Cleanawater TS5000 SS Oil Water Separator – 5000 L/hr

Installation, Operations & Maintenance

Manual

1800 353 788

[email protected]

cleanawater.com.au
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TABLE OF CONTENTS

COMPANY INFORMATION 2
PARTS INCLUSION LIST 3
PRODUCT INFORMATION 4
SYSTEM SPECIFICATIONS 6
TYPICAL INSTALLATION SCHEMATIC 7
INSTALLATION INSTRUCTIONS 12
FINAL INSTALLATION CHECKLIST 17
OPERATIONS & MAINTENANCE GUIDE 18
OPERATIONS GUIDE 18
MAINTENANCE GUIDE 18
WEEKLY MAINTENANCE 18
QUARTERLY MAINTENANCE 19
WARRANTY TERMS 20
TROUBLESHOOTING GUIDE 21
CLEANAWATER TERMS & CONDITIONS 26
PUMP MANUALS & CONNECTION DIAGRAMS REAR

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COMPANY INFORMATION
Water Sustainability is a key to our economic and environmental future

As one of Australia's leading providers of water treatment and recycling solutions; Cleanawater is committed to
building a sustainable future.

Since 1996 our technologies have been helping businesses achieve cleaner water solutions that are both cost
effective and authority and regulatory compliant.

Cleanawater is a 100% Australian owned and operated water technology company that has been providing
water treatment and recycling solutions throughout Australasia for over 17 years. Our manufacturing and
research and development centre are based out of our head office in Thomastown, Victoria, with offices
located in Brisbane, Perth and Adelaide.

Our product range includes:

 Largest Range of Oil Water Separators – Coalescing, VGS, Hydrocyclone and Induced Cyclonic
Separators
 Water Recycling Systems
 First Flush Diversion / Stormwater Management Systems
 Rainwater Harvesting Systems
 AQIS Treatment Systems
 Packaged Pumping Stations
 pH & Chemical Control Systems
 Oil Skimmers – floating oil skimmers / belt oil skimmers

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PARTS INCLUSION LIST

Your package should include the following items. Please check these items off as received. If any items are
missing please contact Cleanawater on 1800 353 788.

Note: If your package is a non-standard package additional/other items may be included in your package.

Item Qty Included

(Y/N)
Oil Separator
TS5000 SS oil water separator unit & lid– stainless steel 1
Galvanized OR stainless steel support frame 1
DN40 ball valve 2
DN40 sludge outlet nipple 2
DN40 internal sludge outlet elbow – factory fitted 2
DN50 internal waste water outlet elbow – factory fitted 1
Coalescing Media Packs – factory fitted 6
Media Packs support grid – factory fitted 8
Inlet splash guard – factory fitted 1
Adjustable Waste Oil Collar – factory fitted (not adjusted) 1
DN40 rubber 90 degree elbow & PVC waste oil outlet pipe 1
Stainless steel worm drive clip to suit waste oil hose 1
20L waste oil collection drum OR 1000L IBC waste oil tank 1
Installation, operations and maintenance guide 1

Oil Separator Feed KwikFlo KDS 50-500 Electric Diaphragm Pump (note other models 1
Pump(s) may be included based on availability – refer to your pump
manual attached for model information)

Controls Float Switch with 10m lead – working float switch 1

Float Switch with 10m lead –high level alarm float switch (optional) 1
Cleanawater pump control panel (refer to pump wiring diagram 1
for all wiring and function information)

Optional Extras Other items may be included in your package based on your
specific site requirements, refer to your packing slip or contact
Cleanawater on 1800 353 788 for confirmation.

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PRODUCT INFORMATION
Cleanawater TS series oil water separators are classified as coalescing type separators (CPS), where oil droplets
in suspension in the moving water stream are removed in a coalescing process by the separating media.

The separating media in the two stages of the Cleanawater TS separator provides a random packed mass of
polypropylene rings with a maximized ratio of surface area to volume. The mass of rings fully occupy the
compartments of the two separation stages providing high surface area with the necessary open area to
allow the waste water stream to pass through. The random placement of the packing ensures that the
waste water cannot “channel” and avoid passing through the media rings.

