Purclean PURWATER RECLAIM 3.0, Technical Manual

Page 1: ...a t i o n s Technical Manual PURWATER RECLAIM 3 0 SYSTEM 2016 New Wave Industries All rights reserved MADE IN THE USA Revision 1 February 2020 3315 Orange Grove Avenue North Highlands CA 95660 1 800...

Page 2: ...Corporate 800 882 8854 2...

Page 3: ...ons Wire unit for correct voltage See Installation Operating Instructions label on the electrical panel cover Meet National Electrical Code and local codes for wiring Follow wiring instructions in thi...

Page 4: ...Corporate 800 882 8854 4...

Page 5: ...ustomer Connections 23 24 Pre Startup Setting the Time and Date on the PLC 25 26 System Start up 27 37 System Operation 38 Key Electrical System Component Overview 39 41 Key Plumbing System Component...

Page 6: ...Corporate 800 882 8854 6...

Page 7: ...bacteria will grow in the reclaim tank Anaerobic bacteria produces hydrogen sulfide and methane gas that has an odor similar to rotten eggs A properly designed reclaim system must both remove solids a...

Page 8: ...case the system is not operating due to a system fault and 2 an automatic pump prime operation for system start up Air Sparger Biological and odor control are accomplished by using one of two methods...

Page 9: ...ning and installing the plumbing one primary and one spare It is also strongly suggested that the suction lines be pressure tested and monitored during backfill of the trench Note The suction line siz...

Page 10: ...n piping Double 45 s or Sweeps rather than 90 s are highly recommended Keep the suction piping below the reclaim pump inlet For ozone units the reclaim tanks should be located outside the wash bay and...

Page 11: ...k valve when the float is in the down position Misc Items Reclaim Tank Plumbing Piping and conduit materials should be PVC PurWater recommends using schedule 80 pipe as it is more durable than schedul...

Page 12: ...ocation and placement The end of the sparger should be 6 12 off the surface of the water Note the location of the Foot Valves on the Suction Lines approx 16 off the tank floor The Low Level Float is a...

Page 13: ...evel Float is also located here Three 2000 Gallon ea Reclaim Tanks Ozone Systems 6000 gals total Note the location and termination of the ozone line It is placed mid chamber at approximately half the...

Page 14: ...a minimum clearance of 18 along the sides front and top of all frames to allow for routine maintenance and inspection The floor frame should be placed with its back along a wall and should be secured...

Page 15: ...t for high pressure pumps 2 City Water Line City water is to be connected which will then provide fresh water for a bypass function to the wash and the pump prime sequence The city water supply line n...

Page 16: ...It should be located so that it is accessible from the manway as frequent inspection and maintenance are required Ensure the wall mount bracket is placed to allow the assembly to be removed easily Th...

Page 17: ...should never go higher than the basket strainer inlet The suction line within the Reclaim tank should have a flapper type foot valve at the very end of it and a union installed for maintenance Unions...

Page 18: ...ing as an orifice that passes water flowing from the manifold at the bottom of the cyclonic seperators Once each day at 2am the system will open the valve and ramp up the pump to flush the underflow f...

Page 19: ...p on the equipment room floor There is no wiring required simply unscrew the black cover from the AOS receptacle and screw in the yellow cable from the AOS control box see photos below Please note The...

Page 20: ...1 valve on the enhanced trench flush During this operation the reclaim pump will maintain a line pressure of about 40 PSI The water going through the valve will be fed down to a ball valve This ball...

Page 21: ...inate as desired by the operator It may be a nozzle assembly or possibly just an open PVC line Flow can be regulated or restricted via a ball valve if desired The site work pre plumbing is key Note If...

Page 22: ...left shows the flow path of the reclaim water in green to the high pressure pump Note The reclaim water is isolated from the fresh water by the check valve indicated by the arrow The picture on the r...

