TEKLEEN - LPF Series - Self-Cleaning Water Filters Brochure

AUTOMATIC FILTERS, INC. Tekleen2672 S. LA CIENEGA BLVD.LOS ANGELES, CA 90034310 839 2828 800 336 1942FAX 310 839 6878www.Tekleen.cominfo@Tekleen.comLPFUSERS’MANUALTable of ContentsSECTION I INTRODUCTION1.1 Description 11.2 Theory of Operation 11.3 Recommended Applications 11.4 Design Features 21.5 Filter Specifications Chart 31.6 Measurement Conversion Table 3SECTION II INSTALLATION AND HOOK-UP2.1 Mechanical Hook-Up and Orientation 42.2 Plumbing Hook-Up 42.3 GB6, DP Gauge, and Electric Ball Valve Connection 5SECTION III OPERATION AND ADJUSTMENTS3.1 Start-up 63.2 Backflush Requirements 7SECTION IV MAINTENANCE4.1 Filter Cleaning 84.2 Dirt Collector Replacement 84.3 Piston Removal/Replacement 84.4 Periodic Inspection 9SECTION V TROUBLESHOOTING GUIDE5.1 Excessive Pressure Drop Through Filter Without Flushing 95.2 Frequent Continuous Flushing While Filling Main Pipeline 105.3 Frequent Continuous Flushing During Normal Operation 105.4 Screen Will Not Clean Properly 11SECTION VI SPARE PARTS6.1 Recommended Spare Parts 126.2 Spare Parts List 12APPENDICESAppendix I Special Construction and Features 13Appendix II System with Discharge to Atmosphere 14Appendix III Piston 14ILLUSTRATIONSParticle Removal Process 15Pressure Drop Chart 16LPF Cutaway 17LPF with GB6 Controller 182XLPF with GB7 Controller 19LPF with Pressure Sustaining Valve 20LPF with Bypass Relief Valve 21WARRANTY 22Automatic Filters, Inc.LPF Filters Manual1SECTION I INTRODUCTION1.1 DescriptionThe LPF series models (Low Pressure Filter) are automatic, self cleaningscreen type water filters. The filtration system consists of a tank body witha coarse screen, fine screen, electric motor, single flush valve and anelectronic controller.1.2 Theory of OperationPressurized water enters the filter inlet and travels through the coarse screenfrom the outside in. The water then travels through the fine screen from theinside out where small contaminants (down to 25 microns) are filtered. Theclean water then exits through the outlet.When the fine screen becomes contaminated, a pressure differential issensed causing the automatic controller to open the flushing valve and startthe electric motor. When the flushing valve opens, the pressure in thehydraulic motor chamber is reduced causing the clean water to reverse flowat the nozzles through the filter element pushing contaminants off the screen,through the dirt collector and out the flushing valve.The electric motor rotates the dirt collector as water passes through the nozzles.Lateral movement allows the dirt collector to vacuum the entire screen.When the screen is clean, the unit automatically closes the electric valve,returning the filter to normal operation.The entire cleaning cycle takes approximately 10-15 seconds. It should benoted that even during the backflush cycle the filtration process continuesuninterrupted.1.3 Recommended ApplicationsTekleen filters are ideal for filtering out silt, scale, sand, rust, dirt and organicmaterial like algae, zebra mussels, and clams from virtually all types of watersources.Automatic Filters, Inc.LPF Filters Manual21.4 Design FeaturesAmong the many features of the LPF models is the avoidance of the dangerof forcing contaminated water back into the system, which often happenswith sand filters. Tekleen filters will deliver clean water or no water at all.The most predominant feature is its ability to remove organics such as algaeand other suspended particles.All filter internal elements can be removed and disassembled from the filterbody without disruption of the plumbing.The backwash cycle, Tekrinse, uses 90% less rinse water than other filterson the market today.For special constructions and applications, see Appendix I, page 13.Automatic Filters, Inc.LPF Filters Manual3Specifications: Carbon steel body with baked on powder epoxy coating or stainlesssteel 316L body at the same price. Internal parts: stainless steel dirt collector,stainless steel screen. Maximum 150 psi, 200° F. Standard screen mesh 50µto 1000µ. Optional high temperature, and high pressure.LPF3SPLPF4LPLPF4PLPF4LPELPF4LPLPF6PLPF6XLPLPF6LPLPF6SPLPF8PLPF8LPLPF8SPLPF10PLPF10LPLPF12PLPF12LPLPF14PLPF14LPLPF16LPLPF16SPLPF18SPLPF20SP334446666888101012121414161618201.42.51.4’2.552.58575877111112.512.516162424242003003004005006008008001,7501,3201,5001,7501,7502,6302,6304,0004,0006,0006,0007,0008,00010,000Model Flange SizeinchesScreen Areasq. ft.Max Flowgpm1.4 Filter Specifications Chart1.5 Measurement Conversion Table25550.00132544.00220074.003140105.004100150.00680177.00760250.01040590.01620850.033MeshMicronInchAutomatic