Operators Booklet A5
Contents
1. CHECK VALVE ONE WAY VALVE CC DRUM ASSEMBLY 4 STEEL PLUG FOR INLET BASKET RING POWER PLUG FOR 220V RECYCLER 5 2 CONTROL WIRE BRACKET DRIP SHIELD COVER PROBE SET CHEMCHAMP LOGO STRAP LABEL HOT SURFACE LABEL LID STAY CLOSE LABEL OPERATION LABEL INSTALLATION LABEL THERMAL OIL LID BOLT CAP BRASS ka PICTURE NOT AVAILABLE MP SPs OQ 4 PICTURE NOT AVAILABLE Lom 7 CHEMCHAMP Resources RANING LX AWA gt PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE 7 Page 19 of 23 2 111 2 817 2 819 PLUG WARNING LABEL SPRING WASHER BRASS SPRING ALIGNER BRASS FRONT PANEL LABELS MINI CHEMCHAMP LABEL 12 5A FUSE CLEAR GLASS A5 2LV 80A FUSE GREEN A5 2LV 110V CONTROL BOARD HD 110V BOTTOM BOARD WITH FUSE LINKS 2 POS TERMINAL PLUG FOR 2 803H 3 POS TERMINAL PLUG FOR 2 803H 110V POWER PLUG TEFLON RECOVERY BAGS VAPOR HOSE ASSEMBLY HD BASKET RING REDUCER HD CHECK VALVE FRONT PANEL FULL ASSEMBLY PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE ew 2 VN PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE Page 20 of 23 OTHER PRODUCTS OFFERED BY CHEMCHAMP PART 3 000 18 GALLON SOLVENT RECYCLER 0150115 eighteen gallons a day ETLlisted for both hazardous and non hazardous location Class 1 Divisi2. Oil changes Liner bags Basket ring Check valve Fuses Paint Defective material or workmanship is not considered normal wear Page 15 of 23 4 1 CHEMCHAMP VEL PARTS LIST THERMAL LID GASKET RING LID FOR 5 DISTILLATION CHAMBER CC DRUM FAUCET CONDENSATION COLUMN 34 WHITE NYLON NIPPLE FOR COLUMN RING HEAT SHIELD FOR COLUMN CONTROL BOARD A5 2 POWER BOARDS A5 2 9 w E CLAMP FOR POWER CORD PICTURE NOT AVAILABLE PROBE WELL HEX BRASS CAP FOR OIL Page 16 of 23 8A FUSE WHITE A5 2 050A FUSE RED A5 2 250A FUSE YELLOW A5 2 AND A5 2LV 4 POS GREEN PLUG 2 POS GREEN PLUG 3 POS GREEN PLUG 5 POS GREEN PLUG RED DISPLAY SCREEN BLACK BOOTS FOR START STOP SWITCH TOP FISH PAPER BOTTOM FISH PAPER 1 081 NYLON POSTS FOR NUTS 1 082 NYLON SCREWS 1 083 BLACK ALLOY MOUNTING POSTS FOR BOTTOM BOARD e la eee PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE PICTURE NOT AVAILABLE Page 17 of 23 LED SMALL BOOTS START OR STOP SWITCH RECOVERY BAGS FRONT PANEL PAINTED BACK PANEL PAINTED LEFT PANEL PAINTED POWER CORD SIDE RIGHT PANEL PAINTED PLUMBING SIDE LID CROSS MEMBER LOCKING HANDLE LID SPRING CC DRUM WITH FAUCET NO LID FLOAT ASSEMBLY PICTURE NOT AVAILABLE ve PICTURE NOT AVAILABLE Page 18 of 23 2 080 2 081 2 091 2 100
3. MODEL A5 2 220V amp A5 2LV 110V OPERATOR S MANUAL SOLVENT amp WATER RECOVERY SYSTEMS EXPLOSION PROOF UNITS FOR PROPER AND SAFE USE OF THIS CHEMCHAMP EQUIPMENT PLEASE FOLLOW THIS DOCUMENT AND LOCAL AUTHORITY KEEP THIS DOCUMENT FOR FUTURE REFERENCE Revision 04012012 Page 1 of 23 TABLE OF CONTENTS TECHNICAL DATA PAGE 3 INTRODUCTION PAGE 4 SAFETY FEATURES PAGE 4 PLEASE NOTE BEFORE OPERATING PAGE 5 INSTALLATION OF UNIT PAGE 6 7 INSTALLATION OF OVERFLOW ASSEMBLY PAGE 8 INSTALLATION OF BAGS PAGE 9 OPERATION OF UNIT PAGE 10 11 OIL MAINTENANCE PAGE 11 COLLECTION VESSEL PAGE 12 TROUBLE SHOOTING PAGE 13 ERROR MESSAGES PAGE 13 WARRANTY PAGE 14 15 PARTS LIST PAGE 16 20 OTHER PRODUCTS OFFERED BY CHEMCHAMP PAGE 21 22 CONTACT US PAGE 23 Page 2 of 23 CHEXIEHAMP Vil T VM 1 Mr ur O Technical Data MODEL 5 2 220V UNIT CHEMCHAMP A5 2LV 110V UNIT CLASSIFICATION CLASS 1 DIVISION 1 GROUPS C D E F G ELECTRICAL PROTECTION INTRINSIC PROTECTION amp EXPLOSION PROOF ENCLOSURES FUSE PROTECTION 8 AMP DELAYED ACTION A5 2 12 5 AMP DELAYED ACTION A5 2LV VOLTAGE 220 VAC SINGLE PHASE 5 2 110 VAC SINGLE PHASE A5 2LV AMPERAGE 7 AMP 5 2 13 AMP A5 2LV POWER 1 8 kW A5 2 1 3 kW A5 2LV CAPACITY 5 28 US GALLONS 20 LITRES OPERATING TEMPERATURE 53 6 TO 379 4 FAHRENHEIT 12 TO 193 CELCIUS SAFETY THERMOSTATS ELEMENT 384 8 FAHRENHEIT ELEME
