INSTALLATION OPERATIONS AND MAINTENANCE DISC FILTER I&O MANUAL 1365 N. Clovis Avenue Fresno, California 93727 (559) 255-1601 www.lakos.com LS-1030A (Rev. 12/17)
INSTALLATIONS, OPERATIONS AND MAINTENANCE MANUAL LAKOS DISC FILTER AUTOMATIC SYSTEMS Original Manual. Revision 0. September 2017 THIS MANUAL CONTAINS IMPORTANT INSTRUCTIONS AND WARNINGS. PLEASE READ THIS MANUAL CAREFULLY BEFORE ASSEMBLY AND STARTING UP YOUR EQUIPMENT. IN ADDITION, YOU MUST OBSERVE WARNINGS RELATED WITH THE COMPONENTS OF THESE EQUIPMENT. LAKOS IS NOT LIABLE FOR THE BREACH OF WARNINGS AND RECOMMENDATIONS FROM USER. THIS MANUAL IS TO BE LEFT WITH THE END USER. 1365 North Clovis Avenue Fresno, California 93727 USA Telephone: (559) 255-1601 info@lakos.com www.lakos.com
Contents 1 INTRODUCTION... 5 2 SAFETY... 6 3 LIMITED WARRANTY... 7 4 RECOMMENDED ACCESORIES... 7 5 TRANSPORTATION AND STORAGE... 8 6 LAKOS DISC FILTER DESCRIPTION... 9 6.1 THE LAKOS DISC FILTER... 9 6.2 FILTER CONNECTIONS... 12 6.3 FILTER COMPONENTS... 13 6.4 CARTRIDGE COMPONENTS... 14 6.5 BACKWASHING SYSTEM... 15 6.6 DISC GEOMETRY WITH INCREASED FILTER AREA... 17 6.7 TYPES OF FILTERS... 20 6.7.1 AUTOMATIC STANDARD FILTER... 20 6.7.2 FILTER FOR LOW PRESSURE BACKWASH CLEANING... 20 6.7.3 SALT WATER FILTER... 20 6.8 FILTER COMPONENTS MATERIALS OF CONSTRUCTION... 21 6.9 SYSTEM MATERIALS OF CONSTRUCTION... 21 6.10 INSTALLATION CONFIGURATIONS... 22 7 FILTER CONFIGURATIONS... 23 7.1 FUNCTIONING OF THE FILTER SYSTEM... 23 7.2 L CONFIGURATION... 25 7.3 V CONFIGURATION... 26 7.4 H CONFIGURATION... 27 8 SPECIFICATIONS... 36 9 INSTALLATION... 38 9.1 PRE-INSTALLATION CHECKLIST... 38 9.2 RECOMMENDATIONS... 38 9.3 INSTALLATION PROCESS... 39 10 AUTOMATIC CONTROLLER CONFIGURATION... 40 11 PERIODIC/MID-SEASON MAINTENANCE... 41 12 SEASONAL SHUTDOWN PROCEDURES... 41 13 COMMISSIONING... 42 14 UPKEEP AND MAINTENANCE... 43 15 TROUBLESHOOTING... 44 15.1 PROHIBITED USE... 44
15.2 CLIMATE CONDITIONS... 45 15.3 WARNINGS RELATED TO ENVIRONMENT... 46
1 INTRODUCTION Lakos systems are the industry standard for operating performance and efficiency. Please read this manual carefully to ensure the best performance possible for your system. This manual contains information regarding assembly, start-up, seasonal shutdown and maintenance, and troubleshooting. Keep this document for future use and reference. Should you have any questions or concerns, contact your Lakos representative for further assistance. The Lakos Disc Filter Automatic provides effective filtration for industrial water filtration, cooling tower filtration and agricultural irrigation in various micron ratings from 5 to 500 microns. The Lakos Automatic Filtration Ring Systems are specially designed to guarantee selective filtration (up to 5 microns in plastic material). The system is 100% automatic cleaning regardless of the flow to be treated, with unprecedented energy and water saving thanks to its functionality, modularity and proven efficiency and effectiveness in use in the agriculture sector, gardening, landscaping, golf & resorts, industrial processes (food, paper, etc.), cooling towers, spraying, sprinkling, osmosis pretreatment, wastewater purification, potable water, desalination processes, etc. The ruggedness of the equipment, simplicity and modularity allow for the filtration of many different application types. The rugged construction and simplicity of design ensures a long service life. The automatic self-cleaning filters have an effective filtration area of 5,050 cm2 (5.44 ft2) which is many times larger than its direct competitors. Thanks to its special multi-inlet design there is space savings with configurations adapted to all kinds of work environments and even limited space applications. Lakos reserves the right to make changes in order to improve its products without prior notice, incorporating amendments or updates to this manual in the text
2 SAFETY CAUTION: Water sources vary and may contain impurities that can adversely affect a filter system. Minerals, biological microbes and other impurities must be identified and addressed by each user on a case-by-case basis. Adhere to seasonal shutdown recommendations to minimize problems. Contact your irrigation system dealer for additional information and further recommendations. CAUTION: It is common to inject chemicals and/or liquid fertilizers into a drip/micro irrigation system. Please check the compatibility of the specific chemicals with the materials of construction of the Lakos Disc Filter system. To obtain the full performance from the disc filter systems, it is required to observe and follow all recommendations given in this manual properly, which will ensure safe operation and long trouble free equipment life. The filter equipment must be installed on a flat surface and protected from direct sunlight and rain exposure. The equipment racks must be safeguarded against frost and protected from extreme high temperature exposure. Neither the equipment nor the manifolds may be used as support. Customer supplied piping and equipment must be independently supported. Do not install near vapors, acids or petroleum products to avoid degradation or explosion risks. The standards and requirements of the regulations of hydraulic installations and low voltage electrical installation must be complied with, as well as