Renco Prelos User manual

Start-Up
Operation & Maintenance
Troubleshooting
RESIDENTIAL
MANUAL
O&M

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.comNIM-EPS-OM-1
Rev. 1 © 03/20
Page 2 of 12
O&M Manual: Orenco®Prelos™Processors
About This Manual ................................................................. Page 2
Standard Product Description ........................................................ Page 2
Tools and Equipment ............................................................... Page 4
Part 1: Start-Up ................................................................... Page 5
Off-Site Preparations .....................................................................Page 5
Physical Inspection ......................................................................Page 5
Start-Up Test ...........................................................................Page 6
Final On-Site Activities ....................................................................Page 6
Part 2: Maintenance................................................................ Page 7
Maintenance Cycle.......................................................................Page 7
Routine Maintenance .....................................................................Page 7
Pumping the Tank .......................................................................Page 8
Final On-Site Maintenance Activities .........................................................Page 8
Part 3: Troubleshooting ............................................................. Page 9
General Troubleshooting...................................................................Page 9
Control Panel Troubleshooting ..............................................................Page 10
About This Manual
Regular servicing of Prelos™Processors optimizes performance, protects public health, and protects the environment. Please read this
manual thoroughly for best-practice information on start-up, O&M, and troubleshooting of the Prelos Processor. This manual does not replace
engineering plans or training. Depending on the model of Prelos Processor, not all components may be covered in this manual. For system
components not described in this manual, contact the project engineer or the component’s manufacturer.
You will find IMPORTANT information, Key Points, and Notes in this manual, marked with easy-to-see visuals:
IMPORTANT — These point out hazards to people and products during and after start-up, O&M, and troubleshooting.
Key Points — These are critical for successful operation of the system.
Notes — These cover useful information and tips that can help make start-up, O&M, and troubleshooting easier. They may
also provide information on variations in components or methods.
Standard Product Description
The Prelos Processor is the on-lot portion of a Prelos Sewer, a liquid-only (effluent) sewer. Pump-discharge models include an access lid,
access riser, watertight tank, Prelos pump vault, passively self-cleaning Biotube®filter, float switch assembly, high-head effluent pump, hanging
discharge assembly, and control panel. Gravity-discharge models do not use a high-head effluent pump or related pump control equipment.
In pump-discharge models, wastewater flows from the building sewer into the Processor’s meander tank, where it separates into a top scum
layer, a bottom sludge layer, and a “clear” layer of liquid effluent between them. On the discharge side of the baffle wall, a pump draws liquid
effluent from the clear layer into the pump vault and through the Biotube filter. The pump then transports the effluent to the liquid-only sewer.

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.com NIM-EPS-OM-1
Rev. 1 © 03/20
Page 3 of 12
O&M Manual: Orenco®Prelos™Processors
Standard Product Description, cont.
Standard Components, Pump-Discharge Models (Control Panel not Shown)
1Inlet
3Support column
2Inlet tee
6Access riser
4Baffle wall (full-length)
5Baffle pass-through
12 Discharge assembly
10 Float switch stem and float switches
11 Pump
8Pump vault
7Access lid
9Biotube®filter
15 Lifting bracket
13 ClickTight™
14 Discharge
From
building
sewer
To sewer line
1
3
2
4 5
6
15
8
9
14
10
11
12
13
15
Top cutaway view
2
Side cutaway view
From
building
sewer
To sewer line
6
5
4
12
10
8
7
9
13
11
14

