Mart EQ-1 User manual

This manual is an unpublished, copyrighted work by The MART Corporation.
The information and drawings in this Manual are the property of The MART
Corporation and shall not be reproduced or copied or used in whole or in part in
other media without written permission.
Copyright 1998 by The MART Corporation. All rights reserved.
NOTE: The information contained in this Manual is subject to change at any time
without notice. Some information contained in this Manual may also be
inaccurate due to undocumented changes in the equipment or operating system
after this version of the Manual was completed. The information contained in this
version of the Manual supersedes all previous versions. No liability is assumed
with respect to the information contained herein.
MART EQ-1
130-GALLON
Wastewater Treatment System
Version 2.0
June 2001
The MART Corporation
2450 Adie Road
Maryland Heights, MO 63043-9978 USA
Phone: [phone]-MART
Missouri Direct: [phone]
Fax: [phone]
2

Table of Contents
Important Safety Instructions and Warnings............…………...4-5
1 Overview ....................................………………………………...... 6
Purpose………………………………………………………….….... 6
Materials and Components….………………………..................6-7
Theory of Operation……………………………………………........ 7
Processor Inspection……………………………………………… .. 8
2 Installation……………………………………………………….…... .9
Safety and Precautions……………..……………………………9-10
3 Basic Operation…………………………………………………….. 10
Control Switch…..…………………………………… ……………..11
Operating Instructions…..……………………………………...11-13
4 Advanced Operation………………………………………………. 14
Chemical Management……………………………………………. 14
pH Adjustment (manual or auto).………………..………..….. … 15
Final Polishing System (optional).………………..………..….15- 16
5 Maintenance……………………………………………………….. . 17
Service Schedule……………………………………………..……. 17
6 Troubleshooting………………………………………………….... 18
3

Important Safety Instructions and Warnings
The following important safety instructions and warnings apply to
installing, operating, maintaining, and troubleshooting the MART EQ-1
Processor. They also apply to repairing the MART EQ-1 Processor, or
working with the system in any way.
Read all of the following safety instructions and warnings thoroughly
before you install, operate, perform service, troubleshoot, repair, or work
with the MART EQ-1 Processor in any way!!
SAVE THESE SAFETY INSTRUCTIONS!!!
GENERAL SAFETY INSTRUCTIONS FOR OPERATING THIS
PRODUCT:
1. Read all safety and operating instructions/procedures before
installing, operating, maintaining, troubleshooting, or repairing
the Processor ... or working with the system in any way.
2. KNOW HOW to operate the MART EQ-1 Processor. Be familiar
with all its controls.
3. Stay alert at all times, and watch what you are doing.
4. Do NOT operate the MART EQ-1 Processor if you are tired, if you
have ingested alcohol, or if you have taken any drugs, including
prescription medications.
5. Keep the operating area clear of people.
6. Do NOT overreach or stand on an unstable support when
operating or servicing the MART EQ-1 Processor. Keep a good
footing and balance at all times.
7. Follow the instructions in this Manual for installation, operations,
maintenance, troubleshooting and repair.
CAUTION! The MART EQ-1 Processor is designed to be plugged into
a 3 prong grounded receptacle only. Ampacity of receptacle to be at
least 15 amp.
CAUTION! If the use of an extension cord is required, use only an
approved 3-wire grounding-type cord of adequate amperage.
CAUTION! Do not process waste solution above 125 F (52 C).
4

CAUTION! Wear the appropriate protective clothing and use extreme
caution when handling acids or any other highly charged chemical.
CAUTION! The MART EQ-1 Processor uses a specially formulated
chemical compounds. DO NOT use unapproved substances. Use of
chemical compounds not recommended by MART will void your
warranty, can result in incomplete waste processing, can be
dangerous, and can result in possible personal injury.
WARNING! Verify that the people installing the MART
EQ-1 Processor are qualified and trained for the work.
WARNING! Install the MART EQ-1 Processor to conform to all local
code requirements.
WARNING! The MART EQ-1 Processor is designed to be installed
inside a building, not outside.
WARNING! DO NOT EVER get inside the MART EQ-1 Processor
while in operation. This could result in severe injury or death.
CAUTION!! WHEN HANDLING, LOADING AND UNLOADING SLUDGE
OR LIQUID -- Always wear gauntlet-type thermally protected and
water-repellent protective gloves, protective eyewear, and a full body
apron that is thermally protected and water-repellent.
DANGER! Improper connection of the equipment-grounding
connector can create a risk of electrocution.
CAUTION! The MART EQ-1 Processor must be unplugged before
performing any electrical maintenance procedures.
WARNING! To reduce the risk of electrocution, keep all connections
dry and off the ground. Do not touch plug with wet hands.
5

