Orival OR-04-IE, OR-03-IS, OR-06-IE, OR-08-IS, OR-10-IS Operation And Maintenance Manual

OPERATION AND MAINTENANCE MANUAL

OR SERIES FILTERS

ORIVAL, INC.

213 S. Van Brunt St.

Englewood, NJ 07631

Tel: [phone]

Fax: [phone]

YELLOW - REV: 07 / 2006

ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

ORIVAL, INC.

EQUIPMENT DATA SHEET

In-Line Models On-Line Models Bypass Models

X – Denotes Filter Model & Configuration Supplied.

Carbon Steel:

Screen Size:

Hydraulic Piston:

Control System:

Options:

OR-03-IS OR-03-PS

OR-03-IE OR-03-PE OR-03-BE

OR-04-IS OR-04-PS

OR-04-IE OR-04-PE OR-04-BE

OR-06-IE OR-06-PE OR-06-BE

OR-08-IS OR-08-PS OR-08-BS

OR-10-IS OR-10-PS OR-10-BS

OR-12-IS OR-12-PS OR-12-BS

OR-14-IS OR-14-PS OR-14-BS

Stainless Steel: High Temp: High Pressure:

Microns Number of Rinse Valves:

38 mm 50 mm

OR-02-PE

OR-08-PE OR-08-BE

OR-10-PE OR-10-BE

OR-16-PS OR-16-BS

OR-18-PS

ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

REVISIONS

Sections Description Date

Installation Procedure Added Pressure Gauge & 3-way 11/98
Mini Valve Mounting and Uses

Manual Flushing Procedure Added the Omnitrol 500 Electrical 11/98
Control System

Electrical Control System Added the Omnitrol 500 Electrical 11/98
Control System

Schedule of Preventive Added operation of Automatic 03/99
Maintenance & Inspection Built-In By-Pass Valve

Piping Connections Added Installation Drawings 10/2000
Spare Parts Ordering Added Pistonless Parts List
All Sections Minor Clarifications

All Sections Minor Corrections & Clarifications 11/2001

All Sections Corrected For New Address 06/2006
Minor Corrections & Clarifications
Section 12 New Special Installations Section

All Sections Minor Corrections & Revised Table 9-1 07/2006

ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

TABLE OF CONTENTS

Page

1. Construction 1

2. Operating Principles 2

3. Installation Procedures 4

3.1 Assembly Prior to Installation

A. Rinse Valve Mounting 4
B. Hydraulic Piston Mounting 4
C. Solenoid Valve Mounting 5
D. Connections of Control Tubing 6
E. Differential Pressure Switch
Mounting and Connections 6
F. Pressure Gauge & 3-way Mini Valve
Mounting and Uses 7

EL1110 - Tubing & Wiring Connections - OR-02-PE 9
EL1120 - Tubing & Wiring Connections - One Valve Pistonless Filter 10
EL1130 - Tubing & Wiring Connections - Two Valve Pistonless Filter 11
EL1140 - Tubing & Wiring Connections - Two Valve Piston Filter 12
EL1150 - Tubing & Wiring Connections - Three Valve Piston Filter 13

3.2 Piping Connections

A. Filter Installation 14
B. Drain Line Installation 14

3.3 Upside Down Installations 15

Installation Drawing – Model OR-02-PE 16
Installation Drawing – Typical Filters with System Bypass 17
Installation Drawing – Typical Filters without System Bypass 18
Installation Drawing – Typical On-Line Multiple Filters 19

4. First Commissioning and Routine Start-Ups 20

4.1 First Commissioning 20

4.2 Start-Up 20

ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

TABLE OF CONTENTS

(continued)

Page

5. Manual Flushing Procedures 21

5.1 OMNITROL 2000 21

5.2 OMNITROL 500 21

5.3 OMNITROL 100 21

6. Shut Down and Drainage Procedures 22

6.1 Shut Down Procedure 22

6.2 Drainage Procedure 22

7. Schedule of Preventive Maintenance and Inspections 23

8. Electrical Control System

By-Pass Valve Control System Schematic 24

OMNITROL 2000 25

OMNITROL 500 25

OMNITROL 100 25

9. Troubleshooting 26

9.1 The filter does not experience rinse cycles 26

9.2 The filter rinses continuously 28

9.3 The filter cycles continuously 28

9.4 The Controller inoperative 28

10. Removal/Installation of Major Components 29

10.1 Coarse Screen 29

10.2 Fine Screen 29

10.3 Dirt Collector 30

ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

TABLE OF CONTENTS

(continued)

Page

11. Spare Parts Ordering Information 31

Model OR-02-PE Filter Assembly Drawing 32

Typical Pistonless Filter Assembly Drawing 33

Typical Filter Assembly Drawing – with Piston 34

12. Special Installations 35

12.1 Pneumatic Control Conversion 35

Model OR-02-PE Pneumatic Control Drawing 37

Typical Pneumatic Conversion Control Drawing
(Three Rinse Valve Piston Filter Shown) 38

12.2 Using a Controlled Outlet Valve 39

12.3 Using an External Source of Rinse Water 39

12.4 Water Hammer Solutions 39

Typical Filter Installations with a COV 40

Typical Filter Installations with External Rinse Water 41

Typical Filter Modification for Water Hammer Reduction 42

12.5 Optimizing Filter Performance 43

Flow Control Needle Valve Installation 45

ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 1 - CONSTRUCTION

The housing and covers of standard OR Series filters are made from high-grade, low­carbon steel. All exposed surfaces, both inside and out, are protected by a thick,
smooth, durable polyester epoxy coating that is electrodeposited, then oven cured, over
a zinc phosphate primer coat. Access to the internal components of the filter is through
a removable front cover, with gripping handles, that is secured to the front end of the
filter housing. This allows for easy access for servicing and maintenance purposes. All
wetted components are constructed of either engineered plastics or non-corrosive
metals, providing for an extended service life.

Optional materials are available for special applications. Stainless Steel filter housings
and covers are readily available. See EQUIPMENT DATA SHEET for more information.

