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Owner`s Operation and Maintenance Manual

1. 0 cece eee ee ee ees 15 1 1 Definitions of Abbreviations ccc cece cece eee ence eee eeneeeneeeeaaeeneeuee 16 1 2 Definitions of Tenis vai A RS 17 1 3 Filtration Applications cercanas 18 1 4 TURBO DISC Basic Technical data 0 eee eee eeee eee ee ee ee ene een ees 19 Section 2 Turbo Disc Product Identification cece eee cence eens 21 2 1 Product Identification Label iii LEAL ada E casa ad 21 2 2 Turbo Disc System Component Identification cece cece serere ereere 24 2 3 System Descriptions Based on Backflush Method ccceeeeeeeee eee es 27 System Supplied Pressure pi A E a a 28 Bo ster Systemi ssonsnsuaass ssa nsesanfsovono Us ss sal EEEE EE EEEE E E RERE 29 Air Assist Systemi np A A IEEE h 30 Pressure Sustaining System oros rre s Eene EVLE E ETENA ah 31 Section 3 Installation and Operating Instructions 0 0008 33 31 OVA A EE Ea 33 3 2 Initial Installation and Set Up ivcesueeengeatswsduacdagseudngsbcascedenduaelaqeasanuee ys 34 3 3 Initial System Start UP iii 35 3 4 Normal System Operation ssssssesseessserrrrerrererrrssreerrrrerrerreresererre 37 3 5 Cold Weather System Operation uti 38 Turbo Disc Operations amp Maintenance CONTENTS Continued Section 4 Regular Maintenance Procedures i ii 39 4 1 Maintenance Schedule spssasnias soa pa EEEN 40 42 Mamtenanes Check List ssasss causas ii 41 Se
2. 76 Section 7 Appendix Turbo Disc Maintenance Work LOS ssessxssusasssatesa eudessetecersdateeyiexexevensiee 78 Turbo Disc Maintenance Schedule Spring Summer sce eee sees ee eee 79 Turbo Disc Maintenance Schedule Fall Winter cece cece iii 80 Section 8 Replacement Parts List cece erre 82 Section 9 Engineering Drawings 00 cece cece eee eee eee ene eeaeens 84 Section 10 Bill of Material ia 86 Limit d Warranty asso ea pu ante sd Dens EEE AEAEE EEE EEEE EEEE 88 Important Contacts Back Cover sssrsserersererresessssssrsressrrererrrrrrrree 89 4 Turbo Disc Operations amp Maintenance Miller Leaman knows the Industrial Markets with thousands of installations and many unique applications Our experience along with our Thompson Strainer line of filtration products Helix HD amp HS Series Filters and our innovative Turbo Disc Filter gives you a selection of filtration equipment that will solve your most challenging problems Typical Applications Include Spray Nozzle Protection Cooling Tower Water Chilled Water Process Cooling Water injection molding extrusion etc HVAC Systems protection of heat exchanger etc Makeup Water Pre Filtration for R O and Other Filters Well Water Surface Water lakes rivers canals etc Intake Water City Water Intake Municipal Water Reclaimed Water Wastewater Scru
3. MILLER lt gt LEAMAN Pure Filtration Solutions Owner s Operation and Maintenance Manual Turbo Disc Operations amp Maintenance The Turbo Disc Filtration System is protected by the following patent 6 419 826 OTHER PATENTS MAY BE PENDING COPYRIGHT 2008 by Miller Leaman Inc All Rights Reserved Miller Leaman Inc e 800 Orange Avenue Daytona Beach FL 32114 e Toll Free 800 881 0320 Phone 386 248 0500 Fax 386 248 3033 e E mail sales Omillerleaman com Web Site www millerleaman com First Edition Copyright O 2006 2013 by Miller Leaman Inc 800 Orange Avenue Daytona Beach FL 32114 Printed in the United States of America All rights reserved This manual or parts thereof may not be reproduced in any form mechanical electronic Internet or in any form without the written permmission of Miller Leaman Inc Toll Free 800 881 0320 Phone 386 248 0500 Fax 386 248 3033 E mail sales Omillerleaman com Web Site www millerleaman com Turbo Disc Operations amp Maintenance CONTENTS Use of this Mandalas A A 6 o A eae Ra GR a eo 7 AQU Company ini dis 8 Safety de Operational WARNINGS cat AAA 9 Safety amp Operational CAUTIONS ri aa 10 Wearing Personal Protective Equipment PPE cscic ccsiceeessacsanevcenedvssevsaenesens 12 General Equipment Lockout Procedures cccceecceeee eee e tent eenee ena eeenens 13 Section 1 Introduction to Automatic Filtration
4. NOTE When using an external power source the input power to the PC Board must be the same as indicated on the upper left side of the Maxim Controller Typically the controller is either 24 volts AC or 24 volts DC however some controllers use 120 volts AC or 12 volts DC Each filter station solenoid is connected to a corresponding Output and Common terminal on the Maxim circuit board The optional Pressure Differential Gauge and Timer ON Enable inputs are connected to a corresponding Input and Auxilliary Power Out terminal on the Maxim circuit board The Pressure Transducers have a three wire connection one assigned to the input IC or ID one to the Common terminal and the third to the Auxilliary Power Out terminal Review the Electrical Schematics in the Engineering Drawings section prior to making any connec tions to the controller If requested custom input output capabilities are not described in this manual please refer to an attached addendum Optional Differential Pressure Gauge Connections The Optional Pressure Differential PD gauge is connected to the system s inlet high and outlet low pressure ports DO NOT TWIST Gauge Case Low Pressure Port WARNING Failure to use a second wrench on the low e E ho E aa pressure port when tightening fittings may result in damage to the internal pressure tubing ere ach tubing Be sure all connection tubing is clean prior to instal lation on the gau
5. amp Maintenance 55 sure that the air lines are fully seated into the manifold block and that the air line numbers and valve numbers match up Each solenoid valve has a red manual actuator lever normally horizontal that can be used to manually actuate the flow control valve for troubleshooting only energize by switching it downward and then returning the lever to the horizontal position Use the troubleshooting chart below for the Bermad 400 valve Other flow control valves may have been used in your sistem but the basic troubleshooting routine remains the same Symptom Inoperative Bermad 400 Series Flow Control Valve Possible Causes Solutions Clogged pilot valve prevents water from Disassemble the pilot valve and remove any reaching the diaphragm for actuation debris buildup See attached instructions for Not all units are equipped with a pilot cleaning the pilot valves Torn diaphragm inside flow valve Remove valve cover by removing the 4 corner bolts If diaphragmis torn contact manufacturer for replacement part Air Solenoid not energizing Verify that solenoid is getting power If not See the previous Section on Inoperative Controller 56 Turbo Disc Operations amp Maintenance 5 9 Main Process Pump Inspection and Maintenance The Turbo Disc system has been thoroughly tested at the factory However at start up for the first time verify the following e Clockwise shaft rotation e No excessive vibrati
6. Disk Maintenance Schedule for Summer Fall and Winter Spring 4 Check for variations or increases in the Filter head loss P1 minus P2 PERIODIC MAINTENANCE 1 Disassemble the pod cover and inspect the housing base O ring Lubricate with silicone grease as needed 2 Disassemble all of the pods and inspect the Piston and O rings Lubricate with silicone grease as needed 3 Check the filter disc stack for clean up If they are dirty wash and inspect the filter discs for wear or damage Replace as needed 4 Check of all the pipe joints and seals for leakage or signs of leakage 5 Manually activate a backwash to verify that the backwash sequences through all of the stations correctly 6 Perform inspections on the Victaulic couplings and do maintenance as required Note 1 The P1 and P2 designations are the pressures at the inlet and outlet manifolds respectively Their difference is the Equipment head loss Note 2 The maintenance period should be determined by the user according to the amount of usage and degree of filtering at their installation Turbo Disc Operations amp Maintenance 41 Page intentionally left blank 42 Turbo Disc Operations amp Maintenance 5 Maintenance of Filter Cartridge Assembly Inspection and Cleaning In this section are described some very useful actions for the preparation of the Equipment Mainte nance Plan The checking period depends on the operation conditions characte
7. Override Valve control Output 10 Backflush Master controls the Backflush Booster Pump or system Miller Leaman Inc sustaining valve to increase pressure during 300 881 0320 millerleaman com backflush B Inputs 1 The optional PD Switch monitors the Inlet and Outlet pressures of the system and in the event of an elevated Pressure Differential will signal the Maxim Controller to start a Back flush cycle Input 2 is the Backflush Timer enable input If a Main Pump control is used this input will enable the timed backflush when ever this pump is running If the system is a Full Flow design an Inlet pressure switch will be used at this input to signal sufficient pressure to enable the Backflush timer C The Analog Digital Input locations allow Miller Leaman Inc to design customer specific programs The se programs are then able to receive and process both digital and analog signals from devices such as Pres sure Transducers Flow meters Level Switches etc Inputs IC amp ID are the Inlet and Outlet Pressure Transducer connections These provide a 0 10Vdc signal into the controller These signals are converted into pressure level values and compared to each other for the pressure differential value When the PD val ue exceeds the PD setpoint the Maxim Controller is signaled to start a Backflush cycle Turbo Disc Operations amp Maintenance 65 Electrical Connections
8. This will help to prevent damage to the filter housing and filter cartridge if severe stoppage or water hammer occurs Water hammer may occur as a result of sudden valve opening or closing The automated opening and closing of valves during backflush may result in pressure spikes that can cause water hammer Insure that all piping connected to the filtration system is properly secured Installation of a pressure relief valve will also help to prevent damage to the system in the event of an extreme water hammer pressure spike System design should ensure that back flow is avoided If necessary back flow prevention devices should be installed upstream of the inlet and downstream of the outlet to prevent back flow or vacuum effects due to pump shut off or topographical differences This filter system is NOT freeze protected If there is a risk of freezing install indoors or properly insulate the system see section 3 4 for additional information 10 Turbo Disc Operations amp Maintenance CAUTIONS continued e This system is designed to work optimally at the engineered specifications Refer to the sys tem label located on filtration control panel to confirm the system s design flow pressure and power requirements Any deviation from these specifications may result in the system s failure to operate effectively and could cause system damage e This system can ONLY filter water Do not use any caustic or acid chemicals t
9. cartridge frame The entire disc cartridge fits inside an injection molded polyamide housing pod Each groove alternates direction causing a torturous path for the water As the water passes through the grooves extremely fine particles are trapped in the media During backflush the discs uniformly separate and release the contaminants from the surface of the discs Turbo Disc Operations amp Maintenance 7 About the Company Miller Leaman Inc was founded in 1991 by Bill Miller Marty Shuster and Robert Leaman Miller Leaman manufactures three unique filtration products a patented line of stainless steel liquid filters strainers commonly known as the Thompson Filter Strainer the Helix Screen Disc Series and the automatic Turbo Disc filter Many new custom Filtration and Ultra Filtration systems are being added to meet the needs of our customers Manufacturing operations and management personnel are located in Daytona Beach Florida in a newly renovated state of the art 52 000 square foot facility If your ever in the area we encourage you to visit our facility for plant tour Miller Leaman promotes the Thompson filter strainer Helix Series and the standard in disc filtra tion Turbo Disc filter for a variety of markets including agricultural and industrial Miller Leaman markets and sells the Thompson filter strainer Helix Series and Turbo Disc products through a network of dealers distributors manufactures reps and OEM s I
10. during a back flush when air is being injected into the tops of the filter pods It is important to the efficiency of the back flush that the air override pressure is present and regulated to about 30 psi Controller Settings Prior to start up read and fully understand the Maxim Controller section in this Manual Turn on the controller by moving the switch to the ON position Check the controller s settings by scrolling through the menu screens The settings are factory preset at nominal values These may need to be adjusted to meet your system s back flush needs Be sure the Pressure Differential gauge setting is properly set once there is water flow The recommended PD setpoint is 1 2 PSID above the clean gauge reading at the systems MAXIMUM flow rate Setting this gauge at too low flow may result in continuous back flushing at higher flow rates Note that the Pressure Differential increases with flow rate Typical PD gauge setpoints are between 3 6 PSID depending on flow rate Turbo Disc Operations amp Maintenance 35 3 3 System Start Up Cont 4 Prime the main pump by filling the suction line and pump volute with water If the main pump does not have a flooded suction then a foot valve will be required to maintain a prime after shut off Once primed make sure all downstream valves are open and briefly a few seconds switch ON the pump to begin manifold flow It may take a few tries to remove any air from the syst
11. during installation transit 1 Check the impeller rotation on the pump s to verify that the impeller is rotating in the correct direction by briefly bumping the starter switch on When looking at the back end of the pump where fan is located the impeller should be rotating clockwise If it is not then two of the three power lines wired into the starter must be switched Make sure all power is disconnected before opening the starter Consult a qualified electrician to adjust these wires If the flow and pressure are achieved according to the pump performance curve then the direction is correct Air pressure If the system does not include an air compressor then connect an air supply line to the standard 4 male air fitting located on the solenoid assembly The regulator at the air hook up point should be set about 10psi above the system s maximum water pressure Typical settings are between 80 120psi but must never exceed 150psi If the air pressure regulator is set below the systems design operating pressure the valves will not close and therefore not back flush the filters If your system contains a sustaining valve the regulator should be set about 10psi above the pump s pressure when the sustaining valve is shut this is the dead head pressure There is also an air override regulator located on the control post either above the gauges or above the electronic controller This should be set between 15 30psi This can be set
