Clack WS1 series, WS1.5 series, WS2 series, CAP 1054, CAP 1248 Installation, Operation & Maintenance Manual
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FILTER AG + Series Filter
Installation Operation Maintenance Manual
Installation
Operation
Maintenance
Manual
FILTER AG + Filter
WS1, 1.5 & 2” Series Valve
Models
CAP 1054 CAP 1248
CAP1354 CAP1465
CAP1665 CAP1865
CAP2160 CAP2469
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FILTER AG + Series Filter
Installation Operation Maintenance Manual
CONTENTS
1 UNPACKING AND PARTS LIST........................................................................................................ 3
1.1 UNPACKING NOTES.................................................................................................................... 3
1.2 BASIC PARTS LIST ...................................................................................................................... 3
1.3 MISSING OR DAMAGED GOODS.............................................................................................. 3
2 TEMPORARY STORAGE.................................................................................................................... 3
3.0 GENERAL NOTES.................................................................................................................... 3
3.1 Turbidity Removal...................................................................................................................... 3
3.2 System Management................................................................................................................... 4
4 REGENERATION/BACKWASH .................................................................................................... 4
4.1 The Backwash Process................................................................................................................ 4
4.2 TIME CLOCK CONTROL OF REGENERATION INITIATION ............................................ 4
5 PRE-INSTALLATION CHECKS..................................................................................................... 4
5.1 MECHANICAL.......................................................................................................................... 4
5.1.1 Foundation/Drainage ......................................................................................................... 4
5.1.2 Operating Space................................................................................................................. 5
5.1.3 Incoming Water................................................................................................................. 5
5.1.4 Pipework................................................................................................................................... 5
5.1.5 Water Supply Company Requirements .................................................................................... 5
5.2 ELECTRICAL................................................................................................................................. 5
6 ASSEMBLY/INSTALLATION............................................................................................................. 6
6.1 MECHANICAL .............................................................................................................................. 6
6.1.1 Pipework................................................................................................................................... 6
6.1.2 Drains and overflow connections ............................................................................................. 6
6.2 ASSEMBLY.................................................................................................................................... 6
7 COMMISSIONING .......................................................................................................................... 7
7.1 INTRODUCTION ...................................................................................................................... 7
7.2 Setting the Time of Day................................................................................................................... 8
Regeneration Programming............................................................................................................... 9
7.3 COMMISSIONING.................................................................................................................. 11
8 ROUTINE MONITORING.................................................................................................................. 11
9 FAULT FINDING AND RECTIFICATION....................................................................................... 12
9.1 NO FLOW TO SERVICE............................................................................................................. 12
9.2 POOR TREATED WATER QUALITY ....................................................................................... 12
9.3 NO BACKWASH ......................................................................................................................... 12
9.4 UNSATISFACTORY CAPACITY BETWEEN BACKWASHES .............................................. 12
10 WARRANTY AND SERVICE.......................................................................................................... 13
10.1 AFTER SALE WARRANTY ..................................................................................................... 13
11 TECHNICAL DATA................................................................................................................ 13
11.1 PROCESS AND OPERATING DATA....................................................................................... 13
11.1.1FILTER AG + CM1054 TO 1465 ......................................................................................... 13
11.1.2 FILTER AG + CM1665 TO CM 2469............................................................................ 13
11.1.3 FILTER AG + CM3072 TO CM4272..............................Error! Bookmark not defined.
11.2 ENGINEERING DATA.............................................................................................................. 14
11.2.1 FILTER AG + Series Filters CM1054 to CM 1465 ............................................................. 14
11.2.2 FILTER AG + Series Filters CM1665 to CM 2469 ............................................................. 14
11.2.3 FILTER AG + Series Filters CM3072 TO CM4272.............Error! Bookmark not defined.
12.0 SPARES LIST................................................................................................................................. 15
12.1 WS1 Valves................................................................................................................................. 15
12.2 WS1.5 Valves.............................................................................................................................. 15
12.3 WS2 Valves................................................................................................................................. 15
13 CE Certificate ..................................................................................................................................... 16
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FILTER AG + Series Filter
Installation Operation Maintenance Manual
1 UNPACKING AND PARTS LIST
1 . 1 U N P A C K I N G N O T E S
The unpacking of the Filter is quite straightforward, and there are no ‘hidden’
items. It is advisable to keep the packages sealed until such time as they are
used, to prevent dust or water entry.
