200 He

Copyright © Hydro Engineering, Inc.
-- Operator’s Manual
OPERATOR'S MANUAL
OPERATION
AND
MAINTENANCE
HIGH PRESSURE WASHING EQUIPMENT
HE/3000
This manual is confidential and proprietary Hydro Engineering, Inc prop-
erty. Any requests for this document must be submitted to the manufac-
turer.
Hydro Engineering, Inc. In Utah: 801-972-1181

865 West 2600 South Toll Free: 1-800-247-8424
Salt Lake City, UT 84119 Fax: 801-972-3265
TRADEMARKS: The HE logo is a registered trademark and Hydroblaster is a trademark of Hydro Engineering, Inc. All other
product names mentioned are trademarks of their respective companies or distributors.
Copyright © Hydro Engineering, Inc. -- Operator’s Manual
IMPORTANT
The following information is necessary for installation, parts, service and
warranty consideration.
Refer to Control Panel Label

for Serial Tag Information
Please fill in the following for your records.
SERIAL NUMBER MODEL NUMBER

Purchased From Date Purchased
Address Telephone
INITIAL INSPECTION AND HANDLING
1. By following the instruction decals on the outside of the container in which this item was shipped, you have
opened the packing units and have either found the equipment in good condition or damaged.
2. If the system was delivered to you by a common carrier and damage is found, even hidden dam-
age, IMMEDIATELY file a claim with your carrier. Their representative must inspect and verify the
damage. It is YOUR responsibility, not Hydro Engineering Inc.'s or your distributor's, to file the
freight damage claim.
3. Check the enclosed packing list to verify that all items have been received! Contact your distributor, or
Hydro Engineering Inc., immediately, if all parts have not been received. Please contact your distributor or
Hydro Engineering, Inc. if assistance is needed with common carriers, identification of parts, assembly, or
installation procedures.
Hydro Engineering, Inc.

865 West 2600 South
Salt Lake City, Utah 84119
1-800-247-8424
NEW PRODUCT LIMITED WARRANTY

Hydroblaster Pressure Washers & HydroKleen Waste Water Recycling and Filtration Equipment
NEW PRODUCT LIMITED WARRANTY Applies to all Hydro Engineering Inc. Equipment
LIMITED WARRANTY COVERAGE:

Products manufactured by Hydro Engineering, Inc., are warranted to the original purchaser to be free from defects in materials and work-
manship under normal use for specific periods. This Limited Warranty is subject to exclusions, is calculated from the date of the original
purchase, and applies to the original components only as shown below. Any parts repaired or replaced under this warranty will fall under
that parts limited warranty.
NINETY DAY LABOR:
This limited warranty includes labor for a period of ninety (90) days from the original purchase date. Labor is provided on the replacement
and/or repair of parts covered by this limited warranty only. Labor is not covered for replacement of parts considered as wear items or
items rejected under the terms of this limited warranty.
LIFETIME PARTS:
Some parts supplied on our equipment carry a lifetime limited warranty such as; forged brass pump manifolds, supplied by General Pump
Company, they are warranted unconditionally, including freeze damage. These pass through warranties are subject to change by their
manufacturer. Please consult our service department for the most recent warranty terms on these items.
FIVE YEAR PARTS:
This applies to all proprietary parts manufactured by Hydro Engineering, Inc., such as equipment frames, Hydropads, stainless steel
equipment covers, panels, guards, coil wraps, and fuel tanks.
FIVE YEAR PRORATED:
Hydroblaster heating coils are covered for full repair or replacement during the first two years; customer pays 40% of replacement cost
during third year, 60% during fourth year and 80% during the fifth year.
ONE YEAR MINIMUM ON PARTS:
All other components will be warranted based on the original component manufacturer's limited warranty. All carry a one year minimum
term. Normal wear items as described below are excluded.
PASS THROUGH REPLACEMENT PARTS WARRANTY:
Many components such as pumps, motors, engines, etc., may be warranted by their respective manufacturers and are serviced through
the manufacturer's local authorized service centers. Hydro Engineering, Inc. is not authorized to provide warranty on many of these items,
but will help you contact and expedite the warranty process with the authorized service centers.
EXCLUSIONS:
1. Normal service and wear items, such as oil filters, fuel filters, nozzles, guns, wands, quick disconnects, o-rings, seals, packing, valve or
valve assemblies, water filter cartridges, belts, brushes, discharge hoses, oil skimming belts, filter media, ozone bulbs, etc.
2. Damage or malfunctions resulting from accidents, abuse, modification, alterations, incorrect installation, improper servicing, and failure
to follow manufacturer's maintenance instructions, or use of the equipment beyond its stated usage specifications as contained in the
operator's manual.
3. Freeze damage, chemical damage, scale/hard water build up, rust, corrosion, or excessive heat.
4. Damage resulting from inadequate- electric, water and venting or fuel supplies.
5. Normal maintenance service, including tune-ups, fuel system cleaning, and clearing of obstructions in fuel or water lines.
6. Freight damage resulting from shipment.
7. Field labor and transportation (mileage) charges for onsite service calls.
ACQUIRING WARRANTY SERVICE:
To acquire warranty service, you must return the product to your Authorized Hydro Engineering, Inc. Dealer, (or directly to Hydro Engineer-
ing Inc. factory), and freight prepaid, with proof of purchase date within the applicable warranty period. If the product is permanently
installed, you must notify your Authorized Hydro Engineering, Inc. Dealer (or Hydro Engineering Inc. factory) of the defect. Your Dealer is
authorized to file a claim with Hydro Engineering, Inc. Ground freight charges on warranted replacement parts will be paid by Hydro Engi-
neering Inc. For warranty service on components warranted by other manufacturers, your Authorized Hydro Engineering, Inc. Dealer (or
Hydro Engineering Inc. factory) can help you obtain warranty service through the manufacturer's local authorized service centers.
LIMITATION OF LIABILITY:
Hydro Engineering, Inc. shall not be liable for special, incidental, or consequential damages and therefore these damages are expressly
disclaimed. Hydro Engineering, Inc.'s liability limit under this limited warranty shall not exceed the purchase price of the product in ques-
tion. Hydro Engineering, Inc. makes every effort to ensure that all illustrations and specifications are correct, however, these do not imply
a warranty that the product is merchantable or fit for a particular purpose, or that the product will actually conform to the illustrations and
specifications. THE WARRANTY CONTAINED HEREIN IS IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUD-
ING ANY IMPLIED WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE, INCLUDING WASTE-WATER TREATMENT. Hydro
Engineering, Inc. does not authorize any other party including authorized Hydro Engineering, Inc. Dealers, to make any representation or
promise on behalf of Hydro Engineering, Inc., or to modify these terms, conditions, or limitations in any way. It is the buyer's responsibility
to ensure that the installation and use of Hydro Engineering, Inc. products conforms to local codes.
Date Effective: 29September 08

Hydro Engineering Inc.
865 W. 2600 S. • Salt Lake City, UT 84119
(801) 972-1181 • (800) 247-8424
RETURN GOODS AUTHORIZATION (RGA) PROCEDURE
RETURN GOODS AUTHORIZATION (RGA) PROCEDURE
This guideline is designed to assist you in understanding the Hydro Engineering, Inc return goods process. We follow this
process when an item is returned for credit, warranty consideration, service repairs, or refurbishing.
ITEM RETURN PROCEDURE
1.Contact the Hydro Engineering, Inc. (HEI) Parts or Service Department to obtain an RGA authorization number. Please
have either the invoice number or the serial number of the equipment that the item was sold or installed on.
2.A Return Authorization Document outlining our understanding of your instructions to us will be sent to you promptly by mail,
fax, or email.
3.Please package the items to be returned carefully.
4.The RGA number should be written legibly on the exterior of the return packaging to expedite handling your return.
5.Ship the product freight prepaid to HEI.
6.Item(s) received for warranty consideration will be evaluated and will either be repaired, replaced, or a credit issued. Upon
receipt of items this process may take up to one week. If warranty is denied, you will be given a written explanation of the
decision, along with a repair estimate. Your authorization will be required before any repairs are made.
7.All parts received by HEI and not covered by warranty may be returned, repaired, or discarded, at your option. Any item(s)
held longer than 30 days after HEI's request for customer's disposition directions will be discarded as scrap.
8.NOTE: Warranted items are returned to you freight prepaid via ground service. You will be responsible for all return ship-
ping & handling costs for item(s) denied warranty repair that you want returned.
NOTE: RGAs are valid for 45 days, if your parts are not returned to HEI within the 45 day period the RGA will be closed.
REPLACEMENT PARTS ORDERS
If replacement items are needed immediately for parts submitted for warranty consideration, an invoice will be generated for
those item(s). This invoice is due and payable per the established customer terms.
Date Effective: 02December14 Printed copies are not controlled Owner: Jim McCormick
Status: Approved, Bug 10057
Hydro Engineering Inc.

865 W. 2600 S. • Salt Lake City, UT 84119
(801) 972-1181 • (800) 247-8424
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Table of Contents
OPERATION & MAINTENANCE MANUAL

FILTERING SYSTEM
HE/3000
Table of Contents
Introduction
SCOPE .................................................................................................................................................................1-1
EQUIPMENT DESCRIPTION AND DATA ...........................................................................................................1-1
Safety
IMPORTANT SAFETY INFORMATION ...............................................................................................................2-1
GENERAL INFORMATION ..................................................................................................................................2-1
GENERAL SAFETY .............................................................................................................................................2-1
ELECTRICAL SAFETY ........................................................................................................................................2-2
MECHANICAL SAFETY .......................................................................................................................................2-2
CHEMICAL SAFETY ............................................................................................................................................2-2
Installation Notes & Setup

LOCATION ...........................................................................................................................................................3-1
SYSTEM CONNECTIONS ...................................................................................................................................3-1
POWER REQUIREMENTS ..................................................................................................................................3-1
BIOLOGICAL CONTROL .....................................................................................................................................3-2
AUTO DISPENSING SYSTEMS ..........................................................................................................................3-2
MEDIA FILTER AND MEDIA................................................................................................................................3-3
SYSTEM FILL AND THE MAKE-UP WATER SUPPLY .......................................................................................3-3
DISCHARGE TO DRAIN (OPTIONAL) ................................................................................................................3-3
Logic Controller
INTRODUCTION ..................................................................................................................................................4-1
CONTROLLER CONFIGURATION......................................................................................................................4-2
CHANGING LC PARAMETERS...........................................................................................................................4-5
Operation
PRE-OPERATION CHECKS................................................................................................................................5-1
PRE-OPERATION MAINTENANCE.....................................................................................................................5-1
PRE-OPERATING NOTES ..................................................................................................................................5-1
SHUTDOWN ........................................................................................................................................................5-2
OPERATION NOTES AND SPECIAL INFORMATION........................................................................................5-2
pH MONITOR/CONTROLLER .............................................................................................................................5-3
ORP MONITOR/CONTROLLER ..........................................................................................................................5-4
Maintenance & Service

GENERAL INFORMATION AND RECOMMENDATIONS ...................................................................................6-1
AIR RELIEF VALVE .............................................................................................................................................6-1
BACKWASHING THE MEDIA FILTER.................................................................................................................6-1
i

FILTERING SYSTEM
HE/3000
Table of Contents (continued)
CLEANING THE MEDIA FILTER .........................................................................................................................6-1

OTHER FILTERS .................................................................................................................................................6-2
ELECTRIC MOTOR .............................................................................................................................................6-2
CIRCULATION PUMP..........................................................................................................................................6-2
INLET FILTER SCREEN ......................................................................................................................................6-2
SHAFT SEAL........................................................................................................................................................6-3
PROCESS TANK .................................................................................................................................................6-3
Troubleshooting
PRES SW #1 INOP or PRES SW #2 INOP..........................................................................................................7-1
PUMP #1 INOP ....................................................................................................................................................7-1
PUMP #1 INOP CONTINUED ..............................................................................................................................7-2
PUMP #2 INOP (available on systems with a second process only) ...................................................................7-2
DEFOAMER INOP ...............................................................................................................................................7-2
SYSTEM WON’T ACCEPT FLUID .......................................................................................................................7-3
UNPLEASANT ODOR COMING FROM SYSTEM ..............................................................................................7-3
MACHINE TURNS OFF AFTER A FEW MINUTES OF OPERATION.................................................................7-3
WATER LEAKAGE...............................................................................................................................................7-4
MACHINE OVERFLOWS .....................................................................................................................................7-4
TANK(S) DRAIN OR EMPTY DURING NORMAL OPERATION .........................................................................7-4
MEDIA IN PUMP INLET STRAINER....................................................................................................................7-4
PROBLEM WITH MEDIA FILTER OPERATION..................................................................................................7-5
HIGH FILTER PRESSURE AFTER BACKFLUSHING ........................................................................................7-5
PUMP/MOTOR WILL NOT OPERATE.................................................................................................................7-5
MOTOR OVERHEATING AND STOPPING.........................................................................................................7-6
MOTOR STOPS ...................................................................................................................................................7-6
AUTOMATIC DISCHARGE INOPERATIVE.........................................................................................................7-6
Suggested Maintenance Stock Items

FILTER PRESSURE READINGS AND MEDIA CHANGE RECORD .................................................................T-1
Diagrams
EXPLODED VIEW: MEDIA FILTER PLUMBING -- HE/3000 ............................................................................D-1
EXPLODED VIEW: PROCESS TANK PLUMBING -- HE/3000 ........................................................................D-2
EXPLODED VIEW: DE-FOAM -- HE/5000 .........................................................................................................D-3
PLUMBING DIAGRAM, DISCHARGE MANIFOLD .............................................................................................D-4
EXPLODED VIEW: MEDIA FILTER BACKWASH VALVE .................................................................................D-5
EXPLODED VIEW: CIRCULATION PUMP #1 PLUMBING ...............................................................................D-6
EXPLODED VIEW: DRAIN PIPE PLUMBING -- HE/3000 .................................................................................D-7
ELECTRICAL DIAGRAM: DOSING PUMP, #1UI042(BUG DOSING), 24VAC ..................................................D-8
ELECTRICAL.DIAGRAM: LOGIC CONTROLLER: SINGLE PUMP: 230/115V, 1PH, 1 & 1.5HP ....................D-9
ii

