AmeriWater CW430 User guide

Rev. 6/07

High Efficiency Sand Filters

CW430 Series

Table of Contents

Preface

1. Installation 2
i. Unpacking Filter System 2

ii. Rigging 2
iii. Locating Filter System 2
iv. Filter System Assembly 3

i. Placing, Arranging, and Leveling Vessel(s) 3

ii. Assembling Manifolds 4

iii. Valve Control Wiring 4

v. Electrical Connections 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 Shutdown 22
iii. Freeze Protection 23
iv. Sequence of Operation 24

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 43

6/07

Installation, Operation, Maintenance AmeriWater Filter
Systems Series CW

This Installation, Operation, and Maintenance manual contains instructions for the
AmeriWater filter series CW. Check the model number on your filter system (located on the inside of
control enclosure door).

f CW is not present in model number - Do Not Proceed.

I

Contact AmeriWater at 800.535.5585 for instructions.

Read and understand each section of this manual before proceeding with installation and
operation of your AmeriWater Filter System.

CAUTION: All WARNINGS AND CAUTIONS MUST BE FOLLOWED TO AVOID PERSONAL INJURY!

T

his filter system has been factory assembled and tested before shipping. The filter system may be

broken down for shipping, with major components remaining assembled.

R

eport damage or missing parts immediately to AmeriWater at 800.535.5585.

This filter system must be started by a Factory Authorized Representative.

TART UP BY ANYONE OTHER THAN AN AUTHORIZED AGENT WILL VOID

S
WARRANTY!

ontact AmeriWater (800.535.5585) at least two (2) weeks in advance to arrange start up.

C

Specifications subject to change without notice. Local codes supersede instructions in this manual.
Contact AmeriWater 800.535.5585 with questions or to report significant deviations between local
code and instructions.

ystem Description

S

AmeriWater High Efficiency Filter System series CW are composed of the following major
components: (Ref: Drawing CW)
Filter Vessel(s)
Filter Pump
Backwash Pump (optional, not shown)
Pre-assembled pipe manifolds (may be packed loose)
Valves
Control / Motor Starter Panel (Ref: CP)
Skid

1 6/07

1 Installation

1.1 Unpacking Filter System

NOTE: Filter components may be attached to sides of crate or packed in boxes within

shipping crate. Be sure to remove all components before disposing of crate.

D

O NOT LIFT OR PULL FILTER VESSELS BY SIDE PORTS; INTERNAL COMPONENTS MAY BE

DAMAGED!

nspect shipping crate(s) and packages for damage. Before signing bill of lading,

a) I

report any damage to AmeriWater 800.535.5585.

b) Remove top of crate then break down sides as necessary to remove contents.

Report any damage immediately to AmeriWater 800.535.5585l
c) Unpack filter system as close as possible to installation location.
d) Flange gaskets, bolts, and pipe stand hangers (if applicable) 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

vibration isolation.

NOTE: Vibration pads, if used, should be placed under all components to ensure
proper alignment.

loor load rating must be sufficient to accept filter weight. (Ref: Drawing CW)

c) F
d) Place system in close proximity to water to be filtered. Factory representative should

be consulted if filter will be over 20 feet from water source.
e) Protect system from water temperatures below 32 degrees F and above 140

degrees F unless filter is designed for those temperature applications.

2 6/07

1

.4 Filter System Assembly

Placing, Arranging, and Leveling Vessel(s)

Skid mounted systems:

a) Place system skid in desired location and level skid.

NOTE: If system was shipped assembled, the pipe assembly may be loose at flanges to
avoid flex damage. Some systems will be shipped broken down to avoid damage from flexing.

b) Arrange vessels with valves front.
c) Multi vessel systems are labeled and should be arranged in order from left to

right. (Use lower pipe manifold as guide for spacing and leveling vessels.)

CAUTION! WARNING! CAUTION!

PERSONAL INJURY MAY RESULT!

READ FOLLOWING CAREFULLY BEFORE PROCEEDING!

T

IPPING HAZARD may exist on empty, freestanding, multi-vessel systems with upper

manifold attached.

R

EAD THE FOLLOWING PARAGRAPH BEFORE PROCEEDING!
With vessels properly aligned and leveled and with lower manifold and pipe stands
attached, add base (stone) media. (See media addition sec 6 in this manual).
This will counter balance the system and reduce tipping hazard.

OTE: Be sure that vessels are properly placed and aligned before adding base

N
media. Vessels will be difficult to move with media added.

3 6/07

Assembling Manifolds

NOTE: Flange bolts, and gaskets are packed in separate cardboard box contained in
filter shipping crate.

a) Align upper and lower manifolds with vessels. Install flange gaskets and bolt

manifold flanges to vessel(s). Do not tighten flange bolts at this time. Minor
adjustments in vessel alignment may be necessary at this time.

b) Assemble all interconnecting manifold flanges and secure unions. Tighten all

connecting bolts at this time.

NING:

WAR
DAMAGE TO MANIFOLD MAY RESULT IF THE MANIFOLD IS PLACED UNDER STRESS OR IF
FLANGE BOLTS ARE OVER TIGHTENED!

Valve Control Wiring

For single vessel systems: valve 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) A

ll wiring must be properly sized, rated, and connected in accordance with local,

state, and national electrical codes.

b) Filter system should be on a dedicated circuit originating at a service disconnect

panel.

NOTE: If filter pump motor starter is not factory supplied it must be wired with a
dedicated disconnect.

c) Penetrations to filter control panel should be made with watertight connectors to

preserve panel NEMA 4X rating.

4 6/07

Control / Motor Starter Package (Ref: Drawing CPMS)

a) Factory installed motor starter package includes a service disconnect, motor starter,

and transformers pre-wired to the PLC. These systems require a single point
electrical connection to the service disconnect. Line service must be rated to pump
motor requirements.

Standard systems are factory set for 460V, 3ph service. Optional power supply
factory wired as ordered.

b) Wire the pump motor from the motor starter with seal tight (provided).

TE: If optional backwash booster pump is used and a second motor starter is

NO
factory supplied, refer (drawing CPMS) for proper connection points.

NOTE: Do not operate pump(s) dry. Damage to pump seal and shaft may occur.

Control 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 should not be installed or removed unless specific instructions are

received from AmeriWater 800.535.5585.

Output #9 will be fused, (if applicable), at start up to convert from city water to
system water backwash.

e) Output #11 will be fused, (if applicable) to change timed backwash from 24 hours to

7 days. Timed backwash should be changed only for systems operating on a

closed loop and only after consultation with AmeriWater.

N

OTE: Changes to these options without instructions from AmeriWater may void

the filter warranty.

5 6/07

1.6 Pipe Connections

Recommended pipe size for all pipe connections are noted in schedule.

(Ref: Drawing CW)

C

onnecting pipe should be of materials compatible in construction to filter manifold.
Dielectric fittings are highly recommended if dissimilar metals are used.

or pipe runs exceeding 20 feet from filter system consult AmeriWater for pipe size

F
recommendations.

he companion full-face flange to the suction side of the filter pump is to be provided by end-

T
user or contractor.

B

asket or Y strainer (with gauges before and after strainer) is recommended ahead of filter
pump.

R

ef: Drawing CWT for typical installation.

roperly secure all pipe runs with M & F clamps (or similar). Pipe movement may cause filter

P
and / or pipe damage.

Supply and Return Lines

NOTE: Isolation valves are recommended convenient to filter.

a.C

onnect influent (supply) line from pre-selected point in cooling system to

suction side of filter pump.

N

OTE: A foot valve / check valve should be installed on suction side of self-priming

pump to prevent loss of pump prime.

onnect effluent (return) line from the outlet connection to the pre-selected point in the cooling

b. C

system (downstream of inlet connection).

NOTE: Filter return must be connected to a point in the cooling system where cooling system
pressure is equal to or less than pressure to filter pump suction.

N

OTE: Filter supply and return lines should be connected to the cooling system where they

are in an area of 'common' flow.

6 6/07

Backwash Supply

NOTE: If filter is designed to use cooling system water for backwash, no backwash supply pipe
is required in this section. (Skip to waste line section)

NO

TE: Clean water supply is always recommended for closed loop filters.

Backwash supply requires min / max 30/70 psig. An isolation valve is
recommended, convenient to filter. Backflow preventer is recommended and
commonly required by local codes when potable water is used for backwash. A
pressure gauge is recommended at the discharge of the backflow preventer.

E: An efficient backflow preventer will create approximately 12 psig loss in line

NOT

pressure. A minimum of 30 psig must be available at outlet side of backflow
preventer. If backwash and cooling tower make up are connected to the same
supply, be sure 30 psig is available when tower is calling for water.

Co

nnect properly 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 20 feet or an 8-foot lift from filter system, consult AmeriWater for pipe
size recommendations.

Co

nnect properly sized drain line to filter backwash drain.

1.7 Media Installation

WARNING! WARNING! WARNING!

PROPER PROTECTIVE EQUIPMENT MUST BE WORN WHEN INSTALLING MEDIA. PERSONNEL
HANDLING MEDIA MUST WEAR A DUST MASK OR RESPIRATOR FOR LUNG PROTECTION AND
GOGGLES FOR EYE PROTECTION. REFER TO ENCLOSED MATERIAL SAFETY DATA SHEET (MSDS)
FOR COMPLETE INFORMATION (Section 2).

a) Med

ia containers are labeled (Ref: ML). Separate containers according to vessel and order of

addition. Before installing media, inspect media containers for loss during shipping. Notify

7 6/07

AmeriWater if media loss is suspected. All loses must be verified by authorized factory
representative.

