Magnum Spill Buster - Clean Earth Technology

Magnum Spill Buster
Product Recovery System
Operator’s Manual
PN 3013
Rev- Initial Release
REVISIONS
DESCRIPTION
REV
Initial Release
INITIALS
DFB
DATE
11/8/13
Magnum Spill Buster Limited
Warranty
All references to the customer herein shall mean the Purchaser or the Lessee as
applicable. CLEAN EARTH TECHNOLOGY, INC. (CET) warrants the Magnum
Spill Buster System to be free of substantial defects in material and workmanship
for one year from the date of shipment. Pumps are warrantied for 90 days.
CET’s sole responsibility under this warranty shall be to either repair or replace,
at its option, any component which fails during the applicable warranty period because of defect in workmanship or material. No other liabilities shall be assumed
by the manufacturer or its agents, nor are they expressed or implied.
This warranty is contingent upon proper use of the Magnum Spill Buster System
by the Customer in accordance with CET’s published specifications. This
warranty shall not be valid if the alleged defect is the result of abuse, misuse,
accident, alteration, neglect, unauthorized repair, or acts of nature. Any repair
shall be deemed unauthorized unless it is made by CET or with the written
consent of CET. This warranty is the sole warranty made by CET to the
Customer and is in lieu of all other warranties or obligations, expressed or
implied.
System upgrades will be made available to customers as they are completed.
Clean Earth Technology, Inc. is not obligated to provide those upgrades without
cost.
WARNING: Logic board dip switch settings other than those shown
herein are not approved by Clean Earth Technology, Inc., and may
cause spillage of product. Please consult the factory for alternate
settings.
WARNING: In the event that equipment is returned to the factory for
any reason, a complete decontamination must be done before
shipment. See page 89 of this manual for the decontamination
procedure. Shipping hazardous materials improperly may be a
Federal offense.
WARNING: Unauthorized user modifications or application beyond
the published specifications may result in electrical shock hazards or
improper operation. Clean Earth Technology, Inc. will not be
responsible for any injuries sustained due to unauthorized equipment
modifications.
i
Restrictions and Liabilities
Information in this document is subject to change and does not represent a commitment by
Clean Earth Technology, Inc. Changes made to the information in this document will be
incorporated in new editions of the publication. No responsibility is assumed by Clean Earth
Technology, Inc. for the use or reliability of software or equipment that is not supplied by Clean
Earth Technology, Inc. or by its affiliated dealers.
Safety Considerations
Use of this instrument is restricted to qualified personnel who recognize shock hazards and are
familiar with safety precautions used when operating electrical equipment. Read the manual
carefully before operating the Magnum Spill Buster.
The following warnings and informational symbols may be found on the Magnum Spill Buster
and/or in this manual:
Symbol
Description
Caution: Risk of electric shock
Direct / Alternating Current
Direct Current
Alternating Current
Protective Earth (ground)
Warning: Refer to accompanying documentation
Off (Power: disconnection from Mains)

On (Power: Connection to Mains)
ii
Hazard Warnings
•
Warning! Explosive Vapors. Always disconnect AC power at its source prior to
connecting/disconnecting any wires and/or cable connections located within any
hazardous locations.
•
Warning! Explosive Vapors. The control panel and Standard Auto Seeker are not
explosion proof or intrinsically safe, and should be located outside of any classified
hazardous areas where explosive vapors may be present.
•
Warning! Electrical Shock. Correct grounding is absolutely necessary for the system to
work properly and safely. Failure to do so may result in damage to the system and/or
electrical shock, which may result in serious injury or death.
•
Warning! Electrical Shock. All AC Power wiring must be done by a qualified electrician.
Disconnect AC power at its source prior to connecting/disconnecting any wires at the
terminal block. Electrical shock may result in serious injury or death.
•
Warning! Chemical Incompatibility. Due to possible adverse reactions with some of the
materials used in the standard Magnum Spill Buster, it should not be used to pump any
Halogenated Hydrocarbon (HHC) solvent containing any of the following elements
(examples are not all inclusive):
o
o
o
o
Flourine (f) “-flour-“ Examples: Dichloroflouromethane, Trichloroflouromethane.
Bromine (Br) “-bromo-“ Examples: Methyl bromine, Ethylene dibromide.
Chlorine (C1) “-chloro-“ Examples: Perchloroethylene, Trichloroethane, Dichloromethane.
Iodine (I) “-iodi-“ Examples: N-butyl Iodide, Methyl Iodide.
If remediation of an HHC solvent is required, we can build the Magnum with an epoxy
probe in place of standard materials and an alternate pump. Failure to heed this
warning could result in severe damage to the system and the resultant possibility of
injury to personnel and damage to the surrounding site.
Any chemical of concern (COC) that may be present on a site must be disclosed to Clean
Earth Technology at the time of all requests for quotes. Disclosure of COCs must also
be made if a system is moved from its original site to another where COCs are present.
Precautions
The following precautions are provided to help you avoid damaging the system:
•
•
Caution: Service. Authorized service personnel should service the Magnum Spill
Buster. Only qualified technical personnel should perform troubleshooting and service
procedures on internal components.
Caution: Site Security. Access to the site and to the Magnum Spill Buster System
must be controlled at all times. The equipment is specialized and must only be operated
by qualified and trained personnel. Locked sheds, vaults, and fenced enclosures are
iii
•
•
good examples of a secured site. Clean Earth Technology does not warranty damage to
equipment due to vandalism or negligence.
Caution: Proper Grounding. It is absolutely necessary to ground every system,
whether powered by AC or battery-operated. Always call the factory if you have any
questions about the proper way to ground your Magnum.
Caution: Regular Maintenance. The down-well probe and pump should be regularly
inspected and maintained, as detailed in Section 5.0, page 65 . The frequency of
maintenance will depend on your site conditions. We recommend that you start with
weekly checks of the pump and probe until experience dictates that a lengthier interval
will suffice. Failure to provide regular maintenance will damage your Magnum and may
result in unsafe operating conditions. Clean Earth Technology is not responsible for
damage to equipment or injury to personnel resulting from improper maintenance
practices.
The policy below applies to both equipment sales and repair orders. For a Return
Material Authorization number, please call our Service Department. (802) 425-3710
Clean Earth Technology, Inc.
Environmental Equipment Return Policy
This policy refers to ANY EQUIPMENT OR PARTS being returned to Clean Earth Technology,
Inc. (CET), whether:
• Customer owned, leased, or rented.
•
In warranty or out of warranty
NO equipment or parts should be shipped to CET without first contacting our service
department for a Return Material Authorization number (RMA). Contact our service department
at (802) 425-3710 to be assigned an RMA number.
•
CET reserves the right to refuse delivery of any equipment without a CET RMA number
clearly displayed on the exterior of the package(s).
•
CET reserves the right to refuse delivery of any equipment improperly decontaminated.
•
CET reserves the right to add a fee of $500.00 to the repair invoice of any equipment or
parts not decontaminated to the satisfaction of CET.
Environmental Equipment Return Guidelines
•
All equipment must be thoroughly cleaned, purged of product and decontaminated prior
to shipment to CET. NOTE: CET recommends the use of Personal Protective
Equipment, level C or D, as defined in OSHA 29 CFR 1910.120.
iv
•
CAREFULLY FOLLOW THE EQUIPMENT DECONTAMINATION PROCEDURES
FOUND ON PAGE 89 OF THIS MANUAL
Any equipment or parts shipped to CET must include the following documentation:
CET RMA/Repair Order form completed by customer. An “RMA number/REPAIR ORDER” form
to copy is found on page 93.
•
Description/name of product pumped.
•
Reason for return.
•
The CET RMA number clearly marked on the outside of ALL packages and paperwork.
All items being returned (including all warranty-claim shipments) must be sent freight prepaid to
our factory location:
Clean Earth Technology, Inc.
445 Long Point Road
N. Ferrisburgh, VT. 05473
When you ship an item to CET, we recommend using UPS, FedEx, or another reputable
shipper. We also recommend that you insure your shipment for its actual replacement cost.
Clean Earth Technology will not be responsible for lost shipments or instruments that are
received in damaged condition due to improper packaging or handling.
Use the original carton and packaging material for shipment. If they are not available, we
recommend the following guide for repackaging:
•
Use a double walled carton of sufficient strength for the weight being shipped.
•
Use sufficient industry approved, shock-absorbent packing material to protect all
surfaces and projecting parts. The items packed should not be able to slide or shift their
position within the box.
v
vi
CONTENTS
Magnum Spill Buster Limited Warranty................................................................................... i
Restrictions and Liabilities...................................................................................................... ii
Safety Considerations ............................................................................................................. ii
Hazard Warnings .................................................................................................................... iii
Precautions ............................................................................................................................ iii
Environmental Equipment Return Policy ...............................................................................iv
Environmental Equipment Return Guidelines ......................................................................... iv
Product Introduction................................................................................................................ 3
Explosion Proof and Intrinsic Safety 101 ............................................................................... 5
Intrinsic Safety ........................................................................................................................ 5
Explosion Proof Enclosures .................................................................................................... 6
Flammability and Combustible Liquids Definitions 101 ........................................................... 7
1.0 System Installation ............................................................................................................ 9
System Equipment List ..........................................................................................................10
Site Security ..........................................................................................................................11
Control Box Installation ..........................................................................................................11
Installing the Standard Auto Seeker ......................................................................................13
Installing the Explosion Proof Auto Seeker ............................................................................14
Product Discharge Tubing .....................................................................................................16
Product Tank Inlet Fitting .......................................................................................................16
Product Tank Override Probe ................................................................................................17
Product Tanks .......................................................................................................................17
System Grounding .................................................................................................................18
Installing System Extension Cables for a Standard Auto Seeker Magnum ............................20
Standard System Wiring Diagram..........................................................................................21
Installing System Extension Cables for an Explosion Proof Auto Seeker Magnum ................22
Explosion Proof System Wiring Diagram ...............................................................................22
Pulling System Cables Through Conduit ...............................................................................24
Connecting Cables at a Non-XP Control Box.........................................................................25
Connecting Cables at an Explosion Proof Control Box ..........................................................26
Control Box Terminal Block ...................................................................................................27
Connecting the Standard Auto Seeker Cables.......................................................................30
Connecting the XP Auto Seeker Cables ................................................................................31
Initial Pump Power Test .........................................................................................................32
Pump Flooding Procedure .....................................................................................................34
2.0 Spill Buster System Operations .......................................................................................35
Initial Power Up .....................................................................................................................36
Magnum Spill Buster Front Panel ..........................................................................................37
Magnum Spill Buster System Cycle .......................................................................................38
System Cycle Schematic with Auto Seeker ...........................................................................39
Product Recovery Cycle (PRC) Control Switch......................................................................41
System Cycle Operation (no Auto Seeker) ............................................................................42
3.0 Spill Buster Advanced System Operations .....................................................................43
DIP Switches .........................................................................................................................44
DNAPLs Operation ................................................................................................................46
DNAPLs System Cycle without Auto Seeker .........................................................................48
4.0 Other Options ....................................................................................................................49
Immediate Response Box......................................................................................................50
1
Battery Operation ..................................................................................................................51
Solar Panel Charging Operation ............................................................................................52
Water Depression ..................................................................................................................53
5.0 Maintenance Operations...................................................................................................65
Probe/Product Pump .............................................................................................................66
Pump Flooding Procedure .....................................................................................................72
Pump Installation ...................................................................................................................73
Logic Board and Power Supply..............................................................................................74
Removing Probe from Auto Seeker Reel ...............................................................................76
Resynchronizing Product Cable With The Standard Auto Seeker Rotation............................76
To Remove the Probe from a Standard Auto Seeker Reel.....................................................77
To Install the Probe on a Standard Auto Seeker Reel............................................................78
To Remove the Probe from an Explosion Proof Auto Seeker Reel ........................................79
To Install the Probe on an Explosion Proof Auto Seeker Reel ...............................................80
6.0 Troubleshooting ................................................................................................................81
7.0 System Specifications .....................................................................................................85
Magnum Spill Buster Pump Performance ..............................................................................87
8.0 Equipment Decontamination Procedures .......................................................................89
9.0 Equipment Return Policy..................................................................................................91
Return Materials Authorization Form ....................................................................................93
2
Product Introduction
The Magnum Spill Buster™ family of equipment is an automated free phase petroleum
contamination pumping system. It is specifically designed to remove NAPL petroleum product
from the water table via a 2″ or larger diameter well. Its unique auto-seeking device allows the
pump intake to automatically follow the elevation of the oil/water interface as it fluctuates
throughout the entire length of the well. The Magnum Spill Buster will not pump any amount of
water.
The Magnum Spill Buster is
composed of three interactive
modules: The Control Box, the Auto
Seeker, and the down well Probe.
Control Boxes mounted
in a NEMA enclosure
The Control Box coordinates and
displays the condition of the system
operation and also allows certain
system parameters to be varied.
Magnum Control Box with
protective cover removed
The Auto Seeker is a small, motorized, reel assembly that automatically
raises and lowers the probe to follow the NAPL interface through the
entire depth of the well.
Standard Auto Seeker
The 1.93” diameter Probe contains the patented ALPHA
ARRAY™ interface sensors, as well as a small but powerful
12vdc electric product pump.
Magnum Spill Buster Probe
“Exploded” view of the Probe,
Showing the pump, filter, spring and end cap
3
The Spill Buster may also be used in a dual pump mode by adding a water depression control
box and water pump (See page 53).
The Magnum Spill Buster has several options for its power source.
Where electrical connection is available, the system can be hard
wired for 115/230 VAC at 60 Hz. The operating system will also
automatically adjust to European 230 VAC at 50 Hz. Battery power
is also an option via two deep cycle 12V batteries in series for 24
VDC power. On remote sites where power is not available, the
Magnum can run on solar power (See pages 52).
The Magnum Spill Buster can be used on a wide variety of
groundwater remediation sites. Many of these sites contain
classified hazardous areas with restrictions on the type of
equipment that can be used within them. It is very important for the operator to be aware of all
applicable codes on their site and confirm that their planned use of the Magnum Spill Buster is
in compliance. Please note that we offer a range of options for meeting the requirements on
different kinds of site situations, including versions that mount the Auto Seeker and/or Control
Box in explosion proof containers for use in Class 1, Division 1, hazardous zones.
