Sterling SGM-250A User's Manual
Contents
1. lt p gt Water Management Systems Filtration and Separation Systems SGM 250A Sand and Gravel Filter CSM Centri Separator BFS Bag Filter SWF Full Flow Strainers Product Manual Stering Inc 2000 S 160 Street New Berin Wi 53151 Tel 262 641 8610 Fax 262 641 8653 Part Number A0568850 Revision C Bulletin No SC7 600 4 Sterling Sterlco is committed to a continuing program of product improvement Specifications appearance and dimensions described in this manual are subject to change without notice Copyright Sterling Sterlco 2008 All rights reserved Effective 4 14 2008 Part No A0568850 Revision C Bulletin No SC7 600 3 Page 2 Water Management Systems and Products Safety Considerations Sterling Sterlco water management systems products are designed to provide safe and reliable operation when installed and operated within design specifications following national and local safety codes To avoid possible personnel injury or equipment damage when installing operating or maintaining this equipment use good judgment and follow these safe practices M M M Follow all SAFETY CODES Wear SAFETY GLASSES and WORK GLOVES Disconnect and or lock out power before servicing or maintaining the system Use care when LOADING UNLOADING RIGGING or MOVING this equipment Operate this equipment within design specifications OPEN TAG and LOCK ALL DISCONNECTS before working on equipment You sh2. s local agent if you discover damage M Hold the damaged goods and packing material for the examining agent s inspection Do not return any goods to Sterling Sterlco before the transportation company inspection and authorization M File a claim against the Transportation Company Substantiate the claim by referring to the agent s report A certified copy of our invoice is available upon request The original Bill of Lading is attached to our original invoice If the shipment was prepaid write us for a receipted transportation bill M Advise Sterling Sterlco regarding your wish for replacement and to obtain an RMA return material authorization number Page 8 Water Management Systems and Products 2 3 If the Shipment is Not Complete Check the packing list The apparent shortage may be intentional Back ordered items are noted on the packing list You should have M Sterling Sterlco water management system equipment or chemical treatment products Bill of lading Packing list Operating and Installation packet Electrical schematic and panel layout drawings R A RAR Component instruction manuals Re inspect the container and packing material to see if you missed any smaller items during unpacking Determine that the item was not inadvertently taken from the area before you checked in the shipment Notify Sterling Sterlco immediately of the shortage 2 4 If the Shipment is Not Correct If the shipment is not what you o
3. best operation Use a fork lift truck when moving the larger units to avoid damage Be sure that piping to the unit has a bypass circuit The bypass circuit allows for removal of the unit for servicing without interrupting water service Connect to the inlet and outlet as labeled on the housing Solids will collect in the bottom of the housing where it will be purged out of the system Always run piping full size Filter housing maximum operating pressure is 100 psi Water Management Systems and Products 4 Specifications Sand and Gravel Automatic Backwash Filters e Model SGM 250A is equipped with automatic valves operated from a time device so that backwash is accomplished periodically on an automatic basis Dimensions in cm Shipping Pressure WwW weight differential Kg backwash SGM 250A a D 1 800 818 SG 250P Model SGM 250P Automatic ar are operated from pressure switch Pressure switch monitors the pressure drop in the filter media and activates backwash cycle at preset pressure drop Centri Separator Systems Note Not to be used for closed loop or chilled water systems back flushing eliminates chemicals added to the system Dimensions in cm Shipping gs ery Description CSM 150 150 ton 453 600 Kcal hr tower maximum e 300 ton 907 200 Kcal hr chiller maximum 29 74 19 CSM 400 400 ton 1 209 600 Kcal hr tower maximum e 800 ton 2 419 200 Kcal hr chiller maximum BFS Series Bag Filte