In the separating process the oil droplets carried in the waste water stream must pass through the maze
of polypropylene rings. The gentle flow used, in conjunction with and high surface area and depth of
the bed in both compartments, ensures that the majority of oil droplets, however small, impinge on a
ring surface. The droplet velocity reduces to zero and gravity takes control. As additional oil droplets
impinge on the ring the droplets ‘coalesce’ together and grow in size. As the droplet volume increases
the buoyancy also increases. This increasing buoyancy drives the droplets to top surface. As the oil level
grows on the top surface it overflows to a waste oil collection container.

Similarly, but in reverse sequence, the solids particles impinge on the ring surfaces and lose their velocity.
Gravity will draw them to the base of the unit as their particle size increases. Upon passing through the
treatment system, created by the two stage packed media coalescing process, water is now treated and via
separator outlet is ready for disposal or to commence next stage of treatment.

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Effluent standards for the Cleanawater TS series oil water separators adhere to the WSAA Product Specification
WSA PS 810, Separator Systems for Light Liquids as listed below.

a. Total Grease 50 mg/L

b. Petroleum Hydrocarbons including BTEX 10mg/L
c. Benzene 0.1mg/L
d. Suspended Solids 200mg/L
e. Flammability < 5% LEL (hexane) at 25OC
f. pH 7-10

Note:

- Quick break and bio degradable detergents and degreasers should be used in conjunction with the system.
- Holding pit capacity should match the hourly throughput of the oil separator system.
- Any solvent based liquids or emulsifiers should be avoided, these may affect the efficiency of the unit performance.
- Coalescing oil separators are designed to remove free oils and mineral grease only.

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SYSTEM SPECIFICATIONS

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TYPICAL INSTALLATION SCHEMATICS

Note these may differ depending on your application. Attached are typical installations only.

TYPICAL GRAVITY DISCHARGE LAYOUT

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TYPICAL PUMPED DISCHARGE LAYOUT

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INSTALLATION INSTRUCTIONS
*-Note: At installation stage, all plumbing works must be completed by a licensed plumber. If electrical works
are required to be completed they must be completed by an electrician with relevant certifications.

Local water authorities should be contacted prior to installation to ensure local requirements have been met.

INSTALLATION PROCEDURES
STEP 1 – PREPARE AREA FOR INSTALLATION
Locate the oil separator in its operating position with sufficient access clearance to operate the sludge drain
valves.
While doing this also position your waste oil container and ensure reasonable work clearances are maintained.

STEP 2 – SETTING UP
Place unit or support frame on a solid and even base. A level concrete slab is preferred. If the slab is uneven it
is preferable to cement slurry the surface and set the separator/frame into the wet cement.

STEP 3 – SETTING UP
If you have been supplied with a separator support stand, dyna bolt your separator support stand into the
concrete slab at the four corners of the stand within the holes built into the stand. For corrosive environments
ensure galvanized fixing materials are used.
Ensure that your foundation has sufficient strength to support the mass of the unit.

STEP 4 – CHECK FOR A LEVEL SURFACE

Ensure that the unit is level within 5 mm on both axes. This can be measured across the top flanges of the unit
(with the cover off).

STEP 5 – PLUMBING CONNECTIONS

Pipe the inlet and outlet water connections. All plumbing shall comply to Australian Standard AS3500.

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Connections as follows should be completed:

 Collection Pit – Pump Inlet
 Pump Outlet – Separator Inlet
 Separator Outlet – Sewer or discharge point

*- Refer to specification sheet for unit inlet/outlet sizes, check the manufacturer data sheet for pump inlet and
minimum diameter piping requirements to ensure pump warranty is not voided.

*- Note: Ensure local piping material standards have been met, any connections to sewer must be completed
by a licensed plumber.

STEP 6 – PLUMBING CONNECTIONS

Plumb the suction line to the pump using the correct diameter pipe as recommended from the pit / suction
source.
Note: It is a requirement in some areas to provide sampling taps on the inlet and outlet pipes of the separator.

