Tekleen LPF series User Manual

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AUTOMATIC FILTERS, INC.

Tekleen

2672 S. LA CIENEGA BLVD.

LOS ANGELES, CA 90034

310 839 2828 800 336 1942

FAX 310 839 6878

www.Tekleen.com

info@Tekleen.com

LPF

USERS’ MANUAL

Table of Contents

SECTION I

INTRODUCTION

1.1

Description

1.2

Theory of Operation

1.3

Recommended Applications

1.4

Design Features

1.5

Filter Specifications Chart

1.6

Measurement Conversion Table

SECTION II

INSTALLATION AND HOOK-UP

2.1

Mechanical Hook-Up and Orientation

2.2

Plumbing Hook-Up

2.3 GB6, DP Gauge, and Electric B

ll Valve Connection

SECTION III

OPERATION AND ADJUSTMENTS

3.1

Start-up

3.2

Backflush Requirements

SECTION IV

MAINTENANCE

4.1

Filter Cleaning

4.2

Dirt Collector Replacement

4.3

Piston Removal/Replacement

4.4

Periodic Inspection

SECTION V

TROUBLESHOOTING GUIDE

5.1

Excessive Pressure Drop Through Filter Without Flushing

5.2

Frequent Continuous Flushing While Filling Main Pipeline

5.3

Frequent Continuous Flushing During Normal Operation

5.4

Screen Will Not Clean Properly

SECTION VI

SPARE PARTS

6.1

Recommended Spare Parts

6.2

Spare Parts List

APPENDICES
Appendix I

Special Construction and Features

Appendix II

System with Discharge to Atmosphere

Appendix III

Piston

ILLUSTRATIONS

Particle Removal Process

Pressure Drop Chart

LPF Cutaway

LPF with GB6 Controller

2XLPF with GB

Controller

LPF with Pressure Sustaining Valve

LPF with Bypass Relief Valve

WARRANTY

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SECTION I

INTRODUCTION

1.1 Description

The LPF series models (Low Pressure Filter) are automatic, self cleaning

screen type water filters. The filtration system consists of a tank body with

a coarse screen, fine screen, electric motor, single flush valve and an

electronic controller.

1.2 Theory of Operation

Pressurized water enters the filter inlet and travels through the coarse screen

from the outside in. The water then travels through the fine screen from the

inside out where small contaminants (down to 25 microns) are filtered. The

clean water then exits

through

the outlet.

When the fine screen becomes contaminated, a pressure differential is

sensed causing the automatic controller to open the flushing valve and start

the electric motor. When the flushing valve opens, the pressure in the

hydraulic motor chamber is reduced causing the clean water to reverse flow

at the nozzles through the filter element pushing contaminants off the screen,

through the dirt collector and out the flushing valve.

The electric motor rotates the dirt collector

water passes through the nozzles

Lateral movement allows the dirt collector to

vacuum the entire

screen

When the screen is clean, the unit automatically closes the electric valve,

returning the filter to normal operation.

The entire cleaning cycle takes approximately 10-15 seconds. It should be

noted that even during the backflush cycle the filtration process continues

uninterrupted.

1.3 Recommended Applications

Tekleen filters are ideal for filtering out silt, scale, sand, rust, dirt and organic

material like algae, zebra mussels, and clams from virtually all types of water

sources.

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1.4 Design Features

Among the many features of the LPF models is the avoidance of the danger

of forcing contaminated water back into the system, which often happens

with sand filter

. Tekleen filters will deliver clean water or no water at all.

The most predominant feature is its ability to remove organics such as algae

and other suspended particles.

All filter internal elements can be removed and disassembled from the filter

body without disruption of the plumbing.

The backwash cycle, Tekrinse, uses 90% less rinse water than other filters

on the market today.

For special constructions and applications, see Appendix I, page 13.

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Specifications: Carbon steel body with baked on powder epoxy coating or stainless
steel 316L body at the same price. Internal parts: stainless steel dirt collector,
stainless steel screen. Maximum 150 psi,

F. Standard screen mesh 50

to 1000

. Optional high temperature, and high pressure.

LPF3SP
LPF4LP
LPF4P
LPF4LPE
LPF4LP
LPF6P
LPF6XLP
LPF6LP
LPF6SP
LPF8P
LPF8LP
LPF8SP
LPF10P
LPF10LP
LPF12P
LPF12LP
LPF14P
LPF14LP
LPF16LP
LPF16SP
LPF18SP
LPF20SP

3
3
4
4
4
6
6
6
6
8
8
8

10
10
12
12
14
14
16
16
18
20

1.4
2.5
1.4’
2.5
5
2.5
8
5
7
5
8
7
7
11
11
12.5
12.5
16
16
24
24
24

200
300
300
400
500
600
800
800

1,750
1,320
1,500
1,750
1,750
2,630
2,630
4,000
4,000
6,000
6,000
7,000
8,000

10,000

Model

Flange Size

inches

Screen Area

sq. ft.