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.comNIM-EPS-OM-1
Rev. 1 © 03/20
Page 4 of 12
O&M Manual: Orenco®Prelos™Processors
Tools and Equipment
Start-up, O&M, and troubleshooting can require a variety of tools, equipment, and spare parts. Before you begin, Orenco recommends the
following tools and equipment:
Tools
• Cordless drill driver
• Flashlight
• Hand tools (common)
• Hanging discharge assembly removal tool (HDATOOL)
• Hex-head bit, 3⁄16-inch
• Portable water sprayer
• Hose and nozzle
• Scum measuring device (SMUG)
• Sludge measuring device (SLUDGE JUDGE ULTRA)
• Tape measure
• Wire stripping/crimping tool
Test Equipment
• Calculator
• Multimeter with amp clamp
Personal Protection and Cleanup
• Bleach/water solution
• Eye protection
• Hand cleanser/sanitizer
• Paper towels
• Protective clothing
• Rags
• Rubber gloves
Supplies and Spares
• Control panel parts (circuit breakers, motor contactors,
relays)
• Effluent pump liquid ends
• Spare pump cord (ClickTight™-compatible)
• Float switches (ClickTight-compatible)
• Lid bolts
• Structural adhesive and sealant/adhesive
• PVC cement and primer
• PVC fittings, ¾-inch to 2-inch (20-50 mm)
• PVC pipe, ¾-inch to 2-inch (20-50 mm)
• Teflon™tape/paste
Reference Material
• NFO-EPS-1, Prelos Inspection/Start-Up Report
• NIM-EPS-2, Prelos Processor Installation Manual
• NIN-CLK-1, ClickTight and ClickTight Control Panel Installation
Instructions
• NIN-CLK-KIT-1, ClickTight Pump Adapter Installation Instructions
• NIN-HDA-1, HDA-Style Discharge Assemblies Installation
Instructions
• NIN-TNK-7, 1000-gal. Meander Tank Assembly Instructions
Off-Site Preparations
Step 1: Confirm the following items with the contractor. When all are
complete, the system is ready for you to perform the start-up.
• The control panel is connected to the home’s electrical service.
~ Check for a separate circuit breaker in the service panel.
• Power to the service panel and to the control panel is turned on.
• The contractor has tested the control panel and it is functional.
Step 2: Arrange to meet the contractor at the site.
• Ask the contractor to bring the site’s engineering plan.
Step 3: Get a copy of NFO-EPS-1, Prelos Inspection/Start-Up Report.
• Fill out the top of the form with the site information. Fill out
the rest of the form on-site during the start-up procedure.
Physical Inspection
IMPORTANT:
•Wear appropriate PPE while performing start-up or O&M work
on the Prelos™Processor.
•Don’t enter the tank. Entering a tank without proper confined-
space procedures and equipment can cause injury or death.
•Before leaving the area of the access riser at any point in this
inspection, reinstall and re-secure the access lid.
Step 1: Confirm with the contractor that the Processor has been
watertightness tested per NIM-EPS-2, Prelos Processor Installation
Manual.
Step 2: Confirm with the contractor whether or not anti-buoyancy
measures are installed on the Processor.
Part 1: Start-Up

