ENCON - Fermilab · ENCON Evaporators1368 Hooksett Rd, Unit 9, Hooksett, NH 03106-1823TEL:...

ENCON Evaporators*1368 Hooksett Rd, Unit 9, Hooksett, NH 03106-1823*TEL: 603-624-5110*FAX: 603-627-9520

ENCONOctober 2, 2013

Fermi National Accelerator LaboratoryReceiving Warehouse 2Kirk Rd. & Wilson St.Batavia, IL 60510

Dear Sir or Madam,

Attached is the most updated Operations Manual for your ENCON Evaporator. Please refer to this version of the ENCON Operations Manual during the installation, startup, and operations phase of your project. Please also remember to contact ENCON Evaporators before starting your system to confirm that your ENCON Evaporator has been installed correctly and is ready for long-term operation. Please contact the ENCON Evaporators Service Department at 603-624-5110 Extension 4 with any questions you may have.

Sincerely,

ENCON Evaporators Engineering Department

ENCON Evaporators OPERATIONS MANUAL

Model Number: E33V1-15

Serial Number: 37350

Evaporation System Exhausts Clean Water Vapor

ENCON EVAPORATORS CONFIDENTIAL

1368 Hooksett Road, Unit 9Hooksett, NH 03106-1823

USATel: (603) 624-5110Fax: (603) 627-9520

ENCONENERGY CONSCIOUS INNOVATION

TABLE OF CONTENTS

I. THERMAL EVAPORATORS ................................................. 4

1. MISSION STATEMENT ....................................................................................... 4 2. INTRODUCTION .................................................................................................. 4

3. SAFETY PRECAUTIONS / INSTRUCTIONS ..................................................... 5 4. GENERAL INSTALLATION REQUIREMENTS ................................................ 6

A. Locating the Evaporator ...................................................................................... 6 B. Removing the Evaporator from Wood Skid ....................................................... 6 C. Securing the Evaporator ...................................................................................... 7

D. Electrical Power .................................................................................................. 7 E. Evaporator Stack ................................................................................................. 7

F. Water Inlet Plumbing .......................................................................................... 9 a. Feed Pump ...................................................................................................... 9 b. Feed Pump Air Solenoid ................................................................................. 9 c. Feed Isolation Valve ....................................................................................... 9

G. Holding Tank Float Switch ............................................................................... 10 H. Oil Decant Outlet Plumbing.............................................................................. 10

a. Manual Decant Plumbing ............................................................................. 10

b. Auto Decant Plumbing .................................................................................. 10 c. Oil Tank Level Probe .................................................................................... 11

d. Oil Decant Pump ........................................................................................... 11 I. Evaporator Cleanout ......................................................................................... 11

a. Residue Pump ............................................................................................... 11

b. Residue Tank Level Probe (Auto-Dump Only) ............................................ 12

J. Condenser Plumbing (Condenser Units Only) ................................................. 12 a. Cooling Water ............................................................................................... 12 b. Condensate Pump.......................................................................................... 12

c. Condensate Tank ........................................................................................... 12 d. Condensate Tank High Level Switch ........................................................... 13

K. Anti-Foam System (AFS) ................................................................................. 13 a. Mechanical Installation ................................................................................. 13 b. Electrical Installation .................................................................................... 14 c. Purging The Anti-Foam System ................................................................... 14

d. Setting the Metering Pump Rate ................................................................... 15 L. Remote Support ................................................................................................ 17

a. Dedicated Phone Line ................................................................................... 17

b. Dedicated Ethernet Line ............................................................................... 18 M. Remote Audible Alarm (Optional) ............................................................... 18

II. ELECTRIC THERMAL EVAPORATOR INSTALLATION

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1. ELECTRICAL SUPPLY ...................................................................................... 19 2. EVAPORATOR STACK...................................................................................... 19 3. RESIDUE TANK AVAILABLE LEVEL PROBE (AUTO-DUMP ONLY) ...... 20

4. CONDENSER PLUMBING (COOLING WATER) ............................................ 20

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III. SYSTEM START UP PROCEDURE .................................. 21

1. INTRODUCTION ................................................................................................ 21 2. System Start Up .................................................................................................... 21

A. Auto Fill Evaporator ......................................................................................... 21

IV. PLC AND OPERATOR INTERFACE PANEL .................. 22

1. INTRODUCTION TO THE DL06 & C-MORE MICRO .................................... 22 2. HAND-OFF-AUTO SCREEN (MODES OF OPERATION) .............................. 22

A. Auto Fill Evaporator ......................................................................................... 23

3. MANUAL FILL SCREEN ................................................................................... 24 4. SCREEN SELECTION (MENU) SCREEN ......................................................... 24 5. SET POINTS SCREEN ........................................................................................ 25 6. ADDITIONAL SET POINTS SCREEN .............................................................. 26 7. WATER TEMPERATURE CALIBRATION SCREEN ...................................... 26

8. EVAPORATOR STATUS SCREEN ................................................................... 27

9. DIGITAL I/O STATUS SCREENS ..................................................................... 28 10. AUTO DUMP OPERATION ........................................................................... 29

11. AUTO DECANT OPERATION....................................................................... 30 12. AUTO DUMP AND DECANT SIMULTANEOUS OPERATION ................ 32 13. FAULT SCREEN ............................................................................................. 33

14. ALARM DESCRIPTION SCREEN ................................................................. 34 15. OPERATION ALARMS SCREEN .................................................................. 35 16. DIAGNOSTIC ALARMS SCREEN ................................................................ 35

17. HIGH WATER TEMPERATURE SCREEN ................................................... 36 18. VFD FAULT SCREEN .................................................................................... 36

19. CYCLE TIMER SCREEN ................................................................................ 37

20. FACTORY SETTINGS SCREEN .................................................................... 38

V. SYSTEM MAINTENANCE ................................................ 39

1. INTRODUCTION ................................................................................................ 39

2. TANK/HEATER RINSE DOWN......................................................................... 39 3. LEVEL PROBE INSPECTION/CLEANING ...................................................... 39

4. MIST PAD CLEANING....................................................................................... 40 5. STACK INSPECTION ......................................................................................... 40

VI. ALARM CONDITIONS ...................................................... 41

1. OPERATION ALARM CONDITIONS ............................................................... 41 A. High Water Temperature .................................................................................. 41

a. Decanting the Floating Oil Layer ................................................................. 41

b. Pumping Out the Concentrated Residue ....................................................... 42

B. High Heater Temperature ................................................................................. 42

C. High Air Pressure .............................................................................................. 42 D. High Water Level .............................................................................................. 43 E. Low Water Level .............................................................................................. 43 F. Holding Tank Level Alarm ............................................................................... 43 G. Residue Tank Full (Auto Dump) ...................................................................... 44 H. High Condensate Level Alarm (Condenser units only) .................................... 44 I. Oil Tank Level Full Fault (Auto Decant) ......................................................... 44

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J. Decant High Level Fault (Auto Decant) ........................................................... 44

K. Cycle Timer Expired ......................................................................................... 45 2. SYSTEM DIAGNOSTIC ALARM CONDITIONS ............................................ 45

A. Low Air Pressure .............................................................................................. 45

B. Water Temperature Failure ............................................................................... 45 C. Heater Temperature Failure .............................................................................. 46 D. Air Pressure Failure .......................................................................................... 46 E. Hi Level Probe Failure ...................................................................................... 46 F. High Auto Probe Failure ................................................................................... 47

G. Low Low Probe Failure .................................................................................... 47 H. VFD Fault ......................................................................................................... 47 I. Limit Switch Open Error .................................................................................. 48 J. Limit Switch Closed Error ................................................................................ 48

K. Decant Valve Closed Failure ............................................................................ 48 L. Decant Valve Open Failure ............................................................................... 48

VII. TROUBLESHOOTING .................................................... 49

1. NOTHING HAPPENS WITH THE MAIN POWER SWITCH ON.................... 49

2. FEED PUMP DOES NOT START ...................................................................... 49 3. HEATERS WILL NOT ENERGIZE .................................................................... 51 4. LEAKAGE OF WASTEWATER FROM THE SYSTEM ................................... 52

5. FOAM OVERFLOWS FROM THE EVAPORATOR ........................................ 52 6. EVAPORATION RATE IS INADEQUATE BUT NO ALARMS ...................... 53

7. ERROR MESSAGE ON THE PLC DISPLAY PANEL ...................................... 54

4

I. THERMAL EVAPORATORS

1. MISSION STATEMENT

ENCON Evaporators has designed the ENCON (Energy Conscious) Evaporator to

address deficiencies of other wastewater evaporators available in the marketplace. Our

extensive experience in applications engineering and fabrication of evaporators has

resulted in a system that has significant advantages over other systems.

Many design improvements have been incorporated into the ENCON Evaporator as a

direct result of listening to operations personnel who have used evaporators. While our

system has addressed many of the operational concerns expressed about other

evaporators, it is our intention to continuously look for ways to improve our system.

Fabrication, quality, and reliability are also critically important to us and we have used

components and established procedures to ensure the highest quality. We think you will

find the ENCON Evaporator to be an excellent system to reduce your wastewater

disposal volumes. If you have questions that cannot be answered by referring to this

manual, please feel welcome to contact us at 603-624-5110. We look forward to working

with you.

2. INTRODUCTION

Thank you for purchasing an Encon Evaporator. We want your new wastewater

evaporator to operate safely. Anyone working with this equipment should read this

manual before installing or operating the equipment.

To minimize the risk of potential safety problems, you should follow all applicable local

and national codes that regulate the installation and operation of your evaporator. These

codes vary from area to area and usually change with time. It is your responsibility to

determine which codes should be followed, and to verify that the evaporator, installation,

and operation are in compliance with the latest revision of these codes. At a minimum,

you should follow all applicable sections of the National Fire Code, National Electrical

Code, and the codes of the National Electrical Manufacturer's Association (NEMA).

There may be local regulatory or government offices that can also help determine which

codes and standards are necessary for safe installation and operation. Equipment damage

or serious injury to personnel can result from the failure to follow all applicable codes

and standards. We do not assume any responsibility for the details of your installation.

Code Compliance is the sole responsibility of the customer. In no event will Encon

Evaporators be responsible or liable for indirect or consequential damages resulting from

the misuse or misapplication of this equipment.

This publication is based on information that was available at the time it was printed. At

Encon Evaporators we constantly strive to improve our products and services, so we

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reserve the right to make changes to the products and/or manuals and publications at any

time without notice and without any obligation. This manual may also discuss features

that may not be available in certain revisions of our evaporators.

Reproduction of the contents of this manual, in whole or in part, without written

permission of Encon Evaporators is prohibited.

This operations manual has been put together to facilitate the start-up, operation, and

maintenance of the ENCON Thermal line of Evaporators. Section I gives the general

installation details of an ENCON Thermal Evaporator. Section II gives unit specific

installation instructions. Section III describes the start up procedures. Section IV gives

PLC and operator interface details. Section V overviews the maintenance procedures.

Section VI details all possible alarms and describes their causes. Section VII gives

troubleshooting advice.

To begin, review the System Layout Drawing found in Appendix B to become familiar

with the ENCON Evaporator and the terminology used to describe the various sections

and components of the system.

NOTE: The system should be initially run with tap water only; and after start-up procedures are

completed only the waste streams that have been qualified by ENCON should be run in the

evaporator. Please refer to the boil analysis letter in Appendix A to confirm these waste streams.

If, after reading this manual, there is any uncertainty or questions relative to transporting,

set-up, start-up, operation or any other aspect of the ENCON system implementation,

contact ENCON Service and Support personnel at (603) 624-5110.

NOTE: IT IS EXTREMELY IMPORTANT THAT THIS MANUAL BE READ AND

UNDERSTOOD BEFORE ATTEMPTING TO OPERATE YOUR ENCON EVAPORATOR.

FAILURE TO DO SO MAY RESULT IN REDUCING THE LIFE EXPECTANCY OF THE

COMPONENTS OR SYSTEM AND POSSIBLE HARM TO THE OPERATORS OR PEOPLE IN

VICINITY OF THE SYSTEM. IF THERE IS ANY QUESTION REGARDING HOW THE

SYSTEM SHOULD BE INSTALLED OR OPERATED, CONTACT ENCON SERVICE

PERSONNEL AT (603) 624-5110 BEFORE ATTEMPTING TO OPERATE THE SYSTEM.

FAILURE TO CALL ENCON SERVICE PERSONNEL BEFORE ATTEMPTING TO START

THE UNIT FOR THE FIRST TIME WILL VOID THE WARRANTY ON THE SYSTEM! CALL

ENCON SERVICE PERSONNEL AT (603) 624-5110.

3. SAFETY PRECAUTIONS / INSTRUCTIONS

Do not install or operate the Encon Evaporator before reading this instruction manual.

Use adequate personal protection, warning and safety equipment necessary to protect

against hazards involved in installation and operation of this equipment

Exhaust blower, stack, residue, and decant piping may be hot enough to cause burns on

contact. Boiling water and steam will cause serious burns.

Disconnect or isolate all potential energy sources using proper lockout / tagout

procedures before doing any work

Do not bypass or render inoperative any safety or protective devices.