The following section on the terms
“Intrinsic Safety” and “Explosion Proof”
provides more detail on the differences
between the two and gives examples
of how the Magnum Spill Buster
systems’ design incorporates them.
Control Box mounted inside
explosion proof enclosure
NEC 2011 compliant explosion
proof Auto Seeker
4
Explosion Proof and Intrinsic Safety 101
Portions of the standard Spill Buster system operate in various “classified” flammable or
explosive vapor zones or areas as defined in the US under the NEC codes. The location of the
equipment on the site must be designed properly; or the equipment must be enclosed in
appropriate enclosures, to prevent ignition of these vapors should the failure of a component
occur. Since this is such an important topic we will present a few basics in this manual to help
you or your customers understand the meaning of the various terms defining safe use when
planning or installing our equipment. Please note that what we have written here is not meant to
supersede anything that may be written in detail in the NEC codes or applicable local codes. It
is your responsibility and the responsibility of the Authority Having Jurisdiction to study
and follow these codes.
The Magnum Spill Buster system may need to be partially or completely located in areas that
are classified as “Class 1, Division 1, Hazardous Atmospheres” as defined in the NEC code
section 500. A Class 1, Division 1, safety rating is the highest rating in the US for flammable and
combustible zones. There are several methods to insure that electrical systems are safe to
operate in these areas. The Standard Spill Buster system can be modified when required to
utilize two of these basic methods to achieve safe operations in these atmospheres per NEC
2011 electrical codes: the Intrinsically Safe method, and the Explosion Proof Enclosure method.
The sections below provide a brief explanation of these two methods and the different ways in
which they make an electrical system safe for operation in Class 1 Div. 1 areas.
Intrinsic Safety
Intrinsic safety (IS) is a protection technique for safe operation of electrical equipment in
hazardous areas by limiting the energy available for ignition of explosive well gases. The
concept of (IS) circuits was originally driven by some devastating coal mine explosions in
Europe due to “firedamp” gases being ignited by “electrical shorts” in the wiring of early
communication devices such as the electric telegraph.
In signal and control circuits that can operate with low currents and voltages, the intrinsic safety
approach simplifies circuits and reduces installation costs over other protection methods. Highpower circuits such as electric motors or lighting cannot use intrinsic safety methods for
protection.
One of the most common methods for protection is to limit the current by using multiple series
resistors (assuming that resistors always fail open); and to limit the voltage with multiple Zener
devices to ground (assuming diodes always fail shorted). Approval standards for intrinsic safety
barriers require that the barrier maintains approved levels of voltage and current to the
5
specified components. This is accomplished by preventing ignition of the protected device and
stopping sparking of damaged wiring to the protected components.
An example of an Intrinsically Safe (IS) certified Zener barrier is shown
here. Signals going to an electrical device located in a classified zone
are wired into one end of the modular barrier and then wired out into the
classified zone. These can be purchased off the shelf and are certified
Intrinsically Safe by various 3rd body testing laboratories.
Explosion Proof Enclosures
Explosion Proof (EXP) enclosures are not intended to seal the electrical equipment they contain
from the entry of explosive atmospheres that may be outside the enclosure. Instead, they
prevent any explosion that might occur within the enclosure from initiating a secondary fire or
explosion in the surrounding area outside of the enclosure. Since they are not tightly sealed,
liquids and gases may flow into the enclosure.
EXP enclosures are usually made of heavy cast aluminum or stainless steel and are of sufficient
thermal mass and mechanical strength to safely contain an explosion should ignition of the
flammable material occur within the housing. These enclosures are typically produced with
wide, flat, flanges but may not have a gasket between those flanges. Should an explosive
mixture ignite inside the enclosure because of an electrical short or an overheated component,
the design of the flanges cools down any hot gases escaping between them enough to prevent
the ignition of the external combustive atmosphere.
This is important to understand because it means that by design these enclosures are neither
completely air tight nor waterproof. The EXP enclosure that can be used with the Magnum’s
control box includes a window to allow the operator to see the instrument panel. We strongly
recommend that these enclosures be mounted in an upright position and raised off of the
ground to prevent possible internal flooding. If the housing must be at ground level, and
especially if it is laid flat with the control panel window in the horizontal position, a protective
cover should be used to keep rain from leaking inside the enclosure and flooding the control box
electronics.
Another example of the Explosion Proof methodology would be the manner in which electrical
wire is fed through piping. Per the NEC electrical code spelled out in section 500, cabling fed
through piping usually utilizes tapered pipe threads. The code requires a minimum engagement
of six threads; and since it is tapered, the spaces between the threads get tighter as the pipe is
tightened up. There still is the potential for vapors to leak through these threads, but once again
any hot gases escaping through the threads are cooled enough to prevent a secondary
explosion.
A third example of EXP methodology would be the use of a multi-conductor cable feed through.
The feed through fittings are once again designed to be strong enough to contain an explosion.
6
These fittings leave sufficient room to provide for stripping the outermost wire jacket and enough
room for separating the individual wires from each other. A powdered mixture is then mixed
together with water and poured in through an access plug to completely surround each
conductor. A common material used is a compound from Cooper Crouse-Hinds called Chico®,
which cures to a cement-like consistency. In the event of an internal explosion, any hot,
explosive gases escaping through the hardened Chico are cooled before entering the explosive
atmosphere outside.
Here are examples of these two types of enclosures:
Flammability and Combustible Liquids Definitions 101
When using a Spill Buster system it is important to understand the difference between the
definition of flammable liquids and combustible liquids. All flammable and combustible liquids
will vaporize into flammable gases at certain temperatures and pressures. The temperature
point at which a liquid turns to a gas vapor is referred to as the “flashpoint” of the liquid. The
determination of the flashpoint for each flammable or combustible liquid is done by performing
what is commonly known as the “closed cup” flashpoint test.
It should be mentioned that flashpoint was selected as the basis for classification of flammable
and combustible liquids because it is directly related to a liquid's ability to generate vapor, i.e.,
its volatility. Since it is the vapor of the liquid, not the liquid itself that burns, vapor
generation becomes the primary factor in determining the fire or explosive hazard.
Furthermore, the liquids vapor pressure is an important factor and is a measure of a liquid's
propensity to evaporate. The higher the vapor pressure, the more volatile the liquid and, thus,
the more readily the liquid gives off flammable or explosive vapors.
The results of flashpoint testing have been used to help regulating bodies determine the
temperatures at which potentially combustible liquids turn into a vapor, creating a flammable or
explosive gas.
7
Hazardous locations are further defined by means of the class/division system and have been
formulated by the NEC, CSA, OSHA, and the National Fire Protection Association (NFPA).
These definitions are as follows:
Flammable Liquids
Flammable fluids are defined as liquids having closed cup flash points below 100°F
(37°C). Flammable liquids are referred to as Class I liquids.
◆
A class IA flammable liquid is a liquid with a flashpoint below 73ºF (22.8ºC) and a boiling
point below 100ºF (37.8ºC). An example of a class IA liquid is n-pentane, since its flashpoint
and boiling point are 56ºF (49ºC) and 97ºF (36ºC), respectively.
◆ A class IB flammable liquid is a liquid with a flashpoint below 73ºF (22.8ºC) and a boiling
point at or above 100ºF (37.8ºC). An example of a class IB liquid is acetone, since
its flashpoint and boiling point are 0ºF (18ºC) and 133ºF (56ºC), respectively.
◆ A class IC flammable liquid is a liquid with a flashpoint at or above 73ºF (22.8ºC) and
below 100ºF (37.8ºC). An example of a class IC liquid is turpentine, since its flashpoint
lies in the range from 95 to 102ºF (35 to 39ºC).
Combustible Liquids
Combustible fluids are defined as liquids having closed cup flash points at or above
100°F (37°C). Combustible liquids are referred to as Class II or Class III liquids.
◆ Class II liquids - flash points at or above 100°F (37.8°C) and below 140°F (60°C).
◆ Class IIIA liquids - flash points at or above 140°F (60°C) and below 200°F (93.4°C). c.
◆ Class IIIB liquids - flash points at or above 200°F (93.4°C).
An example of a Combustible liquid is the Lamplight® Ultra Pure Red Paraffin Lamp Oil that
CET uses for testing new and repaired units before shipment. This material has a flashpoint of
250F (121C) making it a class III liquid. Furthermore, its low toxicity makes it a safe testing fluid
due to its high ignition temperature and the lack of chemicals that are listed in the CERCLA
Hazardous Substance list. CET uses a red colored fluid but it also can be found in clear, or
colored green or blue.
This fluid is easily found and can also be used as a pump priming fluid as defined on page 71.
8
1.0 System Installation
8 Easy Installation Steps
1.
Set up Control Box
Page 11
2.
Install Auto Seeker
Page 13
3.
Install Product Tank Inlet Fitting and Product
Tube
Page 16
4.
Install Product Tank Override Probe
Page 17
5.
Ground System
Page 18
6.
Connect System Cables and Power Cables
Page 20
7.
Power Test
Page 32
8.
Pump Flooding Procedure
Page 34
Time: Set-up time for the complete system should take from 30 to 60 minutes after connection
to the power source is complete.
9
System Equipment List
NEMA 4 weatherproof main Control Box (NON-Explosion proof)
(For a complete Explosion Proof system, Control Box can be
mounted in a Class 1 Div. 1 rated enclosure.)
For a Standard Magnum System: Auto Seeker System (NON
Explosion proof) with 30 foot power cable extension
For a Magnum System w/Explosion Proof Auto Seeker: Auto
Seeker System mounted in Class 1, Div. 1 rated explosion proof
enclosure with 30 foot power cable extension
NEC 2011 section 500 compliant Product Probe with 50 foot probe
product tube. Longer probe cable lengths available upon request.
Product Tank Inlet Fitting
50 foot nylon product discharge tube
NEC 2011 section 500 compliant Product Tank Override Probe with
bung and 30 foot cable
30 foot Probe signal and power cable extension. Longer extension
cables available upon request.
30 foot Auto Seeker power cable extension. Longer extension cables
available upon request.
One Pump Flooding Kit per order consisting of syringe, o-ring, and
tubing.
10
Site Security
Warning
Access to the site and to the Magnum Spill Buster System must be
controlled at all times. The equipment is specialized and must only be
operated by qualified and trained personnel.
Secure every site. Locked sheds, vaults and fenced enclosures are good examples of a
secured site. Clean Earth Technology does not warranty damage to equipment due to
vandalism or negligence.
Control Box Installation
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
The standard Control Panel in its NEMA-4 enclosure is not rated for use in any classified
explosive locations, as determined by the Authority Having Jurisdiction (AHJ). The control box
can be used with an Explosion Proof (XP) Auto Seeker and meet all Class 1, Div 1
requirements as long as the panel is mounted in a nonhazardous area.
Standard Control Box with covers off
Standard Control Box with covers on
11
Location
Mount the Control Box in a suitable non classified location (refer to
all safety codes applicable to your site). Typical installations are in
sheds, vaults, on the side of a building, or on a utility type pedestal
mount. If the control panel is mounted vertically and the box door is
latched with the I/O Extension cover correctly installed, the unit is
weatherproof.
If the Control Box must be located in a Class 1, Div 1 or 2 areas,
Clean Earth Technology can provide an explosion proof enclosure.
This type of enclosed Control Box looks like the units shown in the
figures below.
Standard Control Box
mounted in an Explosion
Proof enclosure with cover
removed.
Standard Control Box
mounted in an XP enclosure.
Note the optional XP power
switch box located at bottom
left.
Warning
Control Box must be
located outside of
any classified
hazardous areas.
This includes
explosive
atmospheres or
vapors. Refer to all
applicable codes.
The optional XP power switch
box located at bottom left.
Without the optional XP power switch, the XP Control Box must be turned on and off at the
circuit breaker panel for the input power.
1. Ensure the unit is de-energized. Mount the Control Box in a suitable location (refer to all
safety codes applicable to your site). Typical installations are in sheds, vaults, on the side of a
building, interior of a building or on a utility type pedestal mount.
2. If the Control Box is installed in an explosion proof enclosure, it must be mounted in a
vertical orientation to prevent the potential of rain water leakage and accumulation within the
enclosure. (See “Explosion Proof 101” on page 5 for an explanation of the enclosure’s design in
regards to weather proofing).
3. To meet the Intrinsically Safe (IS) requirements of this unit, a grounding circuit of one (1)
ohm or less to the grounding electrode is required.
12
4. If the extension cables leading from the Control Box to the Auto Seeker and/or Override
Probe must pass through an unclassified area the cables must be must be sealed at each
boundary in accordance with NEC & local code requirements to prevent migration of
combustible vapors within the cable. It is the responsibility of the AHJ and the local installer to
meet the requirements of the local area.
5. For the initial installation of a Control Box mounted in an explosion proof enclosure, do not
close the door or secure the bolts around the flange until after the initial pump power test has
been performed (See page 32).
Installing the Standard Auto Seeker
If installing an Explosion Proof Auto Seeker, skip to page 14.
The Auto Seeker system is an integral part of the Magnum Spill
Buster system. It is turned ON and OFF with the System Power
switch on the Control Panel. The Auto Seeker is controlled by the
Product Recovery Cycle (PRC) control switch.
The Standard Auto Seeker is not rated explosion proof or
intrinsically safe. It should be mounted outside of all classified
hazardous zones. (See Section 1.1 for information on installing an
Auto Seeker with an Explosion Proof enclosure). Refer to all
applicable NEC and local codes to determine how and where the
Auto Seeker should be installed on your site.
On many sites it is possible to move the Standard Auto Seeker from the classified hazardous
area by raising it above the well head. For example, the use of a wood or metal scaffolds such
as the one pictured here may accomplish this.
Installation
For the example shown above a custom adapter clamp plate was bolted
to the wooden cross support as shown to the right. Slide the Auto Seeker
mounting bracket clamp on to the adaptor plate and then thread the 2
clamping bolts in all the way until the ends engage the adapter plate.
Then using a wrench to tighten the bolts until the Auto Seeker is securely
supported on the adapter plate. Finally, carefully guide the probe through
the white PVC collar and steel tube on the mounting bracket and let it
hang there until the system is fully installed.
Custom Adapter
“Home” Position
The Standard Auto Seeker system is shipped from the factory with the
Probe fully wound on the reel. This is its “home” position. It is critical that the Probe NOT be
unwound from the reel except by use of the motorized reel. The position of the Probe on the reel
13
is synchronized with a cable inside the reel housing. Refer to “Unwinding the Probe Manually”
on page 32 for the correct way to advance or retract the Probe by hand so that synchronization
is maintained.