4. Fuse Protection Page 4 of 23 li tis PLEASE NOTE THE FOLLOWING 1 This unit is designed to distil most solvents with a boiling temperature less than 356 F 180 C Solvents greater than 270 F 132 C may require a High Boiler chip to distil properly 2 The distilled solvent must be collected in the drum provided with unit caution should be taken to prevent accidental spillage 3 This unit should never be used to distil any chemical with an auto ignition temperature below 437 F 225 C Before initiating the distillation process always consult the appropriate material safety datasheet MSDS 4 NITROCELLULOSE must never be distilled in this unit as this may cause conditions of danger Residues must be disposed of in accordance to local laws When cleaning residue from unit use only non sparking tools Opening cover before allowed time will cause gasket swell and dislocate Operators should wear anti static clothing Operating staff must be fully educated on the safe and correct use of unit and protection devices 10 Lid gasket should be replaced every 2 years 11 This unit may come equipped with a non hazardous industrial plug but if installed into a hazardous location the proper connection must be implemented in accordance with the local authority 12 In accordance to UL 2208 unit must be provided with an overflow protection container of a minimum of 5 gallons ee
5. IMPORTANT FAILURE TO FOLLOW ANY OF THE ABOVE COULD CAUSE PERSONAL INJURY AND PROPERTY DAMAGE Page 5 of 23 M NW WT 723525 INSTALLATION OF UNIT 1 LOCATION Caution To reduce the risk of fire or explosion install operate and maintain this equipment in accordance with the instruction manual This unit is for use in 104 F 40 C environment with no forced ventilation Under these conditions the unit shall be spaced a minimum of 3 feet 0 914m from potential sources of ignition such as electrical receptacles switches pilot lights fixtures contacts and other similar equipment that can produce sparks If the equipment is used in higher ambient temperatures an increase in spacing to sources of ignition shall be considered This unit has only been investigated for use with solvent with a maximum ignition temperature of 437 F 225 C This unit is designed for use in Class 1 Division 1 locations and non hazardous locations Note This unit may come equipped with a non hazardous industrial plug but if installed into a hazardous location the proper connection must be implemented in accordance with the local authority 2 OIL AIR RELEASE VALVE Remove back panel and replace oil cap marked with an X with oil cap found in distillation chamber The oil cap in distillation chamber has a hole in center of cap 3 FITTING ROD TO FLOAT Note float may already be installed Remove lid to collection drum Remove
6. TAKE valve Bottom brass cap Remove Oil OUT TAKE cap amp drain Re insert OUT TAKE cap Remove middle level indicator cap Refill oil with ChemChamp Heating Oil through Oil intake 2 US Gallons or 10 41 Liters until oil comes out middle level indicator cap amp Re cap middle level indicator cap and Oil Intake valve 9 Press the START button for 20 seconds All lights will come on and the screen will display Clr and then 8888 indicating self diagnostic and reset of unit is complete 10 Disconnect power 11 Reconnect power and you are ready to set the unit for solvent or water mode E c O UE p Page 11 of 23 ub hi Nk NV Wal COLLECTION VESSEL The collection vessel provided with unit is the only vessel to be used for collection of distilled solvent This vessel holds a maximum of 17 44 US Gallons 66 litres Page 12 of 23 W aly y 9000 TROUBLE SHOOTING Problem Bag is hard to pull out Machine will not come on Dirty distillate rust colored solvent Gasket swelling and dislocating Control panel error message ERROR MESSAGES CODE CHENICHAMP Rue ERROR PROBE 1 FAULT INVALID TEMPERATUE VALUES ROOM TEMPERATURE IS LESS THEN 32 FAHRENHEIT PROBE 2 VALUE TOO DIFFERENT FROM PROBE 1 PROBE 1 VALUE TOO DIFFERENT FROM PROBE 2 OVER TEMPERATURE FAULT HARDWARE OVERTEMP TRIP OVER TEMPERATURE FAULT FROM