12. housings pods are manifolded together with stainless steel inlet outlet manifolds The sizing of the system is a function of the flow rate and the solids loading in the application The back flush cycle is rapid and precise using a fraction of the flush water used by traditional automatic sand media filters on the market Quality of Disc Filtration Although the three dimensional disc media is the heart of the filter there are other principles at work As water enters the filter housing it passes through the Helix Element at the base of the disc cartridge The Helix Element spins the water at a high velocity causing heavier particles i e sedi ment to centrifugally spin outward away from the disc media The dirty water passes through the depth of the discs from the outside to the inside The discs con tain grooves that run radially across the surface of the discs These grooves are precisely molded in the surface of the discs slightly tapered from the outside to the inside On the opposite side of the disc surface the grooves are running in the opposite direction therefore creating a cross hatching of grooves across the depth of the discs The combination of the Helix Turbo Element the grooves molded in the surface of the discs and the caking effect achieved by the depth of the media extremely fine particulate removal is achieved The discs have tapered grooves that the water passes through The discs are stacked tightly onto a
13. o i 1E Js A 26 27 Turbo Disc Operations amp Maintenance 5 2 Parts list of the Filter housing and filter PART ITEM NUMBER DESCRIPTION of PART EX 1 ATD 28v xxx 2 Automatic Turbo Disc Filter specify micron 2 VIC 90 degree connection B A ero wn ATD NV XXx_ Ararat Turbo Disc Filter specify micron 3 VIC 90 degree Mora EN fm ou o TT ET EN EC Co ECI eme mega ET fuso fracos EN o Hetzos Filter Body Gasket 2 VIC connections Inline po m32 Filter Body Gasket 3 VIC connections 90 deg Ld Paes o ee es ne Tr A MOCOS ET oem mer ET fimo mamas O MO eme EA a arose Somes EN a rios merecemos ram fa CNC IS EN CAC EN Turbo Disc Operations amp Maintenance 5 3 Maintenance and cleaning of the filter housing pod and Turbo Disc filter element stack Each filter pod has a Retaining Ring with Safety Clamp attached to prevent the accidental opening of the filter Follow these instructions for safely opening and closing the filter pod assembly Make sure the filter unit is depressurized before opening the clamp ring Close the inlet and outlet valves to isolate the filter Opening instructions Unscrew the safety lock nut Turn the anti opening retaining clip Open the retaining ring using the built in handle Carefully remove the filter lid BOI eR ANTI OPENING DEVICE SAFETY BOLT IN ANTI OPENING HANDLE DEVIGE 1 Unscrew the safety 2 Tum the ant
14. system was designed for specific applications It should not be modified and or used for any application other than originally specified Always wear your Personal Protective Equipment PPE e Eye Protection Must be Worn As added protection tight fitting glasses with side shield protection must be worn at all times Glasses such as wrap around style are most effective e Wear Ear Protection The Turbo Disc Filtration System does not produce a harmful level of noise but users are cautioned that they should wear hearing protection as appropriate to protect against other noise that may be present at the filtration system location e Wear Protective Gloves Always wear protective gloves when working on equipment e Wear Safety Boots Always wear protective footwear when working on equipment 12 Turbo Disc Operations amp Maintenance Equipment Lockout Procedures The following lockout procedure is a minimum requirement Additional precautions should be tak en depending on site specific protocols Always check with the facility manager and senior electri cian for additional precautions Lockout and Tag Procedures 1 A Locate and identify electrical supply to equipment Identify specific breakers or disconnects that service Miller Leaman filtration equipment If unsure contact the facility electrician or maintenance personnel to locate the correct electrical supply Confirm that the control panel and other electri
15. the pump and is self adjusting Seal is cooled and lubricated by the liquid being pumped Do not run the pump dry Pump Protection Cold weather wet weather installations e System Drains Provide drain valves to empty the system including the pump case to pre vent freezing damage e Shelter If possible provide shelter for the unit to protect it from the weather Allow ade quate space around the pump unit for service When effectively sheltered a small amount of heat will keep the temperature above freezing Provide adequate ventilation for the unit when running For severe weather problems or where other shelter is not practical a totally enclosed fan cooled TEFC type motor should be considered e Condensation When the temperature of the metal parts of a motor are below the dew point and the surrounding air is moist water will condense on the metal surfaces which over time will cause corrosion damage In severe conditions a space heater should be considered to warm the motor unit 62 Turbo Disc Operations amp Maintenance 5 13 The 3 Way Flow Valves Inspection and Maintenance The Turbo Disc system has been thoroughly tested at the factory However at start up for the first time verify the following e Water flow through the system in the Filter mode and Backflush mode are correct e Air line pressure on the upper or lower diaphragm on the flow control main valves is correct Troubleshooting and General Mainten
16. three phasa motor by interchanging any two leads See manufacturer s Instructions for reversing single phase motor C Pump not primed Reprime Inspect suction system for air leaks D Internal leakage Check impeller for wear of controlled clearances See Repair Instructions E Loose parts Inspact Repair F Stuffing box not properly adjusted Adjust gland IN SYSTEM AAA A Pressure required by system at design Compare pump pressure and flow rate against pump characteristic curve flow rata exceeds pressure rating of pump Check for closed or partially closad valve in discharge piping system Reduce system pressure requirement Increase pressure capability of pump B Obstruction in suction piping Locata and remove obstruction C Pressure rating of pump exceeds pressure Compare pump pressure and flow rate against pump characteristic curve requirement of system at design flow rate Inspect discharge piping system for breaks leaks open by pass valves atc If necessary reduce flow rate by partially closing discharge valve Turbo Disc Operations amp Maintenance 59 60 5 11 Checking the Direction of Rotation of the Main and Booster Pump Motors on se ES e S o q Viewed from PN this direction na As viewed Engage start switch momentarily bump motor to observe rotational direction The direction of pump rotation is determined by viewing the liquid end of the pump from the back or shaft side and
17. warranty The following maintenance forms are provided in the Appendix Copy them and keep them up to date as an aid in troubleshooting if you have problems later Maintenance Log This information should to be filled out as the maintenance is done These forms can be very helpful when troubleshooting the filter system Again all paperwork should be filled out to ensure that all the warranty requirements are met Do not use the originals Make extra photocopies of the Check List and Maintenance Log provided in the appendix of this manual Turbo Disc Operations amp Maintenance 39 4 1 Maintenance Schedule A regular scheduled system maintenance program is important in keeping your system at it s best performance Routine Inspection Ensure that the controller is properly working and that all backflush settings are properly adjusted Check the system pressures inlet and outlet and that the PD gauge matches the inlet outlet differential Make sure the pressure differential gauge is set at the correct PD setting and that it properly initiates a backflush Look for any leaks in the system and drain the inlet filter of any dirt water that may be inline Monthly Inspection Maintenance Manually initiate a back flush cycle and make sure all valves are actuating and the filters are back flushing properly Open one or all pods and check for any visible damage and ensure that all discs are being sufficiently cleaned If th
18. 2 103 mm X 4 mm Cartridge Base O Rings and groove Carefully push the disc stack in the housing base See section 7 2 2 paragraph 9 amp 10 Disc Cleaning 9 Put the pod lid on the filter stack and secure with the safety clamp See section 6 2 Filter Opening and Closing Follow the instructions below for inspecting the piston and spring mechanisms Open the safety clamp and carefully remove the pod lid See Section 5 5 2 Remove the filter element See section 6 2 Filter Opening and Closing 3 Remove the actuator spring and retainer cup Special tool used to remove cup then dis assemble the piston and cup assembly Clean these parts in clean water 5 Reassemble the actuator spring and retaining cup 50 Turbo Disc Operations amp Maintenance 6 On the housing base start with any two 2 opposite metric M14x1 screws and tighten snuggly 7 Put the two 2 remaining screws on and then tighten all of the screws with the 17mm spanner wrench 8 Unscrew the metric M14x1 screws in the filter element base with a metric 17mm spanner wrench Always unscrew two 2 opposing screws first 9 After the first two 2 screws are removed and set aside unscrew the second two 2 screws Hold the retaining bracket in place for the next step 3 Unscrew the M14x1 screws of the filtering element base with a 17mm sspi eplees teady while box spanner Always steady wh E E unscrewing the begin unscrewing n remaining scre
19. A Backflush Cycle Inlet Pressure Low PSID 00 0 Press OK to Start Inlet Pressure Low gt gt High PSID lt lt Press OK to Start A Backflush Cycle Status AUTO PSID 2 E Status AUTO gt gt High PSID lt lt K to Start A Backflush Cycle 70 Turbo Disc Operations amp Maintenance Status of the controller continued 3 Status ON Indicates that the system is in backflush mode initiated either by the Operator by the Backflush Interval Timer or the Pressure Transducers The controller will stop displaying the PSID value but will instead indicate which Status ON station is currently in a backflush or dwell Pre Dwell Press to FF Pre Dwell is displayed as soon as the Backflush cycle has Press ESC to Sto begun In systems without a Backflush Bypass Pump the Backflush MASTER output is turned on This is connected to the Pressure sustaining valve to allow for a back pressure to develop high enough for a proper backflush to occur On sys tems with a Backflush Bypass Pump this pump will be turned on to allow for a back pressure to develop high enough for a proper backflush to occur This Pre Dwell time is setup nominally for 5 seconds and adjusted on Setup screen 4 This output stays on throughout the entire backflush cycle After this pre dwell time the back pressure will be sufficient and 01 Backflush will be displayed This means that the first filter pod has been selected for backflu
20. EQUIPMENT LOSS OF TIME INCON VENIENCE LOSS OF PROFITS OF ANY DIRECT OR INDIRECT INCIDENTAL OR CONSEQUENTIAL LOSS OR DAMAGES RESULTING FROM OR ATTRIBUTABLE TO THE USE OF THE PRODUCT This warranty is governed by the Laws of the State of Florida Venue and jurisdiction of any case or controversy related to the use of this product or this warranty shall lie exclusively in the State Courts of Volusia County Florida 88 Turbo Disc Operations amp Maintenance Important Contacts Miller Leaman Inc Main Office United States Local Representative 800 Orange Avenue Daytona Beach FL 32114 Toll Free 800 881 0320 Local Phone 386 248 0500 Facsimile 386 248 3033 E Mail sales millerleaman com Internet www millerleaman com Affix System Label Here l If a system Label is not affixed rec ord the Turbo Disc Filtration System 5 serial number in the space below The serial number is located on the System Identification Label Serial TD Revision ML40001 Rev Q Turbo Disc Operations amp Maintenance 89
21. EU Tasks Chack Cledni MS Data Tials AE EA AE Bl E POS A e INSI IO IESO ISS O O O AER AAA E e E e AA EE PORN E O O O E BS AA A O O ee ee Rio S a A E AAA A AAA EA AENA ES AE lo E E Y TA EEES E EAT BAENA E REAL E sp o 2 S S IS AAA EA EE ESE E a EC RR E FF 44 _ EE ACE ep o O ECA E E O O a a E IO IESO O O O S a E SE E ja E EE E E EL es S S T S up o o e e S S T S jo E E OE E E IESO IESO IS O IS IES S BU lt lh lo E oo IESO O O O O ee ENANA SEA 78 Turbo Disc Operations amp Maintenance TurboDisc Maintenance Schedule Spring Summer Spring Tasks Check Clean Overhaul Date imiais Arta 0 0 o _ HAT Monthly Tasks Weekly Tasks Check Clean Overhaul Date Initials Dl o o 1 il il lo Do fo om DJ FE Spring Tasks Turbo Disc Operations amp Maintenance 79 TurboDisc Maintenance Schedule Fall Winter sis Check Clean Overhaul Date mas Mori Lo il il E To it lo to ii Monthly Tasks Weekly Tasks Check Clean Overhaul Date Initials CA E Month 8 November E wwe o o o fo Fourth Quarer o po ee a ECTS HEEE ET Monthly Tasks Weekly Tasks Check Clean Overhaul Date minis meta lo o o o il il il amy Me o o o o po Do Ms po o o o po Do Mes po o o o fo Doo Mes RN oo oo o fo Demi o o o o fo ray Me po o o o o DO Mexe DO Mes TO e 80 Turbo Disc Operati
22. Filter Bodies in the system XXXM 50 100 130 200 No Symbol Process Pump not included 70 2000 GPM No Symbol S3 S4 S6 S8 Sustaining Valve not 3 8 pressure sustaining included No Symbol Air Override Feature not Air Override Feature included Compressed Air Required Modifications No Symbol Standard System Any customer specific non standard modifications B1 B1H B2 B2H Booster System 3 inlet outlet Filter Body amp Disc Stack number of Filter Bodies in the system Air Override Feature Air Compressor mounted on Turbo Disc Operations amp Maintenance 23 2 2 Turbo Disc System Component Identification Miller Leaman Inc offers many configurations and options with the Turbo Disc Filtration System Each system is specifically designed to meet the customer s filtration needs For more detailed product information please refer to the system s product specification and other sections of the Turbo Disc System Owner s Manual The following are descriptions of the primary components of a Turbo Disc Filtration System Filter Housing Pod The filter housings contain the filter cartridges These connect to the inlet and outlet manifolds typically using a series of 3 way flow control valves The number of pods required for a specific system is determined by the flow rate influent water quality and the desired effluent water quality The manifold arrangeme
23. II ELECTRICAL MECHANICAL CIDJE FIGIHJ JITATEJC D Pump runs but no water delivered ES SE x x Not enough water delivered X X A Je ES EE Not enough pressura zm Excessive vibration E i a Y PX TX X Xx Abnormal noise Pump stops X X TX xX Overheating ee ee E RR CAUSE CORRECTIVE ACTION ELECTRICAL A No voltage in power system Check phase to phasa on line side of starter contactor Check circuit breaker or fuses B No voltage on one phasa Check phase voltage on line side of starter contactor Isolate open circuit Three Phase Units circuit breaker fuse broken connections etc C Low voltage at motor Running voltage across each leg of motor must ba 10 of nominal voltage shown on nameplate D Motor leads improperly grouped Refer to lead grouping diagram on motor nameplate for voltage E Control failure Check control devica starter contactor H O A selector switch atc for malfunction F Thermal overload switch open Check phase to phasa on line side of starter contactor G Installation failure Check motor or windings to ground with megohmmeter H Open windings Check leg to leg with ohmmeter Frequency variation Check frequency of power system Must be lass than 5 variation from motor nameplate rating A Flow through pump completaly or Locate and remove obstruction Refer to Repair Instructions partially obstructed for disassembly B Wrong direction of rotation Reverse rotation of
