Tekleen ABW USERS AUTOMATIC FILTERS, INC. MANUAL

Transcription

1 AUTOMATIC FILTERS, INC S. LA CIENEGA BLVD. LOS ANGELES, CA FAX Tekleen ABW USERS MANUAL

2 ABW USERS MANUAL AUTOMATIC FILTERS, INC. Tekleen 2672 S. LA CIENEGA BLVD. LOS ANGELES, CA FAX

3 Table of Contents SECTION I INTRODUCTION 1.1 Description Theory of Operation Recommended Applications Design Features Filter Specifications Chart Measurement Conversion Table 3 SECTION II INSTALLATION AND HOOK-UP 2.1 Mechanical Hook-Up and Orientation Plumbing Hook-Up GB6 Solenoid Connection 5 SECTION III OPERATION AND ADJUSTMENTS 3.1 Start-up Back-Flush Requirements 7 SECTION IV MAINTENANCE 4.1 Filter Cleaning Dirt Collector Replacement Piston Removal/Replacement Periodic Inspection 9 SECTION V TROUBLESHOOTING GUIDE 5.1 Flushing Valve Does Not Close During Start-Up Excessive Pressure Drop Through Filter Without Flushing Flushing Valve Chatter One Flushing Valve Stays Open (in multiple tank installations) Frequent or Continuous Flushing while Filling Main Pipeline Frequent flushing during normal operation Screen Will Not Clean Properly 13 SECTION VI SPARE PARTS 6.1 Recommended Spare Parts Spare Parts List 14 APPENDICES Appendix I Special Construction and Features 15 Appendix II Alternate Flushing Methods 17 Appendix III System with Discharge to Atmosphere 18 Appendix IV Piston 18 ILLUSTRATIONS Filter's Theory of Operation 19 Parts List for Filters without Piston 20 Parts List for Filters with Piston 21 Cutaway of ABW2-LP 22 Cutaway of ABW4L-6L-8 23 Cutaway of ABW6xL-8L-8L ABW 2LP with GB6 Controller 25 ABW 3-4 with GB6 Controller 26 ABWxxP with GB6 (ABW-2in) 27 ABWxxp with GB6 (ABW-BER) 28 Inline Filter Layout with GB6 Controller and 2 Flushing Valve 29 Inline Filter Layout with GB6 Controller and Globe Flushing Valve 31 Particulate Removal Process 32 Pressure Drop Chart 33

4 SECTION I INTRODUCTION 1.1 Description The ABW series models are automatic, self-cleaning screen type water filters. The filtration system consists of a tank body with a fine screen, either single or multiple flushing valves (depending on model) and a hydraulic or electronic controller. Coarse screens are supplied to select filters. 1.2 Theory of Operation Pressurized water enters the filter inlet and travels through a fine screen where small contaminants (down to 10 microns) are filtered. The clean water then exits the outlet. When the fine screen becomes contaminated, a pressure differential is sensed causing the automatic controller to open the flushing valve. When the flushing valve opens, the pressure in the hydraulic motor chamber is reduced causing the clean water to reverse flow through the filter element pushing contaminants off the screen, through the nozzles, through the hydraulic motor and out the flush valve(s) (See Fig. 7.1 Page 19). The water passing through the angular holes in the hydraulic motor creates torsional rotation of the nozzles, thus vacuuming the entire surface area of the filter element. When the screen is clean, the unit automatically returns to the full filtering mode. The entire cleaning cycle takes approximately seconds. It should be noted that even during the backflush cycle the filtration process continues uninterrupted. 1.3 Recommended Applications Tekleen filters are ideal for filtering out silt, scale, sand, rust, dirt and organic material like algae, zebra mussels, and clams from virtually all types of water sources. 1

5 1.4 Design Features Among the many features of the ABW models is the avoidance of the danger of forcing contaminated water back into the system, which often happens with a sand media filter. These filters will deliver clean water or no water. The most predominant feature is its ability to remove organics such as algae and other suspended particles. All filter internal elements can be removed and disassembled from the filter body without disruption of the plumbing. Tekrinse, the new flushing innovation, saves up to 90% of rinsing water. For special constructions and applications, see Appendix I, page 15. 2