7. both nuts from the top of the float rod Slide rod through the bottom center hole of the condensation column until exiting the top hole Re thread both nuts to the end of the float rod which is now above the condensation column See picture Page 6 of 23 4 TOPPING UP COLLECTION DRUM Top up collection drum with the type of solvent the recycler is intended to be used for Top up with solvent until the level reaches the tap on the side of the drum Approx 10 6 US Gallons Fit lid back making sure that the 2 bung is at 6 o clock and vapor pipe is at 12 o clock Fill to tap 5 ATTACHING COLLECTION DRUM CC Drum The collection vessel provided with unit is the only vessel to be used for collection of distilled solvent This vessel holds a maximum of 17 44 US Gallons 66 Litres Please follow the steps below A Verify that both gear clamps on vapor hose of CC Drum clamps are located at each end of the vapor hose next to the brass fittings are loose B Gently move CC Drum into place so that the vapor hose slides into 34 brass bulkhead C Using an adjustable wrench thread vapor hose clockwise into bulkhead until tight D Tighten both gear clamps from step Step A 6 GETTING READY Connect the power Press START button and green light will come on The green light signifies the unit is ready to work and it is safe to open lid Page 7 of 23 INSTALLATION O
8. collar that allows users to adjust for various drum sizes from 5 to 55 gallons Foot valve for hands free operation Interchangeable outfit fittings including a spout and flexible tube PART CC3000 PARTS CLEANER Heavy duty construction Gas shock lid closure with fire link Removable soak tray Stay put spigot Heavy duty brush with flex hose 300 GPH pump Hinged front door with roller base for easy service Page 22 of 23 CONTACT US CUSTOMER SUPPORT MAILING AND SHIP TO ADDRESS MON THU 8AM 5PM CHEMCHAMP FRI 8AM 4PM 1230 OLD INNES RD UNIT 410 P 800 916 2247 OTTAWA ON K1B 3V3 techsupport chemchamp com CANADA P 613 594 3337 F 613 594 3338 SALES GENERAL SALES P 800 916 2247 sales chemchamp com BUTCH DRAKE P 803 920 3452 butch drake chemchamp com Please be sure to visit our website to keep you up to date with ChemChamp products and services offered at WWW Chemchamp com THANK YOU FOR CHOOSING CHEMCHAMP AND HELPING RECYCLE OUR RESOURCES Page 23 of 23
9. that no other remedy including but not limited to incidental or consequential damages for lost profits lost sales injury to person or property or any other incidental or consequential loss shall be available Any action for breach of warranty must be brought forward within ONE 1 year of the date of sale Page 14 of 23 CHEMCHAMP MAKES NO WARRANTY AND DISCLAIMS ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR PARTICULAR PURPOSE CONNECTION WITH ACCESSORIES EQUIPMENT MATERIALS OR COMPONENTS SOLD BUT NOT MANUFACTURED BY These items sold but not manufactured by ChemChamp such as electric motors switches hose etc are subject to the warranty if any of their manufacturer ChemChamp will provide the purchaser with reasonable assistance in making any claim for breach of these warranties LIMITATION OF LIABILITY In no event will ChemChamp be liable for indirect incidental special or consequential damages resulting from ChemChamp supplying equipment hereunder or the furnishing performance or use of any products or other goods sold hereto whether due to a breach of contract breach of warranty the negligence of ChemChamp or otherwise Report all accidents or near misses which involve ChemChamp products to Technical Assistance 1 800 894 0688 The following items are not covered under the ChemChamp warranty policy Seal or packing replacement due to normal wears Lid gasket