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Use proper care and good procedures in handling, lifting, installing, operation, and

maintaining the equipment.

Hearing protection may be required.

4. GENERAL INSTALLATION REQUIREMENTS

A. Locating the Evaporator

The ENCON Evaporator should be positioned on level flooring and be provided a

minimum of 2 feet of space on each side, with at least 3 feet of clear area in front of each

electrical panel (refer to the local code of the authority having jurisdiction, or in their

absence to national codes for additional requirements). In addition, the final location

should have good access to electric and compressed air utilities as well as a straight

vertical run for the evaporator stack. Close proximity to the evaporator feed tank and

residue holding vessel should also be considered.

NOTE: It is EXTREMELY important that the evaporator be located AWAY from combustible

materials such as gasoline or other flammable liquids and vapors.

B. Removing the Evaporator from Wood Skid

Encon systems mounted on wooden skids should be carefully lifted off the skid using a

forklift from the front side, to the right of center, and be lowered onto the floor. A

4”x4”x4’ piece of wood should be placed on the left fork as viewed from the operators

seat to accommodate the sloped bottom of the evaporator tank. See Figure I.1 below.

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Figure I.1 Fork Lift Location

C. Securing the Evaporator

After the evaporator has been leveled mounting bolts should be installed through the

9/16” holes located on the foot pads. For a concrete surface ½” x 3.5” anchor bolts are

recommended to secure the evaporator. For a metal surface ½” grade 5 CAP screws can be

used.

D. Electrical Power

Each ENCON system requires an electrical power supply as outlined in the chart in

Section II of this manual. The power should be wired by a licensed electrician per local

code of the authority having jurisdiction, or in the absence of local code per NFPA-70

National Electric Code in the US, or in the absence of local code per C22.1 Canadian

Electric Code in Canada.

E. Evaporator Stack

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A 22-gauge or heavier galvanized or stainless steel stack should be run from the blower

exhaust through the ceiling of the facility. The stack installation must conform to all local

codes.

NOTE: On some smaller units CPVC may be used. Please refer to the table in Section II for stack

diameter and material requirements.

The stack shall be at least 18 inches from any combustible material along its length.

The stack shall extend at least 2 feet above the highest point of the roof, or any portion of

a building within 10 feet. The stack outlet should also be 5 feet higher than the highest

draft hood outlet or flue collar.

The overall stack height should not exceed 30 feet and every effort should be made to

allow for a straight stack run. If a straight run cannot be made, we recommend a

maximum of two 45-degree bends and strongly advise against the use of 90-degree

bends. If the stack needs to exceed 30 feet contact ENCON Evaporators to discuss the

installation.

It is important to seal any seams of the steel stack to prevent water vapor from leaking

into the building and to prevent condensate from dripping out of the pipe and onto the

floor or equipment. Any seams should be securely fastened and lined with a high

temperature, high moisture sealant (250 F and 100% humidity). Insulating the stack will

only slightly minimize any condensation that may occur in your stack.

The stack outlet shall not be restricted in any way. A zero restriction rain shield (as

described below) is the only permissible cap type.

Figure I.2 Rain Shield

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F. Water Inlet Plumbing

Incoming water piping will be connected to the 1” FNPT coupling located on the

evaporator lid. ENCON Evaporators recommends that high temperature materials (e.g.

stainless, copper) should be used for the 3-4 feet of pipe closest to the machine to handle

the high temperature that is conducted up the line from the inside of the tank. After 3-4

feet, a PVC or CPVC line can be coupled to the high temperature piping if desired.

NOTE: If a PVC or a CPVC water inlet line is connected directly to the evaporator inlet coupling, it

will melt.

a. Feed Pump

If you are attaching a feed pump to the evaporator we would recommend installing

unions on each side of the pump for easy removal of the pump. The pump normally

provided by ENCON Evaporators for feeding the evaporator is either the Wilden P1 or

P2. Both of these pumps have a polypropylene housing.

Please refer to the pump curves for the Wilden P1 and P2 pumps in order to set your

pump to the desired feed rate. We typically recommend operating the pumps at a

pressure of 50-60 PSIG.

NOTE: An electric pump cannot be connected to the terminal blocks directly! Damage to the PLC

will result. Any feed pump that draws more than 1 Amp must be run through a relay contact.

b. Feed Pump Air Solenoid

The ASCO Red Hat solenoid valve that actuates the diaphragm feed pump should be

connected through an open access hole in the back of the control panel. Please see

Appendix C for wiring specifics.

c. Feed Isolation Valve

A feed water isolation valve must be installed in the feed line if the water level in the

holding tank when it is full could be higher than that of the water at normal operating

level in the evaporator tank. If the holding tank level when full is above the operating

level in the evaporator tank and a feed water isolation valve is not used, a siphon effect

can occur and cause the evaporator tank to overflow.

ENCON Evaporators recommends an air actuated, electrically piloted feed isolation

valve. The air supply to the valve should be 80-120 psi. The inlet airline should be

connected to port ‘P’ on the valve. Ports ‘EA’ and ‘EB’ are exhaust ports and should

have air mufflers installed or be left open. Please refer to the electrical schematic in

Appendix C for solenoid wiring instructions.

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NOTE: If an air operated ball valve is used in place of or in conjunction with the feed pump. The ball

valve’s solenoid leads should be wired into the same terminals as the feed pump air solenoid. Any

feed valve that draws more than 1 Amp must be run through a relay contact.

NOTE: ENCON does not recommend the use of diaphragm style valves.

G. Holding Tank Float Switch

The KARI low-level float switch should be connected to an open access hole in the back

of the control panel. See the electrical schematic in Appendix C for wiring instructions.

Customer supplied level devices should provide a contact that is open when the tank is

empty and closed when the tank has sufficient water to begin filling the evaporator.

NOTE: If a float switch is not used with the ENCON evaporator, a jumper wire must be installed

before attempting to operate the system. Note that operating the system with a jumper wire installed

will cause the feed pump to run when the evaporator calls for water regardless of the level of water in

the holding tank.

H. Oil Decant Outlet Plumbing

For wastewater applications that have high concentrations of oils it is important to plumb

the oil decant line. The decanting process is described in more detail in the operations

section of this manual.

a. Manual Decant Plumbing

For most applications a threaded nipple should be attached to the 1" FNPT oil decant

coupling. A 1” ball valve, a 90-degree elbow and extension nipple should be installed

downstream and directed into a waste oil drum where the decanted oil can be stored. All

materials must be resistant to temperatures of at least 250F.

b. Auto Decant Plumbing

If purchased, the auto decant valve will already be installed on the system. The valve will

open and close as necessary. The customer is responsible for installing the auto decant

pump and oil tank level probe.

NOTE: Do not make any alterations to factory installed piping unless the alterations have been

appoved by ENCON Evaporators.

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c. Oil Tank Level Probe

If the auto decant option is installed on your ENCON evaporator, the oil tank level probe

must be connected through an open access hole in the back of the evaporator control

panel. If the auto decant option is not installed, the oil tank level probe is not required.

The oil tank level probe must be wired such that the probe contacts are open when it is

covered and closed when it is uncovered. The probe should be located near the top of the

tank because the system will only actuate when the probe is uncovered.

NOTE: Both the oil tank and the level probe need to be resistant to temperatures of at least 250°F.

d. Oil Decant Pump

If the auto decant option is installed on your ENCON evaporator an oil decant pump will

need to be installed. Encon recommends a Wilden P1 or P2 Stainless Steel pump. The

ASCO red hat solenoid that actuates the oil decant pump should be connected through an

open access hole in the back of the evaporator control panel.

NOTE: Centrifugal or electric pumps cannot be connected to the terminal blocks directly! Damage

to the PLC will result. Any feed pump that draws more than 1 Amp must be run through a relay

contact.

NOTE: The oil decant pump must flow more GPM than the feed pump.

I. Evaporator Cleanout

Each system is supplied with a 6-inch flanged cover (4-inch for systems rated for 10 GPH

and less) on the cleanout with a 1-1/2 inch NPT fitting to connect to the residue pump. A

stainless steel threaded nipple and ball valve should be run between the fitting on the

cleanout cover and the residue evacuation pump. All plumbing materials should be able

to handle temperatures up to 250F. The valve will be closed during normal operation of

the evaporator.

a. Residue Pump

If you are attaching a residue pump to the evaporator, ENCON recommends installing

unions on each side of the pump for easy removal and servicing of the pump. The

residue pump normally supplied by ENCON is a Wilden P2 SS (Stainless Housing) or the

Wilden T2 Kynar (Kynar Housing), which are both designed for high temperature

(250F) applications.

Please refer to the pump curves for the Wilden P2 SS and T2 Kynar pumps for the

purpose of setting your pump to the desired rate. We typically recommend operating the

pumps at a pressure of 50-60 PSIG.

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b. Residue Tank Level Probe (Auto-Dump Only)

If the Auto-Dump option is installed on your ENCON evaporator, the residue tank

available probe must be connected through an open access hole in the back of the

evaporator control panel. If the Auto-Dump feature is not applicable, the residue tank

level probe is not required. The residue tank level probe must be wired such that the

probe contacts are open when it is covered and closed when it is uncovered. See Section

II for proper probe placement.

NOTE: Both the residue tank and the level probe need to be resistant to temperatures of at least

250°F.

J. Condenser Plumbing (Condenser Units Only)

a. Cooling Water

In order for the condenser to effectively condense all of the steam in the unit, it is

imperative that the cooling water be at most 90°F and that the flow rate (gallons per

minute) meet or exceed the required flow rate found in Section II.

By running the cooling water in the opposite direction of the path of steam (counter-flow

arrangement), a greater amount of heat transfer is achieved and therefore, more steam is

condensed. Also, any air in the line will be able to move along the upward angle of the

condenser and escape out of the outlet.

b. Condensate Pump

The condensate pump should be connected to the condenser outlet elbow (a 2” female

coupling is located in this elbow just downstream of the condenser) using the supplied

PVC piping. The outlet should be piped to the condensate tank. When the float switch on

the condensate pump is made, the pump will come on and send any water that has

accumulated in it to the condensate tank.

c. Condensate Tank

The condensate tank should be installed as close to the evaporator as possible. There

should be a check valve installed in the line between the pump and the tank to prevent

water from flowing back into the pump. The condensate tank will hold the clean water

that is discharged from the condenser. Based on the purity of this water, it can either be

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discharged or reused. The shutoff head for the supplied condensate pump is 25ft. If the

head pressure between the condensate pump and the condensate tank is greater than 25ft,

contact ENCON Evaporators service personnel.

d. Condensate Tank High Level Switch

The purpose of the condensate tank high level switch is to shut the evaporator down in

the event that the water in the condensate tank reaches a pre-determined high level. The

high-level float switch should be connected to an open access hole in the back of the

control panel. See the electrical schematic in Appendix C for wiring instructions.

Customer supplied level switches should provide a contact that is closed when the tank

is empty and open when the tank is full.

In the event that the condensate tank is full the heating source is disabled but the blower

continues to run for 30 minutes while the wastewater cools. While cooling, the remaining

steam will be condensed into water and sent to the condensate tank.

NOTE: Be sure to position the level switch such that when it shuts down on high level, there is still

sufficient space to accept 30 minutes of additional condensate. To be conservative, divide the

capacity of your evaporator by 2. Make sure that there are this many gallons of additional space

available when the high level switch is activated. For example, if you have a 260 GPH evaporator,

make sure that there are at least 130 gallons of available volume in the tank when the high level is

reached.

K. Anti-Foam System (AFS)

The AFS consists of a metering pump and essential mechanical installation items. Once

installed and properly setup, the control system of the evaporator will turn on the AFS

pump whenever there is a call to fill the evaporator with wastewater.

a. Mechanical Installation

Refer to the assembly drawing in Appendix F for installation instructions and to confirm

that you have all the necessary parts. The customer should provide a 55-gal drum of anti-

foam solution, a drum stand to orient the drum horizontally, and fittings to connect the

feed tubing from the Anti-Foam pump to the wastewater feed line.

Order of Installation:

1. Locate the metering pump as close as possible to the drum of anti foam solution

and feed pump for ease of installation.

2. The metering pump requires flooded suction, so the PUMP INLET MUST BE

BELOW THE DRUM OUTLET.

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3. Install the supplied fittings into the Anti-Foam drum openings (drum vent and ball

valve assembly), and then position the drum horizontally.

4. Connect suction hose for the pump to the compression fitting near the valve on

the drum. Prime the pump by allowing the tube to fill with Anti-Foam solution.

Direct the suction hose through the 1.5” diameter hole on the pump stand before

connecting the other end to inlet of metering pump.

5. Bolt the pump (with supplied ¾” hex head screws) to the pump stand.

6. Install ‘tee’ upstream of feed pump in wastewater feed line (parts provided by

customer).

7. Connect injection valve assembly to ‘tee’ in wastewater feed line. Cut the

injection tip, as necessary, so end of tip is located approximately in the center of

the feed line.

8. Connect the discharge hose to the compression fitting on the outlet of the

metering pump, and the other end to the supplied injection valve assembly.

b. Electrical Installation

Refer to the electrical assembly drawing in Appendix F for electrical connections.