STEP 7 – PLUMBING CONNECTIONS

The suction line must be terminated close to the base of the collection pit in line with the recommendations on
the typical installation schematic. It is recommended that a barrel union in the suction line is installed to allow
for simple future maintenance. A foot valve (Mono pump only) should be installed to the base of the suction
line. A strainer should be installed to be base of the suction line if a diaphragm pump is feeding the oil
separator.

* - Note: If a floating skimmer oil is installed in the sump a foot valve/strainer cannot be installed as a flexible
vacuum hose is connected to the pressure pipe directly.

STEP 8 – PLUMBING CONNECTIONS

Fit the supplied gate valve (2) to the sludge outlets. Ensure they are closed before filling the separator.

STEP 9 - PLUMBING CONNECTIONS

Fit the suppled clear PVC hose to the waste oil outlet line, secure using worm drive clip supplied. A 20 litre

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chemical drum is recommended to be used as a waste oil container to aid in disposal at required date. For
mining environments it is suggested a high volume waste oil collection container such as an IBC is used to
collect waste oil.

STEP 10 – PLUMBING CONNECTIONS

Plumb the pump to the separator. Barrel unions in the pipes either side of the pump to aid in servicing is
recommended. A lute should be plumed in to the line to ensure pump is always primed (for Mono Pumps
only).

STEP 11 – PLUMBING CONNECTIONS

Plumb the oil separator outlet to discharge source. Barrel unions in the pipe to aid in servicing is
recommended. All discharge pipework must be in accordance with local regulations including any sampling
points and tundishes. Check your local plumbing regulations for pipe work requirements.

QUALIFIED ELECTRICIANS MUST COMPLETE ANY WIRING

STEP 12 – ELECTRICAL CONNECTIONS

Wire the pump into the electrical controller (Controllers have Manual/Auto/Off functions and are available
from Cleanawater; they are designed to be plugged into 240 volt 10amp power points unless specified) Follow
the wiring diagram supplied at all times to ensure the pump is not damaged.

* - Note - 3 phase pump controllers with additional functions may also be supplied, contact your Cleanawater
representative to confirm the model of your pump controller(s).

STEP 13 – ELECTRICAL CONNECTIONS

Install the float switch to deactivate the pump ensuring it has suitable clearance from the suction line inlet
level. Refer to supplied wiring diagram at all times.

* - Failure to do this will cause problems in your pump to prime.

Fasten the float switch lead to the suction line with plastic cable ties with care taken to ensure that the float
travel is not impeded in any way. The pumping range (switch on point) should be set approximately 500mm
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from the (switch off point). This can be increased depending on the collection pit storage size. If you have a
high level alarm included with your package, repeat this step and set the high level alarm float to trigger near
top of your water collection vessel.
Refer to supplied wiring diagram at all times.

STEP 14 – ELECTRICAL CONNECTIONS

Strip the float lead back to expose active, neutral and earth wires. Following the wiring instructions, attach the
float lead wires to the control panel. Switch on the control panel at the power point and ensure it is switched
to the ‘Off’ setting.
Refer to supplied wiring diagram at all times.

STEP 15 – ADJUST WASTE OIL OVERFLOW OUTLET

Fill the oil separator with clean water and ensure pump is primed by using fresh water entered into the pump
chamber.
Switch the pump control panel to ‘Manual’ mode ensuring there is enough water in the collection pit to feed
the separator, this will pump water into the oil separator unit. Whilst the pump is operating adjust the
overflow socket of the Waste Oil Outlet to a level 5 mm above the water surface. This overflow socket can be
moved up or down the pipe and is sealed by means of an “O ring”. This socket adjustment should be made
while the feed pump is operating as the water level will drop when the pump stops.

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STEP 16 – ELECTRICAL CONNECTIONS

Switch the pump controller to ‘Auto’ mode as per included instructions, this will ensure the pump operation is
triggered by the float switch activating the pump at a level when water level triggers its operation. Make final
adjustments to float level controls ensuring pump switch on and switch off points are suitable.

STEP 17 – COMPLETION
Replace cover, check all connections. Fill unit with fresh water for first start.
Refer to installation completion checklist to ensure all items are complete.

Refer to operations and maintenance manual to ensure periodic maintenance on the system is completed.