10. A D READ UNIT HAS OPERATED FOR 3000 HOURS AND REQUIRES AN OIL CHANGE PART 2 099 Reason Dirty inner bucket Surge in power Dirty manifold Dirty collection drum Rusty drum Lid was opened before unit finished it s cool down mode System failure Solution Turn machine on until it reaches 131 Fahrenheit 55 Celcius remove bag and clean Replace fuse s in Explosion Proof box Clean manifold Replace or clean drum Replace collection drum Replace gasket immediately by ordering new gasket Part 1 014 Make sure the ambient temperature is greater then 10 Celsius Take note of error code ERO1 See error code section below Contact ChemChamp immediately Page 13 of 23 M dk WARRANTY ChemChamp warrants all equipment listed in this manual which is manufactured by ChemChamp and bearing its name to be free from defects in material and workmanship on the date of sale to an authorized ChemChamp distributor or to the original purchaser for use Notwithstanding any special extended or limited warranty published by ChemChamp will for a period of TWELVE 12 months from the date of sale repair or replace any part of the equipment determined by ChemChamp to be defective This warranty applies only when the equipment is installed operated and maintained in accordance with ChemChamp s written recommendations This warranty does not cover or make ChemChamp liable for general wear and te
11. F OVERFLOW ASSEMBLY The over flow assembly is a safety feature intended to prevent solvent from overflowing in the event of the recycler overfilled or the C C drum was not properly drained In accordance with UL 2208 this unit must be provided with a minimum overflow capacity of 5 gallons This unit supplies a gt hose barb fitting with a 2 male thread Hose and overflow container are to be provided by the customer gt hose barb 2 male thread Drawing of hose barb fitting The parts required for this installation are as follows a hose barb fitting a length of gt hose a gt hose clamp an empty 5 gallon collection can Unscrew the 2 plug on the lid of the C C drum Screw on the hose barb assembly into lid of C C drum Attach one end of hose to hose barb using a hose clamp Insert other end of hose Into empty 5 gallon collection can Ensure that all connections are tight n WN Page 8 of 23 CHENICHAMP AN INSTALLATION OF BAGS 1 Open lid of unit 2 Remove bag holder 3 Open bag and place inside bag holder 4 Fold top of bag over the top ring of bag holder 5 Squeezing top ring fit bag holder and bag into unit making sure bag is held open once installed and the bag is securely over the bag holder rin 6 Make sure bag is under the vapor manifold and waste intake valve making sure they are not blocked or covered 7 Pour solvent waste into receptacle b
12. NT 196 CELCIUS MATERIAL DIST CHAMBER STAINLESS STEEL PATENT PENDING PROCESS 1 VAPOR MANAGEMENT SYSTEM 2 PROCESS CONTROL METHOD 3 ANTI PRESSURE SYSTEM 4 DIRECT CONDENSATION METHOD DIMENSIONS LENGTH 24 4 INCHES 62CM WIDTH 16 1 INCHES 41CM HEIGHT 32 3 INCHES 82CM WEIGHT 227 7 LBS WITHOUT COLLECTION DRUM AND HOSES 251 8 LBS WITH COLLECTION DRUM AND HOSES COOL DOWN TIME 7 TO 10 HOURS Page 3 of 23 M NW WI 25372 INTRODUCTION In dealing with liquid hazardous waste companies have had to pay a costly rate for pick up and the re purchase of new chemicals for their process The A5 2LV recycler reduces these costs The means of accomplishing the above is through a process known as distillation Each group of chemicals has a vapor temperature which is utilized to separate the solvent from contaminants This unit is explosion proof which can be used for flammable and non flammable solvents ranging from acetone to water SAFETY FEATURES The unit comes equipped with the following safety features A Automated temperature and time setting The unit will automatically set its own time and temperature in accordance with the requirements of the particular solvent or solvents poured into its distillation chamber for recycling The result being the operator only needs to pour the solvent in the unit and press START B Oil immersion element C Element control and safety probes D O