NOTE: For multi-vessel systems be sure that each vessel has the same number of media

containers per layer and same number of layers.

b) b. R

NOTE

c) c. Add media in the order as indicated on media container label. (Ref: ML)

NOTE

d) d. F
e) e. Replace and secure vessel gasket and closure.

NOTICE:

ontact AmeriWater at 800.855.5535 to arrange for factory authorized technician to do

C
startup and training.
TWO WEEKS ADVANCE NOTICE IS REQUIRED.
START UP BY UNAUTHORIZED PERSON MAY VOID WARRANTY!

emove top filter vessel closure.

: Fill vessel 1/3 full with water to cover under drain before adding media. This

will help to level the media, expel air, and reduce dust exposure.

: 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.

ill vessel(s) to top with water.

8 6/07

2 Documentation

2.1 Media MSDS

THE PARRY COMPANY

33630 Old US Route 35

Chillicothe, OH 45601

Ph: 740-884-4893
Fax: [phone]

Material Safety Data

Sheet

I. PRODUCTION IDENTIFICATION

Trade Name as Labeled: Silica Gravel; 6x12 Mesh
Chemica

l Name and Formula: Silica, in the form of quartz; SiO2

II. HAZARDOUS INGREDIENTS

CAS Number: 14808-60-7 ACGIH-TLV: .05mg/m³ (Exposure limits are for
Chemical Name: Quartz OSHA-PEL: 10mg/m³
Percent: >90 %SiO2 +2 particles 10 microns or

NIOSH recommends a Perm
OSHA PEL are not interchangeable limit values.

The exposure limits are time-weighted average concentrations for an eight-hour workday and a 40-hour work week.

Crystalline silica exists in several forms, the most common of which is quartz. If crystalline 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).

issible Exposure Limit (PEL) of .05-mg/m³ respirable free silica. ACGIH-TLV and

respirable fraction or

smaller)

III. HAZARD IDENTIFICATION

Emergency Overview: The crystalline silica produ
primarily used as water filter media. It is not flammable, combustible, or explosive. It does not cause burns or
severe skin or eye irritation. A single exposure will not result in serious adverse health effects. Crystalline silica
(quartz) is not known to be an environmental hazard. Crystalline silica (quartz) is incompatible with hydrofluoric
acid, fluorine, chlorine trifluoride or oxygen difluoride.

Potential Health Effects:

Silicosis: Respirable crystalline silica (quartz) may cause silicosis, a fibrosis (scarring) of the lungs.

ced by The Parry Company material is a white or tan, and is

Page 1 of 7

Prepared January, 2 2018

9

Silicosis may be progressive; it may lead to disability and death.

Cancer: Crystalline silica (quartz) inhaled from occupational sources is classified as carcinogenic to

humans.

Autoimmune Diseases: There are some studies that show excess numbers of cases of scleroderma and

other connective tissue disorders in workers exposed to respirable crystalline silica.

Tuberculosis: Silicosis increase the risk of tuberculosis.
Nephrotoxicity: There are some studies that show an increased incidence of chronic kidney disease and

end-stage renal disease in workers exposed to respirable crystalline silica.

Eye Contact: Crystalline silica (quartz) may cause abrasion of the cornea.
Skin Contact: Not applicable
Ingestion: Not applicable
Chronic Effects: The adverse health effects-silicosis, cancer, autoimmune diseases, tuberculosis, and

nephrotoxicity-are chronic effects.

Signs and Symptoms of Exposure: Generally, there are no signs or symptoms of exposure to crystalline

silica (quartz).

Medical Conditions Generally Aggravated by Exposure: The condition of individuals with lung disease

(e.g., bronchitis, emphysema, chronic obstructive pulmonary disease) can be aggravated by
exposure. See section 11, Toxicological Information, for additional detail on potential adverse
health effects.

Symptoms of Overexposure:

Inhaled

Swallowed: May cause gastrointestinal discomfort. Give one or two glasses of water. If discomfort

First Aid: Emergency procedures.
Eye Contact: Wash with water for at least fifteen (15) minutes. If irritation or redness persists see a

Skin Contact: Wash with soap and water. If irritation persists see a physician.
Ingestion: Not applicable.

: Shortness of breath, coughing, reduced pulmonary function. Prolonged inhalation of repsirable

silica may result in permanent lung damage, silicosis. No specific 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.

persists, see a physician.

physician.

IV. FIRST AID MEASURES

Suspected Cancer Agent: Yes Federal OSHA: No NTP: Yes IARC: Yes

NTP: Respirable crystalline silica has been listed in the Sixth Annual Report on Carcinogens.
IARC: Monographs on the Evaluation of the Carcinogenic Risk of Chemical to Humans (vol. 68, 1997)

concludes that there is sufficient evidence in humans for the carcinogenicity of inhaled crystalline
silica in the forms of quartz and cristobalite (Group 1) in certain industrial circumstances, but that
carinogenicity may be dependent on inherent characteristics of the crystalline silica or on external
factors affecting is biological activity or distribution of its polymorphs.

V. FIRE FIGHTING MEASURES

Crystalline silica (quartz) is not flammable, combustible, or explosive.

VI. ACCIDENTAL RELEASE MEASURES

Spill Response Procedures (including employee protection measures): Clean up using approved, dustless
methods (water or vacuum) to minimize generation of respirable silica particles.
Waste Disposal: Dispose of in a facility approved for silica (also see Section 13).

Page 2 of 7

Prepared January, 2 2018

10

VII. HANDLING AND STORAGE

Ventilation and Engineering Controls: Local mechanical to reduce respirable silica to below safe levels.
Respiratory Protection (Type): Use NIOSH approved equipment. Positive pressure supplied air-type

recommended. Appropriate respiratory protection for respirable particulates is based on consideration of air borne
workplace concentrations and duration of exposure arising from the intended end use. Please refer to the most recent
standards of ANSI (Z88.2), OSHA (29CFR 1910.134), MSHA (30 CFR Parts 56 & 57), and NIOSH RDL. IF you
are unsure as to the type of respirator to be used please consult your employer.

Eye Protection (Type): Safety Glasses
Gloves (Specify Material): Not normally required.
Other Protective Clothing and Equipment: Not normally required.
Work Practices, Hygiene Practices: Clean up spills promptly. Do not engage in activities that will generate

respirable silica particles.
Other handling and Storage Requirements: Avoid generating dust. There are no special storage requirements.
Train all exposed persons in all sections of this MSDS and the proper handling of silica before they work with this
product.

See OSHA Hazard Communication Rule CFR 1910.1200, 1915.99, 1917.28 and 1928.21, state, local worker, or
community “Right to Know” laws and regulations. We recommend that smoking be prohibited in all areas where
respirators must be used. Warn your employees (and your customer users in case of resale) by posting and other
means of the hazard and OSHA precautions to 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 respirators, which may provide respiratory
protection for crystalline silica:

PARTICULATE

CONCENTRATION

10 x PE

50 x PE

500 x PEL

Greater than 500 x
PEL
Escape from
Unknown
Concentrations

L or Less

L or Less

or Less

or Entry and

Any particulate respirator, except single-use or quarter-mask respirator.
Any fume respirator or high efficiency particulate filter respirator.
Any supplied-air respirator.
Any self-contained breathing apparatus.
A high efficiency particulate filter with a full-face piece.
Any supplied-air respirator with a full-face piece, helmet, or hood.
Any self-contained breathing apparatus with a full-face mask.

A type C supplied-air respirator operated in pressure-demand or other positive
pressure or continuous-flow made.
Self-contained breathing apparatus with a full-face piece operated in pressure­demand mode. A combination respirator which includes a Type C supplied-air
respirator with a full-face piece operated in pressure-demand or other positive
pressure continuous-flow mode and an auxiliary self-contained breathing
apparatus operated in pressure-demand or other positive pressure mode.

MINIMUM RESPIRATORY PROTECTION*

Use only

§ 84. See also ANSI standard Z88.2 (latest revision) “American National Standard for Respiratory
Protection.”

NIOSH-approved or MSHA-approved equipment. See 29 CFR § 1910.134 and 42 CFR

Page 3 of 7

Prepared January, 2 2018

11

Exposure Guidelines:

Component CAS

No.

Crystalline

Silica

(Quartz)

14808

-60-7

Percent

age

(by wt.)

99.0-

99.9

OSHA

(TWA)

10

% SiO2 + 2 None .05 None .05 None Mg/m³

OSHA

(STEL)

ACGIH

(TWA)

ACGIH

(STEL)

NIOSH

(TWA)

NIOSH
(STEL)

Unit

IX. PHYSICAL AND CHEMICAL PROPERTIES

Vapor Density: Not applicable Melting Point: 1710°C
Specific Gravity: 2.65 Boiling Point: 2230°C
Solubility in Water: Insoluble Evaporation Rate: None
Vapor Pressure: 10mm @ 1730°C Appearance and Color: White to tan; odorless

X. STABILITY AND REACTIVITY

Stability: Stable
Hazardous Polymerization: Will not occur
Incompatibility (materials to avoid): Contact with powerful oxidizing agents such as fluorine, chlorine trifluoride,

manganese trioxide, oxygen difluoride.
Hazardous Decomposition Products: Silica will dissolve in hydrofluoric acid and produce a corrosive gas (silicon
tetrafluoride).

XI. TOXICOLOGICAL INFORMATION

Silicosis: The major concern is silicosis, caused by inhalation and retention of respirable crystalline silica dust.
Silicosis can exist in several forms, chronic (or ordinary), accelerated, or acute.