Order of Installation:

1. The metering pump power leads should be brought into the control panel through

an available opening at the bottom/back of the panel. If no openings are

available, it is recommended to punch a hole in the bottom of the panel.

2. Use appropriate fittings, cord grip, etc. at the penetration into the panel to protect

the power leads and keep water from entering the inside of the panel.

c. Purging The Anti-Foam System

Confirm that Anti-Foam solution has reached the pump inlet before starting.

Purge the discharge tube of the metering pump by doing the following:

1. Electrically disconnect the wastewater feed pump until the Anti-Foam injection

line is fully purged.

2. Remove the discharge hose from the injection valve assembly and turn the

evaporator selector switch to the AUTO position so that it attempts to fill. The

level in the evaporator tank needs to be below the high-auto probe to fill.

3. Turn the metering pump switch to the ON position and confirm that the metering

pump is pumping.

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4. While the metering pump is running, turn the stroke length and frequency

adjustments on the metering pump to the highest settings. This will speed up the

purging process.

5. Once the hose has filled, take the evaporator out of Auto mode, reconnect the

discharge hose to the injection assembly.

6. Electrically reconnect the wastewater feed pump.

d. Setting the Metering Pump Rate

The metering pump discharge rate needs to be set to provide the proper amount of Anti-

Foam. First determine the wastewater feed pump discharge rate, then determine the

metering pump settings from the proper chart.

Determine the Feed Pump Discharge Rate. This can be measured while pumping through

the feed pump or estimated based on pump type and conditions.

Example A: Direct wastewater discharge into suitable pail or bucket. Turn off the AFS

metering pump at the pump controls. Turn on evaporator so that the feed pump actuates.

Record the time, in seconds, it takes to fill the bucket. Measure volume in the bucket in

gallons. Use the following equation to calculate the feed pump discharge rate in gallons

per minute. Turn AFS metering pump back to On (hand symbol).

seconds)(TimeFill

60*(gallons)VolumeBucket(gal/min) Rate Discharge Pump Feed

If it takes 20 seconds to fill a 5-gallon bucket, then

gal/min 1520

60*5 (gal/min) Rate Discharge Pump Feed

Example B: Use the following chart to estimate the flow rate from the pump. The chart

contains the pumps commonly offered by ENCON. The chart values are based on the

following specific assumptions, and actual flow rates will vary based on specific

installation parameters.

1. Piping from holding tank to pump and from pump to evaporator is 1" stainless

steel, copper or PVC

2. Pump is installed on the floor, suction line comes off the side of the holding tank,

and discharge line runs from the floor to the inlet of the evaporator tank, not

exceeding the height of the lid by more than 2 feet.

3. P1 and P2 pumps are air diaphragm pumps running at approximately 60psig of air

pressure.

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4. Total piping straight length (suction and discharge sides of pump) is 20 feet, with

(5) 90 degree elbows.

5. Holding tank is above ground, with wastewater average level 1 foot above

average level in evaporator tank.

Unless the actual installation is significantly different from the above assumptions,

the chart value will provide a good starting point for determining the metering pump

settings.

Table I.1 Feed Pump Flow Rate

Determine Metering Pump Settings. The following charts show the metering pump

stroke and frequency settings dependent on Feed Pump Discharge Rate and Anti-Foam

Dosage Rate. The typical range of dosage rate to control foaming is 200 to 400ppm

when using DUCEY CS-30. Initially pick settings for 400ppm.

NOTE: Other Anti-Foam products may require different dosing rates and possibly a different Anti-

Foam pump.

Table I.2 Anti-Foam Stroke/Frequency Settings

Pump Type P1 – Poly Feed Pump P2 – Poly Feed Pump G&L Cent. Pump

Feed Rate

(gallons/min)

12 31 39

35 70/30 80/53 90/70 100/84 100/100 -

30 60/30 70/50 80/67 90/80 100/90 100/100

25 60/25 70/42 70/64 80/75 90/83 100/90

20 50/24 70/34 70/50 80/60 90/67 90/80

15 50/18 60/30 70/39 70/51 80/56 80/67

10 50/12 50/24 60/30 70/34 70/42 70/50

100 200 300 400 500 600

CS1 Anti-Foam Dosage Rate (ppm)

AFS1 Settings - Stroke/Frequency

Fe

ed

Pu

mp

Ra

te (

Ga

l/m

in)

55 90/19 90/38 100/51 100/68 100/85 100/100

50 80/18 80/38 90/50 90/66 100/75 100/80

45 80/17 80/34 80/51 90/60 90/75 100/81

40 70/17 70/34 70/51 80/60 90/67 90/80

35 60/18 60/35 70/46 70/60 80/66 90/71

30 50/18 50/36 60/45 70/51 80/56 90/60

25 50/15 50/30 50/45 60/50 70/53 70/64

100 200 300 400 500 600

CS1 Anti-Foam Dosage Rate (ppm)

AFS2 Settings - Stroke/Frequency

Fe

ed

Pu

mp

Ra

te

(Ga

l/m

in)

17

Set AFS Metering Pump Stroke and Frequency. NOTE: Metering pump stroke setting

should only be adjusted while the pump is pumping, and stroke should never be set below

50. Turn the ON/OFF switch to the position showing a hand for ON. Make the system

call to fill the evaporator so that feed pump turns on. Adjust the Stroke and Frequency

settings to those selected in table above.

Monitor Process and Optimize Anti-Foam Feed Rate. Run evaporator for at least several

fill cycles. If your wastewater stream significantly varies in content over time (i.e. foamy

vs. not foamy), the evaporator should be optimized for the worst-case foaming situation

to ensure that the system will function properly.

If there is still significant foaming during evaporation, increase the metering pump rate

by raising the stroke and/or frequency on the pump controls.

If there is no foaming, the metering pump rate may be reduced to avoid using excessive

Anti-Foam solution.

L. Remote Support

A remote support package is standard on all thermal evaporators. There are two types

available one which uses a phone line, and one that uses an Ethernet connection.

a. Dedicated Phone Line

If installed this allows remote diagnostics from ENCON Evaporators through a standard

phone line. In order to take advantage of this feature, a phone line has to be run to the

machine and connected to the “line” port of the modem through an open access hole in

the back of the evaporator control panel. The ideal situation for this connection is to have

a dedicated line (a line with its own phone number) permanently run to the unit.

However, the following choices are acceptable:

A dedicated phone line that can be connected to the machine on an “as needed” basis (i.e.

not permanently connected).

A phone line that does not have a direct phone number but has an extension that can be

reached through an automatic (not human operated) switchboard. This phone line can

either be permanently run or connected to the machine on an “as needed” basis.

NOTE: If ENCON Evaporators has to go through a switchboard in order to connect to the

evaporator, it must be an automatic switchboard. A receptionist cannot put the call through

manually.

NOTE: The phone line must be installed into the “line” connection on the modem. Failure to do so

will result in an inability to connect to the evaporator.

NOTE: Do not run the phone line along any power wires. Doing so will cause a degradation of the

signal and could result in failed attempts to connect to the machine. If the phone line has to be run

near power wires, it must cross the wire at a 90° angle.

18

b. Dedicated Ethernet Line

If installed this allows remote diagnostics from ENCON Evaporators through a standard

Ethernet connection. In order to take advantage of this feature an Ethernet cord must run

through an open access hole in the back of the evaporator control panel. The ideal

situation for this connection is to have a dedicated line. However, a line that can be

connected to the machine on an “as needed” basis (i.e. not permanently connected) is also

acceptable.

NOTE: The customer will need to provide an IP address for the evaporator. Call ENCON Service

department for instructions.

NOTE: Do not run the Ethernet line along any power wires. Doing so will cause a degradation of

the signal and could result in failed attempts to connect to the machine. If the Ethernet line has to be

run near power wires, it must cross the wire at a 90° angle.

M. Remote Audible Alarm (Optional)

In situations where the ENCON evaporator is positioned in an area that is not in clear

sight of the operators during normal operation, a remote audible alarm can be installed to

make the operator aware of any alarm conditions that may exist.

When selecting a remote audible alarm, please make sure that it is a 24V DC alarm and

that the current draw on the device does not exceed 1 amp.

See the electrical schematic in Appendix C for wiring specifics.

19

II. ELECTRIC THERMAL EVAPORATOR INSTALLATION

1. ELECTRICAL SUPPLY

As outlined in Section I, each ENCON system requires an electrical power supply. Refer

to Table II.1 to determine the correct circuit sizing for your specific evaporator.

ENCON Model (In

GPH)

Heater Size Electrical Power Supply Circuit Sizing

8 24 KW 240VAC/3 80 Amp

8 24 KW 480VAC/3 40 Amp

15 48 KW 240VAC/3 150 Amp

15 48 KW 480VAC/3 80 Amp

24 72 KW 480VAC/3 110 Amp

40 120 KW 480VAC/3 200 Amp

Table II.1 Electrical Circuit Sizing

NOTE: If your exact model and voltage cannot be found in table II.1 please refer to Appendix C.

The Auxiliary Panel schematic will reference your evaporator’s full load amps.

2. EVAPORATOR STACK

As outlined in Section I, a stack should be run from the blower exhaust through the

ceiling of the facility. See Table II.2 for unit specific stack requirements.

ENCON

Model (In GPH)

Blower Outlet

Diameter (inches)

Required Stack

Diameter (inches)

Blower Outlet

Adapter

Required

Stack Material of

Construction

8 4 4 No Galvanized, SS, CPVC*




Table II.2 Main Blower Stack Requirements

20

*NOTE: Although a CPVC stack can be used, an adapter (customer supplied) must be used to mate

the CPVC pipe to the blower outlet.

NOTE: Only use a CPVC stack if allowed by local regulations.

NOTE: Condenser units do not require a steam exhaust stack.

3. RESIDUE TANK AVAILABLE LEVEL PROBE (AUTO-DUMP ONLY)

If the Auto-Dump option is installed on your ENCON evaporator, the residue tank

available probe must be connected through an open access hole in the back of the

evaporator control panel. If the Auto-Dump feature is not applicable, the residue tank

level probe is not required. The residue tank available probe must not be installed at the

highest point in the tank! The probe must be positioned such that it has sufficient volume

above it to handle the full dump of the system. Refer to the Table II.3 below to determine

how much room to leave above your residue probe.

ENCON Model (In GPH) Required Tank Volume ABOVE

Probe

8 GPH Unit 60 gallons




Table II.3 Residue Level Probe Position

NOTE: Contact ENCON Evaporators if there are questions or concerns. FAILURE TO

PROPERLY POSITION THE RESIDUE TANK AVAILABLE PROBE COULD RESULT IN A

TANK OVERFLOW!

4. CONDENSER PLUMBING (COOLING WATER)

In order for the condenser to effectively condense all of the steam in the unit, it is

imperative that the incoming cooling water be at most 90°F and that the flow rate

(gallons per minute) meet or exceed the required flow rate found in Table II.4.

ENCON Model (In GPH) Condenser Water Connections Required Flow (GPM@90°F)

8 1 ½” FNPT Inlet/Outlet 13

15 1 ½” FNPT Inlet/Outlet 24

24 2” FNPT Inlet/Outlet 38

40 2” FNPT Inlet/Outlet 60

21

Table II.4 Required Cooling Water Flow Rate

III. SYSTEM START UP PROCEDURE

1. INTRODUCTION

Contact Encon Service personnel before attempting to operate the equipment for the first

time. When starting up an electrically heated thermal evaporator it is important that you

have completed the installation in accordance to this manual and local codes.

The start up procedure begins by powering the system and becoming familiar with the

operator interface. A detailed account of the operator interface and the PLC can be found

in Section IV of this manual. After addressing all alarms (if applicable) the system can

run in automatic or batch fill mode.

2. System Start Up

A. Auto Fill Evaporator

Turn the Auto Switch from the OFF position to the AUTO position. If everything is

wired and plumbed correctly, this will cause the blower to turn on and water to begin

feeding to the system. Once the water level in the evaporator tank reaches the low-low

level probe the heaters will energize. The water level will continue to rise to the high

auto probe (2nd

from the top), at which point the feed pump will stop. For more details

regarding the Auto Fill operation see Section IV of this manual.

B. Batch Fill Evaporator

Switch the Manual Fill switch from the OFF position to the AUTO position. If everything

is wired and plumbed correctly, this will cause the blower to turn on. The operator will

then manually fill the evaporator to 3 inches below the high-level probe. Once the water

level in the evaporator tank reaches the low-level probe the heater(s) will energize.

NOTE: Do not leave the evaporator unattended during batch fill operations. Leaving the evaporator

unattended during batch (Manual) filling can result in an overflow condition, as the operator is

responsible for performing level control.

22

IV. PLC AND OPERATOR INTERFACE PANEL

1. INTRODUCTION TO THE DL06 & C-MORE MICRO

The KOYO DL06 Micro PLC in conjunction with the C-more Micro operator panel

controls and displays all of the functions on the ENCON evaporator and its accessories.

