TEKLEEN - OBF Series - Automatic Self-Cleaning Water Filters Brochure

AUTOMATIC FILTERS, INC. Tekleen®OBF USERS’MANUAL2672 S. LA CIENEGA BLVD.LOS ANGELES, CA 90034310 839 2828 800 336 1942FAX 310 839 6878www.Tekleen.cominfo@Tekleen.comTable of ContentsSECTION I INTRODUCTION1.1 Description 11.2 Theory of Operation 11.3 Recommended Applications 11.4 Design Features 21.5 Filter Specifications Chart 21.6 Measurement Conversion Table 2SECTION II INSTALLATIONAND HOOK-UP2.1 Mechanical Hook-Up and Orientation 32.2 Plumbing Hook-Up 42.3 Electronic Controller Hook-Up 4SECTION III OPERATION AND ADJUSTMENTS3.1 Start-up 53.2 Pressure Differential Adjustment 6SECTION VI MAINTENANCE4.1 Filter Cleaning 64.2 Filter Replacement 7SECTION V TROUBLESHOOTING GUIDE5.1 Flushing Valve Does Not Close During Start-Up 75.2 Excessive Pressure Drop Through Filter Without Flushing 85.3 Flushing Valve Chatter 85.4 One Flushing Valve Stays Open (in multiple tank installations) 85.5 Frequent or Continuous Flushing while Filling Main Pipeline 95.6 Frequent Flushing During Normal Operation 95.7 When Changing Irrigation Blocks, Filter Flushes Rapidly 105.8 Screen Will Not Clean Properly 11SECTION VI ILLUSTRATIONSFilter Assembly 12Filter Assembly (Exploded View) 13Hydraulic Controller Connections 14Electronic Controller Connections 15Filtering and Flushing Sequence 162” OBF Filter 174” OBF Filter 18Cutaway of an OBF Filter 19OBF - 2 with GB6 Controller 20Particulate Removal Process 21Pressure Drop Chart 22Automatic Filters, Inc.OBF Filters Manual1SECTION I INTRODUCTION1.1 DescriptionThe OBF series features automatic, self-cleaning screen type water filters.The filtration system consists of a tank body with a first stage mesh screenand a second stage fine screen, a 2" flushing valve and an electroniccontroller. (See OBF Design Specifications, pages 23 and 24)1.2 Theory of Operation (see Page 16)Pressurized water enters the filter inlet and travels through a 1/8" perforatedstainless steel coarse screen where large particles are pre-filtered. The waterthen passes through a fine stainless steel screen where small contaminants(down to 10 microns) are filtered out. The clean water then exits the outlet.When the fine screen becomes contaminated, a pressure differential issensed causing the automatic controller to open the flushing valve. Whenthe flushing valve opens, the pressure is reduced causing the clean waterto reverse flow through the filter element pushing contaminants off the screen,through the nozzles, through the water motor and out the flush valve.The water passing through the angular holes in the motor creates a torsionalrotation of the nozzles, thus vacuuming the entire I.D. of the filter element.When the screen is clean, the unit automatically returns to the full filteringmode.The entire cleaning cycle takes approximately four to six seconds and uses10 to 12 gallons of water. It should be noted that even during the backflushcycle, the filtration process continues uninterrupted.1.3 Recommended ApplicationsTekleen OBF water filters are ideal for filtering out silt, scale, sand, rust, dirtand organic material like algae, zebra muscles, and clams from virtually alltypes of water sources.Automatic Filters, Inc.OBF Filters Manual2208504059060 1008025MeshMicronInch140 200 325 550250 177 150 105 74 44.033 .016 .004 .001.010 .007 .006 .003 .0021.4 Design FeaturesAmong the many features of the OBF models is their avoidance of the dangerof forcing contaminated water back into the system, which often happenswith 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 algaeand other suspended particles.The entire back flushing mechanism and fine screen assembly is modularand can be removed from the filter body without disruption of the plumbing.1.5 Filter Specifications ChartSpecification: All stainless steel body with engineered plastic internals (determine).Maximum 125 psi, 200° F, triple layered stainless steel screen mesh 10µ to 800µ.2 gallons per rinse with a 1” flushing valve & 8 gallons per rinse with a 2” valve.OBF - 2OBF - 3POBF - 4P2”3”4”0.81.53.0120250500506080122Model # ConnectioninchesScreen Areasq. ft.Max FlowgpmEmpty Wt.lbs.FlushingValve1.6 Measurement Conversion TableAutomatic Filters, Inc.OBF Filters Manual3SECTION 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 it should allow easy access and removal of filter element.