. The position of the Probe on the reel is synchronized with a cable inside t
Product Seeking
After the system is fully installed and the system is turned ON, the Auto Seeker will
automatically track the water table. [See 2.0 System Operation - Magnum Spill Buster System
Cycle, page 38]
NOTE: Always perform the pump flooding procedure found on page 34
before lowering probe inside well.
Installing the Explosion Proof Auto Seeker
The Explosion Proof Auto Seeker system is an integral
part of the Magnum Spill Buster system. It is turned ON
and OFF with the System Power switch on the Control
Panel. The Auto Seeker is controlled by the Product
Recovery Cycle (PRC) control switch.
Adapters
The well head adapter
bracket provides a
reinforced area to mount
the Explosion Proof Auto
Seeker unit and also
locates the Auto Seeker
reel and Probe directly
over the well for proper
operation. PVC fittings are available to accommodate
well head diameters from 2” to 8”. Use PVC adhesive and install the appropriate fittings to
reduce the well head to a 2” diameter.
If you did not receive the appropriate fittings for your application,
please contact the factory for advice or to order preassembled
fittings. These fittings can also be built up from standard PVC
fittings found in most hardware and plumbing stores. The clamp
incorporated into the Auto Seeker bracket can also be used for
steel well heads 3” and larger, if applicable. An example of an XP
Auto Seeker mounted on a 3’ metal culvert recovery well is shown
to the right.
14
Installation
Position the Explosion Proof Auto Seeker over the well and slide the Auto Seeker mounting
bracket steel tube down fully into the well head adapter. Thread the 2 clamp bolts in towards the
adapter until they press against the PVC adapter and then using a wrench tighten the clamp
bolts firmly until the AS is fully secured. Finally, guide the probe through the white PVC tube
collar and steel mounting tube of the mounting the bracket and slide it down into the well itself.
Make sure the probe slides freely in the recovery well.
White PVC Collar
4” PVC Adapter
Clamping Bolts
Clamping Details on a
PVC Well Head
Clamping Details on a Metal
Culvert Recovery Well
For culvert type of recovery wells, position the
Explosion Proof Auto Seeker over the well and
slide the Auto Seeker mounting bracket over the
culvert wall as shown above. Thread the 2
Clamping Bolts
clamp bolts in towards the well until they press
against the metal and then, using a wrench,
tighten the clamp bolts firmly until the Auto Seeker is fully secured. Finally, guide the probe
through the white PVC tube collar and steel mounting tube of the mounting the bracket and slide
it down into the well itself. Make sure the probe slides freely in the recovery well.
Product Seeking
After the system is fully installed and the system is turned ON, the Auto Seeker will
automatically track the water table. [See 2.0 System Operation - Magnum Spill Buster System
Cycle, page 38]
NOTE: Always perform the pump flooding procedure found on page 34
before lowering probe inside well.
15
Product Discharge Tubing
Connect the Product Discharge Tubing to the Instant tube fitting on the front of the Auto Seeker
reel unit by pushing the tube firmly into the fitting until it “snaps”. Secure with a retainer clip. To
remove tubing, remove retainer clip and push locking sleeve of fitting squarely into the fitting
while pulling on tube.] NOTE: The retainer clip is an integral part of the Instant Tube Fitting and
must be in place to maintain the integrity of the fitting. Failure to install the retainer clip could
cause a leaking joint.
Instant Tube Fitting
Retainer Clip
Product Discharge
Tube
Product Tank Inlet Fitting
The Product Tank Inlet Fitting screws into a standard 3/4” NPT fitting. Connect the product
discharge tube coming from the Auto Seeker to the inlet fitting using the Instant Tube fitting
supplied on the fitting assembly. First remove the red retainer clip on the fitting. Push the
product discharge tube firmly into the fitting until it “snaps” into place. Re-install the retainer clip.
NOTE: The retainer clip MUST be installed to insure against leaks. The product tank level can
be checked manually by unscrewing the cap from the top of the fitting and inserting a dipstick
into the product tank. The cap also contains a small vent. In the case of multiple recovery
systems using one product tank the fittings can be stacked.
REMOVE THIS CAP TO USE A DIP
STICK TO CHECK THE TANK LEVEL
PRODUCT TUBE
PUSH IN TUBE FITTING
RETAINER CLIP
16
Product Tank Override Probe
The Product Tank Override Probe must be
connected to the control box prior to
system operation. There is an electrical
interlock to prevent the product pump from
operation without having the Product Tank
Override Probe connected. Dip Switch S24 will override this interlock when turned
ON. However, on this setting a tank full
condition is not detected and a
secondary spill may occur.
Install the product tank override probe in the
product tank and plug the cable into the slot
marked INHIBIT in the I/O Extension of the Control
Box [Second slot from lower left]. The tank fitting
screws into a standard 2” bung threaded hole.
Other options are available
such as a “splitter” to allow use of multiple recovery
systems using one product tank override probe.
The Product Tank
Override Probe fitting
screws into a 2” bung.
Product Tanks
Product tanks are NOT part of the Magnum Spill
Buster system. Suitable receptacles for recovered
product should be sized for the specific job and site,
and should be monitored at regular intervals, along
with the rest of the system. Recovered product
should be labeled and disposed of in an
appropriate manner.
17
System Grounding
WARNING
CORRECT GROUNDING IS ABSOLUTELY NECESSARY
FOR THE SYSTEM TO WORK PROPERLY, AND TO
ENSURE ELECTRICAL SAFETY. ONLY A QUALIFIED
ELECTRICIAN SHOULD INSTALL THE SYSTEM.
The interface sensors take advantage of the RF shielding effect of
ground water normally present in the well. To enable the control to
properly sense this shielding effect, its logic circuits must be
referenced to ground. Grounding procedures are described in the
following sections for five different installations:
1. Standard utility connection.
2. Remote power installations (with a portable AC generator).
3. Bench testing where the test water is not connected to earth
ground.
4. 24 VDC battery operation.
5. 24 volt solar operation.
A proper ground is not
an option! Correct
grounding is
absolutely necessary
for the system to work
properly and safely!
Note: A missing ground connection is indicated when the
HI and LOW LIMITS lights stay off even when the probe is
immersed in water.
Warning!
All power and grounding wiring
should be performed by a qualified electrician. All wiring
must meet the latest NEC and all applicable local codes.
Grounding a Utility Connection
When connecting to a utility power source, the green grounding wire must be connected to the
power input ground terminal in the control box. This connection is marked on the overlay below
the power input terminal block. A three-prong plug with a three-lead cable must be used for
system power; typically a black “hot” lead, a white “neutral” lead, and a green grounding lead.
However, in some cases due to site-specific conditions, it may be necessary to install a
grounding rod, as described below.
18
Installing a Grounding Rod
The metal casing of a driven well can be used as the ground.
Where this is not possible, a grounding rod can be constructed as
follows:
- Drive a copper rod approximately 8 feet into undisturbed soil;
use a 5/8” Copperweld type rod.
- Connect a No. 8 or larger copper wire from the ground rod to the
power source (a generator, battery, or control box).
- Make certain all connections are free of corrosion or oxidation.
Grounding a Portable Generator
A three-lead cable must be run from the generator to the control
box; typically, a black “hot” lead, a white “neutral” lead, and a
green grounding lead. In addition, the generator must be bonded
to an earth ground (See “Installing a Grounding Rod” above).
A grounding rod
employing a 5/8” copper
rod, 8 gauge wire and
copper clamp.
Note: All connections must be clean
without any oxidized layers.
Grounding for Battery Operation
Magnum Spill Buster systems operated from a battery must have the negative terminal of the
battery grounded directly to a copper rod driven into the ground (See “Installing a Grounding
Rod” above). In addition, a 12 gauge or larger copper wire must run from the negative lug on the
battery to the grounding lug on the terminal block in the control box.
Some examples of battery locations requiring a ground rod and cable for operation are as
follows:
- a vehicle battery, whether in or out of a vehicle.
-
a battery inside an Immediate Response Box (whether on the ground, in a truck, etc.)
-
a battery with a solar (photovoltaic) panel
Note: For proper system operation, it is absolutely necessary to ground every battery
operated system!
Grounding for Lab or Bench Testing
For temporary operation in a lab or on the bench, where the test water is not connected to earth
ground, the water must be grounded. This can be accomplished by submerging at least 6
inches of bare copper wire in the water and attaching the other end to the green grounding
terminal of the control box.
19
Installing System Extension Cables for a Standard Auto
Seeker Magnum
If installing system extension cables for an Explosion Proof Auto Seeker system, skip to
page 22.
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
Make sure all cable connectors are free of dirt and debris before making connection. The
standard extension cable lengths are 30 feet, but custom length cables are available up to 400
feet. If PVC conduit pipe is run between the control box and the well head, see “Pulling System
Cables Through Conduit” on page 24.
Cable Connectors
NOTE: ALWAYS turn
off power before
removing or connecting
cables
Slim-line™
CONNECTORS
20
Standard System Wiring Diagram
TYPICAL CABLE CONFIGURATION FOR A STANDARD MAGNUM SPILL BUSTER
Alternate cable lengths are readily available for deeper wells and control box placement further
than 30 feet from the well head. The maximum allowable total cable length from the probe to
the control box is 400 feet.
21
Installing System Extension Cables for an Explosion Proof
Auto Seeker Magnum
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
Explosion Proof System Wiring Diagram
TYPICAL CABLE CONFIGURATION FOR AN EXPLOSION PROOF
MAGNUM SPILL BUSTER
22
Installing the XP System Cables
If the extension cables pass through an unclassified area the cables must be must be sealed at
each boundary in accordance with NEC & local regulations requirements to prevent migration of
combustible vapors within the cable. It is the responsibility of the local installer to meet the
requirements of the local area. A typical cable with coupled connectors is shown below.
Typical cable extension joined to an Auto Seeker cable pigtail.
Make sure all cable connectors are free of dirt and debris before making connection. The
standard cable lengths are 30 feet, but custom length cables are available up to 400 feet. If PVC
conduit pipe is used, see “Pulling System Cables Through Conduit” on page 24.
Note: Cable extensions for an Explosion Proof Auto Seeker system have slim line connectors
on one end. These cable ends should be pulled through any conduits to end nearest the Control
Box and NOT the ends with Circular-Mil Spec connectors. This helps prevent debris or other
contaminants from getting into the pins of the Mil-Spec Connector receptacles and prevent the
degradation of system performance. If there is no way to pull cables from the Auto Seeker side
of the conduit then a secure covering should be used over the connectors while pulling the
cables through.
Turn off power
before removing or
connecting cables.
Cable extensions showing the female socket
receptacles.
Cable extensions for an Explosion Proof Auto Seeker will have a Slim-line™
connector on the Control Box side and a Mil- Spec circular connector one
the other.
23
Pulling System Cables Through Conduit
The minimum recommended diameter is 4” pipe. Use long “sweep” type elbows in a conduit
installation. This will help prevent any damage to system cabling caused by forcing cable
connections through a smaller diameter pipe. Excess cable from the installation should be
coiled and stored in a protected area.
Typical Cable Segment
THE WRONG
WAY TO PULL
CABLES
THROUGH A
PIPE
THE RIGHT
WAY TO DO IT!
Do not use smaller than
4” PVC.
Do not leave connectors
exposed to contamination, especially during
cable pulling operations.
Use 4” diameter pipe or
larger. Tape the pull
rope in place on the
cable to prevent it from
sliding up to the
connectors. Tape the
connectors to prevent
contamination.
Distribute the connectors
over a few feet; don’t
bunch them in one
place.
24
Connecting Cables at a Non-XP Control Box
If connecting a Control Box mounted in an XP Enclosure, skip to page26.
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
I/O Extension Pouch
All cables enter the Control Box via the I/O
Extension Pouch (or I/O Pouch), which makes up
the bottom portion of the control box. Access into
the I/O Pouch is gained by loosening the two
screws on the front of the I/O Pouch and removing
the lid. The Slim-line™ connector cables and
power cable for the system feed through the
bottom of the I/O Pouch.
Remove screws to access
the I/O Extension Pouch
I/O Board and Terminal
Block inside I/O Extension
25
Connecting Probe, Auto Seeker, and Override Cables
Connect Slim-line™ connectors to
receptacles, as labeled. Slim-line™
connector receptacles are keyed to help
facilitate proper placement of plugs.
The power cable connects to the terminal
block inside the I/O Pouch. See “Control Box
Terminal Block” on page 27.
NOTE: The System must be properly
grounded for correct operation.
PROBE CONNECTOR
AUTO SEEKER CONNECTOR
Next, plug in the Override Probe connector as
shown. NOTE: The Magnum Spill Buster
system will not function unless the Override
Probe is connected or the Override dip switch
(S2-4) is ON. [See Dip Switches, page 44].
OVERRIDE PROBE CONNECTOR
Connecting Cables at an Explosion Proof Control Box
When cabling from system components are connected to the Control Panel through an XP
Housing, sealed and potted XP feed-throughs must be threaded into the threaded holes
provided in the XP enclosure. These feed-through fittings will typically look like the picture
shown below.
Example of a control box XP enclosure housing cable feed through.
26
These cable feed-throughs should be threaded tightly into the bottom of the XP enclosure.
There will be three of these fittings. Two will have Slim-line connectors, and one will not have
any cable potted in. This last one will need to have the power wiring fed through it by the
electrician and potted per NEC or local codes for explosive atmospheres.
Once the fittings are threaded in tightly and the power cable is installed and potted, attach all of
them into the I/O section of the control panel as detailed in “Connecting Probe, Auto Seeker,
and Override Cables” on page 26. Upon completion of these connections install the I/O pouch
cover. In these installations the control box main cover has been removed so that the front
panel LED lights can be viewed during operation.
Control Box Terminal Block
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
Hardwiring AC Power
The Magnum Spill Buster is designed to run either 115 or 230 VAC Power without any modifications to the internal wiring. Attach hardwiring to the Control Box as shown on the Power Cable
overlay. The incoming power cable must be able to handle a minimum of 10 Amps.
Terminal Block shown with the
protective cover removed
115/230 Volt Terminal Block with
the protective cover attached.