Chapter 1 Overview
Purpose
This chapter introduces you to the Mart EQ-1 Wastewater Treatment
System. Please read it thoroughly before attempting to install,
operate, maintain or repair the MART EQ-1 Processor system.
Materials and Components
The following figure shows the Mart EQ-1 System. The principal
parts are labeled. Major features of the EQ-1 Processor are
explained in the next section.
The MART EQ-1 Processor is designed to be plugged into a 3-prong
grounded electrical outlet of at least 15 amp capability. Power
requirement is 120 VAC, 15 amp at 60Hz single phase.
Electrical equipment specifications:
Mixing Turbine ¼ hp @1800 rpm.
The Mart EQ-1 Processor has a 130-gallon solution capacity: 65-
gallon mixing/reaction tank and 65 gallon solution Holding Reservoir.
The Processor can be portable and fitted with quick disconnects to
service other aqueous base systems, or can be stationary and hard
piped to a Power Washer or other aqueous washing system. Forklift
pockets are provided for safe transport.
Ground-Fault Circuit Interrupter Protection
The MART EQ-1 Processor is provided with a ground fault circuit
interrupter (GFCI) built into the control box. This device provides
additional protection from the risk of electric shock. Should
replacement become necessary, use only identical replacement parts
that include GFCI protection.
6

Theory of Operation
The MART EQ-1 Wastewater Treatment System is an inventive
technology that chemically separates and clarifies the wash solution
and encapsulates the waste for disposal. The chemical compound
used in the MART encapsulating process is a non-hazardous product
called Magic Dust.
The upper reservoir is the Mixing/Reaction Tank. Wastewater solution
is pumped into Mixing/Reaction Tank where Magic Dust is added and
the batch is mixed. Unlike conventional wastewater treatment
systems that require multiple steps and the addition of several
chemicals, one charge of “Magic Dust” and a few minutes of mixing
completes the MART EQ-1 separating and encapsulating process.
In some cases, a pH adjustment is required before processing a
batch of wastewater (this information is included in the Wastewater
Treatability Report furnished by MART). Magic Dust is added to the
wastewater and the agglomerate is mixed to cause the necessary
complex reactions and microencapsulation: molecules with adsorbed
oil, metallic ions, and charged contaminants are attracted to the
Magic Dust to form a mass. The water is clarified and retains about
75% of its chemical.
After microencapsulation, the flocculated waste is filtered through a
disposable media paper to collect the waste for disposal. Two valves
control the waste flow. The Standpipe Valve controls the flow of the
clarified solution and light floc. The Bottom Valve controls the flow of
heavy floc.
The Filter Paper containing encapsulated waste is rolled up like a
burrito. After several days the burrito displaces solution for easier
handling and disposal.
Clarified solution is collected in the Holding Tank located at the
bottom of the EQ-1 Processor.
7

