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AmeriWater CW130 Series, Operation & Installation Manual

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AmeriWater CW130 Series Operation & Installation Manual Download Page 32

29 

 6/07 

4 Maintenance 

4.1 Maintenance Schedule 

AmeriWater 

High Efficiency Filter Systems are designed for low maintenance. The following 

maintenance procedures are 

minimum 

frequency and will help to ensure continued trouble free 

operation. 

Refer to component cut sheets for maintenance

 

instructions specific to your 

equipment.

 

Note: Keep daily record of pressures, backwash count, performed maintenance and unusual 
occurrences on log sheet provided. The system log provides valuable information should 
factory service assistance be required. Contact AmeriWater 800.855.5535 if log sheets are 
needed. 

Weekly: 

Check automatic pump oilers (if applicable) 
Check pump strainer and clean as necessary 

Monthly: 

Grease pump motors (if applicable) 

Quarterly: 

Check all control functions 

Annual: 

Check pressure differential switch for proper operation 
Inspect pump and pump motor for bearing wear 
Inspect pump for seal wear 
Inspect media. Clean, add, or replace as necessary. 

Note: Expected wear life for pump seal is approximately 2 years. 
This may vary due to site specific operating conditions. 

4.2 Control Functions 

a) Actuate manual backwash by depressing and holding manual backwash button until

backwash light illuminates.

b) Watch system through backwash cycle for smooth valve actuation and water flow.

c) Differential pressure should be 6-12 psig when system returns to filter mode.

See start up data sheet for pressure.

Summary of Contents for CW130 Series

Page 1: ...Rev 6 07 High Efficiency Sand Filters CW130 Series ...

Page 2: ...ctions 4 i General 4 ii Control Motor Starter Package 5 iii Control Package 5 vi Pipe Connections 6 i Supply Return Lines 6 ii Backwash Supply 7 iii Waste Line 7 vii Media Installation 7 2 Documentation 9 i Media MSDS 9 ii Installation Check List 16 iii Request for Startup 17 iv Startup Data Sheet 18 v Filter Log Sheet 19 vi AmeriWater Warranty 20 3 Operation 21 i Seasonal Startup 21 ii Seasonal S...

Page 3: ...6 07 4 Maintenance i Maintenance Schedule 29 ii Control Functions 29 iii Media Level Condition 30 iv Pump Service 30 v Troubleshooting Guide 31 5 Drawings 32 6 System Component Cut Sheets 41 ...

Page 4: ...m may be broken down for shipping with major components remaining assembled Report damage or missing parts immediately to AmeriWater at 800 535 5585 This filter system must be started by a Factory Authorized Representative START UP BY ANYONE OTHER THAN AN AUTHORIZED AGENT WILL VOID WARRANTY Contact AmeriWater 800 535 5585 at least two 2 weeks in advance to arrange start up Specifications subject t...

Page 5: ...ble are contained in cardboard boxes packed in crate s 1 2 Rigging a Pallets should be lifted by a forklift or crane Filter systems should be rigged from lift points Do not allow rigging straps to contact system components 1 3 Locating Filter System a Filter should be located on a level floor or housekeeping pad b Vibration pads not included may be used under components and pipe stands for vibrati...

Page 6: ...lower pipe manifold as guide for spacing and leveling vessels CAUTION WARNING CAUTION PERSONAL INJURY MAY RESULT READ FOLLOWING CAREFULLY BEFORE PROCEEDING TIPPING HAZARD may exist on empty freestanding multi vessel systems with upper manifold attached READ THE FOLLOWING PARAGRAPH BEFORE PROCEEDING With vessels properly aligned and leveled and with lower manifold and pipe stands attached add base ...

Page 7: ...ve wiring is pre wired at factory For multi vessel systems valve wiring for vessel A is pre wired at factory Wiring for remaining vessels is coiled at each vessel Wires are tagged with number corresponding to the output number on the PLC Ref drawing TBIO 1 5 Electrical General NOTE Filter control panel and all pumps must have a solid earth ground Conduit and water pipe are NOT acceptable ground a ...

Page 8: ...ol Package Ref Drawing CPIO a The control package is pre wired at factory b Two sets of terminals located in the control panel are provided for pump control Reference drawing CPMS for terminals c Power for motorized valves is supplied from control panel terminal strip See Section 1 4 for instructions d Fuse holders connected to output terminals 9 11 are intentionally left with no fuses Fuses shoul...