Chronic or Ordinary Silicosis (often referred to as Simple Silicosis) is the most common form of
silicosis, and can occur after many years of exposure to relatively low levels of airborne respirable crystalline silica
dust. It is further defined as either simple or complicated silicosis. Lung lesions (shown as radiographic opacities)
less than 1 centimeter in diameter characterize simple silicosis, primarily in the upper lung zones. Often, simple
silicosis is not associated with 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 symptoms, if
present, are shortness of breath, wheezing, cough and sputum production. Complicated silicosis or PMF may lead to
death. Advanced complicated silicosis or PMF can result in heart disease secondary to the lung disease (cor
pumonale).

Accelerated Silicosis can occur with exposure to high concentrations of respirable crystalline silica over a
relatively short period; the lung lesions can appear within five (5) years of the initial exposure. The progression can
be rapid. Accelerated silicosis is similar to chronic or ordinary silicosis, except that the lung lesions appear earlier
and the progression is more rapid.

Acute Silicosis can occur with exposures to very high concentrations of respirable crystalline silica over a
very short period of time, sometimes as short as a few months. The symptoms of acute silicosis include progressive
shortness of breath, fever, cough and weight loss. Acute silicosis can be fatal.

Cancer:

IARC: The International Agency of Research on Cancer (IARC) concluded that there was “sufficient

evidence in humans for the carcinogenicity of crystalline silica in the forms of quartz and cristobalite from
occupational sources”, and that there is “sufficient evidence in experimental animals for the carcinogenicity of quartz
and cristobalite.” The overall IARC evaluation was that “crystalline silica inhaled in the form of quartz or

Page 4 of 7

Prepared January, 2 2018

12

cristobalite from occupational sources is carcinogenic to humans (Group 1).” The IARC evaluation noted that
“carcinogenicity was not detected in all industrial circumstances studies. Carcinogenicity may be dependent on
inherent characteristics of the crystalline silica or on external factors affecting its biological activity or distribution
of it polymorphs.” For further information on the IARC evaluation, see IARC Monographs on the Evaluation of
Carcinogenic Risks to Humans, Volume 68, “Silica, Some Silicates…” (1997).

NTP: The National Toxicology Program, in its Ninth Annual Report on Carcinogens, classified “silica,
crystalline (respirable)” as a known human carcinogen.

OSHA: Crystalline silica (quartz) is not regulated by the US Occupational Safety and Health
Administration as a carcinogen.

There have been many articles published on the carcinogenicity of crystalline silica, which the reader should consult
for additional information. The following are examples of recently published articles:

“Crystalline Silica and Lung Cancer: The Problem of Conflicting Evidence”, Indoor Built Environ, Volume
8, pp.121-126 (1998);

Crystalline Silica and the Risk of Lung Cancer on the Potteries”, Occup. Environ. Med., Volume 55,
pp.779-785 (1998);

Is Silicosis Required for Silica-Associated Lung Cancer?” American Journal of Industrial Medicine,
Volume 37, pp. 252-259 (2000);

Silica, Silicosis, and Lung Cancer: A Risk Assessment”, American Journal of Industrial Medicine, Volume
38, pp. 8-18 (2000);

Silica, Silicosis, and Lung Cancer: A Response to a Recent Working Group Report”, Journal of
Occupational and Environmental Medicine, Volume 42, pp. 704-720 (2000).

Autoimmune Diseases: Th
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 Exposure to Crystalline Silica and Autoimmune Disease”, Environmental Health
Prospectives Volume 107, Supplement 5, pp. 793-802 (1999);

Occupational Scleroderma”, Current Opinion in Rheumatology, Volume 11, pp. 490-494 (1999).

Tuberculosis: Ind
persons with tuberculosis. The following may be consulted for further information:

Occupational Lung Disorders, Third Edition, Chapter 12, entitled “Silicosis and Related Diseases”, Parkes,
w. Raymond (1994);

Risk of pulmonary tuberculosis relative to silicosis and exposure to silica dust in South African gold
miners,” Occup. Environ. Med., Volume 55, pp. 496-502 (1998).

Kidney Disease: There is evidence that exposure to respirable crystalline silica (without silicosis) or that the disease
silicosis is associated with the increased incidence of kidney diseases, including end stage renal disease. For
additional information on the subject, the following may be consulted:

“Kidney Disease and Silicosis”, Nephron, Volume 85, pp. 14-19 (2000).

ividuals with silicosis are at increased risk to develop pulmonary tuberculosis, if exposed to

ere is evidence that exposure to respirable crystalline silica (without silicosis) or that the

XII. ECOLOGICAL INFORMATION

Crystalline silica (quartz) is not known to be ecotoxic; i.e., there is no data that suggests that crystalline silica
(quartz) is toxic to birds, fish, invertebrates, microorganisms or plants. For additional information on crystalline
silica (quartz), see Sections 9 (physical and chemical properties) and 10 (stability and reactivity) of this MSDS.

XIII. DISPOSAL CONSIDERATIONS

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13

General: The packaging and material may be land filled; however, material should be covered to minimize
generation of airborne dust.
RCRA: Crystalline silica (quartz) is not classified as a hazardous waste under the Resource Conservation and
Recovery Act, or its regulations, 40 CFR §261 et. seq.

The above
and it is the responsibility of the user to assess the appropriate disposal of the used material.

applies to materials as sold by Fairmount Minerals, LTD. The material may be contaminated during use,

XIV. TRANSPORT INFORMATION

Crystalline silica (quartz) is not a hazardous material for purposes of transportation under the US Department of
Transportation Table of Hazardous Materials, 49 CFR §172.101.

XV. REGULATORY INFORMATION

United States (Federal and State):

TSCA No: Crystalline silica (quartz) appears on the EPA TSCA inventory under the CAS No. 14804-60-7.

RCRA: Crystalline silica (quartz) is not classified as hazardous waste under the Resource Conservation

and Recovery Act, or its regulations, 40 CFR §261 et seq

CERCLA: Crystalline silica (quartz) is not classified as a hazardous substance under regulations of the
Comprehensive Environmental Response Compensation and Liability Act (CERCLA), 40 CFR §302.

Emergency Planning and 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 of substances that may be included in coatings used in food contact
surfaces, 21 CFR §175.300 (b) (3) (xxvi).

NTP: Respirable crystalline silica (quartz) is classified as a carcinogen.

OSHA Carcinogen: Crystalline silica (quartz) is not listed.

California Proposition 65: Crystalline silica (quartz) is classified as a substance known to the State of

California to be a carcinogen.

Canada:

Domestic Substances List: Fairmount Minerals, Ltd’s products, as naturally occurring substances, are on

the Canadian DSL.

WHMIS Classification: D2A

Other:

EINECS No: 238-878-4

EEC Label (Risk/Safety Phrases): R 48/20, R 40/20, S22, S38

IARC: Crystalline silica (quartz) is classified in IARC Group I.

National, state, provincial or local emergency planning, community right-to-know or other laws, regulations or
ordinances may be applicable—consult applicable national, state, provincial, or local laws.

XVI. OTHER INFORMATION

H.M.I.S. Rating:

Health Hazard Rating 1* Flammability Hazard Rating 0

Reactivity Hazard Rating 0 Personal Protective Equipment E**

DOT: Not Regulated
SARA Title III: Not listed.

Page 6 of 7

Prepared January, 2 2018

14

*Chronic exposure to respirable size silica will result in silicosis. **Comply with special OSHA respiratory protection if sandblasting.

XVII. ACRONYM LIST

CAS: Chemical Abstract System
ACGIH: American Conference of Governmental Industrial Hygienists
OSHA: Occupational Safety and Health Administration
PEL: Permissible Exposure Limit
TLV: Threshold Limit Value
NIOSH: National Institute of Occupational Safety and Health
NTP: National Toxicology Program
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
WHMIS: Workplace Hazardous Materials Information System
EINECS: European Inventory of Existing Commercial Substances
EEC: European Economic Community
HMIS: Hazardous Materials Information System
DOT: Department of Transportation
SARA: Superfund Amendments and Reauthorization Act

Page 7 of 7

Prepared January, 2 2018

15

2.2 Installation Check List

______ All flange bolts and unions tightened.

______ Media installed. (Sec 1.7)

______ Vessel caps installed and secured.

______ All recommended components installed per Typical Installation Sketch. (Drawing CWT)

______ 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 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.

______ Backwash supply connected. (Sec 1.6)

______ Drain connected. (Sec 1.6)

16 6/07

2.3 Request for Startup

Request for Startup

lease complete this form and return via fax to schedule startup date.

P
2 Weeks advance notice is required for startup.

AmeriWater Fax: [phone]

Please have a factory authorized technician contact me to arrange startup for the
AmeriWater Sand Filter System.

ystem location: ___________________________________________

S

N

ote: All items listed below must be complete before startup personnel arrive. Should installation

not be complete, additional charges may be incurred, including but not limited to, additional labor
hours, travel expenses, and materials provided 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 control wiring connected.

______ Power connected to panel.

______ Pump(s) wired from motor starter(s).

______ Pump(s) rotation correct.

______ Control panel wired with dedicated power supply of correct supply.

______ Backwash supply connected.

______ Drain connected.

Authorized Signature:___________________________________ Date:______________

Printed Name:__________________________________ Phone #:___________________

17 6/07

2.4 Startup Data Sheet

18 6/07

2.5 Filter Log Sheet

19 6/07

2.6 AmeriWater Warranty

AmeriWater warrants the Product to be free from defects in materials and workmanship. The
warranty period shall not exceed (a) twelve (12) months from the date of startup (b) eighteen (18)
months from the date of shipment, whichever occurs first. AmeriWater’s obligation under this
warranty is limited to repair or replacement of any part or parts found to be defective. AmeriWater
shall not be required to incur expenses for labor outside 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 result of any unusual force of
nature such as flood, hurricane, tornado, or earthquake. All implied warranties, including any
implied warranty of merchantability or of fitness for a particular purpose are disclaimed to the
extent they extend beyond the above periods.