any other local or federal requirements. The filtering equipment is designed and manufactured with high quality in order to provide complete automation of the filtering process. Any other use except intended rather than that indicated completely frees Lakos of risks that may occur and from any liability for damage to persons and property. Warning Prior to installation, read these instructions. Installation and operation must comply with local regulations and accepted codes of good practice. If these instructions are not observed, it may lead to personal injury. Only qualified personnel should attempt installation, operation and maintenance of this equipment. Important: This manual contains important and useful information for the proper operation and maintenance of Lakos Disc Filters. It also contains important instructions to prevent potential accidents and damage, and to ensure safe and fault-free operation.
3 LIMITED WARRANTY Lakos products are factory tested to meet the highest quality standards in the filtration industry. Please refer to www.lakos.com/warranty for information about the warranty on this and all other Lakos products. 4 RECOMMENDED ACCESORIES The following items are not been included with your Lakos Disc Filter System. Consider your need, and use your judgement when adding to your system. 1. High Pressure Shut-Off Switch - Installed on inlet, pre-set at maximum operating pressure of the filter system. 2. Air Vents - A continuous air relief valve is recommended on the inlet and backwash manifolds at the highest points to bleed trapped air from the system. 3. Pressure Relief Vents - Quick acting relief valves are required in high-pressure applications. These will protect the filter system from excess spikes in pressure or water hammer. 4. Backwash Sight-Glass/View-Tube - Provides visual verification that a backwash is in progress. 5. Pressure Sustaining Valve - Helps ensure adequate backflow during backwash. Restricts downstream flow to direct necessary flow/pressure for backwashing. 6. Flow Meter - Used to monitor flow rate of the system.
5 TRANSPORTATION AND STORAGE During transportation and storage the safety recommendations indicated in paragraph 2. SAFETY should be observed. The transportation must be in accordance with the requirements of current legislation on transit. See the relevant regulatory bodies and check the requirements before shipment. Once the equipment has been delivered, it must be carefully checked that the packaging has not been damaged during transportation and has not been tampered with and that all parts are contained within. If you find any damaged or missing parts, you must immediately notify the Lakos service center and the carrier presenting photographic documentation of the damage. Place the packaged equipment as close as possible to the place of installation and when unpacking verify the supply matches the specifications of the order. All equipment stored shall be properly protected from damage, and kept free of powder, oil, grease, and other foreign material. The packages containing the equipment shall not be placed on its side or top, or be lifted with hooks or slings. The handling should be carried out by forklifts lifting from the bottom of the base frame. Never use hooks or lifting slings. Safety marks shown on the packing crates must be respected, as well as handling warnings. Lakos is not to be held responsible for any breach of the guidelines established nor for any violation of the handling instructions. For your safety and the safety of the equipment, please handle based on the information contained in this section and the information below. Use no hooks Do not roll
6 LAKOS DISC FILTER DESCRIPTION The proper filtering configuration of any installation ensures the removal of particulate contaminants in the system. This will help ensure the proper operation of downstream equipment and components. When the filtration equipment is installed properly, it ensures a long system service life. The type of network or element to be protected will determine the filter element and the type of filtration to be used. The conditions of the flow, space requirements, pressure, permissible energy consumption or other factors will influence the selection of equipment to be used. Lakos has a wide range of equipment and solutions to address any markets need. Lakos technical department considers each case and proposes the most appropriate solution to customer needs. The Lakos Disc Filter provides unprecedented space-savings thanks to the modularity and functionality of equipment allowing for use in a wide range of areas and sectors: agriculture, gardening, landscaping, cooling towers, industrial installations, micro spray systems, water treatment, osmosis pretreatments, food processing, etc. This IOM Manual provides general layout schemes for installation. The sketches below are shown as a reference guide. Refer to specific project files for exact details. 6.1 THE LAKOS DISC FILTER The Lakos disc filter has a wide working range and operating conditions with discs from the 5 to 500 micron range, allowing the possibility to work in various applications in the world of filtration. It has an automatic cleaning functionality thanks to a backwash system. Below is a rendering of the exterior of a complete filter.