On most models, mounted on the end of the filter housing, is the hydraulic piston
assembly - see EQUIPMENT DATA SHEET for more information. Operating with
filtered water supplied by the filter, its purpose is twofold. During the rinse cycle, the
hydraulic piston regulates the dirt collector's longitudinal velocity, preventing the dirt
collector from traversing the length of the filter too quickly, which could result in an
inefficient rinse cycle. Subsequent to the rinse cycle, the piston returns the dirt collector
to its original position, preparing it for the next cycle.

The standard Control System consists of a microprocessor based Controller housed in
a NEMA 4X enclosure, a Differential Pressure Switch (DPS) and a Solenoid Valve. The
Controller mounted DPS monitors inlet and outlet pressures, has dry contacts, and
comes factory preset to 7 psi, increasing. The housing mounted Solenoid Valve is a 2­way normally closed valve, activated by 24 Vac from the Controller. The supplied
Controller is pre-wired for 110-120 Vac, 60 Hz single phase input power, and the end
user can easily convert to 220-240 Vac, 60 Hz single phase power by re-arranging
jumpers provided on the Controller’s printed circuit board.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 2 - OPERATING PRINCIPLES

A. Normal Flow Pattern - Clean Screen

The raw water enters the filter’s inlet and passes through a cylindrical PVC coarse
screen with a series of 9 mm diameter holes. This is the first stage of filtration. This
prevents passage of any large particles that may damage the fine screen or prevent the
dirt collector assembly from moving.

The water then enters the second stage of filtration, where the fine screen is located.
This cylindrical screen consists of woven stainless steel wire mesh secured and
supported by the inner surface of a perforated PVC cylinder. As the water passes
through this screen from the inside out, suspended solids are trapped and accumulate,
creating a "cake" of dirt on the inner surface of the screen. This cake produces a finer
filtration than the screen itself, increasing the filter’s particle removal capability.

The build-up of cake also creates an increasing pressure differential across the screen.
The DPS senses this differential pressure, and its normally open and common contacts
are closed once the factory preset differential pressure is reached. The Controller
monitors this contact closure and the Controller initiates an automatic rinse cycle based
on high DP.

B. Rinse Cycle Flow Pattern

When the Controller senses DPS contact closure it energizes the coil of a 2-way,
normally closed Solenoid Valve. The energized Solenoid Valve relieves pressurized
water from the control stage of the two-stage pressure manifold that in turn vents the
upper chamber of a 2’’ diaphragm rinse valve causing the valve to open. On filters with
two or three rinse valves, all valves open. Also, pressure on the piston head of the
hydraulic piston (if so equipped) is vented to drain. This venting initiates the rinsing
cycle.

As the rinse valve(s) open, the pressure in the hydraulic motor chamber is reduced to
near atmospheric pressure. As a result, water begins flowing through the dirt collector
nozzles, along the dirt collector tube, out the hydraulic motor and to the drain through
the open rinse valve(s). The pressure differential created at the nozzles provides a spot
backwashing effect, drawing a portion of the water back through the screen and
removing the accumulated solids. The water passing through the dirt collector assembly
is ejected out of the holes in the hydraulic motor, imparting a rotational movement to the
dirt collector assembly. In addition, on the models equipped with a hydraulic piston, the
dirt collector assembly begins to move longitudinally, allowing the nozzles to sweep the
entire screen area in a helical fashion. Those models not equipped with a hydraulic
piston have a dirt collector assembly designed to sweep the entire screen area without
the need for longitudinal motion.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

The rinse cycle duration is determined by a value programmed in the Controller. The
recommended programming of this value is given in the Control System manual, and
should only be changed to a different value when absolutely necessary.

Upon completion of the rinse cycle, the solenoid valve is de-energized. The solenoid
valve closes, and pressure is restored in the top chamber of the manifold via an orifice
connecting the two chambers of the manifold. Pressure is restored on the upper portion
of the rinse valve diaphragms, causing the valves to close. On hydraulic piston models,
the dirt collector assembly returns to its original position in preparation for the next rinse
cycle.

For a parallel bank of filters, one Controller is used. It monitors the inlet and outlet of the
entire system with the DPS, and each filter is rinsed sequentially. A programmable
delay allows a pause between the rinse cycle of each filter.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 3 - INSTALLATION PROCEDURES

3.1 - ASSEMBLY PRIOR TO INSTALLATION

The rinse valves, hydraulic piston and solenoid valve for the filter have been packed
separately in the filter carton and must be installed prior to start-up of the filter. To
ensure proper installation, follow the subsequent procedures carefully.

A. Rinse Valve Mounting

(See EQUIPMENT DATA SHEET for number of valves supplied).

Rinse valves are supplied with a 2’’ nipple attached.

1. Attach each rinse valve’s 2" nipple to the 2" port on the hydraulic motor
chamber end of the filter – see Figure 3.1.

2. Attach a 2’’ drain line to an adequately sized drain as described in
Section 3.2B as shown in dashed lines in Figure 3.1.

NOTE: RINSE VALVES MAY BE ROTATED IN THEIR PORTS TO FACILITATE
CONNECTION OF THE DRAIN LINES

HEXAGONAL OPENING

HYDRAULIC MOTOR
CHAMBER COVER

Figure 3.1 – Correct Valve & Piston Orientation.

B. Hydraulic Piston Mounting - See Figure 3.1 (if applicable)

1. Slide the white PVC shield off the end of the hydraulic piston after cutting the
tie-wrap and threading the drain fitting from the shield.

2. Remove the six nuts from the studs at the back end of the filter housing.

3. Remove the bolts, nuts and washers securing the hydraulic motor chamber
cover, then remove the cover.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

4. The dirt collector tube is now accessible. Reach in and pull the dirt collector
tube back as far as possible. The lower bearing of the dirt collector is now
accessible through the hole at the end of the filter housing.

5. Extend the piston’s shaft by approximately one-half the piston stroke (this can

be done using the anti-rotational pin protruding from the piston housing).

Carefully screw the bushing on the piston shaft’s tip into the lower bearing

in a clockwise direction. The threads on the bushing will pass through the

threads of the lower bearing, and the piston will now have some play
while being retained by the lower bearing.

