MÓDULO PRÉ-FILTRO

MÓDULO DE PREFILTRO
PRE-FILTER MODULE

MANUAL DE INSTRUÇÕES
MANUAL DE INSTRUCCIONES
INSTRUCTIONS MANUAL
 ENGLISH
PRE-FILTER
MODULE

INSTRUCTIONS MANUAL
 Pre-filter Module

INDEX
PREFACE....................................................................................................... 5

USED ABBREVIATIONS ........................................................................ 5

USED SYMBOLS .................................................................................. 6

INTRODUCTION ........................................................................................... 7

ZEPPINI SSAO....................................................................................... 7
PRE-FILTER MODULE ........................................................................... 9

TRANSPORTATION, STORAGE AND RECEPTION ......................................... 10

TRANSPORTATION AND STORAGE ..................................................... 10

MPF COMPONENTS ............................................................................. 11

INSTALLATION ............................................................................................. 12

NECESSARY TOOLS AND MATERIALS ................................................ 12

INSTALLATION PROCEDURE ............................................................... 12

ANCHORAGE ................................................................................................ 27

NECESSARY MATERIALS...................................................................... 27
EXECUTION PROCEDURE.................................................................... 27

OPERATION .................................................................................................. 29

MAINTENANCE ............................................................................................ 30

ANNEX ......................................................................................................... 32
 Pre-filter Module

PREFACE
This manual aims to instruct the installers and operators of the Pre-filter
Module about the best installation and handling practices of the equipment.
The rigorous accomplishment of the instructions here contained warrants a
bigger durability of the equipment and a bigger easiness/reliability of its
installation.
We remember that the no accomplishment of any of the instructions here
contained will annul the product warranty.

USED ABBREVIATIONS
In order to facilitate the reading of this manual, some abbreviations are used,
like as:

MPF Pre-filter Module

EFR Removable Filtering Element
SSAO Water and Oil Separator System
CSAO – ZP5000 Water and Oil Separator Box ZP5000

5
 Preface

USED SYMBOLS

Along this manual, you will found some symbols. Their meanings are de-
scribed bellow:

HINT
This symbol indicates that the following instructions can and
will facilitates the installation/operation of the equipment.

WARNING

! This symbol indicates that the following instructions are of

extreme importance for the good operation of the equip-
ment. The no accomplishment of these instructions will
result on bad operation of the equipment at short or long
term and can, inclusive, to culminate on contamination.

DANGER
! This symbol indicates that the following instructions are of
extreme importance for the security of the involved people
and of the installation and/or operation of the equipment.

Do you have some doubt? Do you have some problem, critique or

suggestion?
If along the reading of this manual or of the equipment installation or
operation you have some doubt, suggestion or critique, feel free for to
contact us!

(55 11) 4393-3600

Estrada Particular Sadae Takagi, nº 673, Bairro Cooperativa
São Bernardo do Campo / São Paulo / Brasil
CEP 09852-070
Att. Technical Assistance

We will have great pleasure on attending you!

6
 Pre-filter Module

INTRODUCTION
Nowadays, many commercial and industrial operations generate oily effluents.
This effluent type can generate environmental contaminations and therefore
needs of previous treatment. The Pre-filter Module is an equipment designed
for, in conjunction with the CSAO – ZP5000 to treat water resultant of this type of
process before to be thrown on the sewerage system or collected, according the
in force legislation, thus preserving the environment.
This equipment realizes a previous filtering of the served water in order to
supply to the CSAO, effluents with the smaller concentration of solid residues,
increasing the efficiency and durability of the entire SSAO system.