6.2 FILTER CONNECTIONS The Lakos Disc filter is composed of two chambers, one for the unfiltered water (whose connections are shown as brown below) and the other is for the filtered water (whose connections are shown as blue below). The filter equipment has two main entrances to the unfiltered water chamber. These two connections are grooved connections of 2" and 3", which are used for the inlet of raw water. The 2 port is used to connect filters in larger applications or as an inlet for small flow applications. The filtered water effluent is in the base of the housing and has a 3 connection grooved in the base. 2 3 3
6.3 FILTER COMPONENTS The Lakos disc filter consists of the following main parts, shown down below. Item 1 is the base of the housing named the 3 x2 housing. It is the part that supports the entire filter and where the inlet and outlet is located. Item 2 is the housing cover that serves as cartridge support and is the filter closure. Item 3 is the disc set assembly, which contains the filter elements/discs and the backwash system. Item 4 is the O-ring between the body and the filter closure. Item 5 is the clamp, whose function is to tighten the cap against the body for securing all elements and seal the filter through item 4 1 3 4 2 5
6.4 CARTRIDGE COMPONENTS The filter cartridge is composed of several parts as shown in the following exploded view in the figure below. The scanner is the moving part and allows the disc cleaning to be hydraulically activated as will be seen later. The lower end of the tubes (item 1) are pressed into the lower presser base (item 2), to the scanner cleaning tubes(item 5). The lower presser base maintains the separation with the selector base (item 4), through a spring (item 3). The selector base(item 4) is adjusted and closes with the support of the cartridge (item 7) that separates both chambers, the filtered water one from the pre-filtered, thanks to the adjustment made in its housing at the base of the body and sealing it with an O-ring (item 6). Finally, the cartridge disc set (item 8) is composed of between 200 and 218 discs. At the top of the scanner is the upper pressure base (item 9), which is fixed with tube terminals (item 10), and the threaded portion is fixed to the upper pressure base by Nylon nuts (item 11). 7 8 9 11 1 2 3 5 10 4 6
6.5 BACKWASHING SYSTEM This improvement consists of an improved self-cleaning filter for agricultural irrigation waters. It describes the mechanism that makes the backwash of the filter more effective thanks to the central mobile scanner and the selector base. Next, we go on to explain this clever cleaning process. The three main positions of the filter are shown in the following images. Below the cleaning process is explained, which includes the three main positions of the filter and are shown in the figure below. Filter at Standby Filtering Position Backwashing position
In the standby position the spring force raises the selector base to its rest position by holding the filter upright and pressing the ring cartridge. In the filtering position, the water enters through the 2" or 3" inlets into the unfiltered water chamber (outside of the disc set), passes through the discs to the outlet of the filter through the 3" outlet. The filter is designed so that the force applied, puts the discs in compression. This ensures that the higher the pressure input the more compressed the discs are and therefore they do not open in high pressure as in some of the competitor s designs. During backwashing, the flow inside the filter reverses by switching the direction of flow in the three-way valve, the selector base closes the outlet of the cartridge. This causes the flow to pass through the cleaning tubes, which sprays water onto the discs through the jet holes and causes the disc set to open and spray them clean. This is possible because of the differential pressure between the outlet manifold and the drain manifolds is 36psid for the standard backwash housing or 15psid for the low-pressure backwash housing. The dominant pressures in this phase are the pressure on the lower support and inside the upper pressure base, which creates the effect that the scanner is opened, releasing the discs. This takes place inside the filter housing that turns one ring over another and leaves the rings completely free of dirt in a short time while using very little water due to the sweeping movement of the backwash and the centrifugal force allowing it to proceed in its filtering position.
6.6 DISC GEOMETRY WITH INCREASED FILTER AREA The filter element has two faces fully differentiated: the underside of the disc consisting in a zigzag pattern and the top face formed by concentric grooves. The figure below shows the detail of the underside of the disc zigzag, which causes the incoming water to be divided into the micro-channels that are created (orange area in the following figure) producing pre-filtrate of 500-micron range at the entrance of the disc. The particles that get into the micro-channels reach the filtration zone, formed by the pores that are created with the superposition of the walls of the micro-channels on the other part of the ring (green zone). The dirt stays in the input of these calibrated pores. Finally, the water is collected in the outlet micro-channels that will flow into the central area of the filter (blue zone in the figure). During the cleaning process, the water flows in the reverse direction and the water pressure from the cleaning tubes causes the discs to rotate and dirt to be removed efficiently.
During the cleaning/backwash process, the water exits the scanner cleaning tubes through holes of a precise diameter forming a pressurized jet to proceed with filter cleaning. With the stacking of the filter discs as shows in the following image, an outer pre-filter of 500- micron range is created. The entrance to the channel is placed with an oblique angle with respect to the perpendicular radial direction of the disc s concentric grooves.
