TruSteel AV30, Pre-Installation

Page 1: ...Copyright 2020 by TruSteel LLC All Rights Reserved AV30 PRE INSTALLATION REQUIREMENTS AV30 Pre Installation Requirements Version 3 0 ...

Page 2: ...the Human Machine Interface HMI 19 Contact Aqua Sierra 20 STAGE 5 ASSEMBLE AV30 20 STAGE 6 PRIME WATER HEATER CHILLER 20 CHILLER FILLING STARTUP 21 System requirements 21 Fill the Chiller 21 Troubleshooting 22 Alarm Reset Procedure 22 b1AC Set Point 23 ALc1 ALARM ON START UP 24 Contact MTA 24 FILL START WATER HEATING SYSTEM 24 Prepare Equipment 26 Prepare To Fill PreHeater Use Port 1 26 Prepare To...

Page 3: ... refer to it throughout your AutoVap pre Installation process It is suggested but not required to place all ancillary equipment water heater chiller vacuum pump PLC outside of your C1D2 solvent recovery lab AUTOVAP30 IMAGES The AV30 is the most efficient solvent recovery system when comparing throughput to footprint With built in fail safes alarms data logging and remote access the AV30 stands alo...

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Page 6: ...EQUIREMENTS AV30 Pre Installation Requirements v 3 0 6 37 STAGE1 RECIEVE EQUIPMENT CHECKLISTS Use the following checklists to keep track of your projects progress Please print each of the following checklists for your records ...

Page 7: ...trol Water Heater The heater unit will be delivered directly from the manufacturer Please be aware that the heater will take at least 2 weeks to be manufactured Tracking will be provided when available Heater Model Heater Serial Electric Water Heater Arrived Manifold Package The manifold package will be shipped directly from TruSteel It will include VFD Variable Frequency Drives Taco Recirculating...

Page 8: ... Flange Set Chiller Bypass Manifold Taco Pump Ball Valve Small 4 Hose Barbs 4 Sharkbite Valves Inline Pump Model Inline Pump Serial Vacuum Pump Vacuum Pump Model Vacuum Pump Serial Vacuum Pump Received AutoVap30 and Control Panel 2 Separate Crates Control Panel Model Control Panel Serial AutoVap30 Control Panel Received ...

Page 9: ...y out of your water heater The flow rate of the water heater will be a determining factor of the efficiency of the heat as the AV30 recovers solvent To ensure maximum flow rate the water heater should be placed as close to the AV30 as possible and the plumbing should have a few 90 degree turns as possible The plumbing run should have as little vertical differential as well 3 The recirculating wate...

Page 10: ...ery room The chiller unit should be placed in a well ventilated area preferably outside of the facility in the open air on a concrete slab or on the roof The chiller should be within 50 feet of the AutoVap30 unit in order to be most efficient The water heater should be placed outside of the C1D2 room The electric water heater does not require ventilation while the gas heater will require proper ve...

Page 11: ...STAGE 3 INSTALL ANCILLARY This section provides important information for each piece of equipment that needs to be installed Most equipment will have manuals with them when they arrive but we have also provided links to the manuals and in some cases some extra installation materials ...

Page 12: ...ly efficient takes up minimal space and reduces operating costs Electric Water Heater Technical Documents Model HX TX Brochure PDF Model HX TX Written Spec PDF Model HX TX O M Manual PDF GAS WATER HEATER Model NX300 Tankless Electric Water Heater Available in 33 36 KW Three Phase Voltages The Hubbell model HX Tankless electric water heater is a highly reliable and easily maintained heater designed...

Page 13: ...ent your heater will work with the AutoVap The flow rate of your closed loop to the AutoVap is VERY important A short straight path will ensure a higher flow rate 2 The heater manifold provided by TruSteel will be installed directly into the water heater To Install Manifold a Remove plastic pex fitting inside of the Sharkbite fitting on the water heater inlet and outlet b Insert straight copper en...

Page 14: ... about 20 gallons You ll need around 50 60 gallons total including the chiller requirements 4 35 gallon reservoir Click Here to Purchase a Reservoir or see example Amazon com Contact Hubbell Heaters Call 800 647 3165 Or 203 378 2659 WATER HEATER MANIFOLD The TACO Inline Recirculating Pump is part of the heater manifold that is supplied by TruSteel It is highly suggested to connect the power of the...