By reading the display on the panel, an operator can quickly see that the evaporator is

running properly and can schedule maintenance procedures easily based on the displayed

information. The introduction screen below is seen each time the main power switch is

turned to the “ON” position. Pressing continue will navigate to the “HAND-OFF-

AUTO” screen seen below in Figure IV.2.

Figure IV.1 Introduction Screen

2. HAND-OFF-AUTO SCREEN (MODES OF OPERATION)

From this screen you have the ability to navigate to all other screens. Pressing the hand

button will navigate you to the “Manual Fill” screen (Figure IV.3). Pressing the MENU

button will bring you to the “Screen Selection” screen (Figure IV.4).

23

Figure IV.2 Hand-Off-Auto Screen

A. Auto Fill Evaporator

Toggling the evaporator to the “On” position will begin the automatic control of the

evaporator. The exhaust blower will turn on and wastewater will begin feeding into the

evaporator. When the wastewater being fed into the evaporator has covered the low-low

level probe (3rd

from the top) for thirty seconds, the heat source will be enabled. After the

waste water level covers the high auto probe (2nd

from the top), the feeding stops and

water heat-up continues. The wastewater will continue to heat up until a boiling

temperature is reached (typically 212°F but can be lower at higher elevations or higher if

solution is heavily contaminated). As evaporation begins, the wastewater level will drop

to below the high auto probe (2nd

from the top). After a period of time has elapsed,

feeding of wastewater to the evaporator begins. Upon reaching the high auto probe,

feeding of wastewater will be stopped. The system will continue cycling in this mode

until there is no more wastewater upstream of the evaporator or it shuts down at the end

of a cycle or due to an alarm condition.

The wastewater level in the evaporator will then evaporate down to the low-low level

probe. The heat source will turn off, the blower will continue to operate until the water

cools, and the system will be in “stand-by” mode until more wastewater accumulates in

the holding tank. Once an adequate volume of water accumulates, wastewater will begin

feeding to the evaporator automatically.

Over time, the boiling temperature may rise until the high water temperature set point is

reached. Upon reaching the high set point, the heat source will turn off and the fault

screen will appear (See Section IV.11). This typically indicates the end of the

evaporation cycle. If purchased and enabled, the system will enter the Auto Dump Mode.

Otherwise, the system will need to be manually emptied. Refer to the Alarm Conditions

section of this manual for further instruction.

24

NOTE: For safety reasons some alarm condition can stop the Auto Run mode at any time. See the alarm

section for more details.

3. MANUAL FILL SCREEN

From this screen the operator is able to manually engage the exhaust blower as well as

manually fill the evaporator with wastewater.

Figure IV.3 Manual Fill Screen

NOTE: The manual fill button is momentary for safety reasons. Press and hold the HAND button

while manually filling the evaporator. The manual fan function is overridden during automatic

operation.

4. SCREEN SELECTION (MENU) SCREEN

This screen allows access to main screens, which allow access to other sub-screens. Use

the UP and DWN commands to scroll through the screens. Press ENT to go to the

highlighted screen. Pressing ESC returns the user to the previous screen.

25

Figure IV.4 Screen Selection (Menu) Screen

5. SET POINTS SCREEN

The necessary set points for proper evaporator operation are set and adjusted on this

screen. Pressing °F alternates between Fahrenheit and Celsius. Pressing MORE takes the

user to an additional set point screen (Figure IV.6).

Figure IV.5 Set Points Screen

NOTE: SETPOINT CHANGES ARE NOT TO BE MADE TO THE SYSTEM UNLESS

AUTHORIZED BY ENCON EVAPORATORS SERVICE PERSONNEL. FAILURE TO

CONSULT ENCON EVAPORATORS SERVICE PERSONNEL PRIOR TO CHANGING

SETPOINTS WILL VOID THE SYSTEM WARRANTY. PLEASE DOCUMENT ALL FACTORY

SET POINTS FOR FUTURE REFERENCE.

26

Note: Units will require different settings depending on the type of heating. The above screen is

representative of a typical gas heated evaporator.

Low Air Pressure Set Point

High Air Pressure Set Point

High Air Temperature Set Point or

High Heater Temperature Set Point (Electric

Units Only)

Blower Shut-off Set Point

High Water Temperature Set Point

High Condensate Temperature Set Point

(Section IV.6)

6. ADDITIONAL SET POINTS SCREEN

Applicable on condenser or condenser ready units only is a cooling water high

temperature set point. Also adjustable on this screen is the delay time for the auto-level

refill and the auto-dump pump out timer. Pressing Cal. will bring the user to the water

temperature calibration screen. Pressing Fact will bring the user to optional settings not

commonly used and therefore not discussed in this manual.

Figure IV.6 Additional Set Points Screen

7. WATER TEMPERATURE CALIBRATION SCREEN

27

If the measured water temperature does not match a known or calibrated water

temperature, the measured value can by adjusted +/- 5° to compensate for this. The

adjustment value is incremented or decremented by pressing the up or down arrows

respectively. The calibrated value is then shown at the bottom of the screen and is also

reflected on the Status screen in Section IV.8. Pressing BACK jumps to the additional

set points screen (Figure IV.6).

Figure IV.7 Water Temperature Calibration Screen

8. EVAPORATOR STATUS SCREEN

This screen can be used to monitor the status of the evaporator. Pressing MORE jumps

to an additional status screens, see Section IV.9. Pressing MENU jumps to the Screen

Selection Screen (Figure IV.4).

28

Figure IV.8 Evaporator Status Screen

NOTE: Figure IV.9 reflects a gas-heated evaporator. Electric units will display the status of the

heater temperature.

9. DIGITAL I/O STATUS SCREENS

This screen reflects the status of the digital inputs on the main PLC, and if you have a V2

panel, the inputs on the expansion digital input module. Pressing MORE jumps to a

similar screen, reflecting the status of the digital outputs on the main PLC, and if you

have a V2 panel, the digital outputs on the expansion digital output module. An input or

output is active when it is highlighted black as shown below. Pressing BACK on either

screen jumps to previously viewed screen.

Figure IV.9 Digital Input Status Screen

29

Figure IV.10 Digital Output Status Screen

10. AUTO DUMP OPERATION

Evaporators with the auto dump feature enabled will automatically empty the evaporator

tank if the high water temperature set point has been reached and the solution has boiled

down to the low-low probe or the secondary high water temperature set point has been

reached. It will also empty the tank if the cycle timer has completed its cycle and the

solution has boiled down to the low-low probe. A high water temperature alarm or an

expired cycle timer is an indication that the evaporation process is complete and that it is

time to empty the evaporator. The auto dump feature makes this an automatic process.

An auto dump will perform the following:

1. Disable the feed pump and boil to the low-low level probe (unless a secondary

high water temperature set point is reached, typically 250 F).

2. Disable the heater(s).

3. The electrically actuated residue valve will open.

4. The residue pump will turn on.

5. The contents will pump out of the evaporator until the water level reaches the auto

dump level probe. It will then continue to pump for an adjustable amount of time

depending on the size of the evaporator (see Section IV.8).

6. The residue pump will turn off.

7. The residue valve will close.

8. The evaporator will then return to automatic mode, refilling the system.

NOTE: The blower will remain on until the water temperature is below 150 F.

The auto dump cycle can also be manually initiated as follows:

30

1. Ensure the Manual Blower status is ‘On’. This ensures that the steam will be

exhausted, see Section IV.3.

2. Toggle the Off-Auto switch to the “Off” position, see Section IV.2. This will

disable the heater(s) and feed pump.

3. Toggle the Auto-Dump Mode button to MANUAL mode, and press the

MANUAL-DUMP START button to begin the dump sequence manually.

Once the evaporator has emptied, in manual dump mode, the evaporator will remain idle

until the user starts the Auto-Run cycle, see Section IV.2. A manual dump can be stopped

at any time by pressing the STOP DUMP button.

Figure IV.11 Evaporator in AUTO Auto-Dump Mode

Figure IV.12 Evaporator in MANUAL Auto-Dump Mode w/Manual-Dump ENABLED

11. AUTO DECANT OPERATION

31

Evaporators with this feature enabled will manually or automatically evacuate floating oil

in the evaporator. Once this feature is enabled, auto decant may be placed in automatic

or manual mode by pressing the AUTO-DECANT button. The Auto Decant feature,

when enabled, will automatically activate an oil pump and an oil decant valve when it

sees any of the following conditions:

1. The high water temperature setpoint has been reached. Since the high water

temperature alarm is a possible indication that there is a floating oil layer that

should be removed, the auto decant feature makes this an automatic process. See

note below.

2. The cycle timer has completed its cycle. Customers who want to decant their oil

after a certain amount of run time can utilize this feature. NOTE: The auto decant mode remains enabled after the auto decant sequence has been completed.

If a high water temperature situation is re-activated within 90 minutes after completing the Auto

Decanting operation, the evaporator will activate the High Water Temp alarm. This is an indication

that the cause for the high water temperature was not due to floating oil, but rather due to normal

concentration of the wastewater solution.

NOTE: The evaporator will shut down when the oil tank probe is covered during an Auto Decant

cycle (see Alarms section under Oil Tank Full).

The auto decant cycle can also be manually initiated as follows:

1. Ensure the Manual Blower status is ‘On’. This ensures that the steam will be

exhausted, see Section IV.3.

2. Toggle the Off-Auto switch to the “Off” position, see Section IV.2. This will

disable the heater(s) and feed pump.

3. Manually open the decant valve by pressing the decant valve open button see

figures IV.13 and IV.14.

4. Manually feed water to the evaporator using the manual fill button until water

begins to overflow the oil weir.

5. Manually turn on the decant pump by pressing the decant pump button.

6. Once the decant cycle is complete the evaporator will remain idle until the user

starts the Auto-Run cycle, see Section IV.2.

32

Figure IV.13 Auto Decant Screen (Manual Operation)

Figure IV.14 Auto Decant Screen (Manual Operation) With Decant Valve Open

12. AUTO DUMP AND DECANT SIMULTANEOUS OPERATION

Evaporators configured with both features may be operated with either individually, or

both simultaneously. In order to set which is active use the configuration screen (Figure

IV.15).

33

Figure IV.15 Dump/Decant Configuration Screen

When both Auto-Dump and Auto-Decant are installed and enabled a high water

temperature situation will result in an Auto Decant. If a high water temperature situation

is re-activated within 90 minutes from the completion of the Auto Decanting operation,

the evaporator will then enter the Auto Dump cycle. This is an indication that the cause

for the high water temperature was not due to floating oil, but rather due to normal

concentration of the wastewater solution. If the high water temperature situation is

reactivated within 90 minutes of an Auto Dump cycle, then the High Water Temperature

alarm will activate and shut down the evaporator. This may be an indication that the High

Water Temperature alarm is set incorrectly. Contact the Encon Service department.

13. FAULT SCREEN

If there are any faults that occur during operation of your evaporator it will be displayed

on the fault screen (typically red). Use the Alarm Conditions section of this manual to

diagnose the alarm, correct any alarm condition, and press the SYSTEM RESET button

to resume operation. Pressing the ALARM DESC button jumps to the Alarm Description

Screen, see Section IV.14. Pressing MENU jumps to the Screen Selection screen, see

Section IV.5.

Note: For safety reasons some fault conditions are only cleared by resetting the system. By using

this button, any latched fault condition that occurs can be reset once steps have been taken to clear

the condition and prevent the fault from occurring again.

34

Figure IV.16 Fault Screen

NOTE: Fault screen shown is an example only and may not be representative.

14. ALARM DESCRIPTION SCREEN

This screen can be used to navigate to the descriptions of all possible evaporator alarms.

To assist in navigating to the correct alarm, the alarms have been categorized into

operation alarms, alarms while the evaporator is operating, and diagnostic alarms, which

refers to hardware related alarms. Pressing Operation Alarms jumps to the Operation

Alarms screen, see Section IV.15. Pressing Diagnostic Alarms jumps to the Diagnostic

Alarms screen, see Section IV.16. Pressing BACK jumps to the Fault Screen, see section

IV.13, and pressing MENU jumps to the Screen Selection screen, section IV.4.

Figure IV.17 Alarm Description Screen

35

15. OPERATION ALARMS SCREEN

The Operation Alarms Screen provides a selectable menu of operation alarms. Pressing

ESC returns to the Alarm Descriptions Screen (Figure IV.17). Pressing NXT shows

more of the operation alarms. UP or DWN scrolls through the various alarms and ENT

selects the specific alarm screen. Section IV.17 is an example of the description seen

when selecting the High Water Temp option as seen below. It is recommended that the

operator refer to the Alarm Conditions section of this manual for additional information.

Figure IV.18 Operation Alarms Screen

16. DIAGNOSTIC ALARMS SCREEN

Below is the Diagnostic Alarm Screen that provides a selectable menu of diagnostic

alarms. Pressing ESC returns to the Alarm Descriptions Screen (Figure IV.17). Pressing

NXT shows more of the diagnostic alarms. UP or DWN scrolls through the various

alarms and ENT selects the specific alarm screen. Section IV.18 is an example of the

description seen when selecting the VFD Fault option as seen below. It is recommended

that the operator refer to the Alarm Conditions section of this manual for additional

information.