EQ-1 Inspection
When you receive your new MART EQ-1 Wastewater Treatment
system, inspect for shipping damage. Note any damage on the bill of
lading and report the damage to MART.
• Inspect the entire unit for dents and scrapes.
• Inspect the Mixing Turbine and Sight Tube for damage.
• Inspect the mixing switch, wiring, pipes and valves for breaks
or
cracks.
• Note that the Material Safety Data Sheet for Magic Dust is
included with the shipment.
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Chapter 2 INSTALLATION
Before you begin the installation, read and follow the
recommended safety/precaution instructions.
To move the MART EQ-1 Processor, use a forklift, rollers or pipe, or
other suitable method that works under the base frame. Set
Processor in place and level.
The Processor must be plugged into a properly grounded electrical
outlet of at least 15-amp capacity. If the use of an extension cord is
required, use only a 3-wire extension cord of at least 15-amp cap.
Verify that the people installing and operating the equipment are
qualified and trained for the work.
Grounding Instructions:
This equipment must be grounded. If the Processor should
malfunction or break down, grounding provides a path of least
resistance for electric current to reduce the risk of electric shock.
This machine is equipped with a cord having an equipment-grounding
conductor and a grounding plug. The plug must be plugged into an
appropriate outlet that is properly installed and grounded in
accordance with all local codes and ordinances.
Extension Cords:
Use only a 3-wire extension cord that has a 3-prong grounding-type
plug and a 3-pole cord connector that accepts the plug from the
product. Use only an extension cord that is designed for outdoor use.
These extension cords are identified by a marking “Acceptable for
use with outdoor appliances; store indoors while not in use.” Use only
an extension cord having an electrical rating not less than the rating
of the product.
Do not use a damaged extension cord. Examine the extension cord
before using and replace if damaged. Do not abuse extension cord
and do not yank on any cord to disconnect. Keep cord away from
heat and sharp edges. Always disconnect the extension cord from
the receptacle before disconnecting the product from the extension
cord.
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Chapter 3 BASIC OPERATIONS
The MART EQ-1 PROCESSOR UNIIT HAS THE FOLLOWING CONTROLS:
Control Switch Center position is “OFF”
Left position turns “ON” Mixer
The FOLLOWING VALVES ARE LOCATED ON THE FRONT OF THE EQ-1:
Standpipe Valve Valve handle is located on the left and
controls flow from the top of the
Mixing/Reaction Tank.
Bottom Valve Valve handle is located on the right and
controls flow from the bottom of the
Mixing/Reaction Tank.
Standpipe The Standpipe is connected to the Valve
Pipe by a coupling.
Note: The Standpipe, located on the inside of the
Mixing/Reaction Tank, can be cut to adjust the height of
the Pipe to the depth of the flocculated material. The
adjustment will enable clarified solution to flow more
quickly and speed the processing of wastewater.
OPERATING INSTRUCTIONS
Before reading this section or operating the EQ-1 Processor for the
first time, MART recommends a thorough review of the following:
• Chapter 1, Overview - “Important Safety Instructions”
WARNING! Verify that the people installing the MART EQ-1
Processor are qualified and trained for the work.
WARNING! DO NOT EVER get inside the MART EQ-1
Processor while in operation. This could result in severe
injury or death.
10

GENERAL SAFETY INSTRUCTIONS FOR OPERATING THIS
PRODUCT:
1. Read all safety and operating instructions/procedures
before installing, operating, maintaining, troubleshooting,
or repairing the MART EQ-1 Processor ... or working with
the Processor in any way.
2. KNOW HOW to operate the MART EQ-1 Processor. Be
familiar with all its controls.
3. Stay alert at all times, and watch what you are doing.
4. Do NOT operate the MART EQ-1 Processor if you are tired,
or if you have ingested alcohol, or if you have taken any
drugs, including prescription medications.
5. Keep the operating area clear of people.
6. Do NOT overreach or stand on an unstable support. Keep
a good footing and balance at all times.
7. Follow the instructions in this Manual for installation,
operations, maintenance, troubleshooting and repair.
Qualified individuals operating this equipment must have
the proper training. Operators must wear the proper safety
equipment (i.e. gloves, apron, face shield).
Mixer Operating Instructions
This EQ-1 is equipped with a MART mixer. It is designed to operate
continuously under all normal conditions.
1. Check the rotation of the propeller to be certain of clockwise
rotation as viewed from the motor end. If rotation is incorrect,
change the wiring according to the nameplate. The air motors are
non-reversing.
2. The mixer should be turned off as the tank is drained and the
liquid level approaches the impeller. Do not run mixer without
11