In the following image, it is possible to observe the junction of the walls of the micro-channels and the adverse part of the next filter element where the filter mesh is produced. Thanks to the shape of the ring, a filter surface is obtained that is superior to the competition, reducing the filtration rate and thus improving filtration.
6.7 TYPES OF FILTERS 6.7.1 AUTOMATIC STANDARD FILTER The Automatic Standard Filter is identified by the blue filter sticker. This filter is able to work with high pressures of 145psi and needs a minimum differential pressure for the backwash of 44 psi (3 bar). The differential pressure is the pressure difference between the outlet manifold and the drain manifold. The effective filter surface is 5.44 sq ft (5,050 cm 2 ). 6.7.2 FILTER FOR LOW PRESSURE BACKWASH CLEANING This filter is identified by the green sticker. It is designed to work at a lower pressure with minimum energy consumption. The minimum pressure for effective cleaning of the filter is 22 psi (1.5 bar) and the filtration surface is 5.44 sq ft (5,050 cm 2 ). The overall system pressure capability is the same as the standard housing. The difference is that the low-pressure backwash filter can backwash at a lower pressure. 6.7.3 SALT WATER FILTER The salt-water filter is an automatic filter where all materials used in contact with salt water are prepared for a longer duration operating life with TDS (total dissolved solids) up to 50,000 ppm.
6.8 FILTER COMPONENTS MATERIALS OF CONSTRUCTION The automatic filter uses the following materials for the different parts. FILTER MATERIALS OF CONSTRUCTION Upper Cover Reinforced Fiberglass Polyamide Lower Body Reinforced Fiberglass Polyamide Selector Base Reinforced Fiberglass Polyamide Crimping Discs Base Reinforced Fiberglass Polyamide Cartridge Support Reinforced Polyamide Clamp Closure AISI 304 Stainless Steel Closing Joint O-ring EPDM Cleaning Tubes AISI 304 Stainless Steel Lower Tubes Support Reinforced Fiberglass Polyamide Upper Tubes Support Reinforced Fiberglass Polyamide Cartridge Support Joint O-ring EPDM Spring AISI 304 Stainless Steel Clamping Nut Nylon Discs High Density Polyethylene The salt-water filter uses the same materials for all parts except for the following two items: Cleaning Tubes Spring Duplex Stainless Steel 316 Stainless Steel 6.9 SYSTEM MATERIALS OF CONSTRUCTION The automatic filter system uses the following materials for the different parts. SYSTEM MATERIALS OF CONSTRUCTION Manifolds HDPE with grooved connections 3 Way Valve Polyamide 6 30GF Black body, 303 stainless shaft and spring, NBR Seals. (duplex steel wetted parts for salt water applications) Base Frame Controller Pressure Hose Solenoid Valve EPCS Alex-Tronix or equal LDPE 316SS Body
6.10 INSTALLATION CONFIGURATIONS The equipment works automatically with three way valves to automatically backwash based off differential pressure and/or a timer. The inlet water (high pressure) is what activates the hydraulic three way valves. The customer can connect a clean water source with a minimum of 10 to 20psi to operate the three way valves instead of using the inlet water if desired. The disc filter includes the filter housings, inlet manifold, outlet manifold, drain manifold, backwash controller, three way valves, solenoid valve operators, base support frames and fittings. The system will ship assembled. The differential pressure is measured between the input and output manifolds which, via a differential pressure switch, sends the signal to the programmer when it exceeds a specified value. Once the value is exceeded, the programmer sends the signal to clean the equipment, where the hydraulic valves come into operation, reversing the flow inside the filter. The following figure shows the configuration of the system assembly using a three-way backwashing valve. The valve actuation is pressurized with the intake manifold pressure through a solenoid NC (normally closed). Note that in the V and H configurations two filters are connected in parallel using the 2 grooved connection ports.
7 FILTER CONFIGURATIONS 7.1 FUNCTIONING OF THE FILTER SYSTEM The previous section identified the various elements of the filtration equipment. Below is an explanation of the operation of the filtering configurations. During the filtration phase, the flow enters from the inlet manifold and enters the filter on the outside of the disc set. Filtration is outside to inside flow of the disc set and the filtered water exits through the bottom of the filter to the outlet manifold. This is shown in the figure below.
During backwash cleaning, the three-way valve reverses the water direction, which then enters from the bottom of the filter (outlet manifold) thanks to the clean water processed by the rest of filters. This is because the pressure difference between the drain manifold and the outlet manifold is large enough to push the filter mechanism upwards and compress the spring allowing the discs to open up and cleaning to commence. The filtered water cleans the disc set then flows to the drain manifold. It is critical that the drain manifold be at atmospheric pressure and be piped downwards. If this is not the case any pressure or head in the drain manifold must be added to the inlet pressure of the system to ensure there is sufficient differential pressure to be able to backwash the disc sets. Downstream pressure is required to be 36psid for the standard housing or 15psid for the low pressure backwash housing.