(A minimum of three feet of clearance to the rear is required for OBF3-P anda minimum of four feet of clearance to the rear is required for OBF4-P)The location of the flushingvalve should provide formaximum unobstructed airdischarge from the valvebonnet; this eliminates valvechatter during closing. Thetank can rest on the inlet/outletnipples or can bc mounted on a stand if desired.If two or more filters are required, it is recommended that they be manifoldedwith stainless steel manifolds above ground or PVC below ground andconnected with 3"diameter r isers extending above ground.Assuming the filters are installed on a horizontal plane, the flushing valveis to be installed on the 2" diameter backflush nipple with the arrow pointingdownstream and the bonnet pointing skyward.When using the electronic controller model, mount solenoid on flushing valveand mount electronic controller in close proximity to the solenoid valve. Thesolenoid should be mounted in a vertical and upright position to reduce thepossibility of contamination by foreign material.STANDARD HOOK-UP AND ORIENTATIONAutomatic Filters, Inc.OBF Filters Manual42.2 Plumbing Hook-UpBackflush discharge pipe should be 2 inches in diameter if line is less than20 feet long with no more than one elbow; pipe with 2-1/2 inches or 3 inchesin diameter should be used if line is longer and may be manifolded if desired.Any restrictions in the backflush line will reduce the cleaning ability of thefilter.The incoming line should have a minimum I in. air vent vacuum relief valveinstalled to prevent water hammer. Discharge lines should never run uphill.This will affect the required pressure differential and reduce cleaning.Strongly Recommended: A block valve should be installed immediatelyupstream of the filter. During start-up, the block valve should only bebarely cracked open to prevent a surge of pressure across the filteronce tne pump is started. Once the pump is on-line, slowly open theblock valve. This would prevent any possible damage to the filter dueto a pressure surge. It is also recommended that a block valve beinstalled downstream of the filter which would enable the filter to beisolated for service.2.3 Electronic Controller Hook-Up (See drawing on Page I5)Before power is applied to the electronic controller, make all connectionsbetween controller and solenoid valves.1. SOLENOID CHECK OUT - using appropriate power source to energizeswitch and proceed as follows: put ear close to solenoid, trip switch andlisten for a "click” open and a "click" shut.2. FLUSHING TIME ADJUSTMENT - the flush time is normally set for fiveseconds. For difficult contaminants, it may be increased to six secondsor longer.3. PRESSURE DIFFERENTL ADJUSTMENT - the triggering differential ispre-set for 7 psi. It can be changed to different setpoints (see your rinsecontroller manual).Automatic Filters, Inc.OBF Filters Manual5Using 1/8 - 1/4 inch diameter tubing:1. Attach tubing to Port #1 on solenoid valve port and attach other end tofitting on the bottom of flushing valve bonnet.2. Attach tubing to Port #2 on solenoid valve port and attach other end toan air or water supply source.3. Attach tubing to fitting on clean water outlet and attach other end to fittingon rinse controller marked “low pressure”.4. Attach tubing to fitting on rinse controller marked “high pressure” andattach other end to fitting on dirty water inlet.Important Note: Do not run tubing more than three feet in length (preferablytwo feet or less). Due to the pressure drop across the tubing, theelectronic rinse controller may not operate properly if tubing is