4. 00 operates at 45 to 70 gpm Liquid enters the upper portion of the separator housing tangentially and the solids are drawn through internal slots to the bottom chamber An electrically operated ball valve automatically back flushes the solids from the separator Periodically inspect and ensure that the purge line is clear to flow freely Water Management Systems and Products Page 15 5 3 BFS Series Bag Filters Bags are easily removed from the top of the filter housing Before removing the bag filter be sure that pressure has been relieved and that the filter housing has been isolated to prevent spill over CAUTION SEVERE INJURY WILL RESULT IF HOUSING COVER IS REMOVED UNDER PRESSURE RELIEVE PRESSURE AND ISOLATE HOUSING BEFORE REMOVING COVER Loosen and unlatch the V clamps or swing type bolts that fasten down the top of the filter housing The top is hinged on one end and will swing open Reach down and lift the bag handle and remove the filter bag Unfold and install the new bag Close the cover and tighten down the swing bolts 5 4 SWF Series Full Flow Stainless Steel Filters Periodically solids that settle to the bottom of the filter housing will need to be purged out The drainage port valve which is piped to an open drain will need to be opened to purge the debris from the reservoir Over time one should be able to accurately determine how often the valve should be opened Do not allow the debris to collect beyond the ca
5. 12 00 to 6 00 3 00 to 9 00 11 00 to 5 00 and 2 00 to 7 00 Bolt torque requirements are 3 8 bolts 15 to 25 ft lbs 4 bolts 45 to 55 ft lbs and 5 8 bolts 80 to 100 ft lbs Service Notes Water Management Systems and Products Page 17 Parts Department Call toll free 7am 5pm CST 800 423 3183 or call 262 641 8610 or fax 262 641 8653 The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to engineering design specifications which will maximize your equipment s performance and efficiency To assist in expediting your phone or fax order please have the model and serial number of your unit when you contact us ACS welcomes inquiries on all your parts needs an is dedicated to providing excellent customer service Service Department Call toll free 8am 5pm CST 800 423 3183 or call 262 641 8610 Emergencies after 50m CST call 847 439 5655 We have a qualified service department ready to help Service contracts are available for most of our products www acscustomerservice com Sales Department Call 262 641 8610 Monday Friday 8am 5pm CST Our products are sold by a world wide network of independent sales representatives Contact our Sales Department for the name of the sales representative nearest you Contracting Department Call 262 641 8610 Monday Friday 8am 5pm CST Let us install your system The Contracting Department offers any or all of t
6. 5 4 SWF Series Full Flow Stainless Steel Filters Water Management Systems and Products 1 Introduction 1 1 General Description Filtration is used on cooling tower systems or chilled water systems requiring removal of large heavy duty suspended solids Four filtration systems are available sand and gravel filters centrifugal separators bag filters and strainers Sand and gravel filters use two layers of gravel and one layer of sand for filtration It is piped in a by pass configuration A timer can be preset at any interval to automatically back wash the sand and gravel The SGM 250A sand and gravel filter is designed to handle up to 250 ton tower systems and 500 ton chiller systems The Centri Separator System uses centrifugal force by directing the water in a circular motion allowing suspended solids to drop out and be purged from the system It is piped in a by pass configuration and is supplied with an integral pump electrically operated ball valve and controls A timer can be preset at any interval to automatically purge the separator The CSM Centri Separator is available for cooling tower systems up to 400 tons and chiller systems up to 800 tons BFS bag filters use a 25 micron bag to filter suspended solids in either a by pass or full flow piping configuration A differential pressure alarm is available to warn when bag is full BFS bag filters are available for tower systems up to 150 tons and chiller systems up to 200 t
7. en release 1 Set skipper wheel so that TO DAY or number one is opposite arrow Lift tabs on skipper wheel corresponding to days regeneration as desired Skipper wheel 2 Set time of day at which unit is to regenerate by loosening this screw and turning this dial in either direction so that arrow points to desired regeneration time in the window of the black dial Then tighten screw 3 Set time of day by lifting up yellow dial and turning it in either direction until actual time is opposite arrow Sand and Gravel Automatic Backwash Filter Adjust the time control of the SGM 250A if desired The factory set timer is set to backwash four minutes every 24 hours Frequency and duration may be reset as required See diagram below to adjust timer MANUAL REGENERATION Red Dial White Dial Yellow Dial ME OF Day To change the length of backwash time rotate the complete dial assembly until the red arrow is at 11 00 Loosen the center screw and lift the black yellow and white dials together pointing to the desired time to on the red scaled dial Lift the black knob and the red dial pointer to 6 on the white scaled dial Then lift the black knob pointer to 6 on the yellow scaled dial Tighten screw Rotate the complete assembly until the red arrow is pointing to the rib on the pressure box 6 00 position The timer will now back wash for six minutes Important Make sure gears are engaged be
