CT SEPARATOR SYSTEM OPERATION & MAINTENANCE MANUAL PLEASE RECORD THE FOLLOWING DATA (Information is located on the product label or packing slip) Model Number: Date Code: Installation Date: Installation Location / Application: The above information will help when ordering replacement parts for your Wingert Purge System. J.L. WINGERT MANUFACTURED PRODUCTS Mixers, Bypass Feeders, Filter Feeders, Bromine Feeders, Sample Coolers, Sludge Traps, Separators, Clean Tower Separator Systems, Tank Stands, Tank Package Systems, Glycol Feed Systems, Coupon Racks, Control Stations, NEMA Enclosures, Custom Packaged Systems and Specialty Welding P.O. Box 6207 Garden Grove, CA 92846-6207 / 800 Monarch St. Garden Grove, CA 9284-23 Phone (74) 379-559 Fax (74) 379-5549 Northern California Region (50) 487-530 Southwest Region (602) 470-05 Email: customerservice@jlwingert.com www.jlwingert.com O&M Manual INT0522.D /08
CONTENTS: PAGE.0 INTRODUCTION 2.0 WARRANTY 3.0 UNPACKING 4.0 MODEL NUMBER VERIFICATION 2 5.0 LOCATION AND ENVIRONMENT 2 6.0 INSTALLATION 3 6. BASIN CLEANSING 3 6.2 SIDE STREAM CLEANSING 4 7.0 ELECTRICAL 5 8.0 START-UP AND OPERATION 5 9.0 MAINTENANCE & SERVICING 5 9. CHECKING FOR LEAKS AND WEAR 6 9.2 SERVICING THE RECOVERY TANK 6 9.3 SERVICING THE MOTORIZED PURGE KIT 6 0.0 PARTS LISTING 7.0 INTRODUCTION Wingert CT Series Separator System are self contained and designed to remove solids from sump basins or closed loop systems. The system includes a pump, pump strainer, separator, recovery tank, control panel and all necessary interconnecting plumbing. Standard flow rates from 38 to 200 GPM at 90 TDH allow for use in basins small and large. When coupled with the tower basin eductors, this systems is ready to clean even the toughest of applications. 2.0 WARRANTY Wingert CT Systems are warranted against manufacturing defects in material and workmanship for one year from the date of shipment. Applications outside the service for which the product is designed will automatically void any warranty. J.L. Wingert Co. will repair or replace a defective unit when returned to the factory with transportation prepaid. Final determination will be made upon inspection at receipt. J.L. Wingert Co. assumes no liability for labor and/or other expenses in making repairs or adjustments. All replacements will be F.O.B. factory. There are no other implied or expressed warranties. Motors and gear reducers are not manufactured by J.L. Wingert Co. and thus are warranted by the original manufacturer. Repair or replacement is contingent upon inspection and determination by the original manufacturer. Their findings are final and beyond our control. 3.0 UNPACKING Wingert CT Systems are assembled and ready for installation. Systems are shipped from the factory bolted to a shipping pallet. Inspect shipment upon receipt for any physical damage. The factory must be notified within 3 days after receipt of any discrepancies. If any product is damaged due to freight handling, contact the freight carrier to register a claim and contact the factory immediately for further assistance. NOTE: Most freight carriers only allow 3-5 days after receipt of goods to file a freight claim. Page
4.0 MODEL NUMBER VERIFICATION CT -0038 / (460) OPTIONS (460) MPK 460V, 3 phase, 60 hertz main power supply - in place of standard 230, 3 phase, 60 hertz Motorized purge kit in place of standard recovery tank FLOW RATE & SIZE 0038 38 GPM @ 90 TDH, " separator, 2HP pump 0065 65 GPM @ 90 TDH, /4" separator, 3HP pump 000 00 GPM @ 90 TDH, /2" separator, 5HP pump 060 60 GPM @ 90 TDH, 2 /2" separator, 7.5HP pump 0200 200 GPM @ 90 TDH, 3" separator, 7.5HP pump 0280 280 GPM @ 90 TDH, 3" separator, 0HP pump 0400 400 GPM @ 90 TDH, 4" separator, 5HP pump 0550 550 GPM @ 90 TDH, 4" separator, 20HP pump 0850 850 GPM @ 90 TDH, 5" separator, 30HP pump 200 200 GPM @ 90 TDH, 6" separator, 40HP pump MODEL CT Clean Tower Separator, Pump and Recovery Tank System 5.0 LOCATION AND ENVIRONMENT Wingert Clean Tower Systems are designed to be placed outdoors, but consideration should be taken for any adverse conditions. When these conditions arise, the separator package should be placed under an awning or covered with a shed. Page 2