toolong.SECTION III OPERATION AND ADJUSTMENTS3.1 Start-UpDuring the initial filling of the main pipeline, there may not be enough backpressure downstream from filter to allow the cleaning cycle to functionproperly. Therefore, it is necessary to install a valve on the outlet line to bepartially closed (e.g. gate valve, ball valve or butterfly valve).If a downstream main line valve is partially closed, enough to provide 35 psion filter pressure gauges, the self-cycle will operate properly. Once the totalsystem is fully charged, the downstream valve can be adjusted as the systemrequires, as long as 35 psi is maintained at the filter.If systems are to come on automatically, it is advisable to install a flow controlor pressure sustaining valve downstream from the filters to create backpressure on the filters in order to enable proper flushing while pipe lines arebeing filled.Automatic Filters, Inc.OBF Filters Manual63.2 Pressure Differential AdjustmentThe hydraulic controller has only one adjustment - a small brass screw witha locking nut, located at the top of the upper bulkhead. After the lock nut isloosened, the screw can be turned by finger pressure. The controller isfactory adjusted to 7 psi differential. If field adjustment is necessary, loosenthe lock nut and turn the screw counter clockwise until the filter flushes.When the filter is clear (4 - 6 seconds), turn clockwise one or two turns andwait for the flushing valve to close. When the flush valve has closed, turnscrew counterclockwise slowly until the emitter on the side of the controllerjust starts to drip. Now each full turn clockwise will produce approximately3 psi differential. Re-tighten locking nut to hold setting.SECTION IV MAINTENANCE4.1 Filter CleaningPeriodic cleaning of the pre-strainer is necessary for removal of large particlestrapped in the chamber. Proceed as follows:1. Turn inlet water off.2. Relieve any pressure on downstream side of filter.3. Unbolt clamp and remove lid.4. Remove pre-strainer cap.5. Remove pre-strainer.Automatic Filters, Inc.OBF Filters Manual74.2 Filter ReplacementIf the filter element should ever need replacing, follow steps outlined inSection 4.1 (Filter cleaning) and continue as follows:1. Grasp flushing mechanism firmly and remove with quick jerking motion.2. If flushing mechanism is not easily removed by method described above,prying may be required as follows:a. Pass a line (rope etc.) through two opposing holes in the pre-strainerand tie ends together, creating a loop approximately one foot long.b. Place a piece of wood (approximately 2 in. x 4 in. x 14 in.) across theface of the tank for protection.c. Insert a lever in the loop and pry against the wood until the screenbreaks loose from its seal (approximately 1/4 in.) after which removalwill be easy.3. Disassemble fine filter element (see Page 13).4. Grease all o-rings with waterproof “O” ring lubricant.5. Re-assemble unit (reverse procedure).6. Turn inlet water on.NOTE: A 1/4 inch open end, box wrench or an adjustable crescent wrenchwill be required for this change over.SECTION V TROUBLESHOOTING GUIDE5.1 Problem: Flushing valve does not close during start-up.POSSIBLE CAUSESystem pressure is too low to close.SOLUTIONPartially close a mainline valve downstream of the filter to maintain 25 psion filter gauges. This pressure will ensure valve closure and also supplyback pressure necessary to clean the screen.Automatic Filters, Inc.OBF Filters Manual5.2 Problem: Excessive pressure drop through filter without flushing.POSSIBLE CAUSES1. Controller is not turned on.2. Flushing valve is installed backwards.3. Filter is installed backwards.4. Electronic controllaer is hooked up with a common negative instead ofa common positive. A common negative causes all solenoids to stayopen.SOLUTION1. Turn on power.2. Install according to directional arrow.3. Install pressure line to leg marked inlet.4. See Pressure Dfflerential Adjustrnent, Section 3.2, page 6.5. See Electronic Control Connection