1 . 2 B A S I C P A R T S L I S T
1. VALVE (c/w flow controllers on outlet and drain)
2. CLACK MANUAL
3. INSTRUCTIONS
4. VESSEL (c/w riser and distribution system)
5. 4” - 2 1/2” REDUCER (if required)
6. FILTER AG + (qty as specified)
1 . 3 M I S S I N G O R D A M A G E D G O O D S
Immediately on receipt of the goods, it is advisable to check that all items
ordered have been received. If you have any doubt that goods have been
supplied as requested, please contact your supplier immediately. If any items
are missing or damaged, the carrier and your supplier must be notified within 2
days of receipt if a claim is to be made.
2 TEMPORARY STORAGE
If installation is not to start immediately after delivery, the equipment should
be stored in a clean dry area, where it will not be damaged, or be subjected
to temperatures below freezing.
3.0 GENERAL NOTES
These instructions cover the FILTER AG + Range of filters, which includes model
numbers from CAP1054 to CAP 2469.
It is recommended that these instructions are read thoroughly before commencing
any work on the unit, particularly if you have no previous experience of installing and
using a filter.
3 . 1 T u r b i d i t y R e m o v a l
Turbidity in the water is removed by filtration as the water passes through the bed. A
support bed of gravel is used to protect the distributer and 2 grades of sand and
anthracite to remove decreasingly smaller particles as the water passes through the
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FILT ER AG + Series Filter
Installation Operation Maintenance Manual
bed. By this method the whole depth of the bed can be used for filtration.
3 . 2 S y s t e m M a n a g e m e n t
In order to remove accumulated deposits from the filter bed, the water flow through
the filter is reversed (backwashed). Water is run to drain at a high rate to
separate the filter media from the deposits. The control valve completes the
backwash cycle automatically at the intervals and times set during installation.
Backwash and fast rinse times are set for 20 minutes per cycle but can be altered to
suit individual requirements.
All filter valves have the option of an additional volt free microswitch, which can be
used to initiate a regen pump etc.
4 REGENERATION/BACKWASH
4 . 1 T h e B a c k w a s h P r o c e s s
The backwash process consists of two stages:-
Backwash - Water flows upwards through the media bed, and out to a drain.
As it does so it separates the deposits from the filter media and cleans off any
particles of dirt or pipework corrosion products, which may have accumulated
during the service cycle.
Fast Rinse - This follows the backwash cycle and entails rinsing away any
residual deposits from the media and re-packing the media bed. This is
carried out down flow with water flowing through the media in the direction of
service.
4 . 2 T I M E C L O C K C O N T R O L O F R E G E N E R A T I O N
I N I T I A T I O N
Most filter application systems are supplied with a time clock
configuration valve, which initiate regeneration at a pre-set time (usually
2:00 AM) after a pre-set number of days. The frequency of regenerations is
fully adjustable, but a minimum of once every 3 days is recommended.
5 PRE-INSTALLATION CHECKS
5 . 1 M E C H A N I C A L
5.1.1 Foundation/Drainage
The filter will not require any special foundations, provided that a firm, level
area, which is capable of supporting the working weight, is available. (See
Engineering Data, Section 11.2)
Unwanted water from the backwash process must flow to drain, and so an
open drain or gully, capable of passing the necessary flow is required (see
Process and Operating Data, 11.1, for relevant flows). The total flow of
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Installation Operation Maintenance Manual
water to drain depends on site conditions, but will be at least the same as the
service flow. Preferably the drain should be level but no higher than 500mm
above the filter valve.
5.1.2 Operating Space
The space occupied by the filter can be found in the Engineering Data (Section
11 .2).
Access will be required to carry out adjustments or maintenance on the
equipment. It is therefore recommended that a minimum of 500mm clearance
be allowed around the unit for this purpose.
5.1.3 Incoming Water
The raw water to be fed to the filter must comply with the following:-
1. Maximum iron level = 20ppm
2. pH range = 6.0-9.0
3. Organic matter = less than 5ppm
4. Free chlorine = less than 0.5ppm
5. Chloride below 100 ppm
6. Temperature = 3 - 45C (35 - 110F)
7. No Oil or Polyphosphates
8. Backwash flow rate should be twice the service
flow rate available with a pressure of 3 bar
5.1.4 Pipework
Pipework to be connected to the filter should not have an excessive amount of
deposits. Piping that is heavily built up with scale (or Iron deposits) should be
replaced.
Make sure that the pipework can be connected to the filter in such a way as
to impose no stresses on the control valve, and that it is properly aligned
and supported.
A system for the complete by-passing and isolation of the filter should be
installed.
5.1.5 Water Supply Company Requirements
During backwash the accumulated debris is flushed to drain. Please contact
your local Water Authority for advice on effluent issues if concerned with flow
to drain.