6 1.5 Filter Specifications Chart Model Flange Size inches Screen Area sq. ft. Max Flow gpm Empty Wt. lbs. Length inches ABW2 - LP ABW2S - P ABW3 ABW3S - P ABW3 - LP ABW4 ABW4 - LP ABW4L ABW6 - LP ABW6 - SP ABW6L ABW6 - XLP ABW8 - P ABW8 - SP ABW8 ABW8 - LP ABW10 - P ABW10 ABW12 - P ABW12 ABW14 - P ABW14 ABW16 - LP ABW16L ABW18 - TP ABW20 - TLP ABW24 - TLP ,300 1,800 1,300 1,600 1,800 1,800 2,500 2,500 4,000 4,000 6,000 6,000 8,000 8,000 12, ,000 1,000 1,600 1,800 2, Specifications: Carbon steel body with baked on powder epoxy coating or stainless steel 316L body at the same price. Internal parts: stainless steel dirt collector, stainless steel screen on a PVC sleeve. Maximum 150 psi, 150 F. Standard screen mesh 50µ to 1000µ. Optional stainless steel screen to 10µ, high temperature, and high pressure. 1.6 Measurement Conversion Table Mesh Micron Inch

7 SECTION II INSTALLATION AND HOOK-UP 2.1 Mechanical Hook-Up and Orientation The positioning of the filter tank should be determined by the disposal of waste water and to allow easy access and removal of filter element (Consult manufacturer for required clearances). The location of the flushing valve should provide for maximum unobstructed air discharge from the valve bonnet; this eliminates valve chatter during closing. The tank can rest on the inlet and outlet nipples or can be mounted on a stand if desired. If the hydraulic controller is being used, it is to be mounted on the filter body. STANDARD HOOK-UP AND ORIENTATION When using the electronic controller model, mount the solenoid on the flushing valve and mount electronic controller in close proximity to the solenoid valve. The solenoid should be mounted in a vertical and upright position to reduce the possibility of contamination by foreign material. 2.2 Plumbing Hook-Up The waste discharge pipe should be at least one inch larger in diameter than the size of the discharge valve (1 valve to 2 pipe & 2 valve to 3 pipe). The waste pipe should be kept as short as possible with less than 2 elbows. 4

8 In case of water hammers, vacuum breaker is to be installed on the top side of the discharge line next to the flushing valve. The incoming line should have a minimum 1 inch of air vent vacuum relief valve installed to prevent water hammer. Discharge lines should not be elevated. This will affect the required pressure differential and reduce cleaning. If it is necessary to run discharge lines uphill, please consult with the manufacturer. For applications requiring custom flushing methods such as low flow or pressure or system discharges to atmosphere, refer to Appendices II and III, page 12 and 13. Note: A block valve should be installed immediately upstream of the filter. During start-up, the block valve should only be barely cracked open to prevent a surge of pressure across the filter when the pump is started. Once the pump is on-line, slowly open the block valve. This would prevent any possible damage to the filter due to a pressure surge. 2.3 GB6 Solenoid Connection Before power is applied to the electronic controller, make all connections between controller and solenoid valves (see page 26). 1. SOLENOID CHECK OUT: Plug controller into appropriate power source. Activate manual start switch and proceed as follows: put ear close to solenoid, trip switch and listen for a "click" open and a "click" shut. 2. FLUSHING TIME ADJUSTMENT: The flush time is normally set for 10 seconds. For difficult contaminants it may be increased to 15 seconds or longer. 3. PRESSURE D DIFFERNTIAL ADJUSTMENT: The triggering differential is pre-set for 7 psi. It can be changed to different setpoints (see your electronic rinse controller manual). 5