27
Correct Terminal Block Connections
This view looking
at the side of the
terminal block
shows the correct
location to insert
the AC supply
wire.
PLACE
WIRE IN
THIS
HOLE
(UNDER
PLATE)
CORRECT
INSTALLATION
Installing the AC
supply wire in the
terminal block.
The wire must be
installed
correctly as
shown.
DO NOT PLACE WIRE
DIRECTLY UNDER SCREW!
CORRECT
INSTALLATION
(UNDER PLATE)
NOTE: Always replace the protective cover on the terminal block after installation
or prior to providing power to the system. See page 29.
28
Sealed I/O Extension with Cables Installed
I/O EXTENSION RUBBER GASKET SEAL
All cables must exit the I/O Extension through the appropriate sized slot in the bottom of the
pouch in order to create a dust- and weather-proof seal. The perimeter of the lid and body
of the I/O extension is lined with a foam rubber gasket that serves as weather stripping.
The weather stripping will cause the lid to seal automatically against the cables when the lid
is closed and fastened with the screws. The weather stripping will seal holes in the I/O Box,
whether they contain cables or not.
I/O extension must be
closed and sealed for
safety and
weatherization!
29
Connecting the Standard Auto Seeker Cables
If connecting an Explosion Proof Auto Seeker, skip to “Connecting the XP Auto Seeker Cables”
on page 31.
Remove safety cover
from Slim-line™
connector box.
Use Probe and Auto
Seeker Slim-line™
connectors with rubber
gaskets affixed.
Plug in Slim-line™
connectors to size-coded
receptacles.
Replace safety cover
over connector box and
tighten screw down
snugly.
30
Connecting the XP Auto Seeker Cables
The XP Auto Seeker has two 5 foot long pigtail cables terminated with Circular Mil-Spec
connectors (see below). The respective cable extensions are connected to the pigtails as shown
and each threaded locking collar should be firmly seated to insure an environmentally tight seal.
NOTE: These connectors should not be laid directly on the
ground or vault. While they are weather resistant, they are not
rated for direct water immersion. We recommend hanging the
cables such that the connectors are above any potential water
flooding areas.
Threaded Locking Collar
Probe Cable Connector
Note the rotational locking
key slot.
Warning:
Auto Seeker Power Cable
Connector
Always de-energize system power
before connecting or disconnecting
cables!
31
Initial Pump Power Test
When all cabling and system components are connected, the system ground is installed, and
power is supplied to the system, it is preferable to test the product pump for operation prior to
putting the probe in the well. It is convenient to have two people for this operation; one near the
Auto Seeker system to listen to the pump in the Probe, and one to operate the control box.
NOTE: The Probe should be held outside of any classified zone around the well head
while this test is being performed. This might be accomplished by manually unwinding
enough of the Probe cable from the Auto Seeker to reach an unclassified zone if the zone is
close enough. The proper procedure for doing this is as follows:
Unwinding the Probe Manually
Disconnect the Auto Seeker cable from the Auto Seeker or the Control Box, whichever is more
convenient. Once disconnected, the Auto Seeker’s reel may be turned by hand without
disrupting the synchronization built into the Auto Seeker assembly. The probe may be rewound
by turning the reel in the opposite direction. To prepare to resume normal operation, rewind the
Probe up to its home position (but no farther - stop when reel becomes difficult to turn). Then
reconnect the Auto Seeker cable.
Pump Power Test Procedure
(Refer to drawing below). The System Power Switch governs all power to the system when it is
connected to an AC power source, including the Control Box, Probe, and Auto Seeker. A yellow
lamp will light indicating that the system power is ON.
1. Turn the System Power switch ON. The System Power lamp, and Processor lamp, on the
control panel will turn ON, and the audio tone in the control box will begin to beep once every 2
seconds.
2. Press and release quickly the TEST SYSTEM side of the Product Recovery Cycle (PRC)
control switch. The product pump (in the probe) will operate for approximately 5 seconds and
then stop. The yellow product pump lamp on the control panel will light and the audio tone in
the control box will produce a warbling tone while the pump is ON. Simultaneously, along with
the audible motor sound, starting the pump usually causes the entire probe and cable to visibly
twist and jerk as a result of the pump torque reaction.
3. Immediately after the test, push STOP at the PRC switch. Otherwise, Auto Seeker will begin
to cycle and unwind Probe cabling off the reel.
4. Turn the System Power switch to OFF.
NOTE: You must remove the pump from the Probe (See “Removing the Product Pump”
on page 69) and perform the Pump Flooding Procedure (page 34) before lowering the
Probe into the well.
32
PRODUCT RECOVERY CYCLE (PRC)
CONTROL SWITCH
PRODUCT TANK
FULL LAMP
(YELLOW)
PUMP ON LAMP
(YELLOW)
HI LIMIT SENSOR
WET LAMP (GREEN)
LOW LIMIT SENSOR
WET LAMP (GREEN)
PROCESSOR ON
LAMP (YELLOW)
HOST CONTROL
MODE – ACTIVE
LAMP (YELLOW)
PUMP CIRCUIT
OVERLOAD LAMP
(RED)
AUDIO ENUNCIATOR
LOCAL SERIAL PORT CONNECTOR
SYSTEM POWER LAMP (YELLOW)
SYSTEM POWER SWITCH
33
Pump Flooding Procedure
Before a probe can be installed down the well (or re-installed after servicing), the pump must be
flooded. The purpose of this procedure is to displace oxygen and vapors from within the pump
body. Once the system is installed, the added fluid will be pumped out to the recovery container
during the first recovery cycle. Note: CET does not ship new or serviced systems with the pump
pre-flooded.
Required Equipment:
• A suction device, such as syringe pictured at right.
NOTE: If purchasing device separately, any O-ring
included should be replaced with a Viton ® O-ring to
prevent swelling.
•
Suitable container for the fluid
•
Approximately 8 fl oz of flooding fluid, such as UltraPure Paraffin Lamp Oil, mineral oil, material from the
subject well, or similar non combustive fluid. DO NOT
USE WATER, the pump internals are NOT corrosion
resistant.
•
Approximately 12”of 3/8 fuel line
•
A product pump, CET P/N 90-1318-019
Flood the pump
• Attach the fuel line to the discharge side of the pump.
•
Attach the other end of the fuel line to the suction
device.
•
Place the pump inlet in the container of fluid.
•
Pull the fluid into the pump until it is observed in the fuel line.
•
Remove the fuel line from the pump.
•
Install (or re-install) the flooded pump into the probe (reference the “Pump Installation”
section of the Maintenance Operations chapter of the Operator’s Manual).
•
If the pump is not immediately installed in the probe, replace the red intake and
discharge caps. The pump can then be bagged for later use or storage.
Note: Always save the red caps from installed pumps for future use.
Once the flooded pump has been replaced in the Probe (See “Pump Installation” on page 68),
check through all the installation steps in this chapter to confirm that all have been completed
properly. You are now ready to begin system operations.
If the Control Box is mounted in an explosion proof enclosure, make sure power at the circuit
breaker panel is switched OFF. Then at the Control Box, turn the System Power switch to ON
and set the PRC switch on Auto. Then close the enclosure door and install the fasteners
around the flange. Torque the bolts to 30 ft. lbs. When ready to begin system operation, turn
the power back on at the circuit breaker panel.
34
2.0 Spill Buster System Operations
7 Easy Operation Steps
1.
Initial Power-Up
Page 36
2.
Front Panel
Page 37
3.
Magnum System Cycle
Page 38
4.
System Cycle and Schematic
Page 39
5.
Indicator Lamps & Audible Indicators
Page 40
6.
Product Recovery Cycle Control Switch
Page 41
7.
System Cycle Operation w/o Auto Seeker
Page 42
35
Initial Power Up
System Power Switch
The System Power Switch governs all power to the system
when it is connected to an AC power source, including the
Control Box, Probe, and Auto Seeker. A yellow lamp will light
indicating that the system power is ON. NOTE: When the
system is connected to a battery, the function of the switch is
overridden. After the system is turned ON and the PRC
switch is in the AUTO position, the system will begin its cycle
after a 5 second delay.
NOTE: Audio tones operate for approx. 5 minutes after the system power is
turned ON and when re-starting the Auto Cycle (PRC Switch). See charts for
Indicator Lamps and Audio Indicators on page 32. The tones can be turned
OFF altogether by altering DIP Switch S1-4 in the I/O Extension.
[See Dip Switch Settings, page 44]
36
Magnum Spill Buster Front Panel
.
PRODUCT RECOVERY CYCLE (PRC)
CONTROL SWITCH
PRODUCT TANK
FULL LAMP
(YELLOW)
PUMP ON LAMP
(YELLOW)
HI LIMIT SENSOR
WET LAMP (GREEN)
LOW LIMIT SENSOR
WET LAMP (GREEN)
PROCESSOR ON
LAMP (YELLOW)
HOST CONTROL
MODE – ACTIVE
LAMP (YELLOW)
PUMP CIRCUIT
OVERLOAD LAMP
(RED)
AUDIO ENUNCIATOR
LOCAL SERIAL PORT CONNECTOR
SYSTEM POWER LAMP (YELLOW)
SYSTEM POWER SWITCH
37
Magnum Spill Buster System Cycle
Seeking the Interface
There is a 5 second delay between the time that the System Power switch is turned ON and the
moment the cycle begins. The system will begin to automatically seek the water table by
lowering the Probe. The Audio Enunciator in the Control Box will beep every 2 seconds. The
Probe will pass through the layer of product and seek the level of water in the well. When the
Low Limit sensor contacts the water, the Low Limit lamp will light, and the system will beep 2
times per second. When the HI Limit sensor contacts water, the HI Limit lamp will also light,
and the Audio Enunciator will emit a continuous tone. When the HI limit sensor gets wet, the
Auto Seeker will raise the Probe until the HI limit band is above the water table PLUS an
additional amount as determined by the “Interface Clearance” dip switch S4-3 and S4-4. [See
Dip Switch Settings, page 44] The HI limit lamp will go out when the sensor becomes dry.
Pump Cycle
Many system
parameters
including cycle
time, pump rate,
and probe interface clearance,
may be altered
by changing dip
switches. See
DIP Switch Settings, page 44
The pump will begin to pump product, the yellow Pump lamp will light, and the
system will emit a warbling tone. The pump will continue to operate until it
pumps air (or unloads).
Cycle Delay Time
The system cycle enters a time delay to allow more product to flow into -or
recharge- the well. The Magnum Spill Buster system will automatically adjust
the delay time interval from 10 seconds to up to 6 hours based on the length of
the pump cycle, according to the standard factory configuration of the dip
switches. The system cycle delay time is a function of the recharge rate. [See
Dip Switch Settings, page 44]
Pump Override
The Magnum Spill Buster system is configured with a Product Tank Override
Probe. This Override Probe will inhibit pump operation when the product tank is
full, or when the Product Tank Override Probe is missing. When one of these
two conditions exists, the “full” lamp will light in the product tank on the Control
Panel. A Dip Switch (S2-4) is available to override this function when a Product
Tank Override Probe is not used. [See Dip Switches Settings, page 44]
NOTE: The Product Tank Lamp should not light when the system is
turned on, unless the Product Tank is full, or the product tank override
probe is not connected.
38
System Cycle Schematic with Auto Seeker
System Power ON
System Power lamp
ON
Processor lamp ON
Communications lamp
ON
1 beep/2
seconds
5 second delay –
system begins to
cycle
Probe lowers into
well
Water level in
well rises and
contracts the Hi
Limit sensor –
pump turns OFF
NOTE: You will
notice a delay
between each
step in the
system cycle.
The delays
enhance
operation in 2
inch (50 mm)
wells.
Low limit contacts
water
Low Limit Lamp ON
2 beeps/second
Hi limit contacts
water
Hi Limit Lamp ON
Continuous tone
Probe raises preset
time
Hi Limit Lamp OFF
2 beeps/second
Product Pump ON
Pump lamp ON
Warbling tone
Pumping air or Hi
limit wet?
Pumping air Pump switches OFF
NO
Pump lamp OFF
Delay for a time
interval according to
DIP switch S4
setting
39
Indicator Lamps
Label
Color
Indication
System Power
yellow
ON when unit has been switched ON
Overload
yellow
ON when a pump overload condition has occurred
Full
yellow
ON when product tank is full (float switch closed)
or when Product Tank Override Probe is not connected to Control
Panel
Pump ON
yellow
On when product pump is energized
HI
green
On when the high limit probe sensor is contacting water
LO
green
ON when the low limit probe sensor is contacting water
Processor
yellow
ON indicates normal control function.
Blinks when (a) pump circuit overloaded (e.g. failed pump) or
(b) pump circuit is open
Audible Indicators
Tone Sequence
Indication
Priority
Continuous tone
Hi limit sensor is contacting water
highest
Warbling tone
Product Pump is operating
***
2 beeps/second
LO limit sensor is contacting water
***
1 beep every 2
seconds
System Power is ON
lowest
40
Product Recovery Cycle (PRC) Control Switch
The PRC is a 3-way rocker switch, and is located on the upper left-hand corner of the Control
Panel.
Auto
At system power up, the
PRC switch is in AUTO (its
rest position), which allows
the system to cycle
automatically; that is, the
Auto Seeker will lower the
probe into the well after 5
seconds, etc. The system
will start to lengthen its
cycle time depending on
the amount of product
being pumped; i.e. a
shorter cycle time for faster
recharge rate. When
depressed, this switch
performs a test cycle,
raises the probe, or stops
the system from operating.
NOTE: System Power
remains ON.
Test System
A momentary push on the top of the PRC Control switch causes the pump to run for 5 seconds;
then the system will initiate a new cycle (i.e. the probe will seek the product/water interface and
start to pump the product. This Test System cycle is typically used during system installation
while holding onto the probe to determine if the pump is functioning properly, prior to lowering
the probe into the well. After testing, press STOP to prevent the system from beginning to
cycle, or AUTO to leave system operating.
Raise Probe
If the top of the PRC Control switch is depressed and held for more than 5 seconds, the Auto
Seeker will raise the probe to its upper limit for ease of Auto Seeker/probe removal. The system
will not start normal operations again until the switch is moved to STOP and then to AUTO.
