863 FILTERING 8ed. 06.06 new controller SA...FIRST COMMISSIONING AND ROUTINE START - UP FIRST...

EuroClean s.r.o. Podbabská 81 /17, Praha 6 , PSČ: 160 00 IČO: 26141477, DIČ: CZ26141477

Tel.: 224 811 900, Fax: 224 810 597, e-mail: [email protected], web: www.euroclean.cz

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SSeerriieess 886633--SSAA

Installation, Operation & Maintenance

Manual

Models

86302 (2”)

86303 (3”)

86304 (4”)

86306 (6”)

86308 (8”)

86310 (10”)

86312 (12”)

86314 (14”)

Board No. 86302



CONTENTS

Page

Technical Specification ……………………………………... 3

Filtration Screens ……………………………………………. 3

Materials ……………………………………………………… 4

Construction ………………………………………………….. 4

Operational Principles ………………………………………. 5

Operational Modes ………………………………………….. 6

Installation ……………………………………………………. 7

First Commissioning and Routine Start-up ……………….. 8

Automatic Operation ………………………………………… 9

Continuous Operation ………………………………………. 9

Changing Parameters On The PLC ……………………… 15

Control Box …………………………………………………… 15

Maintenance …………………………………………………. 17

Trouble Shooting Table …………………………………….. 19

Parts Breakdown …………………………………………….. 20

Parts List ……………………………………………………… 22

Hydraulic Scheme …………………………………………… 23

Head Loss/ Flow Rate Diagram ……………………………. 24

General Dimensions ………………………………………… 25

Electric Drawings ………………………………………… 15

ODIS takes all possible precautions in packing each equipment

item to prevent damage during shipment. Carefully inspect each

item, and if damage occurred, please report ODIS immediately.



General Data

Min. Working Pressure 2 bar 30 psi

Max. Working Pressure 10 bar 150 psi

For other pressure consult ODIS representative

Screen area & Maximum Flow Rates

In/Out – dia. Max. Flow Rate Flush Flow Rate Screen Area

Model Inch mm m3/h gpm m3/h gpm Sq.cm Sq.inch

86302 2” 50 25 110 8 35 2500 390

86303 3” 80 40 170 8 35 2500 390

86304 4” 100 80 350 10 44 4000 620

86306 6” 150 150 660 10 44 4000 620

86308 8” 200 300 1300 12 53 6000 930

86310 10” 250 400 1750 12 53 6000 930

86312 12” 300 470 2050 14 62 8000 1240

86314 14” 350 550 2400 14 62 8000 1240

The max. flow rate refers to screens over 200 microns/ less than 80 mesh

For a finer filtration degrees consult our representative.

Screen Grades

mesh 500 300 200 150 100 80 40

micron 30 50 80 100 150 200 400

* Other screen grades’ are available.

Electrical Data

Mains 3 Phase 380V – 50 Hz, 220V/440V – 60 Hz

Drive Assembly 1/3 HP, 1/4 KW

Control PLC operating at 24V DC

For other power supply consult ODIS representative

TECHNICAL SPECIFICATION



Filter housing : Carbon Steel , electrostatic powder coating

Optional - Stainless Steel .

Filtration Screens :Stainless Steel 316

Gaskets : SBR (Synthetic Rubber)

Optional - other materials

The standard housing of the filter is constructed of carbon steel, which has a 100

micron protective coating of extra durable polyester, applied electrostatically and oven

cured on a zinc-phosphate layer, for maximal anti-corrosion protection both internally

and externally

Access to the internal of the filter is through a removable bolted cover.

This allows for easy access for servicing and maintenance purposes. All immersed

parts are constructed of either plastic or non-corrosive metals, allowing for extended

service life.

Optional materials are available for special applications ;contact our

representative for more information.

On the end of the filter housing the electric worm-gear motor is mounted, performing

simultaneously two movements during the flushing cycle:

a. Rotation of the collector assembly with a unique designed SA (patent pending)

suction nozzles to clean the screen on its entire perimeter.

b. Longitudinal motion of the collector assembly with all the nozzles to clean the

screen on all it’s length.

Both actions clean all the surface of the filtering screen in a helical movement. The

rotation is transmitted from the worm-gear motor to the collector assembly by a sliding

key, while the longitudinal motion is transmitted by a square, double thread screw.

