OPERATOR S MANUAL IN-GROUND SEPARATION SYSTEM WATER MAZE SYSTEMS

Transcription

1 WATER MAZE SYSTEMS IN-GROUND SEPARATION SYSTEM OPERATOR S MANUAL WATER MAZE 4275 N.W. Pacific Rim Blvd. Camas, WA USA For technical assistance or the Water Maze Dealer nearest you, call (800) or (360) or consult our web page at

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3 3 CONTENTS Introduction... 4 General Description Installation Instructions Step 1- Planning... 7 Step 2 - Excavation... 8 Step 3 - Sub-Grade Preparation and Leveling... 9 Step 4 - Internal Bracing Step 5 - Preliminary Concrete Pour Step 6 - Piping Connections and Bulkhead Fitting Installation Step 7 - Gravel Fill Step 8 - Pouring of Concrete Step 9 - Cleanup and Final Grate Installation Existing Wash Pad Installation Tools for Installation Caulks, Grout and Sealants Table Material List and Drawing for Internal Wood Bracing Warranty Model Number Serial Number Date of Purchase The model and serial numbers will be found on a decal attached to the pressure washer. You should record both serial number and date of purchase and keep in a safe place for future reference. IN-GROUND SEPARATION SYSTEM Form # Revised 9/02

4 4 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL INTRODUCTION WARNING READ OPERATOR S MANUAL THOROUGHLY PRIOR TO USE. WARNING: Do not start installation before reading all instructions. Improper installation may void warranty. Congratulations and thank you for ordering the Fiberglass In-Ground Separation System. This manual will provide technical information for the installation of the In-Ground Separation System as well as a general description and special features. All information in this manual is based on the latest product information available at the time of printing. We reserve the right to make changes at any time without incurring any obligation. Owner/User Responsibility The owner and/or user must have an understanding of the manufacturer's instructions and warnings before using these in-ground separation pits. Warning information should be emphasized and understood. If the operator is not fluent in English, the manufacturer's instructions and warnings shall be read to and discussed with the operator in the operator's native language by the purchaser/owner, making sure that the operator comprehends its contents. These industrial grade fiberglass pits enhance the Water Maze line of products. These pits make installing a Water Maze system much easier and more economical. They are lighter, easier to move around and cost less to ship and install than pits made of concrete. The smaller pit can be used as a collection pit and as a light duty oil/water separator. Made of chemical resistant reinforced fiberglass, the pits are designed to satisfy current governmental regulations. FEATURES Reinforced fiberglass construction Less expensive than concrete pits Less weight for ease in shipping and installation Earthquake resistant Optional interior 1700 sq. ft. coalescing plates for increased oil/water separation. COMMON USES Auto Repair Service Parking Garages Gas Stations Food Service Food Processing Plants Manufacturing Plants Restaurants GENERAL DESCRIPTION The Water Maze fiberglass in-ground separation system is designed to pre-separate dirt and oil from wastewater before it enters the Water Maze system. This pre-separation reduces the dirt load, which lengthens the life span of motors and pumps and allows for less maintenance of the filters. The fiberglass pits are less expensive and easier to install than pre-made concrete vaults. The concrete vaults require custom-made baffles by the contractor, which can become quite complicated. The fiberglass pits ensure the customer with the correct interior baffle design which will enhance the performance of the complete Water Maze system. The fiberglass in-ground pit sys- Sump Pit Optional Diamond Plate Aluminum Covers Separation Baffles Collection Pit Return Line Catch Basin Figure 1