41
Stop
Depressing the Stop side of the PRC switch will stop the product pump or the Auto Seeker midcycle. NOTE: System Power will remain ON. Returning the switch to the AUTO position will
initiate a new cycle after 5 seconds. Pressing STOP will also reset the Automatic Cycle Timer
to 10 seconds if dip switches S4-1 and S4-2 are set for AUTO (both OFF). Refer to section 3,
Dip Switches.
System Cycle Operation (no Auto Seeker)
The Auto Seeker is not used in the Magnum Spill Buster system in three modes as follows:
•
•
•
In a water depression mode, where the Magnum Spill Buster is set up in tandem with a
Water Depression Module,
In a DNAPLs or “sinkers” mode, where the probe intake will be positioned as close to the
bottom of the well as practicable,
When there is no water in the well. [See OPTIONS: Magnum Spill Buster used for
DNAPLS, page 46].
The Magnum Spill Buster system will automatically recognize that no Auto Seeker is plugged in.
The pump will continuously pump product until there is no more product to pump, and it starts
pumping air. The pump will cycle periodically (according to DIP Switch S4-1 and S4-2 settings,
page 44) if the Hi sensor is not contacting water. The pump will also cycle whenever the Hi
sensor goes through a transition from wet to dry.
When a Water Depression Interface is connected to the Magnum Spill Buster, the Auto Seeker
is not moved up or down, but rather the probe is fixed at the desired water level. The
depression pump will move the water/product interface past the product pump intake causing
the product pump to cycle.
42
3.0 Spill Buster Advanced System
Operations
DIP Switches
page 44
DNAPLs (Sinkers) Operation page 46
Advanced operations are defined as operating modes that are not set at the factory before
shipment of the unit to customers and/or field sites. Modifying the standard operating modes is
usually accomplished by changing the DIP Switch settings, which are located on the I/O panel
located underneath the main Control Box enclosure.
43
DIP Switches
To access the DIP Switches, unscrew the two screws on the bottom corners of the I/O
Extension and remove the cover.
DIP Switches S3 and S4 are used to adjust and customize the Magnum Spill Buster system to
individual sites and applications. The Magnum Spill Buster comes from the factory with DIP
Switches preset to a standard configuration which automatically adjusts the cycle delay time
interval from 10 seconds up to 6 hours [12 hours for versions previous to V.4], according to the
recharge rate. This configuration will work for most sites. In some cases, changing DIP
Switches from the standard configuration may increase the rate of product recovery or may
increase pump life, depending upon the specific site conditions.
DIP Switches S1-1, S1-2, S1-3, S2-2, & S2-3 are used for factory testing and troubleshooting.
These DIP Switches should NOT be changed unless directly requested by Clean Earth
Technology personnel. DIP Switch Set Nos. 3 thru 4 control user functions of the system, and
affect probe actions, including probe height above interface, pump speed, and pump cutoff. The
DIP Switch functions are discussed below. For further help and instruction with the DIP
Switches and the improvements they may make to your site, please call the factory.
44
S1 - The group of switches labeled S1 and TEST FUNCTIONS are all for CET
test functions, with the exception of S1-4. This switch silences all audible indicators
in the Magnum Spill Buster system. Normal setting is all four switches OFF.
S2 - The group of switches labeled S2 and SPECIAL FUNCTIONS contains more
CET test functions with two exceptions: S2-1, which enables the Magnum Spill
Buster system to pump DNAPLs; and S2-4, which allows the Magnum to operate
without the product tank override probe connected. Normal setting is all four
switches set to OFF. WARNING: WITHOUT OVERRIDE PROBE CONNECTED,
FULL TANK IS NOT DETECTED AND SECONDARY SPILL MAY OCCUR.
S3-1 & S3-2 - The group of switches labeled S3 and PUMP RATE (S3-1 &
S3-2) controls the pump motor speed. Slow is the lowest speed and may be used
when the product layer is thin. A thin product layer may create foam when pumped
too quickly. Normal is a middle speed, and fast is for maximum speed. Fast may
be used when dealing with either medium viscosity product, or greater back
pressure in the product tube, or greater well depth. High viscosity products are
most effectively pumped using our High Viscosity Magnum Spill Buster system.
S3-3 & S3-4 - The group of switches labeled S3 and PUMP UNLOAD
CUTOFF selects pump current cutoff threshold. The system should be started at
normal. If the Magnum pumps air and doesn’t cut off, or if the pump cuts off
prematurely (i.e., product remains in the well that should be pumped out), then
change switches S3-3 and S3-4 as follows: if cutoff is premature, decrease the
setting; if the pump does not cut off while pumping air, increase the setting. Allow
the Spill Buster to run through 2 or 3 cycles between changes in cutoff switch
settings. Any change in PUMP RATE settings (S3-1 and S3-2) will affect PUMP
UNLOAD CUTOFF. Be sure the pump cuts off within 15 seconds when
pumping air. Continued dry pumping will damage the pump. NOTE:
MAX setting is intended for set up/demo use ONLY, and in most cases
will not result in a desirable recovery rate.
S4-1 & S4-2 - The group of switches labeled S4 and CYCLE FUNCTIONS
determines the time delay interval between pump cycles. Automatic is the normal
setting, directing the Magnum control to vary the delay time interval according to
the amount of product pumped. The other three settings are fixed time intervals:
10 sec., 20 min., & 6 hrs. NOTES: The fixed time intervals will override the
automatic delay time adjustment feature of the Magnum system, and it will
continuously cycle at the time delays specified. The 10 second setting is for
test, and it may be useful when setting up the Magnum system. If left in the
10 second setting, the pump will automatically switch to the 20 minute
interval after 20 cycles.
S4-3 & S4-4 - The group of switches labeled S4 and INTERFACE
CLEARANCE determines how high the pump intake will be raised above the
product/water interface. These settings are useful to avoid biological growth that
accumulates at the product/water interface in some wells. The MIN setting is
recommended in a well with no biological growth and will result in the maximum
recovery of product and minimum product thickness (approximately 0.1” (0.25mm).
NORMAL will give a greater distance from the interface, with MAX being the
highest (approx. 2”).
45
DNAPLs Operation
General Description
DNAPLs (or “Sinkers”) refer to those products that are heavier than the water and therefore are
found below the water layer rather than above, as in the case of floating product. By following
the procedure below, the Magnum Spill Buster may be adjusted to automatically pump low
viscosity sinkers from a 2” well from depths of up to 150(?) feet.
DNAPLs Procedure
The system should be run with no Auto Seeker or with Auto Seeker disconnected. Set I/O board DIP
Switches S2-1 to ON and S2-2 to OFF. Lower the probe into the well to a point 3” - 4” above the
bottom. This positions the probe to avoid sediment and sludge which could clog the intake.
CONTROL PANEL
PRODUCT TANK
OVERIDE PROBE
PRODUCT DISCHARGE
TUBING COUPLER
PROBE EXTENSION CABLE
PROBE CABLE CIRCULAR
CONNECTOR
PROBE WITH
PRODUCT PUMP
WATER TABLE
DNAPLS PRODUCT
(SINKERS)
In the DNAPLs mode, the product recovery cycle differs somewhat from the standard cycle. The pump
will run periodically according to the DIP switch S4-1 and S4-2 setting, as long as the HI limit sensor is not
contacting water. As the sinker product is pumped off, the water/product interface will drop. When the HI
limit sensor contacts water, the pump will stop and a delay will occur before the next cycle. If water is not
present in the well, the pump will be stopped when it begins to pump air.
46
I/O board DIP switch setting
for DNAPL operation
47
DNAPLs System Cycle without Auto Seeker
48
4.0 Other Options
1.
Immediate Response Box, page 50
2.
Battery Operation, page 51
3.
Solar Panel Charging System, page 52
4.
Water Depression Control Manual, page 53
49
Immediate Response Box
The Immediate Response Box (I.R. Box) is a rugged plastic box that contains a Standard
Magnum Spill Buster system. The I.R. Box provides an extremely portable system to start
removal of product in a 2” or larger well with minimal equipment set-up. A large forged shackle
is attached on the left end of the box for security. Since the I.R. Box contains a standard control
box, it can be used with any other Spill Buster options.
WARNING
Control Box and
Standard Auto
Seeker must be
located outside of
any classified
hazardous areas.
Refer to applicable
codes
The I.R. box can easily be carried in a small pick-up truck or van. The basic setup involves
mounting the Auto Seeker outside of any classified hazardous atmospheres (on many sites it is
possible to move the Auto Seeker from the classified hazardous zone by raising it above the
well head); then connecting the product tank discharge tube and overflow sensor to the product
tank, and connecting the Auto Seeker cable and the probe signal cable.
The system is powered by 115VAC from an extension cord
(see pg. 63 for extension sizing). In addition, cables can be
provided to operate the system from a 24 volt deep cycle
battery. See page 51 for battery operation of system.
50
Battery Operation
For sites with no utility connection available, batteries can be used. It is necessary to ground
EVERY battery operated system. [See page 18]. The batteries should be deep cycle type.
[NOTE use two 12 volt batteries in series for 24 volt power]. Use 12 AWG wire. One end of the
cables will connect to the Control Box inside the I/O extension on the terminal block labeled
“Batt”. Connect the other end to the battery, making sure that the polarity is correct. NOTE:
hooking up a battery will bypass the power system switch. When the Magnum Spill Buster is
hooked up to the battery, the system will activate, as if the power switch were turned on. No dip
switch settings or board changes are necessary with battery operation. Battery life will be a
function of the battery size, well depth, product viscosity and many other factors.
NOTE:
When operating the
Magnum Spill Buster on
battery power, remember
to ground the system
properly. Refer to page 18
for proper grounding
procedures.
51
Solar Panel Charging Operation
For sites with no utility connection available, batteries with a
photovoltaic recharging system (solar panels) can be supplied. These
systems are 24 VDC and work in conjunction with 2 or more Solar
Panels. The solar system can be integrated with an Immediate
Response box if desired.
The Solar Panel Charging system includes a heavy-duty frame and
mounting hardware for 2 or more Solar Panels (depending on your site
power requirements and geographic location relative to available sun
power), 2 12VDC Deep cycle batteries, a fully potted waterproof control
regulator, and custom cabling. A secondary condition on panel sizing
is the amount of product present at the site to determine the duty cycle
or percentage of time the system will run.
As with all Clean Earth Technology products, the Solar Panel Charging
system features an easy set-up and operation. Complete wiring
directions are supplied with each system and CET is available to assist
if desired. Please contact your Clean Earth Technology products
distributor for a quote specific to your site.
Clean Earth Technology currently uses the Specialty Concepts ASC
line of Charge Controllers which are UL listed, FM and CSA rated
for Class 1, Div. 2, Groups A, B, C, D hazardous locations. These
controllers are fully encapsulated and thus are water proof. We do
however, recommend that they be placed out of direct exposure to
the environment along with the batteries and associated wiring.
The model specifically matched for operation with the Magnum Spill
Buster is ASC 24/16 AE. Please confirm that this is the model
received with your solar system upon delivery from the solar power
manufacturer.
NOTE:
When operating the
Magnum Spill
Buster on battery
power, remember to
ground the system
properly. Refer to
page 18 for proper
grounding
procedures.
52
Water Depression
Dual pump product recovery operation can be accomplished with the Magnum Spill Buster
System plus a Clean Earth Technology Water Depression Control Module and a Grundfos RediFlo 3 SQE-NE pump sized to your well. The Magnum Water Depression system is designed
specifically to take advantage of all the features of the Grundfos Redi-Flo 3 SQE-NE pump.
This Module obtains its water level signals and control logic from the Magnum system control
box and in turn controls water flow by using the soft start feature of the Grundfos pump to turn it
on and off. This line of Grundfos pumps is upgraded to safely bring the high level AC voltage
through the recovery zone to the pump without the need for specialized fittings.
A set of normally open contacts are provided for use with a safety override probe, which will
shut down the water pump when closed.
Typical installation of a Water Depression Control Module
alongside a Magnum Spill Buster Control Panel
53
Water Depression Specifications
Input Power
115 VAC or 230 VAC, 30 AMPS maximum
Operating Temperature Range
40 to +140 degrees F or -40 to +60 degrees C
Pumping Rate
0 to 33 GPM depending on water pump sizing
Standard Well Depth
50’ max
Maximum Well Depth
150’ on special order with 175’ water pump power cable.
Control Box Dimensions: 9” wide x 10.5” high x 6.5” deep. An additional 10” clearance is
required below for cable exit and an additional 9” clearance is required in front and to the left for
door swing.
Auxiliary Override Terminal Block: Provides wire termination for an Auxillary set of Normally
Open switch contacts. Used for emergency water depression pump shutoff if there is a water
treatment failure. Switch contacts need to be rated for 1 Amp at 12 VDC minimum.
Total Water Depression System Weight (w/o pump): 8 lbs.
Pump Requirements
WARNING!
Due to the inherent design features of both the
Magnum Water Depression System and the pump, the
Grundfos Redi-Flo 3 SQE-NE Submersible
Environmental Pump is the only acceptable water
pump.
120 VAC or 240 VAC motors are available
Standard flow ranges are as follow:
The Grundfos
Redi-Flo 3 SQENE is the only
water pump
approved for use
with the Magnum
Water Depression
System.
3 to 15 GPM
7 to 33 GPM
1/2 and 3/4 horse power motors available depending on head pressure.
Options
Power Cable Lengths.
Standard length is 80’ from control box to water pump.
Other lengths available on special order.
54
Water Depression Control Panel (WDCP)
The Water Control Module is a NEMA 4 UL approved enclosure
containing the water pump control solid state relay and the I/O wiring
terminal blocks. The control box door should be kept latched at all
times when not in use, and excessive moisture (e.g. rain) should not
be allowed to enter the box. Although there are no open contacts,
this is not an explosion-proof enclosure; locate the Control
Module in a non-hazardous location!
Front Panel
The Control Panel is accessible by opening the front door of the Control Box. The Control
Panel contains the main power switch for the depression pump. This switch also is a backup
circuit breaker for the water pump, and is rated 25 Amps at 230 VAC.
The first (lower) position of the switch is water pump OFF. Once the switch is turned on the
water system is enabled to follow orders from the Magnum Spill Buster control box, which gets
its water level information from the product probe sensors. The Magnum control box will send
signals to turn the water depression pump on and off as required to maintain the desired water
depression level. All product skimming functions are still controlled by the Magnum Spill Buster
control box as before.
WARNING!
This is not an
explosion-proof
enclosure;
locate the
Control Module
in a nonhazardous
location!