9 Using 1/4 inch diameter tubing: 1. Attach tubing to Port #1 on solenoid valve port; attach other end to fitting on the bottom of flushing valve bonnet. 2. Attach tubing to Port #3 on solenoid valve port; attach other end to an air or water supply source. 3. Attach tubing to low pressure fitting (1/2" nipple) on filter, attach other and to fitting on rinse controller marked "low pressure. Controller fitting should have pressure snubber installed. 4. Attach tubing to high pressure fitting (1/4" nipple) on filter. Attach other and to fitting on rinse controller marked "high-pressure". Controller fitting should have pressure snubber installed. 5. If filter comes with a piston, attach tubing to end of piston; attach other ad to the flushing valve inlet or hydraulic motor chamber port. Important Notes: Do not run tubing more than three feet in length (preferably two feet or less). Due to the pressure drop across the tubing, the electronic rinse controller may not operate properly if tubing is too long. Electronic controller should be sealed completely to avoid moisture from entering. This would prevent possible shorting of circuits. For more operating details and set-up, please refer to your electronic rinse controller manual. SECTION III OPERATION AND ADJUSTMENTS 3.1 Start-Up During start-up, the block valve at the filter inlet should be cracked open to prevent a surge of pressure across the filter when the pump is started. Once the pump is on-line, slowly open the block valve. This would prevent any possible damage to the filter due to a pressure surge. In addition, during the initial filling of the main pipeline, there may not be enough back-pressure downstream from filter to allow the cleaning cycle to function properly. Therefore, it is necessary to install a valve on the outlet line to be partially closed (i.e., gate valve, ball valve or butterfly valve). 6

10 If a downstream main line valve is partially closed, enough to provide 40 psi on filter pressure gauges, the self-cycle will operate properly. Once the total system is fully charged, the downstream valve can be adjusted as the system requires, as long as 40 psi is maintained at the filter. If systems are to come on automatically, it is advisable to install a flow control or pressure sustaining valve downstream from filters to create back pressure on filters in order to enable proper flushing while pipe lines are being filled. 3.2 Back-Flush Requirements The filter needs a minimum flow and pressure during the backflush process to guarantee a fully effective cleaning. The minimum flow depends on the size of the filter s flush outlet and the pressure during backflushing. The table below gives an indication of the required flows. Flush Outlet Size 1 2 Flush Flow at 35 psi (gpm) Flush Flow at 60 psi (gpm) The minimum differential pressure between the filter inlet and the flush outlet should be at least 40 psi. Pressure (psi) The capacity of the pump has to be sufficient to keep the pressure over 40 psi during backflushing at a flow of process flow + rinse capacity Flow (gpm) CRITICAL POINT FIGURE 3.1 BACKFLUSHING: PRESSURE VS. FLOW For example (see Fig. 3.1): Process flow is 200 gpm and rinse capacity is 90 gpm Pressure < 40 psi yields poor cleaning. Process flow is 130 gpm and rinse capacity is 90 gpm Pressure > 40 psi yields good cleaning. 7

11 SECTION IV MAINTENANCE 4.1 Filter Cleaning Periodic cleaning and inspection of the coarse screen, if supplied, is necessary for removal of large particles trapped in the chamber. It is also recommended that the fine screen be inspected during coarse screen cleaning. In hard water applications, it might also be beneficial to wash the fine screen in a mild acid. Proceed as follows: 1. Turn inlet water off. 2. Relieve any pressure on downstream side of filter. 3. Unbolt screws and remove lid. 4. Remove fine screen using screen puller/pusher (see Fig. 4.1). 5. Re-assemble unit (reverse procedure and see Fig. 4.2). 4.2 Dirt Collector Replacement FIGURE 4.1 REMOVING FINE SCREEN WITH SCREEN If the dirt collector should ever need replacing, follow steps outlined in Section 4.1 (Filter cleaning) and continue as follows, while referring to Fig. 4.3: 1. Unscrew collector pin by turning it clockwise (left-handed thread). 2. Remove dirt collector. 3. Remove hydraulic motor either through the flushing port or service port (if available). 4. Grease all o-rings with waterproof O- ring lubricant. 5. Re-assemble unit (reverse procedure). 6. Turn inlet water on. FIGURE 4.2 INSTALLING FINE SCREEN WITH SCREEN PULLER/PUSHER 8