8. er tank with water by opening valves and Valves and are automatically controlled by a timer After you open valves and water flows and is filtered in the normal direction Take a moment now while the filter is clean to record pressure gauge readings at the inlet and outlet of the filter You Il use these readings later to determine the cleanliness of the filter media Complete the installation of the sand and gravel filter by plugging the unit into a 110 volt source of electricity The sand and gravel filter is now ready to use 3 2 Installing the Centri Separator System Selecting an Installation Site Installing Piping Place the unit on a suitable and level foundation preferably a concrete floor or pad and near the pump for best operation The location you select must also have an open drain to a sewer for purging and a 110 volt electrical source Use a fork lift truck when moving the unit to avoid damage Be sure that piping to the unit has a bypass circuit The bypass circuit allows for removal of the unit for servicing without interrupting water service Part of your Centri Separator system includes a three foot about 1 m suction leg including a priming valve connection for startup Connect the pump suction leg to the pump suction connection Sterling Sterlco recommends that you use a hose at least 142 about 38 mm in diameter for clean water flow to the pump tank Your system includes a th
9. fore tightening screw Page 14 Water Management Systems and Products The Model SGM 250P backwashes based upon pressure differential across the filter media Additionally an adjustable timer allows back washing for up to five minutes The factory setting is four minutes The pressure differential switch is adjustable for pressure drop and dead band Backwash will start when the pressure differential reaches set point plus the dead band For example if the pressure differential is set for 6 psi the dead band for 4 psi and the backwash timer for 4 minutes then the backwash cycle will start at 10 psi for a duration of four minutes Replacing Sand and Gravel Anode Replacement Replace the sand and gravel every two years when contaminated or when sand has carried over from excessive water flow There are three layers of filter media First starting from the bottom place 200 lbs of 1 2 x 1 4 round gravel Second place 300 Ibs of 4 x 1 8 round gravel and third the top final layer place 700 pounds of 20 filter sand On top of the filter housing is a sacrificial anode made of magnesium Inspect and replace when it has depleted 5 2 Centri Separator System The CSM 150 and CSM 400 require a 120 1 60 power source and are provided with a standard plug The separators are designed to operate to a prescribed flow range for maximum solid removal The CSM 150 operates at a flow rate of 10 to 20 gpm and the CSM 4
10. hese services project planning system packages including drawings equipment labor and construction materials and union or non union installations Sterling Sterlco 2900 S 160 Street New Berlin WI 53151 262 641 8600 e Fax 262 641 8653 www sterlco com Page 18 Water Management Systems and Products
11. nd flanges Maximum working pressure is 100 psi 689 5 kPa 6 9 bars 150 psi 1 034 5 kPa 10 3 bars is available Maximum operating temperature is 110 F 43 C consult the factory for higher operating temperatures 80 mesh screen size is standard for the stainless steel strainer basket 40 mesh can be used for cooling tower water applications Options include AP pressure alarm and automatic purge valve with timer Note Valving and bypass are not included with SWF Series filters BFS Series and SWF Series full flow filters must be installed with bypass piping so that plugging of the filter or temporary shutdown required for back washing does not hinder process operation Water Management Systems and Products Page 7 2 Shipping Information 2 1 Unpacking and Inspection You should inspect your Sterling Sterlco water management systems and products for possible shipping damage Thoroughly check the equipment for any damage that might have occurred in transit such as broken or loose wiring and components loose hardware and mounting screws etc In case of breakage damage shortage or incorrect shipment refer to the following sections 2 2 In the Event of Shipping Damages Important According to the contract terms and conditions of the Carrier the responsibility of the Shipper ends at the time and place of shipment The Carrier then assumes full responsibility of the shipment M Notify the transportation company