FILTERING SYSTEM
HE/3000
Table of Contents
ELECTRICAL.DIAGRAM: EL511-2LCR5-LEGEND ...........................................................................................D-10
ELECTRICAL SCHEMATIC: COLD WATER 2-8 MINUTE RINSE CYCLE / 230V 1 PHASE ...........................D-11
EXPLODED VIEW: DEFOAM SYSTEM: 1YF055 24DC ....................................................................................D-12
MACHINE MAINTENANCE LOG SHEET ............................................................................................................D-13
iii
Copyright © Hydro Engineering, Inc. -- Technical Manual Introduction
Introduction
SCOPE around any part of the unit requiring access for mainte-
nance.
A. Type of Manual: Operation and Maintenance
D. The HE/3000 units are available as either 115-volt or
230-volt single phase, 60-hertz systems. The unit is to be
B. Model Number and Equipment Name: HE/3000
hard wired into a customer supplied disconnect with an
HydroKleen Filtering System.
amperage rating sufficient to the power requirements listed
on the control panel.
C. Purpose of the Unit: This unit is primarily designed to
filter solids and light emuslified carbons from waste
E. This system is primarily designed to remove oils, light
water in a single polishing loop.
aromatic hydrocarbons, organic compounds, and solids
from an effluent stream created by cleaning operations
D. Maintenance Records, Forms, and Reports: The
associated with equipment and facilities. It will not remove
user is expected to maintain an operational record of
dissolved solids like salts. The outflow is typically accept-
this filtration system according to instructions provided
able for sewer discharge with proper permits or may be
in the “General Information and Recommendations” in
recirculated to the cleaning process and reused.
the MAINTENANCE AND SERVICE section of this
manual. This record should include all maintenance
F. The system computer (logic controller or LC) manages
performed and should list component parts of the sys-
many of the unique operating features of the HE/7000 by
tem which are repaired or replaced. This record should
monitoring sensors and controlling pumps, valves, and
also include the replacement of filters and filter media.
interface devices. The LC also performs most required
It is recommended that a copy of the Machine Mainte-
maintenance chores and can shut down the system if
nance Log Sheet be included at the end of this man-
unexpected operation is detected. When an error condition
ual be used for this purpose and be kept in close
is detected that the system is unable to resolve, error indi-
proximity to the equipment.
cator lights on the control box and the optional service bea-
con will signal the condition. Additionally, the LC (which is
E. Preparation for Storage or Transport: Follow all
located inside the control box) indicates which device trig-
instructions provided in the OPERATION section of
gered the error condition on the LCD display. Details of the
this manual.
various functions that the controller will monitor and control
are addressed in the PROGRAMMABLE LOGIC CON-
EQUIPMENT DESCRIPTION AND DATA TROLLER section of this manual.
n EQUIPMENT CHARACTERISTICS, CAPABILITES, G. The HE/3000 is provided with a 24” diameter hydro-
AND FEATURES sorb media filter as standard, however, an optional diato-
maceous earth (D.E.) media filter may be substituted in
A. The filtration system consists of one processing tank, place of the hydrosorb media filter as designated.
a pump, and a filtering unit. Some units may also come
equipped with an optional stainless steel backflush filter Odor and quality of the wastewater are controlled with liv-
and/or an additional filter in the filtered water discharge ing bacteria called Hydro-biodigesters (also referred to as
line. The capacity of the processing tank is 110-gallons. bugs, biodigesters, or HBD). The biodigesters have been
designed to consume hydrocarbons and various types of
B. The system measures approximately 6’-0”L x 33-1/2”D organic material that are the typical causes of odor and dis-
x 6’-3”H. The HE/3000 filtration system, as shown in Figure coloration in the wastewater. A liquid HBD product (HBD-6)
1-1 is assembled within a steel tubing cage with lower steel is added to the system by either an optional LC controlled
channel frame measuring approximately 6 ft. long x peristaltic pump or a stand alone dosing system. These
33-1/2”D x 6’-3”H. The media filter module and 110-gallon systems inject the bugs into the first process tank in pre-
tank frame is constructed of square tubing with sections of cise quantities and at recurring programmed intervals.
3 or 4 inch c-channel. The unit can be moved from the side
or the end with a fork lift equipped with either standard or The biodigesters require air, food, water, and a suitable
long forks. When installed, there should be adequate temperature and pH to grow and multiply. Optimizing these
space on all sides of the unit to provide access for mainte- conditions will increase the biodigester metabolism and
nance without having to move the unit. Use caution and reproduction rates. This improves the rate that the bugs
keep safety in mind when accessing these areas. consume the hydrocarbon and organic wastes. Reference
the Document Library at www.hydroblaster.com for addi-
C. The unit is designed to operate normally from 34° to tional information on the use and application of Hydro-
110° F at altitudes up to 6,000 feet. The unit should be biodigesters. Additional information regarding dosing rate
installed indoors and not be subjected to freezing tempera- programming is included in the PROGRAMMABLE LOGIC
tures. When installed, there should be adequate free space CONTROLLER section of this manual.
1-1
Copyright © Hydro Engineering, Inc. -- Technical Manual Introduction
The HE/3000 system may be operated and maintained by

a single person.
Systems equipped with Hydrobiodigesters dosing systems

typically will produce land fill acceptable sludge. Sludges
produced by the system should be tested for landfill accep-
tance prior to disposal.
Hydrobiodigesters are added to the system with a peristal-

tic pump that intermittently injects the Hydrobiodigesters
into a tank at set intervals. Refer to the Operation section
for information on the application of the Hydrobiodigesters.
1-2
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Safety
Safety
HydroKleen water filtration systems are designed to provide filtration of the effluent stream collected
from vehicle or equipment wash operations for reuse by a pressure washer or as a filter pretreatment
before effluent discharge to drain. HydroKleen systems may be used individually or in combination
depending on water quality demands. Many safety features have been integrated into the design to
help protect the operator from hazards; however, there are potential safety risks involved with their
use. Please read these safety instructions carefully.
IMPORTANT SAFETY INFORMATION GENERAL INFORMATION
READ AND UNDERSTAND ALL SAFETY PRECAUTIONS This unit is used to filter water generated by wash opera-
AND WARNINGS LISTED. tions. This is the type of waste water which results from
washing buildings, vehicles, aircraft, equipment, etc.
The two definitions, listed below, will be used throughout
this manual to establish the proper action to be taken The filtration system is NOT designed to remove salt from
whenever a “special” condition exists. water. Dirt, oil solvents & trace amounts of heavy metals
(on specially equipped systems), and other contaminates
< WARNING > will be removed allowing the discharge to be directed to
sewer drain (per local codes), back out to the clean-out pit,
“CONCERN FOR PUBLIC SAFETY” or reused by other equipment.
WARNING: This system is designed to be used with a

“ WARNING ” supply of culinary water. Use of a water supply source
other than culinary water may have an adverse effect on
is used when improper use can potentially result in injury to your equipment and the Hydro Engineering, Inc. warranty.
operating personnel. Failure to follow these instructions
could potentially result in serious bodily injury. GENERAL SAFETY
EXAMPLE: The "clean" water produced by this system is not for
human consumption and may subject the user to skin and/
WARNING: Fluid discharged from this system is not or eye irritation depending upon contaminants left in the
suitable for human consumption! solution. Always wear appropriate protective equipment
when using this water.
******
WARNING: Water discharged from this system is not
< CAUTION > suitable for human consumption!
“TO DRAW ATTENTION TO THE PROBABLE RESULTS Before operating, the operator should be thoroughly famil-
OF AN ACTION” iar with equipment operation, limitations, and hazards. This
may be done by thoroughly reading, understanding, and
observing all safety and operating instructions in this man-
“ CAUTION ” ual.
is used when the end item can conceivably be damaged as This system is a large volume water displacing system. Do
a result of improper usage. not operate the system if any water leakage is observed,
guards or components have been removed or defeated, or
EXAMPLE: if any mechanical defect is suspected. Verify that all fluid
connections, tank retainer rings, and/or media filter lids are
secure and tight before operating. Periodically check/
CAUTION: It is important that the toggle switch on record all gauge readings. Be aware of the monitoring
the valve actuators remain in the up (ON1) operating posi- function of each gauge, as well as its normal operating
tion when ever the system is running to guarantee satisfac- level.
tory operation.
WARNING: The media filter operates under pressure.
Air can enter the system and become pressurized in the
media filter. An improperly installed, improperly tightened,
or leaking filter top can potentially separate from the filter
housing and travel a considerable distance at a high veloc-
ity if compressed air is present in the housing. Make sure
2-1
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Safety
that the lid is properly tightened and secured before return- THIS SYSTEM IS NOT DESIGNED TO BE USED WITH
ing the system to service. Open the air relief valve mounted SOLVENTS, FLAMMABLE OR NONFLAMMABLE.
on the filter lid regularly to release any air from the filter
vessel. Be careful not to inhale or ingest effluent liquids or vapor.
Be aware of any chemicals that are being used in the
The air relief valve MUST be opened daily or before the cleaning process, their proper application, first aid proce-
system is placed into operation. It should also be opened dures, and recommended disposal procedures. Make sure
periodically according to a regularly recurring inspection that Material Safety Data Sheets (MSDS) are readily avail-
schedule to relieve the air. The valves should remain open able on all products associated with the process. When
until fluid flows, without air, from the valve discharge port. dealing with chemicals, wear appropriate protective cloth-
ing: gloves, respirator, face mask, glasses, and wet suit as
ELECTRICAL SAFETY necessary.
Before servicing, survey the area for possible hazards and

correct before proceeding. Never stand in water when
cleaning, contacting, or working with, electrically powered
equipment. Verify the correctness of all electrical connec-
tions, especially check for proper electrical grounding
before operation.
WARNING: Turn the system off, disconnect and lock

out the power supply to assure that the unit is electrically
isolated and can not be started during servicing.
The limit switches monitor pump operation to protect the

pumping system, guard against catastrophic leaks, and to
guarantee safe operation. Do not modify the factory setting
of these switches as shown on the wiring diagram.
MECHANICAL SAFETY
All guards, shields, and covers must be in place to prevent

accidental contact with hazardous parts. Turn the machine
off before attempting to make any adjustments unless
directed otherwise. Inspect machine periodically for dam-
aged or worn components and repair or replace to avoid
potential hazards.
CHEMICAL SAFETY
This HydroKleen filtration system is designed primarily to

handle wastewater that contains a wide variety of contami-
nates. Not all contaminates are acceptable. Unacceptable
materials may also enter the system. Many commonly
used chemicals react violently when exposed to water,
some simply separate from the effluent stream creating
flammable, noxious, explosive, or possibly hazardous
vapors. Such material must be removed from the cleaning
area or be contained in waterproof containers to protect the
effluent inflow from the material.
WARNING: YOUR WARRANTY MAY BE VOID IF

CHEMICALS NOT APPROVED IN WRITING BY HYDRO
ENGINEERING, INC., ARE USED IN YOUR
HYDROKLEEN SYSTEM. CERTAIN CHEMICALS MAY
HAVE ADVERSE EFFECTS ON THE EQUIPMENT. CON-
TACT HYDRO ENGINEERING INC. BEFORE ALLOW-
ING UNACCEPTABLE CHEMICALS TO ENTER THE
SYSTEM!
2-2
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Installation Notes & Setup
Installation Notes & Setup

Refer to the OPERATION section of this manual for more
LOCATION information on the OPERATION MODE toggle switch.
The HydroKleen system is designed as a stationary unit
WARNING: This system is designed to be used with
and should be located on a level surface. Sloped surfaces
wash water effluent. Certain hazardous chemicals, sol-
may also be acceptable to a certain extent. Contact Hydro
vents, and cleaning compounds may adversely affect this
Engineering, Inc., to determine acceptablility of sloped sur-
system and the equipment warranty. Contact Hydro Engi-
faces. Each system has been designed to be moved with
neering, Inc. regarding material compatibility questions
the use of a fork lift. Long forks are recommended on the
before allowing questionable materials to run through the
HE/3000 filtration units. Systems are designed for use in
system.
dry, clean locations with access to adequate ventilation.
Protect from wind, rain, snow, extreme temperatures, and
The FILTERED WATER OUTLET port is either a 3/4” or 1-
exposure to the wash area. Enclosed units may be
1/2” line that is pressurized to 20PSI. This connection point
installed outdoors, but may also require that tank heating
is located on the discharge manifold of the process tank.
elements be installed into all water tanks. Contact Hydro
This line provides filtered fluid for use to a pressure
Engineering, Inc., if it is determined that the equipment will
washer, holding tank, or similar device.
need to be installed outdoors to ensure that all adequate
measures will be, or have been, taken to protect the sys-
The 1-1/2” PVC WASTE WATER OUTLET drain line is a
tem from the elements. Install the unit with consideration to
gravity drain. This connection point is located on the back
the location of the water supply, electrical source, chemical
of the machine below the final process tank. Proper func-
storage, and access for maintenance. Check the unit to
tion of the drain requires the attached line to drop in eleva-
determine the location of all utility and electrical connec-
tion from the connection point. This line is typically
tions prior to final positioning.
connected to the customer supplied sump, Hydropad gut-
ter, or Hydropad.
If multiple units are to be used, understand, prior to posi-
tioning of the units, the proper flow of effluent between
This carries the fluid used to backwash the media filters.
each unit.
Additionally, it carries a small flow of filtered water from the
second process tank. Because the line is connected to the
SYSTEM CONNECTIONS effluent source, the continuous flow directed into this line
maintains flow throughout the whole system. This flow car-
The power supply connection box is located on the back of ries Hydro Biodigesters to the effluent source. This
the machine. All hose, conduit, and pipe connections within improves propagation of the Biodigesters, eliminates stag-
the system are factory plumbed. nant water and associated odor and undesirable bacteria
growth. The line also carries excess fluid in the event of a
FRESH WATER INLET: This is a 3/4” hose barb fitting and system overflow. It is connected to the tank overflow ports
should be connected to a fresh water supply source. This and to the media and tank drain lines.
connection point is located on the process tank. This sup-
ply source should be capable of supplying anywhere NOTE: Observe local code requirements and obtain any
between 8 and 10 gallons of water per minute. necessary discharge permits before connecting to sewer
drain. All transport of waste materials must be properly
WARNING: This system is designed to be used with manifested.
fresh water inlet supply of culinary water. Use of water
other than culinary water may have an adverse effect on The 1-1/2” PVC DISCHARGE TO DRAIN option is a pres-
your equipment and the Hydro Engineering equipment surized system. This connection point is located on the dis-
warranty. charge manifold of the final process tank. Discharge
pressures of up to 20PSI are provided to this line. This
The INLET FROM SUPPLY SUMP inflow port is the con- allows the discharge point to be above or at a distance
nection point that the supply effluent pump or system con- away from the system. This line is required on systems that
nects to. This line is offered in either 3/4” or 1 1/2” line operate as filter to drain system.
sizes. This connection point is located on the process tank.
This connection allows effluent, contaminated with solid POWER REQUIREMENTS
particles, oils, and other hydrocarbons, to be pumped into
the coalescing tank where it begins the solids settling and
The HE/3000 system requires a 230/115 volt, single phase,
oil separation processes.
30 amp, 60Hz power source. The neutral conductor is
required to develop power supplied to several 115 volt
NOTE: Power to the supplying sump pump is controlled by
loads. Voltage variation of + or - 10% are acceptable, how-
the logic controller but is ultimately controlled by the lower
ever, low voltage combined with inadequate wiring and
or upper float switch in Process Tank 2 depending on how
the “OPERATION MODE” toggle switch is set. NOTE:
3-1
heavy starting loads may not allow the circulation pump/ HYDRO BIODIGESTERS (HBD)
motor to start and accelerate to full speed.
Hydrobiodigesters compete for food (hydrocarbons and
CAUTION: The pump/motor incorporates thermal over- other organic compounds) with undesirable bacterial
load protection. do not attempt to override this or any other organisms that produce hydrogen sulfide gas (swamp
safety devices. Always depend on a qualified electrician to smell odor) and water discoloration. Once the food is con-
answer questions and perform any necessary electrical sumed, the bacteria population dies and is consumed by
work the HBD.
It is recommended that the HBD are established in the new

system or in a system that has been allowed to operate
without biodigesters for a period of time with a 'seed dose'
using dry powdered product. The application of the seed
1 dose is described in the dosing directions supplied with the
product.
SETUP & APPLICATION: Hydro Biodigesters are injected