Page 23: ...I2 RUN STOP LOGO Q1 Q2 Q4 I 1 I 2 I 4 I 3 L 1 N Q3 RUN STOP 1 2 6 3 4 5 6 7 8 A 1 A 2 1 4 1 1 1 2 100 125 A 1 A 2 1 4 1 1 1 2 100 125 A 1 A 2 1 4 1 1 1 2 100 125 A 1 A 2 1 4 1 1 1 2 100 125 A 1 A 2 1...

Page 24: ...ystem go to the Operation section on page 40 1 2 6 3 4 5 6 7 8 A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 A1 A2 14 11 12 G...

Page 25: ...After arriving at this screen the Date and Time can be set A stylus can be handy to have on hand however a well placed finger will also work fine The Year Month Day and Time were set at the factory fo...

Page 26: ...K button 5 Again using the Down Arrow Key scroll to Set Clock as shown in screen shot 5 and press the OK button 6 Use the Right Arrow Key and scroll through the Time and Date using the Up Down Arrow K...

Page 27: ...n does not initiate open the control box and verify that the 110V wiring is terminated and the single pole breaker in the control box and the one from the breaker is on If power is verified and there...

Page 28: ...ite preference 6 Prime the system per the procedure on page 32 and check for leaks Note If the system is primed multiple times and cannot catch prime contact PurWater The suction line should NEVER be...

Page 29: ...via the Touch Screen itself When scrolling through menus wait 5 seconds between pressing buttons an easy way to be sure of the time is to wait until prompted to press a button by the HMI If system is...

Page 30: ...also a rotation indicator arrow on the pump volute 10 HP Motor System Start up Continued 3 or 5 HP Motor If the motor is rotating in the wrong direction reverse two of the leads in the main breaker b...

Page 31: ...ify that the wash activation signal is working and that the Reclaim responds to that signal If everything is working fresh water plumbed to the Reclaim unit is on and the activation signal is present...

Page 32: ...e way to the foot valve in the tank Once all the air is displaced the basket will fill and eventually overflow As soon as water starts overflowing the basket tighten all 4 T Bolts or close the bleed v...

Page 33: ...he delivery pressure is shown with the Reclaim idling in Auto with no activation signal present Once the Reclaim Machine is holding prime go ahead and initiate a car wash The Touch Screen will indicat...

Page 34: ...from the manway and installed with a union so it can be removed for maintenance Verify the bottom of the sparger nozzle is set 6 12 above the water level and pointed downward or spraying horizontally...

Page 35: ...left side of the unit There is a flow meter that is preset at the factory to 6 with the line disconected When running the flow meter will typically be in the 2 4 range with the line attached The Oxyg...

Page 36: ...p of the machine The 24 gram is larger than the 12 gram unit as shown A quick glance at the internal photo reveals two drive boards two transformers and two of the 12 gram ozone cells requiring the la...

Page 37: ...ir providing pure O2 to the internal ozone cell If the Reclaim Machine is purchased with the 4 gram option it will have one cabinet mounted on the machine The single 4 gram cabinet will run for 30 min...

Page 38: ...water enters in the upper portion of the cyclonic separators and spins the water to separate the solids from the water which get directed downward Five micron or lower treated reclaim water is direct...

Page 39: ...ogrammable Logic Controller PLC The Siemens PLC is mounted inside the control box and operates the system by providing control of various functions of the reclaim unit The PLC is programmed at the fac...

Page 40: ...ecirc and U Fvalves activation signals and optional add ons The standard bank of 9 relays is shown to the left Note that not all these relays are identical in terms of the voltage rating and are not i...

Page 41: ...100 125 I6 r I3 24vDC Power Supply Brown Strip to Fresh Water Bypass Valve Orange Strip to N O Prime Valves Blue Strip is 120vAC power to Oxygen Concetrator Ozone Generator Yellow Strips 120vAC out 2...

Page 42: ...ush valve which opens only when the Reclaim is in the OFF mode U F Flush Valve The 1 Underflow Flush or U F Flush valve is located on the bottom of the cyclone manifold section to remove solids spun d...

