Valve Nest Filter with Time Clock Control Installation and Operation Manual

Transcription

1 Valve Nest Filter with Time Clock Control Installation and Operation Manual Effective 5/24/12

2 Effective 5/24/12

3 Table of Contents Operating Data. 1 Pre-Installation Data... 2 Filter Parameters Installation requirements Major Components Filtration processes Filter Installation... 5 Locating Equipment Assembly of Equipment Drain Line Flow Rate Chart Media Loading Chart Media Loading Diagrams Single Filter Installation Duplex Filter Installation Hydraulic Tubing Installation Regeneration Cycles Service Backwash Rinse Effective 5/24/12

4 Effective 5/24/12

5 OPERATING DATA Fill in the following data for future reference: Model: Type of Controls: Filter Regeneration Time Settings: Backwash Slow Rinse Fast Rinse Effective 5/24/12

6 Effective 5/24/12

7 PRE-INSTALLATION DATA Read the entire instruction manual before you begin installation. Failure to install and operate the system as required will void the warranty. The system will perform at maximum efficiency, when installed and operated as designed. Obtain all the materials and tools needed for the installation before beginning. Always use the correct tools to install and maintain the system. The installation must conform to local plumbing and electrical codes. Code compliance is the responsibility of the installer or contractor. MULTI-MEDIA FILTERS: Parameter Minimum Maximum Turbidity - 50 NTU ** Water Temperature 35 O F 100 O F *** Water Pressure 25 psi 100 psi * GREENSAND FILTERS: Parameter Minimum Maximum Iron (Ferrous) - 10 ppm (ph = ) Manganese - 10 ppm (ph > 8.0) H 2 S (Hydrogen Sulfide) - 5 ppm (ph = ) Temperature 35 O F 80 O F Pressure 25 psi 100 psi * Alkalinity 100 ppm - CARBON FILTERS: Parameter Minimum Maximum Temperature 35 O F 100 O F *** Pressure 25 psi 100 psi * * Maximum pressure dependent on components. High pressure designs are available. ** Consult Factory for higher levels. *** High Temperature systems available on special order consult factory. Protect the system from pressure extremes. Do not expose the system to surging pressures or water hammer. Water hammer will cause damage to control valves, mineral tanks, and plumbing. If a condition of this type exists, a Water Hammer Arrestor must be installed to prevent damage. Protect the system against back-pressure caused by a pump or any type of water storage system. If pressure on outlet exceeds inlet pressure, media can be flushed into the inlet water supply during the service cycle. When routing the outlet piping to an atmospheric storage tank, a valve or flow control must be installed in the outlet piping to prevent over running of the system. A back pressure of 15 to 20 psi should be maintained on the system at all times. 2

8 PRE-INSTALLATION DATA Protect the system from freezing weather conditions. Temperatures at and below freezing will cause damage to tanks, valving and plumbing. Water expands when it freezes and can cause the mineral tanks and plumbing to burst. Protect the system from high temperatures in excess of 100 O F. Some of the components used in the manufacture of the system will not withstand high temperatures. Do not connect the system down stream of a hot water system. Also protect the outlet of the system from backup of hot water from a water heater or boiler. The system operates on 24 Volts AC supplied from a step down transformer using 120 Volts on the primary side. The 120 volts operates from a normal 15 amp wall outlet receptacle which is properly grounded. The power reduction transformer supplied with the equipment is UL listed. Conformance to local and National Electrical Codes must be observed and are the responsibility of the installer. The system must be located within 10 feet of an open floor drain or sump. The drain from the system must contain a vent, in accordance with the local plumbing codes. The flow of water should be capable observation. Back-pressure from overhead drain systems can affect the regeneration performance of the filter, therefore; it is not recommended to run the drains any higher that 8 feet above the control valve assembly. On overhead drains, an air gap must be installed in the highest point of the drain line, and local plumbing codes and regulations are followed. It is recommended that inlet, outlet and by-pass valves be installed on each unit in the system for future service ability. The inlet and outlet valves are utilized to turn off the water to the unit so that the control valve and other components can be serviced. The by-pass valve allows water down stream to the process (by-passing the unit) so that water can still be supplied, even though it is raw water, should it be needed. Metal shavings, solder flux, threading compounds and other contaminating materials from the installation of the piping; must be flushed from the piping prior to allowing water to enter the system. These foreign materials can cause damage to the control valve and isolation valves. 3