into the process tank The dispensing unit discharge line is
plumbed to the top of this tank. The dispensing unit suction
line is inserted into a 6-gallon pail of the HBD product (part
number: HBD-6). The product container is typically situated
in a convenient location on the floor within the HE/3000
cabinet.
2 Regularly recurring doses are applied by the auto dispens-

ing system. The HE/3000 logic controller is factory set to
control the dosage at a daily rate of 4.8 ounces of HBD per
Figure 3-1: HE/3000 Filtration System electrical wiring box day. To achieve this dosage the pump is activated for 2
seconds every hour. The pumping system doses a quantity
of 0.1 ounce of product per second. Dosing only occurs
Item Description while the system is operating in the high process demand
mode (i.e. when the circulation pumps are on).
1 Power to Supplying Pump (3-wires)
2 Incoming Power Supply (4-wires) NOTE: Higher dosage rates may be required for systems
with large total fluid capacity, high organic content, or in
open to drain discharge systems (i.e. system that are pro-
BIOLOGICAL CONTROL cessing wastewater and discharging directly to drain).
Changing the dosage rates, while fairly simple, requires
As indicated in the INTRODUCTION section, this system that the user contact their dealer or the factory for assis-
uses Hydrobiodigesters (HBD) to combat undesirable tance with logic controller programming.
organisms that produce hydrogen sulfide gas (swamp
smell odor) and water discoloration. A brief description of DEFOAMING
HBD and its application is given below. An additional infor-
mation sheet is included in this manual regarding HBD. The defoamer solution is injected in the process tank. A
photoelectric sensor mounted in the top of the process tank
AUTO DISPENSING SYSTEMS produces a signal when foam is detected. The LC waits
until the foam detector signal has been maintained for 2
The HE/3000 may be equipped with Auto Dispensing Sys- seconds before the peristaltic defoamer pump is activated.
tems. The dispensing systems will dose either liquid hydro- The pump is turned off immediately upon loss of the detec-
biodigesters or defoaming agent. These options consist of tion signal. If the doser operates continuously for 60 sec-
a peristaltic pump that is controlled by the HE/3000 logic onds, the system assumes an error condition (defoamer
controller. If the system is ordered without the Auto Dis- supply tank is empty) and the "RUN/SERVICE INDICA-
penser options, stand alone unitized controller and dosing TOR" light on the HE/3000 control box will flash indicating
pump systems may be installed later if required. The sys- a service request. If the system is equipped with a signal
1
tem controlled dispenser is powered by the filtration sys- beacon the beacon will also be activated. The HE/3000
tem. The independent units require 115V power supplies. system continues to operate in normal operating mode but
This manual will address only the dispensing systems without the benefit of the foam control system.
offered as options for the HE/3000.
The peristaltic pump dispensing unit suction line is inserted
into a pail of the defoamer product. The product container
3-2
is typically situated in a convenient location on the floor The system is ready to be started. Refer to the OPERA-
near the HE/3000 or within cabinet if applicable. TION section for further information on the start up proce-
dure.
Foam develops when surfactants in the waste water com-
bine with the air injected into the process tank by the "rum- DISCHARGE TO DRAIN (OPTIONAL)
ble" manifold. The air is injected to oxygenate the water
and provide a more favorable aerobic environment for the The HE/3000 system is offered with an optional motorized
HBD organisms. Additional benefits derived from air injec- valve on the outlet manifold, (see Figure 3-2) that opens to
tion include air stripping of light aromatic hydrocarbon com- allow processed water to be evacuated from the system
pounds and suspension of solids in the solution that and discharged to drain when the water in the process
promotes solids filtration. tanks is sufficient to float the discharge control float valve.
The valve actuation signal is supplied by the logic control-
MEDIA FILTER AND MEDIA ler but is ultimately controlled by the float switch in Process
Tank 2 assigned to monitor discharge control. Two float
The HE/3000 system has one media filter. The media filter switches are installed at the top of this tank. Ones is
has its own designated media type. Refer to the LABEL on assigned to control the discharge to drain valve, the other
the media filter for information on media type. The media of these by the “OPERATION MODE” toggle. When the
filter, typically, is not shipped with media in the tank. This switch is placed in the recycle mode the top switch controls
media will need to be added before the system is put into the auto discharge to drain signal and the lower float the
operation. The label on the media indicates the quantity of call for inflow signal. When the toggle is in the filter to dis-
media required with respect to the size of the media tank. charge mode the responsibilities of these switches is
Use this label to determine the quantity amount for your reversed.
particular situation. Occasionally, media may be put into
the filter at the factory for testing purposes and may also be If problems are encountered and the valve is supect, refer
shipped with the media still in the tank. It is advised to to the TROUBLESHOOTING section for more information.
check your filter tank to determine whether adding media is
necessary. If adding media is necessary, refer item #6
under the “CLEANING THE MEDIA FILTER” heading in the
MAINTENANCE & SERVICE section of this manual for
this procedure.
Motorized Valve
SYSTEM FILL AND THE MAKE-UP WATER
SUPPLY
PROCESS
Once the utility hook ups are complete and teh media filter TANK 2
are charged with media, the system may be filled with fresh
water. This is a manual process that includes filling the filter
housing and the process tank using a garden hose.
Start with the filter; close the filter drain valve at the bottom
of the filter housing, remove the top access port filter cap,
fill the housing completely, replace the cap, and verify that
the air bleed valve on the top of the cap is closed.
Water Filter
Finish with the process tank: close the tank drain valve and
fill the tank to about the 80 gallon level. Figure 3-2: Motorized Auto Discharge Valve
Make-up water flow into the system is controlled by a float

switch controlled solenoid valve or by a float valve
mounted in the second process tank.
NOTE: The system must be filled with fresh water before

starting. Drain and refill the system with fresh water if any
effluent fluid has been allowed to enter the system prior to
start up. This will allow the start up to occur without con-
cern about leakage and effluent loss. It will also protect the
system from excessively high concentrations of waste
material that could plug a pump, valve, or blind a media fil-
ter.
3-3
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Logic Controller
Logic Controller n LCD DISPLAY MESSAGES
As the logic controller monitors the filtration system’s oper-

Read all instruction and caution labels on the system prior ation, various messages are displayed on the controller’s
to operating or servicing! LCD display screen to assist the service technician. These
messages indicate the status of the current operation or
INTRODUCTION condition of the system. Below is a list of the different mes-
sages along with a brief description of their interpretation.
The use of a programmable logic controller allows many of
the unique features built into the system in addition to “Filling Tank”
many of the options that may also be part of the system to
be managed by the controller. The logic controller moni- The logic controller has recieved the signal to perform the
tors the electrical control devices of the system and acts initial filling of the system with fresh water. The controller
upon signals it receives from these devices. The controller will continue to display this message until the water level
will do all of the following: lifts the lower float located in the second process tank to
the off position.
1. Restart the system automatically in the event of a
power outage, provided that the power supply switch on “System OK”
the control panel of the filtration system is turned on.
The system has passed all device checks and is operating
2. Provide a signal or power to activate the sump normally. The controller displays this message upon com-
pump(s) providing effluent to the filtration system. Power pleting the system check routine at start up. The controller
to the supplying sump pump(s) is ultimately controlled by a will continue to display this message as it moves through
signal from the float switch in the final process tank. its various processes.
3. Put the system into “high filter rate” polish mode, the “Resetting...”
15/45 minute program can’t be changed at this time. By
default, the system is scheduled to operate in high filter The logic controller has been either powered off and on or
rate polish mode for 15 minutes every hour, 24 hours per has been reset using the programming software. The con-
day. As part of the normal operation of the system, the troller will continue to display this message until the system
controller will de-energize the pumps for 45 minutes every check routine has been completed.
hour to reduce power consumption. This is known as the
“ENERGY SAVE MODE”. The system may be manually “Pump #1 Inop”,”Pump #2 Inop”,(”Pump #3 Inop”)
taken out of energy save mode and put into high filter rate
polish mode by toggling the switch on the control box of the The pump in the indicated process loop has experienced a
Filtration System. Additionally, the system will automati- problem. As a result of this problem the system has been
cally be placed into high filter rate polish mode whenever turned off and requires service attention before it can be
any of the Hydroblaster pressure washers are activated. started. Refer to the TROUBLESHOOTING section for
possible causes.
When the Hydroblasters are shutdown and/or when the
high-rate toggle switch on the control box is turned off, the This message refers to the pump that is installed on
pumps will continue to run for 15 minutes before the con- the independant Bioreactor. Refer to the TROUBLE-
troller puts the system into energy save mode. SHOOTING section for possible causes.
4. Put the system into a backwash cycle at “user-configu- “Energy Save Mode”
rable” programmed intervals. By default, the system is
scheduled to backwash Monday through Friday at 2:00 The system is running but the circulation pumps are off.
AM. The supply sump pump is still enabled during this period.
If the system is operating in “high filter rate” mode at the “Polishing...”

time a backwash cycle is scheduled, or the filtration system
receives a signal to operate in “high filter rate” mode during The system is running and the circulation pumps are on.
a backwash cycle, the system will suspend the backwash
cycle and proceed to initiate the necessary sequence of “Backwash Needed”
events to bring it into high filter rate mode.
The system has received a signal to queue a backwash
5. Be able to react when a signal is received from the cycle. This signal may have originated from either the
“foaming sensor device,” located within the first process pressure switch on the system or from the “BACKWASH
tank, by sending defoaming agent into the first tank. REQUEST” toggle switch. This message will remain on
the display until the system completes a backwash cycle at
the next “Energy Save Mode” state.
4-1
Power Inputs Output Circuit

Power Input
Mounting Tab Discrete Outputs Output Status Status
(for DC output versions
Indicators Indica-
Communication
Ports
LCD Display
TER
Built-In
Keypad POR PORT2 RUN
Discrete Inputs Input Status Option Slots Mode Switch

Mounting Tab
Figure 4-1: Programmable Logic Controller
“Backwashing...” controller by a Hydro Engineering, Inc. qualified service

technician. The STOP position prevents the controller from
The system is running and performing filter backwashing. running any programs or accepting any program uploads
from a programming device.
“ALERT - Sys Halt”
The Status Indicator LEDs on the CPU front panels have
The controller has been unable to resolve an error condi- specific functions which can help in programming and trou-
tion. As a result, the system has been turned off and bleshooting. The PWR and RUN indicators should be ON
requires service attention before it can be started. Refer to during normal operation. The RUN indicator will go OFF
the TROUBLESHOOTING section for possible causes. when the controller is in STOP or TERM mode. Under nor-
mal conditions, the CPU indicator should be OFF. The
Figure 4-1 shows a diagram illustrating some key locations CPU light ON indicates that the CPU has experienced a
on the logic controller. Areas of importance to the service self-diagnostics error. The CPU light may also blink when
technician include the output and input status indicators, the battery is low or during a firmware upgrade. The TX1/
the discrete output and input contacts, the mode switch RX1 and TX2/RX2 indicators come ON and OFF when
and status indicators. An understanding of what these rep- data is transmitted and/or received through PORT1 and/or
resent may be helpful if troubleshooting the controller’s PORT2, respectively.
operation is necessary.
CONTROLLER CONFIGURATION
The Input and Output Status Indicators are LEDs that illu-
minate when their corresponding Discrete Input or Output Figure 4-2 below shows a table of the various discrete
Points are energized. These lights can be used to identify input and output points along with a discription of their des-
which inputs are receiving signals and which relays are ignated function in regards to the filtration system. This
closed. table is identical to the one affixed to the inside door of the
system control box.
The Mode Switch allows the controller to be placed in one
of three different operating modes. The RUN position Menu instructions are provided to allow the operator to set
allows the controller to “run” its program if no errors are the system time and date as well as the scheduled back-
encountered. This is the position that the controller should wash times.
be in during normal operation of the filtration system. The
TERM position allows the controller to be programmed. The logic controller (LC) will, during the systems check rou-
This position is only used to edit or upload programs to the tine, determine which options or devices are installed by
4-2
checking input points X17 through X23. Systems lacking a After the valve motor timer expires and the pressure switch
specific component or option will ignore the related portion test is passed, first Y1 followed in two seconds by Y0 are
of the following operation sequences. energized to turn on the process pumps. A thirty second
timer is started, when it expires, the system looks for input
 POWER ON OPERATION at input points X6 and X4 to verify that the pumps are oper-
ating and producing pressure. If either X6 or X4 are open
When the system power is on and the system is operating (fail to see pressure) during any time that Y1 and/or Y0 are
properly Y4 is closed to provide power to the run indicator energized for more than 30 seconds, input to Y1 and Y0
LED. If a system error is detected, Y4 blinks (on and off at are turned off to stop the circulation pumps, Y4 is turned on
one second intervals) to indicate that service is required. and off at one second intervals, Y3 is energized continu-
ously to indicate a system maintenance problem, and Y2 is
When the system power is restored after a power outage, turned off to keep the supply sump pump from providing
when the power supply switch is turned on, or when the fluid to the system. The error message: "Pump #1 (or
system returns to “high polish” mode from backwash, out- Pump #2) Inop." is displayed on the LC display.
put from LC relay points Y11 and Y13 are turned on for 15
seconds to allow all valves to motor to their standard oper- During the entire start process "Resetting..." is displayed
ating positions. Input from X4, X5, and X6 is checked to on the LC display. When the start process is successfully
verify that all pressure switches are off. If a problem with completed "Polishing..." is displayed on the LC display.
any of these switches is identified (if any are on) while the
pumps are off the start process is stopped, Y2 is continued  OPERATION
off to keep the supply sump pump from providing fluid to
the system, Y4 is turned on blinking, Y3 is energized con- During operation Y0 and Y1 are programmed to deener-
tinuously to indicate a system maintenance problem, and gize for 45 minutes out of every hour to reduce power con-
an error code is displayed on the LC display: "Pres Sw # sumption. If X1 goes high, the LC changes the system
Inop" where the # indicates the switch number identified in operation to "high polish” mode by turning both pumps on
the input specification table above. continuously. This mode continues for 15 minutes after X1
goes low. This signal is supplied by closing the contacts on
LOGIC CONTROLLER I/O CONFIGURATION