7.2 L CONFIGURATION The L configuration has a single filter connected to a three-way valve. The filter is in the vertical orientation. The image below shows the components of the L Configuration. This configuration is for small to medium flows and minimizes the backwash flow because one filter is backwashing at a time. LAKOS FILTER 3-WAY VALVE BODY CLAMP DRAINAGE MANIFOLD VITAULIC COUPLIG OUTLET MANIFOLD INLET MANIFOLD SUPPOR T
7.3 V CONFIGURATION The V configuration uses multiple sets of filters that are coupled in pairs and connected by the 2" diameter port. These two filters are connected to a three-way valve and this causes the backwash stream to be double the amount of the L configuration. The advantage of the V configuration is it can handle larger flow rates and takes up less space than a corresponding L Configuration system because it has more filter area per given volume compared to the L Configuration. The V configuration is suitable for medium to large flows. LAKOS FILTER BODY CLAMP BACKWASHING VALVE DRAINAGE MANIFOLD VICTAULIC COUPLING OUTLET MANIFOLD INLET MANIFOLD SUPPORT
7.4 H CONFIGURATION The H Configuration is the most compact design and allows for the largest flows. It is similar to the V Configuration in that two filters are also paired together by the 2" port, but the filters orientation is horizontal. With this arrangement, a greater density of filters per volume is achieved. LAKOS FILTER BODY CLAMP VITAULIC COUPLING OUTLET MANIFOLD LAKOS FILTER BACKWASHING VALVE SUPPORT INLET MANIFOLD DRAINAGE MANIFOLD
8 SPECIFICATIONS The chart below shows the specifications of the 27 Lakos Disc Filter Configurations. MODEL Configuration # of Filters Filter Area Valve Diamater Manifold Diameter Length Widgth Height Weight ft 2 cm 2 in in mm in mm in mm in mm lb kg L2F-2V4M L 2 10.9 10100 2 4 110 26 660 28 699 42 1073 126 57 L3F-2V4M L 3 16.3 15150 2 4 110 37 940 28 699 42 1073 172 78 L4F-2V4M L 4 21.7 20200 2 4 110 48 1219 28 699 42 1073 218 99 L5F-2V4M L 5 27.2 25250 2 4 110 59 1499 28 699 42 1073 265 120 L6F-2V4M L 6 32.6 30300 2 4 110 70 1778 28 699 42 1073 309 140 L2F-3V4M L 2 10.9 10100 3 4 110 26 660 31 781 42 1073 139 63 L3F-3V4M L 3 16.3 15150 3 4 110 37 940 31 781 42 1073 185 84 L3F-3V6M L 3 16.3 15150 3 6 160 39 978 31 781 45 1143 220 100 L4F-3V6M L 4 21.7 20200 3 6 160 50 1257 31 781 45 1143 265 120 L5F-3V6M L 5 27.2 25250 3 6 160 61 1537 31 781 45 1143 331 150 L6F-3V6M L 6 32.6 30300 3 6 160 72 1816 31 781 45 1143 419 190 L6F-3V8M L 6 32.6 30300 3 8 200 72 1816 31 781 47 1194 441 200 L7F-3V8M L 7 38.1 35350 3 8 200 85 2159 31 781 47 1194 507 230 L8F-3V8M L 8 43.5 40400 3 8 200 94 2375 31 781 47 1194 573 260 L9F-3V10M L 9 48.9 45450 3 10 250 107 2718 31 781 49 1245 672 305 L10F-3V10M L 10 54.4 50500 3 10 250 118 2997 31 781 49 1245 754 342 V8F-3V6M V 8 43.5 40400 3 6 160 49 1245 42 1067 50 1257 441 200 V8F-3V8M V 8 43.5 40400 3 8 200 49 1245 42 1067 50 1257 518 235 V10F-3V8M V 10 54.4 50500 3 8 200 60 1530 42 1067 50 1257 569 258 V12F-3V8M V 12 65.2 60600 3 8 200 72 1816 42 1067 50 1257 639 290 V14F-3V10M V 14 76.1 70700 3 10 250 85 2159 42 1067 51 1302 864 392 V16F-3V10M V 16 87.0 80800 3 10 250 93 2362 42 1067 51 1302 1007 457 H16F-3V10M H 16 87.0 80800 3 10 250 60 1530 66 1676 46 1156 807 366 H20F-3V12M H 20 108.7 101000 3 12 315 70 1784 66 1676 46 1156 1047 475 H24F-3V12M H 24 130.5 121200 3 12 315 81 2057 66 1676 46 1156 1215 551 H28F-3V14M H 28 152.2 141400 3 14 355 92 2330 66 1676 46 1156 1567 711 H32F-3V14M H 32 174.0 161600 3 14 355 103 2610 66 1676 46 1156 1790 812 The following chart shows the lower and upper limits of the characteristics of the water that is suitable to be filtered. Parameter Units Lower Limit Upper Limit Fluid Temperature F 41 95 Ambient Temperature F 41 122 Fluid Pressure psi 22 145 TSS ppm or mg/l 0 40 TDS (STANDARD HOUSING) ppm or mg/l 0 10000 TDS (SALT WATER HOUSING) ppm or mg/l 10000 50000 ph ph 4 11 Viscosity cp 0.1 1.6
The below shows the naming convention for the Lakos Disc Filter Skids: Example: L5F-2V4M-DS400um-orange Color of the discs 400 microns Disc Housing DS = Standard DC = Salt Water DL = Low Backwash Pressure DCL = Salt water, Low Backwash Pressure 2 Valve, 4 Manifolds L Configuration, 5 Filters