5 . 2 E L E C T R I C A L
All filter valves are supplied as 12v complete with a transformer for 240v. A
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FILT ER AG + Series Filter
Installation Operation Maintenance Manual
continuous supply of 240v, 5 VA is required which should be provided by an
uninterrupted mains supply, which is separately 1 Amp fused, and does not
have any additional switch.
A plug is provided with this filter, the cable should be connected to fused
spur outlet. However if that is not possible then a plug should be fitted to the
cable with a 1 amp fuse. The socket used should be unswitched to prevent the
filter from being inadvertently turned off.
6 ASSEMBLY/INSTALLATION
6 . 1 M E C H A N I C A L
Check all the items against the parts list and shipping documents, and ensure
you have them all before starting work. In addition to the filter you will require
installation materials and basic tools, (i.e., spanners, screwdrivers etc., and
PTFE tape)
6.1.1 Pipework
Pipework can be constructed from any normally acceptable material (Copper,
Galvanised, Plastic), provided it is properly supported and aligned. Ensure
that the pipe is sufficiently large to accommodate the flow of water required,
making due allowance for the pressure drop between the filter and the point of
discharge of treated water.
NOTE: IF BRAZED OR SOLDERED FITTINGS ARE TO BE USED, THE
PIPE WORK MUST BE DISCONNECTED FROM THE VALVE DURING
HEATING AND COOLING. EXCESS HEAT CAN CAUSE PERMANENT
DAMAGE TO SOME OF THE VALVE COMPONENTS.
6.1.2 Drains and overflow connections
The drain connection from the backwash valves is a 3/4" or 1” BSPM thread
for WS 1” 1 ½” for WS 1.5 and 2”. Flexible tube should be run from this
spigot to a drain capable of taking the maximum flow in regeneration (see
Section 11.2), and leaving a similar gap above the drain edge. The drain
must not be higher than 500mm above the control valve and preferably should
have an air break at the same height as the control valve.
6 . 2 A S S E M B L Y
Refer to the installation diagrams in Section 13 and note the
direction of flow through the system.
Ensure the installation site is clear and level.
Ensure that the piping system in the building transfers the treated water
into a vented header tank to feed any hot water systems.
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Installation Operation Maintenance Manual
If possible, place the filter vessel into its final location before filling. Check
that the riser tube has the cap in place before commencing filling.
Using a hose 1/3 fill the vessel with water. This is to prevent damage to the
bottom distributor when pouring in the media.
Using a funnel slowly pour in the support gravel. Next, slowly pour in the
Filter Sand, course first and then the Anthracite, taking care not to spill any
on the floor and that the riser remains central in the vessel during filling.
After pouring in all of the filter media, the vessel should be, at most, 70-75%
full. This is to allow rising space for the media during the backwashing cycle.
Once the vessel is filled, immediately sweep up any spilled filter media.
Remove the cap from the riser tube and brush any debris out of the threads
in the neck of the filter vessel.
Unpack the valve and reducer (if used). Screw the reducer into the filter
vessel, then slip the valve down onto the distributor tube. No top distributor is
used on filter valves to allow the maximum amount of debris to be
backwashed off the media.
Screw the valve into the filter vessel, taking extreme care not to cross the
threads. As the valve is being run into the vessel excessive force should not be
required. Finally tighten to approximately 20ft.lbstorque.
Adjust the position of the filter vessel to line up with the pipework
connections, not the position of the valve on the vessel.
Connect the inlet and outlet pipework to the valve using flexible connections
or plastic high pressure piping. Flexible pipework is essential to prevent
stress on the vessel as it cycles during service since it will expand and
contract longitudinally.
Connect the drain line to the outlet of the drain line flow controller on the
valve.
Ensure that there is an air break in the drain at the same height as the valve
to prevent negative pressure on the vessel.
Connect the power supply to the valve and the unit is now ready for
commissioning.
7 COMMISSIONING
7 . 1 I N T R O D U C T I O N
It is recommended that the commissioning of the plant is undertaken by a
trained service engineer, who will be able to put the plant into service quickly,
and most efficiently. However, if the services of an experienced engineer are
not available, following the steps outlined below will result in the system being
properly commissioned.
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Installation Operation Maintenance Manual
7 . 2 S e t t i n g t h e T i m e o f D a y
1. Press SET CLOCK
2. Adjust hours with UP and
DOWN arrows
3. Press NEXT
4. Adjustminutes withUP
and DOWN arrows.
5. Press NEXT to return to
normal operation
The filter regeneration cycles have been factory programed.