Max Flow

gpm

1.4 Filter Specifications Chart

1.5 Measurement Conversion Table

550

.001

325

.002

200

.003

140
105

.004

100
150

.006

177

.007

250

.010

590

.016

850

.033

Mesh
Micron
Inch

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SECTION II INSTALLATION AND HOOK-UP

2.1

Mechanical Hook-Up and Orientation

The positioning of the filter tank should be determined by the disposal of

waste water and to allow easy access and removal of filter element (Consult

manufacturer for required clearances).

The Tekleen filter can

rest on the inlet and

outlet flanges or can be

mounted on a stand if

desired.

The electronic controller

should be mounted in

close proximity to the

filter tank.

2.2 Plumbing Hook-Up

The waste discharge pipe should be at least one inch larger in diameter than

the size of the discharge valve (1” valve to 2” pipe & 2” valve to 3” pipe).

The waste pipe should be kept as short as possible with

no more than one elbow

Discharge lines should not be elevated. This will affect the pressure difference

required for the cleaning cycle. If it is necessary to run discharge lines uphill,

please consult with the manufacturer.

Note: A block valve should be installed immediately upstream of the filter.

During start-up, the block valve should only be barely cracked open to prevent

a surge of pressure across the filter when the pump is started. Once the

pump is on-line, slowly open the block valve. This would prevent any possible

damage to the filter due to a pressure surge.

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STANDARD HOOK-UP AND ORIENTATION

2.3 GB6, DP Gauge, and Electric Ball Valve Connection

Before power is applied to the electronic controller, make all connections

between controller, DP Gauge, and electric ball valve (see page

1. BALL VALVE: Plug controller into appropriate power source. Activate

manual start switch and visually inspect the open and close movement

of the ball valve.

2. FLUSHING TIME ADJUSTMENT: The flush time is normally set to 10

seconds.

Flush time should be adjusted to allow piston indicator pin to

reach the end of the slot during one backwash cycle

. NOTE:

Excessive

flush time will not improve cleaning, and may lead to filter damage

3. PRESSURE DIFFERNTIAL ADJUSTMENT: The differential switch is pre-

set for 7 psi. It can be changed to different set points (see your electronic

controller manual).

USING 1/4 INCH DIAMETER TUBING

Attach tubing to the low pressure

1/4"

fitting (on the outlet flange). Attach

the other end of the tubing to the fitting on the DP switch marked “low”

pressure.

Attach tubing to the high pressure

1/4"

fitting (on the inlet flange). Attach

the other end of the tubing to the fitting on the DP switch marked “high”

pressure.

3. If the filter comes with a piston, attach tubing to the end of piston. Attach

the other end to the fitting on the flush outlet (before the flush valve).

Important Notes: Do not run tubing more than three feet in length (preferably

two feet or less). Due to the pressure drop across the tubing, the

electronic controller may not operate properly if tubing is too

long.

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Electronic controller should be sealed completely to avoid moisture

from entering. This w

ill

prevent possible shorting of circuits.

or more operating details and set-up, please refer to your electronic rinse

controller manual.

SECTION III

OPERATION AND ADJUSTMENTS

3.1

Start-Up

During start-up, the block valve at the filter inlet should be cracked open to

prevent a surge of pressure across the filter when the pump is started. Once

the pump is on-line, slowly open the block valve. This will prevent any possible

damage to the filter due to a pressure surge.

During the initial filling of the main pipeline, there may not be enough back-

pressure downstream from the filter to allow the cleaning cycle to function

properly. Therefore, it is necessary to install a valve on the outlet line to be

partially closed (i.e., gate valve, ball valve or butterfly valve).

If a downstream main line valve is partially closed, enough to provide 15 psi

on the filter inlet pressure gauge, the self cleaning cycle will operate properly.

Once the total system is fully charged, the downstream valve can be adjusted

as long as 15 psi is maintained at the

inlet flange during the backwash cycle

If systems are to come on automatically, it is advisable to install a flow control

or a pressure sustaining valve downstream from filters to create backpressure

on filters in order to enable proper flushing while pipe lines are being filled.

Once the system is fully charged push the manual flush button on the

electronic controller, check the rotation of the electric motor on the end cover.

The motor should turn clockwise during the flush cycle.

