Clack CB1054/EN, CB1248/EN, CB1354/EN, CF1465/WC, CB1665/WC Installation, Operation & Maintenance Manual
...
BIRM Series Filter
1
Installation
Operation
Maintenance
Manual
Birm Filter
WS1 & WS1.5 Series Valve
Models
CB 1054/EN CB 1248/EN
CB1354/EN CF1465/WC
CB1665/WC CF1865/WC
CB 2160/WC
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BIRM Series Filter
Installation Operation Maintenance Manual
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CONTENTS
NOS. PAGE
1.0 UNPACKING AND PARTS IDENTIFICATION 4
1.1 Unpacking Notes 4
1.2 Basic Parts List 4
1.3 Missing or Damaged Goods 4
2.0 TEMPORARY STORAGE 4
3.0 GENERAL NOTES 5
3.1 Iron & Manganese Removal 5
3.2 System Management 5
3.3 Birm Frequently Asked Questions 6
4.0 REGENERATION/BACKWASH
4.1 The Backwash Process 8
4.2 Time Clock Control of Backwash 8
5.0 PRE-INSTALLATION CHECKS
5.1 Mechanical 9
5.1.1 Foundations/Drainage 9
5.1.2 Operating Space 9
5.1.3 Incoming Water 9
5.1.4 Pipework 10
5.1.5 Water Supply Company Requirements 10
5.2 Electrical 10
6.0 ASSEMBLY/INSTALLATION 11
6.1 Mechanical 11
6.1.1 Pipework 11
6.1.2 Drains Connections 11
6.2 Assembly 12
7.0 COMMISSIONING 14
7.1 Introduction 14
7.2 Programming 14
7.3 Commissioning 17
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BIRM Series Filter
Installation Operation Maintenance Manual
NOS. PAGE
8.0 ROUTINE MONITORING 18
9.0 FAULT FINDING AND RECTIFICATION 19
9.1 No Flow to Service 19
9.2 Poor Treated Water Quality 19
9.3 No Backwash 20
9.4 Unsatisfactory Capacity between Regeneration’s 20
10.0 WARRANTY AND SERVICE 21
10.1 After Sale Warranty 21
11.0 TECHNICAL DATA 22
11.1 Process and Operating 22
11.1.1 Birm Series Filters CB1054 to CB 1465 22
11.1.2 Birm Series Filters CB 1665 to CB2160
11.2 Engineering Data 23
11.2.1 Birm Series Filters CB1054 to CB 1465 23
11.2.2 Birm Series Filters CB 1665 to CB 2160 24
13.0 SPARES LIST 25
14.1 WS1 Valves 25
14.2 WS1.5 Valves 25
15.0 CE CERTIFICATE 26
BIRM WS1 JUNE 2007 \page 26
BIRM Series Filter
Installation Operation Maintenance Man
ual
4
1.0 UNPACKING AND PARTS LIST
1.1 UNPACKING NOTES
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 BASIC PARTS LIST
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. BIRM (qty as specified)
1.3 MISSING OR DAMAGED GOODS
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.
2.0 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.
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Installation Operation Maintenance Manual
3.0 GENERAL NOTES
These instructions cover the BIRM Range of filters, which includes model numbers
from CF1054 to CM 2160.
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 Iron& Manganese Removal
Heavy metallic contaminants, and some non-metallic contaminants can be removed
from water using specific media. These media can be mixed in a multi-layer bed
which, when combined with an appropriate backwash or regeneration system, can be
tailored to solve a wide range of specific contaminant problems.
Iron and manganese and sometimes aluminium and hydrogen sulphide can be
removed with a catalytic filter media, which uses oxygen in the water to convert the
metal ions from the soluble to an insoluble form. The insoluble precipitate is then
filtered out onto the surface of the media. Depending on the composition of the raw
water a choice of media can be used.
Birm filter media is one of these medias and just requires backwashing with the raw
water to clear the bed. The operating parameters for Birm make it suitable for a
number of water types.
3.2 System Management
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.
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Installation Operation Maintenance Manual
3.3 Birm System Operation 'Frequently Asked Questions'
The main uses for a BIRM filter are for domestic and light commercial
removal of Iron, Manganese, Hydrogen Sulphide and general turbidity. The
Birm media is a catalytic media that is not used up in the reaction however
oxygen has to be present in the water to enable the oxidisation to occur. If the
feed water does not contain the necessary level of oxygen then a system for
adding this will be required
The feed water flows under pressure to the control valve on the vessel where
it is directed through to the filtration media. Birm systems built with
WS1/WS1.5 valves will bypass raw water during backwash. For this reason
the systems are set to backwash at 2:00 AM.