12 4.3 Piston Removal/Replacement If the piston needs to be removed or replaced, follow steps outlined as follows and refer to Fig. 4.3: 1. Unscrew all connection bolts. 2. Pull piston out. It may be necessary to jerk slightly the piston in an up and down motion as it is being pulled. 3. Re-assemble unit (reverse procedure). FIGURE 4.3 PISTON AND HYDRAULIC MOTOR REMOVAL 9

13 4.4 Periodic Inspection The following parts should be inspected annually for wear and tear and should be replaced if necessary: - Cover Seal - Coarse Screen - Fine Screen - O-rings - Piston - Hydraulic Motor - Dirt Collector - Upper Bearing - Lower Bearing - Air/Water Connections SECTION V TROUBLESHOOTING GUIDE 5.1 Problem: Flushing valve does not close during start-up. POSSIBLE CAUSE System pressure is too low to close. SOLUTION Partially close a mainline valve downstream of the filter to maintain 40 psi on filter gauges. This pressure will ensure valve closure and also supply back pressure necessary to clean the screen. 5.2 Problem: Excessive pressure drop through filter without flushing. POSSIBLE CAUSES 1. Controller is not turned on. 2. Flushing valve is installed backwards. 3. Filter is installed backwards. 4. Electronic controller is hooked up with a common negative instead of a common positive. A common negative causes all solenoids to stay open. 10

14 SOLUTION 1. Turn on power. 2. Install according to directional arrow. 3. Install pressure line to leg marked inlet. 4. See Differential Adjustment, Section 3.2, page See Electronic Control Connection (check for your model on pages 26-29). 5.3 Problem: Flushing valve chatter. POSSIBLE CAUSE Air in the valve bonnet. SOLUTION 1. Point bonnet "skyward" (to vent trapped air). 2. Manually flush filter several times to flush air from the bonnet, the controller tank, and the filter tank. 3. Add a 1/2 or 1 inch air vent/vacuum relief to the flush line. 5.4 Problem: One flushing valve stays open (in multiple tank installations). POSSIBLE CAUSE Hole in flush valve diaphragm. SOLUTION Disassemble solenoid valve and clean. POSSIBLE CAUSE Dirt in solenoid valve. SOLUTION Disassemble solenoid valve and clean. 11

15 5.5 Problem: Frequent/continuous flushing while filling main pipeline. POSSIBLE CAUSE Downstream pressure is not available to provide vacuum cleaning power. Rapid-filling flow rate exceeds the controllers' pressure differential. SOLUTION Partially close downstream mainline valve; filter gauges should read 30 psi. POSSIBLE CAUSE Filter may have been shut down dirty with a contaminant that is difficult to remove after it dries on the screen. SOLUTION A Superflush needs to be performed as follows: a downstream mainline valve should be adjusted, providing that the static pressure against the valve does not exceed 80 psi. After the valve is adjusted, cycle the filter through several "long" flushings. This process uses the entire available differential pressure in the filter cleaning process. 5.6 Problem: Frequent flushing during normal operation. POSSIBLE CAUSE Very dirty water. SOLUTION (for electronic controller only) Increase flushing time (maximum 15 seconds). POSSIBLE CAUSE The controller pressure differential is set too close causing vibration to initiate a flush cycle. SOLUTION Increase pressure. POSSILE CAUSE Screen may be partially plugged. 12

