SEPARATOR PURGE KIT OPERATION & MAINTENANCE MANUAL PLEASE RECORD THE FOLLOWING DATA (Information is located on the product label or packing slip) Model Number: Service: Code: Installation Date: Installation Location / Application: The above information will help when ordering replacement parts and accessories for your Wingert Separator Purge Kit. J.L. WINGERT CO. MANUFACTURED PRODUCTS Mixers, Bypass Feeders, Filter Feeders, Bromine Feeders, Sample Coolers, Sludge Traps, Separators, 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 / 11800 Monarch St. Garden Grove, CA 92841-2113 Phone (714) 379-5519 Fax (714) 379-5549 Northern California Region Phone (510) 487-5310 Southwest Region Phone (602) 470-1015 Email: customerservice@jlwingert.com www.jlwingert.com OM0520.A 09/12
CONTENTS: PAGE 1.0 INTRODUCTION 2 2.0 WARRANTY 2 3.0 UNPACKING 2 4.0 SAFETY 3 4.1 SAFETY HIGHLIGHTS 3 4.1 SAFETY HIGHLIGHTS CONTINUED 4 5.0 LOCATION AND ENVIRONMENT 4 6.0 DETERMINE PURGE CYCLES 5 7.0 INSTALLATION / OPERATION 5 7.1 MANUAL PURGE KIT 5 7.2 MOTORIZED PURGE KIT 6 7.3 CONTINUOUS PURGE KIT 7 8.0 ECONOMY TIMERS WIRING DIAGRAMS / TIMER SETTING INSTRUCTIONS 8 8.1 WIRING DIAGRAMS 8 8.2 SETTING THE MPK-E-XXXX TIMER 9 9.0 DELUXE TIMERS WIRING DIAGRAMS / TIMER SETTING INSTRUCTIONS 9 9.1 WIRING DIAGRAMS 10 9.2 SETTING THE MPK-D-XXXX TIMER 11 10.0 NOTES 12 1.0 INTRODUCTION Thank you for your purchase of a J.L. Wingert Separator Purge Kit. This kit is designed to complete any separator installation. 2.0 WARRANTY Wingert Separator Purge Kits 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, including any non-factory modifications, will automatically void any warranty. Items returned to J.L. Wingert Co. for warranty consideration must be transported via prepaid freight. Final warranty determination will be made upon inspection. J.L. Wingert Co. will, at their discretion, repair or replace any defective item. Any repair or replacement outside warranted limitations will be considered a repair order and quoted accordingly. All replacements will be F.O.B. factory. There are no other implied or expressed warranties. 3.0 UNPACKING Wingert Separator Purge Kits are assembled and ready for installation. Inspect packaging upon receipt for any damage. Unpack and inspect the product for damage and verify that goods received correlate with the packing list. Notify the factory of any discrepancies immediately upon receipt. If any product is damaged due to freight handling, contact the factory immediately for further assistance. It is recommended that photo documentation of any damage or discrepancy be supplied to support any claims. NOTE: Most freight carriers allow only a limited time after receipt of goods to file a freight claim. Page 2
4.0 SAFETY J.L. Wingert Co s equipment is designed and built with safety in mind. However, proper installation and operation can increase your overall safety. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS. 4.1 SAFETY HIGHLIGHTS Read and understand the following safety highlights. ELECTRICAL SHOCK CAN KILL Do not perform any services without first disconnecting electrical service to all equipment. High voltage electrical power is present inside the electrical enclosure. ELECTRICAL SERVICE CONNECTION Install and ground equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer s recommendations. Electrical installation and repair should be performed by a qualified individual. WATER PRESSURE INSIDE THE UNIT See design specification for maximum operating pressure. Do not perform maintenance or repair without first releasing the water pressure and draining the fluid from the unit. Page 3