12. ons SWF Series full flow filters use a strainer basket to filter the water An 80 mesh strainer screen is standard Other mesh sizes are available upon request The filter housing strainer basket and flanges are made from 304 stainless steel A differential pressure alarm and automatic purge valve are available as an option SWF Series full flow filters are available for tower systems up to 650 tons and chiller systems up to 850 tons Water Management Systems and Products Page 5 1 2 Sand and Gravel Automatic Backwash Filters Sterling Sterlco sand and gravel filters are shipped complete with e Tank e Valve manifold e Gauges e Initial charge of sand and gravel The system switches valves automatically Two backwash control mechanisms are available Backwash cycles can be based on a time cycle SGM 250A or pressure differential across the unit SGM 250P SGM 250A sand and gravel automatic backwash filters are available in a 250 ton 756 000 Kcal hr model for cooling towers and a maximum capacity 500 ton 1 512 000 Kcal hr chiller model The SGM250A model is equipped with automatic valves operated from a timing device so that the backwash cycle automatically activates on a periodic basis Filters must be installed in a bypass line so that plugging of the filter or temporary shutdown required for back washing does not hinder process operation 1 3 Centri Separator Filter Systems Page 6 Sterling Sterlco centrifugal separa
13. ould remove the fuses and carry them with you Make sure that system equipment and components are properly GROUNDED before you switch on power Do not jump or bypass any electrical safety control Do not restore power until you remove all tools test equipment etc and the system and related equipment are fully reassembled Only PROPERLY TRAINED personnel familiar with the information in this manual should work on this equipment Water Management Systems and Products Page 3 Table of Contents 1 Page 4 Mrod CO ar eae ie ee ds 5 General Description Sand and Gravel Automatic Backwash Filters Centri Separator Filter Systems BFS Series Bag Filters J 12 q1 q1 1 SWF Series Full Flow Stainless Steel Filters O AUN Shipping Information 11ccccccneneeeeensnnsnnnsnncennnenneeneees 8 2 1 Unpacking and Inspection 2 2 In the Event of Shipping Damages 2 3 Ifthe Shipment is Not Complete 2 4 Ifthe Shipment is Not Correct 2 5 Returns Installation Law acecacnccccccncncncnccenncncnsncnnencncncnsnensnnansasesnens 10 3 1 Installing the Sand and Gravel Filter 3 2 Installing the Centri Separator System 3 3 Installing the BFS Series Bag Filter 3 4 Installing the SWF Series Full Flow Stainless Steel Filter SDeCCIICGLIIONS tae 13 ODCTAL ON so ais eres oes cgacde des aceeacgeaevenan tenes eaaaen neon 14 5 1 Sand and Gravel Automatic Backwash Filter 5 2 Centri Separator System 5 3 BFS Series Bag Filters
14. pacity of the reservoir An optional automatic purge valve is available to open based upon an adjustable time cycle Periodically inspect and ensure that the purge line is clear to flow freely CAUTION SEVERE INJURY WILL RESULT IF HOUSING COVER IS REMOVED UNDER PRESSURE RELIEVE PRESSURE AND ISOLATE HOUSING BEFORE REMOVING COVER The cover of the SWF full flow filter is removable if the strainer is clogged with debris A pressure drop of 10 psi after purging debris from the reservoir would indicate that the strainer requires cleaning Do not remove the cover under pressure Relieve the pressure and isolate the filter from the system first Lift the strainer element out of the filter housing and scrub it carefully with a rigid nylon brush and water until clean Wash it off with clean water Page 16 Water Management Systems and Products preferably a garden hose if possible Return it to the filter housing ensuring that the U shaped gasket fits securely to the bottom of the strainer Make sure that the strainer head gasket is secure Reposition the strainer cover on top of the filter housing On those models with a band clamp replace the band clamp around the strainer cover and housing latching the T bolt Then push the latch handle towards the filter housing The T bolt latch does not need adjustment when installed It is set at the factory for proper clamp compression Bolted cover models require a torque sequence as follows
15. rdered contact the parts and service department immediately at 262 641 8610 Have the order number and item number available Hold the items until you receive shipping instructions 2 5 Returns Important Do not return any damaged or incorrect items until you receive shipping instructions from Sterling Sterlco Water Management Systems and Products Page 9 3 Installation 3 1 Installing the Sand and Gravel Backwash Filter Selecting an Installation Site Installing the Unit e Page 10 Place the unit on a suitable and level foundation preferably a concrete floor or pad and near the pump for best operation The location you select must also have an open drain to a sewer for backwash a hookup to city water and a 110 volt electrical source Use a fork lift truck when moving the unit to avoid damage Be sure that piping to the unit has a bypass circuit The bypass circuit allows for removal of the unit for servicing without interrupting water service Always run piping full size at 1 2 NPT approx 38 mm Connect the entering water connection of the filter unit to the process supply and the leaving connection to the tank Use 2 NPT approx 51 mm to hook up city water or process water to the backwash connector piping as well as to connect back flush connections to the city waste or sewer Figure 1 Typical Sand and Gravel Filter Water Management Systems and Products Filling the Unit Fill the wat