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FINAL INSTALLATION CHECKLIST

Refer to the checklist below to ensure your Cleanawater TS series oil separator has been setup correctly.

Note: This layout refers to a typical installation only. You may have specific installation instructions provided
due to an alternate layout or additional equipment installed for your waste water treatment solution.

Contact Cleanawater on 1800 353 788 for any questions related to installation and or operation of the system.

Checked
Item Description
(Y/N)
Placement  Unit is installed on flat ground
 Unit has been fixed to floor surface
 Pump and oil separator has adequate service access
Connections -  Plumbing connections are completed with all barrel unions tightened
Plumbing including:

 Sump/Tank pump line to pump inlet

 Foot valve/strainer fitted to base of pump line in pit
 Pump inlet to oil separator inlet
 Waste oil outlet to waste oil drum
 Ball valves fitted to sludge outlets x 2
 Oil separator outlet to discharge source
Connections –  Float switches set at correct on/off heights and wired back to
Electrical control panel
 Control panel is mounted and easily accessible
 Control panel is plugged into mains power point
 Pump and control floats are wired back to control panel
 Pump control panel has power on
Oil Separator  All internal elbows and fittings are fitted and tight
operation
 Internal media packs and pack holders are in place
 Pumps are primed in accordance with manufacturer recommendations
 Unit is filled with fresh water for first start
 Inlet splash guard is set in place
 Waste oil overflow outlet is set to 5mm of surface when pump is
pumping water into the oil separator
 Pump controller is set to automatic mode
 Oil separator lid is placed on top of unit
 Unit is operational

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OPERATIONS AND MAINTENANCE GUIDE

OPERATIONS

Once the unit is entered into operation, it is an automated process activated by the float switch in the collection
pit which controls water throughput the oil separator; discharge from the oil separator is via gravity into sewer or
discharge tank. Pump tanks if pumping to a discharge source can be supplied on request.

Maintenance is to be routinely completed to ensure that the system is operating to its designed efficiency.

MAINTENANCE

The Cleanawater system is a high performance unit capable of separating high levels of hydrocarbons and solids
within the waste water stream. To ensure it is operating to the maximum of its efficiency the following
maintenance should be completed:

WEEKLY MAINTENANCE TASKS

a) Inspect silt traps and collection pits, clean as required

b) Open oil separator lid, inspect water flow and build up of oils on surface
c) When pump is running check water levels in each of the two stages, an even water level in both stages

illustrates the system is working correctly. If the water level in the first stage is visibly higher than the second
stage a system clean is required immediately, refer to Monthly/Quarterly maintenance procedures
d) Check waste oil container for any build up of oil, dispose of any oil in accordance with local regulations

e) Check the pump operation, float operation and ensure it is activating when water level reaches trigger point

f) Check condition of gate valves to sludge outlets and check any piping for damage

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QUARTERLY MAINTENANCE TASKS

a) Refer to Weekly tasks for regular maintenance checks

b) Switch pump control panel of ‘Off’
c) Attach 40mm suction hoses to gate valves at base of unit, open valves to drain water level down,
either dispose of waste water by using an EPA authorized contractor or drain back into collection
pit (ideally)
d) Remove stainless steel grids and separation media packs from unit
e) Rinse stainless steel grids and separation media bags with a pressure washer, a light spray will
achieve the required result
f) Clean out the oil separator using a pressure washer ensuring all walls are clean
g) Re-install the separation media packs and stainless steel grids

h) Remove suction hoses from sludge valves and close

i) Check sludge build up in collection pit, ensure build of sludge is removed periodically
j) Fill the system with fresh water
k) Switch the pump control panel to ‘Auto’ and inspect system ensuring it is operational
l) Replace lid

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WARRANTY TERMS
Pump Warranty

Manufacturer’s warranty is 12 months from the date of sale unless specified

Oil Separator Warranty

The Cleanawater oil separator is supplied with a 5 year perforation warranty period in a selection
of 304 and 316 stainless steel in non corrosive environments.

If any corrosive elements exist within the waste water stream Cleanawater should be contacted
to discuss suitability of the separator shell for the environment.