13. ag Maximum level is 3 1 Inches 8 cm below bottom of vapor manifold The unit is designed for a maximum volume of 5 28 US Gallons 20 litres Cover Vapor Bag Holder Waste Manifold Rack Intake k And Bag Valve Over filling will result in overflow into vapor manifold resulting in dirty recycled solvent Over filling will also cause paint getting in behind the bag This will make it difficult to remove the bag as the paint will act as glue making the bag stick to the bottom If sticking happens press START and let unit warm up for 5 minutes Press OFF and gently pull bag out NOTE We recommend the use of CHEMCHAMP BAGS other types of bags may deteriorate during cycle and create a hard residue at the bottom of distillation chamber that will be difficult to remove Page 9 of 23 CHEMEHAMP 4 OPERATION OF UNIT SOLVENT MODE 1 Connect power 2 Press START button and green light will come on The green light signifies the unit is ready to begin a new batch and is safe to open Remove lock If applicable Open lid Remove bag holder Place new bag inside holder See installation of bag Fold overlap of bag over the top of the holder See installation of bag Place bag and holder inside distillation chamber See installation of bag Pour a maximum of 5 28 US Gallons 20 litres of waste solvent into bag making sure not to pour any liquid into outlet manifold or overfill The m
14. ar or any malfunction damage or wear caused by faulty installation misapplication abrasion corrosion inadequate or improper maintenance negligence accident tampering or substitution of non ChemChamp components parts Nor shall ChemChamp be liable for malfunction damage or wear caused by the incompatibility with ChemChamp equipment with structures accessories equipment or materials not supplied by ChemChamp or the improper design manufacture installation operation or maintenance of structures accessories equipment or materials not supplied by ChemChamp This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to an authorized ChemChamp distributor for verification of the claimed defect If the claimed defect is verified ChemChamp will repair or replace free of charge any defective parts The equipment will be returned to the original purchaser transportation prepaid If the inspection of the equipment does not disclose any defect in material or workmanship repairs will be made at a reasonable charge which charges may include the costs of parts labor and transportation THIS WARRANTY IS EXCLUSIVE AND IS IN LIEU OF ANY OTHER WARRANTIES EXPRESSED OR IMPLIED INCLUDING BUT NOT LIMITED TO WARRANTY OF MERCHANTABILITY OR WARRANTY OF FITNESS FOR A PARTICULAR PURPOSE ChemChamp s sole obligation and the buyer s sole remedy for any breach of warranty shall be as set forth above The buyer agrees
15. aximum level is 3 1 Inches 8 cm below the bottom of elbow elbow being the outlet manifold 10 Close lid and secure 11 Re insert lock into handle and close lock If applicable 12 Ensure collection drum is properly connected and full to the tap 13 Open tap making sure collection drum is empty to the level of the tap 14 Press START yellow light and digital display will come on The display shows the hours of operation and then the temperature of the thermal oil 15 Green light will stay on with yellow light until temperature of the thermic oil reaches 140 degrees Fahrenheit 60 degrees Celsius At this point the green light will turn off Unit will automatically set temperature and time in accordance to the solvent or solvents to be recycled 16 Once distillation is complete the unit will automatically shut off and the yellow light will begin flashing indicating the unit is OFF and is cooling down The yellow light will flash until the unit has cooled to 134 6 degrees Fahrenheit 57 Celsius At this point the yellow light and the digital display will turn OFF The green light will come on indicating the unit is safe to open and is ready to do the next cycle 17 Open cover and remove bag residue Place residue bag into proper collection drum i Um T o Please note that by using bags in the distillation chamber you eliminate the cleaning process Please use necessary safety precautions when following these step