24. OUS OR TOO FREQUENT BACK FLUSH CYCLES Activate the Back Flush Cycle and Observe the Outlet Manifold Pressure Minimum Required Pressure is too low See Technical Specs One or more stations does not backflush properly The Maxim The Differential ee program Pressure Gauge is as been set up not working s there a Verify the incorrectly correctly Sustaining Backflush P Valve in the lao System Backflush Check the Inlet amp Duration time Outlet pressure is too short readings at the increase the Differential value Pressure Gauge Verify there are The Sustaining att no leaks in the Valve is not The interval piping or filters Working property between Check the Repair backflushes is Check the lines and amp User Manuals too short raise connectors at the the Backflush Differential Pressure Verify the Interval timer Gauge for leaks Backflush Pump value and Gauges are operational Check the electrical connections at the Differential Pressure water is Gauge Verify Open worse than contact at power off expected amp no system flow pressure If the Problem Persists or You The water flow Have questions Contact Your distributor Inlet Flow too high rate is greater than expected 76 Turbo Disc Operations amp Maintenance Section 7 Appendix Turbo Disc Operations amp Maintenance 77 TurboDisc Maintenance Work Log TurboDise description Serial Number Do Location o
25. PSID lt lt on dis play or manually by the operator by pressing the green OK button on the controller The controller displays Status OFF when there is no voltage present at input 2 on the con troller On Full Flow Systems an inlet pressure switch is used to sense sufficient inlet pressure and allow for timed backflushes to occur On these systems when the switch senses inlet pres sure is low the backflush interval timer will be paused and a timed backflush will not occure The Status screen will dis play Inlet Pressure Low A backflush can still occur from a high pressure differential via the optional PD gauge indicated as gt gt High PSID lt lt on the display or manually by the oper ator by pressing the green OK button on the controller Status AUTO Indicates that the controller is waiting for a backflush cycle to begin The system is assumed to be in nor mal filtration mode and flowing water The backflush inter val timer is running The controller displays Status AUTO when there is a voltage present at input 2 on the controller and a backflush cycle has not begun A backflush can still occur from a high pressure differential via the Pressure Trans ducers indicated as gt gt High PSID lt lt on the display or manually by the operator by pressing the green OK button on the controller Status OFF PSID 00 0 Press OK to Start A Backflush Cycle Status OFF gt gt High PSID lt lt Press OK to Start
26. SI over the clean filter operating pressure to ensure proper back flush filter operation Note If the system has a booster pump with a relay in the starter box then there will be a second selector switch on the front panel of the motor starter box The Booster Pump HAND OFF AUTO HOA switch on the front panel of the starter box should be set to the AUTO position for normal operation The OFF position will always turn the booster pump OFF and the HAND position will always turn the booster pump ON This switch only controls the Booster Pump motor circuit See the switch labels on the motor starter box for operating instructions Once the system is flowing water out of the outlet manifold it is recommended that the operator manually cycle through several back flush cycles during initialization to insure proper set up and to become familiar with the system This will also help to determine what the operational settings periodic pressure differential need to be for your system 36 Turbo Disc Operations amp Maintenance If there is a booster pump check and make sure it is turning on and developing pressure If the booster pump manifold contains a pressure regulating valve check to make sure the booster mani fold pressure is between 60 and 80 psi during back flush sequence This reading may be higher dur ing the timing dwell period between filter pod sequences but this is normal 3 4 Normal System Operation The automatic Tu
27. Turbo Disc Operations amp Maintenance Section 1 Introduction to Automatic Filtration This manual was written assuming the reader has only limited knowledge of automatic filter sys tems Therefore the filter manual has been divided up into several major sections to illustrate and to give the user the knowledge to troubleshoot and repair Miller Leaman automatic filter systems It is expected that the user have at least a basic understanding of mechanics and electronics However even in these cases the explanations in the manual will guide the user through the process of disassembly cleaning and repairing of all of the basic maintenance items involved with automatic filter systems Through the use of numerous graphics and illustrations the user will be able to quickly find the problem and fix the filter to get it back on line The first part of this chapter will outline the basic parts of the automatic filter system These illus tration while general will allow the user to quickly identify the part its name and description how it works and how to get it cleaned or repaired In many cases an inoperative filter only needs pre ventative maintenance and periodic cleaning of the filter elements Please read and try to identify the basic parts and assemblies of the filter system before attempting maintenance or repair Once an understanding of how the filter system works and what the auto matic control features actually do can the user
28. aling gasket Carefully place the filter pod lid over the housing base and align the safety clamp in place Close the safety clamp handle along with installing the anti opening clip Install and tighten do not force the safety lock bolt in place to avoid accidental opening of the filter unit Be sure to install the Safety lock bolt to avoid accidental opening of the filter unit during maintenance operations Turbo Disc Operations amp Maintenance 49 5 4 Maintenance of Filter Cartridge O Ring Inspection and Replacement Make sure the filter unit is depressurized before opening the clamp ring Close the inlet and outlet valves to isolate the filter The following steps are used for inspecting and replacing the filter stack O rings 4 Check the condition of the O Rings on both the top 1 Open the safety clamp and carefully remove the filter lid See section 6 2 Filter Opening and Closing 2 Carefully remove the filter element stack See sec tion 7 2 2 Disc Cleaning paragraph 3 Remove the piston actuator See section 6 2 para HDPE Split O Ring graph 3 and 4 Disc Cleaning and bottom of the filter stack 5 Replace the O Rings if they are worn or have flat tened sides on them 6 Replace the actuating piston back on the filter stack turning it so that it is aligned See section 7 2 2 Disc Cleaning Inspect the HDPE Piston O Ring for damage Lubricate the housing base of the filter stack at the two
29. amp Maintenance 19 This page intentionally left blank 20 Turbo Disc Operations amp Maintenance Section 2 TURBO DISC Product Identification 2 1 Product Identification label MILLER LEAMAN INCORPORATED 800 881 0320 Each Turbo Disc System ships fully tested and documented Seral Number acid Model Number B1 ATD2 6 x6 130M A A System Identification Label is located on the system see Design Flow 375 GPM 35 PSI E E Max Pressure 125 PSI Fig 1 The label provides key information required for Power Electrical 460 VAC 3 Phase 60 Hz 4A Requirements Air 4 CFM 80 100 PSI system operation as discussed below Air Settings Main regulator filter 80 PSI renas Secondary regulator 25 PSI Figure 1 System Identification Label Serial Number The serial number is assigned by Miller Leaman in order to track system information This number is the primary identifier to track all details on the system including test data warranty information technical phone calls etc Always keep record of this number as it allows for quick tracking of the system should any technical support be required Model Number The model number identifies the type of system and it s components Please reference the Model Number Identification Chart on the following page for a detailed breakdown Design Flow Each system is designed for a specific flow rate and pressure The definition of the flow and pr
30. ance Description The Bermad Model 350 Backflush Remote Control Valve is designed to supply me dia filters or close supply drip tight and backwash the media filters This can be done in response to an electric or hydraulic signal It functions in two modes normally closed supply shut with filters open to backflush or normally open backwash port shut with supply open to filters Note In the standard mode or without any operating devices the valve is normally open a signal is required to close supply port An automatic or manual control device alternately applies pressure into the upper diaphragm chamber to close the supply or by venting pressure from the upper dia phragm chamber to open the supply main valve to feed the filters See the note below for Bermad 2x2 and 3x3 valves which require both pressure and venting for proper operation Installation Allow enough room around the valve assembly for making adjustments and for future maintenance and disassembly work Thoroughly flush the pipeline to remove dirt scale and de bris Failure to do this may render the valve inoperable It is recommended that isolation gate valves be installed upstream and downstream of the control valve to allow for future maintenance operations Apply the proper sealant and or gaskets to the end connections Install the valve in the pipeline with the valve flow arrow on the body casting in the proper direction Install the valve horizontally with the cov
31. and TAG all sources of pow er before performing any maintenance cleaning or repairs on any piece of equipment The power sources may include electrical or stored energy Refer to the general lock out and tag procedures in this manual HIGH PRESSURE Do NOT attempt to remove filter pod or pressure gauges while system is in operation Visually inspect the Turbo Disc Filtration System on a regular basis Never attempt to operate the system with missing or damaged parts Contact a Miller Leaman Service Provider for replacement parts GENERAL INFORMATION NOTE contains information or provides comments to clarify instructions Turbo Disc Operations amp Maintenance Safety and Operational CAUTIONS Informs user when care is needed to prevent equipment damage Always Observe the Following CAUTIONS To prevent electrical shock turn off the system power prior to any maintenance The Turbo Disc filter is rated to an absolute maximum pressure of 125 PSI Exceeding the maximum system pressure may result in system damage or personal injury If the system operating pressure can exceed the filter s maximum pressure rating or if pres sure spikes may occur install pressure relief valves of a sufficient size and volume upstream of the inlet and downstream of the outlet of the filter They should be set to relieve pressure at 1 2 times the maximum operating pressure not to exceed the maximum rated pressure of 125 PSI
32. and correct it e Noise When the unit is operating under load listen closely for unusual sounds that might indicate that the unit is in distress Determine the cause and correct the problem e Operating temperature During operation heat is dissipated from the pump and driver After a short period of time the surface of the pump bracket will be quite warm as high as 150 F which is normal If the surface of the pump bracket or driver is excessive dis Turbo Disc Operations amp Maintenance 61 continue operation determine the cause of the excessive temperature rise and correct Bearing will run hotter fro a brief run in period after which is normal However worm bearings will cause excessive temperatures and need to be replaced The pump is cooled by water flowing through it and will normally be at the temperature of the water being pumped e Stuffing Box After a short period of operation verify that the stuffing box area and gland are not hot If heating is detected loosen the gland nuts evenly until water is just running out of the stuffing box in droplet form Water must not be streaming or spraying out Verify cool operation periodically Adjust gland nuts evenly as necessary for lubrication and cooling of the packing If packing is tightened to the limit of the packing gland travel additional packing is necessary Mechanical Seal Adjustment or maintenance is normally not required The seal is enclosed with in
33. ater hammer occurs Pressure relief valves are available in various sizes consult your local distributor or valve manufacturer to obtain the proper valve for your application e The Turbo Disc Filtration System requires 60 psi of downstream pressure to properly back flush If downstream pressure is less than 60 psi then a booster pump may be required Turbo Disc Operations amp Maintenance 33 3 2 Initial Installation and Set Up Mechanical Connections Connect the inlet outlet and back flush manifolds in a secure method to the system Follow the labels and flow direction arrows on the filters to make sure the system is properly connected for flow The back flush drain typically 2 NPT m connection should be plumbed to drain to atmosphere A restriction in this line or any elevation in this line will prevent the filters from back flushing properly The Back flush drain line requires a 2 minimum connection draining to atmosphere Should two 2 Back flush drain lines be plumbed together a 3 minimum connection draining to atmosphere is required NEVER put a valve in the back flush drain line The Pump suction inlet supply should be at least one pipe size larger than the pump suction connection size Refer to the pump manufactures Installation Operation and Maintenance manual for supply line connection requirements and setup Recommended Isolation valves on the inlet and outlet manifolds Electrical Connection
34. bbers White Water Gland Seal Protection Vacuum Pump Protection Golf Course Turf Irrigation Landscape Irrigation Agricultural Irrigation Automatic Turbo Disc Filter Features Extremely Low Amount of Backwash Water Volume Automatic Self Cleaning System Triggered By Differential Pressure Elapsed Time or Manual Override Centrifugal Separator Action Built Into Design Therefore Keeping Disc Media Clean Longer Before Back Flush Cycle Polypropylene Disc Media Designed for a Long Service Life Interchangeable Color Coded Disc Cartridge Options for Different Micron Levels of Filtration Modular Design with Small Footprint Continuous Supply of Downstream Flow Even During Backflush Cycle Booster Pump Option Available for Low Pressure Applications No Tools Necessary to Service Disc Cartridge Turbo Disc Operations amp Maintenance Use of this Manual Congratulations on your purchase of a Turbo Disc Filtration System This Operations and Maintenance O amp M Manual provides instructions on how to operate the sys tem and carry out routine maintenance The objective of this manual is to provide simple clear and complete instructions It is backed by Miller Leaman Inc s commitment to offer superior customer support Every effort has been made to ensure the accuracy and completeness of information in this manual General Information If any of the information or procedure explanations in this manual are unclear pl