ZEPPINI SSAO

Although this manual treats only the Pre-filter Module, it is important to under-
stand that it is part of a bigger system called “Zeppini Water and Oil Separation
System” (SSAO). The more complete is the system, the bigger will be its effi-
ciency.
The Zeppini water and oil separator system is composed by the following equip-
ments: Affluent Collectors, Inspection Box with Filter, Pre-filter Module (MPF),
CSAO – ZP5000, and Oil Collection Module (MCO).
The served waters are, on the track operations, collected by the Affluent
Collectors (Track Gutters) and after passing by the Inspection Box with Filter
(where the debris like leaves and plastic bags are retained), it are thrown on the
Pre-filter Module for the removal of the solid sediments like earth and sand.
After this, they are thrown on the CSAO – ZP5000 that will separate the water and
the oil. The oil is directed toward the MCO and the treated water could be
directed for the sewerage or collected according to the in force legislation.

7
 Introduction

For the good operation of the system it is necessary to dimension correctly the
served waters flow and to warrant the no emulsification (undue usage of
detergents with high concentrations, solvents, etc.) and whirling (purge of
pressure vases, etc.) of the served waters flow. On commercial and industrial
facilities that has areas for refueling and washing vehicles or parts, it is recom-
mended to have at least one independent CSAO for each area.

MPF CSAO MIE MCO

Zeppini – Water and Oil Separation System (SSAO)

The effluents treated by the CSAO must be frequently

monitored. It is important to foresee on the system installa-
tion, one collection point of the effluents in order to facili-
tate this control.

8
 Pre-filter Module

PRE-FILTER MODULE

The MPF is composed basically of a case and of a removable filtering element

(EFR).
Reaching the MPF, the served water collected by gutters installed on the track,
receives a preliminary treatment. Bigger particles like stones, plastics, woods
are mechanically retained on the EFR interior, providing the arrival of more
clean liquids to the CSAO, what increases the efficiency of the entire system.
These residues are easily eliminated after, removing the EFR from the main
case and making its cleaning.

PRE-FILTER OIL COLLECTION

MODULE CSAO – ZP5000 MODULE
ServedWater Oil Coating Output of the
Input (Rough) water separated
from the oil

Oil
Output

1st STAGE 2 nd STAGE

(Passage by the Coalescent (Passage by the
Sedimentation Chamber) Deflector Element Coalescent Box)

9
 Transportation, Storage and Reception

TRANSPORTATION, STORAGE AND RECEPTION

The MPF correct storage is extremely important for to warrant the equipment
integrity. For to store this product, follows carefully the following instructions:

!
Store carefully the MPF, preserving it from impacts, sharpe-
ned objects and flexion.
Protect the MPF from the ultraviolet rays (UV) keeping it
stored on a protected place until the moment of its installa-
tion.
Don’t put heavy objects over the MPF.
Don’t remove the protective coating from the MPF until the
moment of its installation.
Transport the MPF on adequate vehicles and protected from
sharpened objects that could damage it.
When carrying the MPF, take care for don’t move it during
the transportation. If necessary, tie it, in such a way for
doesn’t deform it.
When transporting the MPF manually or with the aid of
machines, avoid impacts that could compromise its
structures.

If necessary to stack the MPF, do it carefully. Equipments

! bad stacked can slip and to cause personal injuries or
product damages.

10
 Pre-filter Module

MPF COMPONENTS

3
4

5
6
7

9 8
6
5

– Cover ................................................................................. 1 part

– Removable filtering element (cartridge) ............................ 1 part
– Case. .............................................................................. 1 part
– 4 in. Connection on PVC ................................................. 2 parts
– Sealing Ring ................................................................... 2 parts
– Fixing Nut ....................................................................... 2 parts
– 4 in. x 90° Elbow on PVC ................................................. 1 part
? – 4 in. Output Collection Tube on PVC ................................ 1 part
? – 4 in. Input Collection Tube on PVC ................................... 1 part

At the moment of the reception, check if all the materials

! were sent on the correct quantity and if it doesn’t presents
damages or defects. Reject the materials supplied out of
the manufacturer specifications!