20 6/07

3 Operation

Note: Initial Startup must be performed by an Authorized Factory Technician.

3.1 Seasonal Startup

Media

a) Check all bolts and fittings for tightness. Initiate filter backwash.

Note

: Stop backwash cycle before last vessel has completed cycle (about 4 minutes into last

vessel backwash) by de-energizing system at service disconnect on control panel.

form the following steps with the filter system isolation valves closed and power to

Per
service disconnect secured.

b) Start to drain filter system through lower manifold drain valve. Note: Check filter gauges to

ensure pressure is reading zero before proceeding to next step.

c) Remove filter vessel cover. Inspect cover and cover gasket, replace if necessary.

d) Note: Drain 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.

e: Media may appear colored. This condition is common and usually due to the presence

Not
of iron oxide or organics in the system water.

sand is at normal operating level and clean, refill vessel with water.

f) If

g) Repl

p

Pum

a. Remove basket strainer or 'Y' strainer cover (if applicable).

b. Inspect cover gasket. Replace or lubricate as needed and reinstall.

c. Remove and clean strainer basket.

d. Replace basket and secure cover(s).

e. Lubricate pump motor and pump shaft (if required).

f. Turn pump by hand, if possible, to ensure ease of movement.

ace filter access cover gasket and cover, and secure cover bolts.

21 6/07

Manifolds

a.Open isolation valves and check for leaks in fittings and pipe before energizing filter system.

ystem Automation

S

a.Energize control system.

b.Engage manual backwash by depressing and holding manual backwash button (Ref: Drawing CP

ntil backwash light illuminates (approx. 20 seconds).

u

c. Allow system to backwash for full cycle. After last vessel backwashes allow system to return to
filter mode.

d. Pressure differential should now be close to that indicated on startup data sheet (typically 8 – 12
PSI).

e.Check voltage and amperage on pump motor leads. Current /amp draw should not exceed rating
on motor nameplate.

f.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) and leave drain open.

)

d.Open filter vessels and inspect media. Clean or replace as necessary.

g.Replace filter access cover gasket and cap. Leave bolts loose.

3.3 Freeze Protection

If filter is to be installed in an area where freezing is likely, all wetted surfaces should be heat traced
and insulated to protect equipment from freezing. Follow shutdown procedures to reduce the
likelihood of damage during winter shutdown periods.

22 6/07

SEQUENCE OF OPERATION
This section describes the operation of standard High Efficiency Filter Systems as they are
shipped from the factory. It is intended to be an aid to understanding the general operation
of the unit for the equipment operator and should not be considered a technical reference.

Modes of operation

There are two modes of operation for the CW Series.

Service mode – Incoming water is pumped into the top of the filter tank(s), through the filtering
media, out the bottom of the tank(s) and returned to the cooling system.

Backwash mode – This is the CW Series self-cleaning mode. Water is directed to enter the bottom of
the tank at a controlled flow rate. The media bed is lifted and separated loosening the trapped
particles. The water exits the top of the tank carrying away the previously filtered particulates to the
drain.

Start-up

When power is applied to the CW Series filter, 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.

Initiating the backwash cycle

There are three ways to initiate the backwash cycle.

Automatic – The PLC has a built-in timer that is designed to initiate a backwash cycle every 24 hours.

On-demand – A differential pressure gauge monitors the input and output water pressures and
sends a signal to the PLC to start a backwash when the difference between inlet and outlet water
pressure reaches the preset threshold. This feature is also automatic.

Manual – The backwash cycle can be initiated manually at any time by pressing and holding the
“manual backwash” pushbutton on the front of the control box, for a period of 20 seconds. Once
initiated, the backwash cycle will commence without operator assistance.

23 6/07

Backwash sequence of operations

Once a backwash has been initiated by any of the above methods, the sequence of events that
follows will always be the same. The sequence is as follows:

1) If a filter is using city water for backwash, the pump goes off. If the filter uses system

water for backwash, the pump will be deactivated until the cycle valves turn , and the pump is
reactivated.

2) On single and multiple tank filters, all service valves (1&2) close at the same time. Event time is 60

seconds.

3) Tank #1 backwash indicator light is illuminated.

4) Tank #1 backwash valves (3&4) open. Backwash duration is 5 minutes.

5) When Tank #1 backwash is complete the indicator light is extinguished.

6) Backwash valves (3&4) close.

7) Steps 3 through 7 are repeated for each additional tank for multi-tank systems.

8) After all tanks have been backwashed, all service valves open. Event time is 60 seconds.

9) The pump returns to run mode and the CW Series Filter returns to service mode.

Aborting the backwash

In certain situations, it may be desirable to abort a backwash. A backwash in progress can be
aborted by pressing and holding the “manual backwash” pushbutton for a period of 10 seconds.

NOTE: If the backwash is 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 interval by installing a fuse in the fuse
holder labeled 7 for closed loop systems. Consult your AmeriWater representative for information.

Setting the automatic timer

The 24 hour or 7 day automatic backwash timer can be reset to zero by pressing and releasing the
“manual backwash” pushbutton on the control box 5 times within a 5 second interval. All backwash
indicator lights will flash twice to confirm the change. Thereafter, the CW Series will backwash 24
hours or 7 days from the time you reset the timer, unless a manual or on demand backwash is
initiated.

Note: In the event that electrical power is removed from the control box, the timer cannot continue
counting but will maintain the count it held when power was lost and continue counting when
power is restored. The backwash schedule will be delayed by the amount of time the power was off.
If the backwash time is important, the timer will need to be reset to bring it back on schedule. See
above paragraph for timer resetting instructions.

24 6/07

System Backwash Pump Enable

The CW Series is a pressurized filter system designed to operate at a specific water flow rate. To
achieve the specified flow rate, a pump is integrated into the CW Series . Normally, this pump runs
continuously whenever the system is in service mode and is turned off during backwash. Optionally,
the controls can be set up to operate the pump during backwash, as described in the backwash
sequence of operations (Step 1). This is accomplished by installing a fuse at the appropriate location
in the control box labeled P. Consult your AmeriWater representative for information. To disable
(turn off) the pump for maintenance, etc., rotate the pump selector switch on the control box to the
“off” position. This will disable the pump in all modes of operation.

External interface options

Inputs

1) Remote Pump Disable to turn off the pump remotely from external source, i.e. BMS
(Building Management System). Signal is sent from external source to filter PLC
controller to disable pump.

ackwash Interlock input - locks out initiation of a backwash cycle in a multiple

2) B
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.

Outputs

ackwash/Storage Tank Abort – Utilized for filter systems using a backwash storage

3) B
tank. An input signal is sent from the float switch in the storage tank to the system to
abort the backwash cycle in the event the storage tank is approaching an overflow
condition. Once aborted, the filter system will return to normal service mode. Once
the storage tank drains to a sufficient level; the abort signal is reset to allow the filter
to backwash.

1) Dry contact connection activated when unit is in backwash.

2) Backwash Counter contact to read the number of backwash cycles the filter system
has cycled through.

3) P

ump On contact to alert external monitors, when pump is operational.

ry contact to other paired units for Backwash Interlock to prevent more than one

4) D
system from backwashing at same time.

ry contact to signal external monitors in the event that a pump overload is present.

5) D

6) 120 volt powered contact when filter is in backwash.

25 6/07

Electrical Component Description

1) Power Disconnect Switch – Main power supply to filter ON/OFF switch.

2

) Pump On Indicator Light – Illuminated when filter pump is ON.

3

) System Power On Indicator Light – Illuminated when disconnect switch is in the on

position and power is to the filter.

4

) Backwash Indicator Light – Illuminated when filter is in backwash. Light indicates which

specific vessel is in backwash on a multiple tank system.

) Pump Control Switch – Manual switch to deactivate the filter pump.

5

) Manual Backwash Start Button – Manually initiates a backwash when pressed and held

6

for approximately 20 seconds.

7) Backwash Cycle Counter - Totalizes the number of times the filter has backwashed.

) Differential Pressure Switch – Monitors the operating differential pressure of the filter

8

and initiates a backwash at 18 PSID.

Fuse and Input/Output Terminal Description

9) FU1 – Main 2 Amp fuse for PLC power

1

0) FU2 – Main 2 Amp fuse for the control panel power.

1

1) (P) – Installing the fuse enables the filter pump to run during backwash. Primarily used
for system water backwash.

2) (7) – Installing fuse changes frequency of backwash from every 24 hours to every 7 days.

1

(Closed loop systems only)

1

3) (15) – Installing fuse resets the duration of backwash from 5 minutes to 15 minutes (Just
for initial startup).

4) Terminal 1 & 16 (Single Tank) – Input (dry contact) to disable the filter pump.

1

Terminal 1 &19 (Dual Tank)
Terminal 1 & 20 (Three Tank)
Terminal 1 & 22 (Four Tank)

1

5) Terminal 1 & 17 – “Backwash interlock input” is an input (dry contact) from the second
filter system “filter lockout output” terminals 20 & 21 to prevent both units backwashing
at the same time.

26 6/07

16) Terminal 20 & 21 – “Filter Lockout Output” is an output (dry contact) to first filter system
“Backwash Interlock Input” terminals 1 &17 to prevent system from backwashing at the
same time.

17) Te

rminal 2 & 24 – Wet Contact – 120V output when filter is in backwash. Deactivated

when filter is in service.

rminal 1 & 18 – “Storage Tank Abort Input” - Dry contact input from backwash storage

18) Te
tank. When activated aborts the backwash and returns the filter to service.