36

Figure IV.19 Diagnostic Alarms Screen

17. HIGH WATER TEMPERATURE SCREEN

Provides a brief description of a high water temperature alarm condition. The other

operation alarm condition description screens are similar to this screen. It is

recommended that the operator refer to the Alarm Conditions section of this manual for

additional information on alarm conditions. Pressing the BACK button returns the

operator to the Operation Alarms menu screen in Section IV.15.

Figure IV.20 High Water Temperature Screen

18. VFD FAULT SCREEN

37

Provides a brief description of a VFD fault alarm condition. The other diagnostic alarm

condition description screens are similar to this screen. It is recommended that the

operator refer to the Alarm Conditions section of this manual for additional information

on alarm conditions. Pressing the BACK button returns the operator to the Diagnostic

Alarms menu screen in Section IV.16.

Figure IV.21 VFD Fault Screen

19. CYCLE TIMER SCREEN

On evaporators where the wastewater boiling point does not have an appreciable rise as

the water concentrates, the cycle timer on the PLC can be enabled to control the

evaporator run time.

Cycle Time SP (in hours) – sets the number of running hours before the Cycle Timer

expires. After setting or changing the time, use Cycle Timer Reset to update the new

hours value into the cycle timer. This will also reset the counter.

Cycle Timer Enable – enable the Cycle Timer so that it will shut down the evaporator.

Cycle Timer Reset – resets the cycle timer counter. After the Cycle Timer has shut down

the evaporator, it is necessary to reset the Cycle Timer.

Remaining Time – time in hours and minutes remaining before shutdown.

When the timer counts down to zero, an indicator message will appear on the display

panel. At this point the evaporator should be cleaned and prepared for normal operation.

The Cycle Timer must be reset before restarting the evaporator. Please contact ENCON

Evaporators Service Personnel for a suitable cycle timer setting.

38

NOTE: The Cycle Timer will not shut down the evaporator unless the timer is enabled.

NOTE: The cycle timer only counts down when the burner(s) are running and the wastewater

solution is above 200F.

NOTE: If purchased and enabled, the system will enter the Auto Dump operations when the Cycle

Timer times out. Otherwise, the system will need to be manually emptied or decanted.

Figure IV.22 Cycle Timer Screen

20. FACTORY SETTINGS SCREEN

This setting allows the user to access factory settings. ENCON service personnel must be

contacted to gain access to these screens.

Figure IV.23 Factory Settings Screen

39

V. SYSTEM MAINTENANCE

1. INTRODUCTION

The type and frequency of system maintenance will vary widely depending on the type of

waste stream that is being introduced to the evaporator. Waste streams that are heavily

loaded with solids will require more frequent inspection to insure that solids are not

encroaching on or coating the heating elements and/or level probes. Clean rinse water

applications will require inspections perhaps no more than once per year.

For typical applications, we recommend the following system maintenance and

frequency:

2. TANK/HEATER RINSE DOWN

The tank rinse down should be done every 3 months for a typical application. This will

remove any excess build-up or residue from both the evaporator tank and the heaters.

This can be done with a pressure spray and with the heaters in place. Adequate access to

the inside of the unit can be achieved by simply removing the left side lid assembly(s) (as

seen from the control panel of the evaporator) which can be done by removing the ¼-20

UNC bolts.

NOTE: If your wastewater solution has a high solids content or is very dirty, the tank should be

drained down after the first week of operation. If no buildup is apparent, the tank should be refilled,

run for another week, drained and inspected. Repeat this process until a need to clean the heaters

exists. Since everybody’s waste stream is different, it is important to establish the proper time

between cleanings. Once this time has been established, it can be implemented into a formal

preventative maintenance program.

Any contaminants too large to pump from the system can be raked out through the 6-inch

clean out flange at the bottom of the evaporator. Please note that solids will be less likely

to form if the system is drained when the liquid is hot (>200°F).

3. LEVEL PROBE INSPECTION/CLEANING

The level probes should be inspected for any build up either on or between the forks. If

residue begins to cake up on the level probes, they can start to behave erratically or cease

to function. The probes should be manually cleaned with a wire brush. A pressure

washer can also be used.

NOTE: Do not clean the probes with an air operated or electrically operated device. Be careful when

cleaning the probes as to not bend or damage the forks in any way.

40

4. MIST PAD CLEANING

If the Mist Pad Differential Pressure Alarm is not activated (High Air Pressure Alarm),

the mist pad should be routinely removed every 30 days for pressure washing and

inspection.

5. STACK INSPECTION

A visual inspection of the exhaust stack should be done every 3 months to insure that

there are no blockages or leaks. Remove blockages and repair leaks as necessary.

41

VI. ALARM CONDITIONS

The KOYO PLC in conjunction with the CMORE Micro operator panel constantly

monitors and displays information regarding the operation of the ENCON evaporator.

The panel could display either an operation alarm condition or a system diagnostic alarm

condition. Following are the recommended action items to take when an alarm condition

exists:

1. OPERATION ALARM CONDITIONS

A. High Water Temperature

This is a latching alarm condition that will cause the heaters to turn off and requires a

manual reset to reactivate the system. This alarm indicates the high temperature set point

has been reached for the wastewater solution in the evaporator. This may be an

indication that you have reached the end of your evaporation cycle and it is time to pump

out the concentrated residue. It could also indicate that a significant amount of oil has

accumulated in your system and it is time to decant the floating oil layer from your

system. After the evaporator has been off for 10-15 minutes, inspect the solution for any

indication of floating oil. If there is any floating oil, decant it from the evaporator

following the instructions below.

a. Decanting the Floating Oil Layer

Turn the auto switch from the auto to the off position. Open the hinged inlet to

evaporator tank and be in a position to view the oil weir and simultaneously reach the

manual fill switch on the OIT (NOTE: the oil overflow outlet must be plumbed to a drum

for receiving oil). Begin manually feeding water to the evaporator. Allow the level of

solution to rise over the weir and flow to the outlet and into the drum. When the last

droplets of oil are seen going over the weir, turn the auto switch back to the auto position

and resume automatic operation of the system.

If upon boiling, the operating temperature returns to a normal operating range, you can

continue operating in this mode of periodically decanting a floating oil layer indefinitely.

If after decanting, the boiling temperature only drops 1-2 degrees, this is an indication

that you are close to the end of your evaporation cycle and that you will need to pump out

the concentrated residue shortly.

NOTE: If the system is configured for auto dump operation, the high temperature set point will

trigger the auto dump sequence. If the system if configured for auto decant operation, the high

temperature set point will trigger the auto decant sequence. If the system is configured for auto

dump and auto decant operation, the high temperature set point will first trigger the auto decant

42

sequence. If the high temperature set point is reached again within 90 minutes after the auto decant

sequence is complete, the PLC will assume that oil is not the reason for the high water temperature

and the auto dump sequence will be triggered to empty the evaporator of its concentrated residue.

Furthermore, if the high water temperature set point is reached within 90 minutes after a completed

auto dump, then the evaporator will set the High Water Temp alarm.

b. Pumping Out the Concentrated Residue

Open the valve between the clean out flange and the residue pump. Turn on the pump by

opening the air supply valve. Pump the entire contents of the evaporator tank into the

residue tank. Once the evaporator is emptied, visually inspect for build up on the heaters

and clean as necessary. Secure the residue pump and close the valve on the clean out

flange outlet, turn the auto switch to auto and resume normal operation. As mentioned

earlier, if the autodump feature is applicable and is activated, the unit will automatically

empty itself into a residue tank provided that there is enough room in the residue tank to

hold the entire contents of the evaporator.

NOTE: Extreme caution should be taken while pumping hot residue from the evaporator cleanout.

High temperature (rated for >250F) plumbing and components should be used on the discharge line.

B. High Heater Temperature


manual reset to reactivate the system. This alarm indicates the high temperature set point

has been reached for the heaters in the evaporator. This may be an indication that the

heaters have become coated and are therefore not achieving good heat transfer efficiency.

Drain the evaporator tank and inspect the heaters for any coatings or build up of solids

that may restrict the transfer of heat from the heaters to the water. Clean the heaters as

necessary by removing any solids.

C. High Air Pressure


manual reset to reactivate the system. This alarm indicates that the mist pad needs to be

removed for cleaning.

Power off the system and remove the mist pad by loosening the screws on the front of the

mist pad drawer and remove the drawer by grabbing the handle and pulling outward.

NOTE: Be aware of hot water and steam when removing the mist pad. Proper protective equipment

should be worn.

Once the drawer is removed, both the top and the bottom of the pad should be pressure

washed to remove build up. In particular, the bottom side may have significant build up

which is important to clean so that the airflow through the pad returns to normal. Once

the pad is cleaned, reinsert the drawer in the mist eliminator housing, reinsert the screws,

turn on the main power and manually reset the system.

43

NOTE: Do not remove the pad material from the drawer assembly.

NOTE: Do not pressure wash 2 Micron mist pads. 2 Micron mist pads can be identified by the

presence of fiberglass strands within the mesh material.

D. High Water Level

This alarm is activated when the water level in the evaporator tank has reached the high-

high level probe. This may be an indication that the high auto probe is dirty or has failed.

It also may occur after decanting a floating oil layer since the decanting process requires

the water level to be raised near the level of the high-high level probe.

This is a latching alarm condition and requires a manual reset to reactivate the system.

When the high level alarm is activated, the alarm message will be displayed on the OIT.

For the safety of the unit, the feed pump will be disabled and the unit will boil down to

the low-low probe. At this point, all probes should be inspected for coating or caked on

residue of any type. If such residue exists, clean the probes. If the probe has failed, the

display panel should give an indication of failure (See System Diagnostic Alarm

Conditions).

A foaming condition inside the evaporator could also cause the high water level alarm to

come on. If foaming is dense enough (specific gravity is greater than 0.7), the probe

could think that it has water on it when it fact it is covered with foam. If this is the

problem see the troubleshooting section of this manual for more details.

If the cause of the alarm can not be determined contact the ENCON Evaporators service

department.

E. Low Water Level

This is a non-latching alarm condition that is caused by the water level falling to the low-

low level probe. In normal operation, when there is no longer water in the holding tank

upstream of the evaporator, the wastewater in the evaporator tank will evaporate down to

the low-low level probe and thereby activate the low liquid level alarm. Once more water

accumulates in the holding tank upstream of the evaporator, the fill process to the

evaporator will resume automatically.

F. Holding Tank Level Alarm

This alarm is activated when the water level in the evaporator holding tank (if applicable)

falls below the float switch operating level. At this point, the system will continue to

operate normally until the wastewater in the tank evaporates to the low-low level probe

and triggers the low liquid level alarm. Once more water accumulates in the holding tank

upstream of the evaporator, the fill process to the evaporator will resume automatically.

44

G. Residue Tank Full (Auto Dump)

This alarm is applicable on Auto Dump units and indicates that there is insufficient

available residue tank volume for a complete tank dump. The residue tank should be

emptied as soon as possible to keep the evaporator running uninterrupted. If the residue

tank probe is covered and the evaporator attempts to initiate an Auto Dump cycle, then

the machine will enter a latching alarm condition and will not dump. This is a safety that

prohibits the evaporator from discharging residue to a full tank. The operator will need to

empty the residue tank and press the reset button to resume operation. For failsafe

reasons, if there is not a residue tank level probe installed the OIT will display this

message and the system will not operate.

H. High Condensate Level Alarm (Condenser units only)

This is a latching alarm condition that requires a manual reset of the system. This alarm

is activated when the condensate tank has become full. When this alarm occurs, the

heaters will shut off but the blower will continue to run for 30 minutes to discharge all of

the steam from the system. When the tank is emptied and the system is reset, normal

operation will resume.

I. Oil Tank Level Full Fault (Auto Decant)

This is a latching alarm condition that requires a manual reset of the system. This alarm

is activated if the auto decant operation starts and the oil tank level probe indicates that

the oil tank is full. If there is an oil tank present but not an oil tank level probe, a jumper

will have to be installed to the PLC input in order for the auto decant function to work.

NOTE: WITH THE ABOVE MENTIONED JUMPER IN PLACE, THERE IS A POSSIBILITY OF

OVERFLOWING THE OIL TANK DURING AN AUTO DECANT SEQUENCE. MONITOR THE

OIL LEVEL CLOSELY IF A JUMPER IS IN PLACE.

J. Decant High Level Fault (Auto Decant)

This is a latching alarm condition that requires a manual reset of the system. In the event

the oil/water level rises too high above the oil weir, the high water level alarm will

activate. In the event the high water level alarm activates during the decanting process,

the feed isolation valve (if applicable) will close and the feed pump will stop. When the

high water level alarm has been clear for 30 seconds, the feed sequence will re-initiate

and the decanting operation will continue. In the event the high water level alarm remains

active for more than 2 minutes, the decant high level alarm will occur. This indicates

45

there is either a problem with the oil decant valve, oil decant pump, or a blockage in the

oil decant piping.

K. Cycle Timer Expired

This alarm is activated when the evaporator is shut down after the Cycle Timer times out.