NOTE: Filter Dirt Collectors and Hydraulic Pistons may
be supplied without threaded connections. If
this is the case, just place the Piston’s tip in
the recess of the Dirt Collector’s Lower Bearing.

6. Push the piston onto the studs on the end of the filter housing with the slot
and anti-rotational pin in the downward position. Ensure that the O-ring on
the end of the piston seats firmly in the hole in the filter housing. To
facilitate installation, silicone grease may be applied to the O-ring.

7. Reinstall nuts on the studs to secure the piston, and tighten evenly.

8. Place the PVC shield back onto piston, keeping drainage hole in shield at
lowest position to facilitate drainage of any leakage. Reinstall drain fitting
and tubing.

9. Check to ensure that dirt collector assembly rotates and slides freely inside
the filter housing by reaching in and spinning and sliding the dirt collector
assembly.

10. Reinstall the hydraulic motor chamber cover with the bolts, nuts and washers
provided. (Washers are installed under both the bolt head and nut).

C. Solenoid Valve Mounting

Connect the solenoid valve (pre-assembled with elbow and nipple) to the 1/2"
hole on the top of the stainless steel, hex shaped, two-stage pressure manifold
(See Figure 3.1). The solenoid valve should be mounted such that its body is
upright and horizontal, or vertical with its outlet pointing downward, to prevent
backpressure. Ensure that the solenoid valve is mounted in the proper flow
direction, as indicated by an arrow on the bottom of the valve body. Ensure that
the dot on the circular end of the manual override knob is pointing toward the
body’s centerline away from the “MAN” inscription on the valve body.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

D. Connection of Control Tubing

The drawings on pages 9-13 show the proper hydraulic connections.

The stainless steel, hex shaped, two-stage pressure manifold distributes
pressure to the rinse valves and piston. Each face has two ports. The ports
nearest the solenoid valve are the upper or top ports, and the ports nearest the
filter body are the lower or bottom ports.

1. On models with a piston assembly, the manifold has an elbow fitting in one of
the upper ports. This port has tubing attached. Connect the free end of
this tubing to the straight fitting on the end of the hydraulic piston.

2. Faces of the manifold having both an upper and lower port with straight
fittings and tubing attached are used to connect the rinse valves. For each
rinse valve, connect the tubing from the upper port of the manifold to

the top (black plastic domed portion) of each rinse valve.

3. For each rinse valve, connect the tubing from the lower port of the manifold
to the bottom (brass portion) of each rinse valve.

E. Differential Pressure Switch Mounting and Connections

NOTE: Most filters come equipped with the standard DPS pre-wired and
pre-mounted to the Controller. On drawings found in this manual, the
standard DPS is shown mounted to the Controller. High Temperature and
High Pressure applications require a differential pressure switch designed
for these extremes (see EQUIPMENT DATA SHEET to verify
configuration). These switches are mounted separately. Follow
instructions that come with the switch. Once mounted, wire the switch per
the schematic found in the Control System Supplemental Manual. The
tubing connections are as follows:

SINGLE FILTER INSTALLATIONS:

1. The high side of the differential pressure switch must be connected to the inlet
of the filter with hydraulic tubing provided. On all models except the 2"
units, a tee fitting is installed on the inlet leg for this purpose. For 2" units,
a fitting on the filter body has been provided.

2. The low side of the DPS must be connected to the outlet of the filter with
hydraulic tubing. On all models, a straight fitting has been installed on the
lower port on one face of the manifold for this purpose.

3. The differential pressure switch has been preset for a 7 psi increasing set
point.

DO NOT ADJUST!

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

MULTIPLE FILTER INSTALLATIONS:

When multiple filters are installed on a common supply line to form a filtration
system, the high & low connections from the DPS are made to the inlet and outlet
of the system as shown on page 19.

1. If each filter inlet has a tee fitting, replace it with a straight or elbow fitting
provided and reconnect the hydraulic tubing to the 3-way mini-valve.

2. If there is a fitting in the lower port on one face of the manifold, remove this
fitting and replace it with a plug.

3. Using supplied hydraulic tubing, connect the DPS high to the system inlet,
and DPS low to the system outlet.

F. Pressure Gauge & 3-way Mini-Valve

A 3-way mini-valve is provided with each ORIVAL filter to assist in
troubleshooting and commissioning of the filter. Normally installed on either the
manifold (Model OR-02-PE) or on the outlet leg (all other models), the 3-way

valve allows for three independent pressure sources to be individually monitored

with the use of a single pressure gauge. The 3-way valve serves as a selector to

three ports located on alternating sides of the 3-way valve, one for inlet pressure,

one for hydraulic motor chamber pressure and one for outlet pressure. There is

a common port equipped with a 1/4" brass elbow, into which a pressure gauge

should be installed. The range of the gauge should be such that it can read the

maximum inlet pressure the filter will experience. All other connections to the

3-way valve should have been completed as supplied.

Prior to reading the three pressures, it is recommended to identify the three ports
by tracing the tubing. Note that one port will be connected directly to the filter
and will normally serve as the outlet pressure source. This should be verified,
however, in case an alternate installation is experienced.

The procedure for reading the three pressures is as follows:

1. To read inlet pressure:

Rotate knob until the arrow points to the port where tubing from the
inlet leg of the filter is connected.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

2. To read hydraulic motor chamber pressure:

Rotate knob until the arrow points to the port where tubing from the
hydraulic motor chamber is connected. The hydraulic motor
chamber is located at the end of the filter opposite the cover.

Note: During normal (filtering only) operation, the hydraulic motor
chamber pressure should be equal to the inlet pressure. During
the rinse cycle, the hydraulic motor chamber pressure should drop
to 25-40% of the inlet pressure.

3. To read outlet pressure:

Rotate knob until the arrow points to the port connected to the
outlet leg of the filter.

Note: To determine differential pressure across the filter, subtract
the outlet pressure from the inlet pressure.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

3.2 - PIPING CONNECTIONS

Typical installation layouts are shown on pages 16-19, and are provided as a guide to a
correct installation. Bypass (B-Series) filters are not shown, but are identical to the
installation of On-Line (P-Series) filters.