Maximum Iron levels: Birm systems can be used on Iron levels of up
to 5 ppm with certain reservations. There are a number of examples
working satisfactory at higher levels.
Manganese removal: Manganese removal in a Birm system is
dependent on the level of Iron and other contaminants in the raw water. The
greater the amount of Iron, the easier it is to remove the Manganese. With
an Iron: Manganese ratio of 10:1, the Manganese is extracted very well at a
pH of 7.0-7.5. When the ratio reaches 5:1 then the pH needs to be between
7.8-8.2. When the Manganese level exceeds the amount of Iron then a pH of
above 8.3 is required. While the pH correction media in the Birm blend will
raise the pH of acid water, it cannot raise it above 8.0 consistently if the
general level of dissolved solids is high and the Langellier index is saturated.
A full water analysis is essential when considering using the Birm system
primarily for Manganese removal.
Humic acid/tannins: Decaying organic matter in the raw water supply
creates Humic acid or tannins, sometimes seen as light brown colour in low
pH 'peaty' water supplies. These tannins can combine and complex with Iron
and Sulphur, coating and blinding the pH correction and filter media reducing
its effectiveness. The tannin level in the raw water should be less than 2
ppm and ideally less than 1 ppm to eliminate the need for frequent changes
or rejuvenation of the filter media. With high tannin water supplies it will be
necessary to oxidise the tannins to an insoluble floc that is filtered out with
the other contaminants. The most effective oxidiser is Ozone, and an Ozone
generator with injection venturi and off-gas valve has proved to be very
successful at preventing tannin blinding. An alternative is to remove the
tannins with an Organic Scavenger, but these are not simple to install and still
operate the Birm system satisfactorily. Moreover, Organic Scavengers need
to be regenerated with Caustic Brine requiring the control and addition of two
consumables, one of which is corrosive and difficult to handle.
Chlorides: Very high Chloride levels in the raw water can
inhibit the performance of the Birm system by preventing Iron and
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Installation Operation Maintenance Manual
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Manganese from precipitating. In normal circumstances the Chloride level in the
raw water should be less than 100 ppm and ideally below 50 ppm.
Backw as h: While th e Birm system is designed to operat e and
backwash at twice flow rate, it essential that there is sufficient pressure and
volumeof water at the recommended backwash flow. It may be necessary to fit a larger
backwash flow button, or even a higher flow valve on larger systems if the pressure
is low, just to achieve the required cleaning of the filter bed. Alternatively a longer
backwash may be needed to achieve the same effect.
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Installation Operation Maintenance Manual
4.0 REGENERATION/BACKWASH
4.1 The Backwash Process
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 TIME CLOCK CONTROL OF REGENERATION INITIATION
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.
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5.0 PRE-INSTALLATION CHECKS
5.1 MECHANICAL
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
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 OperatingSpace
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 IncomingWater
The raw water to be fed to the filter must comply with the following:-
1. Maximum iron level = 5ppm
2. pH range = 6.0-9.0
3. Organic matter = less than 2ppm
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 must be twice the same as the service
flow rate available with a pressure of 3 bar
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Series Filter
Installation Operation Maintenance Manual
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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 ELECTRICAL
All filter valves are supplied as 12v complete with a transformer for 240v. A
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.
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Installation Operati
on Maintenance Manual
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6.0 ASSEMBLY/INSTALLATION
6.1 MECHANICAL
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.
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.
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Installation Operation Maintenance Manual
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6.2 ASSEMBLY
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.
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
Birm, 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 toapproximately 20ft.lbs torque.
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.
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Installation Operation Maintenance Manual
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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.
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Manual
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7.0 COMMISSIONING
7.1 INTRODUCTION
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.
7.2
Setting the Time of Day
Installation Operation Maintenance
1. Press SET CLOCK
2. Adjust hours with UP and
DOWN arrows
3. Press NEXT
4. Adjust minutes 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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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
NEXT
NEXT
Regen set to NORMAL
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 regeneratuion
(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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7.3 COMMISSIONING
7.3.1 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.
7.3.2 Before opening the inlet water supply switch on the power, which will activate
the piston motor and the timer motor.