Other components

All other components that are supplied with the oil separator including the float switch are sold
with a 12 month warranty.

Compliance Plates

Each Cleanawater oil separator has an identification plate, attached to the top right hand corner
adjacent to the discharge point. Plate material is aluminium foil with overall dimensions of 120mm
x 50mm

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TROUBLESHOOTING GUIDE
SYMPTOM/CAUSE PLAN OF ACTION

WATER IS NOT FLOWING INTO OIL SEPARATOR

Pump is not running  Check that there is power to the pump by

checking local power source
 Check that the pump controller is set to
manual/auto mode
 Refer to the supplied wiring diagram that pump
connections to the controller are correct
 Check pump overload switch is not tripped
Suction line is obstructed  Check pump suction line for obstructions causing
blockage
 Flush suction line with water to remove blockage
 Inspect suction lines for air ingression/cracks and
change if required
 Check foot valve for obstructions
 Check suction line is not submersed in sludge
build up
Pump has lost prime  Prime pump chamber in accordance with
manufacturer’s instructions
 Check foot valve for obstructions
 Float switch working level requires adjustment
and is set too low. Reset the float level off level to
be above the base of the suction line
Pump component is damaged  Pump diaphragm or rotor stator may be worn,
this will cause non suction although you will hear
the pump motor running, contact Cleanawater or
the pump manufacturer for pump spares
Inadequate water level in the sump  Water level in the sump has not triggered the
working float switch to start the pump, check float
is working correctly
 Float switch working level requires adjustment
and is set too low. Reset the float level off level to
be above the base of the suction line


WATER IS INTERMITTENTLY PUMPING INTO THE OIL SEPARATOR

Pump has lost prime  Prime pump chamber in accordance with

manufacturer’s instructions
 Check foot valve for obstructions
 Float switch working level requires adjustment
and is set too low. Reset the float level off level to
be above the base of the suction line
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Check suction line is not submersed in sludge

build up
Suction Line is obstructed  Check pump suction line for obstructions causing
blockage
 Flush suction line with water to remove blockage
 Inspect suction lines for air ingression/cracks and
change as required
 Check foot valve for obstructions
 Check suction line is not submersed in sludge
build up

WATER IS FLOWING INTO WASTE OIL CONTAINER

Waste oil collar on the inside of the unit is set too low  Ensure there is adequate water level in the pit,
switch the pump controller to manual mode to
start the pump operation. Adjust the waste oil
collar inside the oil separator to be 5mm above
water level when the pump is running. This will
ensure that only oils separated from the system
will be skimmed off into the waste oil drum and
no excess water. Switch pump control back to
‘Auto’ mode when complete.
There is a discharge blockage  Media packs are blocked and required to be
cleaned in accordance with operations and
maintenance schedule
 Note: If it is found that blockage occurs regularly
your oil separator system may be undersized or
overload of solids are blocking the system, ensure
all heavy solids are settled out or suction line is
located with adequate clearance from the base of
the pit
The pump flow rate is rated too high for the oil  Excess flow rate is pumping through the system,
separator ensure the correct pump is being used in
accordance with the separator model,
submersible or centrifugal pumps must not be
used.

WATER IS FLOWING OUT OF THE TOP OF THE OIL SEPARATOR

There is a discharge blockage  Media packs are blocked and required to be

cleaned in accordance with operations and
maintenance schedule
Note: If it is found that blockage occurs regularly your oil
separator system may be undersized or overload of solids
are blocking the system, ensure all heavy solids are
settled out or suction line is located with adequate
clearance from the base of the pit
The pump flow rate is rated too high for the oil  Excess flow rate is pumping through the system,
separator ensure the correct pump is being used in
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accordance with the separator model,

submersible or centrifugal pumps must not be
used.
PUMP IS RUNNING BUT NO WATER IS FLOWING INTO THE OIL SEPARATOR

Suction line is obstructed  Check pump suction line for obstructions causing
blockage
 Flush suction line with water to remove blockage
 Inspect suction lines for air ingression/cracks and
change as required
 Check foot valve for obstructions
 Check suction line is not submersed in sludge
build up
Pump component is damaged  Pump diaphragm or rotor stator may be worn,
this will cause non suction although you will hear
the pump motor running, contact Cleanawater or
the pump manufacturer for pump spares