Page 9: ...roperly secure all pipe runs with M F clamps or similar Pipe movement may cause filter and or pipe damage Supply and Return Lines NOTE Isolation valves are recommended convenient to filter a Connect influent supply line from pre selected point in cooling system to suction side of filter pump NOTE A foot valve check valve should be installed on suction side of self priming pump to prevent loss of p...

Page 10: ...ly sized backwash supply line to inlet side of backwash flow control device Waste Line NOTE Ensure drain is adequately sized and free flowing to handle backwash flow A swing check valve is recommended for waste lines with a vertical lift Check valve should be installed immediately after the filter waste line connection Ball Type or Spring Type Checks Are Not Acceptable For drainpipe runs exceeding...

Page 11: ... exposure c c Add media in the order as indicated on media container label Ref ML NOTE To avoid displacement of water in multi vessel systems follow this example Example Add layer 1 to all vessels then add layer 2 to all vessels and continue until all media has been added to all vessels Level each layer before adding next layer d d Fill vessel s to top with water e e Replace and secure vessel gask...

Page 12: ... silica quartz is heated to more than 870 C it can change to a form of crystalline silica known as tydimite and if crystalline silica quartz is heated to more than 1470 C it can change to a form of crystalline known as cristobalite The OSHA PEL for crystalline silica as trydimite and cristobalite is one half of the OSHA PEL for crystalline silica quartz III HAZARD IDENTIFICATION Emergency Overview...

Page 13: ...pecific first aid is necessary since the adverse health effects associated with exposure to crystalline silica quartz result from chronic exposures If there is a gross inhalation of crystalline silica quartz remove the person immediately to fresh air give artificial respiration as needed seek medical attention as needed Swallowed May cause gastrointestinal discomfort Give one or two glasses of wat...

Page 14: ...o be used Provide training about the OSHA precautions See control measures in Section 8 VIII EXPOSURE CONTROL PERSONAL PROTECTION Local Exhaust Use sufficient local exhaust to reduce the level of respirable crystalline silica to below the PEL See ACGIH Industrial Ventilation A Manual of Recommended Practice latest edition Respiratory Protection The following chart specifies the types of respirator...

Page 15: ...ith symptoms detectable changed in lung function or disability Simple silicosis may be progressive and may develop into complicated silicosis or progressive massive fibrosis PMF Complicated silicosis or PMF is characterized by lung lesions shown as radiographic opacities greater than 1 centimeter in diameter Although there may be no symptoms associated with complicated silicosis or PMF the symptom...

Page 16: ... pp 704 720 2000 Autoimmune Diseases There is evidence that exposure to respirable crystalline silica without silicosis or that the disease silicosis is associated with the increased incidence of several autoimmune disorders scleroderma systemic lupus erythematosus rheumatoid arthritis and diseases affecting the kidneys For a review of the subject the following may be consulted Occupational Exposu...

Page 17: ...nd Community Right to Know Act Crystalline silica quartz is not an extremely hazardous substance under Section 302 and is not a toxic chemical subject to the requirements of Section 313 Clean Air Act Crystalline silica quartz mines and processed by Fairmount Minerals Ltd was not processed with or does not contain any Class I or Class II ozone depleting substances FDA Silica is included in the list...

Page 18: ...ram IARC International Agency of Research on Cancer ANSI American National Standards Institute MSHA Mine Safety Health Administration RDL Respiratory Decision Logic TWA Time Weighted Average STEL Short Term Exposure Limit RCRA Resource Conservation and Recovery Act TSCA Toxic Substance Control Act CERCLA Comprehensive Enviro Response Compensation and Liability Act FDA Food and Drug Administration ...

Page 19: ...uent return line connected to cooling system at point where pressure is equal to or lower than filter influent supply line ______ All pipes properly secured to avoid movement ______ Valve control wiring connected Sec 1 4 ______ Power to control panel disconnect from dedicated supply w correct voltage Sec 1 5 ______ Pump s wired from motor starter s Sec 1 5 ______ Pump s rotation correct ______ Bac...

Page 20: ...ided for startup ______ All flange bolts and unions tightened ______ Media installed ______ Vessel caps installed and secured ______ Isolation valves check valves and pump strainer installed ______ Filter effluent return line connected to cooling system at point where pressure is equal to or lower than filter influent supply line ______ All pipes properly secured to avoid movement ______ Valve con...

Page 21: ...18 6 07 2 4 Startup Data Sheet ...

Page 22: ...19 6 07 2 5 Filter Log Sheet ...