Page 15: ...AV30 PRE INSTALLATION REQUIREMENTS AV30 Pre Installation Requirements v 3 0 15 37 CHILLER INSTALLATION ...

Page 16: ...crete slab If placed inside proper HVAC ventilation is required The chiller CANNOT operate in a closed space the unit dissipates a lot of heat Please contact MTA Manufacturer if you have any doubt of chiller placement 2 The bypass manifold provided by TruSteel should be properly installed by a plumber Use plumbers dope AND plumbers tape 3 The copper plumbing Crimped or Push Connect NO FLUX will be...

Page 17: ... cfm Full Chemical Resistant 4 Head Diaphragm Pump The original Welch 2052 is a full chemical resistant not like its cheaper version 4 head oil free dry diaphragm vacuum pump with all PTFE contact surfaces and deep vacuum capability Oil Free portable full chemical resistant means less maintenance and no more frequent and costly oil change or cross contamination MODEL ELECTRICAL RE QUIREMENTS PUMPI...

Page 18: ...N BEFORE CHECKING VOLTAGE AND MEASURING TERMINAL RESISTANCE Tools Needed Volt Ohm multimeter Small terminal block screwdriver Standard flat head screwdriver wrench wrench and or ratchet and socket wrench 13 16 wrench Wire strippers Crescent wrench Check for loose connections Start by checking the wire connections made inside the Operator Panel HMI and in the PLC cabinet Pull softly but firmly on e...

Page 19: ...DO NOT POWER ON THE MAIN BREAKER UNTIL YOU VERIFY THE CORRECT VOLTAGE 208 240V Measure A phase B phase leg to leg by testing the two wires landed in the top side of Main Breaker CB1 with your multimeter Make sure you have 208 230v If you don t have the proper voltage first make sure the breaker or disconnect for PLC is powered ON If you still don t have the correct voltage 208 230V STOP and get an...

Page 20: ...h end if necessary Contact Aqua Sierra For questions concerns troubleshooting the PLC or HMI please call Aqua Sierra located in Pacific Standard Time Call 530 823 3241 STAGE 5 ASSEMBLE AV30 Link to Video Online STAGE 6 PRIME WATER HEATER CHILLER Before proceeding to fill the water heater and chiller you must have the RED and BLUE hoses connected to the AV30 In the image of the AV30 locate the Cold...

Page 21: ...es are open before filling 3 Power on the sump pump and fill through the top of the expansion tank on the backside of the chiller unit 4 Keep topping off the expansion tank and allow it to drain down three quarters of the tank before refilling DO NOT allow the tank to drain completely and allow air into the system 5 Once the system has roughly 50 gallons press the SNOWFLAKE button on the digital c...

Page 22: ...DF 5 MB Alarms display and reset To open the functions menu proceed as follows MENU Open the functions menu by pressing the MENU button With the up or down buttons select the alarm function Press SET If no alarms are present pressing the SET button is not enabled The lower display shows the label with the alarm code the upper display if the alarm is resettable shows the label rSt or NO if the alar...

Page 23: ...inimum ambient air temperature if the chiller is to be installed outdoors Adjust the glycol percentage for the lowest of these temperatures with at a 10F safety factor below the freeze alarm set point For example to operate at 25F coolant outlet temperature indoors set the freeze alarm set point at 15F and adjust the glycol percentage to a minimum of 30 by volume to provide freeze protection to 5F...

Page 24: ...se monitor trips ALc1 check the correct phase sequence on the LINE IN to the disconnect Change only the incoming power The ALc1 alarm may be generated tripping of the protection UP LINE from the chiller check the main fuses Contact MTA Chiller Customer Service MTA USA West Coast USA Joel Gordon p 206 851 8456 e jgordon mta usa com East Coast USA Jim Kirchoff p 248 880 4025 e jkirchoff mta usa com ...

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Page 26: ... near the heating system Also get another small container used to help bleed air water from the system 3 Fill the large barrel with 10 12 gallons of distilled water 4 Get a 1 2 hp sump pump attach a garden hose to it and place it in the barrel Prepare To Fill PreHeater Use Port 1 Prepare To Fill PreHeater Use Port 1 1 Find the heater manifold and look for the 2 fill ports hose bibs 2 Connect the h...