A. Filter Installation

Orival water filters may be installed in any position, although for ease of
maintenance, a horizontal installation is recommended. For upside-down

installation information, see Section 3.3.

1. For best results, the filter should be installed as near as possible to the
system it is required to protect. However, if low filter inlet pressure is a
concern, either before or during rinse, the filter may need to be installed
closer to the pressure source.

2. Ensure that the filter inlet pressure will not fall below 30 psig during the rinse
cycle with the rinse valves open.

3. Ensure that the upstream pipe size from pressure source to filter is equal to or
greater than the filter inlet size.

4. An outlet isolation valve must be installed in all applications.

5. An inlet isolation valve must be installed in situations where the pressure
source cannot be shut down for maintenance.

6. Inlet and bypass valves must be installed in situations where a constant
supply of water is required downstream during filter servicing. Note that
this also applies for installations of B series filters with an Automatic Built-

In Bypass Valve .

7. A check valve should be installed downstream of the filter where water
hammer or reverse flow is possible.

8. Ensure that the filter is mounted in the proper direction of flow as indicated by
the arrows on the filter housing. As a check, the inlet is closer to the
cover end of the filter.

9. Ensure that sufficient space is provided around the filter for maintenance as
indicated on the FILTER DATA SHEET supplied with the filter.

B. Drain Line Installation

1. Ensure that the rinse valves are installed as indicated in Section 3.1 A.

2. A 2" drain line should be attached to each rinse valve, according to the
following conditions:

- Maximum piping run should not exceed 30 feet. If a longer run is
required, a minimum 2-1/2" line should be utilized, up to a
maximum of 100 feet.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

- Piping should not include more than two (2) elbows.

- Piping should be installed level or pitch down to avoid back pressure.

- The open end of piping should be securely mounted to avoid fluttering
during rinse cycle.

3. For multiple rinse valves, connection may be made to a common drain
header as follows:

- For filters with one rinse valve, a minimum 2" header must be used.

- For filters with two rinse valves, a minimum 3" header must be used.

- For filters with three rinse valves, a minimum 4" header must be used.

4. In all cases, the drain lines or header must be connected to an atmospheric
drain. The addition of back pressure on the rinse valve drain lines will
reduce filter efficiency.

5. For ease of maintenance, it is recommended to install a drain line with a
manual valve in the lowest available port of the filter. This will allow for
easier draining of the filter for servicing purposes.

6. A 1/2" drain line should be connected to the solenoid valve, and piped to
a suitable atmospheric drain. For best results, this line should not be
connected to the rinse valve drain lines or header.

3.3 - UPSIDE-DOWN INSTALLATION

Installation of an on-line or bypass model filter is referred to as upside-down installation
when the inlet and outlet legs of the filter are oriented in a vertical position extending
upward from the filter body. In this position, the manifold installed in the filter body is at
the lowest position.

This location of the manifold may allow sediment to collect in the line supplying the
solenoid valve. This may result in a clogged solenoid valve, tubing or fitting. The result
will be an inability to initiate a rinse cycle.

A solution to this problem is to relocate the manifold to the alternate position on either
the filter body or the outlet leg of the filter. For most filters a 1’’ plugged port in the
filter’s outlet leg is provided for this purpose. To do this, disconnect all the tubing
connections at the manifold fittings, switch the manifold and the plug, then reconnect
the tubing. Care should be taken to ensure that correct connections to the top and
bottom chambers of the manifold are maintained. See pages 9-13 to verify that
connections to the manifold are correct.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 4 - FIRST COMMISSIONING AND ROUTINE START-UPS

NOTE: The differential pressure switch (DPS) has been preset for proper operation.

Do not adjust prior to start-up

4.1 - FIRST COMMISSIONING

1. Check that the line pressure will always be at least 30 psig at the filter inlet

during the rinse cycle with the rinse valve(s) open.

2. Check that there are no upstream pipeline restrictions.

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

the arrows on the filter body.

4. Check that the rinse valves are mounted as described in Section 3.1 A.

5. Check that tubing connections are completed as described in Section 3.1 C.

6. Check that power is available to the Controller, but that the power switch is in
the OFF position.

7. Check that the solenoid valve(s) are properly wired as indicated in the

electrical Schematic provided with the controller.

8. Check that the rinse valve and solenoid valve drain lines are installed as

described in Section 3.2 B.

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

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

indicated on the included FILTER DATA SHEET.

4.2 - START-UP

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

2. For models with a hydraulic piston, disconnect the control tube at the end and
bleed until all of the air is displaced by water. Reconnect the control tube.

3. For models with a hydraulic piston, remove the piston’s drain tube and fitting
from the PVC shield and slide the shield to the back half of the hydraulic
piston and check to ensure that the piston is at the top of its stroke. At this
point, the anti-rotational pin should be closest to the filter body.

4. Check for any external leakages and eliminate.

5. Check to ensure that the filter inlet pressure is higher than 30 psig.

6. Ideally, a manual rinse should be initiated with the filter dead headed. Close
the bypass valve and initiate a manual rinse cycle as described in the
Control System manual. During this rinse, observe the inlet and hydraulic
motor chamber pressures. Normally, during the rinse, the hydraulic motor
chamber pressure should ideally fall between 25 and 40 % of the filter inlet
pressure, as described in Section 3.1 F. The exception is for high­pressure applications. If, during the rinse, the pressure difference between
the filter inlet and hydraulic motor chamber exceeds 50 psi, try throttling

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

the drain line(s) after the rinse valve(s) to increase the hydraulic motor
chamber pressure so the difference to the inlet pressure is less than 50
psi. In extreme cases, try eliminating one of the rinse valves to reduce the
pressure difference. Failure to do this could damage the fine screen.

7. For models with a hydraulic piston, during the rinse observe that the anti­rotational pin moves to the back of its slot and returns to the forward
position after the rinse valves close.

8. Slowly open the outlet isolation valve of the filter.

9. Observe the build-up of the pressure differential across the filter. It is
recommended to observe at least one automatic rinse cycle to ensure that
the system is operating properly.