PUMP
POWER
SWITCH
LATCH
55
Installation of the Water Depression Pump
The WDP should be installed near the bottom of the screened section of the recovery well, but
should not rest on the bottom of the well. Placing the WDP on the bottom of the well may result
in pumping sediment that collects on the bottom of the well.
•
•
•
•
Determine the distance from the well head to the WDP intake. Cut a length of pipe that
is 0.25 m longer than the distance from the well head to the WDP intake. We
recommend that 1.25” flexible plastic piping is used. thread the WDP power cord
through the pipe.
Attach the pipe to the pump, using an appropriate fitting. At the well head end of the
pipe, thread the WDP power cable through the “Y” fitting (“Y” fitting will be provided by
CET). Thread the wire so that it enters the “Y” fitting at the bottom, and exits through the
watertight seal. Attach the wellhead end of the pipe to the bottom of the “Y” fitting, using
a 1.25” male NPT/1.25” barbed fitting. Secure the pipe to the barbed fitting, using two
hose clamps.
Secure the WDP at the desired depth, using a steel cable, nylon rope, or chain. Secure
the cable, rope, or chain to the WDP, using the stainless steel loop at the top end of the
pump housing. Lower the WDP into the well using the cable, rope or chain. Secure the
cable, rope or chain at the wellhead to ensure that the pipe is not bearing the weight of
the pump.
Install pipe from “Y” fitting to the water treatment system. It is important to install a
manual flow control valve in the water discharge line between the “Y” fitting and the
water treatment system. The flow control valve is used to adjust the rate at which water
is being pumped from the well. Doing so “sizes” the pump better to the actual well
conditions. This will help maximize pump on/off cycle time, thereby extending the life of
the pump motor. This will also tighten and smooth out depression level control.
Installation of the Water Depression Control Module (WDCM)
Mount the Control Panel in a suitable location (outside of any classified hazardous area) within
a few feet of the Magnum Spill Buster Control box. Typical installations are in sheds, on the
side of buildings, or on a utility type pedestal mount.
Connect the 20 pin cable from the panel to the Auxillary I/O outlet in the MSB control box.
56
Hard Wiring the Water Depression Control Panel
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
The Water Depression Control (WDC) Module is designed to operate on either 115 or 220 VAC
Power just by making the appropriate hook ups into the terminal block. Wiring to the module will
be routed to the 120 VAC or 220 VAC portions of the terminal block depending on the voltage of
the pump. It should be noted that the power into the box should be rated the same voltage and
amperage as the rating for the depression pump.
The cabling coming out of the well head should be long enough that it can be run directly to the
WDC Module box. Excess
cable can be coiled up at
the well head or control
shed. Next have a
certified electrician wire AC
power into the control box
and to the appropriate
spots on the terminal box
as follows:
•
•
•
Feed the WDC Power Cord thru the Control Panel bulkhead strain relief.
Connect each of the three wires in the pump power cord to the connections (green,
black, white) in the control panel at the space labeled “PUMP”.
Connect the power supply cord from the circuit breaker to the WDC panel. Starting from
a 25 Amp., 110 V or 220 V circuit breaker in the distribution box, run the cord (green,
black, white) to the appropriate connections labeled “LINE”.
57
Probe Installation for a Standard System
•
The probe signal cable is hooked to the signal cable
extension via the “No Auto Seeker Connector”.
Insert both plugs into the connector and tightly bolt
together with hardware provided. Connect the other
end of the signal cable to the WDC Module control
panel.
NO AUTO SEEKER
CONNECTOR USED WITH
A STANDARD MAGNUM SYSTEM
•
Hook the product discharge tube to the probe termination module and to the recovery
tank using the fittings provided.
•
Lower probe into well until the HI/LO lights on the control panel just come on. This
signifies that the probe is at the static product / water interface. Now lower the probe by
the amount of depression desired (Example: To depress 1 foot, lower probe 1 more
foot) and secure.
Probe Installation for an Explosion Proof System
•
The probe signal cable is hooked to
the signal cable extension via the MilSpec connectors. Match polarity key
on the connectors, push together and
tighten connection nut Connect the
other end of the signal cable to the WDC Module control panel.
•
Hook the product discharge tube to the probe termination module and to the recovery
tank using the fittings provided.
•
Lower probe into well until the HI/LO lights on the control panel just come on. This
signifies that the probe is at the static product / water interface. Now lower the probe by
the amount of depression desired (Example: To depress 1 foot, lower probe 1 more
foot) and secure.
58
Dip Switch Settings
In order for the Water Depression Module to work in configuration with the main Magnum
Control Box, it is necessary to put DIP switches 1 and 2 on S2 in the UP position and all DIP
switches on S4 in the DOWN position in the Magnum Control Box.
Start Up
•
Turn the power on in the MSB Control Panel. Observe that the HI/LO lights on the MSB control
panel are on. When used with the WTD option, it is necessary to put dip switches 1 and 2 on S2
in the UP position to enable the product pump to come on each time the HI light goes off.
•
Turn the power on in the WTD Control Panel. Watch for proper cycling to develop between the
HI and LO lights. When the oil/water interface is pumped to the level of the High level sensor, the
HI limit light will go out. The product pump will then start pumping product. The water pump will
continue to pump until the LO level light goes out, and then the water pump shuts off. When the
oil/water interface rebounds to the level of the high sensor band on the MSB probe, the water
pump will automatically restart and the product pump will shut off briefly until the high level sensor
goes out again. Throttle the water flow control between the pump restart and shut-off. This will
help minimize pump on/off cycling, thus tightening depression level control and extending the life
of the pump motor. Occasionally adjust further as the cone of depression develops or there are
seasonal flow rate influences.
59
System Schematic
60
Development of a Hydraulic Cone of Depression: Tips and Good Practices
Proper development of a Hydraulic Cone of Depression is not as straight forward as it might
seem. An attempt to rapidly depress to full desired depth during the initial startup can cause
emulsification. The following information is offered to help you understand some of the basic
principles of water depression and the development of a hydraulic cone. Be aware that no two
sites are the same and all sites will behave differently from one another with respect to time and
conditions.
INITIAL WATER REMOVAL
In the event a
depression level of
a foot or more is
required for the site,
the depression
should be started
with a depression
level of 1 foot or
less. Then, over a
period of several
days, the
depression should
be increased a foot
or less at a time.
Figure A
When initially developing a
depression cone, take into
consideration that the initial flow
rates required will be much greater
during steady state operation. This
is due to the fact that initially the
water located in the depression cone
(hatched area in figure A to the right)
must be pumped in addition to the
normal recharge of water. This
would be like pumping water out of a
swimming pool while more water is
being pumped in at the same time.
Only when the pool is empty - and only then - will the pumping rate
equal the recharge rate of the water.
This water can amount to a large quantity and can take days or weeks
to pump out. For instance, a five foot depression with a radius of
influence of fifty feet would require the removal of roughly 150,000
gallons of water! A five G.P.M. pump would require over twenty days
to pump this much water without any recharge water coming in.
If a significant depression level (say several feet) is attempted all at once, many days/weeks
may be required to get the depression level down to the intake of the pump. If product starts to
accumulate during the time that the product pump intake is flooded, no product recovery will be
achieved even when significant product accumulations occur. For this reason alone it is a much
better practice to depress the water table in stages of 1/2’ to 1 foot at a time, so that
accumulated product can be pumped off sooner.
61
Avoiding Cascading Water
It’s important to understand how a hydraulic cone of depression typically develops, and the
problems that can occur if it is not done properly.
When a deep level of
depression is first initiated, the
Water or saturated soil
hydraulic cone should be
developed in a progressive
Soil or bedrock
fashion similar to the one
depicted in Figures B, C, and D.
Figure E shows what happens if
the water depression level is
Figure B
developed too quickly: when
Figure C
the water is initially up against the well screen for most of the
depression height it can lead to water cascading into the well down to
the product water level.
Product Layer floating on water table
Figure E
Figure D
This could be similar to putting a piece of
well screen in a pool and trying to pump
water out of the screened area - it would just
pour in again from all levels. In the ground
the effect on the flow of water into the well
would be minimized by the resistance of the
surrounding soil, but significant cascading
water can occur none the less.
Figure F
Sometimes the cascading water can come
in the form of a stream from a single spot
where a fissure occurs in the soil, as shown
in Figure F. This can actually look similar to
a water fountain. A stream of water like this
may result in serious mixing of water and
product creating emulsions, especially with
heating and diesel oils. Since any product recovery system relies on
some form of liquid level detection sensor to position a pump inlet in
the accumulated product area of the recovery well, this emulsification can significantly impair
product recovery.
62
The Magnum Spill Buster’s sensors will ignore cascading water as long as the water
stream is broken up (like individual rain drops) and won’t allow a conductive path back
to the point of stream entry. However, if the stream becomes solid, then the sensor
will falsely detect the water/product interface where the cascading water enters the
well, rather than at the real interface. The resulting erratic activity of the system may
lead the user to think that the system is defective when in reality the depression level
should be reduced.
When cascading water causes the system to falsely detect that its sensors are
flooded, it may signal the water depression pump to stay on longer than it should. This
could result in lowering the water/product interface to the water pump intake, and
pumping raw product into the water treatment system. This is usually a very bad
situation since most water treatment systems are not intended to, or capable of,
handling pure product and are overwhelmed. Subsequently, raw product can end up
being discharged back into the environment. The moral of this story: don’t depress too
deeply, too quickly.
Conclusions and Warnings
A) Cascading water may cause very erratic Magnum Spill Buster system behavior.
Symptoms may include the panel lights for the product and depression pumps to act
out of sequence and erratically.
B) Cascading water may cause the sensor to detect a continuous false product/water
interface many feet above the real interface. This may cause large quantities of
pure product to be pumped into the water treatment system and be discharged
into the environment.
C) Cascading water may cause product and water to mix creating “mayonnaise like”
emulsions which will immensely complicate product recovery.
63
64
5.0 Maintenance Operations
Procedure
Page
Probe/Product Pump
66
Alpha Array™ Sensor Band Area
66
Cleaning the Probe
67
Product Pump
68
Removing the Product Pump
69
Pump Installation
73
Logic Board and Power Supply
74
Removing the Logic Board
75
Removing/Installing Probe Product
Tube from the Reel
76
65
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
Probe/Product Pump
This is the down-well component of the system. The Probe/Product Pump contains circuits for
sensing the product/water interface, as well as housing the product pump. Sensors assure that
water will never be pumped into the product tank. The Probe/Product Pump assembly is
constructed of state of the art polymer materials for very high corrosion and deterioration
resistance.
Probe Product Cable
The Probe product cable is the “umbilical cord” of the
down-well probe, connecting it to the above ground
components. The cable carries signal and electrical
power to and from the probe along with the product
discharge tube. Examine the entire length of the probe
product cable on a routine basis, looking for signs of
unusual wear or strain. If present, these damaged areas
may compromise the electrical wiring, leading an Intrinsic
Safety barrier to trip which would then need replacement
at the factory. Damage to the Probe product cable could
also cause a leak in the product discharge tubing, potentially causing a secondary spill. Contact
Clean Earth Technology if you detect damage to the Probe product cable.
Alpha Array Sensor Band Location
There is an array of sensor bands, internal to
the probe, including one dispensing a low
limit signal, and one dispensing a high limit
signal. The sensors use a low frequency,
ALPHA ARRAY™
omni-directional signal to sense the
SENSOR BAND AREA
product/water interface. The sensors operate
on the principle that signal transmission
varies significantly due to the transmission
characteristics of the type of fluid surrounding
the antenna. The variation in signal
transmission is used to accurately determine the interface location relative to the product inlet.
The sensors are constructed of “state of the art” polymer materials for corrosion resistance and
long life.
66
Inlet Slot
Probe Inlet slots and holes in the sensor band area of the probe body allow the product and
water to freely enter into the interior of the probe. These slots must be kept clean and free of
debris in order for the system to function properly. Care must be taken when cleaning the inlet
slots and holes to avoid damaging the probe and sensor band area. Avoid using sharp tools
such as screwdrivers, knives, etc. to clean the probe inlet slots and holes.
The product inlet
slots lie toward
the end of the
probe, which
allows the
product to flow
into the pump
filter. There are
also several
round holes,
which allow water
and product to
freely flow into
the inside of the
probe pump
cavity where the
sensor bands are
located. These
holes must all be
kept clean.
PRODUCT
INLET SLOT
PRODUCT/WATER
INLET HOLES
ALPHA ARRAY™
SENSOR BAND
AREA
END CAP
Cleaning the Probe
If the Probe sensors become coated with a very heavy
layer of biological growth, emulsions, or other materials,
the Probe will not function properly. The Probe can be
cleaned, as shown below, using spray cleaner or mild dish
liquid in warm water and a cloth or soft bristled brush.
Care must be taken to avoid damaging the Probe and
sensor bands, either by brushing too hard or by using a
very hard tool to perform cleaning.
67
Make sure that the Product Inlet Slots and holes are clear, and
the interior Alpha Array™ Sensor Band area is free of coating
and debris
If persistent residue sticks inside the sensor area, a soft brush
or tooth brush is recommended to fully clean sensors.
The pump inlet screen and inlet holes should be checked and cleaned also during inspection.
The Product Pump
The product pump is a rugged and chemically
resistant roller vane unit capable of pumping up to
46 gallons (174 liters) per hour of low viscosity
liquids (up to 12 Cp) per day in shallow wells and to
reliably recover product out of wells 150 feet in
depth. In addition, it can withstand a certain amount
of small solids such as dirt or sand passing through
it. See Pump Performance Curve, page 87.
68
The Product Pump is located near the bottom of the probe and is easily accessible. The pump
is inserted into the bottom of the probe body and is held in place by the spring and end cap.
Filter Assembly
Filter Gasket
The pump product nipple and the pump
electrical contacts should also be kept
clean.
Pump Contacts
Product
Discharge
Nipple
Removing the Product Pump
Probe Body
Product Tube
Lock Buttons
Pump
End Cap
Filter Gasket
Filter Assembly
Spring
The Product Pump is located near the bottom of the probe and is easily accessible. The pump
is inserted into the bottom of the probe body and is held in place by the end cap.
To remove pump, push end cap firmly into probe to loosen the locking buttons. While pushing
end cap in, press locking buttons into probe.