19) T

erminals 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 NUMBERS ON MULTIPLE TANK SYSTEMS REFERENCE THE LADDER DIAGRAM.

27 6/07

28 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.

N

ote: 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.

We

ekly:

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

Monthly:

Grease pump motors (if applicable)

Quarterly:

Check all control functions

A

nnual:

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.

N

ote: 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.

ifferential pressure should be 6-12 psig when system returns to filter mode.

c) D

See start up data sheet for pressure.

29 6/07

a.3 Media (level & condition)

a) Backwash filter (De-energize control panel before last vessel is finished backwashing).

b) Isolate filter system from all water sources.

c) Open bottom filter drain (Ensure that pressure drops to zero).

d) Remove vessel cap and gasket.

e) Drain water to top of media then close drain.

f) Inspect sand. Sand should be loose and clean. Some discoloration is normal in

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 cap.

l) Open all water supply valves and energize power supply.

m) Return system to service with manual backwash.

4.4 Pump Service

Follow instructions contained in pump manufacturers cut sheets.

30 6/07

Symptom

Possible Cause

Remedy

Water Running to Waste

During Filter Cycle

Valve Failure

Rebuild valves

Valve Failed Open

Check valve position indicators

(Packed pump seals only)

System in Backwash

Normal operation

Filter in Backwash Mode

Normal operation

Pump Starter Tripped

Reset starter

Pump Fuse Blown

Replace fuse

Service Disconnect or Pump
Switch Off

Switch to on position
Micro Switch Failure

Consult factory representative

Pump Seal Leaks

Normal Wear

Replace pump seal

Abrasive Material Entering Seal

Check pump strainer

Excessive Pressure on Pump
Discharge

Open all valves

Excessive Pressure to Pump
Suction

Check pressure to pump
against rating

Water Lubricated Seal

Normal 5 gallons per hour

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 fuse rating

Bacteria Loading

Consult factory representative

Overloading of Contaminant

Consult factory representative

Air Entering System Causing

Check for air in system and
backwash

Media Disruption

Lines

Properly

function and water pressure

System Piping Unusually Warm

Filter Discharge to Dead Head

Open all valves

Check for proper system
installation

Media Plugged

See media failure

If recommended remedy fails, contact AmeriWater 800.585.5535 for further information.

Filter Pump Not Operating

Symptom Does Not Backwash

Normal Pump Discharge 5 Gallons/Hour water

lubricated pump

Premature Media Failure

System Not Backwashing

Check backwash control

Check automatic valve
functions

31 6/07

SCALE:

DATE: 02JUL18

SHEET OF

THIS DESIGN IS THE

PROPERTY OF AMERIWATER

AND IS ONLY A LLOWED TO

BE USED BY EX PRESS

PERMISSION AN D LI

CENSE

FROM AMERIWAT ER.

3345 STOP 8 ROAD

DAYTON, OH 4 5414

PHONE : [phone]

TOLERANCES UNLESS

OTHER WISE N OTED

.XXX +/- . 007

.XX + /- .01 5

.X +/- .03

X/Y +/- 1 /16

1

THIRD ANGLE PROJECTION

NA

2

HIGH EFFICIENCY FILTER 100-150 PSI

CW430 100-150

G

6.5' D x 12' W x 8' H

10,000 lbs.

DEF

C

82 3/16"

20"

38 1/16"

26" 81 1/2"

122"

60 PSI

320

35

0.25 Micron**

45

400

Inlet Pressure

Maximum Pump

2"

700

900

1.5"

6.0"

2.0"

2.0"

10 / 460V / 14 / 3 / 3600

10 / 208V / 30.8 / 3 / 3600

1 & 2

3 & 4

304L Stainless Steel / 30"

Filter In/Out

Backwash to Drain

City Backwash Inlet

73 7/8"

73 7/8"

81 15/16"

MN

59"

81 3/8"

L

20"

42 3/4"

42 3/4"

38 1/16"

36 3/4"

36 3/4"

26"

30 3/4"

30 3/4"

122"

9 5/8"

9 5/8" 59"

B24OCT18 ADDED PRESSURE GAUGESB

A 02JUL18 ORIGINAL ISSUE ARC

REV DATE ECR DESCRIPTION INIT

Model CW430

Standard Pressu re (100 PSI) Vesse l

High Pressure (150 PSI) Vessel* 110 PSI

Filtration Ratin g 0.5 Micron

Flow Rate GPM

Backwash Flow Rate (GPM)

Backwash Total Gallon s (20 Min. Duration)

Pump (HP / Voltage / Amps / Ph / RPM)

Valve Size

Recommended Piping Size

(PLUGGED)

CITY WATER

PUMP DISCHARGE

Vessel Contruction / Diameter

Recommended Space

Unit Weight Plus Media***

AB

HI J K

22"

22"

140 3/8"

140 3/4"

Piping

Copper

PVC****

Piping

Copper

PVC****

All data shown abo ve are nominal value s and subject to chan ge.

Flow rates depend o n customer piping size and length.

Dimensions a nd weights are ap proximate and subject to chang e.

Design engin eer important no te for schedule: Sizing based on AmeriWater syst ems only.

Substitutions sized per manufacturer published data or industry standard 5-10% of

* Higher pressure systems available

** Closed loop systems only - does no t include tower water backwash piping .

*** Unit Weight Plus Media Excludes weight of water

**** PVC piping only availa ble on 100 PSI system s

recirculation rate.

FILTER INLET

BACKWASH

TOWER WATER

FLOW REGULATOR

WATER BACKWASH

COOLING TOWER FILTERS

INCLUDE OPTIONAL TOWER

CITY WATER BACKWASH INLET

SHOWN WITHOUT

SAFETY RELIEF VALVE

FILTER

VALVE 3

VALVE 4

VALVE 1

VALVE 2

OUTLET

(TO DRAIN)

BACKWASH OUTLET

4 TANK PAGE 1 OF 2

SCALE:

DATE: 02JUL18

SHEET OF

THIS DESIGN IS THE

PROPERTY OF AMERIWATER

AND IS ONLY A LLOWED TO

BE USED BY EX PRESS

PERMISSION AN D LI

CENSE

FROM AMERIWAT ER.

3345 STOP 8 ROAD

DAYTON, OH 4 5414

PHONE : [phone]

TOLERANCES UNLESS

OTHER WISE N OTED

.XXX +/- . 007

.XX + /- .01 5

.X +/- .03

X/Y +/- 1 /16

2

THIRD ANGLE PROJECTION

NA

2

HIGH EFFICIENCY FILTER 100-150 PSI

CW430 100-150

G

10,000 lbs.

DEF

C

82 3/16"

81 1/2"

20"

38 1/16"

26"

122"

60 PSI

Maximum Pump

320

700

110 PSI

Inlet Pressure

35

0.25 Micron**

40045900

0.5 Micron

2"

1.5"

6.0"

2.0"

2.0"

10 / 460V / 14 / 3 / 3600

10 / 208V / 30.8 / 3 / 3600

1 & 2

3 & 4

Filter In/Out

City Backw ash Inle t

6.5' D x 12' W x 8' H

304L Stainless Steel / 30"

Backwash to Drain

81 15/16"

81 3/8"

20"

38 1/16"

26"

122"

73 7/8"

73 7/8"

42 3/4"

42 3/4"9 5/8" 59"

36 3/4"

36 3/4"

30 3/4"

30 3/4"

9 5/8" 59"

B24OCT18 ADDED PRESSURE GAUGESB

A 02JUL18 ORIGINAL ISSUE ARC

REV DATE ECR DESCRIPTION INIT

AB

140 3/4"

HI J KL MN

140 3/8"

22"

22"

Model CW430

Flow Rate GPM

Backwash Flow Rate (GPM)

High Pressure (150 PS I) Vessel*

Filtration R ating

Standard Pressure (100 PSI) Vessel

Backwash Total Gallons (20 Min. Duration)

Pump (HP / Voltage / Amps / Ph / RPM)

Valve Size

Vessel Contruc tion / Diameter

Recommended Piping Size

Piping

Coppe r

PVC****

Piping

Coppe r

Recommended Space

Unit Weight Plus Media***

PVC****

* Higher pressure systems available

** Closed loop systems only - does not include tower water backwash piping.

All data shown above are nominal values and subject to change.

Flow rates depend on customer piping size and length.

Dimensions and weights are approximate and subject to change.

Design engineer important note for schedule: Sizing based on AmeriWater systems only.

Substitutions sized per manufacturer published data or industry standard 5-10% of

*** Unit Weight Plus Media Excludes weight of w ater

**** PVC piping only available on 100 PSI systems

recirculation rate.

L

K

E

D

J

I

H

B

A

C

F

(Optional for non-certified)

ON ASME CERTIFIED SYSTEMS

SAFETY RELIEF VALVE INCLUDED

G

PIPE PLUG

4 TANK PAGE 2 OF 2

CP = Control Panel Enclosure with Labeled Components

TBIO = Input/output strips on Terminal block labeled to indicate connection points

CPIO = Input/output strips on PLC labeled to indicate connection points

39

AC/SB

THIS DESIGN IS THE

PROPERTY OF AMERIWATER

AND IS ONLY ALLOWED TO

BE USED BY EXPRESS

PERMISSION AND LICENSE

FROM AMERIWATER.