4.1 SAFETY HIGHLIGHTS CONTINUED EQUIPMENT IDENTIFICATION LABEL Identification label provides equipment information. Be sure the voltage, phase and frequency of the input power are as specified on the Equipment Identification Label and conform with your requirements. GROUND CONNECTION Input power and ground system for safe operation of the equipment. See your local and National Electrical Codes for proper grounding methods. 5.0 LOCATION AND ENVIRONMENT Every installation is different. The separator and purge kit may be located indoors or outdoors. If outdoors, it is suggested that components be shielded from harsh weather conditions. All electrical connections should be completed by a qualified electrician to meet local building codes. DO NOT ATTEMPT ELECTRICAL INSTALLATION OR SERVICE WORK UNTIL MAIN POWER SUPPLY IS DISCONNECTED. Page 4
6.0 DETERMINE PURGE CYCLES For best results when using a pre-selected purge kit (manual, motorized or continuous), purge while the system is in full operation. To determine the necessary frequency, purge often at first; then calculate the rate with regard to the actual volume of separated solids. Accumulated solids could overfill the collection chamber and adversely affect the separator performance if not purged regularly. 7.0 INSTALLATION / OPERATION There are three standard purging options available. 7.1 MANUAL PURGE KIT (PK) A manual purge kit (Fig. 1) is the most economical method to purge your separator. This purge kit is preassembled and ready to install. Simply thread the male end of the elbow into the drain port of the separator and tighten all components to ensure a leak tight installation. PTFE pipe tape is pre-applied on all threads. Replace any tape that may have been damaged in transit. Take caution against over tightening threaded fittings. FLOW OUTLET INLET FLOW MANUAL PURGE KIT KIT TO DRAIN MANUAL MANUAL PURGE PURGE SYSTEMKIT Figure 1 Page 5
7.2 MOTORIZED PURGE KIT (MPK) Motorized purge kits (Fig. 2) are convenient for remote locations or where frequent purging is required. This system is controlled via a timing device with programmable options for both frequency and duration of purging of an electronically actuated motorized ball valve. Motorized purge kits are available in either economy and deluxe models. Wiring and timer setting instructions are in sections 7.0 and 8.0. These purge kits are preassembled and ready to install. Simply thread the male end of the elbow into the drain port of the separator and tighten all components to ensure a leak tight installation. PTFE pipe tape is pre-applied on all threads. Replace any tape that may have been damaged in transit. Take caution against over tightening threaded fittings. Motorized Purge Kit includes Manual Purge Kit, Motorized Ball Valve and a Timer. FLOW OUTLET FLOW INLET TIMING DEVICE POWER SUPPLY TO DRAIN MOTORIZED PURGE VALVES MOTORIZED PURGE KIT Figure 2 Page 6
7.3 CONTINUOUS PURGE KIT (RT) Unlike the other Wingert purge kits, the continuous purge system (Fig. 3) is always at work. This system removes solids as they collect in the solids collection chamber by bleeding a small amount of water into a recovery tank where the solids are stored. The bleed water is then returned to the system thus providing the least amount of wasted water. This type of purge system is required where there is a high solid count, where solids cannot be flushed into a drain or where water conservation is a paramount issue. This purge kit is supplied with manual purge kit components and a recovery tank and is ready to install. Simply thread the male end of the elbow into the drain port of the separator and tighten all components to ensure a leak tight installation. PTFE pipe tape is pre-applied on all threads. Replace any tape that may have been damaged in transit. Take caution against over tightening threaded fittings. An optional feature for this system is a Recovery Tank Service Indicator Package (Part# IP) which includes a flow controller, switch and isolation valves. This package can be connected to an alarm to indicate that the recovery tank filter bag needs servicing. To service the recovery tank, close the isolation valves. Carefully open the air release valve on the lid to relieve any internal pressure. Only when the tank pressure is neutrallized should the recovery tank lid be removed and the internal filter bag and strainer be cleaned or replaced. OUTLET FLOW FLOW INLET RETURN RECOVERY TANK CONTINUAL PURGE SYSTEM CONTINUOUS PURGE KIT Figure 3 Page 7