69
Releasing First Lock Button
Releasing Second Lock
Button
Removing End Cap
The Pump is removed from the Probe using a Pump Removal Tool supplied with the system.
One end has two pins which are used to spin the filter & filter top off. The second end has a
threaded hole, which is screwed onto the inlet end of the Pump. The Pump then is pushed out
of the Probe.
Pump Removal/Insertion Tool
Threaded Hole
Filter Adapter Pins
Remove the Pump
70
Pump Maintenance
After the filter is cleaned, clean Pump contacts with brush. Make sure that the contacts are free
of any corrosion. If the pump will be immediately reinstalled in the probe and the system will be
turned on again, then proceed to the pump flooding procedure on page 72.
If the pump or the system as a whole is to be decommissioned and stored for a period of time,
then the pump should be lubricated to prevent the pump rotor from corroding (which may lead to
pump failure). In this case lubricate the pump internals with a Non-Flammable oil such as 3 In 1
Oil®. To lubricate, hold Pump upside down (intake hole up) and squirt lubricant into intake hole.
This will allow lubricant to flow into working parts of Pump. Also, squirt lubricant into product
discharge nipple in Pump.
71
Pump Flooding Procedure
Before a probe can be installed down the well (or re-installed after servicing), the pump must be
flooded. The purpose of this procedure is to displace oxygen and vapors from within the pump
body. Once the system is installed, the added fluid will be pumped out to the recovery container
during the first recovery cycle. Note: CET does not ship new or serviced systems with the pump
pre-flooded.
Required Equipment:
• A suction device
•
Suitable container for the fluid
•
Approximately 8 fl oz of flooding fluid, such as UltraPure Paraffin Lamp Oil, mineral oil, material from the
subject well, or similar non combustive fluid. DO NOT
USE WATER, the pump internals are NOT corrosion
resistant.
•
Approximately 12”of 3/8 fuel line
•
A product pump, CET P/N 90-1318-019
Flood the pump
• Attach the fuel line to the discharge side of the pump.
•
Attach the other end of the fuel line to the suction
device.
•
Place the pump inlet in the container of fluid.
•
Pull the fluid into the pump until it is observed in the fuel line.
•
Remove the fuel line from the pump.
•
Install (or re-install) the flooded pump into the probe (reference the “Pump Installation”
section of the Maintenance Operations chapter of the Operator’s Manual).
•
If the pump is not immediately installed in the probe, replace the red intake and
discharge caps. The pump can then be bagged for later use or storage.
Note: Always save the red caps from installed pumps for future use.
72
Pump Installation
Reinstall pump filter assembly. Don’t forget to install filter gasket between filter and Pump.
Make sure that the filter assembly is tight. When installing the Pump make sure the product
discharge nipple is aligned with the Pump discharge seal.
Product Discharge Nipple
Pump Discharge Seal
Probe Contacts
Drop Pump into Probe and push Pump until the Pump contacts are seated firmly against
Probe contacts. The Pump Tool can be used to align the Product Discharge Nipple with
the seal. If firm contact is not made, the Pump may not function. Finally, insert the end
cap such that both lock buttons snap in place.
73
Logic Board and Power Supply
•
.Warning- All AC Power wiring must be done by a qualified electrician
who is familiar with all appropriate NEC and/or local codes. Electrical
shock may result in serious injury or death.
•
Warning- Explosive Vapors. Always disconnect AC power at its source
prior to connecting/disconnecting any wires and/or cable connections
located within any hazardous locations.
On occasion, when troubleshooting with Clean Earth Service about an issue with your system,
our technician may be able to pinpoint the problem to the Control Box’s logic board. Use this
section to properly remove and replace the board as required for service. The Logic Board is
located on the back panel inside the Control Box. The Control Panel is held in place by four
spring loaded catches (see below). The Control Panel can be removed to expose the Logic
Board and Power Supply by carefully prying the Control Panel with a screwdriver near one of
the four corners. The control panel will then “pop” out.
POWER SUPPLY
“Popping” Off the Front Panel with
a Screwdriver
HIGH VOLTAGE
SAFETY BARRIER
LOGIC BOARD
Lift off Front Panel
[NOT SHOWN] UL APPROVED
ISOLATION BARRIER (OPTIONAL)
74
Removing the Logic Board
Indicates Location
of 2 Plug-Ins
Indicates Location
of 4 Stand-Offs
Pump Power
Terminal Block
RS-485
Terminal Block
Indicates
location of 4
Screws
1. Disconnect Power
2. Unplug two (2) plug-ins.
3. Remove pump power wires from terminal block.
NOTE: When replacing wires - Green, White, Red & Black
4. Remove RS-485 wires from terminal block.
[IMPORTANT -- Note/record position of color coded wires]
5. Unscrew four (4) screws.
6. Disengage four (4) stand-offs.
7. Slide board out toward the top of the box.
75
Removing Probe from Auto Seeker Reel
Warning!
To prevent damage to the logic board, DISCONNECT the Auto Seeker Extension cable
from the control box before rotation of the Auto Seeker by hand.
There are two cases in which it is necessary to remove the Probe Product Tubing from the reel:
1) If the Probe stops before reaching the interface; or, if the reel stops before the Probe is fully
rewound when raising the Probe, then the Auto Seeker rotation is not fully synchronized with the
Probe Product Tubing. The tubing must be fully unwound and removed from the reel; then
reinstalled and rewound in order to correct the problem.
2) When decontaminating the Auto Seeker unit to return to the factory for service.
Resynchronizing Product Cable With The Standard Auto
Seeker Rotation
Rotate the Auto Seeker in the DOWN direction until the entire length of the Probe Product Tube
is off the reel. This can best be accomplished by initiating a cycle with the PRC switch (see
Diagram Pg. 29), while keeping the probe away from contact with a grounded surface. The
system will continue to lower the Probe in search of the interface. Press STOP on the PRC
switch when all the Product tubing is off the reel.
If the Auto Seeker stops before the tube is fully unwound, then the unsynchronized Auto Seeker
has reached its extreme DOWN position. Press STOP and remove the remaining tubing by
hand without moving the reel.
If the unsynchronized Auto Seeker continues to rotate past the point at which the Product Tube
is fully unwound, then press STOP and detach the Product Tubing from the Auto Seeker at the
reel. [See instruction, following page.] After the Product Tubing is detached, set PRC switch
back to AUTO and allow the Auto Seeker to go in the DOWN direction until it stops on its own.
The Auto Seeker reel is now in the extreme DOWN position. Set PRC switch to STOP.
Now, reattach the Product Tube to the reel. Don’t forget the retainer clip! Rewind the tubing
onto the reel by 1) moving the HI LIMIT dip switch (S1-1) to ON [see page 37] and then 2) by
placing the PRC switch in the AUTO position. This will cause the Auto Seeker to rotate in the
UP direction. [If the Auto Seeker does not start going up, carefully turn the reel by hand until it
starts moving. It should only take about a quarter turn before beginning to wind automatically.]
Feed the cable carefully back and forth in layers. Switch the PRC to STOP once the probe is in
the full UP position.
Take care that the probe head is not dragged along the ground as the Auto Seeker rewinds.
[Remember to turn OFF the HI LIMIT dip switch.]
76
To Remove the Probe from a Standard Auto Seeker Reel
The Probe is connected to the hub of the reel by instant
tube fittings and a Slim-line™ connector.
SLIM LINE CONNECTOR™
DISCHARGE TUBE FITTING
RETAINER CLIP
DISCHARGE TUBE
Unplug the Slim-line™ Connector using an Allen wrench
and a pair of needle nose pliers to hold the stand-off nut
in place, and remove the screws.
Remove the red locking clip on the discharge tube fitting
by pushing the bottom of the clip up with two fingers and
pulling up at the top with your other hand. Then push
down on the locking sleeve of the discharge tube fitting
with a screwdriver while pulling on the discharge tubing.
Make sure to push the locking sleeve squarely into and
against the fitting; otherwise, the tube will not be
released.
77
To Install the Probe on a Standard Auto Seeker Reel
WARNING: To prevent damage to the logic board,
DISCONNECT the Auto Seeker extension cable from the
Control Box before rotating the Auto Seeker by hand. To
wind the probe onto the reel, turn the reel a couple of turns
by hand in order to reset the safety switch. This is an
important step to ensure that the probe is synchronized with
the Auto Seeker safety limit switches.
Check to be sure the Slim-line™ gasket is in place. Install
the Slim-line™ connector using an Allen wrench to tightly
install the screws.
Insert the product discharge tube into the discharge tube
fitting. Install the red locking clip.
Reconnect the Auto Seeker to the Control Box I/O pouch
Power up system and press the PRC Switch to the RAISE
PROBE position for 5 seconds until the Auto Seeker starts
to rotate upward. [If the Auto Seeker does not start going
up, carefully turn the reel by hand until it starts moving. It
should only take about a quarter turn before beginning to
wind automatically.] Feed the cable carefully back and forth
in layers. Switch the PRC to STOP once the probe is in the
full UP position.
Take care that the probe head is not dragged along the
ground as the Auto Seeker rewinds.
78
To Remove the Probe from an Explosion Proof Auto Seeker
Reel
The Probe Cable is connected to the hub of the reel by
instant tube fitting and the electrical connections are via
a MIL-Spec circular connector.
CONNECTOR RECEPTACLE
CONNECTOR PLUG
DISCHARGE TUBE FITTING
RETAINER CLIP
DISCHARGE TUBE
Remove the red locking clip on the discharge tube fitting
by pushing the bottom of the clip up with two fingers and
pulling up at the top with your other hand. Then push
down on the locking sleeve of the discharge tube fitting
with a screwdriver while pulling on the discharge tubing.
Make sure to push the locking sleeve squarely into and
against the fitting; otherwise, the tube will not be
released.
.
After removing the product discharge tubing remove the
probe cable by threading the MIL-Spec plug collar off
the receptacle and gently pull the connector plug out.
79
To Install the Probe on an Explosion Proof Auto Seeker Reel
WARNING: To prevent damage to the logic board,
DISCONNECT the Auto Seeker extension cable from the
Control Box I/O pouch before rotating the Auto Seeker by
hand. To reinstall the probe, turn the reel by hand to gain
easy access as shown.
Insert the probe cable plug firmly into the MIL-Spec
connector receptacle and then tread the collar down.
Tighten the collar as tightly as possible in order to insure the
connector gasket is fully sealed.
Install the product discharge tube: Insert the product
discharge tube into the discharge tube fitting. Install the red
locking clip
Reconnect the Auto Seeker to the Control Box I/O pouch.
Power up system and press the PRC Switch to the RAISE
PROBE position for 10 seconds until the Auto Seeker starts
to rotate upward. Feed the cable carefully back and forth in
untangled layers . Switch the PRC to STOP once the probe
is in the full UP position.
Take care that the probe head is not dragged along the
ground as the Auto Seeker rewinds.
80
6.0 Troubleshooting
Problem
Possible
Causes &
Solutions
Problem
Possible
Causes &
Solutions
System doesn’t power up when System Power switch is turned ON.
1. Make sure Control Box is connected to the power source.
2. Check for issues with the power source.
System powers up, but pump won’t run.
1. Probe Cable is not plugged in or is broken.
- Check that Probe cable connectors are properly and securely connected
at both the Control Box I/O panel and at the Auto Seeker.- Inspect entire
length of Probe Cable for signs of damage.
2. If the Product Tank lamp is ON:
-
Make sure the Product Tank is not full
-
Make sure Product Tank sensor is connected to Control Box
-
Make sure the Pump contacts are seated firmly against probe
contacts. (Remove end cap from probe and push pump up in probe
using your thumb; then test system)
-
Make sure the Pump is operating correctly. (Replace pump and try
TEST SYSTEM on PRC switch).
Problem
Probe stops before reaching interface, or
when raising probe, Auto Seeker stops before being fully rewound on
reel.
Possible
Causes &
Solutions
Problem
Auto Seeker rotation and probe product tubing are not synchronized. To
correct, See Section 5 on page 76.
Possible
High Limit sensor is not sensing water, or probe moves to the bottom
of the well.
1. Make sure there is enough water in the well for the Magnum to
operate. There must be at least 3” of water in the well below the
81
Causes &
Solutions
product.
2. Make sure the System is properly grounded. See page 18.
3. Make sure that the probe cable is not damaged or disconnected.
4. Make sure that the sensor bands in the probe head are not fouled. If
needed, See page 67.
Problem
Possible
Causes &
Solutions
Pump runs but no product is pumped.
1. Make sure there is enough product in the well for the Magnum to
operate. There must be at approximately ½ inch (12mm) of product
present.
2. Make sure that neither the pump intake nor filter screen is clogged.
See page 67.
3. Make sure that the Interface clearance has not been set too high by
checking the settings on dipswitches S4-3 & S4-4. See page 44.
4. Make sure that the product discharge tubing is not clogged or
frozen.
Problem
Possible
Causes &
Solutions
Make sure the Pump is operating correctly. (Replace pump and try TEST
SYSTEM on PRC switch).
Pump runs briefly, but then cuts off prematurely.
1. Make sure Interface Clearance is not set too high. Check
dipswitches S4-3 & 4. See page 44.
2. Make sure Pump Unload Cutoff setting is not too high. Check
dipswitches S3-3 & 4. See page 44.
Problem
System was cycling, but now appears to be inactive.
Possible
Causes &
Solutions
If the cycle function is set on automatic (dipswitches S4-1 & 2), Magnum
Spill Buster will automatically extend the pump delay time to match the
recharge rate of the well. This delay can be as long as six hours between
cycles. To see if system is still functioning properly, run TEST SYSTEM on
PRC switch (See page 41) to see if pump will run. After the pump runs for
10 secs, STOP the system, and then push the PRC switch to the “Auto”
setting. If it is operating properly, the System should then go through a
cycle.
82
Problem
Possible
Causes &
Solutions
Problem
Possible
Causes &
Solutions
PROCESSOR lamp on Control Panel does not light.
1. If the System is otherwise operating as expected, it is possible that
the LED bulb is simply burned out.
2. If the System is not operating properly, the unlit Processor lamp
indicates a problem with the logic board. Please call the factory to
report the issue.
AUTO SEEKER does not raise.
1. Make sure that the Auto Seeker cable is connected to the Control
Box and shows no sign of damage.
2. Make sure that the System has not been set in DNAPL mode by
checking that dipswitch S2-1 is not set. See page 46.