Filters, Inc.LPF Filters Manual4SECTION II INSTALLATION AND HOOK-UP2.1 Mechanical Hook-Up and OrientationThe positioning of the filter tank should be determined by the disposal ofwaste water and to allow easy access and removal of filter element (Consultmanufacturer for required clearances).The Tekleen filter canrest on the inlet andoutlet flanges or can bemounted on a stand ifdesired.The electronic controllershould be mounted inclose proximity to thefilter tank.2.2 Plumbing Hook-UpThe waste discharge pipe should be at least one inch larger in diameter thanthe 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 no more than one elbow.Discharge lines should not be elevated. This will affect the pressure differencerequired for the cleaning cycle. If it is necessary to run discharge lines uphill,please consult with the manufacturer.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 preventa surge of pressure across the filter when the pump is started. Once thepump is on-line, slowly open the block valve. This would prevent any possibledamage to the filter due to a pressure surge.Automatic Filters, Inc.LPF Filters ManualSTANDARD HOOK-UP AND ORIENTATION52.3 GB6, DP Gauge, and Electric Ball Valve ConnectionBefore power is applied to the electronic controller, make all connectionsbetween controller, DP Gauge, and electric ball valve (see page 18).1. BALL VALVE: Plug controller into appropriate power source. Activatemanual start switch and visually inspect the open and close movementof the ball valve.2. FLUSHING TIME ADJUSTMENT: The flush time is normally set to 10seconds. Flush time should be adjusted to allow piston indicator pin toreach the end of the slot during one backwash cycle. NOTE: Excessiveflush time will not improve cleaning, and may lead to filter damage.3. PRESSURE DIFFERNTIAL ADJUSTMENT: The differential switch is pre-set for 7 psi. It can be changed to different set points (see your electroniccontroller manual).USING 1/4 INCH DIAMETER TUBING1. Attach tubing to the low pressure 1/4" fitting (on the outlet flange). Attachthe other end of the tubing to the fitting on the DP switch marked “low”pressure.2. Attach tubing to the high pressure 1/4" fitting (on the inlet flange). Attachthe other end of the tubing to the fitting on the DP switch marked “high”pressure.3. If the filter comes with a piston, attach tubing to the end of piston. Attachthe other end to the fitting on the flush outlet (before the flush valve).Important Notes: Do not run tubing more than three feet in length (preferablytwo feet or less). Due to the pressure drop across the tubing, theelectronic controller may not operate properly if tubing is too long.Automatic Filters, Inc.LPF Filters Manual6Electronic controller should be sealed completely to avoid moisturefrom entering. This will prevent possible shorting of circuits.For more operating details and set-up, please refer to your electronic rinsecontroller manual.SECTION III OPERATION AND ADJUSTMENTS3.1 Start-UpDuring start-up, the block valve at the filter inlet should be cracked open toprevent a surge of pressure across the filter when the pump is started. Oncethe pump is on-line, slowly open the block valve. This will prevent any possibledamage to the filter due to a pressure surge.During the initial filling of the main pipeline, there may not be enough back- pressure downstream from the filter to allow the cleaning cycle to functionproperly. Therefore, it is necessary to install a valve on the outlet line to bepartially closed (i.e., gate valve, ball valve or butterfly valve).If a downstream main line valve is partially closed, enough to provide 15 psion the filter inlet pressure gauge, the self cleaning cycle will operate properly.Once the total system is fully charged, the downstream valve can be adjusted,as long as 15 psi is maintained at the inlet flange during the backwash cycle.If systems are to come on automatically, it is advisable to install a flow controlor a pressure sustaining valve downstream from filters to create backpressureon filters in order to enable proper flushing while pipe lines are being filled.Once the system is fully charged push the manual flush button on theelectronic controller, check the rotation of the electric motor on the end cover.The motor should turn clockwise during the flush cycle.Automatic Filters, Inc.LPF Filters Manual73.2 Back-Flush RequirementsThe filter needs a minimum flow and pressure during the backflush processto guarantee a fully effective cleaning.The minimum flow depends on the size of the filter’s flush outlet and thepressure during backflushing. The table below gives an indication of therequired