X/Y +/- 1/16

.X +/- .03

.XX +/- .015

.XXX +/- .007

OTHERWISE NOTED

TOLERANCES UNLESS

FILTER INLET

ADDED CITY WATER PRESSURE GAUGE

B22OCT18

A 20AUG18 ORIGINAL ISSUE ARC

REV DATE ECR DESCRIPTION INIT

OPTIONAL TOWER WATER

CITY WATER

BACKWASH INLET*

BACKFLOW

PREVENTER

STRAINER

PHONE: [phone]

DAYTON, OH 45414

3345 STOP 8 ROAD

HIGH EFFICIENCY SAND FILTER TYPICAL FOUR

TANK INSTALLATION

NA

1

SCALE:

PRESSURE

REDUCING

VALVE

BACKWASH

THIRD ANGLE PROJECTION

1

SHEET OF

DATE: 07AUG18

DASHED BORDER SHOWS

PROVIDED FILTER. OUTSIDE

OF BORDER PROVIDED

BY OTHERS. SEE DI MENSIONAL

DRAWINGS FOR SYSTEM DETAI LS

INLET AND OUTLET OF FILTER MUST CONNECT TO SAME COMMON COOLING WATER HEADER

°F (CONSULT CHEMWORKS).

FILTER OUTLET

DRAIN

TO DRAIN

BACKWASH

* CITY WATER OR ALTERNATE CLEAN WATER SOURCE. NOT REQUIRED FOR FI LTERS USI NG OPTIONAL TOWER BACKWASH.

INSTALLATION NOTES:

1) DURING BACKWASH WATER PRESSURE MUST BE BETWEEN 30 AND 60 PSIG ENTERING BACKWASH FLOW REGULATOR,

WITH THE IDEAL PRESSURE SETTING BEING 40 PSIG.

3) CONSULT CHEMWORKS FOR PIPE RUNS GREATER THAN 20' FROM FILTER.

4) CONSULT CHEMWORKS FOR VERTICAL DRAIN PIPE INSTALLATIONS GREATER THAN 8' IN HEIGHT.

5) ALL PIPING MUST MEET STATE AND LOCAL PLUMBING CODES.

a. CITY WATER - INSTALL PRESSURE REDUCING VALVE IF REQUIRED.

b. TOWER WATER - ADJUST TOWER WATER BACKWASH VALVE TO KEEP PRESSURE WITHIN RANGE.

2) MAXI MUM BACKWASH WATER TEMPERATURE IS 140

6) SINGLE POINT ELECTRICAL CONNECTION TO CONTROL PANEL.

ML = Media Label

MEDIA LAYER 1

(LOAD FIRST)

GRAVEL ½ x ¼

Caution: Product contains silica.

See MSDS for proper handling and safety precautions.

__________ OF __________

 The Media Layer number on the Media Label corresponds to the order in which it is to

be loaded (for example, Media 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.

42

6 System Component Cut Sheets

43

OWNERS MANUAL

INSTALLATION AND OPERATING INSTRUCTIONS

REPAIR PARTS LIST

Close Coupled Motor Driven

Centrifugal Pump

1134 0694

IMPORTANT

For best possible performance and continuous, satisfactory operation,
read these instructions before installing your new pump.

Should service be required, this manual can be a valuable guide.
It should be kept near the installation for ready reference.
Record nameplate data from pump on blank nameplate inside this
manual for future reference.

Berkeley Pumps / 293 Wright Street / Delavan, WI 53115

F00634 (Rev. 7/21/09)

Table of Contents

Page 2 F00634

• SAFETY.................................................................................................................................................................3

• INSTALLATION

General Information ................................................................................................................................... 4, 5

Foundation......................................................................................................................................................5

Suction Connection for Centrifugal Pump Installation..............................................................................4, 6-9

Suction Connection for Swimming Pool Installation.............................................................................4, 10-11

Discharge Connection..........................................................................................................................4, 12-13

Electrical Connection ................................................................................................................................4, 14

• START-UP

General Information ......................................................................................................................................15

Check Pump Rotation.............................................................................................................................15, 16

Priming....................................................................................................................................................15, 17

• MAINTENANCE

General Information / Observational Maintenance / Pump Protection..........................................................18

Packing ...................................................................................................................................................18, 19

Mechanical Shaft Seal.......................................................................................................................18, 20-21

• PUMP NOMENCLATURE

General Information ......................................................................................................................................22

Parts Breakdown...........................................................................................................................................23

• TROUBLESHOOTING

Chart .............................................................................................................................................................24

Page

F00634 Page 3

READ AND FOLLOW
SAFETY INSTRUCTIONS!

This is the safety alert symbol. When you see

this symbol on your pump or in this manual, look for
one of the following signal words and be alert to the
potential for personal injury:

warns about hazards that will cause
serious personal injury, death or major property
damage if ignored.

warns about hazards that will or can
cause serious personal injury, death or major property
damage if ignored.

warns about hazards that will or can
cause minor personal injury or property damage if
ignored.

The label NOTICE indicates special instructions which
are important but not related to hazards.

Carefully read and follow all safety instructions in
this manual and on pump.

Keep safety labels in good condition.
Replace missing or damaged safety labels.

Electrical Safety

Wire motor for correct
voltage. See “Electrical”
section of this manual and
motor nameplate.

Ground motor before
connecting to power supply.

Meet National Electrical
Code and local codes for all
wiring.

Follow wiring instructions
in this manual when
connecting motor to power
lines.

General Safety

Do not allow pump, piping, or any other system
component containing water to freeze. Freezing may
damage system, leading to injury or flooding. Allowing
pump or system components to freeze will void
warranty.

Pump approved liquids only with this pump.
Periodically inspect pump and system components.
Wear safety glasses at all times when working on

pumps.
Keep work area clean, uncluttered and properly

lighted; store properly all unused tools and equipment.
Keep visitors at a safe distance from the work areas.
Make workshops childproof; use padlocks and master

switches; remove starter keys.

Swimming Pool and Spa Installation Safety

Incorrectly installed or tested
equipment may fail, causing severe
injury or property damage.

Read and follow instructions in owner's
manual when installing and operating equipment. Have
a trained pool professional perform all pressure tests.

1. Do not connect system to a high pressure or city

water system.

2. Install pump with at least 2 hydraulically balanced

main drains equipped with correctly installed,
screw-fastened, anti-entrapment certified covers.
See Page 11.

3. Trapped air in system can cause explosion. BE

SURE all air is out of system before operating or
testing equipment.

Before pressure testing, make the following safety
checks:

• Check all clamps, bolts, lids, and system

accessories before testing.

• Release all air in system before testing.

• Tighten Berkeley trap lids to 30 ft. lbs. (4.1 kg-cm)

torque for testing.

• Water pressure for test must be less than 25 PSI

(172 kPa).

• Water Temperature for test must be less than

100°F. (38°C).

• Limit test to 24 hours. After test, visually check

system to be sure it is ready for operation. Remove
trap lid and retighten hand tight only.

NOTICE: These parameters apply to Berkeley
equipment only. For non-Berkeley equipment,
consult manufacturer.

Safety First

WARNING

Hazardous voltage.
Can shock, burn, or
cause death.

Ground pump before
connecting to power
supply.

F00634 Page 15

CHECK ROTATION:

Before pump is put into operation, rotational direction
must be checked to assure proper performance of
pump. Refer to illustration on Page 16.

Hazardous voltage. Can shock, burn, or

cause death. Disconnect power to pump before

servicing.
Do not attempt any wiring changes without first

disconnecting power to pump.

PRIMING:

Pump priming is the displacement of air with water in
the pump and suction piping. Pump MUST BE
completely filled with water when operating.

Refer to Page 17 for instruction on the following
conditions:

1. Suction lift with priming pump (water source
below pump).

2. Suction lift with foot valve (water source below
pump).

3. Flooded suction (water source above pump, or
incoming water pressure is greater than
atmospheric pressure).

SPECIAL CASE - HYDRAULIC BALANCED PUMPS:
Hydraulic balanced pumps operate with a very low
positive pressure across the stuffing box, permitting a
much looser fit of the packing rings around the shaft
sleeve to control the loss of water from the pump
through the stuffing box. Because of the looser fit of
the packing rings, air can be more easily drawn into the
pump through the stuffing box when priming the pump
with an air evacuation type primer.

A grease fitting, communicating through the side of the
stuffing box to a lantern ring in the packing set, is
provided to grease-seal the stuffing box to prevent air
leakage during priming.

If pump cannot be primed due to air leakage through
stuffing box, DO NOT tighten packing. Instead, pump
grease into lantern ring until back pressure occurs
forcing grease into the lantern ring, grease-sealing the
stuffing box. After priming, when unit is put into
operation, the grease will be flushed out through the
packing by the water flowing outward through the
stuffing box. Proceed with normal adjustment of the
packing as described on Page 18. Note that the grease
seal only is used for control of air leaking during
priming, and that only the packing gland is used to
control flow of water through the stuffing box during
normal operation.

When necessary to replenish the grease supply use an
NLGI no. 4 Water Pump Grease.

STARTING:

Never run pump dry. Running pump

without water will overheat pump and damage internal
parts. Always make sure pump is primed prior to start­up.

NOTICE: Refer to maintenance section if pump has
packing for adjustment prior to start-up.

Prime pump by one of the above procedures. Turn on
power to pump. Slowly open discharge valve until
desired flow rate is achieved. Place the “Hand-Off-Auto”
selector switch in the “Auto” position. The pump will be
started automatically when the pilot device signals the
motor starter.

STOPPING:

Pump will stop automatically when the pilot device de­energizes the motor starter. Turn the “Hand-Off-Auto”
selector switch to “Off” position if you want to stop the
pump while it is running.