35. cal equipment have been locked out Double check with a multi meter at the filtration systems electrical connection point to insure that the system has been de energized Isolate the system by shutting off all inlet outlet valves to the filter The back flush drain should not be closed but verify it is not connected to a pressurized source Drain water from the filtration system by one of following methods e Manually actuate the 3 way valves to back flush mode via the solenoids e Open any drain valves located on the system manifolds Disconnect and bleed air pressure from the filtration system Verify that there is not any remaining pressure in the system prior to proceeding It is now safe to work on the system Complete all required maintenance After Service Work is Complete Insure that all electrical equipment has been properly secured Insure that all of the filter pods and filtration components have been returned to their original position and properly fastened Remove all lockout devices and tags Reconnect the pneumatic connections Return the filtration system online by opening the isolation valves Slowly open the inlet valve followed by the outlet valve Turn on the controller and other electrical devices Insure that the system is online and functioning properly See Section 4 for more details on system maintenance Turbo Disc Operations amp Maintenance 13 This page intentionally left blank 14
36. ct the rubber dia phragm and internal valve seats seals for wear and pitting This periodic maintenance and inspec tion is done after the system has been shut down and de pressurized The bolts around the dia phragm chamber can be removed with out taking the valve body out of the piping manifold The rubber diaphragm and valve plunger can be removed for inspection and cleaning Replace torn or damaged diaphragms and or worn and pitted valve seats plungers as necessary It is recommend ed that the flow valves be disassembled every two 2 years Troubleshooting Refer to the 3 way Flow Valve Troubleshooting Chart below to diagnose valve symptoms 3 Way Flow Valve Troubleshooting Chart Valve Fails to Open Insufficient inlet pressure Check or create inlet pressure flow Supply to Filters flow Upper diaphragm chamber De pressurize the upper diaphragm chamber Port A is pressurized port A cover Valve plugged with debris Remove valve body and clean Valve fails to Close Debris trapped in main valve Remove valve cover diaphragm and spring to Shut Supply Pressure inspect internal seating area and Back flush Filters Diaphragm in main valve Replace the diaphragm leaking Lower diaphragm side cham De pressurize the lower diaphragm port B ber port B is pressurized side of chamber Note Only available on the 2x2 and 3x3 mod els otherwise port must be vented Note The following information on inspection and mainte
37. ction 5 Maintenance and Inspection of Filter System Components 43 5 1 Exploded View of Filter Housing and Filter o oooooocccccoccocconccnnconcrnncnnns 44 5 2 Parts List of the Filter Housing and Filter esoscrarsescirane agarro rise 45 5 3 Housing and Cartridge Maintenance amp Cleaning Instructions 46 34 Filt r ORINSS uri dlases pancarta ica 50 5 5 Filt r Piston Act ator iii EAEI 51 5 6 Solenoids and Air Valves osssrsesrsssssssoereseesrssessorreessssesseseseseeeee 54 5 7 Air line Override Check Valves scsi ii 55 5 9 Sustain Valves a c 0c2cdaserebsanetmeietdeirne EEEE AEREI E aras 55 5 9 Main Process PUMP ci eserde ti siio ioiireki sides 57 5 10 Main Pump amp Booster Pump Troubleshooting Chart 59 5 11 Checking Pump Direction of Rotation cece eee iria 60 5 12 Booster Pump Inspection and Maintenance cece sees scene eee eens 61 5 13 The 3 way Flow Control valves Inspection amp Maintenance 63 5 14 MAXIM Filter Controller Setup and Troubleshooting 65 5 15 Cleaning and General Maintenance ce ecceenc cence eee eeeeeeeaeeeaeees 73 Section 6 Troubleshooting Troubleshooting Tree Back Flush Cycle Not Complete 74 Troubleshooting Tree Water in the Drainage Manifold e cece eee 75 Troubleshooting Tree Too Frequent Back Flush Cycles System Alarm
38. cturing material of the discs in filtering element section 2 4 Components and spare parts Turbo Disc Operations amp Maintenance 47 6 Clean and wash the filter discs using only clean water Alternately a weak acid solution can be used to clean the filter discs except for polyamide filter discs Caution Be sure to follow and use all the safety protection equipment clothing gloves and safety glasses and follow all the Material Safety Data Sheet MSDS procedures for any giv en acid Note 1 Use only clean water to wash other parts of the filter Do not clean or wash any other parts of the filter in any acid solution Note 2 Polyamide disks can be cleaned and washed in only a weak solution less than 10 of sodium hydroxide Note 3 You can check the material used in the filter discs in Section 2 4 Components and Spare Parts 7 Place the discs in the filter element stack For the correct operation of the filter do not mix of different mesh sizes colors or add or subtract the number of discs on the stack 7 Place the discs in the filtering element For a correct operation of the filter make sure that the discs quantity does not vary with respect to the quantity of the factory 8 Place the filtering element piston and Set the disc height to 13 7 8 in press slightly over the piston at the time that you turn it for its adjustment 9 Lubricate the base of the filter element witha filteri
39. dge Base O rings 103 mm x 4 mm e 1 Piston Cap O ring HDPE Split No lubrication required e 2 Internal Piston Cap O rings 13 mm x 2 mm Replace the filter cartridges in the filter housings and secure the safety clamp If the suction discharge or backwash piping is removed cover openings to prevent foreign matter or small animals from entering the system If you have any questions please call 800 881 0320 to speak to a technical service representative 38 Turbo Disc Operations amp Maintenance Section 4 Regular Maintenance Procedures Visually inspect the Turbo Disc Filtration System on a regular basis Never attempt to operate the system with missing or damaged paris Contact a Miller Leaman Service Provider for replacement paris Turbo Disc Filter System Maintenance Requirements Periodic inspection and service can extend life especially under extreme operating conditions In such conditions it is recommended that an internal inspection be completed periodically Routine maintenance typically consists of partial disassembly cleaning and visual evaluation of system components Maintenance Requirements must be completed to satisfy the warranty requirements Along with the Maintenance Schedule there is a Maintenance Check List Simply put in the date and record the completed task This table should be kept up to date at all times to keep the filter equipment in top shape and to satisfy the requirements of the
40. e 73 Section 6 Troubleshooting Procedures 6 1 System Troubleshooting Backflush Cycle Not Complete BACKWASH CYCLE NOT COMPLETE Only One Station Completes the One Or More Stations Do Not Go Backflush Into Backflush Incomplete or Partial Backflush Command Verify the Clean the Backflush Filter Valve is Open Element If the Problem Persists or You Have Questions Contact Your Distributor Inoperative Control Unit Verify the Control Unitis Turned ON and the Fuse is OK Verify the Output Relays are OK Verify the Electric Solenoids are OK Verify the Pneumatic Valves are OK 74 Turbo Disc Operations amp Maintenance 6 2 System Troubleshooting Water in the Backflush Manifold Water in the Backflush Manifold Check the Operation of the Controller Unit Controller Unit is still in the Verify the Air Line Solenoid Backflush Process Valves are Operational Wait until the Back Flush is Complete Verify there is Air Pressure in the Air Lines Verify the 3 Way Flow Control Valves are Operational Verify the 3 Way Valve Diaphragms are Not Damaged Replace or Repair as Needed Water is still in the Drainage Manifold If the Problem Persists or You Have Questions Contact Your Distributor Turbo Disc Operations amp Maintenance 75 6 3 System Troubleshooting Too Frequent Backflush Cycles System Alarm Consecutive Backflush Alarm CONTINU
41. e discs are not clean and in good condition they need to be cleaned or refurbished Inspect the solenoid manifold making sure there are no air leaks and that the manual overrides are NOT turned on Seasonal Annual Maintenance Inspect the system for any leaks This should include all victaulic couplings The victualic gaskets should be lubricated with silicon gasket grease to prevent them from drying and cracking Remove all Turbo Disc Filter Cartridges Remove the filter cap Inspect the upper o ring as shown in Figure 5 1 Page 44 If the o ring shows any signs of wear or cracking replace it If this o ring does not seal the filters will NOT backflush We recommend replacing these o rings every 2 years Remove the disks for cleaning Keep each disc stack separately to make sure the disc count does not change Check all of the 3 way valves to make sure they are operating properly Remove the top valve cover and inspect a few of the valves for signs of wear on the upper diaphragm and lower seat Depending on the back flush frequency and water conditions these 3 way flow control valves may need to be rebuilt We recommend disassembling and inspecting the flow valves after every 2 years of operation 40 Turbo Disc Operations amp Maintenance 4 2 Maintenance Check List The chart below should be used as a general guide for every day inspections and seasonal mainte nance In the Appendix of this manual is a specific Turbo
42. ease contact a Miller Leaman Service Provider for assistance ONLY service personnel trained in electrical and mechanical safety should undertake operation re pairs or servicing of this equipment If there is any concern regarding the level of training skill or comprehension of the manual s in structions please have the work done by a qualified operator or a Miller Leaman representative Failure to do so could result in injury or damage to the equipment Common sense and good judg ment are crucial to the safe and successful operation and maintenance of the Turbo Disc Filtration System 1 Read the Warnings and Safety Precautions and General Equipment Lockout Procedure in this section before operating or performing any maintenance on this equipment 2 Read the Safety Procedures thoroughly before starting 3 Review all warnings and cautions that accompany any procedure and review the Warnings and Precautions section each time you prepare to perform maintenance in the Turbo Disc Filtration System 6 Turbo Disc Operations amp Maintenance Preface The Evolution of Automatic Filtration The Automatic Turbo Disc Filter sets the standard for reliable high efficiency filtration Utilizing a stack of injection molded polypropylene disc media the Automatic Turbo Disc Filter is exceptional ly durable and engineered for longevity Automatic Turbo Disc Filter systems are designed with a modular approach where multiple filter
43. em Check for leaks once there is water flow Especially around the pump 3 way valves and manifold flange connections 5 Pressurize system If your system contains both inlet and outlet valves first open the inlet valve slightly to allow the system to pressurize slowly Check for any leaks around the pump valves or flanges during this start up period Once the system has been checked carefully open the inlet and outlet valves the rest of the way If your system has an external filter bypass valve close it slowly after the Turbo Disc is running and there is water flowing in the outlet manifold Note If the motor starter box has a relay in it then the Main Pump ON OFF switch on the front panel should be set to the ON position and the Booster Pump HAND OFF AUTO HOA switch should be set to AUTO If there is NO relay in the Starter Box then the Main Pump H O A switch should be set to the HAND mode for normal operation See the switch labels on the motor starter box for operating instructions 6 Switch and leave the booster pump starter in the Automatic Mode The controller will turn the booster pump on and off during a back flush cycle The back flush cycle is set at the factory for every four 4 hours but this can be set using the menu system in the electronic controller Alternately the Pressure Differential gauge can be set to a lower pressure momentarily to initiate a back flush cycle Be sure to re set the pressure indicator to 2 to 3 P
44. ems are offered in a variety of configurations These systems can be dis cussed based on the method of back flush Except for the Air Assist model all Turbo Disc filter car tridges require 60 psi or more in order to back flush effectively In some situations when this pres sure is not adequate and other means such as and air assist or booster pump system may be required to generate sufficient pressure Note that all of the configurations may come with or without a process main pump Please review the following descriptions to understand how your system operates and how the required back flush pressure is achieved System Supplied Pressure System is used only for sites where the provided system pressure at the filtration site exceeds the required back flush pressure and where a standard manifold of filters is typ ically sufficient This system includes inlet outlet and back flush manifolds Each filter loop con tains a 3 way valve to re direct the water flow during back flush Booster Systems are ideal for higher flow situations where the process pump or provided system pressure is not adequate for back flushing the filters Booster systems are designed to filter at the pro vided system influent pressure but require a booster pump to operate during the back flush mode to increase the pressure only to the filter s that are back flushing The purpose of this type of system is to produce adequate pressure for the backwash cycle with a relat
45. er up for best performance Make certain the valve is positioned so the valve cover assembly can easily removed for future maintenance After installa tion carefully inspect or correct any damaged accessories piping tubing or fittings Tighten all fittings Startup Operation Initially insure there is flow through the valves system piping and filters In sure that a downstream demand is created a lower pressure to atmosphere Verify the air com pressor is operational and produces at least 140 psi the connections to the electrical mains and system AC voltages are correct Next open the manifold pipeline isolation valves if applicable On the main 3 way flow control valves verify the upper diaphragm chamber is de pressurized vented Likewise note that in the backflush mode the upper diaphragm chamber must be pressurized Turbo Disc Operations amp Maintenance 63 Note On the Bermad 2x2 and 3x3 valves there are two diaphragm chambers One chamber on the top cover and another on the side of the valve body In this case one chamber must be vented while the other chamber is pressurized or the valve will not operate in either the open or closed position Inspection and Maintenance Weekly inspect the system and specifically the flow control valves for proper operation Check for water leaks at the Victaulic couplings and in and arount the flow con trol valves Depending on the water effluent or at least two times a year inspe
