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Newwave PUREWATER PW 100-M5 Series Technical Manual

5 micron series water recovery systems
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  • Page 5 Warning! Hazardous Voltage: Can Shock, Burn or Cause Death. Disconnect power at main panel before connecting electrical power supply to reclaim unit panel or working on electrical connections. Ground reclaim unit before connecting to the electrical power supply. Failure to ground reclaim unit can cause severe or fatal electrical shock hazard.

  • Page 6: Table Of Contents

    Table of Contents Reclaim Water Systems Reclaim General Description ...............5 PurWater Reclaim System Description ……………………………..…5-9 System Installation Frame ....................10 Reclaim Unit Piping …………………………………………………..10-14 Reclaim Tanks ……………………………………………….………..14-17 Electrical Safety ................18 Controls and Electrical Wiring …………………………………….…19-21 System Start-Up, Operation and Maintenance Electrical Component / Control Functions …………………………22-25 Start-Up ………………………………………………………………..26-29 Operation ………………………………………………………………30-34 Maintenance Schedule for Air Sparger Systems ………………….35-42...

  • Page 7: Reclaim Water Systems

    Reclaim Water Systems General Description: The use of reclaim water has become an important method for the car wash operator to reduce his / her operating expenses (water / sewer costs) and start-up costs (impact / connection fees). Many municipalities are requiring the use of reclaim water in car wash operations and operators are continually looking for ways to increase profits, so reclaim systems are becoming essential in the overall operation of the wash.
  • Page 8 PWFS (Flood) Series Systems: The PWFS (Flood) series systems consist of a cyclonic sand separator, pump / motor, controls, and an air sparger designed to treat 60 or 100 gpm of reclaim water. The sand separator will remove down to 70 micron solid particles and is adequate for use in Auto Dealer or Fleet / Flooder Arch Friction wash applications.
  • Page 9 Ozone The third method utilizes ozone to kill the bacteria (models ending in 5M12O or 5M24O). Ozone is a contact killing agent, similar to chlorine used in city water. Ozone (O ) is generated by concentrating the oxygen (O ) in ambient air and passing the concentrated oxygen through a high voltage electric current to produce ozone.
  • Page 10 Drawing #1G Drawing #2G...
  • Page 11 Pressure Pressure Solenoid Transmitter Gauge PurWater Reclaim Water System Valve By Customer To Car Biological (Enzyme) Design Wash City Water ByPass Solenoid Process & Instrumentation Diagram (P&ID) Valve (N.C.) Check Solenoid City Valve Valve Pressure Pressure Water (N.O.) Check Switch Gauge Overflow Valve...

  • Page 12: System Installation

    System Installation PurWater systems are designed for easy installation. However, if you should have any questions, please contact us at (916) 978-9990 or (800) 882-8854 in Sacramento, CA. Office hours are 7AM to 5 PM, Pacific Standard Time, Mon-Fri. PW 100/200/300-5M Series Reclaim Systems, including: a) Model PW100-5MAS (3HP, 30 GPM, Air Sparger) b) Model PW100-5MB (3HP, 30 GPM, Enzyme Feed System and Air Sparger)
  • Page 13 Ozone Generator Control Box Oxygen Concentrator Treated Water Line City Water Line Cyclones Recirculation Line Pump Suction Line Pump / Motor and Basket Strainer Underflow Line 1) Treated Water Line: This line has a pressure gauge (and a pressure transducer on some units) and is to be connected to the wash. Solenoid valves (supplied by others) need to be installed and controlled by the wash controller when water is demanded by the wash.
  • Page 14 Plumbing Direct from Pur-Water Reclaim Unit to High Pressure Pump City Plumbing Reclaim Water Direct to the High Pressure Pump Prevents Water Inlet Reclaim Water from Setting Stagnant in the Suction Storage Tank. Mechanical Float / Biological Activity Will Accelerate in Stagnant Reclaim Water, Causing Valve Growth in the Tank and Odor in the Area.
  • Page 15 Ensure the wall mount bracket is placed to allow the assembly to be removed easily. The assembly consists of the air sparger, mounting brackets, and inlet piping with a union. The bottom of the sparger nozzle should be set 6-12” above the water level and pointed downward. If this is not possible, mount the sparger horizontally so that it sprays against a side wall.

