ECO-TRAP 110 AND 160 WASTE SOLIDS REMOVAL SYSTEM

Transcription

1 AQUATIC ECO-SYSTEMS ECO-TRAP 110 AND 160 WASTE SOLIDS REMOVAL SYSTEM INSTALLATION GUIDE IMPORTANT SAFETY INSTRUCTIONS READ AND FOLLOW ALL INSTRUCTIONS SAVE THESE INSTRUCTIONS

2 i CUSTOMER SERVICE / TECHNICAL SUPPORT If you have questions about ordering Pentair Aquatic Eco-Systems replacement parts and products, please use the following contact information: Customer Service Monday to Thursday: 8 AM to 7 PM EST Friday: 8 AM to 5 PM EST US Phone: (877) Fax: (407) International Phone: (407) Fax: (407) Web site Visit TABLE OF CONTENTS Figure Reference... Overview... System Components Installation... Installing Particle Trap Base in the Center of a Circular Tank Floor Adhesive and Sealant Application Installing Particle Trap Plate and Insert Main Drain and Solid Drain Assembly (Under Tank) For the Solids Drain Assembly, Follow These Steps Sludge Collector and Bracket Assembly Bracket Bolt Installation Sealant Application Valve Assembly... Piping System... ii P/N Rev. A 10/22/14 ECO-TRAP 110 and 160 Waste Solids Removal System Installation Guide

3 ii FIGURE REFERENCE Figure 1: Overview of System with Callouts...1 Figure 2: Sludge Collector System Outside Tank...1 Figure 3: Model of Center of Tank...2 Figure 4: Rendering of Particle Trap in Tank Floor...2 Figure 5: Maximum Inset of Particle Trap Base into Tank Floor...3 Figure 6: Dimensions of ECO-Trap Figure 7: Dimensions of ECO-Trap Figure 8: Completed Installation...4 Figure 9: Assembled Particle Trap Insert, Plate & Base...5 Figure 10: Components of Particle Trap...5 Figure 11: Particle Trap Base Sitting in Tank...5 Figure 12: Particle Trap Base Fully Seated in Tank...6 Figure 13: Trap Plate Removed...6 Figure 14: Installed Trap Plate and Insert...6 Figure 15: Main Drain Assembly...7 Figure 16: Solids Drain Assembly...7 Figure 17: Particle Trap Base with Metric Adapter...8 Figure 18: C-Channel Attached to I-Beam Bracket...10 Figure 19: Attach I-Beam...10 Figure 20: Level I-Beam...10 Figure 21: Line up I-Beam Bracket with Pre-Drilled Holes...11 Figure 22: Sludge Collector Support and C-Channel...11 Figure 23: Sludge Collector Held in Place by Strap...12 Figure 24: Bending Aluminum Strap Around Collector...12 Figure 25: Attaching Strap to U-Channel...13 Figure 26: Opposite Side Attachment...13 Figure 27: Attach Sludge Collector System to C-Channel...14 Figure 28: Adjust Height...14 Figure 29: Application of Polyurethane-Based Sealant...14 Figure 30: Adjustment of Discharge Outlet...14 Figure 31: Applying PTFE Tape to the Sludge Collector...15 Figure 32: Screwing on the Drain Valve...15 Figure 33: Attaching Nipple to the Valve...15 Figure 34: Conduit Pipe from the Main Drain and Vinyl Reinforced Tubing from the Solids Drain...16 Figure 35: Attach Clear Reinforced Vinyl Tubing to the Sludge Collector Inlet with Stainless Steel Hose Clamp..16 ECO-TRAP 110 and 160 Waste Solids Removal System Installation Guide

4 1 OVERVIEW System Components FIGURE 1: OVERVIEW OF SYSTEM WITH CALLOUTS FIGURE 2: SLUDGE COLLECTOR SYSTEM OUTSIDE TANK

5 2 INSTALLATION Figure 3 and Figure 4 illustrate the Eco-Trap 110 and 160 Waste Solids Removal System drain installed in the center floor of the tank. Installing Particle Trap Base in the Center of a Circular Tank Floor FIGURE 3: MODEL OF CENTER OF TANK FIGURE 4: RENDERING OF PARTICLE TRAP IN TANK FLOOR

6 3 Figures 5, 6 and 7 show the dimensions along with the tolerances of the Particle Trap Base and Particle Trap Plate installed in a tank. FIGURE 5: MAXIMUM INSET OF PARTICLE TRAP BASE INTO TANK FLOOR It is recommended to install the drain flush in the bottom of the tank. The particle trap base may be a maximum of 1/8 below the plane of the tank bottom, but should not protrude. If the particle trap base is protruding from the bottom of the tank solids may become trapped in the system. FIGURE 6: DIMENSIONS OF ECO-TRAP 160