46. essure specification can vary depending upon how the water flow is provided e Ifa process main pump is included with the system The provided number is a function of the flow curve from the system s process pump The outlet control valve should be throttled until the inlet manifold pressure matches the specified pressure on the design flow Note that the identified pressure does not consider any incoming pressure to the pump e Ifa process main pump is not included with the system customer provided flow The Design Flow is based on specifications identified by the customer during the approval process It is imperative that the customer provide the proper flow and pressure as identified Providing too much pressure or flow may result in damage to the system Providing too little flow or pressure may result in poor backflushing of the filters Turbo Disc Operations amp Maintenance 21 The flow capacity of the system can greatly depend upon the influent water quality If the actual flow does not closely follow the design flow rate or pressure please contact a Miller Leaman Technical Representative Maximum Pressure This indicates the maximum pressure allowed within the system Exceeding this pressure in any situation may cause severe injury to operators and damage to the system Note that the maximum allowed influent pressure may be less than the Max Pressure since the pressure may increase during backflush due to a pressure
47. f you are interested in becoming a distributor please complete our response form on the distributor inquiries web page We thank you for your interest in our innovative line of filtration systems Message from our Vice President Chris Shuster THANK YOU for considering our innovative Turbo Disc filtration products This manual is de signed to give you all the necessary information about our Turbo Disc filtration products If you find that you need additional information or clarification on information that you see please do not hesi tate to contact us In addition to the exceptional quality of our products customer satisfaction is our highest priority There are many filtration manufacturers competing in our market therefore we will endeavor to differentiate ourselves by offering unique products backed by a dedication to customer satisfaction On our website you will find extensive technical information including 3D model drawings prod uct owner s manuals and other valuable information 8 Turbo Disc Operations amp Maintenance Safety and Operational WARNINGS Three types of notices are used in this manual This section of the O amp M Manual contains Im portant Contacts Warnings and Precautions and a Glossary of Terms Contains information that if not heeded may result in personnel injury or equipment damage Because of the potential hazard from this power source it is pru dent to use LOCK OUT procedures
48. find the problem and get the filter back on line This chapter will start out by identifying the different parts and assemblies of an automatic filter sys tem While there are many possible setups depending on your filter unit they all use the same basic assemblies Motor and pumps supply and discharge manifolds filter pods and electronic con trols for the different valves Turbo Disc Operations amp Maintenance 15 1 1 Definitions of abbreviations The list below defines some of the words and abbreviations used in the automatic filter system Some words and definitions are commonly used in the water filter industry and some are used only on Miller Leaman filter systems CFM Cubic Feet per Minute GPM US Gallons per Minute O amp M Operations amp Maintenance PD Pressure Differential ppm parts per million psi pounds per square inch TEFC Totally Enclosed Fan Cooled as relating to pump motors TSS Total Suspended Solids 16 Turbo Disc Operations amp Maintenance 1 2 Definitions of terms Air override Air assist Back flow Back flush Booster pump Chemical bath Controller Debris Inlet pressure Manifold Outlet pressure Pressure relief valve Main process pump Supply pressure Throttling valve Turbidity Water hammer A feature that injects compressed air into the top of the filter in order to drain water from the filter pod during back flush A met
49. g install the system indoors or otherwise insulate the system in a small shed with heating Alternately use electric heating tape or foam insulation on the piping and valves If there is a potential for freezing weather Turbo Disc filter systems installed out doors must be winterized The following steps are recommended for freeze protection DO A Oy Oe ah 11 12 13 14 15 Shut Automatic Turbo Disc system down Turn off the pump at the motor starter Turn off the Maxim controller Shut off the air supply Disconnect power supply to the motor starter s the controller and the air compressor Relieve system pressure air and water Drain all water from the filter system Much of the water can be drained through the inlet and outlet of the system Hose bibs are located on some manifolds and can be used to drain some of the water The pump have drain plugs at the volute Remove the plug on the bottom of the volute to completely drain the pump Note A small hose and valve can be used to divert the water to a desired location The filter pods have chambers in the housing base that trap water This water needs to be removed with a water vacuum Alternately the filter pods can be removed at the clamps and the water poured out Rinse off and drain all filters filter housings valves manifolds backwash lines and pumps to remove any residual debris Inspect and lubricate filter cartridge O ring gaskets e 2 Cartri
50. ge The gauge contains orifices that may become clogged by larger particles CAUTION Make sure not to foul the pressure orifices with pipe dope or dirt as the gauge will not operate Optional Differential Pressure Gauge Set point Adjust the front face needle contact to the desired PD set point that will trigger a backflush cycle The recommended PD setpoint is 1 2 PSID above the clean gauge reading at the systems MAXIMUM flow rate Setting this gauge at low flow may result in continuous backflushing at higher flow rates since the Pressure Differential increases with flow rate Typical PD gauge setpoints are between 3 6 PSID depending on flow rate 66 Turbo Disc Operations amp Maintenance Scrolling through Menu Screens The MAXIM controller allows the operator to scroll through a selection of menu screens by pressing the A or B buttons Press A to scroll backward to the previous menu or press B to scroll forward to the next menu The LCD backlight will automatically turn on for 5 minutes when a button is pressed thus allowing the operator to easily view the menus in low light situations Power Up Screen Screen 8 the Company Information Screen is the Power Up Screen Each time the Maxim Controller is turned on or when power is returned after PEA 800 881 0320 a loss this screen will be displayed for 15 seconds The Company information Screen MAA 01 24 12 12 09 can be viewed by turning off the Maxim Contro
51. hat can attack the metal or plastic components of the pump or filters in the system Do not attempt to filter other fluids without approval from Miller Leaman Inc e Acids used for cleaning the filter disc media may cause burns Wear protective clothing and protective eyewear when using these materials After cleaning rinse the filter disc media thoroughly with clean water Always follow the safety precautions recommended by the manufacturer of the cleaning solution e Never operate the unit empty or without flow for an extended period Never run any pumps when dry e Connect this system only to AC power that conforms to the information on the system label as regards to voltage and voltage specification e De pressurize and drain the system prior to any maintenance To prevent equipment damage or personal injury be sure to always relieve the water pressure from the system e For correct installation follow the installation instructions in Section 3 Refer to the appro priate electrical diagram in the Appendix to confirm the wiring connection locations Turbo Disc Operations amp Maintenance 11 Wearing your Personal Protective Equipment PPE Safety precautions are essential when any filtration equipment is involved These precautions are necessary when using storing and servicing your Turbo Disc Filtration System If safety precau tions are overlooked or ignored personal injury or product damage may occur The filtration
52. hod of using compressed air and water to back flush the filter Water flowing in the opposite direction of the design flow direction The process of flowing water in the reverse direction through a filter in order to clean the filter element A pump that increases the water pressure in order to sufficiently back flush the filter A diluted ratio of a cleaning chemical to water for example a 5 acid bath solution to 95 water A mechanism used to regulate or guide the operation of a machine apparatus or system The remains of something broken down or an accumulation of fragments For example the particulate matter found in a water sample The pressure at the system s inlet manifold for the purposes of this manual the pressure at the inlet side of the Turbo Disc Filter A pipe fitting with several lateral outlets for connecting one pipe with others The pressure in the system s outlet manifold after the filters A valve that will release and open when the system pressure exceeds a predetermined safe limit A pump that provides flow of water through the filter system The pressure provided to the filter system often the same as the inlet pressure unless the Turbo Disc Filter includes a process main pump A valve generally located on the outlet side of the system used to control the flow rate going through the system A measurement of the amount of suspended solids within water This number is based on the amount of light that can pas
53. hould be adjusted to meet the filter s backflush requirements Refer ence the filter manufacturer s owner s manual for further information Backflush Interval The user defined interval at which the system will initiate an automatic backflush cycle The backflush Interval timer resets after any backflush cycle occurs by timer PD gauge or operator This value is adjustable from 1 minute to 1000 hrs Setting both values to zero will turn off the backflush timer It is recom mended that the operator adjust the backflush interval timer so that the i Backflush Interval reached Factory Preset value is 4 Hours HOURS MM 00004 00 Enter system backflushes by time before the pressure differential set point is PSID Setpoint 07 PSID Setpoint The Pressure Differential setting in PSI which when compared to the calculated Differential Pressure from the Inlet and Out let pressure transducers will cause a Backflush cycle to begin when ex ceeded The recommended PD setpoint is 1 2 PSID above the clean PSID reading at the systems MAXIMUM flow rate Setting this PSID Setpoint at low flow may result in continu ous backflushing at higher flow rates since the Pressure Differential increases with flow rate This value is ad justable from 1 to 30 PSID Factory preset is 7 PSID Backflush Duration The time allotted for each individual filter station to backflush This time should be set according to the type of filter and Backf
54. i opening SAFETY CLAMP lock bolt device 4 Remove the filter lid carefully 3 Open the clamp with its handle 46 Turbo Disc Operations amp Maintenance Follow these instructions for cleaning the individual filtering discs in the filter element 1 Open the safety clamp and carefully remove the pod lid See section 6 2 Filter opening and closing for procedure details Carefully remove the filter element Turn the piston until it is loose Lift and remove the piston Take the filter discs off of the filter stack Do not mixed the filter discs with other filter ele ments colors Likewise do not add or subtract the number of filter discs in the filter stack QU 40 wn 2 Extract the filtering 3 Tum the piston until it 4 Remove the piston element carefully loosens A weak solution of Water and Ammonia Sulfuric acid or Hydrochloric ac id can be used to clean these filter discs except if they are made out of polyamide plastic 6 Clean the discs using clean water or an acid solution if you cannot remove the dirt from the discs In this case you should follow the protection measures according to the Safety Sheef regarding the acid to 5 Extract the discs Do not use For discs made of polyamide do not use an mix discs from different acid solution You can clean this discs using a filters to avoid changes in diluted solution of sodium hydroxide lt 10 the number of discs per Check the manufa
55. ill automatically run when the electronic controller initiates a back flush cycle Turbo Disc Operations amp Maintenance 29 Air Assist System Automatic Turbo Disc Single Pod Air Assist SPAA utilizes an air accumulator tank and a water reservoir When the system goes into backwash mode the pressurized air and the water stored in the reservoir combine to create a powerful high pressure backwash through the discs This eliminates the need for an external water source and guarantees efficient filter cleaning Illustrations from Training Short Version pdf System Operation Modes A Filtration Mode water is supplied to the system at the design flow rate not to exceed 70 GPM and at a pressure not to exceed 125 PSI The PVC gate valve at the discharge of the system must be throttled until the system pressure is the same as the design pressure As the filter produces clean water the water reservoir fills with the filtered water B B Back flush mode is initiated by pressure differential pressure timer or manually The two flow con trol valves are activated 5 seconds before the air injection valve opens This isolates the pump and dis charge before from the filter for the duration of the back flush During this time the pump is running at the shut off head The stored air and clean water are forced through the filter cartridge in reverse caus ing the debris to exit via the backwash drain Once filtration is resumed the recharge sole
56. is considered in properly sizing a Turbo Disc System the technical ex perience of a Miller Leaman Representative is often the best tool A representative who has experi ence with similar applications can greatly assist in the system specification Filter Micron Ratings Turbo Disc filters are offered in a variety of micron ratings This is a nominal rating determined based on the geometry of discs and from gathered test data It is possible for some particles greater than the filter s rating to pass through However test data has shown many particles smaller than the filter s rating are captured 18 Turbo Disc Operations amp Maintenance This increased filtration ability is often referred to as the caking effect As particles are captured within the discs the open area within each water flow path is reduced As particles continue to be captured the micron efficiency of the filter increases Smaller micron particles then become trapped within the disc channels The performance of the discs can vary depending on the properties of the media being filtered Soft er particulate are more likely to extrude and may be able to change shape in order to pass through the filter The depth of the Turbo Disc media is designed to minimize the amount of possible parti cle extrusion Harder particulate cannot easily change shape and are much easier to capture In ad dition the incoming water could contain particles in a range of micron si