THERE IS NO OIL IN THE WASTE OIL CONTAINER

Waste oil collar on the inside of the unit is set too  Ensure there is adequate water level in the pit,
high switch the pump controller to manual mode to
start the pump operation. Then adjust the waste
oil collar inside the oil separator to be 5mm
above water level when the pump is running.
This will ensure that oils separated from the
system will be skimmed off into the waste oil
drum and not contained within the unit. Switch
pump control back to ‘Auto’ mode when
complete.
 There is little or no oils in the waste water stream
 The oils in the waste water stream are not free oils
or oil droplets in suspension have been emulsified
due to use of solvents or other contaminants
effecting oil water separation efficiency,
coalescing oil separators will efficiently remove
free oils and grease from water, emulsified oils
cannot be removed and requires secondary
filtration. Contact Cleanawater on 1800 353 788
for further information on correct use of system
 Ensure that quick break, biodegradable
detergents and degreasers are used with the oil
separator, mixture with other detergents and
degreasers or other contaminants may affect the
waste water stream and discharge results

PUMP OVERLOAD SWITCH CONTINUES TO TRIP

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Pump motor overheating  Pump motor is located in an area with minimal

airflow and causing the motor to overheat,
relocate motor or remove heat sources to ensure
adequate ventilation is available of pump motor

Faulty pump motor  Pump motor may have defects, contact

Cleanawater on 1800 353 788 or the pump
manufacturer for further information
Power supply is faulty  The pump power supply may have faults or the
breaker on the main board may be tripped
Ambient temperature conditions high  Pump motor is located in an area with minimal
airflow and causing the motor to overheat,
relocate motor or remove heat sources to ensure
adequate ventilation is available of pump motor

THE SYSTEM WILL NOT SWITCH ON/OFF

No power to pump  The pump power supply may have faults or the
breaker on the main board may be tripped
 Check power switch is on to the pump control
panel
Mode incorrectly set on control panel  Refer to wiring diagram and instructions to
activate pump controller modes correctly.
 Manual mode will start the pump manually
regardless of the water level in the sump, Auto
mode will start the pump on float level switch on
point and switch off the pump on float level
switch low point. Never leave the pump control
mode on manual or you will risk damaging the
pump.
Overload switch adjustment If applicable your pump controller may have an
overload switch adjustment, refer to wiring
diagram and instructions for correct adjustment,
contact Cleanawater on 1800 353 788 for further
assistance.
Float switch is stuck  Check float switch levels to ensure they are not
entangled or obstructed, flick the switch manually
by hand up and down to ensure the pump
switches on and off accordingly
Float switch failed  Check float switch levels to ensure they are not
entangled or obstructed, flick the switch manually
by hand up and down to ensure the pump
switches on and off accordingly.
 Check float switch wiring connections in pump
controller and/or junction box

THERE IS OIL PRESENT IN THE DISCHARGE

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Oil spill has occurred or excessive load of oil  Oil spillage event or disproportionate loads of oil
ingression is pumping through the system, attend to the
spillage as soon as possible
Contamination of waste water stream  Ensure that quick break, biodegradable
detergents and degreasers are used with the oil
separator, mixture with other detergents and
degreasers or other contaminants may affect the
waste water stream and discharge results

Discharge blockage  Media packs are blocked and required to be
cleaned in accordance with operations and
maintenance schedule

THERE IS A SMELL COMING FROM THE PIT OR THE OIL SEPARATOR SYSTEM

Pump is not running  Check pump operation to ensure pump is

switching on/off correctly.
Sludge build up in pit or separator  Check sump levels for build up of sludge and
have pit pumped out regularly
 Oil separator requires a service in accordance
with operations and maintenance manual
Stagnant water  Run fresh water into the pit to flush existing
contents and run the oil separator feed pump to
clear stagnant water.

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CLEANAWATER TERMS & CONDITIONS

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PLEASE REFER TO YOUR WIRING DIAGRAM AND

PUMP MANUAL FOR OTHER IMPORTANT PACKAGE
INFORMATION.

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