7 4 FIGURE 7: DIMENSIONS OF ECO-TRAP 110 Figure 8 is a cutaway view of the drain after correct installation into the bottom of the tank. FIGURE 8: COMPLETED INSTALLATION

8 5 Figure 9 Illustrates what the Particle Trap Insert, Plate & Base will look like before installation in the tank. The Particle Trap Plate can be removed from the Particle Trap Base by unscrewing the plate from the base (Note: For every full revolution the gap opens or closes 1/8. Figure 10 shows the individual components of the Particle Trap and how they are aligned in the system. FIGURE 9: ASSEMBLED PARTICLE TRAP INSERT, PLATE & BASE FIGURE 10: COMPONENTS OF PARTICLE TRAP Adhesive and Sealant Application The Particle Trap Base is installed using a marine-grade construction adhesive holding it in place, and then a marine-grade sealant is used to fully seat the system in place. Figure 11 shows the base sitting in the tank. On the next page, Figure 12 shows the base fully seated in the tank. FIGURE 11: PARTICLE TRAP BASE SITTING IN TANK

9 6 FIGURE 12: PARTICLE TRAP BASE FULLY SEATED IN TANK Installing Particle Trap Plate and Insert Figure 13 shows the Insert connected to the Trap Plate which is then threaded into the Trap Base once the Base is seated in the tank. Figure 14 shows the Insert, Trap Plate and Trap Base all installed in the bottom of the tank. FIGURE 13: TRAP PLATE REMOVED FIGURE 14: INSTALLED TRAP PLATE AND INSERT

10 7 Main Drain and Solid Drain Assembly (Under Tank) Vinyl Tubing Effluent Pipe FIGURE 15: MAIN DRAIN ASSEMBLY Use Schedule 80, or Schedule 40 fittings. The Eco Trap 110 Waste Removal System has a 4 SOC diameter drain, and the Eco Trap 160 has a 6 SOC diameter drain. FIGURE 16: SOLIDS DRAIN ASSEMBLY

11 For the Solids Drain Assembly, follow these steps: 1. For the Eco-Trap 110 Waste Solids Removal System, connect 1¼" vinyl reinforced clear tubing to the Sludge Collector inlet with a 1½ stainless steel hose clamp. Connect the other end of the tubing to the Solids Drain outlet with 1½ stainless steel hose clamp. For the ECO-Trap 160, use 1½" or 1¼ vinyl reinforced clear tubing from the valve of your choice, but you must use the appropriate barb adapter from the valve. The tubing must be long enough to reach the Sludge Collector located outside the tank with smooth curves and no kinks in the tubing. A small amount of PTFE-lubricant can be placed on the barb fitting to allow the fitting to be fully inserted into the tubing. NOTE: IT IS NOT RECOMMENDED THAT LUBRICANT BE USED TO CONNECT THE VINYL TUBING DIRECTLY TO THE SLUDGE COLLECTOR DUE TO THE POSSIBILITY OF IT SLIPPING OFF. THE INLET/OUTLET OF THE SLUDGE COLLECTOR ARE NOT BARBED FITTINGS. 2. For metric installations, the 4 or 6 Eco Trap metric adapter must be installed into the Particle Trap Base main drain (Figure 16) and then plumbed into the effluent pipe. 3. The Particle Trap will collect the waste solids and deposit them into the Sludge Collector by way of the 1½ conduit pipe. The effluent pipe will recycle the water back into the Sludge Collector to continue the filtration process. 8 FIGURE 17: PARTICLE TRAP BASE WITH METRIC ADAPTER

12 9 Sludge Collector & Bracket Assembly The Eco-Trap Waste Removal System Sludge Collector can be mounted on the tank, WLC, or a wall for the collection of waste solids. The mount has the ability to be adjusted vertically, allowing access to multiple different heights to maintain proper gravity flow. For the attachment of the sludge collector the following steps must be taken: 1. Attach the I-Beam Bracket to the tank with two nuts and bolts, and to the floor with two bolts. Be certain the bracket is level. See Figures Attach longer C-Channel to the I-Beam Bracket on the tank with four nuts and bolts (Figure 21). 3. Assemble Sludge Collector Support Bracket to the shorter C-Channel with two nuts and bolts (Figure 22). 4. Insert Sludge Collector into the hole of the Support Bracket with the large open end in the upright position. 5. The Sludge Collector is held in place within the Support Bracket and C-Channel by the use of an aluminum strap that is bent around the Sludge Collector (Figures 23-24) and bolted to the C-Channel (Figures 25-26). One of sides of the strap is assembled with the nut on the outside and the bolt on the inside due to the tension on the strap that is holding the Sludge Container in the proper upright position. 6. Attach assembled Sludge Collector with C-Channel to the longer C-Channel mounted vertically on the I-Beam bracket with the use of a Bracket Bolt (Figure 27). This bolt is used to position the C-Channel at the proper elevation in relation to the operating water level of the tank. The Eco Trap 110 must have the U-profile 1.57 below the water level in the tank; the Eco Trap 160 must have the U-profile 6.7 below the water level in the tank. Figure 28 shows how the Bracket Bolt is inserted to hold the sludge collector at the proper elevation for the system. 7. Using the polyurethane sealant provided in the package, apply a layer around the outer rim of the top of the sludge collector body (Figure 29). 8. Assemble the Sludge Collector collar when the desired direction of the discharge is determined. When this is determined, 100% of the polyurethane sealant should be applied. Additional sealant may be applied if the placement of the discharge hose outlet must be changed. Make sure the vinyl tubing is not kinked (Figure 30).