57. ively small pump that only operates for short periods of time Automatic Turbo Disc Single Pod Air Assist SPAA utilizes an air accumulator tank and a water reservoir When the system goes into backwash mode the pressurized air and the water stored in the reservoir combine to create a powerful high pressure backwash through the discs This eliminates the need for an external water source and guarantees efficient filter cleaning Pressure Sustaining System utilizes a variable flow control valve on the outlet manifold to sustain sufficient back flush pressure based on the pump capacity This may reduce or shut off the down stream outlet manifold flow during back flush Some valves may also include a throttling stem to regulate or maintain the design flow during normal filtration This valve then closes during the back flush mode to generate the required back flush pressure to clean the filters Note that the throttling stem should not require any adjustment from its factory setting it is part of the system design and should not be changed Turbo Disc Operations amp Maintenance 27 System Supplied Pressure For sites where the provided system pressure exceeds the required back flush pressure and where a standard manifold of filters is sufficient This includes inlet outlet and back flush manifolds Each filter loop contains a 3 way valve to re direct flow during back flush Illustrations from Training Short Version pdf System O
58. ler s lifetime This includes cycles initiated both manually and automatically This counter cannot be reset Time Since Last Backflush Screen 5 This screen is READ ONLY for information and is not adjustable The screen shows the amount of time that has elapsed since the system last backflushed example 00011 30 Time Since Last is 11 hours and 30 minutes and how the last backflush was Backflush 00000 04 triggered There are three trigger possibilities Triggered By PD Gauge 1 Operator backflush triggered manually by an operator 2 Timer the backflush was triggered by time as set on the Backflush Interval screen 3 PD gauge the backflush was triggered by a high pressure differential as set on the PD gauge or pressure transducers Turbo Disc Operations amp Maintenance 69 The Status Screens The Status screens provide system feedback allowing the opera tor to monitor when and how the backflush cycle is occurring A backflush cycle can be started manually or automatically via the Backflush Interval Timer or the Pressure Differential Switch PSID The current Status of the controller is displayed as follows 1 Status OFF Indicates that the backflush interval timer is paused The system will not backflush by the timer There is assumed to be no flow going through the system A back flush can still occur from a high pressure differential via the optional PD gauge indicated as gt gt High
59. llers power then turning it back on again After 15 seconds Screen 8 will be changed to the Manifold Pressure Screen The i Manif P Manifold Pressure Screen displays the scaled and filtered transducer signals in PSI for ar rol d 0034 0 both the Inlet Manifold and the Outlet Manifold Also displayed is the calculated MES MRIN Pressure Differential between the Inlet and Outlet Manifolds in PSI The PSID is also displayed on the Status Screen Press the B button to scroll forward to the Status screen The next section describes the menus in the order they are seen by scrolling with the B button from the Initial Power Up screen Status AUTO Backflush Interval Pre dwell Time Seconds 00005 Dwell Time Seconds 1939 5 Backflush Duration Seconds 00040 Air Override Time Seconds 00095 1939 5 HOURS MM 00004 0909 Enter PSID Setpoint 07 aata D 4939 5 PAND E CE2 Press OK to start A Backflush Cycle Screen 1 Status Screen 2 BF Interval Screen 3 BF Duration Screen 4 Pre Dwell amp PSID Setpoint amp Air Override time time amp Dwell time E Crouzer rouzet Mila 3 ooo E Crouzet Z i Backflush Counters Maxim 10 TurboDisc Manifold Pressure Trip 00010 Controller v 3 5 Inlet 0034 0 Life 000000010 Copyright c 2013 Outlet 0032 0 Press ESC to ML31081 06 PSID 0002 0 O o O a 3103945 1903715 19394 b aata 5 Screen 5 Time Since Screen 6 BF Counters Sc
60. lling for con secutive backflushes or the Pressure Transducer values are indicating an excessive DP as compared to the individual Pressure Gauges then the operator should verify proper set ting and operation of the PSID or Pressure Transducers as well as the wiring into the Maxim Controller To reset the Consecutive Backflush Alarm first correct the cause of the alarm then push the red ESC button on the controller while a Status screen is displayed 72 Turbo Disc Operations amp Maintenance 5 15 Cleaning and Stainless Steel Maintenance Before the units leave the factory all of our filter systems are professionally cleaned using the Walter Surfox 203 stainless steel cleaning process to help prevent rust and corrosion Even though all of our filter systems use 304 316 and other stainless steels they will still rust given enough time out in the elements and weather To clean the units it is recommended that they be periodically washed with any one of the 3 in 1 car care washing detergents wash and wax products sold at auto supply stores and a green clean ing pad ScotchBrite product to remove the surface rust After they are dry applying mineral oil over all the surfaces will help protect the stainless steel from corrosion Alternately any one of the better marine anti corrosion products LPS and other manufacturers that are sold at marine supply stores can be used on the units Turbo Disc Operations amp Maintenanc
61. lush Duration the nature of the material being filtered This value is adjustable from 5 a conn Aa de Te to 300 seconds Factory Preset value is 40 seconds Seconds 00005 Air Override Time The amount of time that the Air Override solenoid turns on at the start of each filter station backflush This value is adjust able from 5 to 300 seconds Factory Preset value is 5 seconds 68 Turbo Disc Operations amp Maintenance Pre dwell Time The time allotted between the Backflush Master output signal and the first filter station backflush This period allows time for the system to build pressure via a Sustaining valve booster pump etc before backflushing begins This value is adjustable from 0 to 300 seconds Factory Preset value is 5 seconds A pre dwell time is only i necessary when using the Backflush Master output Dwell Time The amount of time allotted between the end of the backflush cycle for one filter station and the start of the backflush cycle for the next filter station in sequence This value is adjustable from O to 300 seconds Factory Preset val ue is 30 seconds Backflush Counters Screen 6 Trip The numter of backflush cycles that have occurred since the counter was last reset This includes cycles initiated both manually and automatically This counter can be reset by pressing the red ESC button from the Backflush Counters screen Life The numter of backflush cycles that have occurred in the control
62. me power failure saving of energy and low heat generation It is applicable for switching systems with impulse control Troubleshooting and Maintenance The solenoid air valves are fully tested before they leave the factory and should need little or minimal maintenance Ensure that the air lines are fully seated into the manifold block and that the air line numbers and valve numbers match up Each solenoid valve has a red manual actuator lever normally horizontal that can be used to actuate the solenoid valve for troubleshooting only energize by switching it downward and then returning the lever to the horizontal position The electric solenoid coil over time may become weak or inoperative If a spare solenoid actuator coil is available it can be swapped out to see if the problem is resolved Also verify that the sole noid plug lights up when the air solenoid valve is being actuated by the microprocessor controller and that there is air pressure and air flow to the corresponding down line process valve 54 Turbo Disc Operations amp Maintenance 5 7 Air Override Check Valves Inspection and Maintenance Troubleshooting and Maintenance Normally the check valves will need no maintenance However if water is found leaking from the solenoid air valve manifold unit then there could be several causes for this leakage One is a torn or damaged backflush water flow valve diaphragm The other is a failure of one of the air override check val
63. mp and driver After a short period of time the surface of the pump bracket will be quite warm as high as 150 F which is normal If the surface of the pump bracket or driver is excessive discontinue opera tion determine the cause of the excessive temperature rise and correct Bearing will run hot ter fro a brief run in period after which is normal However worm bearings will cause exces sive temperatures and need to be replaced The pump is cooled by water flowing through it and will normally be at the temperature of the water being pumped e Stuffing Box After a short period of operation verify that the stuffing box area and gland are not hot If heating is detected loosen the gland nuts evenly until water is just running out of the stuffing box in droplet form Water must not be streaming or spraying out Verify cool operation periodically Adjust gland nuts evenly as necessary for lubrication and cooling of the packing If packing is tightened to the limit of the packing gland travel additional packing is necessary Turbo Disc Operations amp Maintenance 57 Packing Starting a new or replacement pump Before starting a pump for the first time loosen the gland nuts and retighten to finger tight Proceed with pump start up procedure Allow the packing to leak liberally for a few moments Then tighten the gland nuts one complete turn each until the leakage is reduced to 40 to 60 drops per minute Mechanical Seal Adjus
64. nance of flow control valves is from the Bermad 350 series User Manual pdf file and is for basic troubleshooting only Complete information on this and other flow control valve products can be found online 64 Turbo Disc Operations amp Maintenance 5 14 MAXIM Controller Setup and Troubleshooting MAXIM Controller Settings Prior to start up read and fully understand this MAXIM Controller section of the Manual Turn on the controller by moving the switch to the ON position Check the control ler s settings by scrolling through the menu screens The settings are factory preset at nominal values however these may need to be adjusted to meet your system s backflush needs Be sure the Pressure Differential setpoint is properly set once there is water flow The recommended PD setpoint is 1 2 PSID above the clean gauge reading at the systems MAXIMUM flow rate Setting this PD setpoint at low flow may result in continuous backflushing at higher flow rates since the Pressure Differential increases with flow rate Typical PD setpoints are between 3 6 PSID depending on flow rate The following is a typical configuration of the Maxim 10 controller inputs and outputs CAUTION Disconnect controller from power source before removing cover Maxim Millennium III circuit board configuration A Outputs 1 7 control the backflush valves Output 8 is a relay output for the System Alarm Output 9 is an optional Air
65. ng element in chemically neutral prod the filter base by uct preferably silicone A pushing it down grease carefully 10 Put the Ro 8 Place the filter element piston over the disc stack Press the piston down and then turn clockwise to lock it into position 9 Lubricate the two 2 lower sealing O rings of the filter stack with Silicone grease or other similar lubricating grease Check the chemical compatibility of the grease with the housing base plastic molding 48 Turbo Disc Operations amp Maintenance 10 Carefully put the filter stack on to the housing base and press it down firmly 11 Place the pod lid on the filter stack and put the closing ring around the filter joint Secure the ring with the safety screw and clip See section 6 2 Filter Opening and Closing Incorrect alignment of the filter element in the housing base could cause the unit to not filter the supply water Be sure to install the Safety lock bolt to avoid the accidental opening of the filter unit during maintenance operations Always use adequate Personal Protection Equipment PPE be fore working on hazardous equipment All personal should have approved Clothing gloves and safety glasses Closing instructions 1 UB un Inspect the inside of the housing base for any foreign objects or debris in the unit Clean or flush out the debris as necessary Inspect the sealing lip around the safety clamp for scale or defects in the se
66. noid is ener gized for 15 seconds allowing the water reservoir to vent the trapped air and again fill with clean water 30 Turbo Disc Operations amp Maintenance Pressure Sustaining System Utilizes a variable flow control valve on the outlet manifold to sustain sufficient back flush pressure based on the pump capacity This may reduce or shut off the down stream outlet manifold flow during back flush Some valves may also include a throttling stem to regulate or maintain the design flow during normal filtra tion This valve then closes during the back flush mode to generate the required back flush pressure to clean the filters The system is a complete package of filters valves pumps and solenoids and controller mounted on a single frame that can easily be installed to filter water from a reservoir or sump typically not under pres sure System Operation Modes A Filtration Mode water is supplied to the system at the design flow rate The design conditions are achieved by throttling the discharge valve until the system pressure is the same as the design pressure The systems usually have a green colored flow control valve with a mechanical throttling stem This valve closes slightly to restrict the outlet flow and thereby maintains the system pressure B Back flush mode is initiated by a differential pressure gauge an internal timer or manually When the con troller initiates the start of a back flush cycle the filters will seque
67. not from looking into the impeller eye or front volute case A rotation arrow is cast into the pump body and shows the correct rotation If a centrifugal pump is running back ward it will still pump liquids However the GPM and head discharge pressure will only be a frac tion of the published performance ratings Electric motors Single phase Refer to the wiring information on the motor plate to obtain proper rotation Three phase If the pump runs backwards reverse any two leads coming off the incoming power mains at the starter box L1 L2 and L3 until the proper rotation is obtained You can reverse L1 amp L2 L2 amp L3 or Ll amp L3 CAUTION Be sure to completely disconnect all power from the electrical control panel before making nay changes If you are not sure how to safely do this have a qualified electrician do the electrical work Turbo Disc Operations amp Maintenance 5 12 Booster Pump Inspection and Maintenance The booster systems are equipped with a booster pump that draws filtered water from the outlet manifold and directs it through the booster manifolds to backwash the filters The advantage of this type of system is to produce adequate pressure for the backwash cycle with a relatively small pump that only operates for short periods of time The booster pump is sized according to the conditions of the main system primarily the flow and pressure that are supplied to the filter system Booster Pump operation d