11
 Installation

INSTALLATION
NECESSARY TOOLS AND MATERIALS

For to install the MPF it’s necessary, at least, the usage of the following tools
and materials as described below:
1. Hack-saw frame
2. Saw for plastic material (PVC)
3. Cup Saw with diameter of 133 mm
4. Electrical drill
5. Adhesive for plastic tubes (PVC)
6. Sandpaper for plastics (PVC)
7. Spade
8. Hoe
9. Medium sand (according to the pit opening)
10. Type 1 stone

INSTALLATION PROCEDURE
The MPF installation is divided on 6 main phases, as follows:

1st Phase – Pit Preparation

2nd Phase – Case Positioning
3rd Phase – Pit Grounding/Filling
4th Phase – MPF Drilling
5th Phase – Connections Installation
6th Phase – Tubing Installation

!
Observe the procedures and security warnings described
along of the installation instructions.

12
 Pre-filter Module

1st Phase – Pit Preparation

Step 1
Prepare a pit with rectangular shape and such dimensions that the dis-
tances between each one of the pit lateral walls are of .30 m.

1.52 m

0.3 m
1.52 m

0.3 m 0.3 m
0.3 m
1.1 m

0.2 m

13
Installation

Step 2
The pit depth must be such that, after to add a .20 m sand layer (as de-
scribed on the Step 4). The upper cover of the module must remain at a dis-
tance of .10 m to .60 m from the finished floor. For the pit depth adjustment, it
must be considered a fall between the served waters gutters and the MPF
entry of at least 2% related to its distance (L), according to the figure below.
On the cases where this dimension can’t be accomplished, please contact
the manufacturer.

2% x L

It’s recommended to install the MPF on a place of easy

access for operation and maintenance and near to the
CSAO entry, keeping the necessary fall.

During the pit preparation and while it remains open, isolate

! it with cones and striped tape for to avoid the fall of peoples
and vehicles.

.
Step 3
Remove the earth removed from the place for an area away from the pit.

!
It’s important to use adequate material for grounding/filling
of the MPF pit. The local earth must be discarded and not
used with this purpose.

14
 Pre-filter Module

Step 4
At the bottom of the pit, create a layer of gross sand with depth of .20 m for
the MPF deposition. Compact it hydraulically (the depth of .20 m must be
the layer final measure, after the compactness). For your reference, see the
step 1 figures.

On the cases where the MPF is installed on the following

! conditions: masonry pit not stanch, absence of track over
the box or the elevated groundwater, follow the anchorage
procedures before to go on with the installation according to
the instructions of the“ANCHORAGE”chapter, page 27.

Check if the layer was created according to the project.Take

! care for don’t impeach the MPF leveling: check if the layer
measure at the finished floor level is equal to the measure
from the bottom up to the MPF cover plus the tolerance of
.10 m to .60 m.
Never create a layer with less than .20 m.

15
Installation

2nd Phase – Case Positioning

Step 1
Position the MPF in order to keep a minimum distance between the MPF
side faces and the pit walls of .3 m.

Step 2
Be sure that one of the MPF faces is perpendicular to the effluents entry
network and the other face is perpendicular to the CSAO entry.

16
 Pre-filter Module

3rd Phase – Pit Grounding/ Filling

!
Observe attentively the prescriptions of this manual about
the pit grounding/filling in order to don’t compromise the
MPF structure.

Step 1
Fill the MPF with clean water.

Step 2
Put the side covers and the central cover on the MPF.

Step 3
Make a .20 m layer of medium sand distributed evenly around the MPF.

Step 4
Compact hydraulically the sand layer put on the Step 3.

Step 5
Repeat sequentially the Steps 3 and 4 up to reach the MPF input and output
connections.

Step 6
Remove the covers and install the connections and tubing according to the
4th , 5th and 6th Phases and finalize the pit grounding/filling until the complete
tubing coverage.

17
 Installation

Step 7
After the last sand layer, for a best finishing, put a type 1 stone layer around
the MPF up to the access cover level.

! Don’t compact mechanically the earth put over the pit, as

this can damage the MPF.

Concrete

Sand
6 thSand Layer

5 th Sand Layer
4 th Sand Layer

3 rd Sand Layer
2 nd Sand Layer

1rd Sand Layer

18
 Pre-filter Module

If the height between the MPF central cover and the

sidewalk chamber cover is superior to the sidewalk
chamber shroud height, make at the tip perimeter, a
masonry wall for to close this space, being the height of this
masonry variable according to the MPF installation depth.