6.0 INSTALLATION Wingert Clean Tower Systems come pre-plumbed with the inlet and outlet isolation valves. Locate the system near the basin or line to be cleaned. Suction and discharge piping should be kept as short as possible. The CT system should be placed on a firm, level surface that will not degrade or collapse over time. There are three main types of installations that can be done. Follow the diagrams to install the plumbing in an orderly fashion, avoiding high and low piping configurations, long runs and multiple bends or elbows. 6. BASIN CLEANING When cleaning the basin, the pump suction and discharge are very critical. Because the suction can very rarely be flooded, a small high point should be plumbed preceding the pump suction. This is done to ensure that the pump will prime when started. Then the discharge should be plumbed to an appropriate opposing side to aid in sweeping the settled debris to the suction plumbing. This installation can be completed by using Wingert Tower Basin Eductors. Page 3
6.2 SIDE STREAM CLEANSING INSTALLATION # The preferred method for side stream cleaning is acheived by installing the separator system across the recirculation pump. This type of installation allows for maximum pressure drop through the separator. The diagram to the right depicts this type of installation. INSTALLATION #2 Another acceptable installation is the return to the system flow line. This type of installation only allows for the pressure drop that the separator system pump can provide. Although this is sufficient for separation, the greater the pressure drop - the better the separation. The diagram to the left depicts this type of installation. Page 4
7.0 ELECTRICAL BE SURE THAT POWER IS DISCONNECTED BEFORE SERVICING Once you are sure that the control power has been disconnected, open the control panel, and located behind the front door in RED letters is the main power supply. Consult factory if this is not the desired or available voltage. Have qualified personnel or an electrician place the power supply to the first three terminals (follow diagram located in control panel). Optionally the CT system can be wired to initiate with a remote or automatic signal. This signal is a switch closure of 0V, phase, 60 hertz and less than 5 amps. This can be done by placing a hot wire to terminal strip #2 pole #3 and the control wire to terminal strip #2 pole #4. Once the circuit is closed and maintained, the system will operate in an automatic fashion. Additionally, a service indicator remote signal or motorized purge signal can be wired to a control booth such that maintenance personnel can be alerted when service is needed or when the package is doing a blow down. This signal is also 5V, phase, 60 hertz and less than 5 amps. To get this signal to the control booth or external alarm, place a wire for neutral to terminal strip #2 pole # and a hot lead to terminal strip #2 pole #2. This connection needs to ground to the box or to the control booth panels. When finished with wiring, close and secure the control panel. Make sure all electrical connections are in compliance with local codes and that outdoor installations have no open exposures. 8.0 START-UP AND OPERATION Before starting the system up, check that all valves are open, all latches on the recovery tank and the pump strainer are secure. When ready, turn the main power switch to ON and the green indicator light will then come on. To prime the system and remove the air, turn the system switch to H or hand. The pump will energize and the system will begin to flow. Visually check all components for leaks that may have developed in shipment. Once flow has been establish for a few minutes and there is no sign of leaks, begin to remove the air from the system via the air release valves on the pump strainer and recovery tank. 9.0 MAINTENANCE & SERVICING Once in operation, the only maintenance that is needed for the Clean Tower Systems that have the standard recovery tank is a periodic check for leaks, wear, and a cleaning of the recovery tank and pump inlet strainer. When you service the recovery tank, it is always best to clean the pump pre-strainer although this is not a requirement. Page 5