10. Slide the PVC shield back into its original position on the hydraulic piston.

SECTION 5 - MANUAL FLUSHING PROCEDURES

Periodically, it may be necessary to activate a manual rinse cycle of the filter. Some
typical reasons are:

- Routine inspection of proper filter operation.

- Emergency cleaning of the filter.

- Troubleshooting/start-up.

- Drainage of the filter prior to maintenance.

5.1 OMNITROL 2000 Controller

The manual rinse is activated through the Controller by cycling through the screens until
the display shows “Manual Start <ENTER>”. Depressing the black center key will
activate a manual rinse cycle. The rinse cycle will continue for the time period that was
previously selected and stored in the Controller’s memory.

5.2 OMNITROL 500 Controller

The manual rinse is activated through the Controller by setting the Flushing Mode rotary
switch to the Manual position. The rinse cycle will continue for the time period that has
been selected with the Flushing Time Per Station rotary switch.

5.3 OMNITROL 100 Controller

The manual rinse is activated through the Controller by depressing and holding the
MANUAL RINSE BUTTON for at least one second.

Note: For complete Control System information, refer to the Operation & Maintenance

Manual Supplement. Values have been given in each manual for settings and
should not be adjusted unless necessary. Improper settings may result in
inadequate or lengthy rinse cycles, leading to filter malfunction.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 6 - SHUT DOWN AND DRAINAGE PROCEDURES

The filter may have to be shut down periodically, for several reasons, including
servicing, winterizing, etc.

When the filter is to be shut down for a long period of time, such as protection for the
winter, it is recommended to be sure that the housing, valves, hydraulic piston and
control tubing are emptied of water. The fine screen should also be removed, cleaned,
dried and reinstalled.

6.1 - SHUT DOWN PROCEDURE

1. Open the system bypass valve.

2. Close the isolating valve on the outlet of the filter.

3. Initiate a manual rinse as described in Section 5.

4. Close the isolating valve on the inlet of the filter.

5. Initiate an additional manual rinse cycle to relieve the pressure in the filter.

6.2 - DRAINAGE PROCEDURE

Prior to accessing filter internals, it is necessary to drain the filter. Note that uncontrolled
emptying of the filter may result in excessive water spillage in the area around the filter.
In order to prevent any damage to surrounding equipment or property, it is
recommended that a drain line equipped with a manual valve be installed at the lowest
available port for this purpose.

To empty the filter:

1. Perform the shut down procedure as described in Section 6.1.

2. Check the pressure in the filter housing to ensure that it is atmospheric. If not,
initiate a manual rinse until the pressure is atmospheric. If the pressure
does not drop to atmospheric in two rinse cycles, repeat the procedure in
Section 6.1.

3. Disconnect the tubing from the highest available fitting to vent the filter.

4. Open the manual valve on the drain line.

5. For each rinse valve, disconnect the tubing at the valve fitting and remove the
rinse valve actuator from the body of the filter. Push down on the plunger
disc and release. Water will be ejected from both fittings. Repeat until
water flow stops. Reassemble actuator and reconnect tubing.

6. For the hydraulic piston, remove the tubing at the back of the piston and use
the anti-rotation pin to push the dirt collector fully rearward. This will cause
the water in the piston cylinder to be ejected. Reconnect the tubing.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 7 - SCHEDULE OF PREVENTIVE MAINTENANCE AND INSPECTIONS

Following is a schedule of preventive maintenance and inspections based on average
filtration duty, and should be used as a guideline only. For best results, a maintenance
schedule should be compiled based on experience gained from using the filter.

Monthly

- On OR-xx-Bx models equipped with a built-in bypass valve, the by-pass should
be activated at least once a month. This will clean the valve seat of any
accumulated dirt, as well as ensuring proper by-pass operation.

To manually activate the by-pass valve, follow the procedures below. (Refer to the
drawing on page 24).

Solenoid Valve operated By-Pass Valves (Standard)

- Rotate the Manual Override slotted screw on the solenoid valve body
attached to the By-Pass Valve. The valve will open. After a few seconds,
rotate the Manual Override Knob back to its original position to close the
By-Pass Valve.

Pilot operated By-Pass Valve (Optional)

- Rotate the three way mini valve, installed in the valve control system, to the
port marked "Open". The valve will open. After a few seconds, rotate the
three way mini valve to its original position, port "Auto", and the valve will
close.

Should system requirements change, or the filter be retrofitted to a different application,
it may be desirable to disable the automatic by-pass (prevent it from opening). To
disable the by-pass follow the procedure below.

- Rotate the three way mini valve to the port marked "Closed". This will by-pass
the differential pilot and disable the valve.

Quarterly

- Check coarse screen and clean as required.

- Trigger a manual rinse and check for proper filter function by observing the
pressures as described in Section 4.2. This step should be performed for
all individual filters in multiple installations.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

NOTE: Large particulates (greater than 3/8’’) trapped by the coarse screen are not

removed by automatic or continuous cleaning, and will accumulate over a period of
time. The recommended semi-annual interval for the inspection for and removal of
these particulates may have to be shortened based on site conditions. During normal
filtration, the inlet pressure and chamber pressure should equal each other. A
decreasing chamber value over time is an indication that large particulates are
accumulating on the outside of the coarse screen. This reduces filter efficiency by
increasing the frequency of rinse cycles since the filter is starting at a higher DP after a
rinsing cycle due to these retained particles.

SECTION 8 - ELECTRICAL CONTROL SYSTEMS

The OMNITROL 2000 is the latest generation of controls available. It provides for
control of up to ten filters or functions, and includes many options.

The OMNITROL 500 is a powerful controller, which provides for control of up to two
filters (optional 4 or 6 filters), and includes many options at a low cost.

The OMNITROL 100 is a powerful battery powered controller, which provides for control
of one or two filters, all at a low cost.

For complete information on the control system supplied with your filter, please refer to
the Operation & Maintenance Manual Supplement, which accompanied your control
system.