Page 43: ...nto a PVC manifold The solids that move to the bottom of each individual cyclone will flow through the manifold exit the Reclaim System via the Underflow Flush Valve Prime Solenoid Valve The prime sol...

Page 44: ...resent The valve will vary in size depending on system model but the purpose remains the same NOTE The valve may not close if the incoming pressure exceeds 70psi Treated Water Line Components The trea...

Page 45: ...iled NOTE Ozone tubing is PVC Never replace with polyflow or alternative type Ozone will eat the tubing from the inside Flow Inlet high pressure Mazzei Check Valve Ozone In Connection Outlet low press...

Page 46: ...x 7 The screen description on the right is a capture of the type of information displayed when turned off The next screen is an example of what might be seen should a fault of some sort occur in Auto...

Page 47: ...as kept up on the machine For more information please contact PurWater Oxygen Concentrator Ozone Cells VFD Touch Screen 1 8 years 16 000 hours 1 8 years 16 000 hours 2 5 years 6 years Please note that...

Page 48: ...ult Screen Normal Screen Indicates Reclaim in Bypass Check Pump Pressure Gauge Weekly The pump pressure gauge should show pressure when the motor is running This pressure will vary If a wash activatio...

Page 49: ...eplace the lid and the dogear bolts Tighten the dogear bolts in a cross pattern to ensure the strainer basket housing lid is evenly seated on the housing Leave the rear two slightly loose Press Off fo...

Page 50: ...nd may require removal complete disassembly U F Flush Valve with Water Flowing Through Pump Out Settling Tanks A Minimum Of Every 6 Months Call a local company that pumps out septic tanks and have the...

Page 51: ...ve the cover s retaining the filter element on the bottom of the ozone generator s Note that 4gram and 12gram units have one filter each The 24gram has two Once the cover is off remove the filter elem...

Page 52: ...t 8 000 hours of elapsed run time which does not require any action beyond acknowledging the message When elapsed run hours reach 16 000 hours a Full Life message will be displayed indicating it is ti...

Page 53: ...Check the air intake port on the sparger and ensure it is not clogged Flush with water to clear any debris Check the recirculation water inlet and ensure it is not clogged Flush with water to clear an...

Page 54: ...12 100 125 A1 A2 14 11 12 6 24 A1 A2 14 11 12 6 24 A1 A2 14 11 12 6 24 A1 A2 14 11 12 6 24 A1 A2 14 11 12 100 125 I4 I5 R2 12 R3 12 R3 14 R2 14 RECIRC MBV U F MBV RECIRC MBV U F MBV U F MBV Recirc MBV...

Page 55: ...PUT 4 X RELAY 10A Q1 Q2 Q4 I5 I6 I7 I8 I1 I2 I4 I3 L1 N Q3 ESC OK L N W V V 0 45A IDEC PS5R SB24 Power Supply 100 240VAC 24VDC 0 65A 15 L O W LOGO X1 1 PE L M L M V1 M I1 V2 M2 I2 RUN STOP LOGO Q1 Q2...

Page 56: ...RELAY 10A Q1 Q2 Q4 I5 I6 I7 I8 I1 I2 I4 I3 L1 N Q3 ESC OK L N W V V 0 45A IDEC PS5R SB24 Power Supply 100 240VAC 24VDC 0 65A 15 L O W LOGO X1 1 PE L M L M V1 M I1 V2 M2 I2 RUN STOP LOGO Q1 Q2 Q4 I1 I2...

Page 57: ...ON VFD RED R1 11 to VFD term 01 H 02 ON VFD ORANGE R1 14 to VFD term 02 9 1 2 3 4 5 6 7 8 RELAY DESCRIPTIONS Relay 1 Run signal to VFD Relay 2 2 Recirc motorized ball valve wired as normally open so t...