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Rev. 1 © 03/20
Page 5 of 12
O&M Manual: Orenco®Prelos™Processors
Part 1: Start-Up
Physical Inspection, cont.
Step 3: Confirm the service lateral valve is accessible and open.
Step 4: Inspect the access riser and access lid.
• Confirm the final grade slopes away from the riser and lid.
• Confirm the riser is backfilled to within 3 in. (75 mm) of the lid.
• Confirm the riser and lid are level.
• Confirm the riser, grade ring adapter (if used), and lid are
installed correctly.
• Note any discrepancies.
Step 5: Remove the access lid and set the lid bolts aside.
Step 6: Inspect the inlet tee.
• Confirm the inlet tee is firmly attached and plumb.
• Note any discrepancies.
Step 7: Remove the float switch/Biotube filter assembly.
• Confirm the assembly is easily accessible and removable for
maintenance.
• Confirm the float switch setting heights match the settings on
the engineering plans.
• Note any discrepancies.
Step 8: Inspect the pump vault.
• Confirm the vault is properly installed.
• Note any discrepancies.
Step 9: Inspect the pump and hanging discharge assembly (HDA).
IMPORTANT: DON’T raise or lower the pump by the
power cord! This can damage the pump and void the
pump warranty.
• Uncouple and remove the HDA, along with the hose and pump.
• Confirm the pump is properly installed on the HDA.
• Confirm the HDA’s anti-siphon valve functions properly.
• Confirm the HDA’s line check valve functions properly.
• Note any discrepancies.
Step 10: Inspect the ClickTight.
• Confirm the ClickTight is properly installed.
• Confirm the float switch cord plugs and pump cord plug are
installed in the correct locations and fully seated.
• Confirm that excess lengths of the cords are secured with hook-
and-loop fasteners to the ClickTight.
• Note any discrepancies.
Physical Inspection, cont.
Step 11: Reinstall all components removed during the inspection.
• Lower the pump into the vault and recouple the HDA.
• Confirm the HDA is properly installed and fully seated.
• Confirm the pump is not resting on the floor of the vault.
• Reinstall the float switch/Biotube filter assembly and confirm
that it’s fully seated in the vault.
Step 12: Turn off the power supply to the control panel.
IMPORTANT: Do not physically inspect an energized panel.
Step 13: Open the control panel’s door.
Step 14: Inspect the control panel, its components, and its wiring.
• Confirm the panel operator’s guide is located on the inside of
the panel door.
• Confirm the panel is wired according to the diagram clipped
inside the panel door.
• Confirm the float switch wires and pump wires are installed in
the correct terminals.
• Confirm the float switch wires and pump wires are secure in
their terminals by gently tugging on the individual wires.
• Note any discrepancies.
Step 15: Fill out the operator name/number on the “For Service
Call” label inside the panel, if it isn’t already filled out.
Step 16: Close and secure all access to the Prelos Processor if you
are not going to perform the start-up tests immediately after physical
inspection.
Start-Up Test
IMPORTANT:
•Wear appropriate PPE while performing start-up or O&M work
on the Prelos Processor.
•Before leaving the area of the access riser at any point in this
inspection, reinstall and re-secure the access lid.
Key Points:
•The Processor must pass the physical inspection before test-
ing begins.
•All tests involving pumping will require enough water in the
tank to prevent the pump from running dry.

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.comNIM-EPS-OM-1
Rev. 1 © 03/20
Page 6 of 12
O&M Manual: Orenco®Prelos™Processors
Start-Up Test, cont.
Step 5: Measure and record the pump-run amperage on the Prelos
Inspection/Start-Up Report.
Step 5a: Place an ammeter clamp around the wire to the pump’s
circuit breaker.
Step 5b: Toggle the “AUTO/OFF/MAN” switch to “MAN,” while
reading the pump amperage.
• Once the amperage stabilizes, record it on the Prelos Inspec-
tion/Start-Up Report.
• It should be no more than the pump’s maximum service factor
amperage.
Step 6: Toggle the “AUTO/OFF/MAN” switch to “AUTO.”
Final On-Site Activities
Step 1: Be sure the Prelos Inspection/Start-Up Report is completed.
Step 2: Record all notes, remarks, and discrepancies for the site
in the site’s maintenance diary.
Step 3: Make sure all of the wiring diagrams, schematics, and
instructions for the control panel are placed back in the holder on
the panel door.
Step 4: Make sure all of the control panel circuit breakers are “On.”
Step 5: Make sure the “AUTO/OFF/MAN” switch is in the “AUTO”
position.
Step 6: Close and secure the control panel.
Step 7: Close and secure all access to the Prelos Processor.
IMPORTANT:
•Children or adults who enter open wastewater tanks are at
risk for serious injury or death.
•Replace any missing lid bolts with spares.
•If you have no spare lid bolts, fasten the lid with a self-tap-
ping screw and immediately call your engineer for replace-
ment bolts.
•If the lid is unbolted or if the lid or riser are damaged, secure-
ly block access to the tank opening before leaving the site.
Part 1: Start-Up, cont.
Start-Up Test, cont.
Step 1: Open the control panel; turn on the circuit breakers for
panel power, float switches, and pump.
Step 2: Toggle the “AUTO/OFF/MAN” switch to “AUTO.”
Step 3: Check the function of the float switches.
Note: This test is best when performed with an assistant.
Step 3a: Remove the float switch/Biotube filter assembly from the
Processor.
Step 3b: Lift the bottom float switch.
• The pump should activate.
Step 3c: Lower the bottom float switch.
• The pump should deactivate.
Step 3d: Lift the top float switch.
• The pump should activate.
• The audible and visible alarms should activate.
Step 3e: Lower the top float switch.
• The pump should deactivate.
• The audible and visible alarms should deactivate.
Step 3f: Reinstall the float switch/Biotube filter assembly back
into the pump vault.
• Make sure the assembly is properly seated in the pump vault.
Step 3g: Neatly coil the float switch cords and secure them to the
ClickTight with the hook-and-loop fasteners.
Step 4: Measure and record the pump’s static and dynamic
voltage on the Prelos Inspection/Start-Up Report.
Step 4a: Measure the static voltage across the pump terminal
while the pump is not running.
Step 4b: Toggle the control panel’s “AUTO/OFF/MAN” switch to
“MAN.”
Step 4c: Measure the dynamic voltage across the pump terminal
while the pump is running.
Step 4d: Toggle the “AUTO/OFF/MAN” switch to “AUTO.”
Step 4e: Record the pump’s static and dynamic voltages on the
Prelos Inspection/Start-Up Report.
• There should be no more than 3% difference between static
and dynamic voltages (3.6V for 120V systems and 7.2V for
240V systems).