This is a latching alarm that will cause the evaporator to cease to operate. This is an

indication that the tank contents have been fully concentrated and that the tank residue

needs to be dumped and cleaned before continuing operation. The cycle timer will need

to be reset before continuing to evaporate. To reset the timer refer to Section IV of this

manual.

2. SYSTEM DIAGNOSTIC ALARM CONDITIONS

A. Low Air Pressure

This alarm is activated in the event that the blower motor on top of the unit should fail or

power is somehow lost to it. This is a non-latching alarm condition that will cause the

evaporator to cease to operate since the pressure transducer does not detect any airflow.

Should this alarm occur, all circuit breakers and fuses to the blower should be inspected

thoroughly to ensure that power has not been interrupted. If the blower motor has power

going to it and still does not operate, contact ENCON Evaporators service department.

B. Water Temperature Failure

This alarm is activated in the event that the thermocouple that measures the wastewater

temperature should break or be damaged in any way that results in a failure of operation.

This is a non-latching alarm condition that will cause the evaporator to cease to operate

due to the nature of operation of the thermocouple in conjunction with the PLC. Should

this warning be displayed, the operator should turn off power to the evaporator and check

the thermocouple wire connections at the water thermocouple transmitter on the blower

side of the evaporator. Please note that in order to get to the transmitter, the operator must

unscrew the cover to the protective transmitter head. Once the cover is unscrewed, verify

that there are no loose connections and no damaged wires. If all connections are tight and

the message is still displayed when power is restored to the evaporator, contact ENCON

Evaporators service department.

46

C. Heater Temperature Failure

This alarm is activated in the event that the thermocouple that measures the temperature

of the heaters should break or be damaged in any way that results in a failure of

operation. This is a non-latching alarm condition that will cause the evaporator to cease

to operate due to the nature of operation of the thermocouple in conjunction with the

PLC. Should this warning be displayed, the operator should turn off power to the

evaporator and check the thermocouple wire connections for the heater thermocouple

transmitter in the control/aux panel. If all connections are tight and the message is still

displayed when power is restored to the evaporator, contact ENCON Evaporators service

department.

D. Air Pressure Failure

This alarm is activated in the event that the pressure transducer located on the back of the

blower shelf fails to send a signal back to the PLC. This is a non-latching alarm

condition that will cause the evaporator to cease to operate due to the airflow limits set

inside the PLC. Should this warning be displayed, the operator should turn off power to

the evaporator and check the wire connections running from the transmitter to the PLC.

The translucent plastic tubing running from the mist eliminator to the transmitter should

also be checked to make sure that they have not become loose or cracked. Remove the

hoses from the pressure transducer one at a time and blow them out to eliminate any

moisture in the tubes. Replace the tubes after moisture has been eliminated. If all

connections are tight and the integrity of the tubing has not been compromised, contact

ENCON Evaporators service department.

NOTE: Do not blow toward the sensor. Blowing toward the sensor will destroy the sensor.

E. Hi Level Probe Failure

This alarm is activated in the event that the high-high probe fails to send a signal back to

the PLC. This is a latching alarm that will cause the evaporator to cease to operate.

However, since the high-high level probe acts as a redundant safety, in the event that both

the high-high and the high-auto probes failed, the PLC would not know to shut the feed

pump off and would overflow the system. Should this warning be displayed, the operator

should open the hinged lid on the top of the system to inspect the probe for any corrosion

or sediment caked on the forks. If the forks on the probe are dirty, drain the wastewater in

the evaporator down below the level of the forks and use a pressure washer and/or a small

wire brush to remove any caked on sediment. If the message still appears turn off power

to the unit and remove the black probe receptacle connection to check for loose wires or

condensation inside the connector. If there are no loose wires or condensation, tighten the

connection. If the message still appears when power is restored, contact ENCON


47

F. High Auto Probe Failure

This alarm is activated in the event that the high-auto probe fails to send a signal back to


However, since the high auto probe controls the level at which the feed pump stops

feeding water to the evaporator, the wastewater would fill up to the high-high level probe

before the pump was shut off. Since the high-high level probe acts as a safety, in the

event that both the high-high and the high-auto probes failed, the PLC would not know to

shut the feed pump off and would overflow the system. Should this warning be displayed,

the operator should open the hinged lid on the top of the system to inspect the probe for

any corrosion or sediment caked on the forks. If the forks on the probe are dirty, drain the

wastewater in the evaporator down below the level of the forks and use a pressure washer

and/or a small wire brush to remove any caked on sediment. If the message still appears

turn off power to the unit and remove the black probe receptacle connection to check for

loose wires or condensation inside the connector. If there are no loose wires or

condensation, tighten the connection. If the message still appears when power is restored,

contact ENCON Evaporators service department.

G. Low Low Probe Failure

This alarm is activated in the event that the low-low probe fails to send a signal back to


Since the low-low probe is used to enable the heaters the unit will not operate until the

problem is rectified. Should this warning be displayed, the operator should open the

hinged lid on the top of the system to inspect the probe for any corrosion or sediment

caked on the forks. If the forks on the probe are dirty, drain the wastewater in the

evaporator down below the level of the forks and use a pressure washer and/or a small

wire brush to remove any caked on sediment. If the message still appears turn off power

to the unit and remove the black probe receptacle connection to check for loose wires or

condensation inside the connector. If there are no loose wires or condensation, tighten the

connection. If the message still appears when power is restored, contact ENCON


H. VFD Fault

This alarm is activated in the event that the VFD fails to send a signal back to the VFD

Fault Input of the PLC. If the VFD fails, the blower will not run. The VFD fault is a

redundant safety.

NOTE: The main blower should not be turned back on within 5 minutes of being shut off.

48

I. Limit Switch Open Error

This message is applicable for auto dump units only. If the auto dump valve doesn’t send

a signal back to the PLC indicating that it is open, (i.e. the valve is closed and it is

supposed to be open) this message will be displayed. Check the wires in the panel and

valve to ensure that they are tight. If there are no obvious problems and the message is

still displayed after the system is reset, contact ENCON Evaporators service department.

J. Limit Switch Closed Error

This message is applicable for auto dump units only. If the auto dump valve doesn’t send

a signal back to the PLC indicating that it is closed, (i.e. the valve is open and it is

supposed to be closed) this message will be displayed. Check the wires in the panel and

valve to ensure that they are tight. If there are no obvious problems and the message is

still displayed after the system is reset, contact ENCON Evaporators service department.

K. Decant Valve Closed Failure

This message is applicable for auto decant units only. If the oil decant valve fails to open

when it is supposed to or it opens but the open indication switch in the valve does not

operate during the auto decant sequence, this alarm will be displayed. Check the wires in

the panel and valve to ensure that they are tight. If there are no obvious problems and the

message is still displayed after the system is reset, contact ENCON Evaporators service

department.

L. Decant Valve Open Failure

This message is applicable for auto decant units only. If the oil decant valve fails to close

when it is supposed to or it closes but the closed indication switch in the valve does not

operate during the auto decant sequence, this alarm will be displayed. Check the wires in

the panel and valve to ensure that they are tight. If there are no obvious problems and the

message is still displayed after the system is reset, contact ENCON Evaporators service

department.

49

VII. TROUBLESHOOTING

Please refer to the following list of symptoms and corrective actions. Any work must

conform to OSHA requirements and local codes of the authority with jurisdiction. In the

absence of local codes in the United States, the work must conform to the latest editions

of NFPA-70, National Electric Code. In the absence of local codes in Canada, the work

must conform to the latest edition of C22.1, Canadian Electric Code, and Safety

Standard for Electrical Installations:

1. NOTHING HAPPENS WITH THE MAIN POWER SWITCH ON

Check the following to determine the cause of the problem:

Is there 110 VAC coming into terminals 4X1 and N of the control panel?

Yes: Continue troubleshooting.

No: Ensure that the main power feed to the auxiliary panel is the correct voltage.

NOTE: On three phase units, 110 VAC is provided to the control panel through a transformer.

Are the fuses/circuit breakers inside the control/Auxiliary panel blown?

Yes: Check for any loose connections or a condition that would cause a short circuit. If

nothing out of the ordinary is found contact ENCON Evaporators service personnel.

No: Refer to the electrical schematic in the back of the manual to determine the

problem. If the problem can’t be determined, contact ENCON Evaporators service

department.

2. FEED PUMP DOES NOT START


Is the evaporator calling for water (is the level below the high auto probe)?


No: If the water level in the evaporator tank is not lower than the high auto probe (2nd

down from the top), the unit will not call for water.

Is the feed tank empty?

50

Yes: If the feed tank is empty and a holding tank level probe is installed, the feed pump

will not operate. The machine is designed this way to prevent the pump from running

dry.

No: Continue troubleshooting.

Is there a holding tank float switch wired into the machine?

Yes: Ensure that the leads for the holding tank float switch are wired into the proper

terminals. If the wires are connected properly, continue troubleshooting.

No: If there is no holding tank level switch wired into the machine, the feed pump will

not operate. A jumper wire must be installed.

NOTE: By putting a jumper in place, if the holding tank empties the feed pump will run dry until

water starts to fill the holding tank again. Although the Wilden air actuated pumps can be run dry,

caution should be taken to prevent this.

Are you using an air actuated pump to fill your system?


No: If you are using something other than an air actuated pump, the current draw for

the pump must be less than 1A. Otherwise, a motor starter must be installed to operate

the pump. If you have tried to drive a pump that draws more than 1A, it is possible that

you have burnt out the PLC output. Contact ENCON Evaporators to discuss this

possibility.

Is the air to the pump on?

Yes: Verify that proper air pressure is present at the filter regulator of the pump and that

the regulator and needle valve are open. The pump requires 50-60 psig of air pressure to

operate well. If everything checks out, continue troubleshooting.

No: Turn the air to the pump on.

Do you have an isolation valve in your feed line?

Yes: Verify that the isolation valve is wired into the same terminals as the feed pump air

solenoid. Make sure that the combination of the current draw of the valve and the current

draw of the feed pump air solenoid does not exceed 1A. If you have tried to drive a valve

and a pump that draws more than 1 A combined, it is possible that you have burnt out the

PLC output. Contact ENCON Evaporators to discuss this possibility.


Is the feed pump air solenoid wired into the proper terminals?

Yes: Continue Troubleshooting.

51

No: If the feed pump air solenoid is not wired into the proper terminals, the pump will

not operate correctly.

Is the Cycle Timer enabled?

Yes: Reset the cycle timer if the evaporator was shut down by the cycle timer. The

machine will not restart after timing out until the operator accesses the Cycle Timer

submenu on the operator interface panel and resets the timer.

No: If the problem cannot be resolved after checking the above list of symptoms, please

call ENCON Evaporators service department.

3. HEATERS WILL NOT ENERGIZE


Is the main power switch in the on position and auto switch in the auto position?


No: Put the switches in their proper positions and try to start the heaters again.

Is the evaporator tank full to at least the low-low probe (3rd

probe down from the

top)?


No: Let the unit fill up to the low-low probe. 30 seconds after the probe has been

completely covered, the heaters should receive power and begin warming.

Is the evaporator in an alarm state?

Yes: Read the message that is displayed on the operator interface. Determine if you can

solve your problem based on the information in the alarm section of this manual.


Is the heater light illuminated on the panel?

Yes: This indicates the PLC output is ON.

No: Open the panel and check for 24 VDC across the heater light socket. If 24 VDC is

present, check the LED to ensure that it is tight in the socket. If it is tight, call ENCON

Evaporators to order a new LED and continue troubleshooting.

52

Is the Cycle Timer enabled?

Yes: Reset the cycle timer if the evaporator was shut down by the cycle timer. The

machine will not restart after timing out until the operator accesses the Cycle Timer

submenu on the operator interface panel and resets the timer.

No: Continue Troubleshooting.

If the heaters will still not start after checking the above list of symptoms, please call

ENCON Evaporators service department for assistance.

4. LEAKAGE OF WASTEWATER FROM THE SYSTEM

There may be a small amount of leaking at start-up around the cleanout flange due to the

gaskets needing to soften, setup, and seal. If there is a leakage detected sometime after

the first few hours of operation, check the following:

Is the leak coming from the tank?

Yes: If leak appears to be coming from the evaporator tank, pull a 1-quart sample of

water from the evaporator and send to ENCON Evaporators. Contact ENCON

Evaporators immediately to notify of findings. If the water leaking from the tank is clear

water, chances are that it is steam that is condensing from somewhere and leaking out. If

the water leaking from the tank is similar to the wastewater being processed, there could

be a tank leak.


Is there foam in the evaporator/is the boil very vigorous?

Yes: If there is a lot of foam in the evaporator during boiling and/or the boil is very

vigorous, the wastewater could be running down the sides of the tank.


If you are unable to determine the cause of your leak, contact ENCON Evaporators

service department.

5. FOAM OVERFLOWS FROM THE EVAPORATOR

Some customer’s waste streams have a tendency to foam. The following steps can be

taken if this is a problem.

53

Is it important that your evaporator run at full capacity to keep up with your

wastewater generation?