16 SOLUTION Perform super flush as described above. POSSIBLE CAUSE Rotor may be jammed which results in only cleaning the screen area that is directly in front of the nozzles. SOLUTION Open tank and check for free movement of rotor mechanism. POSSIBLE CAUSE Coarse screen is contaminated. SOLUTION While running, check pressure between filter inlet and hydraulic pressure chamber (if available). The difference between these two readings is the pressure drop through the pre-strainer. It should be zero. 5.7 Problem: Screen will not clean properly. POSSIBLE CAUSE The flush cycle might be set too short. Flushing valve may not open fully. SOLUTION Restriction in flushing valve dump line due to long "run" distance (e.g., running uphill, 2" line more than 20' long, 2" line has more than one elbow). POSSIBLE CAUSE Filter was shut down dirty with contaminant drying on the screen. SOLUTION Perform Superflush as described on Section 5.5. If unsuccessful, remove filter screen (see Page 8) and spray the screen with a high pressure hose to remove the contaminant. After reinstalling the filter, perform another super flush. 13

17 SECTION VI SPARE PARTS 6.1 Recommended Spare Parts The following are recommended spare parts to keep in stock: - Fine Screen - Set of O-rings - Cover Gasket - Dirt Collector - Upper Bearing - Lower Bearing 6.2 Spare Parts List See page 20 for filters without a piston and page 21 for filters with a piston. 14

18 APPENDICES Appendix I Special Construction and Features I. AUTOMATIC COARSE SCREEN CLEANING In applications where a lot of large particles are to be expected, TEKLEEN water filters can be delivered with an automatic coarse screen flushing. In this case, the filter is designed with a coarse screen flushing valve. The coarse screen flush valve is programmed to flush at a preset time interval (depending on the dirt load). During backflushing, all large particles are removed from the coarse screen. It should be noted that the coarse screen and the fine screen flushing are locked ant can not occur at the same time. AUTOMATIC COARSE SCREEN CLEANING FILTER II. (AUTOMATIC) BY-PASS Sometimes it is necessary to have flow even when the filter is out of service for periodical maintenance. In this situation, it is recommended to create a by-pass. FILTER WITH BY-PASS with another block valve (see drawing). It is very simple to create a by-pass, especially for the on-line models. To do so, add a block valve on both the inlet and outlet and a bypass If the by-pass valves are provided with actuators, it can be converted to an automatic by-pass system with the addition of a control box. 15

19 III. ASME CODED FILTERS ASME coded filters for the ABW series are available on special order. The lead time on these is approximately 30 to 90 days. IV. FILTERS FOR SEVERE APPLICATIONS The ABW series filters are available in stainless steel construction or other special alloys for severe applications. Filters with corrosion resistant coatings are also available. Consult with manufacturer for availability. 16

20 Appendix II Alternate Flushing Methods There are several possible solutions if there is not enough pressure and/or flow to successfully achieve a backwash. For low flow installations with pressure greater than 35 psi, proceed as follows: 1. The easiest method is to place an automatic valve (pressure sustaining valve) at the filter outlet. The valve would close when the filter is flushing. During the backwash cycle, there would be no water available to the system and the full pump capacity will be used for backflushing the filter. 2. The required extra flow can be obtained by means of an expansion tank installed FLUSHING WITH EXPANSION directly upstream of the filter inlet. The expansion tank would contain water at operating pressure to supply to the filter during the backflushing cycle. When the filter goes into a backflush, the system pressure would drop and would result in an increase of flow rate through the pump. EXTERNAL FLUSHING: NORMAL EXTERNAL FLUSHING: BACKFLUSH 17

21 Appendix III System with Discharge to Atmosphere If the filter freely discharges to the atmosphere, it is recommended that a control valve be installed at the filter discharge. Depending on the process upstream of the filter, the flow may be higher than the filter handling capacity. In this case, the control valve at the outlet would be used to create a back pressure on the system and control the flow across the filter. FILTER WITH DISCHARGE TO ATMOSPHERE In addition, the discharge valve can be used as a pressure sustaining valve in cases where pressure (> 40 psi) is not adequate during backwash. Appendix IV Piston Due to longer screens on larger filters, it is necessary to employ a piston for the cleaning mechanism. The piston is used to move and control the axial velocity of the dirt collector during the rinse cycles. This would enable the dirt collector to clean the entire surface area of the screen in a spiraldownward movement. At the end of the cleaning cycle, the flush valve closes and the normal filtration process continues again. At the same time, the piston is energized with water pressure which pushes the dirt collector up and back in position for the FILTER WITH PISTON next rinse cycle. 18