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.com NIM-EPS-OM-1
Rev. 1 © 03/20
Page 7 of 12
O&M Manual: Orenco®Prelos™Processors
Part 2: Maintenance
Maintenance Cycle
Orenco strongly recommends developing a regular, consistent
program of preventative maintenance for Prelos Processors used in
Prelos Sewers or other liquid-only (effluent) sewers.
Typically, a Prelos Processor requires service only once every three
to five years or sometimes longer, depending on conditions. Contact
the design engineer for more information.
Routine Maintenance
Perform the following maintenance activities once during each
regular maintenance cycle.
IMPORTANT:
•Wear appropriate PPE while performing start-up or O&M work
on the Prelos Processor.
•Before leaving the area of the access riser at any point during
routine maintenance, reinstall and re-secure the access lid.
Step 1: Measure the scum and sludge layers in the tank.
Step 1a: Unscrew the access lid bolts; remove the access lid.
Step 1b: Use a scum measurement tool to measure the scum
layer’s thickness on both sides of the baffle wall.
• See the measurement tool’s instructions for proper use.
• Add the measurements from both sides and divide by two for
the average thickness.
Step 1c: Use a sludge measurement tool to measure the
sludge layer’s thickness on both sides of the baffle wall.
• See the measurement tool’s instructions for proper use.
• Add the measurements from both sides and divide by two for
the average thickness.
Step 1d: If the average thickness of the scum layer is ±10 in.
(254 mm), or if the average thickness of the sludge layer is ± 20
in. (508 mm), pump the tank according to this manual’s “Pump-
ing the Tank” section before continuing with the remaining routine
maintenance.
Step 2: Lay out a tarp next to the access opening.
Routine Maintenance, cont.
Step 3: Clean the Biotube filter.
Step 3a: Remove the float switch/Biotube filter assembly from the
pump vault.
Step 3b: Remove the filter’s cover plate and mounting hardware;
set them on the tarp.
Step 3c: Hold the assembly on the inlet side of the access riser.
Step 3d: Use a hose and sprayer to clean off the filter and float
switches.
• Allow debris and cleaning water to flow back into the inlet side
of the tank.
Step 3e: Set the float switch/Biotube filter assembly on the tarp.
Step 4: Inspect and test the float switches.
Step 4a: Confirm the float switches are in good condition and
properly secured to the float stem.
• Confirm there are no nicks in the float switch cords.
• Confirm there is no swelling in the float switch cords.
Step 4b: Test the function of the float switches.
• See Step 3 in the “Start-Up Test” section of this manual.
Step 4c: Perform any necessary repairs or replacements.
Step 4d: Reinstall the filter’s cover plate and mounting hardware.
Step 4e: Reinstall the float switch/Biotube filter assembly into the
pump vault.
Step 5: Inspect the HDA and pump.
Step 5a: Decouple the male side of the HDA (with hose and
pump) from the female side of the HDA, mounted to the riser wall.
Step 5b: Remove the HDA, along with the hose and pump, from
the tank and place them on the tarp.
IMPORTANT: DON’T raise or lower the pump by the
power cord! This can damage the pump and void the
pump warranty.