9 INSTALLATION For proper installation and use of equipment, please read these instructions and systematically follow all the points listed below. If in doubt, consult Lakos Technical Department before performing any operation. A level concrete pad is recommended for placement of the Lakos Disc Filter Systems. Position the pad and the filter system for the most efficient placement of piping from the pump to the irrigation system and the backwash line. Minimize the number of elbows and changes in elevation to and from the filter system. All electrical work and components should meet all applicable codes. Protect all wires and electrical components from moisture. 9.1 PRE-INSTALLATION CHECKLIST Inventory that all parts are included with the system. See Chapter 4 for Recommended Accessories. Check inside each filter tank to be sure no foreign objects or debris are present in the tanks. Verify that the underdrain is in place securely with no damage. Be sure the lower-dome clean-out port is securely tightened. Check all grooved-end connections for any damage that could hinder proper assembly. 9.2 RECOMMENDATIONS During installation, processes must satisfy the safety recommendations included in section 2. SAFETY, of this manual. Materials that show signs of pitting due to corrosion, deformations, impacts, encrustations or discontinuities, must be rejected. Before being installed, the components must be free of any dirt. Sharp kinks or bends will be cause for the rejection of any part or component. Straightening or dimensional correction of the parts and components are not allowed. Lakos supplies the disc filters in fully assembled racks. The racks include: The disc filters Supporting structure Manifolds Controller Accessories The racks are designed to be installed on a concrete base. The disc filter boundary limits for Lakos are the connections of the inlet, outlet and drain/backwash pipes of service. The installation shall not be near vapors, nor acids or petroleum products to avoid degradation or explosion risks.
The inlet and outlet connections shall be made properly and all piping connected to them are required to be self-supporting. Piping cannot be supported by the manifolds and cannot transmit bending moments or loads to the system manifolds. Filtration will be done with the use of external pumps, and the fluid used during the backwash will be the water that has already been filtrated. It is recommended that the filters be installed Indoors and not in direct sunlight. The general layout of equipment shall ensure adequate accessibility to allow regular operating and maintenance tasks to be performed. The minimum clearance distance between any neighboring equipment shall not be less than 2 ft. (600 mm). 9.3 INSTALLATION PROCESS Upon receipt of the equipment, proceed to unpack, review and inspect, taking care not to damage any of the elements of the filter. 1) Before installation, ensure that the filtering equipment is located on a flat surface and is covered/protected from the elements. 2) Attach the connecting piping as set out in the table of dimensions and weights for your specific Lakos Disc Filter System. 3) Connect the backwash pipe. The outlet end of the backwash pipe must be discharged to atmospheric pressure and not cause any friction pressure drop. The backwash must be piped downwards in order to not add backpressure. In case you need more height for the backwash discharge, convert the head required into pressure and this must be added to the 44 psi (3 bar) operating pressure for the Standard Housing and added to the 22 psi (1.5 bar) minimum operating pressure of the low pressure backwash housing. At these pressures, the filters need a flow rate of approximately 70 gpm (16 m³ / h) per filter. 4) The manifolds are HDPE material so please use suitable connecting piping. Lakos recommends the use of expansion joints to allow for thermal expansion and to eliminate bending moments transferred to the systems piping. HDPE can be damaged if connected improperly to metal piping. 5) HDPE pipe can have thermal expansion if subjected to temperature swings. Customer is required to factor this in a use suitable expansion joints and fittings to account for this. 6) If the equipment is located in a new installation, verify that the installation meets all site requirements. 7) Plumb the exhaust tubing of the solenoid valves to a suitable drain location. This is the water used to activate the three way valves to initiate backwashing. 8) Ensure that all fittings and wires are connected properly. Refer to the P&ID example submitted with this manual. 9) All pipes have grooved joints for connection to the customers piping. Flanged adaptors are sold as an optional extra.