Page 27: ... Make sure to keep the barrel full of enough water at all times as to not push air back into the system 9 The person at the AutoVap will be releasing air and then catching the excess water that comes out of the preheater Once you start to see a steady flow of water coming out of the preheater close the ball valve and the person at the heater manifold can close the hose bib fill port and unplug the...

Page 28: ...ystem and once you have a steady flow of water coming out close the blue ball valve 6 Now the person back at the heater manifold will open FILL PORT 1 and collect the water into the same barrel bucket used to fill the system This creates a loop through the entire heating system forcing water in one side of the system and out the other end 7 Let this circulate for 2 3 minutes ensuring all the air i...

Page 29: ... the system Allow Pressure To Rise In System 1 Look at the pressure gauge on the heater manifold and start to close the hose bib on the left 2 Once the pressure reaches above 15 20 PSI make sure both hose bibs fill ports are closed The system is now filled primed 3 Turn off the sump pump Power On Heater and Recirculating Pump and check system for leaks 1 If you haven t already power on the circula...

Page 30: ... points Look for the flow rate set point 5 The flow rate should be between 10 15 gallons per minute 6 Set the heater temperature to a safe temperature around 95F while we check for leaks 7 Check all your plumbing and the AutoVap system for leaks Check the red hose ports on the AutoVap and anywhere the hot water flows ...

Page 31: ...tween 15 20 Gas heater set the pressure to 45 55 PSI 4 The heating system is now filled primed and ready to operate Contact Hubbell Support For questions concerns troubleshooting regarding your water heater please contact Hubbell Keep in mind that they are located in Eastern Standard Time Call 800 647 3165 Or 203 378 2659 info hubbellheaters com STAGE 7 VACUUM TEST AV30 This step will ensure the A...

Page 32: ...ou or someone capable of swapping wires on the PLC We may have to change the phasing on the pump motors and the recycle valve Familiarize yourself with certain parts of the AV30 Recycle Valve Feed Valve Pre Heater Sightglass Feed Pump Residue Pump Solvent Pump On PLC Hand Mode Auto Mode Have tools ready to swap wires in the PLC Small terminal block screwdriver Have at least 15 gallons of clean sol...

Page 33: ...ve at least 5 gallons of distilled water and 5 10 gallons of clean solvent available to run a cleaning cycle TruSteel Project Management will coordinate with you the date of the on site training and IQ OQ Note that we require all stages throughout this installation manual to be complete before arriving to your facility We also require at least a 2 week advance to arrange travel APPENDIX REQUIRED C...

Page 34: ...lation location needs to be ready All the items on this list are required to be completed BEFORE the arrival of TRUSTEEL installation technicians Chiller Installation Requirements The chiller has power and is wired correctly Note you can turn the power on and see STANDBYdisplayed The chiller has sufficient airflow as per the manufacturerʼs suggestion The remote control is wired up and in a mounted...

Page 35: ...s Proper supply of gas to water heater Flow Meter Switch is installed Aquastat is properly installed on water line Altitude was taken into account when calabrating over 2000 ft needs calibration Vacuum Pump Installation Requirements There is a 110V outlet or switch located where the Welch 2052 Vacuum Pump will be The vacuum pump hosing is able to go through your wall from the AutoVap to the Vacuum...

Page 36: ... standard hose fittings on both ends Distilled Water At least 50 Gallons of DISTILLED WATER NOT TAP WATER on site Propylene Glycol See Chiller Manual to determine how many gallons you require Minimum 20 gallons Clean Solvent At least 20 gallons of clean solvent To run cleaning cycle Tincture At least 60 gallons of tincture To run for training and performance testing Required personnel on site duri...

Page 37: ...ay 8 30am 5pm PST MTA USA Chiller West Coast Customer Service Joel Gordon 206 851 8456 jgordon mta usa com Monday Friday 8am 5pm PST East Coast Customer Service Jim Kirchoff 248 880 4025 jkirchoff mta usa com Monday Friday 8am 5pm EST Hubbell Heaters Water Heater Tech Support 203 378 2659 Doug ext 103 tech hubbellheaters com Monday Friday 8am 5pm EST Aqua Sierra AV30 Control Panel HMI Call 530 823...