Problem
Possible
Causes &
Solutions
Processor Lamp on Control panel blinks on and off and the System is
not cycling
1.
The Pump may have experienced an overload. Make sure that
neither the pump intake nor filter screen is clogged. See page 67.
2. The pump circuit may be stuck open, possibly due to a failed pump.
Replace pump and try TEST SYSTEM on PRC switch.
3. Make sure that the probe cable is connected to the Control Box.
83
84
7.0 System Specifications
Complete Magnum Spill Buster™ System includes:
Magnum Spill Buster™
Control Box, Magnum Spill Buster™ Probe with 50’ down well cable, Auto Seeker with 30’
cable, and Product Tank Shutoff Probe with 30’ cable, and 50 ft. Nylon Product Discharge
Tubing.
Input Power:
115vac or 230vac, 100 watts max. or 24vdc, 75 watts max. with optional
battery cable and deep discharge batteries. A 5 amp AC circuit breaker is built into the System
Power switch.
Operating Temperature Range:
Ambient air temperature of -40F to +140F (-40C to
60C).
Pumping Rate:
up to 46 gal/hr (175 liter/hr) @ 0 psi (zero depth & no discharge back
pressure), or up to 37 gal/hr (140 liter/hr) @ 25 psi discharge back pressure.
Product Viscosity: Products with viscosity of less than 10 Cp at 70 degrees F.
Examples: gasoline, diesel fuel, #2 heating oil, JP-4, JP-5, paint thinners.
Well Diameter:
2 inch minimum for product recovery only.
Standard Well Depth:
Maximum Well Depth:
50 ft.(15.2m.) max
150 ft (45.7 m) on special order with 150 ft (45.7m) down-well
cable.
Probe
The Probe is certified compliant with NEC2011 specifications for use in Class 1, Div 1 locations.
DC power for the pump is supplied using a conductor pair that has an over woven metal shield
along with a Tefzel overcoat. The signal wires also have a separate over woven metal shield.
The two cable bundles, along with the discharge tubing, are contained in a tough woven plastic
protective scuff jacket.
Probe Dimensions: 1.93” (4.9cm) dia. x 15.25” (38.7cm) long [cable size including the
discharge tube is 5/8” thickness x 1 1/2’ width]. Standard Probe cable length is 50 ft. (15.2m)
Control Box
Certified IS barriers are wired into the Probe and Override circuits in the Control Box in order to
make them compliant with NEC2011 specifications.
Dimensions & Weight: 14” (36cm) wide x 23” (59cm) high x 6” (15.4cm) deep. An additional
10” is required below for cable exit and an additional 14” is required in front and to the left for
door swing. Weight: 25 lbs. (11.34 kg)
85
Standard Auto Seeker
The Standard Auto Seeker is not rated for use in hazardous locations.
Dimensions & Weight (with 50’ probe attached): 14” (36cm) wide and deep; 20” tall (15.8cm).
Weight: 32 lbs. (14.51 kg)
Optional Explosion Proof Auto Seeker
The Explosion Proof Auto Seeker is certified compliant with NEC2011 specifications for use in
Class 1 Div 1 locations. Connections to all cabling now have positive threaded Mil-Spec circular
connectors.
Dimensions & Weight (with 50’probe attached): 52 lbs. (23.59 kg)
Minimum Well Head Clearance for EXPLOSION PROOF AUTO SEEKER: 28”x24”x24” Deep
(71 cm x 61 cm x 61 cm deep). (Does not apply to Standard Auto Seeker, which must be
mounted outside of any classified hazardous areas)
Optional Explosion Proof Enclosure for the Control Box
The Explosion Proof enclosure is certified compliant with NEC2011 specifications for use in
Class 1 Div 1 locations. Comes with the control box mounted in a certified XP enclosure and
includes three XP cable feed through fittings with Chico® seals.
Dimensions & Weight: 29” (73.66cm) tall; 11’ (27.9cm) deep; 18’ (45.7cm) wide, with an
additional 18” required in front and to the left for door swing and an additional 10” (25.4cm)
required below for cable exit. Weight (with Control Box mounted inside): 210 lbs. (95.25 kg)
Optional Explosion Proof Enclosure AC Power Switch
This feature provides a convenient AC power switch mounted directly to the XP control box
enclosure to enable the Spill Buster to be turned on and off at the box instead of back at the AC
main power panel.
Standard Extension Cable length:
Override Product Tank Probe:
30 ft (9.1m) from Control Box to well head.
Threads into a standard 2” barrel bung. Standard
cable length is 30 ft (9.1m)
Total System Shipping Weight:
Complete Standard Magnum System – aprox. 68 lbs. (30.84 kg)
Complete Magnum System with Explosion Proof Auto Seeker- aprox. 92 lbs.
(41.73 kg)
Complete Explosion Proof Magnum System- aprox. 277 lbs. (125.65 kg)
(includes Exp. Enclosure for Control Box)
86
Magnum Spill Buster Pump Performance
87
88
8.0 Equipment Decontamination Procedures
Prior to return to Clean Earth Technology, Inc., all equipment must be thoroughly cleaned and
decontaminated. Please follow your organization’s prescribed decontamination procedures,
and also carefully observe each step of the following procedure. During decontamination, make
sure personnel are wearing the appropriate protective clothing and observing all safety
precautions.
1.
REMOVE PUMP- (See page 69). Remove pump, wipe off with absorbent cloth or paper
towel, clean the filter, and seal parts in a plastic bag to send with your system.
2. REMOVE PROBE FROM AUTO SEEKER- (See page 76). Unwind the probe tubing
from the Auto Seeker reel and disconnect the discharge hose and Slim-line connectors.
3. Depending on the individual requirements for your site, you may need a container to
catch the waste for this step. Hold the probe upright and pour several gallons of hot
soapy water through it. (Alconox, Simple Green, or other similar detergents work well).
4. Place the entire probe and tubing in a large tub with enough hot soapy water to cover
the entire probe assembly. Soak for several hours or overnight.
5. Remove the probe from the tub and rinse with clean fresh water . Using a garden hose
with an attachment, flush several gallons of water through the probe tube and the tubing
(as in step 3).
6. Remove all remaining fluid left in the tubing by gravity: starting at the probe tube end,
hold the tubing over your head and pass the entire tubing through your hands, holding it
high all the while.
7. Wipe off the outside of the tubing with a dry absorbent cloth or towels. Push a clean rag
into the end of the probe tube and secure a plastic bag around the end of the probe to
contain any possible remaining leakage.
8. Wipe down the Auto Seeker reel with a cloth and hot soapy water.
9. If you have not already done so, call CET at (802) 425-3710 to request an RMA number
AND an RMA form, if needed.
10. Completely fill out the RMA form. If at all possible, fax the form to us or scan it to attach
to an email so that our service department has it ahead of your equipment’s arrival.
Make sure to include a copy with your return- preferably in a packing slip pouch on the
outside of the box, or else placed inside the box.
11. Pack the equipment with care to ship to CET. If possible, use the custom foam box set
that came with the system; otherwise use sturdy boxes and a generous amount of
packing material. MAKE SURE that the RMA number is clearly written on the outside of
all boxes. CET reserves the right to refuse delivery of any equipment without a
CET RMA number clearly displayed on the exterior of the package(s).
89
90
9.0 Equipment Return Policy
Any equipment return must be authorized by Clean EarthTechnology (CET) prior to shipment.
Call or FAX CET. A Return Material Autorization (RMA) number will be issued upon receipt of
your request to return parts or equipment. An “RMA Number/ REPAIR ORDER” form must be
completed by the user and the RMA number should appear on the form along with reasons for
the return. Your shipment to CET must have the RMA number clearly marked on the outside of
each packaged item.
This policy applies to both equipment sales and repair orders. For a Return
Material Authorization, please call our Service Department at (802) 425-3710.
Clean Earth Technology, Inc.
Environmental Equipment Return Policy
This Policy refers to any equipment or parts being returned to Clean Earth Technology (CET),
whether:
• Customer owned, leased or rented.
• In warranty or out of warranty.
NO equipment or parts should be shipped to CET without first contacting our service
department for a Return Materials Authorization number (RMA). Contact our service
department at (802) 425-3710 to be assigned an RMA number.
•
•
•
CET reserves the right to refuse delivery of any equipment without an RMA number
clearly displayed on the the package(s).
CET reserves the right to refuse delivery of any equipment improperly
decontaminated.
CET reserves the right to add a fee of $500.00 to the repair invoice of any equipment
or parts not decontaminated to the satisfaction of CET.
Environmental Equipment Return Guidelines:
•
All equipment must be thoroughly cleaned, purged of product and decontaminated
prior to shipment to CE, as detailed in Section 8 of this manaul- Equipment
Decontamination Procedures. NOTE: CET recommends the use of Personal
Protective Equipment, level C or D, as defined in OSHA 29 CFR 1910.120.
Any equipment or parts shipped to CET must include the following documentation:
•
•
CET RMA/Repair Order form fully completed by customer, including description/name
of product pumped, and the reason for the return.
The CET RMA number clearly marked on the outside of ALL packages and
paperwork.
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Return Materials Authorization Form
RMA Number: ____________
Customer Name and Address:
_______________________________________
_______________________________________
_______________________________________
_______________________________________
Phone Number:__________________________
Fax Number:____________________________
Qty.
Clean Earth Technology, Inc.
445 Long Point Road
N. Ferrisburgh, VT 05473
T: (802) 425-3710 F: (802) 425-2896
Date: ___________________________
Contact Name:___________________________
Contact Email:___________________________
Items Being Returned (eg. Auto Seeker, Cables, etc.)
Serial Number(s)
Reason for Return:
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
_____________________________________________________________________________________
Type of product(s) this equipment has been used to pump: ____________________________________________
System Decontamination Date:_________________________________
The undersigned confirms that the equipment or parts being returned to Clean Earth Technology have been
properly and thoroughly decontaminated using the approved procedure described on page 2 of this document.
Name _________________________________
*Signed:____________________________________
(printed)
*No evaluation or repair work will be performed unless this form is signed.
Clean Earth Technology (CET) reserves the right to add a fee of $500.00 to the repair of any equipment
or parts not decontaminated to the satisfaction of CET.
Clean Earth Technology, Inc.
Environmental Equipment Return Policy
This policy refers to any equipment or parts being returned to Clean Earth Technology (CET), whether
customer owned, leased, or rented; in warranty or out of warranty. NO equipment or parts should be
shipped to CET without first contacting our service department for a Return Materials Authorization
Number (RMA). Contact our service department at (802) 425-3710 to be assigned an RMA number.
•
•
•
CET reserves the right to refuse delivery of any equipment without a CET RMA number clearly
displayed on the exterior of the package(s).
CET reserves the right to refuse delivery of any equipment improperly decontaminated.
CET reserves the right to add a fee of $500.00 to the repair invoice of any equipment or parts
not decontaminated to the satisfaction of CET.
93
Environmental Equipment Return Guidelines
- All equipment must be thoroughly cleaned, purged of product and decontaminated prior to shipment
to CET. NOTE: CET recommends the use of Personal Protective Equipment, Level C or D, as defined in
OSHA 29 CFR 1910.120.
- Any equipment or parts shipped to CET must include this RMA form, completely filled out by the
customer; and the CET RMA number clearly marked on the outside of all packages and paperwork.
Equipment Decontamination Procedure
For the Magnum Spill Buster
(Also found in Section 8 of the manual)
The following procedures are aimed at protecting people and the environment from potential contact
with hazardous materials. Please be aware that CET reserves the right to refuse delivery of any
equipment improperly decontaminated. CET also reserves the right to add a fee of $500.00 to the
repair invoice of any equipment or parts not decontaminated to the satisfaction of CET.
Please follow your organization’s prescribed decontamination procedures, and then carefully observe
each step of the following procedure prior to shipping anything back to CET (check each step off as you
go). During decontamination, make sure personnel are wearing the appropriate protective clothing and
observing all safety precautions.
CALL CET AT (802) 425-3710 FOR ASSISTANCE IF YOU HAVE ANY QUESTIONS ABOUT ANY PART OF THIS
PROCEDURE.
12. ______ REMOVE PUMP- (See “Removing the Product Pump”- page 69- in Chapter 5“Maintenance Operations” in the manual). Remove pump, wipe off with absorbent cloth or
paper towel, clean the filter, and seal parts in a plastic bag to send with your system.
13. ______ REMOVE PROBE FROM AUTO SEEKER- (See “Removing the Probe from the Reel” – page
76 in Chapter 5- “Maintenance Operations” in the manual). Unwind the probe tubing from the
Auto Seeker reel and disconnect the discharge hose and slimline connectors.
14. ______ Depending on the individual requirements for your site, you may need a container to
catch the waste for this step. Hold the probe upright and pour several gallons of hot soapy
water through it. (Alconox, Simple Green, or other similar detergents work well).
15. ______ Place the entire probe and tubing in a large tub with enough hot soapy water to cover
the entire probe assembly. Soak for several hours or overnight.
16. ______ Remove the probe from the tub and rinse with clean fresh water . Using a garden hose
with an attachment, flush several gallons of water through the probe tube and the tubing (as in
step 3).
17. ______ Remove all remaining fluid left in the tubing by gravity: starting at the probe tube end,
hold the tubing over your head and pass the entire tubing through your hands, holding it high all
the while.
18. ______ Wipe off the outside of the tubing with a dry absorbent cloth or towels. Push a clean
rag into the end of the probe tube and secure a plastic bag around the end of the probe to
contain any possible remaining leakage.
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19. ______ Wipe down the Auto Seeker reel with a cloth and hot soapy water.
20. ______ If you have not already done so, call CET at (802) 425-3710 to request an RMA number
AND an RMA form, if needed.
21. ______ Completely fill out the RMA form. If at all possible, fax the form to us or scan it to
attach to an email so that our service department has it ahead of your equipment’s arrival.
Make sure to include a copy with your return- preferably in a packing slip pouch on the outside
of the box, or else placed inside the box.
22. ______ Pack the equipment with care to ship to CET. If possible, use the custom foam box set
that came with the system; otherwise use sturdy boxes and a generous amount of packing
material. MAKE SURE that the RMA number is clearly written on the outside of all boxes. CET
reserves the right to refuse delivery of any equipment without a CET RMA number clearly
displayed on the exterior of the package(s).
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