MATERIALS

CONSTRUCTION



1. INLET 5. OUTLET 9. WORM GEAR MOTOR

2. COARSE SCREEN 6. FLUSHING VALVE 10. CONTROLLER

3. FINE SINTERED SCREEN 7. FLUSHING CHAMBER

4. SUCTION NOZZLE (P) 8. COLLECTOR

(P) – Patent Pending

A. Normal flow pattern

The raw water enters the filter inlet and passes through the coarse screen, the first

stage of filtration. This prevents passage of large particles which may damage the

filter internals.

The water then enters the second stage of filtration, where the fine sintered screen

is located. This screen consists of a multi-layer sintered screen of stainless steel

woven mesh sintered together.

As the water passes through this screen, the solids accumulate creating a “cake” of

dirt on the surface of the screen. This cake performs finer filtration than the

screens itself, resulting in increased filter efficiency. The cake creates also a

pressure differential across the screen.

This differential is monitored by the control system, and a flushing cycle is

activated once the predetermined differential is achieved.

OPERATING PRINCIPLES



B. Flushing cycle

When the predetermined differential pressure is reached (as preset on the D.P.

switch gauge) the controller activates the flushing valve (opens it) and the gear

motor.

The pressure differential between the pressure inside the filter and at the open valve

to the atmosphere produces a back-flushing effect at the unique SA (patent pending)

nozzles, removing accumulated solids from the screen to the drain.

The unique design of the S.A nozzles achieves an increased suction and

significantly decreasing in the water consumption during flushing, due to accurate

contact point between the unique S.A nozzle and the screen. The spiral motion of the nozzles as mentioned above cleans the all area of the

screen.

The same Flushing cycle may be activated by the controller - by the Preset Timer or

by the Manual Flushing button (Test).

C. Continuous flushing

Means the flushing of the fine sintered screen continuously, through the suction

nozzles. The flushing valve and the worm-gear motor are activated continuously.

The “Continuous Flushing” is selected manually by the operator.

This efficient filter is automatic and easy to operate.

Its operating modes are as follows:

1) Filtration - The normal function of the filter, until a flushing mode is activated.

2) Automatic Flushing – Flushing of the screen through the suction nozzles, when

activated by time or DP. The gear-motor and the flushing valve are activated

simultaneously by the controller. The Yellow Flushing light (on the control board)

is ON.

The timer activates the flushing cycle, if the D.P. is not activated.

3) Continuous Flushing -

Back flushing of the screen through the suction nozzles. The gear motor and the

flushing valve are activated continuously and the Yellow Flushing light is ON.

This manual mode is selected by the operator.

4) Malfunction mode – This mode takes place

a. When the overload is tripped.

b. When both micro-switches are pressed down at the same time, or when

both micro-switches are short-circuited.

OPERATING MODES



c. The motor works for more than T2 (= 60 seconds) between micro

switches.

Then the RED Fault Light (on the control board) is ON.

WARNING : Maximal pressure 10 bar (150 psi).

If the pressure is not controlled effectively, a pressure relief valve must be installed

before the filter.

Prevent back-pressure or reverse flow - install a mechanical non-return valve on each

filter outlet.

NOTE: Install isolation valves at inlet & outlet. These valves would service the filter whenever needed, and in addition the outlet valve can be used to adjust the flow rate

whenever needed.

Install the filter in any position with enough space for servicing and dismantling, but

horizontally is recommended.

Water inlet and outlet directions are clearly marked by an arrow.

Install a mechanical non-return valve at outlet.

Connect a drain pipe with no appreciable resistance.

Check for leaks.

INSTALLATION



NOTE: The differential pressure switch and timers have been preset to the proper

settings. Do not adjust prior to start-up.

1. Check that the line pressure will always be at least 2 bar (20mWC) at the filter

inlet during the flushing cycle.

2. Check that there are no upstream pipeline restrictions.

3. Check that the filter is mounted in the correct flow orientation as indicated by

the arrows on the body.

4. Check that the flushing valve is mounted properly.

5. Check that the tubing connections are completed.

6. Check that power is available to the Electrical Control Box and that the main

switch on the control box is in the “OFF” position.

7. Check that the flushing valve drain lines are installed.

8. Check that the upstream and downstream isolation valves are closed.

9. Check that adequate space is available around the filter for maintenance as

indicated in dimensions drawing page 21.

1. Slowly open the inlet valve to the filter allowing the filter to pressurize.

2. Check for any external leakage and eliminate.

3. Slowly open the outlet valve of the filter (if installed).

4. Turn the main switch ON.

NOTE: An automatic procedure will find the right moving direction.