19
Installation

If the height of the MPF must be adjusted, this could be done

on up to 2 levels, marked by the grooves existing on the
machined areas as bellow. The equipment cut should be
done with a miniature saw in a regular and linear way and
afterwards trimmed off.

!
The MPF must be installed under a sidewalk layer, since this
equipment isn’t designed for to support any type of traffic.
The equipment can’t remain exposed to the sunrays for
long time, with the risk of to compromise the resistance of
the material used for its manufacturing, could still, be
damaged during its installation or operation.
If the compactness procedure isn’t followed (3rd Phase), there
is the risk of collapsing or crack of the MPF.
The usage of mechanical compacters isn’t recommended,
due the risk of damaging the product.
After the end of the installation phase, make a general
cleaning of the entire system, removing any remaining
debris.

20
 Pre-filter Module

4th Phase – MPF drilling

Step 1
Define the MPF faces that will receive the input and output connections.

Step 2
Mark the positions to be drilled.

Step 3
Drill the MPF faces according to the defined on the Steps 1 and 2 using a
cup-saw (See specification on “Necessary Materials”).

Step 4
Install the Input Connection according to the Phase 5 of the installation
procedure.

Step 5
Install the Output Connection according to the Phase 5 of the installation
procedure.

21
 Installation

Step 6
Install the EFR on the MPF and drill it with a cup-saw in a way that the drilling
remains aligned with the effluents entry connection (see specification on
“Necessary Materials”).

22
 Pre-filter Module

5ª Phase – Connections Installation

Step 1
Put the sealing flange by the reservoir external side.

Step 2
Position the sealing ring by the internal side.

Step 3
Still by the internal side, thread the fixing nut on the flange in order for to
compress the sealing ring against the MPF wall, providing the assembly
tightness.

3 1

– Fixing Nut
– Sealing Ring
– Sealing Flange
– MPF Wall

23
 Installation

6th Phase – Tubing Installation

Step 1
Clean the ends of the PVC tubes and connections in order to remove all the
dirty and oiliness existing. For to provide an efficient connection, apply an
even layer of plastic tube adhesive on the tubing ends.

Step 2
On the MPF affluent input connection, connect the 4 in. PVC tube coming
from the Affluent Manifold, following the connection instructions described
on the Step 1.

Step 3
Define the length and cut a segment of 4 in. PVC tube.

Step 4
Install the tube prepared on the Step 3 on the internal portion of the affluent
entry connection, following the connection instructions described on the
Step 1.

Step 5
Considering that output Collection Tube must remains at a distance of 10
cm from the MPF bottom, adjust the collection tube length according to the
output connection position (see figure).

24
 Pre-filter Module

Step 6
Connect the output collection tube on the 4 in. x 90° elbow following the
connections instruction described on the Step 1.

Step 7
Connect the elbow on the internal portion of the MPF output connection
following the connection instructions described on the Step 1.

Step 8
Connect the extension tube on the external portion of the output connection
following the connection instructions described on the Step 1.

!
Be sure that hole made on the EFR is aligned with the
effluent entry hole.
Warrant that the MPF entry tubing hasn’t entered on the
EFR, as this will avoid the EFR removal, impeaching the
equipment operation and maintenance.

WARNINGS
Defects caused to the equipment due installation errors will not be
covered by the product warranty.
If some abnormality on the equipment is detected, contact Zeppini before
the product installation.

25
Anchorage

ANCHORAGE
The Pre-filter Module anchorage procedure is used when the equipment is
installed inside of masonry pit not stanch, there isn’t track over the equipment
or when it’s installed on locals that have elevated groundwater, for to warrant
the equipment stability on the ground.

NECESSARY MATERIALS
For to make the MPF anchorage is necessary the usage of the following
materials:

1. Concrete - 0.02 m³.

2. 4 moulds for the anchors manufacture (buckets or cans of 5 liters)
3. 4 portions of 20 cm of iron bar
4. Chain inserted on polyethylene circular tube of 1 in. or polyester tape of
appropriate width with hooks on the extremities.