9 PRE-INSTALLATION DATA The system, normally is not completely assembled at the factory. The following should be used as a reference for the correct parts against what was received. Different size units have different quantities of media and style of internal distributors. All systems up to and including 30 diameter have a single-point lower distributor. Systems 36 and larger have hub-radial lower distributor systems. Multi-media Filter COMPONENTS Mineral Tank Valve Nest Header Time Clock Control Transformer Sand Garnet Anthracite Gravel Underbedding Backwash Flow Control Tank Internals Carbon Filter COMPONENTS Mineral Tank Valve Nest Header Time Clock Control Transformer Carbon Media Gravel Underbedding Backwash Flow Control Tank Internals Greensand Filter COMPONENTS Mineral Tank Valve Nest Header Time Clock Control Transformer Garnet Greensand Anthracite Gravel Underbedding Backwash Flow Control Tank Internals The Time clock control comes mounted on the piping, with all the tubing lines connected. The tank internals along with the distributors are assembled inside the tank ready for use. The media is shipped separately and must be loaded into the tank. If there are multiple layers of media, be sure each is leveled prior to putting in next layer. Transformers are shipped separately. 4

10 FILTER INSTALLATION Filtration is probably the best known of all water treatment processes, but in some ways the most difficult to accomplish. Many types of filters are available. The specific type of filter required depends on the problem and its severity. Basically, filters trap the contaminants in the water as they flows through the filter. If particles are sufficiently large, the filter will trap them. In other cases, a chemical reaction is required to increase the size of the particles before they can be removed by the filter. MULTI-MEDIA FILTERS Multi-media Filters combine more than one media in a single vessel, with coarse media on top, medium media below it, and finest media on the bottom. As water flows downward through the filter, it encounters media layers, each finer than the previous. The coarse top layer traps the largest particles, preventing them from migrating downward through the bed. The middle layer traps medium sized particles, and the fine layer traps the smallest particles. Several layers enable the filter to operate through its full depth, resulting in higher flow rates and longer time between backwashing. As a result, the multi-media filter is like having several filters in one. CARBON FILTERS Carbon Filtration is based upon a naturally occurring phenomenon called adsorption, in which molecules of a liquid or gas are trapped by either the external or internal surface of the media. Activated carbon has a very high internal surface area and is thus an ideal material for adsorption. Raw water quality can be improved with the removal trace components. Different types of carbon can be used to remove undesirable organic compounds. GREENSAND FILTERS Greensand filters chemically convert soluble particles in solution into an insoluble form (particles), which permits easy filtration. They can be used to treat waters with medium concentrations of iron, manganese, and hydrogen sulfide. A continuous regeneration method is typically used on commercial applications. Potassium permanganate (KMnO 4 ) and/or chlorine is injected prior to the filter bed to oxidize and allow filtration of the particles. The top layer of the bed acts as a filter, the greensand portion of the bed acts as both a catalyst and a redox buffer capable of reducing excess potassium permanganate or oxidizing soluble iron, magnesium or hydrogen sulfide. NOTE: All filters must be BACKWASHED periodically. Multi-media and Greensand filters are backwashed to remove the insoluble particles accumulating in the bed. Carbon filters must be backwashed periodically to expose new adsorption sites in the media. After backwash, a down-flow rinse prepares the media for service. 5

11 FILTER INSTALLATION LOCATING THE EQUIPMENT Locate the mineral tank on a firm, level foundation, preferably concrete. The system should be installed within 10 feet of an electrical outlet, and a floor drain capable of handling the maximum flow rate (refer to Drain Line Flow Control Chart). An air gap must be maintained at the drain in accordance with the local plumbing codes. Remove the fill plug and load the mineral tank with the gravel underbedding and filter media. Once loaded, the mineral tank is not easily moved. ASSEMBLY OF EQUIPMENT The majority of the system is assembled prior to shipment. The components for the various systems are listed on page 4. A funnel is recommended for loading the media and gravel into the mineral tank. Load the gravel into the mineral tank. Level the gravel. Load the filter media into the mineral tank. In the case of a Multi-media Filter or a Greensand Filter, level each layer media prior to loading the next layer. After loading the gravel and filter media, fill the mineral tank with water. See Filter Media Loading Chart for media quantities and proper layering. The valve nest is pre-assembled to the tank A drain line flow control (DLFC) is already installed onto the drain line. A missing flow control can result in media being washed out of the mineral tank and down the drain. See the Filter Drain Line Flow Rate Chart. Piping can now be connected to the inlet and outlet of the valve nest. Note: mating flanges and gaskets are to be supplied by others. It is recommended that inlet, outlet and by-pass valves be installed on each system. See the typical installation drawings 10 and 11. 6

12 FILTER INSTALLATION Install the controller to the front of the control valve. Connect the transformer and Flow Meter to the control as required. Plug in transformer and cycle system through a regeneration cycle without water. Make sure everything is functioning properly. See Control Section of manual. Turn on water and check for leaks. Installation is complete. Program control as required. FILTER DRAIN LINE FLOW RATE CHART Valve Type Filter Tank Diameter (inches) Filter Type Carbon Multi-media Greensand Valve Nest gpm gpm gpm 150 gpm 150 gpm gpm 180 gpm 180 gpm gpm 300 gpm 300 gpm gpm 420 gpm 420 gpm gpm 570 gpm 570 gpm 7