5. Verify that all power supply and all machine elements are connected.

6. Verify input voltage is correct.

7. Turn on main switch wait 5 sec.

8. Push the TEST push button for two seconds. See the movement of the screw.

NOTE: The filter will perform its first flush and will stop, (between the limit

switches). During flushing ensure that the filter inlet pressure is higher than

2 bar (20mWC).

After this first operation the filter passes into automatic mode (command

switch: on "AUTO" position), at any given time pressing the TEST button

will cause one flush cycle.

9. Initiate a manual flushing; observe the inlet and flushing chamber pressures.

The flushing chamber pressure should be between 1.2 to1.5 bar below inlet

pressure during the flushing cycle.

FIRST COMMISSIONING AND ROUTINE START - UP

FIRST COMMISSIONING

START - UP



1. The filter will perform a flushing cycle after interval (T6) time in which no

flushes took place.

2. The filter will perform a flushing cycle due to the pressure differential switch

command (D.P.), and will stop near the limit switches.

3. If the pressure differential remains on, the filter will continue its flushing.

4. Counter CTMR (C2) will count the number of flushes due to TFmin time.

5. Counter CDP (C3) will count the number of flushes due to pressure differential.

6. Counter fault (C4) will count the number of faults.

In this mode the filter will flush continuously.

AUTOMATIC OPERATION

CONTINUOUS OPERATION



INTERVAL CHANGING INSTRUCTIONS:

1. At normal operation the PLC displays the time, date and I/O table (FIG.1)

2. To change and read parameters press Menu/OK – the following screen will show

(FIG. 2). Use the up/down arrow to reach the PARAMETER (it will blink) and

press Menu/OK.

CHANGING PARAMETERS ON THE PLC

FIG.1

FIG.2



3. The following screen will show (FIG. 3)

4. Use the up (∧) arrow till the following screen will show (FIG. 4)

5. Push the left key (<), the time value will start blinking. Use the up (∧) and down

(∨) keys to change the time interval (hours: minutes).

6. Press Menu/OK to confirm changes the following screen will show (FIG. 5).

Select YES by using up (∧) and down (∨) keys and confirm by pressing Menu/OK.

FIG.3

FIG.4



MASTR./ SLAVE CHANGING INSTRUCTIONS:

Another change - required only on first use (installation) - is C1:

− If operated as single filter or master filter in cascade – P=00001 (MSTR).

− If operated as slave filter in cascade – P=00002 (SLAVE)

• On main menu (FIG 1) press Menu/OK

• On the menu shown in (FIG 2) press down arrow to reach the PARAMETER

(it will blink) and press Menu/OK.

• Press up (∧) arrow to choose C1 (FIG 6).

• Press Right (>) arrow until the value (P=0001) will blink, and change it by

using the vertical [up (∧) or down (∨)] buttons.

FIG.5

FIG. 6 FIG. 7



P=00001 – MASTER. (FIG 6)

P=00002 – SLAVE. (FIG 7)

• Press Menu/OK to confirm changes the confirm screen will show (FIG. 5).

• Select YES by using up (∧) and down (∨) keys and confirm by pressing

Menu/OK.

• Press Menu/OK to return to main screen.

GENERAL DATA

When the PLC is on the main screen (FIG 1), pressing one of the keys below the

numbers: 2, 3, 4 will show one the following data:

2 INTERVAL Time between last flushing cycle to following flushing cycle

(interval) h : m

3 FAULT Number of faults. (Counter)

CTMR Number of flushing cycles due to timer (Counter). 4

CDP Number of flushing cycle due to pressure difference (Counter).



The fault condition (RED light on) is generated in following cases:

1. If the two motor limit switches are pressed simultaneously (or both are shorted).

2. The motor works continuously for more than 60 seconds without stopping.

Turn the command switch to RESET (spring loaded) to eliminate FAULT

continuation. RED light should turn off.

Check always the reason for the FAULT.

FAULT

RESET

CONTROLS



EXTERNAL

Lights : YELLOW - Flushing

RED - Malfunction Command Switch: RESET – (Exit fault mode)

AUTO – (Automatic Operation)

CONT.– Continuous Flushing

Yellow Button: TEST – Manual Flush

INTERNAL

PLC : Programmable Logic Controller, for

service personnel ONLY.

Counter : For monitoring the number of flushings

See PLC instructions.

D.P. - differential pressure switch gage

The D.P. monitors the differential pressure of the filter at

inlet/outlet, to activate the PLC for a single back-flushing cycle.