The time of day for regeneration to take place has been entered as 2.00 AM
and this can be altered depending on site requirements.
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Installation Operation Maintenance Manual
Regeneration Programming
(All programming below is Factory set)
To alter settings – Press “” and “” keys To
back up at any stage – Press “REGEN” To save
any changes – Press “SET CLOCK”
NEXT
NEXT
NEXT
NEXT
Press and hold together for 5 seconds
“Filtering” will be flashing in top right corner
Set 1stcycle time in minutes –
BACKWASH set at 10 min
Set 2ndcycle time in minutes – RINSE set at6min
Regen set to oFF
Regen set to NORMAL
NEXT
NEXT
Programming Finished– Return to time of day
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Installation Operation Maintenance Manual
User Programming
To alter settings – Press “” and “” keys To
back up at any stage – Press “REGEN” To save
any changes – Press “SET CLOCK”
NEXT
NEXT
NEXT
NEXT
NEXT
Press together and hold for 5 seconds
Set influent Hardness to nA
Set effluent Hardness to nA
Set number of days to next regeneration (set to 3
days)
Set time for regeneration.
Time for Immediate regeneration valves cannot
be altered and will show “on 0”
Returns to time of day
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Installation Operation Maintenance Manual
7 . 3 C O M M I S S I O N I N G
The objective of commissioning is to fill the filter with water, check for leaks
and prepare it for service. The simplest way to commission the unit is to
initiate a backwash. This will eliminate the air from the system and flush the
media prior to use.
Before opening the inlet water supply switch on the power, which will
activate the piston motor and the timer motor.
Next, start a manual backwash by pressing the regen button for 3 sec or until
the motor starts to turn.
When the motor has stopped switch off the power and slowly open the inlet
water supply. At first, air will be expelled from the drain line, followed by water
once the vessel is full. Allow water to run to drain on the backwash cycle for
10-15 minutes in order to rinse the filter media and remove any fines.
Turn the power back on and allow the complete a manual regen in full by
pressing the regen button for 3 sec and allowing the valve to complete the
cycle.
The filter is now commissioned.
8 ROUTINE MONITORING
The following recommendations are made to help the user of the filter
confirm that it is performing as required, and to give early warning of
possible problems. The operation of the filter is completely automatic,
and should not require adjustment.
Weekly
Check the treated waterqualitywith a testkit.
Monthly
Check raw water quality, and record. Compare with original quality and
adjust frequency of backwash if required.
Six Monthly
Perform a chlorinated backwash to remove any organic build up on the
media. Check filter media depth against original level.
Annually
Inspect and clean/replace as necessary the piston and the internal
seals. A competent engineer familiar with Clack valves should perform
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FILT ER AG + Series Filter
Installation Operation Maintenance Manual
this.
9 FAULT FINDING AND RECTIFICATION
9 . 1 N O F L O W T O S E R V I C E
Check mains pressure is above 1.7 bar.
Check inlet water supply
Check inlet and outlet isolating valves are open.
Check service outlet valve is open.
Check pressure drop across media. If excessive, media may be
fouled, or internals blocked. Initiate a backwash. If this does not free
up the media the filter will need to be inspected and serviced by a
competent engineer.
Backwash with chlorine solution to remove organic build up
9 . 2 P O O R T R E A T E D W A T E R Q U A L I T Y
Check manual by-pass closed.
Check raw water pressure above minimum. If flow is less than design rate,
channeling of water can occur in media, which results in inadequate treatment.
Backwash with chlorine solution to remove organic build up
Increase frequency of backwash as media may be becoming
overloaded.
Increase backwash flow.
Check piston and seals & spacers. Check raw
water analysis for changes
9 . 3 N O B A C K W A S H
Check electrical supply, fuses etc. satisfactory.
Check program.
Check timer motor is running.
Check drive motor runs, by manually initiating a backwash, and listening for
drive motor as it advances between cycles. Replace if necessary.
9 . 4 U N S A T I S F A C T O R Y C A P A C I T Y B E T W E E N
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Installation Operation Maintenance Manual
B A C K W A S H E S
Increase frequency of backwash
Check age of media and media level
Backwash withchlorine solutionto removeorganicbuildup
Increase backwash flow
10 WARRANTY AND SERVICE
1 0 . 1 A F T E R S A L E W A R R A N T Y
Your filter is covered by a parts warranty for a period of one year from
installation or 14 months from purchase.
Consumable filter media is excluded from this warranty
Should you have any problems with your filter or require a routine
service, please contact your supplier.