fig. 6.5, page 15.5.3 Problem: Flushing valve chatter.POSSIBLE CAUSEAir in the valve bonnet.SOLUTION1. Point bonnet "skyward" (to vent trapped air).2. Manually flush filter several times to flush air from the bonnet, the controllertank and the filter tank.3. Add a 1/2 or 1 inch air vent/vacuum relief to the flush line.5.4 Problem: Flushing valve stays open.POSSIBLE CAUSES1. Hole in flush valve diaphragm.2. Dirt in solenoid valve.SOLUTION1. Disassemble solenoid valve, open flush valve and replace valve diaphragm.2. Disassemble solenoid valve and clean.8Automatic Filters, Inc.OBF Filters Manual95.5 Problem: Frequent or continuous flushing while filling main pipeline.POSSIBLE CAUSES1. Downstream pressure is not available to provide vacuum cleaning power.2. Rapid-filling flow rate exceeds the controllers' pressure differential.SOLUTIONPartially close downstream mainline valve; filter gauges should read 25 psi.POSSIBLE CAUSEFilter may have been shut down "dirty,” with a contaminant that is difficultto remove after it dries on the screen.SOLUTIONA super flush needs to be performed as follows: a downstream mainlinevalve should be adjusted providing that the static pressure against the valvedoes not exceed 80 psi. After the valve is adjusted, cycle the filter throughseveral "long" flushings. This process uses the entire available differentialpressure in the filter cleaning process.5.6 Problem: Frequent flushing during normal operation.POSSIBLE CAUSEVery dirty water.SOLUTIONIncrease flushing time to 6 seconds or more.POSSIBLE CAUSEThe controller pressure differential is set too close causing vibration to initiatea flush cycle.SOLUTIONIncrease pressure differential (see Page 2 for both electronic ant hydrauliccontroller).Automatic Filters, Inc.OBF Filters Manual10POSSIBLE CAUSEScreen may be partially plugged.SOLUTIONPerform super flush as described above.POSSIBLE CAUSERotor may be jammed which results in only cleaning the screen area thatis directly in front of the nozzles.SOLUTIONOpen tank and check for free movement of rotor mechanism.POSSIBLE CAUSEPre-strainer is contaminated.SOLUTIONWhile running, check pressure between filter inlet and filter outlet, use portprovided on waste nipple. The difference between these two readings is thepressure drop through the pre-strainer. It should be zero.5.7 Problem: When changing irrigation blocks, filter flushes rapidly.POSSIBLE CAUSEWater flow in new block is causing an increased pressure drop through filterwhich exceeds the controller setting.SOLUTIONRe-adjust controller for the highest flow rate. (See pages 2 and 3).Automatic Filters, Inc.OBF Filters Manual115.8 Problem: Screen will not clean properly.POSSIBLE CAUSEThe flush cycle might be set too short (5 seconds is normal). Flushing valvedoes not open fully.SOLUTIONRestriction in flushing valve dump line due to long "run" distance, runninguphill, 2" line more than 20' long, 2" line has more than one elbow.POSSIBLE CAUSEFilter was shut down "dirty" with contaminant drying on the screen.SOLUTIONPerform super flush as described on Section 5.5, page 9. If unsuccessful,remove filter, see Page 5 and soak in swimming pool acid solution (I qt.muriatic acid to 5 gal. water) for 15 minutes. Then spray the filter with a highpressure hose to remove the contaminant. After reinstalling the filter, performanother super flush.Automatic Filters, Inc.OBF Filters Manual12Automatic Filters, Inc.OBF Filters Manual13Automatic Filters, Inc.OBF Filters Manual14Automatic Filters, Inc.OBF Filters Manual15Automatic Filters, Inc.OBF Filters Manual16Automatic Filters, Inc.OBF Filters Manual17Automatic Filters, Inc.OBF Filters ManualAutomatic Filters, Inc.OBF Filters Manual1819Automatic Filters, Inc.OBF Filters Manual20Automatic Filters, Inc.OBF Filters Manual21Automatic Filters, Inc.OBF Filters Manual22Automatic Filters, Inc.OBF Filters ManualPRESSURE DROP DATA10 1 0.120”16”14”12”8”10”6”4”3”2”2”1.5”1”Filter Flange SizeDELTA P (psi)110100FLOW RATE (gpm)1000200010000