  • Page 16: Ii. Reclaim Tanks

    Underflow Orifice Assembly Some units will have a few components that will mount off of the main reclaim unit frame: a) Enzyme Systems: For models ending in -5MB, the enzyme feed tank will set on the floor close to the reclaim unit and must be connected to the enzyme feed pump mounted on the reclaim unit frame.
  • Page 17 1) The Catch Basin is typically located in the bay and is part of the trench used to collect water from the wash that goes to the Reclaim Tanks. 2) The Catch Basin will collect heavy, large solids (rocks) and floating materials (plastic bags & bottles), keeping these items out of the Reclaim Tanks.
  • Page 18 Reclaim Tank Plumbing – Suction Lines: 1) Two suction lines are recommended. One is used and one is a spare. 2) The minimum suction line size for a PW100 & 200 series is 2”. Larger units require a 3” suction line. 3) Unions can be used above the water level to allow removal of the suction line from the manway without draining the tank.
  • Page 19 3) The switch should be installed a minimum of 9” above the bottom of the check valve when the float is in the down position. Reclaim Tank Plumbing – Sewer Overflow: 1) The sewer (overflow) connection is above the normal liquid level and should only overflow when washing cars.
  • Page 20 Safety Warning! Hazardous Voltage: Can shock, burn, or cause death. Disconnect power at the main panel before connecting the electrical power supply to the reclaim unit panel or working on electrical connections. Ground the reclaim unit before connecting to the electrical power supply. Failure to ground the reclaim unit can cause a severe or fatal electrical shock hazard.
  • Page 21 Controls and Electrical: Ground 110 V Power (Common) 110 V Power (Hot) 3-Phase Power (230 V Red / Blue / Black) or (460 V Orange / Yellow / Brown) 5 6 7 8 9 10 Safety Warning! Hazardous voltage. Can shock, burn, or cause death.
  • Page 22 The control panel provided has been pre-wired to the pump motor, the Variable Frequency Drive (VFD), the motorized ball valve, the pressure switch, the solenoid valves within the floor frame, the enzyme pump (if supplied), and the oxygen concentrator / ozone generator (if supplied and on the floor frame). Incoming power and ground, reclaim tank level switches, and wash activation signals need to all be wired (by others) once the system is set into place.
  • Page 23 3) Wash Activation Signal #2: Wiring for the second wash activation signal can be brought in through one of the conduit connectors on the control box, and connected to Terminal #7 (hot) and Terminal #8 (common) on the block in the lower left corner. This signal runs through activation signal relay #3.

  • Page 27: System Start-Up, Operation And Maintenance

    System Start-Up, Operation and Maintenance Before starting up the PurWater Reclaim system, it is necessary to understand the major electrical components and controls. Electrical Component / Control Functions: a) Variable Frequency Drive (VFD): The VFD is located within the control box in the upper left corner.
  • Page 28 off. Hand Mode – In By-Pass: The Control Switch has been placed in the Hand position and will automatically provide city water to the wash with an activation signal instead of reclaim water. All other functions have stopped. PurWater, No. Highlands, CA 800-882-8854: The Control Switch is in the Auto position and all functions are operating normally.
  • Page 29 temperature on an ozone cell indicating a potential problem with the cell or the fans in the ozone generator. The ozone generator is turned off and all other functions will operate normally. Internal Ozone Fault! Ozone Off.: The internal diagnostics of the ozone generator has tripped indicating that there is a potential problem with one of the ozone generator components.
  • Page 30 wash activation and provide city water to the wash instead of reclaim water. The reclaim pump will not run unless the Prime Button is pushed, which will also open the Pump Prime solenoid. The enzyme pump (Models ending in –M5B) and oxygen concentrator / ozone generator (Models ending in –M512O and –M524O) will not operate with the switch in the Hand position.