13 FILTER INSTALLATION FILTER MEDIA LOADING CHART The following chart shows the quantity of the media and gravel in the various filter systems. The quantities are based on mineral tank type, mineral tank diameter, and type of filter. Media Type Tank Type Tank Dia. Gravel Carbon (ft 3 ) Multimedia (lbs) Greensand (lbs) (ft 3 ) (lbs) Anthracite Sand Garnet Anthracite Greensand Garnet Fiberglass Steel To use the chart, select the type of mineral tank (Steel or Fiberglass) and the diameter. Select the type of filter from the header across the top of the chart. Find the type of media, under the type of filter and move down the column until intersecting the row with the proper diameter tank. 8

14 FILTER INSTALLATION FILTER MEDIA LOADING DIAGRAMS 9

15 FILTER INSTALLATION SINGLE FILTER INSTALLATION: The Filter is supplied with 3 flanged inlet and outlet connections. Mating flanges and gaskets are not supplied. It is recommended that manual inlet, outlet and by-pass valves be installed to allow ease in servicing the system. A backwash flow control is installed on the drain connection of the unit. This restricts the flow of water to prevent the loss of media while providing the proper backwash flow rate. Note: Soak Carbon Media for a minimum of 8-hours before backwashing. Air trapped in the carbon will cause it to float and be washed down the drain during backwash, if not allowed to soak. NOTE: Install the drain line so that an air gap can be maintained in accordance with local plumbing codes. Fill unit with water by first tuning off the water. Then index the controller to backwash. Slowly open the inlet valve to make sure all the air has been evacuated from the tank. Once the water is flowing steady out of the drain line advance the control into the service position. See programming the regeneration cycles located in the control manual. 10

16 FILTER INSTALLATION DUPLEX FILTER INSTALLATION: Install the two filters utilizing a Reverse Return Header System as shown below. The inlet is shown on the left and the outlet on the right. The distance from the inlet tee on the first unit through the filters to the outlet tee on the second unit are equal distant, therefore the flows will be balanced. Manual inlet, outlet and by-pass valves should be installed to provide ease of service. NOTE: Install the drain line so that an air gap can be maintained in accordance with local plumbing codes. Fill the units with water by first tuning off the water to both. Then index each the controller to backwash. Slowly open the inlet valve to each unit, one at a time to make sure all the air has been evacuated from the tanks. Once the water is flowing steady out of the drain line advance each control into the service position. See programming the regeneration cycles. 11

17 FILTER INSTALLATION PNEUMATIC TUBING INSTALLATION: The timer comes mounted on the plumbing with the hydraulic lines connected. Check to make sure they are connected as shown in the diagram below. It is recommended that air pressure be used to operate the diaphragm valves. The required pressure is 10 psi greater than the incoming water pressure. 12

18 REGENERATION CYCLES FILTER REGENERATION CYCLES: All filters required backwashing and rinsing of the filter bed. The frequency depends on the amount of contaminants collected. Carbon filters normally remove chlorine and or organics from the water by adsorption, but may also collect some turbidity. The media bed must remain fluid in order to be most affective, therefore backwashing is required. Multimedia filters collect turbidity during the service cycle. The pressure drop across the bed increases as the amount of turbidity collected increases. Backwashing is required to return the bed to the normal condition. Filters with Manganese Treated Greensand media collect precipitated iron from the water supply. The amount of iron collected creates a pressure drop across the filter bed. The collected iron must be removed from the filter by backwashing and rinsing. The following regeneration cycles are normal for all backwashing filters. SERVICE Unfiltered water enters the top of the tank through the Inlet Valve (1) and flows down through the media in the tank. Filtered water flows through the distributors and out through the Outlet Valve (2) to the outlet of the system. Valves (3), (4) and (5) are all closed during the service cycle. 13

19 REGENERATION CYCLES BACKWASH The Inlet Valve (1) and the Outlet Valve (2) are closed. Water is directed through the Backwash Inlet Valve (3) to the outlet side of the unit and directed into the distributors at the bottom of the tank. The water then flows out through the distributors up through the media and out the top of the tank through the Backwash Outlet Valve (4), through the backwash flow control to drain. RINSE Unfiltered water enters the top of the tank through the Inlet Valve (1), similar to the Service Cycle, and flows down through the media in the mineral tank. Filtered water flows through the lower distributors, and out of the bottom of the tank through the Rinse Valve (5) and through the flow control to drain. This cycle compacts the bed and prepares the filter for the next service run. 14

20 Effective 5/24/12