5 PRESSURE TEMPERATURE CONTROL CHEMICAL VALVE OPERATING INSTRUCTIONS LANDA STEAM VALVE START STOP WARNING RUNNING HOURS BURNER VOLTAGE ON PUMP ON IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL 5 TABLE 1 SPECIFICATIONS SEPARATION PIT CATCH BASIN SUMP PIT SEPARATION PIT COVER SUMP PIT COVER CATCH BASIN GRATING Part Number Load Capacity 600 gallons 159 gallons 47 gallons 550 lbs 550 lbs,260 lb./ft. 7 2 D imensions (L/W/H) 120"x 46"x 56" 46"x 46"x 58" 33.5"x 33.5"x 39" 110"x 36"x 2" 24"x 24"x 2" 24"x 24" x 2" D ry Weight 302 lbs. 130 lbs. 75 lbs. 127 lbs. 23 lbs. 92 lbs. Material Fiberglass Fiberglass Fiberglass NOTE: Load Capacity of Separation and Sump Pit Cover is 550 lbs. It is not designed for vehicle traffic. Aluminum Diamond Plate 1/2" x 2" HR to Flatbar tem also provides the added benefit of double wall construction; fiberglass on the interior and concrete poured around the exterior of the pit. The Water Maze fiberglass in-ground pit system generally contains a catch basin, a collection pit and a sump pit. The actual number of each component depends on the customer's personal needs and their site plan. For example, some customers require several catch basins while others do not need a sump pit. Water Maze provides a variety of piping locations on the fiberglass pits to give the customer the optimum number of choices to best fit his particular site and budget. VNG VNG WATER LANDA

6 6 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL Wash Bay Concrete Slope Fiberglass Catch Basin Water Maze P/N With Steel Grating Design for H820 Truck Load Landa P/N Slope Slope 3" PVC Pipe from Catch Basin to Collection Pit 3" PVC Pipe From Delta 1000 Return Line to Catch Basin Slope Rain Water Overflow To Pressure Washer Rinse Water Fresh Water Make Up 5' 8' Slope Concrete Slab Collection Pit 3' Water Maze 3 Stage Fiberglass Collection Pit Part No Water Maze Cover Assy Made of Aluminum Diamond Plate with Steel Frame and Hinges, Part No Note: Load Capacity is 550 lbs Notes: 1. All information shown is for REFERENCE only and is intended as a guideline to be used by a professional engineer or architect in preparing a final design to meet the specific site requirement. 2. Water Maze system should be enclosed with proper freeze protection Slope 9'-2" 6" Concrete Curb Backfill Fiberglass Collection Pit with Concrete on Bottom and Sides Figure 2 Water Maze fiberglass in-ground pits are chemical and ph resistant. They are corrosion resistant to virtually any chemical normally found in the pressure washer environment, unlike normal concrete which would have its limestone contents etched by a low ph environment. The fiberglass pits are also earthquake resistant. This is important to assure against involuntary cracking and soil contamination. In fact, the Water Maze fiberglass inground system is designed to stay in the ground with no seepage around the perimeter of the tank because of a unique lip design that allows the concrete to form over the edge, holding the tank in place (See Figure 3.) Water Not Able to Seep Between Concrete and Fiberglass Pit Water Able to Seep Between Concrete and Fiberglass Pit Water Pressure Figure 3

7 Collection Pit Part No IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL 7 The collection pit is the work horse of the Water Maze fiberglass in-ground pit system. The collection pit receives the waste water from the catch basins and filters it through a series of baffles and optional coalescing grids (see Figure 4 and Table 2 ). Water then goes directly into the Water Maze system or into a sump pit. When the customer is discharging directly into a sanitary sewer, many times the fiberglass in-ground collection pit is all he needs to meet the discharge regulations of that city. And by adding coalescing packs to the system you greatly increase the oil/water separation performance. The inground pit can also be used in parking lot rain water collection to minimize oil getting into public waterways. There is no physical difference between the fiberglass catch basin and the fiberglass sump pit. The only difference between the two is their final use. The catch basin receives the waste-water directly from the wash pad. The sump pit is for temporary storage of water which has already been through some treatment, generally performed by the collection pit. The sump is an alternative to installing long distances of electrical conduit and wiring to the collection pit. The new pits will help simplify the installation of the Water Maze system as well a make the whole system work better. INSTALLATION INSTRUCTIONS A superior 3-stage separation system from Water Maze. Water Maze provides economical and easy-to-install inground water treatment systems which eliminate expensive and time consuming form work. By following the installation techniques outlined in the manual you can achieve a fast, efficient installation. INSTALLATION INSTRUCTIONS FOR A NEW SITE: Step 1: Planning Before any work is done, a thorough site plan must be done. No two customers are alike, thus no two site plans are exactly alike. Landa's component design of the Water Maze fiberglass in-ground collection pit system facilitates the diversity of site plans to aid the individual customer's need. The site plan is important because it indicates the location and number of catch basins, collection pits and sumps needed. There is no shortcut for a good site plan. (See Figures 1 & 2). Coalescing Pack Side View Collection Pit Shown with Optional Coalescing Pack Figure 4