16. il maintenance timer and indicator The unit will automatically indicate when an oil change is required If oil is not changed within a safe time period the unit will automatically shut down indicating the word OIL on the display panel until the oil is changed This ensures proper and safe operation of the unit for years to come E Intrinsically safe controls F Self cooling enclosed collection drum G A superior vapor management system The vapor management system limits VOC emissions during distillation resulting in a safe healthy working environment while maximizing solvent recovery H STOP button for manual shut off at any time If the unit is in cycle and the stop button is pressed the unit will shut off and automatically go into cool down mode with the yellow light flashing and the digital displaying temperature until the unit reaches 134 6 F 57 C The yellow light and display will turn off and green light will come on indicating unit is safe to open and re start cycle l Automatic shut off when cycle is complete J Unit operates at zero pressure Cover will release at 0 15 Bar 2 PSI K Temperature Probes monitor each other 256 times per second to ensure the other is working within 50 F 10 C of itself M Temperature Probes are linked to an Analog circuit as well as the microprocessor In the event the processor malfunctions the Analog circuit will turn the unit off at 384 8 F 196 C until the unit cools N
17. on 1 groups C D E F G Fully automatic one button operation Patented Anti Pressure System Stainless steel construction Low emissions and odors PART 6A 000 A AUTOMATIC GUNWASHER Stainless steel brass and Teflon construction Unique pump system that has proven to be reliable across thousands of units Easy to use durable foot pedals A Large working area A Ability to use clean or recirculated solvent Adjustable automatic recycle time Internal air hose for quick drying NESHAP N6H compliant Part 6 000 M 1 SPOUT MANUAL GUNWASHER Uses recirculating solvent Stainless steel brass and Teflon construction Unique pump system that has proven to be reliable across thousands of units Easy to use durable foot pedals Large working area compliant Manual Operation Manual with Clean Rinse Part 6 000 M CR 2 SPOUT MANUAL GUNWASHER Ability to use clean or recirculated solvent compliant Page 21 of 23 Part CC2000 CONSTANT CLEAN RECYCLER Clean up to 24 gallons per day Can attach to any parts cleaner Automatic hands free operation Can easily be moved from one parts washer to another Almost no moving parts to fail and low maintenance requirements No bags required Part 9 02 000WFP DRUM PUMP WITH FOOTPEDAL Explosion proof and chemical resistant Inexpensive pneumatic operation Durable long lasting construction Secure drum
18. s Very Important Eye wear boots gloves and masks should be worn at all times CAUTION Unit surfaces will be hot when in use Cover should not be open unless green light is on should be changed between each cycle Page 10 of 23 WATER MODE Operation of unit in water mode is the same as above In order to switch unit into water mode you must follow these steps 1 Disconnect power 2 Reconnect power 3 Press and hold down on the START button for 10 seconds The unit will display LLLL Release button 4 Press START button 10 times The green light will come on You are now in water mode The unit will remain in water mode until power is disconnected OIL MAINTENANCE The unit will automatically indicate when it requires an oil change by flashing the word OIL on its display panel Oil appears after 3000 hours of use Once it appears you will have 50 more hours to use the unit until it locks down until oil maintenance can be done We recommend you schedule an oil change immediately when the oil light comes on ChemChamp recommends an oil change every 3000 hours or every year whichever comes first Please follow the steps below to perform an oil change 1 Disconnect power Remove back panel Remove Oil intake cap Top brass cap with hole Caution Make sure when emptying oil that the unit is completely cold Place collection pan under Oil OUT
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