solution tank full. This will prevent excessive splashing and
mixer vibration, and help prevent mechanical damage.
3. Mounting hardware and drive shaft set screws should be
checked for tightness on a weekly basis.
Instructions
1. Place Filter Paper on roller at back of EQ-1 Processor, feed
paper through rear slot and pull over expanded steel Platen so
that paper extends 6 inches in front of Platen.
2. Pump wastewater into the Reaction/Mixing Tank to the Fill Line
Marker on the Sight Tube. (Note: A separate pump must be used
to fill top mixing tank.)
3. Turn on Mixer.
WARNING! Magic Dust is hygroscopic (moisture attracting).
Magic Dust should be kept in a cool and dry area. Wetted
chemical may present slipping hazard. Even a small Magic
Dust spill should be cleaned up immediately.
WARNING! Inhalation of chemical or frequent contact with
bareskin present health and safety hazards. Any individual
working with Magic Dust should wear personal protection
equipment such as chemical resistant gloves, safety goggles,
protective clothing, and a dust mask.
4. Open hinged lid on top of Processor and slowly pour in
recommended dosage of Magic Dust compound. Close lid.
Reaction time will be approximately 5-10 minutes.
WARNING! Magic Dust exposed to moisture may form lumps
that are difficult to dissolve. Check dust prior to addition to
make sure no lumps are present.
5. Turn off Mixer and allow a few minutes for settling of the
separated floc. (The settling time is dependent on the amount of
contaminants in your waste stream.)
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6. After settling/separation, one of three conditions may exist: the
floc is light and buoyant, and floats; the floc is heavy and settles
to the bottom; or the floc is a combination of both (light and
buoyant, heavy and settles to bottom).
NOTE: Never discharge solution or waste unless Filter Paper is in
place and fully covers Platen. Adjust flow of Valves so clarified
solution or floc does NOT spill over edges of Filter Paper.
FLOATING FLOC: Only the Bottom Valve is used to discharge
solution and floc. Open Bottom Valve slowly to regulate clarified
solution flows without splashing. Clarified solution will fill Holding
Tank. Observe flow and shut off Valve when floc begins
discharging. Note that Filter Paper fully covers Platen and open
Bottom Valve again to discharge encapsulated waste. As waste
discharges, slowly pull Filter Paper forward, and roll and fold
waste into burrito. When a sufficiently large burrito has formed,
shut off Valve, cut Filter Paper 6 inches beyond end of burrito to
form flap and remove encapsulated waste. Repeat process until
all wastewater has been processed.
SETTLED FLOC: Open Standpipe Valve slowly to regulate flow of
clarified solution without splashing. This valve will remain open
until most of the clarified solution has been discharged. Close
Standpipe Valve. Note that Filter Paper fully covers Platen, and
open Bottom Valve to discharge encapsulated waste. Follow
balance of procedure in FLOATING FLOC (above) to complete
processing.
FLOATING AND SETTLED FLOC: Follow procedure for
SETTLED FLOC, taking special caution not to open Valves so
that solution and floc splash over Filter Paper.
7. The only service required after processing is a washdown to flush
the walls of the Reaction/Mixing Tank and the Discharge Valves.
The procedure follows:
• Position Filter Paper to fully cover Platen sides, and 6 inches
forward of front edge of Platen.
• Fill top reservoir with water.
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• Open Bottom Valve to discharge solution through filter paper
into the lower reservoir.
• Repeat the above steps until thoroughly clean.
8. Return clarified solution to the washer reservoir by placing a
transfer line from the washer into the EQ-1 Processor lower
reservoir. Shut Pump off when all clarified solution is returned to
washer reservoir.
Chapter 4 ADVANCED OPERATION
CHEMICAL MANAGEMENT
Your MART EQ-1 Wastewater Treatment System uses Magic Dust, a
non-hazardous chemical, to process your wastewater. A site-specific
Magic Dust formulation was developed according to your unique
application and requirements, and your local water conditions. You
have been assigned a formula number and a dosage rate for your
wastewater. Keep this information accessible to reorder Magic Dust
and to report problems or changed operating/processing conditions to
MART.
It is important to note that changes in your cleaning process may
warrant additional testing of your wastewater stream to ensure that
the Magic Dust formula developed for you remains effective.
It is also important to note that, if you maintain your wash solution at
a high pH, it may be necessary after EQ-1 processing to add fresh
cleaning chemical to your solution.
Adjusting pH
CAUTION! Wear the appropriate protective clothing and use
extreme caution when handling acids or any other highly
charged chemical..
In some cases an adjustment in pH will be necessary to maximize the
effectiveness of your Magic Dust compound.
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FINAL POLISHING ION EXCHANGE SYSTEM (FPS)
The Final Polishing System is a basic ion exchange system. The
exchange is cationic (cation = positive charged ion). Polystyrene
beads with sodium ions are the resin media used for this unit.
The ion exchange system should be used only as directed for
wastewater applications. (Note: This will help extend the life of the
resin)
The Equipment:
Acrylic pre-filter chamber (located on front part of the unit):
a) 3 in. diameter
c) 25 in. tall
d) requires (1) 20 in. 15 micron filter cartridge (2 included)
Refillable resin chamber (located in the rear of the unit):
a) CPVC cover includes a dispersion inlet to prevent channeling
through the resin (basically ensure solution contact with resin).
b) CPVC base
c) .5 cu. ft. capacity
d) PVC shell with (3) 250 micron polypropylene strainers– (the
purpose of the strainers are to prevent resin migrating with
solution.)
e) Magnetic coupled pump (made of glass filled polypropylene).
f) ¾” Reinforced vinyl PVC hose (10 ft. for discharge)
g) To be filled with .5 cu. ft. of Resin Tech CG (provided with unit)
Complete unit specifications:
Flow rate=72 GPH for maximum removal efficiency.
Maximum flow rate=480 GPH
Max. PSI =13
1/6 HP motor (115/230V)
15