8 8 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL Step 2: Excavation An excavation must be provided that will ensure a minimum of 4" of bedding concrete on ALL sides of the fiberglass pits in the in-ground collection pit system. The collection pit requires the most consideration in installation, therefore Figure 5 depicts the dimensions needed for the collection pit. Nevertheless, every fiberglass pit (i.e. catch basins, sump pits, etc.). mandates the excavation to be deep and wide enough to provide bedding concrete equal to the slab thickness. (The only exception is when the slab thickness exceeds 8". Then an 8" maximum of bedding concrete is sufficient.) The edges of the excavation should be sloped to provide a smooth transition to the slab subgrade. Trenches for piping can be dug simultaneously with the pit excavation or after the initial concrete pouring. 6' 5'-7-1/2" 3'-8" End View 11'-10" Concrete Level 9'-10" 4'-6-1/2" 5' Concrete Blocks Side View Figure 5

9 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL 9 Step 3: Sub-Grade Preparation & Leveling Concrete blocks should be placed on the sub-grade level (the bottom of the pits) to aid in leveling the fiberglass pits and to support the pits in the initial concrete pouring. Catch basins and sump pits need only one concrete block. The collection pit requires 3 concrete blocks (see Figure 6) which must be leveled individually and as a whole. A simple piece of 2" x 4" lumber may be laid across the three blocks and used to level the blocks laterally. The fiberglass pits can suffer lateral and vertical movement during the concrete pour. Therefore precautions must be made to prevent this from occurring. Bolt 2" x 4" lumber to the top of the fiberglass pit with 3/8" x 2-1/2" bolts and matching nuts. (See Figure 6 at right/bottom). The 2" x 4" lumber braces are attached to wooden stakes which are driven into the ground. The length of the 2" x 4" lumber braces depends upon the customer s need and the ease of use. The only restriction is that the braces are long enough to extend beyond the edges of the dirt hole. These 2" x 4" lumber braces can then be used to level the upper portion of the fiberglass pit. Drive Support Stakes into Ground Check for Level End View 3/8" x 2-1/2" Bolt with Nut NOTE: Nut to Underside Floor Level Bolt 2" x 4" Wood to Fiberglass Pit Nut to Fiberglass Side New Concrete EARTH Fiberglass Collection Pit EARTH New Concrete 2" x 4" Wood Anchor to Stake New Concrete Floor Top View Figure 6

10 10 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL Step 4: Internal Bracing The three stage Water Maze fiberglass in ground collection pit requires internal bracing when pouring concrete. There are two options for internally bracing the collection pit: 1. Landa offers an optional precut wood bracing kit (Part # ) to insert into the collection pit. This kit includes eight side panels and various lengths of 2" x 4" lumber. The kit eliminates the hassle of constructing the internal bracing on site. 2. The customer can construct the bracing himself. (See Figure 12 for details). Insert the reinforced plywood into the pits as shown in Figure 7A. The 2" x 2" bracing should face the inside of the pit, except the 2" x 2" bracing which fits into the lip of the fiberglass pit (see Figure 7B). The plywood should be flush against the sides of the collection pit to avoid any abrasive action. Various lengths of 2" x 4" lumber are used to wedge the plywood side panels against the sides of the collection pit. The shorter lengths of 2" x 4" lumber are used on the narrower base of the pit while the longer pieces are used closer to the top. The 2" x 4" lumber rests atop the 2" x 2" stripping attaching to the plywood side panels. Remember, this bracing is designed to resist the external pressure of the wet concrete during pouring, NOT to withstand the vertical weight of humans. Do not stand on top of the internal bracing. Plywood Figure 7A 2" x 2" Bracing Plywood Reinforcing 2" x 4" Brace Fiberglass Pit Figure 7B