10 AUTOMATIC CONTROLLER CONFIGURATION For specific information and wiring diagrams, refer to the correct manufacturer's IOM manual when using a NON-LAKOS controller. The control panel comes fully wired to the solenoid valves from the factory as standard. Only the power supply needs to be connected. The standard is 115VAC single-phase input power. Refer to the Alex-Tronix website to access your corresponding controller's IOM Manual when using an Alex-Tronix controller. http://alextronix.com/ownerss-manuals/. Note that in the V and H configurations two filters are piped in parallel so that one 3-way valve backwashes two filters at a time. Follow all instructions for proper installation and set-up. It is.good practice that the following settings must be verified before operating the controller. Pre-Dwell Time - Duration of time between when the backwash cycle is initiated and the first filter begins flushing. This allows time for a master/control valve to be energized. Alex-Tronix Controller - Adjustable setting Dwell Time - Duration of time between backwashing each tank in the system. Alex-Tronix Controller - Adjustable setting Periodic Flush Time - Ensures that the filter system will experience a backwash cycle as set, regardless of the pressure differential. If the contaminant build-up on the filter media does not cause a backwash cycle before this setting, the periodic timer will initiate a full backwash cycle of all filters. The recommended maximum periodic setting is 24 hours, but should be more frequent when dealing with a higher concentration of contaminants. Pressure Differential Switch - The automatic controller includes a pressure differential switch (located inside the control box) that must be set for proper operation. This device measures the line pressure difference between the inlet and outlet manifolds on your media filter system. When the pre-set pressure differential is reached and sustained for 30 seconds, the PD switch will automatically initiate a full backwash cycle of all filter tanks, one tank at a time. Access this switch by opening the inner panel of the controller. Your LAKOS filter system operates effectively with a pressure differential setting of 7 psi. For more frequent backwashing, you can set the differential pressure lower. This will produce more backwash water. NOTE: When pressure differential triggers a backwash sequence, the Periodic Flush Time (see above) is reset.
11 PERIODIC/MID-SEASON MAINTENANCE During an operating season, inspection should be performed regularly. How often you inspect and maintain your filter system will determine how long your filter system will last. 1. Shut off the system pump and disconnect power to the automatic controller. 2. Via the automatic controller, initiate a manual backwash cycle. Each filter tank should backwash as programmed. Note the dwell time and backwash duration. 3. Inspect all tubing & componentry for proper connections and any damage. 4. Check the spin-clean filter on the water uptake kit; clean internal screen if necessary. 5. Check the pressure gauges for expected readings. 6. Check that air/pressure relief valves are correctly set and are operating properly. 12 SEASONAL SHUTDOWN PROCEDURES Lakos recommends that all Disc Filter Systems be shut down when not in active use for long periods. To do this: 1. Perform a long and somewhat aggressive backwash cycle for all filter tanks in the system, backwashing each tank for at least two minutes and opening the backwash throttling valve a bit more than normal operation. CAUTION: If any chemicals are introduced to the irrigation system at shutdown, please verify chemical compatibility with the materials of construction of the Lakos Disc Filter System. 2. Shut down the system pump and disconnect power to the automatic controller. 3. Drain the filter system completely of all water. It is best to drain from the lowest point in the system to ensure that all water is drained from the lowest point of the filter system. 4. All systems: Clean the y-strainer on the water uptake kit.
13 COMMISSIONING It is important as part of the commissioning to follow the instructions and meet the requirements included in the Alex-tronix Controller operation manual. During commissioning, the customer will perform a detailed inspection of all elements of filtration equipment to verify that no deformation or leakage of any kind occurs. It shall be carried out after verifying that the installation is adequate and has followed the correct arrangement with the instructions set out in section 9. INSTALLATION. During normal operation, the system and filter housing must be sealed completely which must be checked during commissioning to ensure no leaks. Operator is to check the normal operation and that no problems are present as described further in section 15. TROUBLESHOOTING.
14 UPKEEP AND MAINTENANCE The Lakos Disc Filter Automatic are specially designed to ensure selective filtration from 5-500 microns, ensuring at all times the selected micron is filtering regardless of the flow of filter. The self-cleaning filters lack critical elements that wear, so no maintenance is required inside of the filter housing. The Lakos Disc Filter in addition to its quick and easy installation and operation, are accompanied by the lack of maintenance and replacement materials, at least for the first five years of operation. In the lifecycle design, Lakos filters require no reset operations, replacement parts due to wear, erosion maintenance, manual cleaning or replacement are not considered necessary. Lakos Automatic equipment requires minimal maintenance and control to achieve full effectiveness of the filtration and installed components. The filters on these assemblies do not require maintenance because of the absence of internal mechanisms of wear (hydraulic systems, piston or piston friction joints or membranes, and other components). For proper operation of the equipment, Lakos recommends reviewing the following: - Periodically check the gauge readings located at the entrance, exit of equipment, and determine that they are in the proper operating ranges. - Ensure that the fittings and tubing are in proper working condition and are not leaking or damaged by UV. - Ensure the opening / closing of the three way valves work properly. - Check that the differential pressure sensor is working properly. - Activate the manual cleaning with some regularity to ensure that the procedure works properly. - Visual inspection is recommended to ensure that there is no leaking, for example: after a period out of operation, after extreme temperature change, changes upstream or downstream from the installations or equipment, or changes in the fluid characteristics. - Changes in the water pumping installation must be verified and confirmed, as well as different electrical supply.