NOTE: Controllers allow the user to easily adjust such parameters as rinse cycle

duration, differential pressure switch delay, rinse cycle frequency, dwell time
between filters, and others. A value is given in the Control System manual for

the rinse cycle duration, which should not be adjusted from this value unless
absolutely necessary. Improper adjustment may result in inadequate or lengthy
rinse cycles, which can lead to filter malfunction.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 9 - TROUBLESHOOTING

A malfunctioning filter can be found in one of the following modes:

Section 9.1 - The filter does not experience rinse cycles (automatic or manual).
Section 9.2 - The filter rinses continuously (rinse valves do not close).
Section 9.3 - The filter cycles continuously (rinse valves open and close

repeatedly).

Section 9.4 - Controller inoperative.

Listed below are steps to be followed in troubleshooting the filter to determine the cause
of the situation. Prior to proceeding with the following, all tubing connections should be
verified against the schematics provided on pages 9 - 13 of this manual.

9.1 - The filter does not experience rinse cycles (automatic or manual).

1. Check the differential pressure across the filter versus the preset on the differential

pressure switch. If the differential is higher than the preset, go to step 5.

(NOTE: All differential pressure switches are factory preset for 7 psig increasing).

2. If the differential is lower than the preset, monitor the differential pressure across the
filter to determine whether it is increasing. If it is increasing, allow the differential
to increase to the preset value and monitor operation.

3. If it is not increasing, or is increasing very slowly, shut down the filter and extract the
fine screen. Carefully inspect the screen and o-rings for damage. Replace parts
as necessary. When reinstalling the screen, check to ensure that it is seated
properly inside the housing and that the dirt collector moves freely.

4. If the screen is intact and was seated properly, then the screen openings (micron

size) may be too large for the particular application. Contact your Orival

representative for assistance.

5. If the differential is higher, check to ensure that the Controller power switch is on.

6. Close the isolation valve on the filter outlet and allow the inlet and outlet pressures
to equalize. Initiate a manual rinse cycle by depressing the rinse cycle button. If
the filter rinses, check the differential pressure switch and connections and
repair or replace as necessary. Recheck operation. Go to step 11.

7. If the filter does not rinse, check to ensure that the solenoid valve is being

energized. (most standard valves have a small light illuminated when energized).

Repair or replace as necessary.

8. Check to ensure that the solenoid valve is attempting to drain the top chamber of
the manifold by observing its flow to the drain. If not, check for blockages in
the solenoid valve.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

9. If the solenoid valve is draining, but the rinse valve(s) do not open, then remove the

tubing from the top portion of any rinse valve or from the piston and observe
whether the valve(s) open. If the valve(s) open, check for blockages in the tubing
or fittings connecting the manifold and the rinse valves.

10. If the valves still do not open, remove the tubing from the bottom portion of the
rinse valves and check for flow from this tube. If there is low flow or pressure,
check for blockages in the tubing and manifold. If flow is present at line
pressure, shut down the filter, remove rinse valve actuators and check for
blockages, which may prevent valves from opening. Replace as necessary and
recheck operation.

11. If the filter rinses, open the outlet valve and recheck the differential. If the
differential has recovered, the filter was probably blocked due to an influx of dirt.
Allow the differential to buildup and monitor for proper filter operation.

12. If the differential has not recovered, check to ensure that the inlet pressure during
the rinse cycle is greater than the minimum required (see Section 3.2 A). If not,
the pressure must be greater. Contact your Orival representative for assistance.

13. Check the inlet pressure versus the hydraulic motor chamber pressure for sufficient
pressure drop as indicated in Section 4.2. If not sufficient, check for restrictions
or sources of back pressure in the rinse valve drain lines.

14. If the pressure drop is sufficient and the differential is not recovering after several
additional manual rinse cycles with the outlet valve closed, the filter must be shut
down and the screen extracted and cleaned manually. Check the dirt collector
nozzles for damage or excessive wear against the heights indicated in Table 9.1
below. Note that nozzle heights for PVC dirt collectors are measured from the

surface of the dirt collector tube, whereas those for Stainless Steel dirt collectors

are measured from the face of the coupling.

TABLE 9.1 DIRT COLLECTOR NOZZLE HEIGHTS FOR PISTON MODELS

FILTERS COLLECTOR HEIGHT

OR-03-xE PVC 2.8

Stainless Steel 2.6

OR-04-xE, OR-06-xE, OR-08-xS PVC 2.4

Stainless Steel 2.3

OR-08-PE

OR-10-xS, OR-10-PE, OR-12-xS

OR-14-xS, OR-16-PS, OR-18-PS, OR-20-PS

Stainless Steel
Stainless Steel
Stainless Steel

2.3

3.1

3.7

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

9.2 - The filter rinses continuously (rinse valves open but do not close).

1. Check the solenoid valve to determine if it is being energized continuously by the
Controller. If not, go to step 4.

2. If the solenoid is continuously energized, check the time setting for the length of
the rinse cycle to ensure that it is set properly (this time should be set between
5-15 seconds, depending on the model of the filter.) Correct, if miss set.

3. The problem may lie within the controller. Contact the office listed on the front of
this manual for assistance.

4. If the solenoid valve is not continuously energized, disconnect the tubing to the
top portion of the rinse valves and check for flow from this tube. If there is low
flow or pressure, the orifice connecting the upper and lower chamber of the
manifold may be partially or fully blocked. Isolate the filter, remove the manifold
and unplug this orifice using a rigid piece of wire.

5. If flow is present at line pressure, the rinse valve actuators should be replaced.

9.3 - The filter cycles continuously (rinse valves open and close repeatedly).

1. Check the preset on the differential pressure switch. This should be set to 7 psi.

2. Check the flow rate through the filter to ensure that this value is within the maximum

flow rating as indicated on the appropriate FILTER DATA SHEET. If the flow is

too high, adjust as necessary.

3. Check the differential pressure across the filter following a rinse cycle. If the
differential does not recover, go to Step 12 of Section 9.1.

4. If the flow is within the operating range of the filter and the differential recovers, a
larger screen and/or additional filters may be required. Contact your Orival
representative for assistance.

9.4 - Controller inoperative.

1. Check to ensure that the switch on the controller is in the ON position.

2. Check to ensure that power is available to the controller.

3. Check the fuses inside the controller and replace as necessary.

4. For further assistance, contact the office listed in the front of this manual.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 10 - REMOVAL/INSTALLATION OF MAJOR COMPONENTS

NOTE: Prior to performing any procedures described in this section, it is necessary to

first isolate and drain the filter as outlined in Sections 6.1 and 6.2.