9. CHECKING FOR LEAKS AND WEAR Checking the system at the threaded and flanged fittings for leaks is essential to the performance of any piping system. Leaks can cause external corrosion when the system is not in use and allow air pockets to develop. When the system has been installed and is running, it will develop a pressure drop. A pressure drop is the systems way of settling the solids through the separation chamber. Typically the first item to show wear will be the pump impeller. Once the pump impeller starts to wear, the pressure drop will start to recede. To monitor this, mark the pressure gauges where the pressure drop has been established in the system. After doing this, any deviations noted from these markings either means that the impeller is wearing, that the recovery tank needs servicing or that the separator has become clogged. 9.2 SERVICING THE RECOVERY TANK The required servicing is indicated on the control panel by the service light. This means that the recovery tank has become full and needs to be cleaned out. Once this light has come on there are two types of servicing. ) The recovery tank can be serviced, while in operation, by closing the isolation valves, opening the drain valve and the air release valve. Once the recovery tank is empty, the four (4) securing clamps can be opened and the lid removed. Remove the basket and filter by the basket handles. Discard and rinse out solids collected. Replace and return the recovery basket and filter. Secure the four hook latches and close the drain valve. Open the isolation valves and close the air release valve after purging the air from the recovery tank. At this point the service light should go off. 2) (RECOMMENDED) Once the recovery tank has become full, it is assumed that the pump strainer should have caught some, if not a lot, of large debris. To service the recovery tank and pump strainer, the systems power needs to be turned off and the system isolation valves need to be closed. The system can then be drained by opening the strainer drain valve and the recovery tank drain valve. Opening both of the air release valves aids in this process. Once the system has been drained, open the strainer and recovery tank latches and clean the strainer. Once cleaned, replace the strainer and filter, secure the latches and close the drain valves. Open the isolation valves and turn the system power on. Once flow has been established, close the air release valves after the air has been purged from the system. 9.3 SERVICING THE MOTORIZED PURGE KIT The required servicing for the motorized purge kit will have to be on a maintenance schedule. The amount of dirt in the environment dictates how often the valve will need to checked for wear and how it is sealing. Because the dirt and system water is being discarded, the trap or waste filter will have to be checked or installed so that the plumbing does not clog. Page 6
0.0 SYSTEM PARTS MODEL 2 3 4 5 6 CT-0038 0520-500 0520-520 0520-540 RT-2 0520-550 XTI-000 6 CT-0065 0520-50 0520-52 0520-540 RT-2 0520-55 XTI-025 CT-000 0520-502 0520-522 0520-540 RT-2 0520-55 XTI-050 4 CT-060 0520-503 0520-523 0520-54 RT-5 0520-552 XTI-0250 CT-0200 0520-504 0520-525 0520-542 RT-5 0520-552 XTI-0300 CT-0280 0520-505 0520-526 0520-543 RT-5 0520-552 XTI-0300 CT-0450 0520-506 0520-527 0520-544 RT-0 0520-553 XFD-0400 CT-0550 0520-507 0520-528 0520-545 RT-0 0520-554 XFD-0400 CT-0850 0520-508 0520-529 0520-546 RT-0 0520-555 XFD-0500/6 CT-200 0520-509 0520-530 0520-547 RT-0 0520-555 XFD-0600 0520-500 through 0520-506 comes wired for 230/3/60. Add "-460" for wiring on 460/3/60 2 Add "-MPK" to the end of the control panel part number for motorized purge kit controls. 3 Consult factory for replacement parts on motorized purge kits. 0. RECOVERY TANK PARTS 2 5 3 MODEL 2 3 4* RT-2 0520-600 PE2-25 0520-620 0520-625 RT-5 0520-60 PE5-25 0520-62 0520-625 RT-0 0520-602 PE0-25 0520-622 0520-625 * Sold individually 0.2 PUMP STRAINER PARTS MODEL 2 3* 0520-550 0520-630 0520-640 0520-625 2 3 0520-55 0520-63 0520-64 0520-625 0520-552 0520-632 0520-642 0520-625 0520-553 0520-633 0520-643 0520-625 0520-554 0520-634 0520-644 0520-625 0520-555 0520-635 0520-645 0520-625 * Sold individually 4 2 3 Page 7