PLC - control

The PLC activates a single flushing cycle when either the DP or

time is activated

DP is set to 6 psi ,0.4bar, the time is set to 3 hrs. (normally 3-8

hours).

The PLC may be in CONTINUOUS mode - the Timer is then by-passed .

For details of control modes, see the operating modes.

NOTE: before installing bolts back to their places spread the bolts treads with

grease.

1. Every 1 month apply MOLYKOTE G-n Plus Paste to the screw of the drive

assembly (item 17 on breakdown drawing).

2. Every 1 month apply “DOW CORNING 4” or EQUAL grease to the shaft

extension (item 15 on breakdown drawing).

3. Repair any damage to the protective coating of the filter without delay. Prior to

application of protective paint, thoroughly clean the damaged spot with wire

brush.

CONTROL BOX

MAINTENANACE



4. In case that there is needs to take out the screen for maintenance, prior to

installation lubricate the screen seals and the cover gasket with “DOW

CORNING 4” or EQUAL grease.

OdisMatic® Filter Check

(Refers to drawing D-C863-001-04 on page 19)

NOTE: before installing bolts back to their places spread the bolts treads with

grease.

• Close filter’s inlet and outlet valves, wait until the pressure is reduce to ‘0’.

• Open drainage valve located on the inlet chamber bottom, and wait until the

water stops to flow.

• Open flushing chamber service port cover (9).

• Dismantle the drive protection cover (13).

• Dismantle the drive pin (22) split pin and pull out the drive pin.

• Open cover (32), verify that cover gasket (28) is intact.

• Pull out the collector assembly and then pull out the filters assembly.

• Verify that filters coarse (3) and fine (4.1) screens are intact.

• Verify that screen seals (4/2) are intact.

• Check that collector (2/2) and suction nozzles (2/3) are intact.

• Verify that screen seals are in there place, lubricate the screen seals with

“DOW CORNING 4” or EQUAL grease; Insert the screens assembly and

then the collector assembly into the filters body.

• Verify that cover gasket (28) is in its place, lubricate the gasket with “DOW

CORNING 4” or EQUAL grease, close cover (32) and tighten the cover bolts.

Before installing bolts back to their places spread the bolts treads with thin

layer of grease.

• Use the service port (29) to install the collector assembly.

• Close flushing chamber service ports cover (9); verify that gasket (29) is in its

place.

• Connect the shaft extension (15) to the drive shaft (17) Install the drive pin (22)

and secure the pin with split pin.

• Install the drive protection cover (13).

• Gradually open filter’s inlet and outlet valves and check for leakage.



Item Problem Check If Solution

1 System

does

not work

Power

Main switch OFF Check Main Switch is ON

Check Power supply is available

(electricity).

Check Fuses/overload

2 Fault Lamp ON Check for possible reason - remedy

then press RESET

3 No water

flowing

Isolation

Valve

not open Open then press RESET

Manual

Valves

those required to

be open are not

open

Open them

4 Flowrate

is low or

Outlet

pressure is

low.

Water

pressure

(inlet) or

Line pressure

Pressure is Low

(usually below

35psi),

Press Manual Flush button: TEST

(when all required valves are open).

Increase pressure to normal:

�Water company

�Pumps

�Remote valves

�Main Line blocking

Normal

Go to next line

5 Pressure

drop too

high

Pressure drop

on filter -

difference in

readings of

pressure gage

D.P. is high,

over 0.5 bar, (7

psi).

Press TEST: Manual Flush button.

(on panel).

6 D.P. remains high Check flow rate - if not excessive

(higher than design flow rate).

TROUBLE SHOOTING



Item Problem Check If Solution

7 Repeat the above mentioned (Manual

Flush) and if D.P. is high:

a - Check for any

- disconnected or leaking control

tubes.

� disconnected wires

b – Unusually high dirt load

beyond design- call service

meanwhile reduce flow rate.

c – Unusual Blocking of filter

(close isolation valves)

dismantle filter and clean

screens .

8 Flush

valve does

not close

dirt on the

valve’s seat

Dirty Close water entry - release pressure

and clean.

9 Flush

valve does

not open

Solenoid

valve lamp

light not ON

Wiring problem

Replace solenoid if Faulty.

10 Gear

motor

rotating

but Drive

Shaft not

advancing

At extremity of

travel (left or

right) and drive

pin is in place

Check that the Limit Switches are

operating:

a) they are properly positioned

b) wiring problem

c) press on Limit Switch and see if

activated.