Operating Instructions:
1. Follow instructions for EQ-1 Basic Operating Instructions.
2. After treats with the MART EQ-1 system. Turn the power switch to
the “ON” position to use the Final Polishing System.
The clarified solution will be suctioned into the pre-filter to remove
oil and grease and other contaminants that may hinder the
effectiveness of the beads. The solution will enter at a rate not to
exceed 72 GPH (1.2 gpm). The rate is controlled by a flow meter
(range is .5 to 4 gpm). Next, the solution is sent through the resin
chamber. Here, the heavy metals are removed by ion exchange
(sodium ion replaces the metal ion in solution).
[The metal ions are captured on the beads. The resin has
approximately a 1 lb per .5 cu. ft. capacity. Since we are dealing
with the metals in ppm, the resin should last about 2-3 months.
There is no way to visually determine if the resin is spent.
However, it can be determined by one of two ways. First, by
placing a conductivity/resistivity meter on the influent and effluent
solution (incoming solution from the EQ-1 lower reservoir will have
a high conductivity due to the remaining metal ions in the solution,
the effluent should have a lower conductivity due to the removal of
these ions. Secondly, by purchasing a kit to determine the level of
ion concentration (in this case Cadmium).]
After exiting the resin chamber, the final effluent is ready for
discharge. The discharge rate will be 1-2 gallons per minute. The
FPS choice was based on the flow rate required. The Ohio Air
National Guard will process and discharge about 80-100 gallons
per week.
Important Note: Prior to discharge into local POTW, The MART
Corporation suggests that solution be sampled to ensure
discharge limits have been met. Treated solution in the interim
should be stored.
16

Chapter 5 MAINTENANCE
Preventative Maintenance
The MART Corporation recommends that you set up a preventative
maintenance schedule for clarifying your wastewater. The more
frequent you treat (weekly is suggested), the shorter the treat time,
and the lower your dosage rate. This is very important. If you allow
your reservoir to become to heavily contaminated, the treatment
process will be hindered or impossible.
The following chart is an example of a PM schedule that may be
useful. It also illustrates what could happen if the schedule is not
followed.
DATE Treatment pH Chemical concentration
( from Titration) Chemical added
11/2/97 EQ-1 11.2 3.5 oz. Per gal. none
11/9/97 EQ-1 10.5 1.7 oz. Per gal. 2 oz. Per gal.
11/16/97 EQ-1 11.0 2.3 oz. Per gal. 1.5 oz. Per gal.
12/30/97 Not
possible 13.2 6.7 oz. Per gal. none
Service Schedule
The only servicing to the MART EQ-1 Processor, as explained in
Step 7 of the Operating Instructions, is a thorough washdown after
each use.
Empty and rinse the processor after each use. Never leave solution
in the Processor for extended periods. Aggressive chemicals can
damage the finish and corrode the tanks.
For maintenance and servicing of the EQ-1 Transfer Pump and
Mixer, refer to the vendor supplied operating manuals or call
1-800-567-MART.
17

Chapter 6 TROUBLESHOOTING
Problem Solution
Mixer will not start. 1. Check electrical connections.
2. Unplug unit from electrical
receptacle and check internal
GFI unit. Press “RESET” button.
3. Check Fuses for continuity.
Transfer pump will not start. 1. Check electrical connections.
Filter paper clogging. 1. Pull forward and roll up used
portion of Filter Paper so fresh
clean paper is on Platen.
Filter paper tears. 1. Too much material on the filter
paper will cause it to tear from the
weight of water and material.
2. Reverse the Platen so that bottom
Side faces upward.
3. Reposition the Filter Paper to
Extend beyond the Platen on all
Sides.
No floc, or Very little floc, or Pin
floc. 1. Verify that the specified Magic Dust compound is being used.
2. Verify that correct amount of
Magic Dust is being used.
3. Add more Magic Dust.
Mixer Pump vibrates while
running. 1. Unplug electrical connection. Process wastewater to empty
Reaction/Mixing Tank.
Remove top cover. Inspect
propeller blades and remove any
dried waste from blades.
2. Inspect motor shaft for
straightness.
For technical assistance please call the MART Technical Services
Department at 1-800-567-MART.
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