Output Relay Controls: Input Point Assignments:
Function Relay points Function Relay points
4-3
a relay controlled by the device that the filtration system is Y13 are turned on for 15 seconds to allow all valves to
supplying fluid to or by turning on the “HIGH FILTER RATE” motor to their standard operating positions. During this
control toggle switch. These devices are wired in parallel. period Y2 remains off to stop inflow from the supply sump
pump. Then the pumps are turned back on and the system
For systems operating with the “OPERATION MODE” runs in high polish mode.
toggle set in the “Discharge to Drain” position: The
upper float switch, X2, provides the signal that controls The auto backwash process starts at 2:00 AM on the
power to the inlet sump pump the lower float switch, X3, scheduled backwash days unless the system is receiving a
provides the signal that controls power to the discharge to high polish rate demand signal at input point X1.The high
drain control valve. This control configuration allows simul- use demand trumps the backwash. "Backwashing" is dis-
taneous inflow and outflow. played on the display panel of the LC during the process.
The first filtration loop is turned off by turning off output to
The system is programmed to automatically discharge Y1 (if provided, Y0 continues normal operation) and ener-
water when the discharge to drain float is raised to the dis- gizing Y10 for fifteen seconds. This stops the pump while
charge level by the fluid in the tank. Whether the system is the valve is motored to the backwash position. After Y10 is
in the “energy save” mode or not this signal tells the LC de-energized Y1 is energized for 15 seconds followed by a
that water is available for discharge so the system enters 15 second off period, then on again for 15 seconds to back-
the “high polish” mode until the float switch has been open wash the filter. Then Y1 is de-energized to stop the pump
for 15 minutes.The auto discharge to drain valve opens while Y11 is energized for 15 seconds to motor the valve
and closes with the action of the float switch. back to the standard filtration position. Finally Y1 is re-
energized for 15 minutes to allow the process tanks to fill
For systems operating with the “OPERATION MODE” with water to the normal operating level. Y2 remains closed
toggle set in the “Closed-Loop” position: The upper to allow fluid to be pumped from the sump or solids settling
float switch, X3, provides the signal that controls power to tank into the filtration system during the entire backwash
the discharge to drain control valve the lower float switch, process.
X2, provides the signal that controls power to the inlet
sump pump. With this control configuration the only The autobackwash process is programmed to operate
response to the flow of inlet water into the system is the again if the system receives a high signal at X5 for five sec-
removal of power to the supplying sump pump until the onds while the backwash is running its final 15 minute fill/
water level drops sufficiently to reenable power. There is polish cycle. This is an indication that the backwash was
no signal to force the system into “high polish” mode. not sufficient to reduce the back pressure created by the
media bed. If the system receives this signal from X5 dur-
 BACKWASH & AUTOBACKWASH FUNCTIONS ing the last fill fill/polish cycle of the second backwash
cycle, the system enters maintenance mode: the circula-
The backwash process may be initiated manually on sys- tion pumps operate in high polish and energy saver modes
tems equipped with motor operated backwash valves by but further backwash cycles are locked out. The Y3 (bea-
closing the momentary backwash demand toggle switch or con) relay is turned on to indicate a system maintenance
automatically when the backwash pressure switch is problem and Y5 is energized blinking to indicate that media
closed. These switches are wired in parallel to X5. If X5 change is required. "Media Change Required" is displayed
stays high for five seconds the controller will initiate the on the controller LCD panel.
auto backwash when the system next enters the power
saving (circulation pump off) mode. Y5 is closed to light the BACKWASH GUARANTEE JUMPER: Installation of the
backwash required LED until the backwash has been per- Backwash Guarantee Jumper on the logic controller will
formed. force the system to complete the daily programmed back-
wash even if the high rate toggle switch or a supplied
The schedule auto backwash process timer is a user pro- device dry contact is closed and calling for fluid.
grammable process that starts at 2:00 AM on Monday,
Tuesday, Wednesday, Thursday, Friday and Saturday (the  AUTODISCHARGE TO DRAIN & SUMP PUMP
scheduled backwash time and days unless factory pro- RELAY OPERATION
gramming is changed). Autobackwash is followed by a sec-
ond auto backwash cycle if the system pressure fails to • If system is configured with only the single upper float
drop sufficiently. switch only the X2 (upper float switch) input is moni-
tored;
The relay and timer operations for the backwash and auto
backwash operations are identical. • If the system is polishing when X2 goes high, Y6 (auto
discharge solenoid relay) is turned on and stays on (to
The backwash processes may be delayed or halted by power the auto discharge to drain motorized valve
turning the system power switch off or upon receipt of a relay) until X2 goes low. During the first 10 seconds
high polish rate demand signal at input point X1. If X1 goes that X2 is high Y2 (supply sump pump relay) is turned
high during backwash the system cycles through the nor- off to turn off the supply sump pump until the valve is
mal start up process: output from LC relay points Y11 and open sufficiently to be discharging fluid.
4-4
• If the system is in the energy conservation state (the The LC is programmed to control a #1YB017 peristaltic
circulation pumps are off) the system is returned to the pump option with output point Y16. By default, the pump is
high polish rate upon the X2 signal (Y0 and Y1 are turned on for two seconds every hour. The doses are
closed) and operation proceeds as outlined in the pre- applied hourly but only when the system has been in high
vious paragraph. polish mode for about 12 seconds and has at least 5 min-
utes left on the polish timer. If less than 5 minutes is left on
• If the system is engaged in a backwash cycle, input the timer when the dose request is received the duration of
from X2 maintains normal control of output to Y2 but this timer is reset to 15 minutes. This guarantees that the
all output to Y6 is stopped until the backwash is com- bugs are regularly supplied while the tanks are well oxy-
plete. When X2 goes low Y2 is energized and Y6 is genated and no fluid is leaving the system.
de-energized to allow water to flow into the system
while simultaneously stopping outflow from the sys- The hourly dose may be changed by the user with the
tem. menu provided on the LC. The user can specify the num-
ber of tenths of seconds per hour between the range of 10
• If the system is configured with both upper and lower and 350 for the pump to dose. The memory address that
float switches and the operation mode toggle switch is holds the value is 15020. The LC responds to LCD pro-
in the ‘discharge to drain’ position, the input to X2 gramming input within the valid value range with a loud
(upper float switch) controls output to Y2 and input beep. To test the program change, return the LCD to the
from X3 (lower float switch) controls output to Y6. default menu. Next power the system off then on and wait
for the 'Energy Saving' status to display on the LCD. Toggle
• If the system is polishing when X2 goes high, Y2 is de- the High Rate Polish toggle on. The doser will perform a
energized and when X2 goes low Y2 is energized to dose for the currently programmed time after the pump(s)
control power supplied to the inlet sump pump relay. have been running for about 12 seconds.
When X3 goes high, Y6 is energized to power the auto
discharge to drain motorized ball valve relay and allow The #1YB017 option will dose one tenth of an ounce in one
water to exit the system. second of operation. The recommended dose for a 500gl
system is 3.5 ounces per day. To achieve this dose rate
• If the system is in the energy conservation state (the change the dose timing from factory default of 20 to 15
circulation pumps are off) the system is returned to the tenths (1.5seconds) per hourly dose. This is calculated as
high polish rate upon the X3 high signal and operation follows:
proceed as outlined in the previous paragraph.
(0.1 oz/sec) x (1.5sec/dose) x (24 doses/day) = 3.6 ounces
• If the system is in the backwash mode when a high per day.
signal is received from X3, the system is returned to
the high polish rate by executing the power up routine:  SETTLING TANK & AUTODRAIN PROGRAMMING
output from LC relay points Y11, Y13, and Y15 are
turned on for 15 seconds to allow all valves to motor to This function will run immediately following the auto back-
their standard operating positions and Y2 stays off to wash routine or at 2:00AM if the system is not auto back-
stop fluid inflow from the supply sump pump. Once wash equipped. The program runs for 30 seconds: a 30
high polish rate is resumed, input from X2 and X3 second signal is sent to Y7 to open the valve. When the
maintain normal control of output to Y2 and Y6 respec- signal stops the valve closes.
tively.
CHANGING LC PARAMETERS
• If the system is configured with both upper and lower
float switches and the operation mode toggle switch is  INTRODUCTION TO THE LCD DISPLAY PANEL
in the ‘closed loop’ position, X3 will never go high.
When X2 goes high output to Y2 stops. This stops The Logic Controller LCD Display Panel (Figure 4-3) is a
input from the supply sump pump preventing the upper 16 character, two row display that mounts directly on the
float switch from ever going high. face of the logic controller. The LCD is backlit for easy
readability in most lighting situations.
 BIOREACTOR (OPTIONAL)
The Bioreactor is a continously running process. The LC is

programmed to control the Bioreactor. The LC monitors the
operation of the pressure switch located on the Bioreac-
tor’s polishing pump. If a loss of pressure is detected the
logic controller will go into a system default and the LC will
display “Pump 3 In/Op”.
 HYDROBIODIGESTER DOSING
Figure 4-3: Logic Controller LCD Display Panel
4-5
There are multiple ways of interacting with the LCD Display

Panel:
• Built-in keypad
• LCD ladder instruction
• Using ladder instructions to write bit status changes to

specified memory locations
The seven function keys on the face of the LCD Display

Panel give the user access to clock and calendar setup, V-
memory data values or I/O status, etc. Individuals with
password authorization can:
• Change clock or calender settings or formats
• Monitor or change V-memory values (including DWord

values)
• Force individual bits on or off (up to 16 per screen)
• Review error code history
• Set or change the password
• Turn the back light or buzzer on or off
The potential uses for the logic controller's LCD display

vary widely. An operator can change values for setting up
batch processes or machine timing for manufacturing dif-
ferent products. Maintenance personnel can interface in
the control cabinet to identify machine problems. LCD
messages can be preprogrammed for process events or
alarms. The LCD can satisfy these and many other opera-
tor interface needs.
The following pages provide instructions on interacting with

the controller using the keypad allowing the operator to
perform various tasks such as changing the prepro-
grammed values entered for backwash times, time of day,
date and any other such parameters.
CAUTION: Use extreme care when changing val-

ues in the logic controller. Access to sensitve program
data has not been prohibited. Inadvertant changes to
sensitive program data will affect the operation of the logic
controller and subsequently the performance of the filtra-
tion system. If program data is changed that adversely
affects the performance of the filtration system, reprogram-
ming may be necessary that may require onsite service by
a qualified service technician at the owner’s expense.
4-6
 KEYPAD
The LCD Display Panel keypad (Figure 4-4) has seven

keys you can use to navigate through the menu hierarchy.
Each screen displayed has a specific set of active keys
associated with it. All other keys (those not associated with
the current screen) are inactive.
 MENU NAVIGATION
Beginning at the default screen (Figure 4-5), each time

you press the MENU key the display will scroll to the next
menu option. The up arrow and down arrow keys also Figure 4-4: LCD Display Panel Keypad
scroll through the list of menus (in the direction indicated by
the arrow), but you must initially press the MENU key (at
the default screen) to activate the up and down arrow keys.
There are seven built-in menus selections. Some of the

menu items have sub-menus. The menus and sub-menus
are described in this chapter. Each menu selection
requires that you press the ENT key to view or change set-
tings or values within the domain of that main menu selec-
tion.
Seven Menu Choices
Pressing and holding the MENU key will cause the display
to scroll through the following menu options:
• M1 : PLC information Figure 4-5: Default MENU Screen
• M2 : System configuration
• M3 : Monitor
• M4 : Calendar read/write
• M5 : Password read/write
• M6 : Error history read
• M7 : LCD test and set
In the illustrations showing the LCD Display Panel and key-

pad, the shadowed areas indicate the operator’s selection
as selected using either the arrow button or the highlighted
button below the arrow buttons. This type of representation
is used throughout the following sections. When inside the
4-7
menu hierarchy, the ESC key returns the display to the pre-
vious screen.
 MONITORING AND CHANGING DATA VALUES
MENU 3, (M3:MONITOR)
From the default screen, press MENU three times to arrive

at the M3:MONITOR menu option (Figure 4-6).
The M3:MONITOR sub-menu contains the data monitor

and the bit monitor. The data monitor allows you to exam-
ine the contents of memory registers or pointers to deter-
mine their contents. It is in this menu that changes can be
made to: the time of day that polish cycle begins and ends;
backwashes are scheduled; and the duration for dosing of
hydrobiodigesters. In the bit monitor menu, changes can
be made to: the days of the week that backwashes are
scheduled and days of the week that the polish cycle is set
to run.
Figure 4-6: M3: MONITOR and SUB-MENU
If changes to any of the default settings is required, call our
Hydro Engineering service department for assistance at 1-
800-247-8424 in the U.S. or directly at 1-801-972-1181.
 CHANGING THE DATE AND TIME
Menu 4, (M4 : CALENDAR R/W)
From the default screen, press the MENU key four times to
arrive at Step 4.1 (Figure 4-7).
Figure 4-7:
4-8
At Step 4.4, use the up and down arrows to change the

value for month, day, or year. Use the left and right arrow
keys to move between the different digits in the date. After
making the necessary changes using the arrow keys, press
the ENT key to register the changes (Figure 4-8).
Figure 4-8:
You will be asked if you want to set the date to the chosen
value (Figure 4-9). Press ENT again if the date is correct.
You will automatically return to Step 4.2, and the new date
will be displayed.
Figure 4-9:
In order to change the time or date/time format, press ENT

again at Step 4.2 (Figure 4-10).
Figure 4-10:
4-9
Use the up or down arrow keys or the MENU key to scroll

through the submenu choices. At this point in our example,
we will change the time setting (Figure 4-11).
Figure 4-11:
At Step 4.4, use the up and down arrows to change the

value for hour, minute, or second (Figure 4-12). Use the
left and right arrow keys to move between the different dig-
its in the time. After making the necessary changes using
the arrow keys, press the ENT key to register the changes.
Figure 4-12:
You will be asked if you want to set the date to the chosen
value (Figure 4-13). Press ENT again if the date is correct.
You will automatically return to Step 4.2, and the new date
will be displayed.
Figure 4-13:
4 - 10
If you want to change the format for the date or time, return
to Step 4.2 and press ENT (Figure 4-14).
Figure 4-14:
Press ENT, MENU, MENU to arrive at the menu selection

for changing the date or time formats (Figure 4-15). Press
ENT again to enter the format changing location.
Figure 4-15:
Press ENT again to enter the date format changing loca-

tion, or press MENU, ENT to change the time format (Fig-
ure 4-16).
Figure 4-16:
At Step 4.4, use the up and down arrow keys to scroll

through the date formats (Figure 4-17).
The choices are as follows:
MM-DD-YY (US format)

Figure 4-17:
DD-MM-YY (European format)
YY-MM-DD (Asian format)
Press the ENT key to save the format changes.
4 - 11
If you have chosen to make a time format change (Figure