No: The cheapest and quickest option is to reduce the heat input to the evaporator. In

most cases disabling one heater by removing the fuses/switching off the circuit breaker

will reduce the foam to manageable levels. However, if the evaporator will not keep up

with the wastewater generation of the plant at a reduced rate, other options will have to

be looked into.

Do you have a floating oil layer?

Yes: If you have a floating oil layer in your evaporator, it must be removed by

following the procedure for decanting the floating oil layer. A floating oil layer will

reduce the evaporation efficiency of the unit and it will cause the solution to foam when

boiling.


Do you have the optional Anti-Foam System (AFS)?

Yes: Continue troubleshooting

No: Contact ENCON Evaporators to discuss the details of adding the AFS. The system

automatically meters in the proper amount of anti-foam solution to control foaming in

your evaporator.

Is the AFS metering pump connected, turning on and pumping anti-foam solution

when the Wastewater Feed Pump turns on?


No: Verify that the pump receives power when the Wastewater Feed Pump is on, that

the on/off switch on metering pump is on and that the system is purged of air and that the

anti-foam container is not empty.

Is the AFS pump pumping the proper dosage?


No: Adjust the frequency/stroke settings as necessary. See Section I for antifoam

settings.

6. EVAPORATION RATE IS INADEQUATE BUT NO ALARMS

54

The evaporation rates of ENCON Evaporators are based on boiling tap water at sea level.

Wastewater solutions that have a high solids concentration, are heavily oil laden, or

installed at high altitudes may not boil at the quoted rate. However, if your evaporation

rate has been decreasing over a period of time, check the following.

Pull the heaters and inspect for build up.

Is there any coating on the outside of your heaters?

Yes: Any build up on the outside of the heaters will decrease the evaporation efficiency

and could cause damage to the heaters over time.

NOTE: The best way to keep the efficiency of your unit high is to keep the heaters clean. A good

preventative maintenance program should include an inspection of the heaters.


Is the air gate open an excessive amount?

Yes: The air gate on the end of the unit opposite the blower should be opened

approximately ½”.


If you are unable to determine the cause of your problem, contact ENCON Evaporators

service department.

7. ERROR MESSAGE ON THE PLC DISPLAY PANEL

Review the Alarm Conditions section of the manual to determine the cause of the error

message and contact ENCON Evaporators to determine if any item needs to be replaced.

Evaporation System Exhausts Clean Water Vapor

EVAPORATOR

www.evaporator.com

Distillation System Converts Wastewater to Clean Water

THERMAL

A Wide Variety of Heat Sources Including: • Natural Gas • Propane • Steam • #2 Fuel Oil • Diesel • Kerosene • Electricity • Waste Oil • Off-Spec Landfill Gas

Helps Reduce the Costs and Liabilities of Waste Disposal

Easy to Install and Operate

Eliminates Need to Discharge Wastewater

Dramatically Reduces Disposal Volume and Cost

Handles Different Wastewater Streams…Simultaneously!

Cost Effective Wastewater Minimization

High Quality Components and Superior Design

ENCON Evaporation and Distillation Systems are engineered to provide you with the most effective and economical method of wastewater minimization possible.

All ENCON systems are assembled with the highest quality components, ensuring years of trouble free operation.

Our unique heat exchanger design on our thermal units provides extremely efficient heat transfer, resulting in reduced fuel costs.

Key to the effectiveness of out ENCON Thermal Evaporators is the Mist Eliminator. This feature captures unwanted contaminants before exhausting, thus enabling you to comply with today’s stringent emissions regulations (evaporation) or to return high quality water to your process (distillation).

Put Our Engineering and Regulatory Expertise to

Work for You

ENCON Evaporators provides the following services relative to evaporation/distillation projects:

• Free wastewater qualification analysis to ensure application feasibility

• Regulatory compliance and paperwork

• System design and compliance for hazardous waste applications

• PLC programming to optimize system automation

• Closed loop recycling evaluation and analysis

Redundant Burner Contactors Each burner has a duty contactor and a redundant contactor. This design ensures maximum safety by opening the redundant contactor in the event the duty contactor should fail electrically or mechanically.

Built-in Ethernet Port Every control panel has a built-in ethernet connection, which allows for easy remote program modifications and/or troubleshooting of the system by ENCON personnel.

Level Sensing

Tuning fork level probes provide reliable auto-filling and shutdown operations even in conditions of severe foam. The durable level probes are made of stainless steel for excellent corrosion resistance. Hastelloy level probes are available for highly corrosive applications.

PLC Control Panel NEMA 4 PLC control panel with touch screen OIT provides readout of wastewater and heated air temperatures, mist pad pressure, plus alarm and operating conditions for maximum operator feedback. The OIT also includes a built-in cycle timer.

Before purchasing an evaporation or

distillation system, challenge the

vendor to explain their mist eliminator

design.

Over the years,

evaporators have been

notorious for exhausting

contaminants, which

can be detrimental to

the environment.

Effective mist capturing

systems must have the

following features in

order to pass the ever

tightening federal and

state environmental

regulations:

• Compression fit mist pad to capture entrained contaminants

• Mist pad rated to 10 microns or less to capture even the smallest droplets

• Stainless steel mist pad and housing to ensure long term integrity and aesthetics

• Adequate buffer zone between the water level and mist pad, to allow fallback of the contaminants

• Monitoring of mist pad loading to ensure consistent airflow and evaporation rates

• Easy removal of the mist pad to minimize manpower requirements

Result in Excellent Long Term Performance!!!

Mist Eliminator System The stainless mesh filter is designed for easy removal from its compression fit housing. The system is monitored for contaminant loading and airflow, which is interlaced to the control panel for maximum operator feedback.

Forced Draft Burner Each fuel heated system consists of a burner with: Honeywell controls; pressure gauge and gas volume meter for monitoring gas inlet conditions; airflow detection and lockout; spark ignition; redundant main valve and burner cont- tactors for maximum safety. FM gas trains and gas flow transmitters are standard on larger systems. The stainless steel burner protection shroud is mounted on a track hanger for ease of removal and reattachment. Natural gas, Propane, Dual Fuel, Oil, Diesel, Waste Oil and Low NOX burners are available.

Blower System 1725 RPM, TEFC Motor with Class B Insulation rated for high temperatures. Extremely quiet operation and as much as three times the longevity of 3450 RPM motors. Heavy gauge aluminum blower provides durability and longevity.

Cleanout Flange Large six inch cleanout with flange cover and a 1 ½” NPT fitting for pump connection and ease of residue removal.

Exhaust Scenarios

ENCON Evaporators

1368 Hooksett Rd, Unit #9 • Hooksett, NH 03106-1823 USA

T 603-624-5110 • F 603-627-9520

www.evaporator.com • [email protected]

Typical Operation 1. Wastewater is either

pumped or gravity fed into the system through a 1” NPT fitting on lid.

2. As the wastewater flows into the system and reaches the low-low level probe, the burner(s) will fire.

3. Wastewater will continue to feed until it reaches the high-auto level probe.

4. The burner(s) fire into the combustion chamber and the hot gases travel past the vertical tubes inside the heat exchanger until they reach the insulated chimney outside the evaporator tank (see Exhaust Scenarios).

5. The wastewater is heated to boiling and is driven off as clean water vapor.

6. As the water vapor is driven off, the liquid level will gradually fall to the low-auto level probe. Upon reaching the low-auto level, the system will refill itself to the high-auto level.

7. This process will continue until either the water reaches the high temperature set point or the cycle timer counts down to zero.

We Encourage You to Speak to Our Valued Clients

about the ENCON Systems

and Our Superior

Customer Service

Evaporation System

The flue gases are pulled back

into the evaporator, mixed

with the ambient air and drawn

across the surface of the

boiling water. The exhaust

blower pulls the combined

steam and gases through the

mist eliminator and pushes

them up through the stack and

outside the building.

Distillation System

The flue gases are not pulled

back into the evaporator.

Instead, they are vented

separately up their own stack.

The recirculation blower pulled

the steam through the mist

eliminator and pushed it

through the condenser. The

clean water is directed to a

sump and the dehumidified air

is returned to the system.

Project Item Number Quantity _________________________________ ______________________________ ________________

ENCON Evaporators

www.evaporator.com

1368 Hooksett Rd., Unit 9, Hooksett, NH 03106 USA Tel. (603) 624-5110 Fax: (603) 627-9520 Email: [email protected]

ENCON ENERGY CONSCIOUS INNOVATION

ENCON

EEnneerrggyy CCoonnsscciioouuss IInnnnoovvaattiioonn

Printed in the USA Rev 3

TH

ER

MA

L E

VA

PO

RA

TO

R

Ex

xV

x-1

5

MADE IN THE USA ExxVx-15

ENCON Thermal Evaporator

� Handles Different Wastewater Streams Simultaneously

� Dramatically Reduces Disposal Volume and Cost

� Eliminates Need to Discharge Wastewater

� Easy to Install and Operate

Put Our Engineering and Regulatory

Expertise to Work for You! ENCON Evaporators provides the following services relative to evaporation/distillation projects:

� Free wastewater qualification analysis to ensure application feasibility

� Regulatory compliance and paperwork � System design and compliance for

hazardous waste applications � PLC programming to optimize system

automation � Closed loop recycling evaluation and

analysis

ENCON Thermal Evaporators and Distillation Systems are engineered to provide you with an effective and economical method of wastewater minimization. All ENCON systems are assembled with the highest quality components, ensuring years of trouble free operation. Key to the effectiveness of ENCON evaporation systems is the mist eliminator. This feature of the ENCON design captures unwanted contaminants before exhausting, thus enabling you to comply with today’s stringent emissions regulations (evaporation) or to return high quality water to your process (distillation).

Model Number Nomenclature

E32V1-15: First character equals heat source, in this case electric heaters.

E32V1-15: Second character indicates the evaporation tank material of construction, in this case 316ss.

E32V1-15: Third character indicates the heat exchanger material of construction. In this case it is Hastelloy C.

E32V1-15: Fourth & fifth characters indicate the type of control unit. In this case it is the version 1 logic and controls.

E32V1-15: The last character indicates evaporation rate based on tap water. In this case it is 15 gallons per hour.

ENCON ExxVx-15 SPECIFICATIONS


ENCON ENCON Evaporators

www.evaporator.com


Printed in the USA Rev 3

PHYSICAL EVAPORATION UNIT DISTILLATION UNIT

Dimensions : 68” x 30” x 81” (L x W x H) 68” x 41” x 81” (L x W x H)

Weight (Empty): 850 lbs (empty) / 1200 lbs (crated) 1100 lbs (empty) / 1400 lbs (crated)

Condenser Size: N/A 4”∅ x 18”L (1-1/2” FNPT chill water fittings)

Vent Stack Diameter: 4” OD N/A

Blower Volume: 300 CFM, 1/2 HP, 1725 RPM

Inlet Pipe Diameter: Fluid - 1” FNPT

Cleanout Diameter: 6” Flanged Cap with 1.5” FNPT fitting

Heating Elements: Two 20 kW low watt density immersion heaters

Tank Capacity: 89 gallons @ Low level, 110 gallons @ Auto-run level, 123 gallons at High level

Tank Bottom: 8° downward slope to a 6” cleanout flange

UTILITIES EVAPORATION UNIT DISTILLATION UNIT

Electric Requirements: 480 VAC, 3 Phase, 55 Amps (or 240 VAC, 3 Phase, 110 Amps)

Cooling Water: N/A 24 gallons per minute @ 90°F (11 tons)

FABRICATION 316SS VERSION 6% MOLY VERSION HASTELLOY

VERSION

Tank: 316L Stainless, 14 ga 6% Molybdenum, 14 ga Hastelloy, 14 ga

Heating Elements: 316L Stainless Sheath Titanium Sheath Titanium Sheath

Mist Eliminator Pad: 316L Stainless

Skins and Lids: Polished 304 Stainless Steel, 18 ga

Insulation: All 6 sides, rated to 450F, R = 4.3

CONTROLS ALL UNITS

Temperature Controls: Four (4) channel analog card with 2 Type J Thermocouples:

Fluid Concentration Monitoring & Element Intake/Redundant Low Level Shut-off

Control Inputs: 3 Frequency Shift Level Probes and Mist Pad Differential Pressure Transducer

Remote Connection: Ethernet port for direct connection by ENCON Engineers

UL Listed, NEMA 4, PLC Control Panel

Touch screen operator Interface Display with messages for normal & alarm conditions.

Main power selector switch

Indicators (2) – Main Power, Heater(s)

Control Panel:

QUALITY ALL UNITS

Leak Test: Dye penetrant test performed on tank welds

I/O Simulation: All I/O and controls are fully tested to insure accuracy/functionality

Warranty: One Year for Parts and Workmanship Issues

Specifications subject to change without notice.

THE ENCON ADVANTAGE High Quality Components and Superior Design




www.evaporator.com


Printed in the USA 11/09

PLC Control Panel NEMA 4 PLC touch screen control panel provides readout of wastewater and heated air temperature, mist pad pressure, plus alarm and operating conditions for maximum operator feedback. The panel also includes a built-in cycle timer.

Built-in Ethernet Connection Every control panel has a built-in Ethernet connection. This allows for easy remote monitoring and/or troubleshooting of the system by ENCON personnel.