flows.The minimum differential pressure between the filter inlet and the flush outletshould be at least 15 psi during backwash.The capacity of the pump has to be sufficient to keep the pressure over 15psi during backflushing at a flow of process flow + rinse capacity.For example (see Fig. 3.1):Process flow is 210 gpm and rinse capacity is 90 gpmPressure < 15 psi yields poor cleaning.Process flow is 130 gpm and rinse capacity is 90 gpmPressure > 15 psi yields good cleaning.0 40 80 120 160 200 240 280 320102030405060Pressure (psi)Flow (gpm)0CRITICAL POINTFIGURE 3.1 BACKFLUSHING:PRESSURE VS. FLOWFlush Outlet Size Flush Flow at 35 psi(gpm)160402”1”Automatic Filters, Inc.LPF Filters ManualSECTION IV MAINTENANCE4.1 Filter CleaningPeriodic cleaning and inspection of the coarse screen, if supplied, is necessaryfor removal of large particles trapped in the chamber. It is also recommendedthat the fine screen be inspected during coarse screen cleaning. In hardwater applications, it is beneficial to wash the fine screen in a mild acid.Proceed as follows:1. Turn outlet valve off completely.2. Open the bypass valve.3. Close inlet valve.4. Relieve any residual pressure by detaching the 1/4” plastic tubing fromany fitting.5. Unscrew nuts and remove lid.6. Remove coarse screen if supplied.7. Remove fine screen using screen puller/pusher.8. Grease all o-rings with waterproof o-ring lubricant.9. Re-assemble unit.4.2 Dirt Collector ReplacementIf the dirt collector should ever need replacing, follow steps 1 through 7 insection 4.1 (Filter cleaning). Then remove the dirt collector for inspection.4.3 Piston Removal/ReplacementIf the piston needs to be removed orreplaced, follow steps outlined as followsand refer to Fig. 4.3:1. Follow steps 1-4, section 4.12. Unscrew all connection nuts.3. Remove piston from the filter housing.4. Re-assemble unit (reverse procedure).8Automatic Filters, Inc.LPF Filters ManualFIGURE 4.3 PISTON REMOVAL9Automatic Filters, Inc.LPF Filters Manual 4.4 Periodic InspectionThe following parts should be inspected annually for wear and tear andshould be replaced if necessary:- Cover Seal - Coarse Screen- Fine Screen - O-rings- Piston - Electric Motor Packing- Dirt Collector - Upper Bearing- Lower Bearing - Air/Water ConnectionsSECTION V TROUBLESHOOTING GUIDE5.1 Problem: Excessive pressure drop through filter without flushing.POSSIBLE CAUSEController is not turned on.SOLUTIONTurn on Power.POSSIBLE CAUSEFilter is installed backwards.SOLUTIONInstall filter according to manual drawings.POSSIBLE CAUSEElectric valve is wired to the controller incorrectly.SOLUTIONVerify proper wiring, pages 18-21.105.2 Problem: Frequent/continuous flushing while filling main pipeline.POSSIBLE CAUSEDownstream pressure is not available to provide vacuum cleaning power.Rapid-filling flow rate exceeds the controllers’ pressure differential.SOLUTIONPartially close downstream mainline valve; filter inlet gauge should read 15 psi.POSSIBLE CAUSEFilter may have been shut down “dirty” with a layer of contaminant that isdifficult to remove after it dries on the screen.SOLUTIONA Superflush needs to be performed as follows: a downstream mainlinevalve should be partially closed to increase inlet working pressure. After thevalve is partially closed, run the filter through several flush cycles. Thisprocess uses the entire available differential pressure in the filter cleaningprocess. If this fails, the screen may be removed and cleaned manually.5.3 Problem: Frequent/continuous flushing during normal operation.POSSIBLE CAUSEVery dirty water.SOLUTION (for electronic controller only)Increase flushing time so the indicator pin on the piston reaches the end ofthe pin grove.POSSIBLE CAUSEThe set point on the differential pressure switch is set too close to zero,causing vibration to initiate a flush cycle.SOLUTIONIncrease pressure differential set point.Automatic Filters, Inc.LPF Filters Manual11POSSIBLE CAUSEScreen may be partially plugged.SOLUTIONPerform Superflush as described above in section 5.2.POSSIBLE CAUSEDirt collector may be jammed which results in only cleaning the screen areathat is directly in front of the nozzles.SOLUTIONOpen tank and check for free movement of dirt collector mechanism.POSSIBLE CAUSEPiston is jammedSOLUTIONRemove piston from the filter housing and make sure it is moving freely. O-rings and U-cups may need lubrication. Check mini-filter for unrestricted flow.POSSIBLE CAUSECoarse screen is contaminated.SOLUTIONWhile running, check pressure between filter inlet and hydraulic pressurechamber (if available). The difference between these two Readings is thepressure drop through the coarse screen. It