General Information

Start-up

Page 16 F00634

Determine Pump Rotation

Start-up

• Electric Motors:
Single Phase: Refer to wiring information on the

motor plate to obtain proper rotation.
Three Phase: If pump runs backwards, reverse any

two leads coming off incoming power (L1, L2, L3)
until proper rotation is obtained. Reverse L1 and L2,
or L2 and L3, or L1 and L3.

• Pump running backward - Centrifugal pumps will still
pump liquids, however, GPM and head (discharge
pressure) will be a fraction of the published
performance.

n

o

i

t

a

t

o

r

e

s

i

w

k

c

o

l

C

12

9

3

Viewed from
this direction

6

As viewed

Engage start switch momentarily
(bump motor) to observe rotational
direction.

1129 0694

Direction of Pump Rotation is determined by viewing liquid end of pump
from the back or shaft side, and not from looking into the impeller eye
or front of volute case. A rotation direction arrow is cast into the pump
body and shows correct rotation.

F00634 Page 17

Pump Priming

Start-up

• Close air tight valve on discharge.

• Remove pipe plug from highest opening on pump
case.

• Completely fill pump and suction piping with water.

• Rotate shaft slowly allowing any air trapped in
impeller to escape.

• When all air has been forced out of pump, replace
pipe plug. Use pipe joint compound on plug threads
and tighten as necessary to prevent leakage.

• Open air vent (or pipe plug) in the highest tapped
opening in pump case.

• Open inlet isolation valve, allowing water to fill the
pump completely and force all air out through vent.

• Rotate shaft slowly allowing any air trapped in
impeller to escape.

• Close vent opening when water without air emerges.

• Close air tight valve.

• Hand primer operation:

1. Open hand primer isolation valve.

2. Work handle of hand primer up and down to
evacuate air from the suction line.
(Refer to primer owner’s manual for proper
procedure).

3. When water flows freely from primer, close hand
primer isolation valve.
(Pump case should now be filled with water).

• Immediately start pump.

• Slowly open butterfly valve (if used) until desired flow
is achieved.
(Discharge Priming Valve will open automatically).

Installations With Suction Lift and Priming Pump.

Installations With Suction Lift and Foot Valve.

Installations With Flooded Suction.

Discharge Priming
Valve

787 0394A

Hand
Primer

Primer Isolation
Valve

Suction to
Water Source

Page 18 F00634

LUBRICATION:

LIQUID END of 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 packing area is for priming only.
See

PRIMING

in start-up section for instruction.

MOTOR bearings are lubricated at the factory. Re­lubrication at intervals consistent with the amount of use
will provide maximum bearing life. Refer to motor
Instruction Manual for proper motor lubrication and
maintenance instructions.

PERFORMANCE CHECK:

Periodically check the output of the pump. If perform­ance is noticeably reduced, refer to Troubleshooting
Chart.

OBSERVATIONAL MAINTENANCE:

When the pump and system operation have been
stabilized, verify that pump unit is operating properly.
Observe the following:

VIBRATION: All rotating machines can be expected to
produce some vibration, however, excessive vibration
can reduce the life of the unit. If the vibration seems
excessive, discontinue operation, determine cause of
the excessive vibration, and correct.

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.

OPERATING TEMPERATURE: During operation, heat
is dissipated from the pump and the 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 temperature of the pump bracket or
driver is excessive, discontinue operation, determine
cause of the excessive temperature rise, and correct.
Bearings will run hotter for a brief run-in period after
packing which is normal. However, worn bearings will
cause excessive temperatures and need to be
replaced. The pump unit is cooled by the water flowing
through it, and will normally be at the temperature of
the water being pumped.

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 stuffing box in a

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 has been tightened to
the limit of the packing gland travel, additional packing
is necessary.

PACKING:

Starting new pump.

Before starting pump for the first time, loosen gland nuts
and retighten finger tight. Proceed with pump start-up
procedure. Allow packing to leak liberally for a few
moments. Then tighten gland nuts one complete turn
each until leakage is reduced to 40 to 60 drops per
minute.

REPACKING:

Refer to Page 19.

MECHANICAL SEAL:

Adjustment 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. Refer to Pages 20 and 21 for removal
and replacement. Do not run dry!

PUMP PROTECTION­COLD WEATHER/
WET WEATHER INSTALLATIONS:

SYSTEM DRAINS: Provide drain valves to empty
system, including pump case, to prevent freezing
damage.

SHELTER: If possible, provide shelter for unit to protect
from weather. Allow adequate space around pump unit
for service. When effectively sheltered, a small amount
of heat will keep temperature above freezing. Provide
adequate ventilation for unit when running. For severe
weather problems, where other shelter is not practical, a
totally enclosed fan-cooled enclosure can be considered
for electric motors.

CONDENSATION: When the temperature of metal parts
is below dew point and the surrounding air is moist,
water will condense on the metal surfaces and can
cause corrosion damage. In severe situations, a space
heater can be considered to warm the unit.

General Information

Maintenance

F00634 Page 19

Packing Ring Replacement–All Models

Maintenance

Removal

• Unfasten hardware holding Packing Gland in place
and slide back on shaft to expose packing rings. A
split Packing Gland is shown.

• Remove packing rings from Stuffing box using two
commercially available Packing Hooks as shown.

• Slide Lantern Ring (if used) back to expose any
remaining rings, including metallic. Remove them in
the same manner.

• Clean shaft sleeve and Packing Gland.

• Inspect shaft sleeve for wear, replace if needed.

• Install new packing rings in stuffing box by placing
over shaft sleeve and pushing them in as far as they
will go.

• Rotate ring joint 90 degrees when installing each ring
as shown.

• Slide packing gland into position, then gently and
evenly tighten nuts to force rings into place and seat
(do not overtighten). Loosen nuts again to hand tight.

• Start primed pump and allow packing to leak liberally.

• Tighten gland nuts one complete turn each until
leakage is reduced to 40 to 60 drops per minute.

Installing New Rings

1 2

Packing
Gland

Motor / Engine not shown
for clarity.

826 0394

Packing
Hooks

Motor / Engine not shown
for clarity.

Typical Packing Arrangement

Ring Joints

Packing
Rings

Lantern Ring

Motor / Engine not shown
for clarity.

1147 0794

Metallic Ring

Page 20 F00634

Mechanical Shaft Seal

Models B4ZPBH, B5ZPBH, B6ZPBHH. All other models turn to Page 22.

Maintenance

Removal

6059 0609

Gear Puller Finger

Behind Vane

Gear Puller Finger

Behind Vane

Gear Puller

Jackscrew

Note:
A hexnut placed between the
jackscrew and shaft end will
prevent damage to the shaft
and impeller screw threads.

6061 0609

Stationary
Seat

Rotating
Seat

Spring

Spring
Retainer

1189 0794

• Unfasten hardware holding volute to bracket.

• Remove volute to expose impeller.

• Peel off old gasket or O-Ring and discard.

• Hold impeller stationary and remove impeller screw
and associated hardware.

• Install a standard gear puller to shaft end and
impeller, placing puller fingers behind impeller vanes
as shown.

• Rotate gear puller jackscrew until impeller clears
shaft. Remove shaft key.

• If a seal retaining ring is part of the assembly, remove it.

• Pull seal plate out of bracket. Mechanical shaft seal
will come off with seal plate.

• Push stationary seal out of seal cavity from the back
of seal plate.

• Clean seal cavity in seal plate thoroughly.

Procedure and parts will vary slightly depending on pump style.

3

4

21

5

6060 0609

Stationary
Seat

Shaft
Sleeve

6062 0609

6063 0609

F00634 Page 21

Mechanical Shaft Seal

Models B4ZPBH, B5ZPBH, B6ZPBHH. All other models turn to Page 23.

Maintenance

Installing New Seal

6068 0609

6066 0609

6067 0609

Key

• Place seal plate on a smooth, flat surface, pump
side up.

• Apply a small amount of mineral oil to O-Ring on
stationary seal and press into seal cavity. Cover

ceramic face with cardboard washer and press
straight in using a piece of pipe or tubing.

• Reinstall seal plate in bracket using extreme care not to
scratch or chip ceramic face of seal with shaft.

• Apply a small amount of mineral oil to inside diameter
of rubber ring in rotating seat and outside of shaft
sleeve. Slide rotating seat onto shaft, polished face
first, until it is tight against ceramic face.

• Compress seal spring and install retaining ring in
shaft sleeve groove (if used).

• Place impeller key in motor shaft keyway. Slide
impeller on to shaft as far as possible.

• Clean threads thoroughly.

• Apply non-permanent thread adhesive to impeller
capscrew and shaft threads.

• Install impeller washer, shakeproof lockwasher, and
capscrew.

• Install gasket and volute on bracket. Use a new
gasket or O-Ring when reassembling to prevent
leakage ( a coat of grease on gasket will aid in future
disassembly and maintenance).

• Apply anti-seizing compound to capscrews and
tighten securely.

Procedure and parts will vary slightly depending on pump style.

3 4

21

5

Do not scratch or chip
polished ceramic face.
Also . . .do not touch
polished surface

Cardboard washer

(Supplied with seal)

Polished Face

6064 0609

6065 0609

Page 22 F00634

Mechanical Shaft Seal

Maintenance

Removal

1135 0794

Gear Puller

Finger

Gear Puller

Finger

Gear Puller

Jackscrew

Note:
A hexnut placed between the
jackscrew and shaft end will
prevent damage to the shaft
and impeller screw threads.

1138 0794

Stationary
Seat

1140 0794

Stationary
Seat

Rotating
Seat

Spring

Spring
Retainer

1189 0794

• Unfasten hardware holding volute to bracket.
NOTE: For model B4EY, consult factory for special
instructions.

• Remove volute to expose impeller.