13 10 FIGURE 18: C-CHANNEL ATTACHED TO I-BEAM BRACKET FIGURE 19: ATTACH I-BEAM FIGURE 20: LEVEL I-BEAM

14 11 FIGURE 21: LINE UP I-BEAM BRACKET WITH PRE-DRILLED HOLES FIGURE 22: SLUDGE COLLECTOR SUPPORT AND C-CHANNEL

15 12 FIGURE 23: SLUDGE COLLECTOR HELD IN PLACE BY STRAP FIGURE 24: BENDING ALUMINUM STRAP AROUND COLLECTOR

16 13 FIGURE 25: ATTACHING STRAP TO U-CHANNEL FIGURE 26: OPPOSITE SIDE ATTACHMENT

17 14 Bracket Bolt FIGURE 27: ATTACH SLUDGE COLLECTOR SYSTEM TO C-CHANNEL FIGURE 28: ADJUST HEIGHT Sealant Application FIGURE 29: APPLICATION OF POLYURETHANE-BASED SEALANT FIGURE 30: ADJUSTMENT OF DISCHARGE OUTLET

18 15 VALVE ASSEMBLY The valve that is attached to the Sludge Collector (not included in the package) must be 1½ NPT thread for the Eco Trap 110 and 2 NPT thread for the Eco Trap 160. A 1½ nipple must be used to connect to the 1¼ reinforced clear vinyl tubing (Eco Trap 110) and 1½ reinforced clear vinyl tubing (Eco Trap 160) that will run to the drain. 1. Apply PTFE thread seal tape to the Sludge Collector outlet (Figure 31). 2. Screw on drain valve (Figure 32). 3. Apply PTFE tape to the nipple and attach the nipple to the drain valve (Figure 33). FIGURE 31: APPLYING PTFE TAPE TO THE SLUDGE COLLECTOR FIGURE 32: SCREWING ON THE DRAIN VALVE FIGURE 33: ATTACHING NIPPLE TO THE VALVE

19 16 PIPING OF THE SYSTEM The ECO-Trap Solids Waste Removal System filtration will be the wall of the containment and the Sludge Containment will be outside the containment. The Filtration will collect the sludge and will then deposit it into the Sludge containment by way of the Conduit pipe. The Effluent pipe will recycle the water back into the containment to continue the filtration process. The tubing that will be used is TVR Tubing, TVR125 (ECO110) and TVR150 (ECO160), the clamps that will be used should be all Stainless Steel hose clamps, SSE (1½ ) and SSD (1¾ ) FIGURE 34: CONDUIT PIPE FROM THE MAIN DRAIN AND VINYL REINFORCED TUBING FROM THE SOLIDS DRAIN FIGURE 35: ATTACH CLEAR REINFORCED VINYL TUBING TO THE SLUDGE COLLECTOR INLET WITH STAINLESS STEEL HOSE CLAMP

20 APOPKA BLVD., APOPKA, FL US (877) INT. (407) All Pentair trademarks and logos are owned by Pentair or one of its global affiliates. Pentair Aquatic Eco-Systems is a trademark and/or registered trademark of Pentair Aquatic Eco-Systems and/or its affiliated companies in the United States and/ or other countries. Unless expressly noted, names and brands of third parties that may be used in this document are not used to indicate an affiliation or endorsement between the owners of these names and brands and Pentair Aquatic Eco-Systems. Those names and brands may be the trademarks or registered trademarks of those third parties. Because we are continuously improving our products and services, Pentair reserves the right to change specifications without prior notice. Pentair is an equal opportunity employer Pentair Aquatic Eco-Systems, Inc. All rights reserved. This document is subject to change without notice. *930015* P/N Rev. A 10/22/15