Level Sensing Tuning fork level probes provide reliable auto-filling and shutdown operations even in conditions of severe foam. The durable level probes are made of stainless steel for excellent corrosion resistance. Hastelloy level probes are available for highly corrosive applications.

Redundant

Burner Contactors Each burner has a duty contactor and a redundant contactor. This design ensures maximum safety by opening the redundant contactor in the event the duty contactor should fail electrically or mechanically.

Blower

System 1725 RPM, TEFC motor with class B insulation rated for high temperatures. The unit’s design provides extremely quiet operation and

as much as three times the longevity of 3450 RPM motors. Heavy gauge aluminum blower provides durability and longevity.

THE ENCON ADVANTAGE High Quality Components and Superior Design




www.evaporator.com



Forced Draft Blower Each fuel-heated system consists of a burner with:

• Honeywell controls • Pressure gauge and gas volume meter for

monitoring gas inlet conditions • Airflow detection and lockout • Spark ignition • Redundant main valve and burner

contactors for maximum safety FM gas trains and gas flow transmitters are standard on larger systems. The stainless steel burner protection shroud is mounted on a track hanger for ease of removal and reattachment. Natural gas, Propane, Duel fuel, Oil, Diesel, Waste oil and low NOX burners are available.

Mist Eliminator System The stainless mesh filter is designed for easy removal from its compression fir housing. The system is monitored for contaminant loading and airflow, which is interfaced to the control panel for maximum operator feedback.

Cleanout Flange Large six inch cleanout with flange cover and a 1 ½” NPT fitting for pump connection and ease of residue removal.



www.evaporator.com

1368 Hooksett Rd. Unit 9, Hooksett, NH 03106 USA Tel. (603) 624-5110 Fax: (603) 627-9520 Email: [email protected]

PROCESS DESCRIPTION OF ELECTRICALLY HEATED

ENCON EVAPORATORS 1. Wastewater is collected in a primary holding tank/sump. 2. Water is either pumped or gravity fed into the evaporator through a 1” NPT fitting on lid. 3. The three (3) level controls in the standard auto-fill system provide the following:

a) The low level controls the low watt density heating elements operation (on/off). b) The auto-run level controls water level in tank when in auto run mode. c) The high level acts a redundancy to the auto-run level.

4. As the fluid flows into the evaporator and reaches the low level, the heating elements will energize. 5. Fluid will continue to flow until it reaches the auto-run level. The feed pump or actuated ball valve will be

de-energized/closed. 6. As the fluid comes to a boil and begins the evaporation process, the liquid level will drop below the auto-run

level. The feed pump or actuated ball valve will be energized and more fluid will be fed into the Evaporator based on a timed cycle controlled by the PLC and the auto run probe until it reaches the auto-run level.

7. This process will continue until either the fluid temperature reaches the high set point or the optional cycle

timer counts down to zero. 8. When activated, the heating elements will heat the wastewater. As the wastewater heats up, it will begin to

generate water vapor. There are two ways the water vapor may be vented:

a) If the customer has chosen an Evaporation Unit (vent to atmosphere), the exhaust blower pulls the water vapor through the mist eliminator and pushes it through the stack to the outside of your building.

b) If the customer has chosen the “closed loop” Distillation Unit (condenser package), the exhaust blower

pulls the water vapor through the mist eliminator and pushes it through the connection from the blower exhaust to the inlet side of the condenser. The condenser is horizontally mounted on the back-side of the evaporator tank. The water leaving the condenser is separated from the air stream and directed to an automated condensate sump while the air stream is returned to the evaporator.

VAPORATOR

NCON

EE

ENCON EVAPORATORS

ENCON ENCON Evaporators www.evaporator.com

1368 Hooksett Rd. Unit 9, Hooksett, NH 03106 USA Tel. (603) 624-5110 Fax: (603) 627-9520 Email: [email protected]


ENCON Electric Thermal Evaporators

Model

(Electric

Designations)

Evaporation

Rate

(Gals/Hour)

Heater

KW

(Electric)

Tank

Capacity

(Gallons)

Dimensions (Inches)

Length x Width x Height

Power

Required

Blower Description

CFM HP RPM Cleanout

Vent

OD

E33V1-8 8 24 70 55 x 30 x 72

480v/3ph/35A

or

240/3ph/70A

200 1/2 1725 4" + 1.5” NPT 4"

E33V1-15 15 40 115 68 x 30 x 81

480v/3ph/55A

or

240/3ph/110A

300 1/2 1725 6" + 1.5” NPT 4"

E33V1-24 24 72 165 85 x 30 x 83

480v/3ph/95A

Not Available

In 240v

450 3/4 1725 6" + 1.5” NPT 5"

E33V1-40 40 120 330 98 x 52 x 84

480v/3ph/150A

Not Available

In 240v

780 3/4 1725 6" + 1.5” NPT 6"

FABRICATION: PLC CONTROL PANEL:

Tank: 316L Stainless Steel, 14 Gauge 1 - Watertight main enclosure (NEMA 4,12,13) (6 % Moly Super Stainless(SSA) & Hastelloy C are also available)

2 - Selector switches (Main Power, Manual Fill) 1 - LCD Display for all status and alarm conditions including:

Heating Elements: 316L Stainless Steel Sheathed liquid temp & high liquid temp shut off, heater temp & high (Titanium available) heater temp shut off, mist pad loading, level probe malfunction. Skins: 304 Grained Finish Stainless Steel 1 - Warning lamp - All Alarm Conditions Insulation: 1” thick, all 6 sides, rated to 450°F 2 - Indicator lamps for: main power and burner 1 - Keypad for Setpoint modification CONTROLS: 1 - Cycle Timer - included – LCD Display PLC Controller: Koyo (Automation Direct) 1 – Modem – for remote service support (Allen Bradley available) Temperature Controllers: Thermocouple via PLC QUALITY:

Control Inputs: 4 - Frequency Shift Level Probes 1 - Primary Water Thermocouple

Leak Test: Dye penetrant test on welded tank I/O Simulation: To ensure accuracy of controls

1 -Heater Thermocouple 1 - Redundant Low Water Level Shutoff WARRANTY: One Year parts and workmanship

AVAILABLE OPTIONS

HEAT SOURCE

Electric

MATERIALS OF CONSTRUCTION 316 Stainless Steel

6% Moly Alloy (SSA) Tank with Titanium Heating Elements

Hastelloy C Tank with Titanium Heating Elements

CONTROL SYSTEMS

Auto-Fill (Standard) Auto-Fill & Auto-Dump Auto-Fill & Auto-Decant

Auto-Fill, Auto-Dump & Auto-Decant

MISCELLANEOUS Condenser

Combustion Kit Air Diaphragm Pumps

Holding Tanks Air Fluid Coolers

1 - Differential Pressure Transducer for Contaminant Loading

ENCON Evaporators

Common Parts to Stock for Exxx-15 ENCON #Recommended

QtyGASKET, CLEANOUT FLANGE 6" 3000128S 1GASKET, MIST PAD DRAWER 3001178S 1DRAWER, MIST PAD w/ GASKET INSTALLED 3001176S 1MOTOR, 1/2 HP, 230/460V, 3 PH, 60HZ, 1725 RPM, 56C, TEFC (Non Condenser) 2000741 1PROBE, LIQUIPHANT LEVEL SWITCH FTL20-331C, 316L, 3/4" 2001540 2TRANSFORMER, 240/480 PRIMARY, 120/240 SECONDARY,500VA, 1-PH 2000088 1FUSE, TIME DELAY, 3-1/2 AMP, 250V, TYPE FNM (230 or 460v Unit) 2000689 1FUSE, TIME DELAY, 2 AMP, 500V, TYPE FNQ (460v Unit) 2000547 3FUSE, FAST ACTING, 40AMP, 600V, TYPE JJS 2000736 6FUSE, TIME DELAY, 1-1/4 AMP, 500V, TYPE FNQ (460v Unit) 2000688 2CONTACTOR, MINI 120V, 10A INDUCTIVE W/1.1-1.6 OVERLOAD (460v Unit) 2000738 1CONTACTOR, 3-POLE, 40A RESISTIVE, 600V CH 2000740 2FUSE, TIME DELAY, ?? AMP, 500V, TYPE FNQ (230v Unit) TBD 3FUSE, FAST ACTING, ?? AMP, 600V, TYPE JJS (230v Unit) TBD 6FUSE, TIME DELAY, ?? AMP, 500V, TYPE FNQ (230v Unit) TBD 2CONTACTOR, MINI 120V, 10A INDUCTIVE W/ ?? OVERLOAD (230v Unit) TBD 1CONTACTOR, 3-POLE, ??A RESISTIVE, 600V (230v Unit) TBD 2LIGHT, LED RED - LSPD-120-R 2000158 2LIGHT, LED WHITE - LSPD-120-W 2000159 2SWITCH, LIGHTED 2-POS SELECTOR, GREEN 2000406 1THERMOCOUPLE WIRE FOR ELECTRIC HEATER (20FT) 2000537 1

Additional Parts to Stock for ExxY-15 (DL05 PLC Panel) ENCON # QuantityTHERMOCOUPLE, PROBE ASSY, TYPE J 2000332 1TRANSMITTER, DIGITAL TYPE J, 0-500DEG, 8-38VDC 2000334 1TRANSMITTER, DIGITAL TYPE J, 0-1000 DEG, 8-38VDC 2000640 1TRANSMITTER, DIFFERENTIAL PRESSURE, 0-1"WC WET/WET 2000369 1PLC, CPU KOYO DL05 2000136 1PLC, MODULE DL05 - ANALOG 4 CHANNEL INPUT 2000137 1PLC, MODULE DL05 - 24V PS 2000138 1PANEL, OPERATOR INTERFACE - 10 BUTTON 2000139 1

Additional Parts to Stock for ExxZ-15 (DL205 PLC Panel) ENCON # QuantityTHERMOCOUPLE, PROBE ASSY, TYPE J 2000332 1TRANSMITTER, DIGITAL TYPE J, 0-500DEG, 8-38VDC 2000334 1TRANSMITTER, DIGITAL TYPE J, 0-1000 DEG, 8-38VDC 2000640 1TRANSMITTER, DIFFERENTIAL PRESSURE, 0-1"WC WET/WET 2000369 1PLC, CPU KOYO DL205 W/250 PROCESSOR 2000337 1PLC, MODULE DL205 - ANALOG 4 CHANNEL INPUT 2000338 1PLC, MODULE DL205 - 6 SLOT BASE AND 24V PS 2000339 1PLC, MODULE DL205 - 16AC INPUTS, 120V 2000340 1PLC, MODULE DL205 - 12 AC OUTPUTS, 120V 2000341 1PLC, BATTERY FOR CPU CLOCK 2000343 1PANEL, OPERATOR INTERFACE - 10 BUTTON 2000139 1RELAY, 24VDC 2000463 1

Additional Parts to Stock for ExxZ-15C (Condenser Unit) ENCON # QuantityBLOWER, AF9-F10020-4 CCW, LESS MOTOR 2000590 -BLOWER, IMPELLER F07620RX5/8, CCW TBD -MOTOR, 1/2 HP, 230/460V, 3 PH, 60HZ, 1725 RPM, 56C, WASHDOWN 2000924 1PAD, MIST - 4"ODx4" TMGLEC/316SS W/0.217 GRID 2000843 1GASKET, FLANGE 4" CONDENSER (xxxx - 8/10C) 3002322S 2PUMP, CONDENSATE SYSTEM, 5 GAL TANK 2000330 -PAD, MIST - 4"ODx4" TM1107/316SS W/0.217 GRID 2000206 1GASKET, LID CONDENSATE SUMP (xxxx-xxxC) 3001231S 1GASKET (WASHER), 1-1/2", RUBBER 2000687 2

Other Spare Parts Available for Exxx-15 ENCON # QuantityKNOB, KNURLED - QUICK OPENING, CAPTIVE SCREW 2000031 -BLOWER, AF9-F10020-4 CW, 5/8" BORE FOR 56C, LESS MOTOR 2000037 -BLOWER, IMPELLER F10020RX5/8, CW 2000626 -HEATER, 24KW,SS,480V,3PH,16W/IN2 W/ 12' LEAD, CBSS9-36-24 2001377 -THERMOCOUPLE ASSY, ELECTRIC HEATER, 316SS (E33x-24) 3004317S -ENCON Evaporators97 Eddy Rd.Manchester, NH 03102Phone: (603) 624-5110Fax: (603) 627-9520

Spare Parts List for Exxx-15

ENCON - Fermilab · ENCON Evaporators1368 Hooksett Rd, Unit 9, Hooksett, NH 03106-1823TEL:...

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Transcript of ENCON - Fermilab · ENCON Evaporators*1368 Hooksett Rd, Unit 9, Hooksett, NH 03106-1823*TEL:...

ENCON - Fermilab · ENCON Evaporators1368 Hooksett Rd, Unit 9, Hooksett, NH 03106-1823TEL:...

Transcript of ENCON - Fermilab · ENCON Evaporators1368 Hooksett Rd, Unit 9, Hooksett, NH 03106-1823TEL:...