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.comNIM-EPS-OM-1
Rev. 1 © 03/20
Page 8 of 12
O&M Manual: Orenco®Prelos™Processors
Part 2: Maintenance, cont.
Routine Maintenance, cont.
Step 5c: Clean out the pump screen and inspect the pump.
• If necessary, replace the pump screen.
• Confirm there are no nicks in the pump cord.
• Confirm there is no swelling in the pump cord.
• Confirm the pump is securely attached to the hose.
Step 5d: Confirm the hose is in good condition.
• Confirm the hose has not stretched.
• Confirm the hose is not torn or worn.
Step 5e: Confirm both sections of the HDA are in good condition.
• Confirm the HDA’s line-check valve functions properly.
• Confirm the HDA’s anti-siphon valve functions properly.
Step 5f: Perform any necessary preventative maintenance on the
HDA, pump, and pump cord.
Step 5g: Lower the pump into the vault and recouple the HDA.
• Confirm the HDA is properly installed and fully seated.
• Confirm the pump is not resting on the floor of the vault.
Step 6: Wash the tarp off over the access riser.
Step 7: Close and secure all access to the Prelos Processor if you
are not immediately going to perform a tank pump-out.
Pumping the Tank
If the tank requires pumping, follow the steps below to assure the
best results.
IMPORTANT:
•Wear appropriate PPE while performing start-up or O&M work
on the Prelos Processor.
•Without proper antibuoyancy measures in place, pumping the
tank under conditions of high groundwater can result in the
tank “floating” out of the ground.
•Don’t pump the tank dry with extreme high groundwater
present.
•For emergency situations during extreme high groundwater
events, always consult with the pumper.
Step 1: Open the control panel’s door.
Step 2: Turn off the circuit breakers for panel power, float switch/
Biotube filter assembly, and pump.
Step 3: Lay out a tarp next to the access riser.
Pumping the Tank, cont.
Step 4: Remove the access lid and set the lid bolts aside.
• Don’t lose the lid bolts.
Step 5: Remove the float switch/Biotube filter assembly and lay it
on the tarp.
Step 6: Remove the filter’s cover plate and mounting hardware and
set them aside on the tarp.
Step 7: Hold the assembly on the inlet side of the access riser.
Step 8: Use a hose and sprayer to clean off the filter and float
switches.
• Allow debris and cleaning water to flow back into the inlet side
of the tank.
Step 9: Remove the cleaned filter from the Processor and lay it on
the tarp.
Step 10: Reinstall the filter’s cover plate and mounting hardware.
Step 11: Remove the HDA and pump.
IMPORTANT: DON’T raise or lower the pump by the
power cord! This can damage the pump and void the
pump warranty.
• Inspect the pump and clean the screen, if necessary.
• When finished, place them on the tarp.
Step 12: Remove the pump vault from the Processor.
• Inspect the pump vault and clean it, if necessary.
• When finished, place the vault on the tarp.
Step 13: Pump out both sides of the tank.
Step 14: Reinstall the pump vault into the Processor.
Step 15: Lower the pump into the vault and recouple the HDA.
IMPORTANT: DON’T raise or lower the pump by the
power cord! This can damage the pump and void the
pump warranty.
• Confirm the HDA is properly installed and fully seated.
• Confirm the pump is not resting on the floor of the vault.
Step 16: Reinstall the float switch/Biotube filter assembly into the
pump vault.
• Make sure the filter seats properly in the pump vault.
Step 17: Check that the ClickTight connections are all secure.
Step 18: Close and secure all access to the Prelos Processor.

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.com NIM-EPS-OM-1
Rev. 1 © 03/20
Page 9 of 12
O&M Manual: Orenco®Prelos™Processors
Part 2: Maintenance, cont.
Final On-Site Maintenance Activities
Step 1: Record all notes, remarks, and discrepancies for the site
in the site’s maintenance diary.
Step 2: Make sure all of the wiring diagrams, schematics, and
instructions for the control panel are placed back in the holder on
the panel door.
Step 3: Make sure all of the control panel circuit breakers are “On.”
Step 4: Make sure the “AUTO/OFF/MAN” switch is in the “AUTO”
position.
Step 5: Close and secure the control panel.
Step 6: Make sure that the access lid is installed and secure.
IMPORTANT:
•Children or adults who enter open wastewater tanks are at
risk for serious injury or death.
•Replace any missing lid bolts with spares.
•If you have no spare lid bolts, fasten the lid with a self-tap-
ping screw and immediately call your engineer for replace-
ment bolts.
•If the lid is unbolted or if the lid or riser are damaged, secure-
ly block access to the tank opening before leaving the site.