4-18), your choices, as shown in Figure 4-19, are:
HH:MM US (12 hour 12:00 - 11:59AM/PM US format )
HH:MM AS (12 hour 00:00 - 11:59AM/PM Asian format )
HH:MM:SS (24 hour format) Figure 4-18:
Press the ENT key to save the format changes. Press ESC
until the default screen reappears.
Figure 4-19:
BUG DOSING INSTRUCTIONS
Main screen (Figure 4-20).
Figure 4-20:
Press the “MENU” key 3 times to arrive at Step 5.2. Press

the “ENT” key again to go to Step 5.3
Figure 4-21:
There are two options: DATA MONITOR and BIT MONI-
TOR. The DATA MONITOR configures time and the BIT
MONITOR configures days of the week. The DATA MONI-
TOR (>) is flashing, press the “ENT” key.
Figure 4-22:
4 - 12
Step 5.4, DATA TYPE: Press the enter key. The DATA
TYPE will always be (V). Using the UP/DOWN and LEFT/
RIGHT arrow keys will allow the user to enter the code for
Bug Dosing. The code to enter is 15020. Press the “ENT”
key.
Figure 4-23:
Step 5.5 shows the codes. The current code just entered
and the previous code numerically available if programmed
into the system. Press the “ENT” key. To change the “VAL”
time in (seconds) that the bugs will be dosed every hour.
Press the “ENT” key.
Figure 4-24:
Step 5.6 The time is now set at 20 tenths of a second or 2

seconds to dose every hour. To change use the UP/DOWN
and LEFT/RIGHT keys and then press “ENT” key to com-
plete the change.
Figure 4-25:
Press the “ESC” key to return to the main screen.
Figure 4-26:
DAILY MAINTENANCE AND FULL POLISH
INSTRUCTIONS
Press the “MENU” key 3 times to arrive at Step 6.2. Press

the “ENT” key again to go to Step 6.3
Figure 4-27:
To change the day(s) of the week to run the Daily Mainte-

nance (back flush). Arrow down so that the BIT MONITOR
(>) is highlighted and flashing. Press the “ENT” key.
Figure 4-28:
4 - 13
Press the “ENT” key again. Step 6.4 now shows the
ADDRESS to be entered. The code to enter the day(s) is
15000. Using the “UP/DOWN” and “LEFT/RIGHT” keys,
enter the code. This is shown in Step 6.5. Press the “ENT”
key. This takes you to Step 6.6.
Press the “ENT” key. The flashing LCD now shows small Figure 4-29:
circles across the bottom of the screen. From right to left
are the days of the week beginning with Monday as the far
right circle which should be flashing. Press the “ENT” key
to select Monday. You will hear a beep sound which tells
you that it is set. Continue using the “LEFT” arrow key to
add more days, using the “ENT” key to add each day.
Figure 4-30:
Figure 4-31:
Step 6.7 shows how the small circles will fill in once cho-
sen.
Step 6.8. Press the “ENT” key, the display now shows,
CHG=OFF, STAT:ON. The days are set. To make changes
use the “UP” arrow key to now show CHG=ON, press Figure 4-32:
“ENT” key and it will take you back to the screen showing
the days. You can make changes or press the “ESC” key to
keep what is displayed. If you press the “ENT” again it will
take whatever day that is flashing out of the cycle.
To make changes to the Backwash time of day you will

press the “ESC” key until you see the screen shown in
Step 5.3. Using the arrow keys select the DATA MONI-
TOR. Press the “ENT” key and enter the code 15001 to
change the Hour of Day using the “UP/DOWN” and “LEFT/ Figure 4-33:
RIGHT” keys. Press the “ENT” key and the time is set.
To change the Minute of Hour use the “UP/DOWN” keys to

go to the next code which will be 15002.
4 - 14
Once changes are made you can use the “ESC” to set/
reset the Polish Cycle. Use the same sequence starting
with Step 5.3 you will use code 15005 to change the day.
To change the Hour of Day Start Time use code 15006,
Minute of Hour Start Time code 15007, Hour of Day End
Time code 15010, and Minute of Hour End Time code
15011.
The system is now set and will run automatically.
NOTE: All time is military (0-24 hundred hours).
4 - 15
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Operation
Operation
Operation of the HE/3000 HydroKleen is primarily con-
into the housing. This toggle switch sets the direction of
trolled by the integrated logic controller which monitors and
actuator rotation The normal operating position for this
acts upon signals received from various input devices;
switch is the up (ON1) away from the valve position. Plac-
pressure switches, float switches, photo-electric sensors,
ing the switch in the down (ON2) position will cause the
relay contacts and selector switches.
actuator to operate in the reverse of the normal operating
mode.
The controller directs various processes based on a pre-
programmed schedule. Multiple system flow control valves
One of two input signals are sent to the actuators; a pulsed
will automatically open and close and the circulation pumps
signal that lasts only long enough to move the valve from
will turn on and off as the system executes the operation
one position to another or a continuous on signal. The
schedule.
pulsed signal is supplied to devices that are only controlled
by the logic controler like the media filter control valves.
If the system encounters a problem in its operation that it is
The continuous signal is supplied to devices that may
unable to resolve, the controller will indicate a system
require manual activation by a user like the drain valve
maintenance problem by activation of various system sta-
mounted on the Process Tank or the Auto Discharge to
tus light indicators on the control panel. If the system is
Drain Valve.
equipped with the optional service call beacon, the beacon
will activate when owner service intervention is required.
CAUTION: It is important that this toggle switch remain
in the up (ON1) operating position when ever the sytem is
The controller has an LCD screen which will also display
running to guarantee satisfactory operation.
the status and state of the sysem. The messages dis-
played on the LCD screen are outlined in the PROGRAM-
Logic Controller “Run-Term-Stop” Switch
MABLE LOGIC CONTROLLER section of this manual.
The logic controller includes a three position toggle switch
NOTE: Before operating the system, it is recommended
that places the controller into one of three different modes
that the operator understand the flow of effluent through
of operation. This switch is located in the lower right portion
the HydroKleen system. Use the flow diagrams included
of the controller adjacent to the I/O ports. For normal oper-
with the system to assist operators during the various oper-
ation of the filtration system, this toggle switch should
ation and maintenance procedures.
remain in the “RUN” position.
PRE-OPERATION CHECKS CAUTION: It is important that this toggle switch remain

in the run position and not be tampered with during system
1. Read and abide by all SAFETY INSTRUCTIONS. operation.
2. Inspect all connections and verify integrity of lines to Operation Mode Toggle Switch
and from the system.
The Operation Mode toggle switch, located in the control
PRE-OPERATION MAINTENANCE panel, allows the system to be placed in “closed-loop” or in
“discharge to drain” operating mode. Two float switches are
1. Drain sludge from the Settling Tank on systems not installed in the process tank. One is assigned to control the
equipped with the auto sludge drain option by opening the discharge to drain valve, the other to control the inlet sup-
tank drain valve fully for approximately 5 seconds. Opening ply pump. Control is assigned to one or the other of these
the optionally supplied motorized valve is not required by the “OPERATION MODE” toggle. When the switch is
because this is a programmed function of the logic control- placed in the recycle mode the top switch controls the auto
ler. However, the valve may be opened manually by mov- discharge to drain signal and the lower float the call for
ing the toggle switch mounted on the actuator housing to inflow signal. When the toggle is in the filter to discharge
the down position. It takes about 15 seconds for the valve mode the responsibilities of these switches is reversed.
to open or close fully.
When the closed-loop mode is selected and the lower float
2. Verify that all connections are secure, and that all ball switch controls power to the supplying sump pump inflow
valve(s) are positioned for the desired flow. to the system is turned of when this float rises. As a result
the upper float switch never floats and the auto discharge
PRE-OPERATING NOTES to drain motorized valve never receives a signal to open.
This mode should be selected when the process fluid is
Motorized Ball Valve Toggle Switch returned to the process for reuse.
The optional motorized actuator that is mounted to the flow When the discharge to drain mode is selected, the lower
control valve(s) has a small 3-position toggle switch built float switch controls the auto discharge to drain motorized
4-1
valve and the upper float switch controls the supply sump 5. Adjust, if necessary, the 3-way (diverter) ball valve
pump. As a result, whenever the lower switch floats, the located on the return line to the second process tank to
auto discharge to drain valve is opened to discharge fluid. maintain approximately 20-25 PSI operating pressure on
This guarantees that the upper switch never sees suffi- the second media filter pressure gauge.
cient fluid to turn power off to the supply sump pump. This
mode is selected when the filtration system is required to 6. Observe the BACKWASH/MEDIA CHANGE LED. If
evacuate fluid from the process to a drain.The supplying the light is off no action is required. If the light is on either
sump pump will continue to operate until the water lever in an operator has activated the BACKWASH REQUEST
the supply sump drops sufficiently to turn off the supply momentary toggle switch for five seconds or the system
sump pump. has detected excess pressure caused by an accumulation
of debris in the filter bed. Systems equipped with the auto-
SYSTEM START-UP INFORMATION backwash option will automatically perform this operation
at the beginning of the next energy saver mode period or at
Power to the HE/3000 is controlled by the “SYSTEM MAIN the user programmed daily backwash time which ever
POWER” switch on the control panel. When the filtration comes first. Systems without the option require manual
system is turned on, the logic controller runs through a sys- backwash.
tem check/initialization routine.
7. Systems equipped with the auto-backwash option will
If a problem is identified with either pumping unit during the monitor the condition of the media filter and indicate that
initialization routine the system will turn off, the LCD will the media requires changing by blinking the BACK-
indicate where the problem originated, and the panel WASH/MEDIA CHANGE LED.
“RUN/SERVICE” indicator light wtll blink on and off.
SHUTDOWN
During the initial system start it may require more than one
(but never more than three) start cycle to prime the pump 1. To turn off the system rotate the SYSTEM MAIN
and establish normal process rates. If a flashing POWER switch to the “off” position.
“RUN/SERVICE” LED occurs in combination with a “PUMP
INOP” message on the logic controller LCD, simply power OPERATION NOTES AND SPECIAL INFOR-
off and restart the system. MATION
OPERATING PROCEDURES LOGIC CONTROLLER
1. Rotate the SYSTEM MAIN POWER switch to the “on” Default settings for scheduled BACKWASH times, DATE
position to start the system. and TIME OF DAY are factory programmed and may be
changed by the user.
NOTE: Once the system enters the energy saver mode, it
will remain in this state for 45 minutes before its first sched- The DATE and TIME OF DAY are set to the United States
uled 15 minute high polished cycle. The system will con- Mountain Time zone and require changing to the local time
tinue to toggle back and forth between these two modes of prior to operating the filtration system.
operation every hour.
The default settings for the regularly scheduled filter BAK-
2. To change the operating mode to the high polish mode CWASH is 2:00AM on T,W,TH,F, and S. The days and
turn the “HIGH FILTER RATE” toggle switch on the control times may be adjusted to meet a special schedule or just
panel to the on position. The system will continue to oper- left at their respective default settings. Refer to the PRO-
ate in this mode for 15 minutes after the toggle is turned GRAMMABLE LOGIC CONTROLLER section of the man-
off. ual for information on changing these default settings.
NOTE: Leaving the “HIGH FILTER RATE” toggle switch on BACKWASH & AUTOBACKWASH
will lock out the energy save mode.
The system backwash cycles are handled automatically by
3. When the system is on and operating properly the the logic controller at the scheduled times or as a result of
“RUN/SERVICE” indicator LED will be on. If a system error a backwash request if the system is equipped with the auto
is detected, the indicator will blink on and off at one second backwash option. Typically, the system will perform the
intervals indicating that service is required. backwash when the LC enters the energy saver mode. If
the energy saver mode is locked out by the user or by a
4. Open the air relief valves on the top of the media filters supplied device the LC will wait until the recurring sched-
while the pumps are operating until the air trapped in the uled backwash. This scheduled routine takes precedence
top of the filter housing is completely purged, then close over the user or supplied device requests for fluid outflow
the valves. This should be done daily. and forces the completion of the backwash.
HYDROBIODIGESTERS
4-2
Ordor and waste water quality are improved by the use of

living Hydro-biodigesters. The system is programmed to Use this Key: To:
dose a system with a total fluid volume of about 500 gal-
lons. The dosing rate may be changed. Once the dosing < Select numerical position from right to left
rate is correct, operation is automatic. There should be no

other operator required intervention other than to periodi- ^ Select number from 0-9
cally check the level of the product container.

Figure 3-1: Key Pad Description
NOTE: Prior to application of Hydro-biodigesters, all disin-

fectants must be eliminated from the sytem. This includes This Display: Indicates:
chemicals such as ozone, bleach, hydrogen peroxide, etc.
pH Controller in pH mode
PREPARATION FOR STORAGE OR SHIPMENT
CAL pH calibration mode; display shows
7.00,4.01 and 10.01; CAL annunciator off
The system must be thoroughly drained and the media when calibration complete
removed before storage or shipment:
Hi High alarm relay activated
Open all tank and filter drain valves.
Lo Low alarm relay activated
Open the air relief valves on the top of the media filters to Figure 3-2: Front Panel Displays
allow air to flow into the filters.
The pH controller is powered by the HE/3000’s electrical
Used a wet-vacuum to remove the media and the pea circuitry. Verify that the pH electrode connection to the BNC
gravel in the media filters. connector in the electrical control box is snug. The pH
monitor/controller may be calibrated at this point.
Open the drain valves on the pump inlet strainer housings.
n CALIBRATING THE pH ELECTRODE
Remove the lids on the pump filter housings and remove
any remaining fluid. Calibration of the electrode to the pH meter is essential for
accurate pH measurement. It is necessary to periodically
Remove the decanter from the oil skimmer, clean and dry calibrate the electrode. The frequency of calibration is sys-
before reinstalling. tem dependent.
Clean the interior of all tanks, pumps, and filter housings The pH calibration procedure is as follows:
with a Hydroblaster if possible.
1. Remove the electrode protector (if supplied) from the
Close all drain valves and replace all caps and covers. end of the pH electrode; rinse the electrode with distilled
water, and place it in standard pH buffer 7.00 solution.
Disconnect all utility connections. Press the CAL key.
pH MONITOR/CONTROLLER 2. At this time the “CAL” annunciator light will appear.

When the light goes off, the first point is calibrated. If “7-E”
This information is pertinent only if the system is equipped appears in the display, this means the pH buffer 7.00 was
with the PHCN-410 pH Controller. The controller is a micro- not used or the pH electrode has failed.
processor-based pH controller with automatic temperature
compensation, a 4-digit LED display, two SPDT mechani- 3. Remove the pH electrode from the pH buffer 7.00.
cal relays, and a fixed 4-20 mA output. Rinse the electrode with distilled water and place the elec-
trode in standard pH buffer 4.01 or 10.01. Press the CAL
The controller features four keys for entering all set-up key.
parameters and performing calibration. These are as
shown below: At this time the “CAL” annunciator light will appear. When
the light goes off, the slope is calibrated.
Use this Key: To: n ENTERING THE Hi/Lo SETPOINTS

SET/TEMP Select set point relay modes (Lo and Hi)
1. Press the SET/TEMP key, until the desired “Hi” or “Lo”
CAL/ENTER Initiate calibration procedure using stan- annunciator is lit on the front panel.
dard pH buffers 7.00, and 4.01 for acidic
solutions, or 10.01 for caustic solutions, to 2. Use the < and ^ keys to change the displayed
enter selected setpoints values value to the desired value.
4-3
3. When the desired value is showing in the display,

press the CAL/ENTER key to store this value into memory. This Display: Indicates:
OUT Control outputs activated

n ERROR MESSAGES
ATC Controller in ATC mode
“7-E”:The calibration standard 7.00 pH was not used or
the pH electrode has failed. Figure 3-4: Front Panel Displays
“--E”:The pH/mV value is over range. The ORP controller is also powered by the HE/3000’s elec-
trical circuitry. Verify that the ORP electrode connection to
the BNC connector in the electrical control box is snug.
ORP MONITOR/CONTROLLER
With power to the system, press the pH/mV keypad to
enter into the mV operating mode. The unit should display
This information is pertinent only if the system is equipped
the mV value and the temperature value simultaneously.
with the PHCN-430 pH/ORP Controller. The controller is a
The temperature display will default to 25o C since ORP
microprocessor-based controller with two time proportional
does not require temperature compensation. The ORP
relay contacts and a 3-digit LED display. This unit also has
monitor/controller may be calibrated at this point.
automatic temperature compensation, and simultaneously
displays pH and temperature in addition to having two
n CALIBRATING THE ORP ELECTRODE
mechanical time delay SPDT mechanical relays.
The ORP measurement is not calibrated. The only calibra-
The PHCN-430 controller features eight keypads for enter-
tion procedure that you can follow is to check the electrode
ing all set-up parameters and performing calibration. These
in a known mV standard solution. The discrepancy
are shown in fig. 3-3.
between the known mV standard and the ORP electrode
reading is referred to as the “electrode offset.” You must
take this offset into account when setting High and Low set
Use this Key: To: point values.
pH/mV Select pH or mV (for ORP or checking pH

electrode offset)
CAL Initiate calibration procedure using stan-

dard pH buffers 7.00, 4.01, 10.01
DIGIT Select numerical position from right to left
COUNT Select number from 0-9
SET/ENTER Set selected value into memory
Hi-SET Set HI alarm relay value
Lo-SET Set LOW alarm relay value
OUT Activate controller outputs
This Display: Indicates:
pH Controller in pH mode
mV Controller in mV mode
o
C Temperature in oC
CAL pH calibration mode; display shows 7.00,