16. readed barbed fitting and clamps to install the hose Priming the Pump and Preparing for Operation Be sure that the pump on your Centri Separator system is primed before you start up the system To do this connect a city water line to the priming valve Allow enough time for the suction leg to fill with water then close the priming valve Water Management Systems and Products Page 11 Complete the installation of your Centri Separator system by plugging the unit into a 110 volt source of electricity The Centri Separator system is now ready to use 3 3 Installing the BFS Series Bag Filter Selecting an Installation Site Installing Piping Place the unit on a suitable and level foundation preferably a concrete floor or pad and near the pump for best operation Use a fork lift truck when moving the larger units to avoid damage Be sure that piping to the unit has a bypass circuit The bypass circuit allows replacement of bag filter without interruption of service Connect to the inlet and outlet as labeled on filter housing Solids will collect inside the bag filter preventing spill over when the bag is removed Always run piping full size Filter housing maximum operating pressure is 150 psi 3 4 Installing the SWF Series Full Flow Stainless Steel Filter Selecting an Installation Site Installing Piping Page 12 Place the unit on a suitable and level foundation preferably a concrete floor or pad and near the pump for
17. rs Note Can be used for full flow or bypass Max flow No filter bags Pipe size Model opm lpm niet sup pees inches BFS 30 30 113 1 NPT on mm BFS 65 65 246 2 2 NPT 63 mm BFS 90 90 340 2 2 NPT 63 mm BFS 200 200 757 3 flanged 76 mm flanged BFS 300 300 1 135 4 flanged 102 mm flanged BFS 450 450 1 703 5 flanged 127 mm flanged Single cell filters include bypass pressure gauges and 25 micron filter bags Multi cell filters include pressure gauges and 25 micron filter bags SWF Series Full Flow Stainless Steel Filters e Maximum working pressure is 100 psi 689 5 kPa 6 895 bars 150 psi 1 034 25 kPa 10 343 bars is available e Maximum operating temperature is 110 F 43 C Consult factory for higher temperatures Maximum flow Connection size flange Model O g lpm inches mm SWF 100 378 2 flange 51 mm flange SWF 200 757 3 flange 76 mm flange SWF 350 1 325 4 flange 102 mm flange SWF 750 gt 6 flange 152 mm flange SWF 1300 8 flange 203 mm flange SWE 2000 i i 10 flange 254 mm flange 80 mesh screen size is standard for stainless steel strainer basket 40 mesh can be used for tower water Specify mesh size Valving and bypass are not included with SWF Series stainless steel filters Water Management Systems and Products Page 13 5 Operation 5 1 Adjusting Timer For manual regeneration move lever in direction of arrow as far as it will go th
18. tion systems are used on cooling tower or chilled water systems requiring large capacity heavy duty suspended solids removal The Centri Separator System CSM 150 is designed to handle up to 150 ton 567 000 Kcal hr cooling tower systems and up to 300 ton 907 200 Kcal hr chiller systems The CSM 150 includes a centrifugal separator hp 0 25 kW pump 2 PVC electrically activated ball valve and a 115 volt single phase 60 hertz control station The CSM 150 can be mounted on a pump tank or piped in a bypass line The system performs all operations including separator purging automatically The CSM 400 is designed for larger tower water system applications up to 400 ton 1 512 000 Kcal hr cooling tower systems and up to 800 ton 2 419 200 Kcal hr chiller systems Water Management Systems and Products Note Centrifugal separation systems must not be used for closed loop or chilled water systems back flushing eliminates chemicals added to the system 1 4 BFS Series Bag Filters BFS Series bag filters can be used for full flow or bypass applications BFS Series filters feature single cell 25 micron polyester filter bags and include pressure gauges BFS bag filters are available for tower systems up to 150 tons and chiller systems up to 200 tons 1 5 SWF Series Full Flow Stainless Steel Filters SWE Series full flow stainless steel filters feature 304 stainless steel construction of filter housings strainer baskets a
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