• Peel off old gasket or O-Ring and discard.

• Hold impeller stationary and remove impeller screw
and associated hardware.

• Remove capscrews holding bracket to motor.

• Install a standard gear puller to shaft end and motor
bracket placing puller fingers in the area shown.

• Rotate gear puller jackscrew until impeller clears
shaft. Mechanical shaft seal will come off with motor
bracket.

• If a seal retaining ring is part of the assembly, it will
need to be replaced.

• Push stationary seal out of seal cavity from the back
of bracket.

• Clean seal cavity in bracket thoroughly.

Procedure and parts will vary slightly depending on pump style.

3

4

21

5

1137 0794

Key

1139 0794

Shaft
Sleeve

Mechanical Shaft Seal

• Place bracket on a smooth, flat surface, pump side

up.

• Apply a small amount of mineral oil to O-Ring on

stationary seal and press into seal cavity. Cover

ceramic face with cardboard washer and press
straight in using a piece of pipe or tubing.

• Reinstall bracket on motor using extreme care not to
scratch or chip ceramic face of seal with shaft.

• Apply a small amount of mineral oil to inside diameter
of rubber ring in rotating seat and outside of shaft
sleeve. Slide rotating seat onto shaft, polished face
first, until it is tight against ceramic face.

• Compress seal spring and install retaining ring in
shaft sleeve groove (if used).

• Place impeller key in motor shaft keyway. Slide
impeller on to shaft as far as possible.

• Clean threads thoroughly.

• Apply non-permanent thread adhesive to impeller
capscrew and shaft threads.

• Install impeller washer, shakeproof lockwasher, and
capscrew.

• Install gasket and volute on bracket. Use a new
gasket or O-Ring when reassembling to prevent
leakage ( a coat of grease on gasket will aid in future
disassembly and maintenance).

• Apply anti-seizing compound to capscrews and
tighten securely.

Procedure and parts will vary slightly depending on pump style.

3 4

21

5

Do not scratch or chip
polished ceramic face.
Also . . .do not touch
polished surface

F00634 Page 23

If shaft is threaded, cover threads
with tape to protect seal during
installation.

Cardboard washer

(Supplied with seal)

11 2 079

Polished Face

11 079

11 3 079

Key

11 5 079

11 6 079

Page 24 F00634

General Information

Pump Nomenclature

ORDERING REPLACEMENT PARTS:

Locate the Berkeley nameplate on the pump; plate is
normally on the motor bracket. Information found on this
plate is shown below. To be sure of receiving correct
parts, provide all nameplate data when ordering. The
BM (Bill of Material) number is most important. Write
your nameplate information on the blank nameplate
below for future reference as nameplates can become
worn or lost.

Illustrations on the following page show typical
components used in the assembly of motor drive
centrifugal pumps. Both mechanical seal and packing
styles are shown. Refer to these drawings when
ordering any replacement parts.

SAMPLE ONLY

BERKELEY PUMPS

MODEL

B3TPMS

IMPELLER DIA.

6-1/8"

S.N. OR DATE

G100894

B.M.

B54598

788 0394

BERKELEY PUMPS

MODEL

IMPELLER DIA.

Record your nameplate data here.

S.N. OR DATE

B.M.

344 1093

F00634 Page 25

Electric Motor Drive—with removable seal plate

Models B4ZPBH, B5ZPBH, B6ZPBHH

Pump Nomenclature

Mechanical Seal

Motor
Bracket

6070 0609

Volute

Case

Impeller Capscrew

Shakeproof Lockwasher

Wear Ring

Impeller Washer

Impeller

O-Ring
or Gasket

Shaft

Sleeve

Lantern

Ring

Metallic

Ring

Grease

Fitting

Seal

Plate

Packing

Gland

Packing

Rings

Motor
Bracket

6069 0609

Volute

Case

Impeller Capscrew

Shakeproof Lockwasher

Wear Ring

Impeller Washer

Impeller

Seal
Plate

Seal Retaining

Ring

Mechanical

Seal

Gasket
or O-Ring

• Electric motor not shown.

• Drawing shows typical motor drive pump with packing or
a mechanical shaft seal. Parts on some models will vary
slightly.

Packing

Page 26 F00634

Electric Motor Drive—with fixed seal plate

Pump Nomenclature

Mechanical Seal

5530 1006

Volute

Case

Impeller Capscrew

Shakeproof Lockwasher

Wear Ring

Impeller Washer

Impeller

Seal Retaining

Ring

Motor
Bracket

Gasket
or O-Ring

Shaft

Sleeve

Mechanical

Seal

Clack Weight

Rubber Clack
(Check Valve)

Clack Washer

Suction
Cover

Pump Case
(Volute)

Impeller

Case Gasket

Impeller
Lock Nut

• Electric motor not shown.

• Drawing shows typical motor drive pump with packing or
a mechanical shaft seal. Parts on some models will vary
slightly.

Packing

Packing

Gland

Impeller
Lock Nut

Case Gasket

Pump Case
(Volute)

Impeller

Rubber Clack
(Check Valve)

Clack
Weight

Packing

Rings

Clack
Washer

Metallic

Ring

Lantern

Ring

Shaft

Sleeve

Suction
Cover

Packing Grease

Cup or fitting

Motor

Bracket

Impeller
Washer

Impeller

Capscrew

Balance Ring

Gasket

Balance

Ring

Impeller

Shakeproof

Lockwasher

Volute Case

Gasket
or O-Ring

5531 1006

F00634 Page 27

Troubleshooting

Maintenance

CAUSE CORRECTIVE ACTION

I. ELECTRICAL

A. No voltage in power system Check phase-to-phase on line side of starter contactor.

Check circuit breaker or fuses.

B. No voltage on one phase 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 be ±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 device, starter contactor, H-O-A selector switch, etc.,

for malfunction.
F. Thermal overload switch open Check phase-to-phase 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.
I. Frequency variation Check frequency of power system. Must be less than 5% variation from

motor nameplate rating.

II. MECHANICAL

A. Flow through pump completely or Locate and remove obstruction. Refer to Repair Instructions

partially obstructed for disassembly.

B. Wrong direction of rotation Reverse rotation of three phase 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 Inspect. Repair.
F. Stuffing box not properly adjusted Adjust gland.

III. SYSTEM

A. Pressure required by system at design Compare pump pressure and flow rate against pump characteristic curve.

flow rate exceeds pressure rating of pump Check for closed or partially closed valve in discharge piping system.

Reduce system pressure requirement. Increase pressure capability of pump.
B. Obstruction in suction piping Locate 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, etc.

If necessary, reduce flow rate by partially closing discharge valve.

PROBABLE CAUSE

SYMPTOM GROUP I GROUP II GROUP III

ELECTRICAL MECHANICAL SYSTEM

ABC DE FGH I ABCDEFABC

Pump runs, but no water delivered X X X X
Not enough water delivered X X X X X X X X
Not enough pressure X X X X X X X X
Excessive vibration X X X X X X
Abnormal noise XXX XX XX
Pump stops X X X X X X X X
Overheating X X X X X X X X X

Page 28 F00634

Warranty

Berkeley

LIMITED WARRANTY

BERKELEY warrants to the original consumer purchaser (“Purchaser” or “You”) of the products listed below,
that they will be free from defects in material and workmanship for the Warranty Period shown below.

Product Warranty Period
Water Systems:

Water Systems Products — jet pumps,

whichever occurs first:

small centrifugal pumps, submersible pumps 12 months from date of original installation, or
and related accessories 18 months from date of manufacture

Pro-Source

TM

Composite Tanks 5 years from date of original installation

Pro-Source

TM

Steel Pressure Tanks 5 years from date of original installation
Pro-SourceTMEpoxy-Lined Tanks 3 years from date of original installation
Sump/Sewage/Effluent Products 12 months from date of original installation, or

18 months from date of manufacture

Agricultural/Commercial:

Centrifugals – close-coupled motor drive, frame 12 months from date of original installation, or
mount, SAE mount, engine drive, VMS, SSCX, 24 months from date of manufacture
SSHM

Submersible Turbines, 6” diameter and larger 12 months from date of original installation, or

24 months from date of manufacture

Our limited warranty will not apply to any product that, in our sole judgement, has been subject to negligence,
misapplication, improper installation, or improper maintenance. Without limiting the foregoing, operating a
three phase motor with single phase power through a phase converter will void the warranty. Note also that
three phase motors must be protected by three-leg, ambient compensated, extra-quick trip overload relays of
the recommended size or the warranty is void.

Your only remedy, and BERKELEY’s only duty, is that BERKELEY repair or replace defective products (at
BERKELEY’s choice). You must pay all labor and shipping charges associated with this warranty and must
request warranty service through the installing dealer as soon as a problem is discovered. No request for
service will be accepted if received after the Warranty Period has expired. This warranty is not transferable.

BERKELEY SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL, INCIDENTAL, OR CONTINGENT
DAMAGES WHATSOEVER.

THE FOREGOING LIMITED WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER EXPRESS AND
IMPLIED WARRANTIES, INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF
MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE. THE FOREGOING WARRANTIES
SHALL NOT EXTEND BEYOND THE DURATION EXPRESSLY PROVIDED HEREIN.

Some states do not allow the exclusion or limitation of incidental or consequential damages or limitations on
the duration of an implied warranty, so the above limitations or exclusions may not apply to You. This warranty
gives You specific legal rights and You may also have other rights which vary from state to state.

This warranty supersedes and replaces all previous warranty publications.

In the U.S.: BERKELEY, 293 Wright St., Delavan, WI 53115

In Canada: 269 Trillium Dr., Kitchener, Ontario N2G 4W5