EXECUTION PROCEDURE
The anchored MPF installation is divided on 2 main phases, as follows:

1st Phase – Anchor preparation

2nd Phase – Anchored system installation

26
 Pre-filter Module

1st Phase – Anchor preparation

Step 1
Bent the portions of iron bar in an omega shape “?”.

Step 2
Fulfill the 5 liters moulds with concrete.

Step 3
Insert the bent iron bars on the superior portion of the moulds with concrete
still fresh in order to form the anchors hooks where it will be fixed the belt.

Step 4
Wait the concrete cure.

2nd Phase – Anchored system installation

Consider that the following steps must be executed after the Phase 1 of the
Installation Procedures, Chapter “INSTALLATION” on the page 12.

Step 1
Increase the pit depth in .3 m on the lateral portion between the pit wall and
the MPF, according to the figure.

27
Ancoragem

Step 2
Position the anchors on the pit bottom in order to align the fixing hooks for
the coupling of the polyester belt.

Step 3
Cover the anchors with sand and made the compactness, leaving visible
the hooks.

Step 4
Follow the Phase 2, Chapter “INSTALLATION” on the page 16.

Step 5
Execute the 4, 5 and 6 Phases, Chapter “INSTALLATION” on the pages 21,
23 and 24.

Step 6
Put the side covers on the MPF..

Step 7
Fixate the belts on the anchors hooks by the extremities in order to pass
over the module side covers according to the figure.

Step 8
Tension the belts through the turnbuckles on the hooks, two by two,
according to the figure bellow.

Step 9
Conclude the installation following the Phase 3 of the “INSTALLATION”
Chapter on the page 17.

28
 Pre-filter Module

OPERATION
The MPF operation is summarized on the removal of solids coming from the
served waters, retained on the filtering element, what must be done according
the following sequence:

Step 1
Remove the MPF upper cover.

Step 2
Remove the EFR pulling it up by hand.

Step 3
Made the EFR cleaning removing the existing solids and taking care for to
the holes doesn’t become obstructed.

For a more efficient cleaning can be used water jet.

Step 4
Reinstall the EFR on the MPF case.

! On the reinstallation, it’s important to follow the MPF drilling

according to the effluent entry and output tubing.

Step 5
Reinstall the MPF upper cover.

!
Keep the MPF cover always fitted and fixed to the case
avoiding the entry of the water coming from track to the
interior, causing overflow and possible earth contamina-
tion.

The frequency of the solids removal coming from the

served waters will be defined according to the quantity of
debris collected by the system. It’s recommended to
execute initially this operation weekly.

29
Maintenance

MAINTENANCE
The maintenance of this equipment consists on the verification of the
components integrity and on the cleaning of the debris existing at the bottom
according to the sequence:

Step 1
Block up the served water flow on the MPF entry.

Step 2
Remove the MPF upper cover.

Step 3
Remove the EFR pulling it up by hand.

Step 4
Remove the liquids and residues contained on the MPF interior and storage
it on stanch containers appropriated.

Step 5
Clean the MPF bottom removing the existing debris.

Step 6
Make a visual inspection on the side covers, on the EFR and on the MPF
case for to verify the existence of cracks, deformations or breakages that
could impair the system operation.

Step 7
Reinstall the EFR and the covers on the MPF.

Step 8
Return the served waters flow to the MPF.

Step 9
Through the collection gutters, return carefully the liquids and residues
stored before on the Step 4.

30
 Pre-filter Module

The MPF maintenance frequency will be defined according

to the residues quantity received by SSAO system. We
recommend realizing this operation initially at least at each
2 months.
The MPF maintenance must be done on periods without the
contribution of the served waters.

!
When making the visual inspection, if any unconformity is
detected on the equipment, get in contact with Zeppini for
analysis and product repair.

31
Anexx

ANEXX

32
Rev.: 01 - Nov.13