15 TROUBLESHOOTING Below is a table showing the most common troubleshooting issues. Problem Possible Cause Solutions Poor Filtration Consistently High Pressure Differential Automatic Backwash Fails to Cycle Backwash Valve Leaks Water Hammer Troubleshooting 1. Flow is above the design flow 2. Air in filters/piping 3. Incorrect Disc Micron 4. Damage to disc sets 5. Solid loading is above design parameter 1. Excessive contaminent load restricts flow through filters 2. Damaged differential pressure switch 1. Controller power may be off or circuit breaker tripped 2. Improper setting of differential switch 3. Solenoids malfunctioning or incorrectly plumbed 4. Loss of sufficient pressure to actuate valves 1. Obstruction in the valve seat 2. Ruber seating disc is worn or damaged 3. Diaphragm damaged 1. Air in system 2. Long backwash line causing vacuum 1. Lower Flow Rate 2. Bleed off trapped air in system 3. Contact Lakos for correct disc sets 4. Contact Lakos for replacement disc sets 5. Contact Lakos 1. Drain the system and clean out contaminents 2. Verify function of differential pressure switch. Replace if needed 1. Ensure wiring is connected correctly. Reset circuit breaker and turn on power 2. Adjust as necessary. Typically 15psid 3. Check connections, clean ports and check for the sound of the solenoid actuating. Replace solenoids if necessary 4. Check filter screen on water uptake and hydraulic lines for clogs, breaks or leaks. Replace as necessary. 1. Remove the obstruction 2. Replace the seat disc 3. Replace diaphragm 1. Bleed off trapped air in the system. Air vent maybe required 2. Install vacuum breaker on backwash line 15.1 PROHIBITED USE Lakos manufactures its equipment to perform responsible water management. Any use to solve problems that arise with fluids other than water are not allowed. For other applications, please consult the Lakos technical department. No use is allowed in systems or processes other than those specified by Lakos. Any use other than that indicated frees Lakos of risks that may occur and from any liability for damage to persons and property. Lakos cannot be held responsible in relation to not complying with the recommendations, features and specifications stated is this operation manual.
15.2 CLIMATE CONDITIONS The normal operation described in this manual is effective for a range of temperatures between 41º and 122º Fahrenheit (5º and 50 Celsius) ambient and maximum fluid temperature of 95º Fahrenheit (35 Celsius). Although the rain, wind and other atmospheric agents do not have a direct and immediate impact on the stability of the plastic materials or stainless steels, etc.., in order to prolong and maintain properly during a long life of the installations, it is advised to protect the system from the weather. Lakos recommends that the filtering equipment be installed indoors or if this is not possible to be under cover to avoid direct UV. In certain climates the existence of agents such as hail, sand storms or excessive dust in the air, etc., can damage the outer envelopes, cause abrasion, impacts, scratches, etc., which can deteriorate the installations by erosion. Also in excessively hot climates, continuous exposure to the sun's rays can end up affecting the longevity of the plastic materials and therefore is advised to be installed indoors or covered. For cold climates, frost damage may occur with the expansion of water, which may cause components to burst and therefore needs to be avoided.
15.3 WARNINGS RELATED TO ENVIRONMENT Our society is increasingly demanding in terms of environmental quality and is sensitive to everything that is related to practices that can affect the environment. Consequently, users of filtration equipment must ensure that their production processes are respectful of the environment, as well as that the techniques used during operation provide adequate water quality filtered and without residues that can affect the health of consumers. Normal operation of the filtration equipment is environmentally friendly, non-self-generating any waste, emissions or pollutants of any kind. However, products from filtration processes should be treated responsibly and controlled to not harm the environment. After dismantling the equipment once its life cycle is over, or after replacing or substituting its parts and components, they must be managed by a waste manager depending on the involved material and establish the separation by types of waste, such as plastic, metal, etc. In any case, a responsible management of the materials, parts and components must be carried out, as well as the delivery to environmental managers or authorized green points. It expressly prohibits the destruction of the elements constituting the filtering configurations after the useful life of them by incineration. Lakos is expressly excluded from participating in the irresponsible use by the user of the configurations materials, parts and components upon delivery at destination, declining any improper management regarding the environment or jeopardizing sustainability. 1365 North Clovis Avenue Fresno, California 93727 USA Telephone: (559) 255-1601 info@lakos.com www.lakos.com