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3.2

Back-Flush Requirements

The filter needs a minimum flow and pressure during the backflush process

to guarantee a fully effective cleaning.

The minimum flow depends on the size of the filter’s flush outlet and the

pressure during backflushing. The table below gives an indication of the

required flows.

The minimum differential pressure between the filter inlet and the flush outlet

should be at least 15 psi during backwash.

The capacity of the pump has to be sufficient to keep the pressure over 15

psi during backflushing at a flow of process flow + rinse capacity.

For example (see Fig. 3.1):

Process flow is 2

0 gpm and rinse capacity is 90 gpm

Pressure < 15 psi yields poor cleaning.

Process flow is 130 gpm and rinse capacity is 90 gpm

Pressure > 15 psi yields good cleaning.

120

160

200

240

280

320

Pressure (psi)

Flow (gpm)

CRITICAL POINT

FIGURE 3.1 BACKFLUSHING:

PRESSURE VS. FLOW

Flush Outlet Size

Flush Flow at 35 psi

(gpm)

160

2”

1”

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SECTION IV

MAINTENANCE

4.1

Filter Cleaning

Periodic cleaning and inspection of the coarse screen, if supplied, is necessary

for removal of large particles trapped in the chamber. It is also recommended

that the fine screen be inspected during coarse screen cleaning. In hard

water applications, it is beneficial to wash the fine screen in a mild acid.

Proceed as follows:

1. Turn outlet valve off completely.

2. Open the bypass valve.

3. Close inlet valve.

4. Relieve any residual pressure by detaching the 1/4” plastic tubing from

any fitting.

5. Unscrew nuts and remove lid.

6. Remove coarse screen if supplied.

7. Remove fine screen using screen puller/pusher.

Grease all o-rings with waterproof o-ring lubricant.

9. Re-assemble unit.

4.2

Dirt Collector Replacement

If the dirt collector should ever need replacing, follow steps

1 through 7 in

section

4.1 (Filter cleaning)

Then

remove the dirt collector for inspection.

4.3

Piston Removal/Replacement

If the piston needs to be removed or

replaced, follow steps outlined as follows

and refer to Fig. 4.3:

Follow steps 1-4, section 4.1

2. Unscrew all connection nuts.

3. Remove piston from the filter housing.

4. Re-assemble unit (reverse procedure).

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FIGURE 4.3 PISTON REMOVAL

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4.4 Periodic Inspection

The following parts should be inspected annually for wear and tear and

should be replaced if necessary:

Cover Seal

Coarse Screen

Fine Screen

O-rings

Piston

Electric Motor Packing

Dirt Collector

Upper Bearing

Lower Bearing

Air/Water Connections

SECTION V

TROUBLESHOOTING GUIDE

5.1

Problem: Excessive pressure drop through filter without flushing.

POSSIBLE CAUSE

Controller is not turned on.

SOLUTION

Turn on Power.

POSSIBLE CAUSE

Filter is installed backwards.

SOLUTION

Install filter according to manual drawings.

POSSIBLE CAUSE

Electric valve is wired to the controller incorrectly.

SOLUTION

Verify proper wiring, pages 18-21.

5.2

Problem: Frequent/continuous flushing while filling main pipeline.

POSSIBLE CAUSE

Downstream pressure is not available to provide vacuum cleaning power.

Rapid-filling flow rate exceeds the controllers’ pressure differential.

SOLUTION

Partially close downstream mainline valve; filter

inlet

gauge should read 15 psi.

POSSIBLE CAUSE

Filter may have been shut down “dirty” with a layer of contaminant that is

difficult to remove after it dries on the screen.

SOLUTION

A Superflush needs to be performed as follows: a downstream mainline

valve should be partially closed to increase inlet working pressure. After the

valve is partially closed, run the filter through several flush cycles. This

process uses the entire available differential pressure in the filter cleaning

process.

If this fails, the screen may be removed and cleaned manually.

5.3

Problem: Frequent/continuous flushing during normal operation.

POSSIBLE CAUSE

Very dirty water.

SOLUTION (for electronic controller only)

Increase flushing time so the indicator pin on the piston reaches the end of

the pin grove.

POSSIBLE CAUSE

The set point on the differential pressure switch is set too close to zero,

causing vibration to initiate a flush cycle.

SOLUTION

Increase pressure differential set point.

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POSSIBLE CAUSE

Screen may be partially plugged.

SOLUTION

Perform Superflush as described above in section 5.

POSSIBLE CAUSE

Dirt collector may be jammed which results in only cleaning the screen area

that is directly in front of the nozzles.