68. nt of the filter housings allow for back flushing the filters sequentially This is the most efficient method to assure consistent results with the least amount of water usage Filter Cartridge The heart of the Turbo Disc Filter is the patent pending filter cartridge The filter cartridge is comprised of a vertical stack of grooved rings discs and the frame that holds the discs in place This frame also contains the Helix Element disc cap check valve and backflush posts that enable automatic cleaning of the discs 3 Way Backflush Valves The 3 way valves are located between the filter housing and the manifolds In order to back flush the filters the 3 way valves are actuated to redirect flow paths between the inlet and outlet water manifolds This allows the flow of water to be reversed through the filter sending pressurized filtered water through the filter post nozzles and out to the back flush drain The valves are actuated by the solenoids which are triggered by the controller Backflush Controller The back flush controller monitors and operates the back flush cycle as required by the system The controller can initiate a back flush cycle by pressure differential between the inlet and outlet manifolds time or a manually by an operator All of the critical back flush parameters are user adjustable with the menu screens Please reference the controller owner s manual for detailed operating instructions 24 Turbo Disc Opera
69. ntially back flush one at a time During the cycle a 3 way flow control valve is activated to cut off the system flow thereby increasing the back pressure on the filters being back flushed Alternately if the system is equipped with a outlet flow shut off valve this valve will close completely during back flush to generate as much pressure as possible by the pump Further if the system is equipped with a flow restrictor valve this valve will only activate partially to generate adequate pressure This type valve has an integral pilot valve that regulates the design flow Turbo Disc Operations amp Maintenance 31 This page intentionally left blank 32 Turbo Disc Operations amp Maintenance Section 3 Installation and Operating Instructions Installation and operation of the Turbo Disc system 3 1 Overview e Before installing the Turbo Disc Filtration System make sure the filter is placed on a firm and level supporting surface Failure to do this may cause stress on the weld joints Miller Leaman recommends that a concrete pad be poured for the filter frame to rest on e Be sure that a quick response pressure relief valve has been installed upstream of the inlet and downstream of the outlet of the filter system It should be set to relieve pressure at 1 2 times the maximum operating pressure but never higher than the filter s absolute maximum pressure of 125psi This is to prevent damage to the filter if severe clogging or w
70. on and Maintenance The Turbo Disc system may be built with different sole noids and or air valves However most of the current sys tems use Burkert manifold type solenoid air valves Manufacturer Burkert Contromatic USA 2602 McGaw Ave Irvine CA 92614 www burkert usa com Phone 940 223 3100 General Description The Burkert type 5470 solenoid air valves include high cycle life diaphragm seat design valves in 3 2 and 4 2 way versions The valves consists of three modules valve body with servo diaphragm plungers and valve seal solenoid operator and sub base assembly The body and air valve internal parts are made of high quality thermoplastic and a stainless steel return spring A 16mm rocker solenoid valve type 6106 with rectifier is used as the pilot Spade connectors are used for electrical contact per DIN 43 650 Form C Spades are compatible with type 2506 cable plugs or female receptacles or Berkert valve manifolds Coils can be rotated to position the spades in front for cable plugs or out the back for modular connection The manifolds can be powered through various field bus systems multi pole or common terminals The block assembly is made with pneumatic modules using integrated locking technology Type 6106 impulse version is a bi stable valve used as pilot valve for Type 5470 The operation has to be done through external pole reversal e g PLC The advantages of the impulse version are functional safety during short ti
71. on or noise e No overheating of the motor e No or low water output Troubleshooting and General Maintenance Lubrication The Liquid End of the pump requires NO lubrication Wear rings Packing rings and models using a mechanical shaft seal are lubricated by the liquid being pumped Do not run dry NOTE Grease fitting in the packing area is for priming only see PRIMING in the start up section for instruction The motor bearings are lubricated at the factory Re lubrication at intervals con sistent with the amount of use will provide maximum bearing life Refer to the Motor Instruction Manual for proper motor lubrication and maintenance instructions Performance Check Periodically check the output of the pump If performance is noticeably re duced refer the Troubleshooting Chart Observational Check When the pump and system operation have been stabilized verify the pump unit is operating properly by observing the following conditions e Vibration All rotating machines can be expected to produce some vibration However exces sive vibration can reduce the life of the unit If the vibration seem excessive discontinue opera tion determine the cause of the vibration and correct it e Noise When the unit is operating under load listen closely for unusual sounds that might indi cate that the unit is in distress Determine the cause and correct the problem e Operating temperature During operation heat is dissipated from the pu
72. ons amp Maintenance Page intentionally left blank Turbo Disc Operations amp Maintenance 81 Section 8 Replacement Parts List 82 Turbo Disc Operations amp Maintenance Page intentionally left blank Turbo Disc Operations amp Maintenance 83 Section 9 Engineering Drawings 84 Turbo Disc Operations amp Maintenance Page intentionally left blank Turbo Disc Operations amp Maintenance 85 Section 10 Bill of Material 86 Turbo Disc Operations amp Maintenance Page intentionally left blank Turbo Disc Operations amp Maintenance 87 Warranty Miller Leaman warrants its products against defects in material and workmanship under normal use and service for which such products were designed for a period of twelve 12 months after shipment from our factory Our sole obligation under this warranty is to repair or replace at our option any product or any part or parts thereof we find to be defective SELLER MAKES NO OTHER REPRESENTATIONS OR WAR RANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE The warranty set forth above is the only warranty applicable to Miller Leaman products Our maximum liability shall not in any event exceed the contract price for the product INNO EVENT SHALL MILLER LEAMAN BE LIABLE FOR ANY DELAY WORK STOPPAGE CARTAGE SHIPPING LOSS OF USE OF
73. peration Modes A Filtration Mode as described previously B Backwash Mode is initiated by pressure differential timer or manually by the controller When the controller is energized to start a backwash cycle all the filters consecutively backwash either one or two filters at a time 28 Turbo Disc Operations amp Maintenance Booster System Booster Systems are ideal for higher flow situations where the process pump or provided pressure is not adequate for back flushing the filters Booster systems are designed to filter at the provided influent pressure while a booster pump turns on during back flush to increase the pressure only to the filter s that are back flushing The advantage of this type of system is that it will produce adequate pressure during the back flush cycle with a relatively small pump that only operates for short periods of time The booster pump is sized according to conditions of the main system primarily the flow and pressure that are supplied to the filter system Illustrations from Training Short Version pdf System Operation Modes A Filtration Mode as described previously B Backwash Mode is initiated by pressure differential timer or manually by the controller When the controller is energized to start a backwash cycle all the filters consecutively backwash either one or two filters at a time The booster pump is actuated by a relay that is wired to a master Hand Auto switch in the controller that w
74. rbo Disc filter systems are designed for indoor and outdoor use There are limita tions in cases of outdoor installations and measures must be taken to prevent damage to system com ponents when exposed to the elements All Turbo Disc pump systems have a Totally Enclosed Fan Cooled TEFC motor This allows the pump to be exposed to elements including heavy rain however the pump should not be submerged in water so it is necessary that adequate drainage be provided All of the electronic control boxes and motor starter boxes are NEMA 4X The NEMA 4X enclo sure protects the electronic equipment against dirt dust hose down corrosion rain snow and sleet the des stork bom the otide da te medo Pia discs cine argred fiand bes by he de op on tap of te x stad wba on de L o a bens of the contre om the axan warns beeping his A ph dita dos oredr erpen od ISTO mts mig de t ah ima 7 hough fe cartel otter bine or 50 ispses me ha ni oba Des FILTRATION De dix cop ift hdr decompressing te de ect de scr beds tows by be gom oxen E then copied hugh he reed ip rarities bhoan by Pe omp amv pd viik m cost prg wi pag de ds dom Pia mete com lnb cot orah the alet When he bocifirh cyche is completo e dex mp compress te Gx sud ed care eron e regard Turbo Disc Operations amp Maintenance 37 3 5 Cold Weather System Operation This filter system is not freeze protected If there is a risk of freezin
75. reen 7 Machine amp Screen 8 Manifold Last BF Triggered By Trip Life Controller ID Pressure Note pressing the B button to scroll forward from Screen 8 Manifold Pressure screen causes the display to cycle back around to the beginning and display the Screen 1 Status screen Also pressing the A button to scroll backwards from Screen 1 Status screen causes the display to cycle back around to the end and display the Screen 8 Manifold Pressure screen Turbo Disc Operations amp Maintenance 67 Changing Values To change an adjustable value first scroll to the appropriate menu screen using the A or B button Follow the di rections below to modify the value 1 The current selected value will show flashing blocks Use the or keys to select another value if desired 2 Press OK on the selected value The value will change from flashing blocks to flashing numbers Flashing blocks indicate the value is locked into memory Flashing numbers indicates the value is unlocked and can be changed 3 Press the or buttons to change the value Holding the or button will allow the value to increase at a faster rate after the first 10 increments have passed 4 When finished press OK to save the change to memory The value will return to flashing blocks The following screens contain values that are operator adjustable The controller s factory preset values may not be the final operating values These values s
76. ristics of the water to be filtered operation hours number of backwash cycles and pressure differential recuperation after backwash Miller Leaman Inc recommends a three month period between the inspection of the components which involve the disassembly of the filtering element This maintenance period should be deter mined by the user according to the unique characteristics of their installation Turbo Disc Operations amp Maintenance 43 5 1 Exploded View of the Filter housing and filter 1 COMPLETE FILTER 2 LID P N H 2301 3 COMPLETE CARTRIDGE P N ATD CART XXX 4 CLAMP ASSY P N H 1101 5 FILTER BODY GASKET P N H 1501E EPDM 6 FILTER BODY 7 PRESSURE GAUGE 8 PORT CAP GASKET 9 THREADED CAP 10 PISTON CAP ASSEMBLY SEE 19 TO 24 11 DISC STACK P N ATD DISC XXX 12 PISTON CAP O RING PIN ATD 5505 13 CARTRIDGE FRAME W HELIX PLATE 14 CHECK VALVE W GASKET 15 CHECK VALVE SPRING 16 C V SPRING RETAINER 17 PORTED BASE NUTS 4 18 BASE O RINGS 2 P N H 5106E 19 PISTON CAP A PIECE 20 SS P C WASHER 2 21 PISTON CAP SPRING P N ATD 5502 22 PISTON SHAFT O RING P N ATD 5503 23 PISTON CASE B PIECE 24 PISTON CAP RETAINER CLIP PIN ATD 5518 5 PIECE O RING KIT P N ATD 5528 24 to 29 CLAMP COMPONENTS INDIVIDUAL COMPONENTS ALSO AVAILABLE 19 20 21 20 2 25 Re
77. s Connect power to the required components on your system making sure the correct voltage and amperage is supplied Systems containing a pump typically require 460 VAC standard 3 phase and must be hard wired Make sure that any pump is rotating in the correct direction clockwise when looking at the back of the motor The Controller requires 115 VAC However systems with a single point electrical connection only require a power supply that matches the pump s voltage Refer to the System Identification Label for system specific electrical requirements Compressed Air Connections Unless an air compressor is provided the Turbo Disc Filtration System requires a compressed air supply to pneumatically operate the system s valves and air override for backflush Connect a supply line to the standard 1 4 male air connector that is provided on the system The typical air requirement is 80 120psi 4 CFM Please see the System Identification Label for system specific air requirements It is recommended that an air dryer be installed for systems located in high humidity environments 34 Turbo Disc Operations amp Maintenance 3 3 Initial System Start Up For an initial start up or a seasonal restart follow the procedure below Before pressurizing the system ensure that the cartridge covers are securely fastened and the band clamps are securely latched Also check for any components that may have been damaged or disconnected
78. s necessary Remove the washers and piston spring from the outer piston shell Clean and replace as II Separate B piece from A IV Check the nuts and piston spring state 52 Turbo Disc Operations amp Maintenance Follow the steps below for actuator piston components assembly Step 1 Apply Silcone grease to the threaded rod in the outer piston shell Step 2 Place the 14 5x25x15 washer and the 64x24x4 piston spring ESP metric type and the se cond 14 5x25x15 nut on the threaded rod Step 3 Place the two 13 x 2 O rings into the inner piston cup Use Silicone grease on these parts Step 4 Insert the inner piston cup into the outer shell Be sure the O Rings stay in place during as sembly II Place a 14 5x25x15 nut the 64x24x4 5 9 ESP piston spring and the Silicone other Grease 14 5x25x15 nut in the rod of Piece A in this order I Apply lubricant in the threaded rod of Piece A 4 Step 5 Insert the C ring into the groove in the inner pis ton shaft using the C ring pli ers HI Place the two 13x2 mm joints in the interior housings of Piece B Then use lubricant in both joints IV Insert the inner piston cup into the outer shell Be sure the O rings stay in place during assembly V Insert the C ring into the groove in the inner piston shaft using the C ring pliers Turbo Disc Operations amp Maintenance 53 5 6 Solenoids and Air Valves Inspecti
