottom. B. Inspect filter B. If it appears free of perc, then place it in the A filter housing. C. Place a new B-1 filter in B housing. [ ] INSPECT C FILTER Inspect filter C the particulate filter. If it appears dirty, replace it. These filters can last for up to three months, and do not directly affect perc reduction; they ensure that the B-1 filters are not clogged with particles, and so increase the efficiency of the B-1 filters. [ ] CLEAN PROBES Clean the electronic probes with a soft cloth soaked in either a detergent solution or isopropyl alcohol. These probes must be kept clean for the machine to operate correctly. The tip end of the nylon encased probe must have 1/8 inch of stainless steel showing. Cut back the nylon sheath to expose 1/8 inch of the probe end and polish this end with emery cloth. [ ] BLEED PERC FROM TANK YEARLY This perc can be returned to the dry-cleaning machine and reused. 12
INSTALLING THE HEAT EXCHANGER. NOTE: It is important that the heat exchanger go in the main steam header line as close to the boiler as possible, and that it goes in series with the steam line. DO NOT INSTALL AFTER THE PRESSURE REDUCING VALVE!!! 1. Measure the length of the heat exchanger (approx. 34 ). 2. Cut out a length of steam header pipe equal to the length of the heat exchanger and add the measurement of both couplers. 3. Using the couplers install the heat exchanger. The exchanger is symmetrical, and so may be installed in either direction. Choose either of the ½ nipples for Water In. The other will be Steam Out. 4. Using ½ inch copper fittings add 6 feet of ½ copper tubing to the Waste-In port (furthest from boiler) to protect the plastic tubing feed line from the heat of the boiler. Waste- Water In Steam Out To The Roof 5. Using ½ inch copper fittings the steam-out port (closest to the boiler). The ½ inch copper tubing can be fed to the roof alongside the boiler vent. Remember to insulate this line. Wastewater inlet diameter: 1/2 Steam pipe diameter: 1 Length approx. 34 13