10.1 - COARSE SCREEN REMOVAL AND INSTALLATION

1. Remove the nuts and washers from the cover studs or bolts.

2. For filters with up to 8" flanges, remove the cover and place it out of the way. Larger

filters are equipped with a longer stud, which is used for support of the cover.

The cover is heavy and attempting to remove the cover without assistance may

result in personal injury.

3. For filters with up to 8" flanges, the coarse screen can now be easily pulled out of

the filter. For filters with 10’’ flanges or larger, the coarse screen is threaded into

the fine screen, and the coarse screen must either be unscrewed off the fine

screen or removed with the fine screen as an assembly. A special extraction tool

is available from ORIVAL to simplify the removal process. A set of spanner

wrench tools is available to assist in the separation of the coarse and fine

screens.

4. Installation is in the reverse order of removal.

10.2 - FINE SCREEN REMOVAL AND INSTALLATION

1. Remove the coarse screen as described in Section 10.1.

2. For filters with up to 8’’ flanges, the fine screen is now visible inside the filter body.

Removal is accomplished through the application of light tension on the fine

screen handle. CAUTION: Excessive force may result in the fracture of the fine

screen handle. Should this occur, the fine screen will be extremely difficult to

remove. For easier and safer fine screen removal and installation, the use of an

Orival Screen Extraction tool is highly recommended.

3. To reinstall the fine screen, first ensure that the upper and lower O-rings are intact
and fully seated in their appropriate grooves.

NOTE

Fine screens for filters with flanges up to 8’’ have a screen with two grooves in

the end with the handle and upper bearing. The lower groove is used. No O-ring

is installed in the upper groove. The only exceptions are the 3’’ filters with

extended screens (with a top section and bottom section only), Models

OR-03 -BE, OR-03-IE and OR-03-PE. For these three models only, the O-ring is

installed in the upper Groove with no O-ring in the lower groove. All screens have

an O-ring in the inside groove at the bottom of the filter.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

4. The application of silicone grease to the O-rings will make insertion much easier.

5. Carefully insert the screen into the filter body until the screen nearly contacts the first

dirt collector nozzle. Care should be taken not to damage either the fine screen

or dirt collector nozzles.

6. The dirt collector shaft must now be positioned to pass through the upper bearing in

the center of the fine screen handle. This can be done by inserting a long,

slender tool (such as the ORIVAL Extraction Tool, or similar), to align the hole in

the handle’s upper bearing on the fine screen with the dirt collector shaft. Again,

care should be taken not to create excessive contact between the fine screen

and dirt collector nozzles, as damage may result.

7. Ensure that the dirt collector shaft has passed through the upper bearing located in
the center of the fine screen handle. Continue to push the fine screen into place

until it seats firmly into position. With larger multi-sectioned screens, care must

be taken to insure that the back end of the screen is centered over the back

bulkhead’s disc before trying to set the screen in place.

10.3 - DIRT COLLECTOR ASSEMBLY REMOVAL AND INSTALLATION

1. Remove the coarse and fine screens as described in Sections 10.1 and 10.2.

2. Remove the hydraulic motor chamber cover and place it out of the way.

3. Remove the hydraulic piston from the end of the filter and unthread the bushing
assembly from the lower bearing in the dirt collector.

4. Remove the lower bearing from the end of the dirt collector assembly.

5. Remove the hydraulic motor by gently pulling it out through the service hole.

6. The dirt collector can now be removed through the cover end of the filter.

7. Installation is in the reverse order of removal. Care should be taken when
reinstalling the hydraulic motor into the dirt collector that the proper orientation is
maintained. The large hole in the hydraulic motor should open towards the dirt
collector tube, and the small hole should be used for retention of the hydraulic
motor by the lower bearing as it is threaded into the back of the dirt collector
tube.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 11 - SPARE PARTS ORDERING INFORMATION

A FILTER DATA SHEET, spare parts list for the filter along with spare part lists for the
rinse valve and hydraulic piston (if so equipped) have been provided with the
documents for the filter. The following three (3) pages depict typical filter assemblies
and indicate proper part description and location. Please refer to these descriptions
when ordering spare parts from the parts list. Each drawing’s identification numbers are
the same as the first digits of the part number.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

SECTION 12- SPECIAL INSTALLATIONS

The prior sections of this manual describe typical filters and typical installations. Since
every installation is different, this section describes unusual conditions and the special
instructions that need to be followed to correctly install the filter(s) and special options
and accessories.

12.1 Pneumatic Control Conversion

Occasionally, conditions may arise that require the use of compressed air to operate the
filter control system rather than filtered water. We refer to this system as a
pneumatically controlled filter. Typical applications are:

• To provide freeze protection when a filter is to be installed outdoors.

• To insure proper filter rinsing when available water pressure is too low.

• When water quality precludes the use of water in the Control System.

Dry, filtered compressed air is distributed as the working fluid in the Control System,
rather than water. The pneumatic control system utilizes most of the same components
as the standard control system, allowing it to be easily retrofitted to existing installations.
The following steps are taken in installing a pneumatic control system.

• A pneumatic manifold replaces the standard two-stage manifold.

• The two-stage pneumatic manifold has a ½" connection on one end for

connection to a dry compressed air line. The opposite end of this manifold is
equipped with a ½" connection for the solenoid valve, the same as in the
standard system.

• The air pressure should be approximately 15-20 psig higher than the inlet
pressure to the filter for proper operation.

• The Differential Pressure Switch (DPS) remains as the only component,
which requires water for proper operation. For freeze protection, precautions
must be taken to ensure that these lines are adequately protected.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

To install a pneumatic control system on a new filter, the following steps should be
followed:

1. Confirm the presence of a 1” plastic plug in the 1’’ port on the top of the filter
body near the rinse valves. Install plug using Teflon tape, if not present.

2. Connect a ½’’ dry compressed air line (at least 15-20 psig higher than filter inlet
pressure) to one end of the pneumatic two-stage manifold. This becomes the
supply end.