should be zero..Automatic Filters, Inc.LPF Filters Manual125.4 Problem: Screen will not clean properly.POSSIBLE CAUSERestriction in flushing valve dump line due to long “run” distance (e.g., runninguphill, 2” line more than 20’ long, 2” line has more than one elbow).SOLUTIONIncrease pipe size, remove any elbows, avoid elevation gain of pipe afterflush valve.POSSIBLE CAUSEFilter was shut down “dirty” with a layer of contaminant dried on the screen.SOLUTIONPerform Superflush as described on Section 5.2, page 10. If unsuccessful,remove filter screen (see section 4.1, page 8) and spray the screen with ahigh pressure hose to remove the contaminant.SECTION VI SPARE PARTS6.1 Recommended Spare PartsThe following are recommended spare parts to keep in stock:- Fine Screen - Set of O-rings- Cover Gasket - Dirt Collector- Upper Bearing - Lower Bearing- D/P Switch - Controller Board6.2 Spare Parts ListSee filter cutaway on page 17.Automatic Filters, Inc.LPF Filters Manual13Automatic Filters, Inc.LPF Filters ManualAPPENDICESAppendix I Special Construction and FeaturesI. (AUTOMATIC) BY-PASSSometimes it is necessary to have flow even when the filter is out off servicefor periodical maintenance. In this situation, it is recommended to create aby-pass.FILTER WITH BY-PASSIt is very simple to create a by-pass,especially for the on-line models.To do so, add a block valve on boththe inlet and outlet and a bypasswith another block valve (seedrawing).If the by-pass valves are providedwith actuators, it can be converted to an automatic by-pass system by wiringit to the control box ( see controller manual).II. ASME CERTIFIED FILTERSASME certified filters for the LPF series are available on special order. Thelead time on these is approximately 30 to 90 days.III. FILTERS FOR SEVERE APPLICATIONSThe LPF 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.FILTER WITH BY-BASS14Automatic Filters, Inc.LPF Filters ManualAppendix II System with Discharge to AtmosphereIf the filter freely discharges to the atmosphere, it is recommended that a controlvalve be installed at the filter discharge. Depending on the process upstream ofthe filter, the flow may be higher than the filter handling capacity. In this case, thecontrol vale at the outlet would be usedto create a back pressure on the systemand control the flow across the filter.In addition, the discharge valve can beused as a pressure sustaining valve incases where pressure (> 15psi) is notadequate during backwash.Appendix III PistonDue to longer screens on larger filters, it is necessary to employ a piston for thecleaning mechanism. The piston is used to move and control the linear velocityof the dirt collector during the rinse cycles. This would enable the dirt collector toclean the entire surface area of the screen in a spiral-downward movement.At the end of the cleaning cycle, the flush valve closes and the normal filtrationprocess resumes. At the same time, the piston is energized with water pressurewhich pushes the dirt collector back into position for the next rinse cycle.FILTER WITH DISCHARGETO ATMOSPHEREFILTER WITH PISTON15Automatic Filters, Inc.LPF Filters Manual16Automatic Filters, Inc.LPF Filters ManualPRESSURE DROP DATADELTA P (psi)FLOW RATE (gpm)10 1 0.120”16”14”12”8”10”6”4”3”2”2”1.5”1”Filter Flange Size110100100020001000017Automatic Filters, Inc.LPF Filters Manual18Automatic Filters, Inc.LPF Filters Manual19Automatic Filters, Inc.LPF Filters Manual20Automatic Filters, Inc.LPF Filters Manual21Automatic Filters, Inc.LPF Filters Manual22Automatic Filters, Inc.LPF Filters ManualWARRANTYAutomatic Filters, Inc. (AFI) warrants its filters and controllers to be free from originaldefects for one year from the date of original sale. The manufacturer will replace,free of charge, any part found defective under normal use and service within theguarantee period, provided the product is installed, used, and maintained inaccordance with good engineering practice and all applicable instructions orlimitations issued by AFI. The manufacturer assumes no liability for incidental orconsequential damage sustained in the adoption or use of our engineering data,service, or products. Liability is limited to the repair or replacement of the products.No agent or representative of AFI has the authority to waive or add to this agreement.Altered products or use of products in a manner not intended shall void this warranty.All warranty claims must be sent along with the defective product, freight prepaidto AFI at its business address. All warranty shipments are for the account of thebuyer. The warranty period shall be 12 months from the date of shipment to theclient.