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29 Process Dirty Water Clean Water N1 INLET N2 OUTLET N3 FLUSH VALVE N REVISIONS ZONE REV DESCRIPTION DATE APPROVED GB6 ELECTRIC CONTROLLER PD DWELL 1 2 ALARM Differential Pressure Gauge OF POWER MANUAL START/ ADVANCE COUNTER RESET ALARM RESET BACKWASH COUNTER TEKLEEN AUTOMATIC FILTERS, INC S. La Cienega Blvd. Los Angeles, CA (310) MODEL: GB6 (Sec) W (Hour) (Sec) OF / / R W R C 1 2 M A P SOLENOID VALVE (ASCO) F.V. BackWash Water WATER SUPPLY FLUSH VALVE UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANC DECIMALS ANGULAR AUTOMATIC FILTERS, INC S. La Cienega Blvd. Los Angeles, CA (310) FAX (310) XX DEG..XXX +.01 DRAWN DATE DMITRIY POLISHCHUK TITLE ABW 2LP-1in FV W/ GB6 Controller CHECKED DESIGN SIZE A DWG NO. A2LP-GB6 REV 0 SHEET OF E D C B A O P E R I O D I C F L U S H D E L L

30 GB6 ELECTRIC CONTROLLER P DWELL 1 2 ALARM MANUAL START/ ADVANCE COUNTER RESET ALARM RESET BACKWASH COUNTER (Hour) U 25 6 POWER OFF ON TEKLEEN (Sec) 90 0 W (Sec) R W R C 1 2 M A PD Power Supply AC 110V/220V INLET FLUSH VALVE REVISIONS ZONE REV DESCRIPTION DATE APPROVED Differencial Pressure Controller HIGH PRESSURE LOW PRESSURE OUTLET UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANC AUTOMATIC FILTERS, INC. DECIMALS ANGULAR TITLE.XX DEG..XXX +.01 DRAWN DAT ABW-xx Filter DMITRIY POLISHCHUK CHECKED w/ GB6 Controller w/ GB6 Controller DESIGN SIZE A DWG NO. SCALE 1:11 ABW3-GB6 1 SHEET OF REV 0 1 E D C B A P E R I O D I C F L S H D E L L OF / /

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32 REVISIONS ZONE REV DESCRIPTION DATE APPROVED GB ELECTRIC PD 1 2 DWELL ALARM HIGH PRESSURE (RED FITTING) LOW PRESSURE (BLUE FITTING) D/P SWITCH PSI OFF ON POWER MANUAL START/ ADVANCE COUNTER RESET ALARM RESET BACKWASH COUNTER TEKLEEN 2672 S. La Cienega Blvd. Los Angeles, CA (310) C (Hour) (Sec) (Sec) OFF 1/ 4 1/ R W C R 1 2 M A PD 1 3-WAY SOLENOI D VALVE (ASCO) FLUSH VALVE 2 WATER INLET OUTLE BY-PASS VALVE UNLESS OTHERWISE SPECIFIED DIMENSIONS ARE IN INCHES TOLERANC DECIMALS ANGULAR.XX DEG..XXX +.01 TITLE 2672 S. LA CIENEGA BLVD. LOS ANGELES, CA (310) FAX (310) DRA DAT DMITRIY POLISHCHUK ABWxxP w/ GB6 3in Flushing Valve CHECKE DESIG SIZE DWG A ABW-3in SCALE 1:14 SHEET OF RE 0 E D C B A P E R I O D I F L U S H D W E L L

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34 PRESSURE DROP DATA 2 16 Filter Flange Size FLOW RATE (gpm) 20 DELTA P (psi) 31