4.01 and 10.01; CAL annunciator off when
calibration complete
Hi High alarm relay activated
Lo Low alarm relay activated
Figure 3-4: Front Panel Displays
4-4
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Maintenance & Service
Maintenance & Service

GENERAL INFORMATION AND RECOMMEN- PSI, the “BACKWASH MEDIA CHANGE” light will illumi-
DATIONS nate. THis indicates that a high pressure condition exists
and that a backwash is required (i.e. the system is queued
In order to maintain filtration efficiency, the system must be for a backwash cycle). The backwash cycle will be per-
serviced periodically. The filters continuously remove formed when the system next enters “energy saving mode”
debris from the effluent flow. The debris increases the pres- or during the regularly scheduled backwash cycle.
sure drop across the filters. As the filters load the operating
pressure of the circulation pump increases and the flow When the backwash is performed the LC checks the oper-
through the filter decreases. If the filters are not cleaned on ating pressure of the system to guarantee that the back-
a regular schedule, the system will not perform at an opti- wash was successful. If the pressure drop across the
mal level. media is still high, the system will perform the backwash
process again. If the pressure drop across the media is still
This section contains information on how the system is too high at the end of the second backwash, the system
designed and how to maintain its operating efficiency. This will call for service by blinking the “BACKWASH MEDIA
section also gives instruction on when and how to perform CHANGE” light and the service beacon.
required maintenance on the various components of the
system. The user is expected to maintain an operational CLEANING THE MEDIA FILTER
record of this filtration system. The record should include
all maintenance performed and should list component When the “BACKWASH MEDIA CHANGE” LED is flashing,
parts of the system which are repaired or replaced. This follow the procedure outlined below to perform the media
record should also include the dates and times of replace- change operation.
ment of filters and filter media.
Check the label on the media filter (Figure 6-1) to deter-
The system should generally be kept as clean as possible. mine how much gravel, media, and media type is required
It must be protected from the weather and especially, it for each filter.
should be protected against freezing and temperatures
above 110°F degrees.
WARNING: Turn the system off and disconnect from

power to assure that the unit is not inadvertently started
during servicing, unless procedures indicate otherwise.
WARNING: The media filters operate under pressure.

When any part of the circulating system (e.g. pump, filter,
valves, etc.) is returned to service, trapped air should be
relieved by opening the air relief valve on the top of the
housing. Pressurized air can cause an improperly installed
filter top, control valve, or hose to be blown off. This could
result in severe bodily injury and /or property damage.
WARNING: Never attempt to remove the filter top

while the system is running and there is pressure in the fil-
Figure 6-1: Media Filter Label
ter!
The following procedures outlines a full system cleaning of
AIR RELIEF VALVE the media filter. Refer to exploded view of the filter, if
needed.
The air relief valve assembly is located on the top of the
media filter cap. It is used to purge air from the filter hous- 1. Shut the system down by rotating the “SYSTEM MAIN
ing. Open the valve until water flows from the outlet port. POWER” switch to the “off” position.
The valve may be easily cleaned by forcing a small amount
of compressed air or water back through the valve or it may 2. Turn the “make-up” water supply off to the system.
be removed from the system for cleaning or replacement.
Clean if obstructed or replace if leaking. 3. Rotate the 2-way ball valves on the circulation pump
inlet line to the “closed” position on each pump.
BACKWASHING THE MEDIA FILTER
4. Open the air relief valves of each of the media filter
The system is designed to operate at pressures between tanks and drain the filters using the drain valve (located at
15 PSI and 35 PSI. When filter back pressure exceeds 30
6-1
the bottom of the media filter). Disconnect the hose con- 15. Connect power to the filtration system at the breaker
nected between the air relief valve and the tank. switch or disconnect. Then turn power on at the “SYSTEM
MAIN POWER” switch.
5. Remove the media tank lid. Care should be taken not
to damage the internal air relief valve assembly on top of 16. During the initial system start it may require more than
the lid. one (but never more than three) start cycle to prime the
pumps and establish normal process rates. If a flashing
6. It is recommended that the overdrain be rotated out of “RUN/SERVICE” LED occurs in combination with a “PUMP
the way of the opening into the filter housing to provide INOP” message on the logic controller LCD, simply power
access. off and resatrt the system.
7. Alternately, if the overdrain is to be removed to OTHER FILTERS

improve access, it will be necessary to remove the screen
filter from the hose that protrudes through the overdrain Other filters on the system will need to be periodically
assembly by pulling it straight off of the tube. Next, slide the checked and cleaned. These may be located in the fresh
tube out of the overdrain and then unscrew the overdrain water inlet line at the connection manifold, and within the
from the pipe. Protect the exposed pipe and tube from filter bowl on the discharge line adjacent to the 3-way dis-
media with a plug or plastic bag taped securely in place charge ball valve.
and don’t lose the screen filter.
ELECTRIC MOTOR
8. Remove the media from the filter housing with a scoop
or wet vacuum. The electric motor should be protected from foreign matter,
water spray, and weather. Whenever a motor has become
NOTE: It may not be necessary to remove the underlying wet, let it dry before running it. Keep it clean and provide
pea-gravel bed within the filter housing. This gravel bed is ample ventilation.
situated at the bottom of the housing and protects the
underdrain laterals. It must be removed with a wet vacuum 1. Keep motor, motor vents, and surrounding area clean.
to prevent damage to the laterals.
2. Avoid sweeping or stirring up dust near the motor
9. The system will now have to be recharged with new while it is running.
media. Use the amount required for the media filter size as
indicated by the media filter label (Figure 6-1). 3. Avoid storing (or spilling) chemicals near the motor.
NOTE: If the gravel is replaced it is absolutely essential 4. Do not wrap motor with plastic or other air-tight materi-
that the gravel be thoroughly washed before being placed als except to protect it when cleaning surrounding areas
in the filter. The use of ‘washed’ gravel is not satisfactory. and for storage. Never enclose a motor that is running, or
Punch some small holes in the bottom of a five gallon expected to be running.
bucket, place the gravel in the bucket and wash the gravel
with tap water until the water runs clear from the holes in
CIRCULATION PUMP
the buscket. Stirring the gravel and washing it again is
highly recommended.
INLET FILTER SCREEN
10. Replace the overdrain if it was removed using the
reverse of the steps outlined above for its removal or rotate The circulation pump requires that the inlet filter basket be
it back into position. serviced regularly. This basket must be kept clean of debris
at all times.
11. Close the filter drain valve and fill the filter housing
with tap water. This unit, sometimes referred to as the “Lint Pot”, “Inlet Fil-
ter Screen Basket” or “Strainer Basket” is located in front of
12. Lubricate the filter cap seal o-ring and reinstall the fil- the pump volute or impeller. The lid is screwed onto the pot
ter cap securely. Install the tube on the discharge port of and should be hand tightened only. DO NOT OVER-
the air relief valve. TIGHTEN!
13. While the system is off, remove the filter screen from Regardless of the length of time between filter cleaning, it
the circulation pump filter basket, inspect and lubricate the is important to visually inspect the strainer basket at least
gasket, clean the screen and the housing cover. Before once a week. A dirty basket will reduce the efficiency of the
reassemblng, refill the pump filter screen basket with water system. View the basket through the see thru lid to inspect
and reopen the pump’s 2-way inlet ball valve. for debris.
14. Turn the fresh water supply to the filtration system To clean this filter:
back on.
6-2
1. Turn off motor and close pump inlet control valve. channel lock pliers to remove it from the shaft. Be careful to
avoid cracking the impeller with the pliers.
2. Remove lid by rotating the clamp ring counterclock-
wise. 5. Remove the rotating portion of the seal from the impel-
ler with a pair of needle nose pliers. Clean the impeller
3. Remove the plastic basket and empty the debris. around the seal area. Lubricate the rubber on the new seal
and press the seal fully into the impeller and place a thin
4. Replace the plastic basket, fill with water and replace coating of lubricant on the surface of the seal that meets
the lid and clamp securely to prevent air from entering the the other seal half.
pump inlet.
CAUTION: Failure to seat the seal properly in the
NOTE: It is important to clean and lightly lubricate the lid impeller will cause the seal to leak immediately or fail
seal o-ring with water resistant grease before reassembly. quickly.
5. Open pump inlet supply control valve. CAUTION: The entire seal must be replaced. Do not
attempt to replace only one side or the other. The polished
6. Restart system. and lapped faces of the seal can be damaged by improper
handling. Avoid touching the rotating seal sufaces as much
DO NOT run the pump dry! If pump is run dry, the mechan- as possible, especially the black carbon impregnated plas-
ical seal will be damaged and the pump witll start leaking. tic surface that rotates against the ceramic.
In the event this occurs, the damaged seal must be
replaced. 6. Remove the seal plate from the motor to expose the
rear of the rotary seal. Tap the stationary half of the seal
SHAFT SEAL from the housing using a soft mallet. Clean the seal plate
housing to prepare it for a new seal.
If a shaft seal is damaged or begins leaking it must be
replaced. This is indicated by water discharge between the 7. Coat the seal plate housing and the seal where the
pump and motor housings. The shaft seal consists primar- two are joined with a small amount a GOOP sealant (part
ily of two parts: a rotating member and a stationary ceramic number: 1ZR431) and insert the stationary half of the seal
seat. into the bore of the seal plate using a (part number: 61319)
plastic 1-1/2” King NIpple as a pusher tool. This is a press
To access the shaft seal, the pump housing that contains fill and will require the use of this tool and a mallet to insert
the impeller must be disassembled. Refer to the exploded the seal completely into the seal plate housing.
pump diagram for assistance with visualizing this process.
8. Install the impeller on the shaft by threading it in a
1. Turn off motor, close pump inlet control valve and clockwise direction. Install the impeller retainer screw and
remove the hose from the pump inlet at the union. its associated seal washer with the Phillips screw driver by
rotating the screw in a counter clockwise direction.
2. Remove the six bolts that secure the housing together
and separtate the housing. Inspect the housing seal for 9. Install the diffuser assembly with the two stainless hex
damage. Make every effort to leave the seal in place for head screws.
reassembly. Once removed, even with grease, it is rather
difficult to retain in place while the housing is bolted back 10. Join the pump housing together with the six bolts.
together.
NOTE: If the housing seal has fallen out of the seal groove
3. Remove the two small stainless steel hex head bolts clean the groove thoroughly, lubricate the seal with grease,
that hold the diffuser assembly in place. and reinsert it in the groove.
NOTE: It may be necessary to tap the housing gently with PROCESS TANK
a soft rubber mallet to aid separation of the main housing
or of the diffuser assembly. The process tank must be purged of debris that accumu-
lates at the bottom of the tank. This is done by opening the
4. To remove the impeller, lock the motor shaft in place 2-way ball valve at the bottom of the tank for a few seconds
by inserting a screw driver through the ventilation holes at and then closing it. The frequency of this recurring task var-
the shaft end of the motor so that the fan blades on the ies with the application. It may be required daily or as infre-
armature are stopped by the screwdriver. Place a Phillips quently as monthly.
screwdriver on the screw that retains the impeller and
rotate the screw in a clockwise direction. Once the screw If the system includes the auto tank sludge drain option, a
and the associated rubber seal washer is removed, rotate motorized valve is used in place of the manual ball valve.
the impeller in a counter clockwise direction with a pair of this valve may be actuated manually by moving the toggle
switch on the actuator from the ON1 to the ON2 position.
6-3
Typically the vavle is controlled by the logic controller

which is programmed to open and close the valve periodi-
cally.
DEFOAMER SYSTEM
The defoamer system is comprised of a photoelectric sen-

sor, a dosing pump with associated tubing, and a supply of
de-foam agent.
The lens on the sensor should be cleaned regularly. The

task should be performed with a moist cotton towel or
swab.
The supply of de-foam agent should also be checked regu-

larly.
The operation of the dosing pump can be observed by

placing the control toggle in the run position. Return the
switch to the auto position to return control to the logic con-
troller.
BIODIGESTER DOSER
The Biodigester doser system is comprised of a dosing

pump with associated tubing and a supply of the liquid
Biodigesters.
The supply of the Biodigesters should be checked regu-

larly.
The operation of the dosing pump can be observed by

placing the control toggle in the run position. Return the
switch to the auto position to return control to the logic
controller.
6-4
Copyright © Hydro Engineering, Inc. -- Technical Manual Troubleshooting
Troubleshooting
WARNING: DISCONNECT THE SYSTEM FROM POWER BEFORE ACCESSING ELECTRICAL COMPONENTS.
If the equipment shocks the operator or trips a ground fault interrupter (GFI), remove it from service and repair immediately.
Check for improper ground and for defective wires or connectors. If a short is discovered on the output side of a GFI and
the short was not detected by the GFI, replace the GFI.
TROUBLESHOOTING TABLE
PROBABLE
PROBLEM SOLUTION
CAUSE
LCD MESSAGE:
PRES SW #1 INOP or PRES SW #2 A problem exists with one of the Check the pressure switch in question. Remove the
INOP circulation pump-mounted pres- cover and verify that the contacts on the switch are not
sure switches. stuck in the closed position.
PUMP #1 INOP The pump discharge line must Repair or replace as necessary.
be secure and defect free. No
evidence of leakage is permit-
ted.
The ball valve at the pump inlet Open the 2-way ball valve. The handle should be parallel
may be closed. to the line it is mounted in.
The pump inlet basket strainer Defoamer should be added to the process tank to “kill” the
should be full of fluid. If the foam. If this is a regularly occurring problem, the surfac-
strainer is full of foam, the sys- tants should be removed from the inflow or the “Defoam
tem is processing a fluid that option” should be installed on the system.
contains a large quantity of sur-
factants.
Pump basket may be dry or Check the pump inlet lines for damage that might allow air
largely full of air. to be drawn into the pump.
Remove the inspection lid from the top of the filter basket
and check the o-ring seal for damage or debris in the seal
groove.
Second process tank fluid level The tank fluid level should be above the middle of the
may be low. tank. Verify that the make-up water supplied to the float
valve in the last process tank is on and that the float is
operating properly.
6-1
PROBABLE
PROBLEM SOLUTION
CAUSE
PUMP #1 INOP CONTINUED Potential problem with the syp- Check the fluid source where the supplying sump pump is
plying sump pump, as indicated located. The source may be a sump pit, side gutter or
by low fluid level in the first pro- prefiltering system. The source should have adequate
cess tank. fluid available. If the source is dry, refer to the appropriate
operator’s manual for additional information.
Make sure that the supplying sump pump is properly

located in the tank.
Verify that the pump inlet is clear of debris and that the
pump mounted float switch moves freely.
If pump operation is in question, attach the pump to a

known power supply and observe pump operation. The
pump should operate on and off with the action of the
pump mounted float switch. The fluid should discharge
through the discharge lines and into the filtration system
at a rate consistent with the pump rated flow.
Flow rate from supplying sump Check the discharge lines for obstructions. Low points or
is low. sags in connection lines are a natural location for debris
accumulation. Clear obstructions or replace lines as
required.
Circulation pump flow rate is Inspect the pump inlet screen and the impeller. Clean the
low. screen, clean and/or replace the impeller or replace the
pump as necessary.
PUMP #2 INOP (available on sys- This message is indicative of Refer to solutions for “Pump #1 Inop” section above.
tems with a second process only) the same problem and trouble
shooting requirements outlined
in the “Pump #1 Inop” section
above. This message is only
displayed when the system is
configured with two filtration
system processing loops (the
LCD associated with X17 is illu-
minated on the LC when this
configuration is active). The
message occurs if the pressure
switch mounted on the second
process loop circulation pump
fails to see pressure for a 30
second interval. This switch will
cause the LED associated with
input point X4 on the LC to illu-
minate when is sees pressure.
DEFOAMER INOP The system has run out of Replenish supply of defoaming solution in container.
defoaming solution.
Moisture has gotten into the Remove defoamer sensor device from Process Tank 1.
defoamer sensor device. Clean and/or replace as necessary.
6-2
PROBABLE
PROBLEM SOLUTION
CAUSE
SYSTEM WON’T ACCEPT FLUID Power not being provided to the A float switch controls the operation of the device. On
input supply device properly. systems equipped with two float switches, the upper float
switch (mounted in the last process tank) controls power
The System is equipped with a to the relay that control power to the device. When the
switched outlet or terminal con- float falls, power to the relay is interrupted, this causes
nection point that provides power to be supplied to the input supply device. When the
power to the inlet pump or sole- float rises, power is supplied to the relay which interrups
noid valve. power to the device. Make sure that the float switch is
operating freely.
Supplying sump pump not If the device is a sump pump, check for 120VAC at the
receiving power. terminal strip in the electrical control housing where the
pump connects to control power. The proper terminals
are identified on the system wiring diagram. If power is
properly supplied, the device is defective and must be
replaced.
UNPLEASANT ODOR COMING Problem with Hydrobiodigest- Check Hydrobiodigester supply and dosage frequency.
FROM SYSTEM ers effectiveness. Refer to “BIOLOGICAL CONTROL” paragraph under
INSTALLATION section for dosage information.
Check dosing pump operation. If a problem is found with