11 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL 11 Step 5: Preliminary Concrete Pour We suggest dividing the concrete pour into two separate applications for ease of construction. Depending on your individual site plan, one truckload of concrete will generally cement the bases of the fiberglass pits and pour a retaining curb for the wash pad area. This system is designed to eliminate soil contamination and some method of water retainment in the wash pad area must be utilized. The second load of concrete can be applied at a later time to finish the project. If the concrete is poured in one application, the fiberglass pits have a tendency to "float". Pour the first application of concrete into the holes covering the concrete blocks and bottom third of the fiberglass pit. Let concrete set for 24 hours. Concrete End View Concrete Side View Figure 8

12 12 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL Step 6: Piping Connections and Bulkhead Fitting Installation All three fiberglass pits are equipped with preformed surfaces for pipe fittings, (See Figure 9). The collection pit has three separate piping locations to choose from, for placement of both an inlet and an outlet pipe. The catch basin/sump pit design allows a piping connection on all four sides. Temporarily remove the internal bracing of the collection pit and set aside for later use. Dig the trenches for the piping, if not already done, and place piping inside. Align the fiberglass pits and the piping to correspond exactly (see end view and figure 9). The preliminary pour of concrete ensures a reduced amount of stress on the pipe fittings since the fiberglass pits are fully secured. Remember the less stress on the fittings, the less the possibility of future leaks and contamination. Use a 4-1/2" hole saw to cut out the holes for the pipe fittings (Water Maze offers a 4-1/2" hole saw and arbor for our customer s convenience. See Table 2 on page 14). It is very important to double check fitting locations before holes are cut into the fiberglass, because no alterations may be made afterwards. Be sure to place pipe fittings at appropriate elevations to enable proper gravity feeds. The 3" bulkhead fittings can be inserted into holes after they are cut. Tighten securely. Attach the pipe connection to the bulkhead fittings and tighten. Replace internal bracing. NOTE: Consult with your electrician for any electrical piping connections that may be needed. Follow local codes. Typical Trench 3" Pipe Lines Return Line from Alpha 90 See Detail "A" End View Detail "A" Waste Water Plumbing Line Side View Figure 9 Exit Line to Sump or Drain

13 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL 13 Step 7: Gravel Pit After the preliminary concrete is fully set and the pipes are placed in the trenches and attached appropriately to the fiberglass pits, gravel should be used to fill in the trenches and those areas where the bedding concrete does not need to go. Reinforcement rods should be installed in a grid pattern to support the concrete slab (See Fig. 10). Step 9: Cleanup and Final Grate Installation Remove all forms used and clean all internal surfaces of the fiberglass pits. Be sure to grout all exposed holes in the lips of the fiberglass pits to ensure against future water damage. Install gratings and covers as desired. Water Maze offers hinged aluminum diamond tread plate covers and steel gratings (See Table 2). Existing Wash Pad Installation The Water Maze fiberglass water collection system is easily installed into existing hard surfaces. The same instructions for new construction can be followed with the dimensions as shown in Figure 14. Lag bolts must be used to attach the 2" x 4" lumber braces (mentioned in step 3) to the existing hard surface. Then after the project is finished, the holes created in the concrete by the lag bolts must be filled. 5'-3-1/2" Figure 10 3'- 8" Step 8: Pouring of Concrete Bedding concrete must conform to the minimum standards for thickness (4" minimum) and must be poured following the same procedure whether the finished surface will be asphalt or concrete. Pour concrete into the excavation equally on both sides of the fiberglass pits to provide more even distribution. Vibration may be required to ensure even distribution of bedding concrete along the sides of the fiberglass pits. Remember to have internal bracing in the fiberglass pits during all concrete work. A finished slope of 1/8" per foot for the wash pad area is recommended. This will provide positive drainage flow into the fiberglass catch basins. 6' Existing Concrete Floor Figure 11 11'-10" 9'-10" 4'-6-1/2" 5' Concrete Blocks