Page 23: ...side of the place s of business of AmeriWater nor travel expenses to fulfill its obligations hereunder AmeriWater neither assumes nor authorizes any person to assume for it any other liability in connection with the sale of Products This warranty shall not apply to any Product that has been subjected to abuse misuse alteration neglect or accident nor to any Product that has been damaged as a resul...

Page 24: ...rain water to top of sand then close drain Inspect filter media Sand should appear clean and loose Manually remove any debris from top of sand e Level of sand in the filter vessel should be approximately 7 5 8 5 from bottom of filter inlet If media level is below normal or appears other than loose sand contact AmeriWater 800 855 5535 Note Media may appear colored This condition is common and usual...

Page 25: ... Check system for unusual noise or vibration Contact AmeriWater 800 535 5585 if any unusual conditions are noted 3 2 Seasonal Shutdown If the filter system will be shut down for a prolonged period of time over 1 week the following procedures should be performed a Backwash the system to remove debris from media b Isolate and secure the filter system c Drain system from system drain Ref Drawing CW a...

Page 26: ...ter the filter cycle valves will advance to the service mode In service mode all service valves 1 2 will be open and all backwash valves 3 4 will close The filter pump will be disabled for a period of 60 seconds to allow the cycle valves to move into proper position Applying power to the control box also starts a timing mechanism that initiates automatic backwash cycles at predetermined intervals ...

Page 27: ... being initiated by demand from the differential pressure switch the backwash will be delayed only briefly Demand for a backwash will continue until the differential pressure is brought below the preset threshold Automatic backwash timer The backwash timer will automatically initiate a backwash at pre determined intervals The standard interval is every 24 hours This can be changed to a 7 day inter...

Page 28: ...kwash Interlock input locks out initiation of a backwash cycle in a multiple paired system When one system is in backwash all other paired units in a multi system are locked out of going into a backwash cycle until the previous system finishes the backwash cycle 3 Backwash Storage Tank Abort Utilized for filter systems using a backwash storage tank An input signal is sent from the float switch in ...

Page 29: ...l Pressure Switch Monitors the operating differential pressure of the filter and initiates a backwash at 18 PSID Fuse and Input Output Terminal Description 9 FU1 Main 2 Amp fuse for PLC power 10 FU2 Main 2 Amp fuse for the control panel power 11 P Installing the fuse enables the filter pump to run during backwash Primarily used for system water backwash 12 7 Installing fuse changes frequency of ba...

Page 30: ...activated when filter is in service 18 Terminal 1 18 Storage Tank Abort Input Dry contact input from backwash storage tank When activated aborts the backwash and returns the filter to service 19 Terminals 22 23 Dry Contact Dry contact output when unit is in backwash 20 Memory Module Provides a read only status of the PLC TERMINALS DESCRIBED IN ITEMS NUMBERED 14 THRU 19 WILL BE DIFFERENT TERMINAL N...

Page 31: ...28 6 07 ...

Page 32: ...kly Check automatic pump oilers if applicable Check pump strainer and clean as necessary Monthly Grease pump motors if applicable Quarterly Check all control functions Annual Check pressure differential switch for proper operation Inspect pump and pump motor for bearing wear Inspect pump for seal wear Inspect media Clean add or replace as necessary Note Expected wear life for pump seal is approxim...

Page 33: ...systems with iron oxide or organic particles Remove any loose debris or small amount of accumulated cake g Push a broomstick or other rod into sand Rod should penetrate media with relative ease until gravel is contacted h Top of sand should be approximately 7 5 8 5 below bottom of inlet manifold i Add or replace sand as necessary j Refill vessel s with water k Replace vessel cap gasket and secure ...

Page 34: ...Normal 5 gallons per hour Symptom Does Not Backwash Control Power Failure Energize control panel Blown Control Panel Fuse Replace fuse Differential Switch Failure Consult factory representative Improper Control Sequencing Low Voltage to Panel Check power supply Consult factory representative Fuses Blowing High Voltage to Panel Check power supply Short Circuit Check wiring Wrong size fuse Check fus...

Page 35: ...ng A B C D E F G Copper PVC 40 11 16 H I J K L M N 40 5 16 30 3 4 30 3 4 36 3 4 42 3 4 27 1 2 27 1 2 49 82 5 16 82 3 16 75 15 16 75 11 16 8 7 8 53 32 20 15 73 7 8 49 32 20 36 3 4 42 3 4 8 7 8 53 15 73 7 8 Higher pressure systems available Closed loop systems only does not include tower water backwash piping PVC piping only available on 100 PSI systems All data shown above are nominal values and su...