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.comNIM-EPS-OM-1
Rev. 1 © 03/20
Page 10 of 12
O&M Manual: Orenco®Prelos™Processors
Part 3: Troubleshooting, cont.
General Troubleshooting
This troubleshooting chart is intended to help diagnose and address issues with Prelos Processors.
To use this chart ...
• Look for the symptom or symptoms you are experiencing in the left-hand column.
• Check the row to the right of the symptom for causes. Causes are numbered simplest to most complex, with “1” being the simplest correction.
• Address each cause in order, beginning with “1,” until the causes have been corrected and the symptom is gone.
Symptom Common Causes Main Circuit Breaker Tripped Off MOA Switch OFF Pump Circuit Breaker OFF Poor Electrical Connections Tangled or Inoperative Floats Duty (Lower) Float Failed Improper Wiring/Loose ClickTight™Connections Inoperative Pump Broken Discharge Plumbing Pump Inlet Fouled Improper Float Settings Worn Pump Impellers Service Connection Valve Shut Off Mainline Valve Closed Biotube®Filter Dirty Mainline Pressure Exceeds Pump Capability Infiltration and Inflow (I&I) Check Valve Installed Backwards Inlet Tee Plugged House Plumbing Plugged Pump Air Locked Discharge Valve Closed
Sewage backed up into home 1 5 4 6 7 8 2 3
Alarm light on (High-Level) 1 2 9 5 8 10 4 6 13 11 12 14 15 7 3
Alarm sounds intermittently 2314 56
Pump does not run 31245 76
Pump runs, does not pump 2 3 5 6 7 8 4 1
Short pump cycles 2 3 1
Excessive pump counts 2 4 3 1
Control panel breaker trips 1 3 2

Orenco Systems®• 800-348-9843 • [phone] • www.orenco.com NIM-EPS-OM-1
Rev. 1 © 03/20
Page 11 of 12
O&M Manual: Orenco®Prelos™Processors
Part 3: Troubleshooting, cont.
Control Panel Troubleshooting
This troubleshooting chart is intended to help diagnose and address issues with Prelos control panels.
Symptom Common Causes
Pump does not operate with control panel
toggle switch in “MAN” or “AUTO” position
• Pump circuit breaker off/fuse blown
• Inadequate power supply to control panel
• Incorrect float switch wiring
• Incorrect pump wiring
• Faulty ClickTight™connectors
• Failed connection in the pump wiring circuit
• Failed motor contactor
Pump operates with control panel toggle
switch in “MAN” position; does not operate
with switch in “AUTO” position
• Incorrect float switch wiring
• Incorrect float switch model
• Failed float switch
• Faulty ClickTight connectors
Audible alarm activated • Control panel toggle switch in “Off” position
• Pump circuit breaker in “Off” position
• Closed service connection valve
• Failed pump
• Clogged pump
• Incorrect float switch settings
• Incorrect float switch wiring
• Incorrect model of float switch
• Failed float switch
• Power outage
Circuit breaker trips repeatedly or fuse
blows repeatedly
• Inadequate power supply to circuit breaker
• Loose wiring connections
• Corroded wires or wiring connections
• Bound pump
• Incorrect pump wiring
• Incorrect float switch wiring
Motor contactor “chatters” • Corroded contacts
• Inadequate voltage to motor contactor
• Failed float switch
• Incorrect float switch model

RESIDENTIAL
800-348-9843 • 541-459-4449
www.orenco.com
MANUAL
O&M
NIM-EPS-OM-1
Rev. 1 © 03/20
Start-Up
Operation & Maintenance
Troubleshooting