  • Page 31: Start-Up

    Start-Up: After the reclaim has been set into place, all the piping connections have been made, all the control and electrical connections have been made, and the reclaim tanks are filled with water, the system is ready for start-up. 1) Check Pump Rotation: Turn the Power Switch to the “On” position and the Control Switch to the “Auto”...
  • Page 32 should be done when the system is running in recirculation only and with wash demand. Re-tighten any threaded connections on the piping. The cyclones are made in several pieces and the connection of these pieces also can come loose during shipment. For leaks around the victaulic (orange metal clamps) connections or the metal band around the mid-section, re-tighten the connection (careful not to over-tighten).
  • Page 33 water should be coming through the nozzle of the sparger. If possible, put your finger over the top opening of the air sparger to ensure a vacuum is being pulled. 8) Charge Enzyme Feed System (For Models Ending in -M5B Only): The enzyme feed pump is factory set to add approximately one ounce of enzyme solution per hour, and will operate when the Power Switch is in the “On”...
  • Page 34 making ozone. The temperature switch(es) will turn on, and the blue light on the ozone cabinet will be lit and get brighter or lighter as the potentiometer switch is adjusted to make more or less ozone. The ozone generator will not operate unless there is enough inlet pressure from the oxygen concentrator (a minimum of 8-9 psig).