Page 36: ...33 CP Control Panel Enclosure with Labeled Components ...

Page 37: ...34 ...

Page 38: ......

Page 39: ...36 TBIO Input output strips on Terminal block labeled to indicate connection points ...

Page 40: ...37 CPIO Input output strips on PLC labeled to indicate connection points ...

Page 41: ...RESSURE SETTING BEING 40 PSIG a CITY WATER INSTALL PRESSURE REDUCING VALVE IF REQUIRED b TOWER WATER ADJUST TOWER WATER BACKWASH VALVE TO KEEP PRESSURE WITHIN RANGE 2 MAXIMUM BACKWASH WATER TEMPERATURE IS 140 F CONSULT CHEMWORKS 3 CONSULT CHEMWORKS FOR PIPE RUNS GREATER THAN 20 FROM FILTER 4 ALL PIPING MUST MEET STATE AND LOCAL PLUMBING CODES 5 SINGLE POINT ELECTRICAL CONNECTION TO CONTROL PANEL 6...

Page 42: ......

Page 43: ...edia Layer 1 is loaded first Media Layer 2 second etc The Media Label identifies the total quantity for example 1 OF 2 to ensure that each media layer is loaded at the correct quantity MEDIA LAYER 1 LOAD FIRST GRAVEL x Caution Product contains silica See MSDS for proper handling and safety precautions __________ OF __________ ...

Page 44: ...41 6 System Component Cut Sheets ...

Page 45: ...Model MCC INSTALLATION OPERATION AND MAINTENANCE INSTRUCTIONS INSTRUCTION MANUAL IM060R04 ...

Page 46: ...ion 4 Maintenance 4 Disassembly 4 Reassembly 5 Troubleshooting 5 Components List 6 Mechanical Seal Application Chart 6 Limited Warranty 7 Declaration of Conformity 21 Pump Model Number Pump Serial Number Dealer Dealer Phone No Date of Purchase Date of Installation Current Readings at Startup 1 Ø 3 Ø L1 2 L2 3 L3 1 Amps Amps Volts Volts ...

Page 47: ...roper voltage Motor wir ing diagram is on motor nameplate Wire size must DANGER WARNING CAUTION WARNING Hazardous fluids can cause fire burns or death limit maximum voltage drop to 10 of nameplate voltage at motor terminals or motor life and pump performance will be lowered 1 4 Always use horsepower rated switches contactor and starters 1 5 Motor Protection 1 5 1 Single phase Thermal protection fo...

Page 48: ...run dry rotating parts will seize and mechanical seal will be damaged Do not operate at or near zero flow Energy imparted to the liquid is converted into heat Liquid may flash to vapor Rotating parts require liquid to prevent scoring or seizing 6 1 Before starting pump must be primed free of air and suction pipe full of liquid and discharge valve partially open 6 2 Make complete check after unit i...

Page 49: ...with petroleum jelly to ease assembly 9 5 Check reassembled unit for binding Correct as required 9 6 Tighten casing bolts in a star pattern to prevent O ring binding 10 TROUBLESHOOTING CHART MOTOR NOT RUNNING See causes 1 through 6 LITTLE OR NO LIQUID DELIVERED See causes 7 through 17 POWER CONSUMPTION TOO HIGH See causes 4 17 18 19 22 EXCESSIVE NOISE AND VIBRATION See causes 4 6 9 13 15 16 18 20 ...

Page 50: ...r channel Rubber 304 Impeller locknut AISI 316 SS 357 Nut motor AISI 300 SS 370 Socket head screws casing AISI 410 SS 371 Bolts motor Plated steel 383 Mechanical seal See chart 513 O ring casing BUNA N Motor NEMA standard 56Y flange Rotary Stationary Elastomer Metal Parts Part No Casing O ring Ceramic BUNA 18 8SS 10K10 BUNA Carbon EPR 10K18 EPR Viton 10K55 Viton Sil Carb Sil Carb EPR 316SS 10K81 E...

Page 51: ...ir or replacement directions shall terminate Seller s obligations under this Warranty and render the Warranty void Any parts repaired or replaced under the Warranty are warranted only for the balance of the warranty period on the parts that were repaired or replaced Seller shall have no warranty obligations to Buyer with respect to any product or parts of a product that have been a repaired by thi...

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