Replace Limit Switch if faulty .

Drive nut drive pin is not in

place

Install pin in its place and fit split pin

11 Flush

cycles are

too

frequent

Raw water Dirt load is high

or very soft and

“sticky”

Go to CONTINUOUS MODE

(Command Switch: CONT.).



OdisMatic® - 863 - Parts breakdown



OdisMatic® - 863

PART LIST (refer to drawing D-C863-001-04– issue 1)

NO DESCRIPTION 86302

86303

86304

86306

86308

86310

86312

86314

1 Filter Body A86302N-SA-2”

A86303F-SA-3”

A86304 F-SA -4”

A86306 F-SA -6”

A86308-8”

A86310-10”

A86312F-SA -12”

A86314F-SA -14”

2 Dirt Collector ass. E8632021 E8632041 E86302081 E8632121

2/1 Collector bearing E86002060 E86002060 E86002060 E86002060

2/2 Collector Body E8632022 E8632042 E86302082 E8632122

2/3 Suction Nozzle assy. E8632211 E8632211 E8632811 E8632811

2/3-1 Suction Nozzle pipe E8632212 E8632212 E8632812 E8632812

2/3-2 Suction Nozzle E8632213 E8632213 E8632213 E8632213

Suction nozzle "O" ring ER00106 ER00106 ER00106 ER00106

3 Coarse Screen E86302020 E86304020 E86308020 E86312020

4 Fine Screen ass. E86302030 E86304030 E86308030 E86312030

4/1 Fine screen E86302031 E86304031 E86308031 E86312031

4/2 Fine screen seal E263003 E263003 E8628000 E8628000

4/3 Collector lower guide E86007060 E86007060 E86007080 E86007080

4/4 Guide Base E86302033 E86302033 E86308033 E86308033

4/5 Guide Stopper ER00113 ER00113 ER00113 ER00113

5 Electrical Board E86336060 E86336060 E86336060 E86336060

6 Solenoid Valve – N.O N512009 N512009 N512009 N512009

7 3 way valve PM202500 PM202500 PM202500 PM202500

8 Pressure Gauge N6111025 N6111025 N6111025 N6111025

9 Service port Cover E400260-SFR E400260-SFR E400260-SFR E400260-SFR

10 Flush valve NB20501502T NB20501502T NB470863020T NB470863020T

11 Drive base support E86302040 E86302040 E86308040 E86308040

12 Shaft Seal (set) E86302162 E86302162 E86302162 E86302162

13 Drive protection cover E86010060 E86010060 E86010060 E86010060



OdisMatic® - 863

PART LIST (refer to drawing D-C863-001-04– issue 1)

NO DESCRIPTION 86302

86303

86304

86306

86308

86310

86312

86314

14 Limit switch N598605 N598605 N598605 N598605

15 Shaft Extension E86022060 E86022060 E86022060 E86022060

16 Limit switch disk E86024060 E86024060 E86024060 E86024060

17 Drive shaft E86012060 E86012060 E86012060 E86012060

18 Worm gear motor V5397 V5397 E86035060 E86035060

19 Drive shaft cover E86026060 E86026060 E86026060 E86026060

20 Drive key E86025060 E86025060 E86025060 E86025060

21 Disk positioning nut E86011060 E86011060 E86011060 E86011060

22 Drive pin E86023060 E86023060 E86023060 E86023060

23 Drive base E86021060 E86021060 E86021060 E86021060

24 Drive nut E86020060 E86020060 E86020060 E86020060

25 Shaft guide E86302041 E86302041 E86302041 E86302041

26 Air valve N131010 N131010 N131120 N131120

27 Guide seal E86302043 E86302043 E86302043 E86302043

28 Cover gasket ER02004 ER02004 ER10033 ER10033

29 Service port gasket E004365 E004365 E004365 E004365

30 D.P switch N6040 N6040 N6040 N6040

31 Collector guide E86015060 E86015060 E86015080 E86015080

32 Cover E86302050 E86302050 E86308050 E86308050

33 Drain valve PM1075110 PM1075110 PM1075110 PM1075110

34 Pressure Control Box Y8510201 Y8510201 Y8510201 Y8510201



3x380VAC



3x220VAC



User’s Notes

863 FILTERING 8ed. 06.06 new controller SA...FIRST COMMISSIONING AND ROUTINE START - UP FIRST...

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Transcript of 863 FILTERING 8ed. 06.06 new controller SA...FIRST COMMISSIONING AND ROUTINE START - UP FIRST...