11 TECHNICAL DATA
1 1 . 1 P R O C E S S A N D O P E R A T I N G D A T A
11.1.1FILTER AG + CAP 1054 TO 1465
Model
Parameter Units
Flow Rate M3/hr 0.6 0.85 1.0 1.2
Backwash Flow M3/hr 1.2 1.7 2.0 2.4
Regeneration
Time
Max. Operating
Temperature
11.1.2 FILTER AG + CM1665 TO CM 2469
Mins 20 20 20 20
DegreesC45 45 45 45
CAP 1054 CAP1248 CAP1354 CAP1465
Model
Parameter Units
Flow Rate M3/hr 1.5 1.9 2.6 3.4
Backwash Flow M3/hr 3.0 3.8 5.2 6.8
Regeneration
Time
Max. Operating
Temperature
Mins 20 20 20 20
DegreesC45 45 45 45
CAP 1665 CAP1865 CAP2160 CAP2469
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Installation Operation Maintenance Manual
1 1 . 2 E N G I N E E R I N G D A T A
11.2.1 FILTER AG + Series Filters CAP1054 to CAP 1465
Model
Valve WS1 WS1 WS1 WS1
Filter Vessel 1054 1248 1354 1465
Parameter Unit
Height of Filter Mm 1607 1458 1601 1984
Diameter of
Filter
Height of Valve mm 170 170 170 170
Filter Inlet
Conn.
Filter Outlet
Conn.
Drain Conn. Inches
Qty of Gravel Bags 0.5 0.5 0.75 1.5
Qty of
FILTERAG+
Electrical Power Watts 1.2 1.2 1.2 1.2
Mm 254 305 331 356
Inches
BSPM
Inches
BSPM
BSPM
Bags 1 1.5 2 2.5
CAP1054 CAP1248 CAP1354 CAP1465
1 1 1 1
1 1 1 1
3/4 3/4 3/4 ¾
PRESSURE 1.7 Bar MAXIMUM OPERATING TEMPERATURE 45.0C
HEADROOM - Allow 100 mm greater than overall height.
11.2.2 FILTER AG + Series Filters CAP1665 to CAP2469
Model
Valve WS1.5 WS1.5 WS2 WS2
Filter Vessel 1665 1865 2160 2469
Parameter Unit
Height of Filter Mm 1988 2088 2098 2348
Diameter of
Filter
Height of Valve mm 170 170 170 170
Filter Inlet
Conn.
Filter Outlet
Conn.
Drain Conn. Inches
Qty of Gravel Bags 1.5 2 3 5
Qty of Sand Bags 4 5 6 8
Electrical Power Watts 1.2 1.2 1.2 1.2
Mm 407 460 534 610
Inches
BSPM
Inches
BSPM
BSPM
CAP1665 CAP1865 CAP2160 CAP2469
1 1 1.5 1.5
1 1 1.5 1.5
1 1 1.5 1.5
PRESSURE 1.7 Bar MAXIMUM OPERATING TEMPERATURE 45.0C
HEADROOM - Allow 100 mm greater than overall height.
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12.0 SPARES LIST
1 2 . 1 W S 1 V a l v e s
PART NO. DESCRIPTION
XCV3011 Piston
XFR1 Riser Tube c/w 1” Dist
XCV3005 Seal & Spacer kit
XCV3107-01 Drive Motor 12v
XCV3108 PCB
VDLFC3 3/4” Brass flow controller (please specify)
VDLFC4 1” Brass flow controller (please specify)
1 2 . 2 W S 1 . 5 V a l v e s
PART NO. DESCRIPTION
XCV3407 Piston
XCV3430 Seal & Spacer kit
XCV3107-01 Drive Motor 12v
XCV3108 PCB
1 2 . 3 W S 2 V a l v e s
PART NO. DESCRIPTION
XCV3725 Piston
XCV3729 Seal & Spacer kit
XCV3107-01 Drive Motor 12v
XCV3108 PCB
FILTERAG+ WS Rev 1 Page 15 of 16
13 CE Certificate
Manufacturer's Declaration of
EURAQUA UK, HITCHIN, ENGLAND
FILT ER AG + Series Filter
Installation Operation Maintenance Manual
Conformity
We the undersigned
Certify that the product
TYPE: FILTER AG + FILTER WITH WS1, WS 1.5 or WS2 AC VALVE
has been designed and manufactured in accordance with the
specifications of the following:
Directive Standard
Machinery Directive 89/392/EEC EN 292-1, EN 292-2
Low Voltage Directive 73/23/EEC EN 60 335-1
EMC-Directive 89/336/EEC EN 55 014
RT Adam Hitchin, England
03/01/02Director Issue place & date
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