Page 58: ...n Bradley R1R2R3 01 02 03 04 05 06 11 12 13 14 15 16 U T1 V T2 W T3 DC DC LOGO X11 PE L M L M V1 M I1 V2 M2 I2 RUN STOP LOGO Q1 Q2 Q4 I 1 I 2 I 4 I 3 L1 N Q3 RUN STOP I8 0 10V TRANSDUCER RECLAIM BOX u...

Page 59: ...n and are prioritized to show in sequence by importance For example if the VFD is faulted and the recirc ball valve is out of position the Touch Screen will display the VFD fault and disregard the bal...

Page 60: ...ged message every 168 hours The operator should touch the flagged message which then opens the next message The message to Clean the basket is a brief overview of the procedure that is outlined in dep...

Page 61: ...nding on exactly how the system was built have reached 8 000 elapsed hours indicating half life This is nothing more than a heads up for the operator All that is required at this point is to acknowled...

Page 62: ...n Full Life will take the operator to the second screen full of text The operator can contact the local distributor for parts If the ozone components are still functional keep the system running until...

Page 63: ...recognized externally based on the color seen in the viewport Green indicates open and Red indicates closed If either the Reciculation or Underflow Valve is out of the expected position a Reclaim MBV...

Page 64: ...screen If the valve does not move it is time to determine if the issue is related to the motor or if it is a mechanical bind in the PVC portion of the valve itself System Troubleshooting Minor Fault R...

Page 65: ...ve and note the stem of the valve Using a 1 2 wrench rotate the valve position Clean the valve in the open closed positions Once the valve is clean rotate it several times is it relatively easy to do...

Page 66: ...ews from the underside of the motor cover This will expose the area where the switches are mounted There are small studs or alignment pins for mounting each switch Each switch has a white plastic keep...

Page 67: ...item it should be cleaned quarterly Reference the procedure on page 52and clean the Mazzei if overlooked After cleaning reinstall the Mazzei and leave the lower union loose Restart the Reclaim there...

Page 68: ...em was built with the 4 gram ozone option or no ozone option at all there will not be an oxygen concentrator It is an indicator that the pressure switch inside of the ozone generator is not satisfied...

Page 69: ...leaks Remove the line as shown in the picture on the right Adjust the black knob on the flowmeter and set the ball to 6 Cover the output fitting with a finger and verify the ball crashes to the floor...

Page 70: ...nerator itself It s a good idea to do visual checks of the 48Vdc Power Supply the drive board s the transformer s and the reaction chamber s also known as cells See the following pages Internal faults...

Page 71: ...r board has a red fault LED lit up there is a problem Normal Displays are also shown The ball in the flowmeter is difficult to see but is typically around 8 5 9 0 The picture shown on the right shows...

Page 72: ...ble stacked 24V netting 48Vdc out If operating there will be a green LED lit on each layer providing 48 V to the drive boards There is also a fuse on the upper portion of each layer Occasionally but n...

Page 73: ...a 24gram generator it makes troubleshooting a bit easier if one of the two combined components is operating The transformers are very stable devices and rarely fail Usually a good visual check for ca...

Page 74: ...the ear If water or sloshing sound is heard replace the transformer Reaction chamber or High Voltage wire is bad High Voltage wire not making a good connection Check at both transformer and resction c...

Page 75: ...Corporate 800 882 8854 75 System Troubleshooting Minor Fault Ozone Fault Factory Manual Troubleshooting Tips...

Page 76: ...As a work around in order to get the Reclaim running simply disconnect the float in the control box Reference the Customer Connections on page 24 and in this case simply pull the low float wires out o...

Page 77: ...rainer basket lid oring and sealing surface The suction line in the tanking may have a problem with the foot valve The flap may be damaged it could be obstructed with an object such as a plastic bag o...

Page 78: ...st be opened to gain access to the PLC and the two extension array There is a way to defeat the main disconnect and leave the power on to the internals of the control box but this must only be attempt...