  • Page 35: Operation

    Operation: After the above start-up procedures have been satisfactorily performed, the reclaim system is ready for operation. As long as the water level in the reclaim tank is above the low-low level switch, the reclaim system will continuously run … even if there is no wash demand.
  • Page 36 Pressure Pressure Solenoid Transmitter Gauge PurWater Reclaim Water System Valve By Customer To Car Sparger Design Wash City Water ByPass Solenoid Wash Activation Mode Valve (N.C.) Check Solenoid City Valve Valve Pressure Pressure Water (N.O.) Check Switch Gauge Overflow Valve (Treated Water) Basket Strainer...
  • Page 37 Pressure Pressure Solenoid Transmitter Gauge PurWater Reclaim Water System Valve By Customer To Car Sparger Design Wash City Water ByPass Solenoid Automatic Pump Prime Mode Valve (N.C.) Solenoid Check City Valve Valve Pressure Pressure Water (N.O.) Switch Gauge Check Overflow Valve (Treated Water) Basket...
  • Page 38 Ozone Generation System Operation: Oxygen Concentrator: The Oxygen Concentrator draws in ambient air that is 21% oxygen and produces a 90-95% pure oxygen gas stream. The ambient air is drawn in by a compressor and pushed through sieve beds that remove nitrogen and moisture from the air, leaving concentrated oxygen.
  • Page 39 the flow meter. The flow should be set with the top of the ball in the meter between 30-50%. There is also a desiccant filter on the concentrated oxygen outlet tubing to remove any residual moisture and particulate from the concentrator. Ozone Generator: The ozone generator takes the concentrated oxygen (O2) and converts some to ozone (O3).
  • Page 40 Recommended Maintenance Schedule PurWater™ 5 Micron Reclaim Systems With Air Sparger Maintenance Task Daily Weekly Monthly Quarterly Est. Time Required 1) Check Control Box Power / ● <1 Min Control Switches and Lights 2) Check Pump Seal ● <1 Min 3) Check Pump Pressure ●...
  • Page 41 Task #1: Check Control Box Power / Control Switches and Lights. Main Control Box Power Indicator Light Manual Pump Prime Green Button Indicator Light Hand/Off/Auto Switch in “Auto” Mode Control Box The Main Power switch should be in the “On” position. The Hand/Off/Auto switch should be in the “Auto”...
  • Page 42 Visually check the area between the pump motor and the pump housing for water leaks. Also check the area of the frame beneath the pump/motor interface for water. If a leak is found contact Pur-Water for replacement parts. Task # 3: Check Pump Pressure. Pump Pressure gage: 15 to 55 psig...
  • Page 43 Weekly Maintenance Tasks In addition to performing the Daily Maintenance Tasks, perform the following tasks weekly: Task # 4: Clean Basket Strainer. Basket Strainer with on ‘dog ear’ Strainer basket being Basket Strainer lid removed and lid rotated for removed removed removal Turn the Hand/Off/Auto switch to the “Hand”...
  • Page 44 Task # 5: Clean Underflow Orifice. Underflow Underflow piping Orifice Underflow Orifice housing Location of Underflow Orifice Clean Underflow Orifice / Housing...
  • Page 45 Turn the Hand/Off/Auto switch to the “Hand” position. This will put the system in By-Pass mode so that the wash does not need to be closed. Locate the orifice housing and loosen the two unions holding it in place. Visually inspect the orifice to ensure it is not plugged. If plugged, clean as needed.
  • Page 46 Task # 7: Check Sparger Operation Air Intake Port (On Top) Recirculation Water Inlet Wall Mount Bracket Sparger Nozzle Air Sparger Remove the cover from the tank where the Sparger is located. Check to see if there is a stream of water flow from the end of the sparger mixing tube.
  • Page 47 with water to clear any debris. Check the Sparger Nozzle outlet and ensure it is not clogged. Flush with water to clear any debris. If flushing with water does not clear the debris, the Air Intake and Sparger Nozzle pieces can be removed from the main sparger body for better cleaning access.
  • Page 48 Recommended Maintenance Schedule PurWater 5 Micron Reclaim Systems with Ozone Odor Control Maintenance Task Daily Weekly Monthly Quarterly Every 12- Est. Time 18 Months Required 1) Check Control Box ● <1 Min Power / Control Switches and Lights 2) Check Pump Seal ●...
  • Page 49 Daily Maintenance Tasks Ozone Generator Control Oxygen Concentrator Motorized Ball Valve Mazzei Eductor Reclaim Pump Underflow Orifice Basket Strainer PW300-5M24O Check Control Box Power / Control Switches and Lights. Task #1: Main Control Box Power By-Pass Indicator Light Green Indicator Light Manual Pump Prime Button Hand/Off/Auto...
  • Page 50 The Main Power Switch should be in the “On” position. The Hand/Off/Auto Switch should be in the “Auto” position. The Green Light should be “On” and steady. It will only blink in the Automatic Prime mode. The Red (By-Pass) Light should be “Off”. o If the light is “On”...
  • Page 51 Note: The pump will only come on if there is water in the reclaim tank to satisfy the low- low level switch in compartment #3, or if the low-low level switch is manually overridden. The pump pressure gage should show pressure when the motor is running.
  • Page 52 The pressure on the pressure gage should read about 11 psig either a 12g or 24g ozone system. A 12g ozone system will have one temperature switch on the front of the cabinet and a 24g ozone system will have two temperature switches on the front of the cabinet. Contact Pur-Water immediately if there is a 2-3 psig difference.
  • Page 53 Temperature Ozone Fault Switches Light Ozone Output Potentiometer Ozone Output Light Back Pressure Transformer Gauge & Valve Power Light Power Switch Breakers Safety Notes: Breathing concentrated ozone can create severe breathing problems. Precautions must be made to prevent exposure to concentrated ozone. If breathing problems occur, immediately get into fresh air.
  • Page 54 Weekly Maintenance Tasks In addition to performing the Daily Maintenance Tasks, perform the following tasks weekly: Clean Basket Strainer. Task # 6: Strainer basket being removed Basket Strainer with on ‘dog ear’ Basket Strainer lid removed removed and lid rotated for removal Turn the Hand/Off/Auto switch to the “Hand”...
  • Page 55 Task # 7: Clean Underflow Orifice. Underflow Orifice Underflow piping Underflow Orifice housing Clean Underflow Orifice and Housing Location of Underflow Orifice Turn the Hand/Off/Auto switch to the “Hand” position. This will put the system in By-Pass mode so that the wash does not need to be closed. Locate the orifice housing and loosen the two unions holding it in place.
  • Page 56 With the Hand/Off/Auto switch set to “Auto” and the reclaim unit in recirculation mode, the ball valve status indicator, located on the stem of the blue valve assembly, should be “Red”. When a wash activation signal occurs, the solenoid will energize causing the ball valve to rotate and a give a “Green”...
  • Page 57 Monthly Maintenance Tasks In addition to performing the Daily and Weekly Maintenance Tasks, perform the following tasks Monthly: Verify Ozone Production Task # 10: With the power on and the system operating in Auto, check for ozone production. Remove the manhole cover over the underground reclaim tank where ozone gas is injected.
  • Page 58 Inspect the Ozone Generator Internals. Task # 11: Door Safety Ozone Switch Generator Door w/ Latches Ozone Cells Transformers Turn the Power Switch to the “Off” position. Loosen the door fasteners and open the ozone generator door until it catches on the latches to remain open.
  • Page 59 Task # 12: Inspect the Oxygen Concentrator Internals With the power on and the system operating in Auto: Remove the front cover of the oxygen concentrator. Check that the compressor fan blades are turning. Check that the indicator lights on the circuit board are going through their sequence.
  • Page 60 Task # 13: Clean the Ozone Generator Internals Turn the Power Switch to the “Off” position and open the ozone generator door until the latches catch to keep the door open. Warning! Ensure the ozone generator power is off before proceeding. The Power Switch and Door Safety Switch will cut power to the ozone Note: generator.
  • Page 61 Venturi throat Mazzei Eductor nozzle/ball check valve assembly Mazzei Venturi Throat Mazzei Eductor Assembly 12-18 Month Maintenance Tasks Task # 15: Replace Oxygen Concentrator and Ozone Cells: Every 12-18 Months, the ozone cells and oxygen concentrator will need to be rebuilt. The oxygen concentrator will need to be removed in its entirety from the frame and replaced with a rebuilt concentrator.

