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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
19
1. ELECTRICAL SUPPLY ...................................................................................... 19 2. EVAPORATOR STACK...................................................................................... 19 3. RESIDUE TANK AVAILABLE LEVEL PROBE (AUTO-DUMP ONLY) ...... 20
4. CONDENSER PLUMBING (COOLING WATER) ............................................ 20
2
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
3
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
5
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.
6
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.
7
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
8
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
9
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.
10
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.
11
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.
12
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
13
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.
14
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.
15
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.
16
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*
15 4 4 No Galvanized, SS, CPVC*
24 5 5 No Galvanized, SS, CPVC*
40 6 6 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
15 GPH Unit 100 gallons
24 GPH Unit 150 gallons
40 GPH Unit 290 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
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 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
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 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
Evaporators service department.
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
the PLC. This is a latching alarm that will cause the evaporator to cease to operate.
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
the PLC. This is a latching alarm that will cause the evaporator to cease to operate.
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
Evaporators service department.
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
Check the following to determine the cause of the problem:
Is the evaporator calling for water (is the level below the high auto probe)?
Yes: Continue troubleshooting.
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?
Yes: Continue troubleshooting.
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.
No: Continue troubleshooting.
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
Check the following to determine the cause of the problem:
Is the main power switch in the on position and auto switch in the auto position?
Yes: Continue troubleshooting.
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)?
Yes: Continue troubleshooting.
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.
No: Continue troubleshooting.
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.
No: Continue troubleshooting.
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.
No: Continue troubleshooting.
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?
Yes: Continue troubleshooting.
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.
No: Continue troubleshooting.
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?
Yes: Continue troubleshooting.
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?
Yes: Continue troubleshooting.
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.
No: Continue troubleshooting.
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”.
No: Continue troubleshooting.
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 qual- ification 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; redun- dant 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
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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 ENERGY CONSCIOUS INNOVATION
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]
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
EEnneerrggyy CCoonnsscciioouuss IInnnnoovvaattiioonn
ENCON ENERGY CONSCIOUS INNOVATION
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]
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
EEnneerrggyy CCoonnsscciioouuss IInnnnoovvaattiioonn
ENCON ENERGY CONSCIOUS INNOVATION
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]
Printed in the USA 1/09
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.
ENCON ENERGY CONSCIOUS INNOVATION
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]
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]
Printed in the USA 4/10
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