8.0 ECONOMY TIMERS WIRING DIAGRAMS / TIMER SETTING INSTRUCTIONS Note: There are separate wiring instructions for small (3/4 and 1 1/2 ) and large (2 ) valves. All electrical connections should be completed by a qualified electrician to meet local building codes. DO NOT ATTEMPT ELECTRICAL INSTALLATION OR SERVICE WORK UNTIL MAIN POWER SUPPLY IS DISCONNECTED. 8.1 WIRING DIAGRAM ECONOMY MODELS (Fig 4) for 3/4 and 1-1/2 valves (MPK-E-0075 and MPK-E-0150) and (Fig. 5) 2 valve (MPK-E-0200). Figure 4 Figure 5 Page 8
8.2 SETTING THE MPK-E-XXXX TIMER All three MPK-E s use the same timer. The Factory Settings are On Time (time valve is open): 30 seconds, and Off Time (time valve is closed): 1 hour. Refer to Figure 6. for explanation of what the Timer Knobs are. To change the On Time, select the desired time range, then adjust the On Time, Time Value Selector. To adjust the Off Time, select the desired time range, then adjust the Off Time, Time Value Selector. Note that the Time Value Selectors are scaled 1-10, so if 30 seconds is desired, set the Range Selector to 6-60s, then set the Time Value Selector to 5. Figure 6 9.0 DELUXE TIMERS WIRING DIAGRAMS / TIMER SETTING INSTRUCTIONS Note: There are separate wiring instructions for small (3/4 and 1 1/2 ) and large (2 ) valves. All electrical connections should be completed by a qualified electrician to meet local building codes. DO NOT ATTEMPT ELECTRICAL INSTALLATION OR SERVICE WORK UNTIL MAIN POWER SUPPLY IS DISCONNECTED. Page 9
9.1 WIRING DIAGRAM DELUXE MODELS (Fig 7) for 3/4 and 1 1/2 valves (MPK-D-0075 and MPK-D-0150) and (Fig. 8) 2 valve (MPK-D-0200). Figure 7 Figure 8 Page 10
9.2 SETTING THE MPK-D-XXXX TIMER 1. Key Protection Indicator 2. Control Output Indicator 3. Reset Indicator 4. Present Value 5. Time Unit Indicators 6. Set Value Display 7. Set Value 1, 2 Indicator 8. Mode Key 9. Reset Key 10. Up Keys 1-4 11. Down Keys 1-4 12. Key Protect Switch 13. DIP Switches Factory Default Settings: Dip Switch 1: ON Dip Switch 2: ON Dip Switch 3: OFF Dip Switch 4: ON OFF Time: 60 minutes ON Time: 30 seconds OFF Time range 0:01min to 99.59min On Time Range 1 sec to 9999 sec Change Timer Settings: Turn power to the MPK-D-XXXX off. Open the control panel and locate the Key Protect Switch (#12) and turn OFF. Turn power ON and Press Mode (#8) until 1 is displayed (#7). Press #10 or #11 to adjust the ON Time until the desired time is reached. Press Mode (#8) until 2 is displayed (#7). Press #10 or #11 to adjust the OFF Time until the desired time is reached. Turn #12 to ON to enable the Key Protection, and close the control panel. If the ON or OFF time range is not the desired range, you will need to change the range. To change the range settings turn OFF the unit and open the control panel. Turn the Key Protect Switch (#12) OFF and adjust the DIP Switches (#13) based on the following chart to achieve desired time range. Turn power ON and Press Mode (#8) until 1 is displayed (#7). Press #10 or #11 to adjust the ON Time until the desired time is reached. Press Mode (#8) until 2 is displayed (#7). Press #10 or #11 to adjust the OFF Time until the desired time is reached. Turn #12 to ON to enable the Key Protection and close the control panel. Pin 2 Pin 3 OFF Time Range Pin 4 Pin 5 ON Time Range OFF OFF 0.01 s to 99.99 s OFF OFF 0.01 s to 99.99 s ON OFF 0.1s to 999.9 s ON OFF 0.1s to 999.9 s OFF ON 1 s to 9999 s OFF ON 1 s to 9999 s ON ON 0 min 01s to 99 min 59s ON ON 0 min 01s to 99 min 59s Page 11
10.0 NOTES Page 12