7.2.3 Next, start a manual backwash by pressing the regen button for 3 sec or until
the motor starts to turn.
7.2.4 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.
7.2.5 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.
7.2.9 The filter is now commissioned.
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8.0 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 water quality witha test kit.
Monthly
Check raw water quality, and record. Compare with originalqualityand
adjust frequency of backwash if required.
BIRM Series Filter
Installation Operation Maintenance Manual
Six Monthly
Perform a chlorinated backwash to remove anyorganicbuild 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
this.
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9.0 FAULT FINDING AND RECTIFICATION
9.1 NO FLOW TO SERVICE
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 POOR TREATED WATER QUALITY
Check manual by-pass closed.
Check raw water pressure above minimum. If flow is less than design rate,
channelling 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
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Installation Operation Maintenance Manual
9.3 NO BACKWASH
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 UNSATISFACTORY CAPACITY BETWEEN BACKWASHES
Increase frequency of backwash
Check age of media and media level
Backwash with chlorinesolution to remove organicbuild up
Increase backwash flow
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nstallation Operation Maintenance Manual
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10.0 WARRANTY AND SERVICE
10.1 AFTER SALE WARRANTY
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.
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11.0 TECHNICAL DATA
11.1 PROCESS AND OPERATING DATA
11.1.1 BIRM CB1054 TO 1665
BIRM Series Filter
Model CB
1054/EN
Parameter Units
Flow Rate M3/hr 0.6 0.85 1 1.2
Backwash Flow M3/hr 1.2 1.7 2.0 2.4
Regeneration
Time
Max. Operating
Temperature
11.1.2 BIRM CB1665 TO CB 2160
Model CB1665/
Parameter Units
Flow Rate M3/hr 1.5 1.9 2.6
Backwash Flow M3/hr 3.0 3.8 5.2
Regeneration
Time
Max. Operating
Temperature
Mins 20 20 20 20
DegreesC45 45 45 45
WC
Mins 20 20 20
DegreesC45 45 45
CB1248
/EN
CB1865
/WC
CB1354
/EN
CB2160
/WC
CB1465
/WC
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11.2 ENGINEERING DATA
BIRM Series Filters CB1054 to CB 1465
Model CB1054/ENCB1248
/EN
Valve WS1 WS1 WS1 WS1
Filter Vessel 1054 1248 1354 1465
Parameter Unit
Height of Filter Mm 1601 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 Birm Bags 1 1.5 2 2.5
Qty of gravel Bags 1 1 1 2
Electrical Power Watts 50 50 50 50
PRESSURE 1.7 Bar MAXIMUM OPERATING TEMPERATURE 45.0C
HEADROOM - Allow 100 mm greater than overall height.
Mm 254 305 331 356
Inches
BSPM
Inches
BSPM
BSPM
1 1 1 1
1 1 1 1
3/4 3/4 3/4 ¾
CB1354
/EN
CB1465
/WC
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BIRM Series Filters CB1665 to CB 2160
BIRM Series Filter
Model CB1665/
WC
Valve WS1 WS1 WS1.5
Filter Vessel 1665 1865 2160
Parameter Unit
Height of Filter Mm 1984 1984 1984
Diameter of
Filter
Height of Valve mm 170 170 200
Filter Inlet
Conn.
Filter Outlet
Conn.
Drain Conn. Inches
Qty of Birm Bags 3 5 6
Qty of Gravel Bags 2 2 3
Electrical Power Watts 50 50 50
PRESSURE 1.7 Bar MAXIMUM OPERATING TEMPERATURE 45.0C
HEADROOM - Allow 100 mm greater than overall height.
Mm 407 460 534
Inches
BSPM
Inches
BSPM
BSPM
1 1 1
1 1 1
3/4 3/4 3/4
CB1865
/WC
CB2160
/WC
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13.0 SPARES LIST
14.1 WS1 Valves
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)
14.2 WS1 Valves
PART NO. DESCRIPTION
XCV3407 Piston
XCV3430 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)
BIRM WS1 NOV 2007 \page
15.0 CE Certificate
Manufacturer's Declaration of
EURAQUA UK, HITCHIN, ENGLAND
BIRM Series Filter
Installation Operation Maintenance Manual
Conformity
We the undersigned
Certify that the product
TYPE: BIRM FILTER WITH WS1 & WS1.5 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
BIRM WS1 NOV 2007 \page 26
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