Filtration systems use one of two dif-
ferent types of odor controlling units. its operation, refer to the ULTRADOSE AUTOMATIC
DISPENSING SYSTEM manual for troubleshooting infor-
Hydrobiodigesters and Ozone gener-
mation; if so equipped.
ating systems. Refer to the ozone
generator manual for troubleshoot- Check environmental factors. Lack of oxygenation, low
ing information as required. Hydro-
temperatures, low or high pH levels, disinfectants in sys-
biogester information only is outlined
tem, all have detrimental effects on Hydrobiodigester
here. organisms. Refer to the Hydrobiodigesters Information
Sheet for more information. Correct conditions as neces-
sary.
Check storage life of the Hydrobiodigesters supply.

Hydrobiodigester supplies in storage in excess of 1 year
may lose their effectiveness.
MACHINE TURNS OFF AFTER A See PUMP #1 INOP

FEW MINUTES OF OPERATION
6-3
PROBABLE
PROBLEM SOLUTION
CAUSE
WATER LEAKAGE Leakage from hose connec- Tighten hose clamps. Test for leakage. If still leaking,
(Determine leakage point(s)) tions. loosen hose clamps and check for torn or perforated hose
around clamp area. Repair or replace hose and/or clamp.
Leakage from tank bulkhead fit- Check tightness of bulkhead lock nut. If still leaking,
tings. check rubber washer on bulkhead for possible defects.
Replace as necessary.
Leakage from threaded plastic Unscrew connection, clean and apply pipe joint com-
fittings. pound only to male threads (for proper sealant to be used
call service department (800-247-8424). Reconnect joint.
Leakage from threaded metal Unscrew connection, clean and apply teflon “pipe” tape,
fittings. or pipe joint compound to male threads. When using
tape, do not apply too much tape. Reconnect joint.
Leakage from glued joints. Once a glued joint begins to leak, it will be necessary to
replace the entire joint assembly. The leaking section will
need to be cut out and replaced with a new assembly.
Leakage from pump. If leakage is between pump and motor, check shaft seal.
Replace if defective. Also check large clamp tightness
around pump head and large o-ring. If leakage is around
the filter pot, check filter pot clamp tightness, o-ring, and
the gasket seal between the filter pot and pump head.
Check for housing cracks. Repair or replace as neces-
sary.
MACHINE OVERFLOWS Follow the instructions outlined in the “SYSTEM WON’T ACCEPT FLUID” heading in this
section.
TANK(S) DRAIN OR EMPTY DUR- Media control valve not fully Refer to the diagram “VALVE ACTUATOR KIT” in the
ING NORMAL OPERATION adjusted to normal operating manual for adjustment information on motorized valves.
position.
Systems may use either manual Move handle 2-3 degrees back from the stop position and
or motorized rotary valves. Fol- recheck system operation.
low instructions for the type
used on your system. If problem persists the valve must be removed from the
filter and inspected. Drain filter before removing the valve.
If thru tubes are exactly aligned with supply and dis-
charge ports when handle is in the filter position, replace
the valve.
MEDIA IN PUMP INLET STRAINER Overflow check valve may have If the check valve located in the tank overflow port fails
failed. and remains open, media may be washed into the tank
during the backwash cycle. Clean the check valve and
the pump inlet filter. Replace the check valve if necessary
and continue operation.
Media filter laterals or other Remove all media from the filter. Remove gravel bed from
internal filter plumbing failure. filter. Inspect plumbing, repair and/or replace as required.
Check overdrain asembly for cracks and breaks.
6-4
PROBABLE
PROBLEM SOLUTION
CAUSE
PROBLEM WITH MEDIA FILTER Short cycle runs. If the system is started with the process tank full of con-
OPERATION taminated water, short filter runs (between backflush
cycles) are normal until the water has been thoroughly fil-
A brief “cloud” of dirt may appear in tered. If very contaminated water is to be clarified, start
the process tank immediately when the system with fresh water and add the contaminated
the filter starts. This is a characteris- solution slowly to avoid maintenance problems associ-
tic of media filters. ated with an excessively impacted filter bed. When the fil-
ter requires cleaning and recharging with new media, it is
The nature of a multiple pass filter an indication that it is doing its job. If, however, this ser-
system, is to catch the large particles vice is required too frequently, install a pre-filter or solids
first and gradually remove the small settling tank in front of the system.
material (fines) as the pore size of the
media is reduced by the filtrate that is Clogged inlet filters. If the pressure drops on the filter, remove the strainer
bowl and check the screen to see if it is clogged. It is rec-
deposited on it's surface.
ommended to dry the screen before checking to exhibit
any scale build-up. Check the inlet valve to verify it is in
the proper operating position and clear the inlet line if it is
clogged. Make sure the pump is properly primed. Finally
remove the front pump housing and clean the impeller.
HIGH FILTER PRESSURE AFTER Filter needs cleaning and new Check diverter valve for proper position. If the filter back
BACKFLUSHING media. pressure remains high after the backflush cycle, back-
flush the filter again. If it is still high, disassemble & clean
the filter and replace the media.
PUMP/MOTOR WILL NOT OPER- No power to system. Inspect supply breakers, fuses, disconnect boxes, plugs,
ATE receptacles, and cords. The wiring diagram in this manual
illustrates the power supply and how it should be attached
to the unit.
Ground Fault Circuit Interrupter Check the operation of the power supply GFI. If the GFI
tripped, if so equipped. can not be reset, disconnect the system and attempt to
reset the GFI. If the GFI doesn’t reset, the GFI is wet or
defective. If the GFI resets when the system is discon-
nected, the problem is in the system.
Motor overload switch tripped, if Check the motor. The motor may be equipped with a
so equipped. manual overload switch. Push in the button to reset the
overload. Motors equipped with automatic overload pro-
tection must be allowed to cool before the overload switch
will reset automatically.
Bad capacitor’s on motor. On single phase motors, the motor capacitor(s) may be
bad. They can be replaced by a qualified technician.
Bound motor shaft. Turn the motor shaft manually to verify that it is not
bound. A bound shaft might indicate a frozen bearing in
the motor or an obstruction in the pump.
Internal motor components are Make sure motor is completely dry.

wet.
6-5
PROBABLE
PROBLEM SOLUTION
CAUSE
MOTOR OVERHEATING AND Voltage and/or amperage prob- Reset the motor by depressing the motor overload button
STOPPING lem. or the reset switch on the GFI device. If the problem per-
sists, test the voltage and amp draw while the system is
under load. If the result of the tests indicate that the volt-
age is more than 10% under or the amperage more than
15% over the nameplate rating, a problem is indicated.
If the voltage is satisfactory when the system is off and

low when it is running under load, the size of the wire sup-
plying the system is too small. Replace the supply wire.
If the voltage is satisfactory when the system is running

under load but the amperage is excessive, check the
pump impeller and make sure it rotates freely.
If the voltage and amperage are within specifications,

inspect the motor for foreign material in ventilation ports.
If the problem persists, repair or replace the motor.
MOTOR STOPS Low system pressure Low system pressure.
AUTOMATIC DISCHARGE INOP- No power to ball valve. Move the toggle switch mounted on the valve actuator to
ERATIVE the ON2 position to move the valve and verify power sup-
(Auto Discharge to drain ball valve) ply to the valve. If the valve moves, position the switch to
the ON1 position and verify that the valve closes. If these
tests are passed the valve actuator is OK, the next proba-
ble cause is that the valve stem is broken and the valve
must be replaced.
If these tests fail, check the power supply to the valve

control relay. Using a test meter, verify that the relay COM
terminal has 24VAC when the main power switch is on. If
no power is observed, check output at the 24VAC trans-
former. Depress the manual reset overload switch if nec-
essary and check power again. If no power is observed,
check for 115VAC at the input and output of the 1 amp
fuse supplying power to the 24VAC transformer.
If these tests are passed and the valve actuator doesn’t

operate, replace the actuator.
No water being discharged. Check to see if the air relief hose, item #9 on the
exploded view diagram of the media filter, is connected. If
this hose becomes disconnected, carbon can get into the
system, thus blocking the discharge from the solenoid.
Another possibility is that one or more of the laterals could
have been broken when filling the media filter.
6-6
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Filter Checklist Chart
Suggested Maintenance Stock Items
Table 1: FILTER PRESSURE READINGS AND MEDIA CHANGE RECORD

MEDIA-1 STARTING MEDIA-2 (if applicable)
DATE MEDIA CHANGE
PRESSURE STARTING PRESSURE
DATE: Record date of each pressure reading taken.
MEDIA-1
STARTING PRESSURE: With fresh or cleansed media in filter 1, take a pressure reading1 to establish a baseline for this polishing
unit (i.e., when the media control valve is in the normal operating position).
MEDIA-2 (if applicable)
STARTING PRESSURE: With fresh or cleansed media in filter 2, take a pressure reading1 to establish a baseline for this polishing
unit (i.e., when the media control valve is in the normal operating position). Use this column only if the filtra-
tion system is equipped with two media filter modules, otherwise, leave it blank.
MEDIA CHANGE: Record any media changes and to which tank.
1. To take proper pressure readings in the final polishing unit, set the 3-way ball valve to direct 100% of flow into the process tank.
T- 1
Diagrams
Copyright © Hydro Engineering, Inc. -- Operator’s Manual Diagrams
DIAGRAM 1: EXPLODED VIEW: MEDIA FILTER PLUMBING -- HE/3000
1A
PUMP
MEDIA1 MOUNTING
1B 11 PLATE
7
32
7
31
2A,2B 29 11
30
28
13 10
APPLIED TO SIDE E
OF TANK
8
22
6 24
12
PARTS 24" 22
FILTER DRAIN C
4
5
PARTS 30" 6
B
9
FILTER DRAIN 17 23
20
3
16
18 E
19 4
15 14
21
10 A
25 28
26 6 A OUTLET TO DISCHARGE MANIFOLD/TANK
25
27 B INLET FROM PUMP DISCHARGE
28
10 CONNECT TO DRAIN C BACKWASH TO DRAIN/ TANK OVERFLOW
PARTS LIST
# PART # DESCRIPTION # PART # DESCRIPTION
1A 2UW946 AIR RELIEF VALVE ASSY. 24" FILTER 16 0UJ298 BUSHING, REDUCER, PVC, 1-1/2" MPT x 3/4" FPT
1B 2ON295 VALVE, MANUAL AIR RELIEF. 30" FILTER 17 0DQ949 PLUG, 3/4", BRASS HEX BAR STOCK
2A 0GO708 FILTER,CARBON/SAND MEDIA 24" 18 0UC229 ADAPTER, FEMALE,PVC,1 1/2"SL X 1 1/2"FPT
2B 0GO707 FILTER,CARBON/SAND MEDIA 30" 19 1SM567 BUSHING,REDUCER PVC,1 1/2"SPIG X 1/2"FPT
3 2ZG082 VALVE, MEDIA FILTER BACKWASH, CPVC, BLK 20 0ED075 ELBOW, BRASS, BAR STOCK, 1/2FPT
4 0UI285 BUSHING, REDUCER, 2" SPIG x 1-1/2" FPT 21 0EM169 ELBOW, STREET, BR, BAR STOCK, 1/2MXFPT
5 0DY029 NIPPLE, 1/4", BRASS, HEX BAR STOCK 22 1SO587 ELBOW,STREET,PVC, 2" SPIG X SLIP
6 0SZ937 ELBOW, STREET,PVC,1 1/2"MPT X 1 1/2"SLIP 23 2ZG083 NIPPLE, 2"CPVC, 4"L W/1/2"OFFSET, BLACK
7 0XE022 GAUGE, 0-60# 24 3BL651 HOSE, PVC-FLEX, SPIRALITE, BLACK, 2"
8 2ZG085 UNION KIT, MEDIA FILTER, 2"PVC SLIP 25 0KN733 NIPPLE, CLOSE, BRASS, 1/2MPT
9 0JV552 BUSHING, REDUCER, BRASS, HEX, 1/2X1/4 26 1EC829 VALVE, BALL, 1/2NPT, 2 WAY
10 1JP252 CLAMP, HOSE, 5/16"- 7/8" 27 0EE087 TEE, BRASS, BAR STOCK, 1/2FPT
11 0FY541 HOSE BARB, 1/4"X1/8", BRASS HEX STOCK 28 0FZ554 HOSE BARB, BRASS, HX STOCK, 1/2HBX1/2MPT
12 2RC962 ACTUATOR VALVE, 90 DEGREE 29 1VS408 TUBING, CLEAR VINYL, 1/4" ID X 3/8" OD
13 2UW947 STICKER, MEDIA FILTERS, GLASLOCK 30 0PA906 PIPE 'T' ADAPTER, 1/2MPTX1/8FPTX1/2FPT
14 1BT219 NIPPLE, CLOSE, PVC, 1 1/2" 31 1RX414 VALVE, CHECK, PVC, 1/2" FPT
15 0SV898 TEE, PVC, 1-1/2" FPT 32 0DZ031 NIPPLE, 1/2", BRASS, HEX BAR STOCK
D-1
DIAGRAM 2: EXPLODED VIEW: PROCESS TANK PLUMBING -- HE/3000
2KF170
8 OPTIONAL INLET FROM RST
16
25 6 21
24 22
9 8
20
25
10 19
23
FRESH WATER INLET 10
FROM CONNECTION
11
18
12
6
A
5 13
17
4
15 RUMBLE MANIFOLD
3
2
1 INSTALL SO INJECTOR
FLOWS HORIZONTAL
BACK FLUSH 7 ACCROSS THE TANK
FROM FILTERS 11
TO MEDIA FILTER OR
OVERFLOW DRAIN VALVE
TO DRAIN
6
INLET FROM MEDIA
NOTE: SEE PENETRATION DRAWING
FOR HOLE LEVELS AND LOCATIONS
* PARTS LIST *
1 2KG181 HOSE, SPA-FLEX, SPIRALITE, WHITE, 1 1/2" 14 1KZ614 HOSE, SUCTION, 2"
2 0SR858 TEE, PVC, 1 1/2" SLIP X SLIP 15 2MI720 ANTI-VORTEX ADAPT,FOR 2" BULK HEAD FIT.
3 1SL553 ADAPTER, MALE,PVC,1 1/2"SPIG X 1 1/2"MPT 16 1UV173 BUSHING,REDUCER,PVC, 2"MPT X 3/4"FPT
4 0AH823 CHECK VALVE, 1-1/2" FPT, PVC 17 2UW945 RUMBLE MANIFOLD, PROCESS TANK, 110GAL
5 1BT219 NIPPLE, CLOSE, 1-1/2" PVC 18 0YO387 TANK, MIX, 110 GALLON, BLACK
6 0TC960 ELBOW, STREET, PVC, 1-1/2" MPT x 1-1/2" FPT 19 0GF610 HOSE, ALL-PURPOSE, 3/4",BLUE
7 0YM361 FITTING, BULKHEAD, 1-1/2" DOUBLE THREADED 20 1DZ790 CLAMP, HOSE, 9/16" TO 1-1/4" STAINLESS
8 0FX533 HOSE BARB, BRASS 3/4" HB x 3/4" MPT 21 0EM165 ELBOW, STREET, BRASS, 3/4" MPT x 3/4" FPT
9 1FT259 SOLENOID VALVE, 3/4" FPT, PVC, 24V AC 22 0YN375 FITTING, BULKHEAD, 3/4" DOUBLE THREADED
10 1SM568 NIPPLE, KING, PVC, 3/4"HB X 3/4"MPT 23 0DY027 NIPPLE, 3/4", BRASS, HEX BAR STOCK
11 0QO308 FITTING, HD BULKHEAD, NYLON, 2" FPT 24 1LM743 FILTER, 3/4", POLY. GRAY BOWL
12 0UF250 ADAPTER, MALE, PVC,2"MPT X 2"SLIP 25 3BP693 ELBOW, STREET,PVC,3/4"MPT X 3/4"FPT
13 1KZ619 PIPE, PVC, 2" SCH 40
D-2
DIAGRAM 3: EXPLODED VIEW: DE-FOAM -- HE/5000
NOTE: SEE INDIVIDUAL EQUIPMENT PENETRATION DRAWING FOR MOUNTING LOCATION
CONNECT TO
DISCHARGE OF
9
1 PERISTALTIC PUMP
2
DISCHARGE ASSEMBLY
CONNECT TO
TERMINAL BLOCK
3 (SEE WIRING DIAGRAM)
4
5
DRILL 11/16"
6 HOLE
OPTION INFORMATION
* AUTO DISPENSER, DE-FOAM (REQUIRES LC)
** STAND ALONE AUTOMATIC DE-FOAM SYSTEM
PN: PL1YB017R1
D-3
DIAGRAM 4: PLUMBING DIAGRAM, DISCHARGE MANIFOLD
18
10
12 9
15 10
8
19 2
4
5" 1
3 16
OPTIONAL
DISCHARGE 2 3.5"
VALVE
11 12 3
5 10
PARTS LIST
OUTLET TO TANK
7
6 17 # PART #
1 0SX914
DESCRIPTION
VALVE, 3-WAY, CPVC, 1-1/2" F-SLIP
INLET FROM FILTER