SOLUTION

Open tank and check for free movement of dirt collector mechanism.

POSSIBLE CAUSE

Piston is jammed

SOLUTION

Remove piston from the filter housing and make sure it is moving freely. O-

rings and U-cups may need lubrication.

Check mini-filter for unrestricted flow.

POSSIBLE CAUSE

Coarse screen is contaminated.

SOLUTION

While running, check pressure between filter inlet and hydraulic pressure

chamber (if available). The difference between these two Readings is the

pressure drop through the

coarse screen

. It should be zero.

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5.4

Problem: Screen will not clean properly.

POSSIBLE CAUSE

Restriction in flushing valve dump line due to long “run” distance (e.g., running

uphill, 2” line more than 20’ long, 2” line has more than one elbow).

SOLUTION

Increase pipe size, remove any elbows, avoid elevation gain of pipe after

flush valve.

POSSIBLE CAUSE

Filter was shut down “dirty” with a layer of contaminant dried on the screen.

SOLUTION

Perform Superflush as described on Section 5.2, page 10. If unsuccessful,

remove filter screen (see section 4.1, page 8) and spray the screen with a

high pressure hose to remove the contaminant.

SECTION VI

SPARE PARTS

6.1 Recommended Spare Parts

The following are recommended spare parts to keep in stock:

- Fine Screen

- Set of O-rings

- Cover Gasket

- Dirt Collector

- Upper Bearing

- Lower Bearing

- D/P Switch

- Controller Board

6.2 Spare Parts List

See filter cutaway on page 17.

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APPENDICES

Appendix I Special Construction and Features

(AUTOMATIC) BY-PASS

Sometimes it is necessary to have flow even when the filter is out off service

for periodical maintenance. In this situation, it is recommended to create a

by-pass.

FILTER WITH BY-PASS

It is very simple to create a by-pass,

especially for the on-line models.

To do so, add a block valve on both

the inlet and outlet and a bypass

with another block valve (see

drawing).

If the by-pass valves are provided

with actuators, it can be converted to an automatic by-pass system by wiring

it to the control box ( see controller manual).

II.

ASME CERTIFIED FILTERS

ASME certified filters for the LPF series are available on special order. The

lead time on these is approximately 30 to 90 days.

III.

FILTERS FOR SEVERE APPLICATIONS

The LPF series filters are available in stainless steel construction or

other special alloys for severe applications. Filters with corrosion

resistant coatings are also available. Consult with manufacturer for

availability.

FILTER WITH BY-BASS

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Appendix II System with Discharge to Atmosphere

If the filter freely discharges to the atmosphere, it is recommended that a control

valve be installed at the filter discharge. Depending on the process upstream of

the filter, the flow may be higher than the filter handling capacity. In this case, the

control vale at the outlet would be used

to create a back pressure on the system

and control the flow across the filter.

In addition, the discharge valve can be

used as a pressure sustaining valve in

cases where pressure (> 15psi) is not

adequate during backwash.

Appendix III Piston

Due to longer screens on larger filters, it is necessary to employ a piston for the

cleaning mechanism. The piston is used to move and control the linear velocity

of the dirt collector during the rinse cycles. This would enable the dirt collector to

clean the entire surface area of the screen in a spiral-downward movement.

At the end of the cleaning cycle, the flush valve closes and the normal filtration

process resumes. At the same time, the piston is energized with water pressure

which pushes the dirt collector back into position for the next rinse cycle.

FILTER WITH DISCHARGE

TO ATMOSPHERE

FILTER WITH PISTON

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PRESSURE DROP

DELT

A P

(psi)

FLOW RA

TE (gpm)

0.1

20”

16”

14”

12”

8”

10”

6”

4”

3”

2”

1.5”

1”

Filter Flange Size

100

1000

2000

10000

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WARRANTY

Automatic Filters, Inc. (AFI) warrants its filters and controllers to be free from original

defects for one year from the date of original sale. The manufacturer will replace,

free of charge, any part found defective under normal use and service within the

guarantee period, provided the product is installed, used, and maintained in

accordance with good engineering practice and all applicable instructions or

limitations issued by AFI. The manufacturer assumes no liability for incidental or

consequential damage sustained in the adoption or use of our engineering data,

service, or products. Liability is limited to the repair or replacement of the products.

No agent or representative of AFI has the authority to waive or add to this agreement.

Altered products or use of products in a manner not intended shall void this warranty.

All warranty claims must be sent along with the defective product, freight prepaid

to AFI at its business address. All warranty shipments are for the account of the

buyer. The warranty period shall be 12 months from the date of shipment to the

client.

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