Page 79: ...s the red stop button This should clear the fault and the system will start the pump on its own If there is no display verify there is power going to the VFD by checking the bottom side of the three p...

Page 80: ...ower at the bottom of the three phase breaker both to each other and each leg to ground for an inconsistent reading between power legs a low voltage reading or a reading that jumps around erratically...

Page 81: ...Try to reset if fault will not reset power down disconnect pump and check and see if fault is still present If not check motor connections in motor junction box and replace pump if needed This fault w...

Page 82: ...tor Step 7 Use two screwdrivers Figure 4 or bearing puller to carefully sep arate motor from adapter seal plate bringing rotating half of seal Key No 10 off with adapter seal plate Shaft sleeve Key No...

Page 83: ...plate to motor being careful not to scratch seal face Step 10 Apply liquid soap to inside diameter and outside face of rubber drive ring on rotating half of seal Step 11 Slide seal assembly onto shaf...

Page 84: ...ate gear puller jackscrew until impeller clears shaft Mechanical shaft seal will come off with motor bracket If a seal retaining ring is part of the assembly it will need to be replaced Gear Puller Fi...

Page 85: ...st ceramic face Compress seal spring and install retaining ring if used in shaft sleeve groove Place impeller key in motor shaft keyway Slide impeller on to shaft as far as possible Apply non permanen...

Page 86: ...split while passing through the high voltage electrical field the corona forming single oxygen atoms O1 These oxygen atoms then recombine with other oxygen molecules in the air stream forming ozone Th...

Page 87: ...cates ozone is being p r o d u c e d The E x t e r n a l L o o p does n o t h a v e c o n t i n u i t y w h e n t h e LED is illuminated which indicates no ozone production HI TEMP HI TEMP AIR PREP DR...

Page 88: ...rocedures CAUTION The ozone generator operates at high voltages Follow these steps carefully before performing any semi annual or annual maintenance procedures Step 1 Turn off power to any peripheral...

Page 89: ...s required Operating conditions in the equipment area will dictate the frequency required for this procedure Remove the filter element and clean with soap and water drying them completely before re in...

Page 90: ...entered air prep system Unit does not have constant power Excessive duty cycle Excessive relative humidity Solenoid valve not operating Air dryer board not functioning Unit must have constant power Du...

Page 91: ...eck board to be sure it is attached securely to the mother board Bad high voltage drive board replace as required External Loop LED is illuminated The external loop does not have continuity System is...

Page 92: ...ulate Filter Main Mother Board Remote 4 20mA Control Leads Cover Safety Switch External Loop Manual Ozone Output Adjustment Knob Fuse Carrier Ozone Outlet and Check Valve Power Entry Module OFF ON Swi...

Page 93: ...ver Safety Switch Mother Board Manual Ozone Output Control Remote 4 20mA Ozone Output Control Fan Control Board LED Display Board Solenoid Valve Dryer 1 Dryer 2 High Voltage Board 1 High Voltage Board...

Page 94: ...WARRANTY VALIDATION SITE DATE COMPANY NAME MODEL SERIAL MODEL SERIAL MODEL SERIAL ADDITIONAL INFORMATION SOLD TO ADDRESS CITY STATE ZIP PHONE CONTACT COMPLETE AND RETURN FOR WARRANTY CONSIDERATION PLE...

Page 95: ...een sent to and received by NEW WAVE INDUSTRIES LTD This warranty is expressly limited to the repair or replacement of the defective component Excluded from warranty are gauges strainer baskets and pu...

Page 96: ...hen returned parts are received by NEW WAVE INDUSTRIES LTD credit for the parts is contingent upon credit evaluation inspection and warranty terms If the customer wants to place an order for the part...

Page 97: ...on 2 0 Reclaim upgrade HMI external screen automated Underflow Valve added Recirculation Valve modified both Underflow Recirculation Valves give feedback status to PLC 2020 Complete re write Generatio...