  • Page 62: Troubleshooting Guide

    Troubleshooting Guide Please contact PurWater with any issues regarding troubleshooting. Main PLC Text Control Box Message Problem Recommended Action to be Indicator Screen Performed Lights The reclaim Red Light is on The Control Switch is in the Off pump is not and steady Operations position.
  • Page 63 Main PLC Text Control Box Message Problem Recommended Action to be Indicator Screen Performed Lights The reclaim Red Light is on The system is in city water by-pass pump is not and blinking Pressure at mode. The pressure switch on the operating or Pump.
  • Page 64 Main PLC Text Control Box Message Problem Recommended Action to be Indicator Screen Performed Lights There is not Green light is PurWater, Check that the treated water piping enough on and steady from the reclaim unit is at least 2” treated Highlands, until it reaches the wash.
  • Page 65 For ozone systems only: Ozone PLC Text Cabinet Message Problem Recommended Action to be Indicator Screen Performed Lights The ozone All ozone lights The pressure switch on the oxygen generator is are off Oxygen feed line from the oxygen off. Pressure! concentrator has tripped on low Ozone Off...
  • Page 66 33.9 5 6 7 8 9 10 t ON Bussmann (N)7L S 271 S 272 K 6 A K 30 A CDNF32 - 230 / 400 - 400 0 OFF 0 OFF 0 OFF 0 OFF (N)8T 01 02 03 04 05 06 07 08 09 11 12 13 14 15 16 17 18 19 Neg.
  • Page 67 33.9 5 6 7 8 9 t ON Bussmann (N)7L S 271 S 272 K 30 A CDNF32 K 6 A - 230 / 400 - 400 0 OFF 0 OFF 0 OFF 0 OFF O3 Vac I6 (N)8T O3 P.Switch I4 O3 Temp I7 01 02 03 04 05 06 07 08 09 Auto, I1...

  • Page 69: Warranty

    WARRANTY NEW WAVE INDUSTRIES, LTD. LIMITED WARRANTY NEW WAVE INDUSTRIES, LTD. warrants to the original purchaser only, that all PUR-WATER RECLAIM SYSTEMS will be free of defects in materials and/or workmanship for a period of (1) one year from the date of delivery to the original customer, provided the enclosed instructions for operation, maintenance and care have been strictly complied with and the validation page has been sent to and received by NEW WAVE INDUSTRIES, LTD.
  • Page 70 RETURN GOODS POLICY NEW WAVE INDUSTRIES, LTD. RGA POLICY AND PROCEDURE POLICY All returns must be authorized by NEW WAVE INDUSTRIES, LTD. (Service Department) with a Returned Goods Authorization (RGA) form prior to return. All returned goods must be received by NEW WAVE INDUSTRIES, LTD. within 30 days or you will not receive credit.

  • Page 71: Start Up Warranty Validation

    START-UP 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 PLEASE RETURN VIA FAX TO: (916) 978-9995...

This manual is also suitable for:

Purewater pw 200-m5 seriesPurewater pw 300-m5 series purewater pwfs seriesPurewater pw400-5masPurewater pw100-5masPurewater pw100-5mbPurewater pw100-5m12o ... Show all

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