79. s through the water as measured by a turbidimeter A rapid change in pressure caused by a rapid change in velocity Turbo Disc Operations amp Maintenance 17 1 3 Filtration Applications Turbo Disc Filter systems are used in a variety of markets The following list describes some of the more common markets End Use Industry Application HVAC Plastics Textiles Met Heat exchanger protection nozzle Cooling Water al protection Agriculture Landscape Mu Nozzle protection for sprinklers Irrigation nicipal Irrigation Municipal Plastic Textiles Nozzle protections pre filtration for Process Warer Electronics Food amp Beverage membranes and other media filters Municipal Plastic Textiles Nozzle protections pre filtration for Waste Water Electronics Food amp Beverage membranes and other media filters System Sizing The quality and quantity of influent water can vary greatly from one application to another The fil tration goal may also vary for different applications These items dictate the sizing of a Turbo Disc system Turbo Disc systems are typically sized based on the following data e Required flow rate or flow range e Influent water quality solids loading TSS turbidity etc e Water quality goal micron size TSS or turbidity e Other factors that may include Temperature pH and specific properties of particles being filtered While all of the data above
80. shing and its flow Status ON direction valves have started to change from the filtration po 01 Backflush sition to the backflush position At the same time the Air Press to FF i Press ESC to Sto Override output is turned on for about 5 seconds This pro vides additional air pressure to the top of the filter pods to assist with the backflush The Backflush Duration is nominal ly set for 40 seconds The Backflush Duration time and Air Override time are adjustable see Setup screen 3 for infor mation After this backflush duration time 01 Dwell will be dis played This means that the first filter pod backflushing is complete and its flow direction valves have started to change ON from the backflush position to the filtration position This pe 01 Dwell riod of time also allows for a re buildup of back pressure in Press to FF Press ESC to Sto the system for the next backflush cycle This Dwell time is setup nominally for 30 seconds and adjusted on Setup screen 4 After this dwell time 02 Backflush will be displayed The remaining filter pods will be backflushed in this same cycle pattern until all have been backflushed Turbo Disc Operations amp Maintenance 71 Status of the controller continued 3 Status ON continued After all filter pods have been backflushed the Backflush Master output will be turned off and the sustaining valve will Status AUTO open The display will show
81. sustaining valve or booster pump Power Requirements In order for the system to operate power must be provided to the system as identified on the label This includes the required electricity voltage phase frequency amps If compressed air is required the minimum CFM and pressure range will be indicated on the label Air Settings Compressed air is typically used to open close valves and to assist the backflush process The air regulators provided on the system should be set to the specifications listed on the label On systems with the air override feature the secondary regulator can only be set when the air override is on during the backflush cycle since the regulator is located after the solenoid valve Each Turbo Disc Filtration System has been designed for specific filtration applications Further information regarding each system s specific applications can be derived from the system model number This number is located on the system s product specification packing list and the System Identification Label The System Identification Label is located on the Important Contacts page of this guide and on the front of the system s control panel 22 Turbo Disc Operations amp Maintenance Turbo Disc Filtration System Model Number Identification Backflush Method No Symbol AA Sufficient backflush Air Assist System Filter Size Number of Filter Pods 2 inlet outlet Filter Body amp Disc Stack number of
82. terfly or gate valve to throttle the flow of water through the system Some systems utilize pressure sustaining valves to guarantee sufficient back flush pressure Solenoids The air solenoids provide actuation to each of the 3 way flow valves during back flush using the computer controlled Back Flush Controller The solenoids typically switch compressed air in order to open and close the 3 way flow control valves Some valves may use water pressure for actuation instead of compressed air Where compressed air is used the solenoids should be provided with clean compressed air that is regulated to the specified pressure Most solenoids contain manual override levers or buttons that allow the user to individually actuate filters into backflush for testing and troubleshooting purposes These should be used only during troubleshooting or maintenance and should never be left in the actuated position Turbo Disc Operations amp Maintenance 25 Figure 25 Typical Turbo Disc System Components Filter Cartridge SE Outlet Manifold Inlet Manifold way Valve Back flush tvianifold D Backflush Controller A Filter Housing Pod E Outlet Manifold E Inlet Manifold C 3 Way Valves 48 F Flush Manifolds H END VIEW AX Illustrations from Training Short Version pdf 26 Turbo Disc Operations amp Maintenance 2 3 System Descriptions Based on Backflush Methods Turbo Disc Filtration Syst
83. the last filter pods number and BEID 03 2 Press OK to Start Dwell This means that the last filter pod s flow direction POR seo aa ES valves have started to change from the backflush position to the filtration position After this dwell time the backflush cycle is complete and Status AUTO will be displayed To initiate a manual backflush press OK while on the status screen To skip the current backflushing station press to fast forward to the next station Note that holding the but ton will hold the cycle in a dwell until it is released At any time during the backflush cycle press ESC to stop the cycle Status System Alarm On any of the Status screens OFF Inlet Pressure Low AUTO or ON a System Alarm screen can be activated The second line down will be alternate h lyflashing gt gt System Alarm lt lt and whatever was on SESSION line 2 before the system alarm occurred gt gt System Alarm lt lt A system alarm can be any customer specific alarm The only Bee s to FF ress ESC to Sto standard system alarm is the Consecutive Backflush Alarm This alarm occurs when the backflush cycle has been initiat ed three times in a row by the Pressure Transducers or op tional Pressure Differential Switch PSID Normal operation will cause a timed backflush every four hours Nominal Backflush Interval Setting see Setup Screen 2 for adjust ment information If the PSID input is on and ca
84. tions amp Maintenance Inlet and Outlet Manifolds The inlet and outlet manifolds direct the flow of water to and from the filter housings These manifolds direct influent water into the filter housings and direct filtered water from the filter housings to the outlet The manifolds are typically constructed of type 304 Stainless Steel Optional construction materials include 316 Stainless Steel HD Polyethylene and PVC Backflush Manifold The backflush manifold directs backflush water from the filter housing to drain The discharge for this manifold should always be to atmosphere pressure Never plumb the discharge against pressure or a vertical rise This will seriously reduce backflush performance Booster Pump Booster Manifold optional booster systems Booster systems utilize a booster pump in order to increase the pressure of the filter being back flushed A booster pump takes filtered water from the outlet manifold and increases the pressure into the booster manifold This water is then used to back flush the filter s at a higher pressure Process Main Pump optional A process pump may be included as part of any system to generate flow This pump is sized specifically for the system and is designed to generate sufficient pressure for back flush often in combination with a sustaining valve or booster pump Flow Control Valve optional Many systems include a flow control valve on the outlet manifold This may be a simple but
85. tment or maintenance is normally not required The seal is enclosed within the pump and is self adjusting Seal is cooled and lubricated by the liquid being pumped Do not run the pump dry Pump Protection Cold weather wet weather installations e System Drains Provide drain valves to empty the system including the pump case to pre vent freezing damage e Shelter If possible provide shelter for the unit to protect it from the weather Allow ade quate space around the pump unit for service When effectively sheltered a small amount of heat will keep the temperature above freezing Provide adequate ventilation for the unit when running For severe weather problems or where other shelter is not practical a totally en closed fan cooled TEFC type motor should be considered e Condensation When the temperature of the metal parts of a motor are below the dew point and the surrounding air is moist water will condense on the metal surfaces which over time will cause corrosion damage In severe conditions a space heater should be considered to warm the motor unit Note The following information is from the Berkeley Motor Driven Pump User Manual pdf file and is for basic troubleshooting only Complete information on this and other motor pump products can be found online 58 Turbo Disc Operations amp Maintenance 5 10 Main Process Pump Booster Pump Troubleshooting Chart PROBABLE CAUSE SYMPTOM GROUP GROUP II GROUP I
86. uring the Backwash Mode is initiated by pressure differential timer or manually by the controller When the controller is energized to start a backwash cycle all the filters consecutively backwash either one or two filters at a time The booster pump is actuated by a relay that is wired to the master switch in the controller so it will automatically run when the controller initiates a backwash cycle The same basic procedures are followed as outlined previously in the section on main process pump maintenance and troubleshooting Study and review the Main Process Pump section on pages 59 thru 61 Maintenance and troubleshooting The Turbo Disc system has been thoroughly tested at the factory However at start up for the first time verify the following e Clockwise shaft rotation e No excessive vibration or noise e No overheating of the motor e Noor low water output Lubrication The Liquid End of the pump requires NO lubrication Wear rings Packing rings and models using a mechanical shaft seal are lubricated by the liquid being pumped Do not run dry Observational Check When the pump and system operation have been stabilized verify the pump unit is operating properly by observing the following conditions e Vibration All rotating machines can be expected to produce some vibration However excessive vibration can reduce the life of the unit If the vibration seem excessive discon tinue operation determine the cause of the vibration
87. ves located on the top of the filter covers To check for a faulty check valve remove the 1 4 black air line from the air override check valve assembly at the top of the filter pod and determine if water is passing from the filter up through the check valve Also verify that the indicator arrow on the side of the check valve is pointing downward into the filter 5 8 Sustaining Valves Inspection and Maintenance The Turbo Disc filter requires 60 PSI downstream pressure to properly backflush If the downstream pressure is less than 60 PSI a pressure sustaining valve should be installed directly downstream of the filter outlet manifold or alternately a booster pump could also be installed off the outlet manifold A pressure sustaining valve is also recommended for applications where there are high PPM concentrations and also where there is an irrigation area at a lower level elevation than the filter system site The sustaining valve should be set to activate prior to and for the duration of the backflush cycle and should be deactivated when not in the backflush cycle During the backflush mode a check of the system pressure and the differential pressure are a good indication the sustaining valve is working correctly Troubleshooting and Maintenance The water flow control valves are fully tested before they leave the factory but do need periodic maintenance over time Do a visual inspection first to en Turbo Disc Operations
88. ws two opposite screws Unscrew the first two screws 5 Remove the holder 6 Clean them carefully 7 Fit correctly the with water holding spring piece on the rods spring the spring and the disc cap 8 First tighten two opposite screws by hand afterwards tighten them with the spanner 9 Tighten the remaining screws in the same way as seen before Turbo Disc Operations amp Maintenance 51 5 5 Filter Piston actuator maintenance 1 Open the safety clamp and carefully open the pod lid Remove the filter element See section 7 2 2 paragraph 2 Disc Cleaning Remove the actuator piston See section 7 2 2 paragraph 3 and 4 Disc cleaning Disassemble the actuator piston parts and inspect for wear and damage Replace as necessary See section 2 4 Components and spare parts Follow the steps below for actuator piston removal and cleaning Step 1 Step 2 Step 3 Step 4 Remove the snap ring p n Metric 10 25mm DIN 5254 with C ring pliers p n xxxx and save the C ring off to the side Replace the c ring if it is deformed necessary I Remove the elastic ring with pliers for 10 25 mm DIN 5254 washer of straight nosed with both pliers extremes in the ring holes and opening it HI Check the 13x2 ring state housed in the B piece Remove the inner piston cup from the outer piston Shell Check the 13mm x 2mm O Ring s in the inner piston cup Clean and replace a
89. zes and often mixed with both organic algae and microbes and inorganic sand and silt particles that need considered in the filter selection process 1 4 Turbo Disc Basic Technical Data Filter Flow Rates Turbo Disc Filter systems are typically comprised of a manifold of Turbo Disc filter pods The maximum flow rate of the system is based upon the amount of filter pods the disc micron rating and the influent water quality Miller Leaman has developed test data for the maximum recom mended flow per filter cartridge based upon the micron rating However this flow rating may be reduced depending upon the influent water quality Filter Pressure Loss As flow rate through each filter increases the pressure loss will also increase Lower micron discs will have a greater pressure loss due to the smaller flow paths through the disc media Miller Leaman has developed test data for the clean filter pressure loss based on the flow rate per filter pod Note that these figures represent the pressure loss across the filter only Other pressure losses that need to be included are those in the system s piping and valves Other Filter Technical Information Ratings Permissible Temperature Range 40 to 140 degrees F Maximum Pressure 125 PSI Permissible pH Range 4 to 10 Minimum Required Backflush Pressure 60 PSI Square Inches of Surface Area per pod 231 sq in Materials of Construction Housing Polyamide Turbo Disc Operations

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