14 14 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL Tools for Installation The following tools may be required for your particular installation. 2" x 4" lumber stringline / chalkline caulking gun grinder grout / adhesives masonry saw / diamond blade square cold chisel large hammer 4-1/2" hole saw with arbor drill / masonry bits plywood wooden or steel stakes shovel level screwdriver vibrator Caulks, Grout and Sealants Where required, openings, fittings and joints may be filled with one of several different materials. When a flexible filler is required, silicone caulk is recommended. When rigid filler is required two component epoxy grouts may be used. Where high durability is not required, fast setting cementation grouts may be used. Please call your Water Maze distributor for specific recommendations. TABLE 2 Part No. Description Fiberglass oil/water separator & collection pit (3' x 9 'x 5') Maximum flow: 60 gpm Fiberglass sump or catch basin (3' x 3' x 4.5') (159 gals) Fiberglass sump or catch basin (2' x 2' x 3') ( 47 gals) Coalescing grid pack 850 sq. ft. (2 required). Enhances oil/water separation when discharging to sanitary sewer (58 total plates). Collection pit cover, hinged aluminum diamond tread plate with steel tube frame (3' x 9') Cover, sump pit, aluminum diamond tread plate with steel tube frame (2 'x 2') Grating, catch basin (2' x 2') hot rolled steel (1/2" x 2" flatbar) Grating, catch basin (1.5' x 3') hot rolled steel (1/2" x 2-1/2" flatbar) Cover sump pit aluminum diamond tread plate with steel tube frame (3' x 3') Strainer, catch basin, stainless steel " Bulkhead fitting, threaded (specify quantity) /2" Hole saw for installation of bulkhead fitting Arbor for hole saw (7/16") for installation of bulkhead fitting Wood brace kit (specially designed bracing to reinforce fiberglass while pouring concrete)

15 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL 15 MATERIALS REQUIRED TO CONSTRUCT BRACING QTY DESCRIPTION 4 2" x 4" x 29-1/2" 4 2" x 4" x 25" 1 2" x 4" x 29-3/4" 1 2" x 4" x 15-1/4" 1 2" x 4" x 12-3/4" 6 2" x 2" x 22" 6 2" x 2" x 48" 6 2" x 2" x 10" 6 2" x 2" x 19" 2 3/4" x 22" x 48" Plywood 2 3/4" x 48" x 48" Plywood 2 3/4" x 10" x 48" Plywood 2 3/4" x 19" x 48" Plywood For clarification of bracing, see figure 7 " " "

16 IN-GROUND SEPARATION SYSTEM OPERATOR'S MANUAL 16 ACCESSORIES AND PARTS ACCESSORIES AND PARTS WARRANTY (Effective October 1998) LIMITED MINIMUM 90 DAY WARRANTY We warrant to the original consumer that each new part and accessory sold by LANDA will be free from manufacturing defects in materials or workmanship in normal service for the duration specified by the original component manufacturer with a 90 day minimum from date of purchase, provided it is installed properly and the equipment is maintained in accordance with LANDA S instructions and manuals. Components manufactured by LANDA, such as frames, handles, coil wraps, fuel tanks, belt guards and heating coils have a one year warranty from date of purchase. Our obligation under this warranty is expressly limited as to the replacement or repair, at our option, at LANDA Inc., Camas, Washington 98607, or at a service facility designated by us, for such part or parts as inspection shall disclose to have been defective. EXCLUSIONS: This warranty does not apply to defects caused by casualty or unreasonable use, including faulty repairs by others and failure to provide reasonable and necessary maintenance. THE FOLLOWING ITEMS ARE NOT COVERED BY THIS WARRANTY: Generators, motors, engines and engine parts. These are subject to the warranties, if any, of their manufacturers. WE SHALL NOT BE LIABLE FOR SPECIAL, INDIRECT, INCIDENTAL, OR CONSEQUENTIAL DAMAGES OF ANY KIND, including but not limited to labor costs or transportation charges in connection with the replacement or repair of defective parts. ANY IMPLIED OR STATUTORY WARRANTIES, INCLUDING WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY LIMITED TO THE DURATION OF THIS WRITTEN WARRANTY. We make no other express warranty, nor is anyone authorized to make any on our behalf. Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights which vary from state to state. TO OBTAIN WARRANTY SERVICE: Purchaser must bring the accessory parts to an authorized LANDA Dealership. For the dealership nearest you consult our web page: or write: LANDA Inc NW Pacific Rim Blvd, Camas, WA

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18 WATER MAZE SYSTEMS 4275 NW Pacific Rim Blvd. Camas, WA USA Form # Revised 9/02 Printed in U.S.A. by Water Maze, Camas, WA 98607