13 2
3
3BL652
0SY926
HOSE, PVC-FLEX, SPIRALITE, BLACK,1 1/2"
ELBOW, STREET, PVC, 1-1/2" SPIG x SLIP
4 1RH254 VALVE, 2-WAY, CPVC, 1-1/2" SLIP
14 5 0MW346 VALVE ACTUATOR, 24VAC, MOTORIZED KIT
6 0XE022 GAUGE, 0-60#
7 0UI281 BUSHING,REDUCER,PVC,1 1/2"SPIG X 1/4"FPT
15 8
9
0SR858
1LM745
TEE, PVC, 1 1/2" SLIP X SLIP
FILTER, WATER, INLET, CLEAR, 1-1/2" FNPT
10 1SL553 ADAPTER, MALE,PVC,1 1/2"SPIG X 1 1/2"MPT
11 1SK545 CROSS, PVC, 1-1/2" SOCKET
12 1SM567 BUSHING, PVC, 1-1/2" SPIG x 1/2" FPT
13 0KN733 NIPPLE, CLOSE, BRASS, 1/2" MPT
14 1EC829 VALVE, BALL, 1/2" NPT, 2-WAY
15 0FZ550 HOSE BARB, BRASS, 3/8" HB x 1/2" MPT
16 0VG528 ADAPT,FEMALE,PVC,1 1/2"SPIG X 1 1/2"FPT
17 0EM169 ELBOW, STREET, BR, BAR STOCK, 1/2MXFPT
18 0SW905 ELBOW, PVC, 1 1/2" SLIP X SLIP
19 0UT399 PLUG, PVC, 1 1/2"MPT
P/N: PLHE3DMANIFOLD 12-28-09
D-4
DIAGRAM 5: EXPLODED VIEW: MEDIA FILTER BACKWASH VALVE
1
ITEM PART REPLACEMENT KITS PARTS LIST
QTY.
NO. NO. DESCRIPTION
1 2ZX256 LID REPLACEMENT KIT
LID TOP -KEYED 1
LID, BOTTOM - KEYED 1
1 O-RING 151 2
3 O-RING 116 4
SCREWS, MACHINE #14 16
INSTRUCTIONS, REPLACEMENT KIT 1
2 2ZX250 DIVERTER REPLACEMENT KIT
DIVERTER SHAFT 1
2 DIVERTER ASSEMBLY, TOP, BLUE SEAL 1
DIVERTER ASSEMBLY, BOTTOM, BLACK SEAL 1
3 2ZX253 O-RING REPLACEMENT KIT
3 PAR RING 2
LID O-RING 2
DIVERTER O-RING 8
FROM FILTER
INLET
PENDING
PATENT
TO FILTER
INLET
WASTE
2
3
3
1
D-5
DIAGRAM 6: EXPLODED VIEW: CIRCULATION PUMP #1 PLUMBING
4 PSI 28 PSI
28 PSI
PUMP OUTLET TO
MEDIA #1 TANK
4 PSI VALVE
8
10
9
13 7
11 6B
12
11
WIRE PRESSURE 6A
SWITCHES USING 5
18/8 CABLE
4
3
PUMP ASSEMBLY TABLE

MOTORS PUMPS
6A/6B 6A 6B 6B 6B 6B
MODEL NO. 2RB951 2TN595 2SZ451/60Hz 2RB957/50Hz 2RB957/60HZ 2SZ452/50Hz INLET FROM BOTTOM OF
HE/S1-H PROCESS TANK #1
SPL24 * * *
HE/3000 * * *
HE/5000 * * *
HE/7000 * * *
ACF3 * * *
BR210 * * *
BR500 * * *
HE/S1H-500 * * *
HE/8000 * * *
DPL30 / SPL30 * * *
* * *
PARTS LIST
1 3BL651 HOSE, PVC-FLEX, SPIRALITE, BLACK, 2" 8 2PG483 ELBOW, ST. PVC, 1 1/2"SPX1 1/2SX1/2 OUT
2 0UF250 ADAPTER, MALE, PVC, 2" MPT X 2" SLIP 9 3BL652 HOSE, PVC-FLEX, SPIRALITE, BLACK,1 1/2"
3 0YN378 VALVE, BALL, 2", PVC W/UNION, TWO WAY 10 2RG004 TEE, REDUCER, PVC,1 1/2"X 1 1/2"X 1/2"
4 1BU221 CLOSE NIPPLE, 2", PVC 11 2PG485 BUSHING,REDUCER PVC, 1/2"SPIG X 1/4"FPT
5 0TC961 STREET ELBOW, PVC, 2" MPT x FPT 12 3LR313 SWITCH,PRESSURE,GOLD POINTS,5PSI,1/4"
6 SEE PUMP ASSEMBLY TABLE 13 3LR318 SWITCH,PRESSURE,GOLD POINTS,28PSI,1/4"
7 0UF254 ADAPTER, RDCG MALE, PVC, 2" MPT x 1-1/2" SOC 14
DWG P/N: PLFILTPUMP1 Rev Date: 12-20-13
D-6
DIAGRAM 7: EXPLODED VIEW: DRAIN PIPE PLUMBING -- HE/3000
D-7
DIAGRAM 8: ELECTRICAL DIAGRAM: DOSING PUMP, #1UI042(BUG DOSING), 24VAC
FOR USE WITH A HYDROKLEEN SYSTEM

WITH LOGIC CONTROL
TO 24VDC (-) SEE CURRENT L/C DIAGRAM FOR CONNECTION POINTS

TO 24VDC (+) SEE CURRENT L/C DIAGRAM FOR CONNECTION POINTS
TO 24VAC (-) SEE CURRENT L/C DIAGRAM FOR CONNECTION POINTS

TO 24VAC (+) SEE CURRENT L/C DIAGRAM FOR CONNECTION POINTS
YL18
BL18
2
RD18
BK18
BK22
RELAY
SPDT
1 24VAC COIL
AUTO
RD22
OFF
BK22
ON
(MANUAL)
CONNECT 24VDC NEUTRAL (-)

TO TERMINAL WITH RED DOT
PERISTALTIC
PUMP MOTOR 4
24VDC
0.4A
PERISTALTIC PUMP 3
* REFER TO MANUAL FOR INFORMATION ON SETTING PROPER DOSING RATE.
** REFER TO FILTRATION SYSTEM WIRING DIAGRAM FOR WIRING OF PHOTOELECTRIC SENSING DEVICE (#1XV950) INTO FILTRATION SYSTEM.
PARTS LIST
D-8
DIAGRAM 9: ELECTRICAL.DIAGRAM: LOGIC CONTROLLER: SINGLE PUMP: 230/115V, 1PH, 1 & 1.5HP
MOUNT SWITCH IN P/W CONTROL BOX

CURRENT SENSING SWITCH
230/460VAC
MBV CONTROL SIGNAL
MAKEUP WATER VALVE

SUMP PUMP CONTROL
CONTROL SIGNAL
D-9
DIAGRAM 10: ELECTRICAL.DIAGRAM: EL511-2LCR5-LEGEND
D - 10
DIAGRAM 11: ELECTRICAL SCHEMATIC: COLD WATER 2-8 MINUTE RINSE CYCLE / 230V 1 PHASE
PARTS LIST
D - 11
DIAGRAM 12: EXPLODED VIEW: DEFOAM SYSTEM: 1YF055 24DC
STAND ALONE
OPTION
3 8
12 50 Hz system
11
RD18
BK18
RD18
BK 10 9
WH RD18 60 Hz system
2
RD18
BK18
BK18
RELAY
SPST
1 24V DC COIL
AUTO
YE18
OFF BR22
6
WH22
BL22
ON BK22
(MANUAL) RD18 FOAM SENSOR
BK18
SOLENOID VALVE
24VDC
7
BK18
BK18
3 RED DOT
2 1
INSTALL OFY547
4
PERISTALTIC PUMP 5
PERISTALTIC
PUMP MOTOR
24VDC
0.4A
PARTS LIST
D - 12
MACHINE MAINTENANCE LOG SHEET
Customer _________________________________________________ Model No. ______________________________

Machine Location ___________________________________________ Serial No. ______________________________
Dealer________________________________ Address____________________________________ Ph. No.__________
This page was designed to help you track all repairs and problems you may have had with this
machine. Use this tool as a referral and record. If contacting Hydro Engineering Inc. for Service, please
have this sheet available for review.
Serviced
Date Hours Problems and Resolutions Parts Used
By
D - 13

200 He

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Copyright © Hydro Engineering, Inc.

HIGH PRESSURE WASHING EQUIPMENT

Hydro Engineering, Inc. In Utah: 801-972-1181

Refer to Control Panel Label

Please fill in the following for your records.

SERIAL NUMBER MODEL NUMBER

INITIAL INSPECTION AND HANDLING

Hydro Engineering, Inc.

NEW PRODUCT LIMITED WARRANTY

LIMITED WARRANTY COVERAGE:

Date Effective: 29September 08

RETURN GOODS AUTHORIZATION (RGA) PROCEDURE

RETURN GOODS AUTHORIZATION (RGA) PROCEDURE

ITEM RETURN PROCEDURE

3.Please package the items to be returned carefully.

5.Ship the product freight prepaid to HEI.

REPLACEMENT PARTS ORDERS

Status: Approved, Bug 10057

Hydro Engineering Inc.

OPERATION & MAINTENANCE MANUAL

Installation Notes & Setup

Maintenance & Service

OPERATION & MAINTENANCE MANUAL

Table of Contents (continued)

CLEANING THE MEDIA FILTER .........................................................................................................................6-1

Suggested Maintenance Stock Items

OPERATION & MAINTENANCE MANUAL

The HE/3000 system may be operated and maintained by

Systems equipped with Hydrobiodigesters dosing systems

Hydrobiodigesters are added to the system with a peristal-

IMPORTANT SAFETY INFORMATION GENERAL INFORMATION

WARNING: This system is designed to be used with a

Before servicing, survey the area for possible hazards and

WARNING: Turn the system off, disconnect and lock

The limit switches monitor pump operation to protect the

All guards, shields, and covers must be in place to prevent

This HydroKleen filtration system is designed primarily to

WARNING: YOUR WARRANTY MAY BE VOID IF

Installation Notes & Setup

It is recommended that the HBD are established in the new

SETUP & APPLICATION: Hydro Biodigesters are injected

2 Regularly recurring doses are applied by the auto dispens-

Make-up water flow into the system is controlled by a float

NOTE: The system must be filled with fresh water before

Logic Controller n LCD DISPLAY MESSAGES

As the logic controller monitors the filtration system’s oper-

If the system is operating in “high filter rate” mode at the “Polishing...”

Power Inputs Output Circuit

Discrete Inputs Input Status Option Slots Mode Switch

Figure 4-1: Programmable Logic Controller

“Backwashing...” controller by a Hydro Engineering, Inc. qualified service

LOGIC CONTROLLER I/O CONFIGURATION

The Bioreactor is a continously running process. The LC is

There are multiple ways of interacting with the LCD Display

• LCD ladder instruction

• Using ladder instructions to write bit status changes to

The seven function keys on the face of the LCD Display

• Change clock or calender settings or formats

• Monitor or change V-memory values (including DWord

• Force individual bits on or off (up to 16 per screen)

• Review error code history

• Set or change the password

• Turn the back light or buzzer on or off