3. Connect the 1/2" solenoid valve with elbow and nipple to the opposite end of this
manifold. This becomes the control end.

4. On filters equipped with a piston, mount the absorber tank vertically with its side
fill port facing up. Locate this tank near the piston and slightly higher than the
piston.

5. Connect the control tubing to the pneumatic manifold as per sample drawings on
pages 37 & 38 --- top of the rinse valve actuators are connected to the control
ports of the manifold (nearer to the solenoid valve), the bottoms of the actuators
are connected to the supply ports of the manifold (nearer the air supply); and the
piston, if equipped, is connected to a control port of the manifold in series with an
absorber tank (manifold to top of tank, bottom of tank to the piston).

6. For freeze protection installations only, remove the 3-way mini-valve with both
tubing connections from the filter’s outlet, if present, and discard.

7. For freeze protection installations only, remove the fitting going to the hydraulic
motor chamber near the rear of the filter body and plug the opening.

8. For freeze protection installations only, remove the ¼’’ Tee fitting from the filter’s
inlet, if present.

9. Make tubing connections from the open ¼’’ inlet and outlet ports to the DPS.
Supplied tubing and ¼’’ fittings can be used, but for freeze protection heat traced
stainless steel tubing and fittings should be used. For a bank of filters in a parallel
arrangement, these ports are plugged, and high and low DPS pressure points
are from points on the main line before the filter’s branch point and after the
filter’s outlets are rejoined.

10. For piston models, use a 50/50 water/anti-freeze mixture to fill the absorber tank
and piston cylinder. Before filling, use the piston’s anti-rotation pin to slide the pin
fully rearward in its slot. Remove the absorber tank’s side fill port plug and slowly
fill the tank with the fluid mixture. When the fluid overflows, slide the piston’s anti­rotation pin fully forward in its slot to draw the mixture into the piston’s cylinder.
Refill the port until overflowing, and plug the port.

11. Continue with the installation of the filters following the instructions in this
manual.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

12.2 Using a Controlled Outlet Valve (COV)

A Controlled Outlet Valve (COV for short) is a valve installed after the outlet of the filter,
and is used to control the flow through the filter during the rinsing cycle. A COV is used
when inlet pressures are low or drop below the 30 psi minimum with the rinse valves
open. In most cases, the Controller will activate the COV prior to rinse valve activation.
This throttles the flow out of the filter’s outlet, to develop more inlet pressure to better
provide adequate pressure for a proper rinse.

A COV is installed on the outlet leg of the filter, usually before the outlet isolation valve.
For multiple filter installations, the COV is located at a point on the main line after the
multiple filter outlets are rejoined. The drawings on page 40 show typical filter
installations with a COV installed.

12.3 Using an External Source of Rinse Water & a COV

There are installations where there is insufficient pressure or flow to properly perform a
rinse cycle. This can sometimes be overcome by the use of a COV and an external
source of water with sufficient pressure and flow. For these installations, a COV is
installed as described in section 12.2, above, and an external water source is connected
in the inlet area of the filter. To further enhance rinse performance, the two-stage
pressure manifold is relocated on the external water source line. When a rinse cycle is
required, a valve on the external source line is opened as the COV is closed. The filter’s
flow to the outlet is stopped and the higher-pressure external source water is used to
clean the filter. Once the COV is closed and the external water line opened, then the
rinse cycle is initiated by energizing the solenoid relocated on the external source line
along with the two-stage manifold. At the end of the rinse, the rinse solenoid is de­energized, the COV is opened and the external source valve is closed to return the filter
to normal operation. The drawings on page 41 show typical external water source
installations including a COV, external source control valve and two-stage manifold with
rinse solenoid moved to the external source line. These drawings also show check
valves on the inlet and external water lines. These valves are highly recommended to
prevent flow or contamination problems.

12.4 Water Hammer Solutions

Water hammer is a natural phenomenon that can be present in typical water filtration
installations. It occurs as a result of the rapid flow of dirty rinse water from the rinse
valve(s) suddenly being stopped as the rinse valve(s) close at the end of the rinse cycle.
The results range from a soft tap to a loud bang that echoes throughout the drain line.

ORIVAL has had some success in reducing this offensive noise by adding vacuum
breaker valves to the drain lines. Two valves are added to the tops of the ½’’ pipe
columns extending above each of the drain lines. See page 42 for a typical installation.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

12.5 Optimizing Filter Performance

Filter performance is dependent on various parameters that can change as site
conditions change. It makes sense to try to optimize the filter’s cleaning and rinsing
action to help overcome varying site conditions.

For efficient self-cleaning of the filter’s fine screen, the dirt collector nozzles must sweep
the entire open area of the screen while the suction at the nozzles tips pulls the particles
off the screen’s surface and draws filtered water back through the screen to dislodge
particles wedged in the weave of the screen.

Proper suction depends on sufficient inlet pressure during the rinse and free flow of the
dirty rinse water to an atmospheric drain. As previously stated in this manual, the inlet
pressure should never drop below 30 psig. This means that during normal filtration, the
inlet pressure should be 35-40 psig or greater to allow for a pressure drop when the
rinse valves are open (more flow demand = lower pressure). Higher inlet pressures
(above 40 psig) help guarantee ideal rinsing conditions. Suction at the nozzle tips is
dependent on an adequately sized drain line that runs a short distance downward
without many bends. This insures proper draining with a minimum of backpressure
losses.

To determine proper suction, use the 3-way mini-valve and a pressure gauge installed
on the common port of this valve to read inlet pressure and hydraulic motor chamber
pressure during the rinse (see section 3.1 F for additional information). The hydraulic
motor chamber pressure ideally should be about 25 – 40 % of the inlet pressure during
the rinse.

The other way to optimize filter rinsing is by observing the movement of the dirt
collector. This is only required for filters with a piston. Non-piston filters have a fixed dirt
collector with elongated nozzles that sweep the entire open area of the fine screen. To
observe dirt collector movement on a filter with a piston, the white PVC shield on the
piston must be slid back to reveal the front stainless steel tube with a protruding pin that
rides in a slot. The pin is connected to the piston shaft that in turn is connected to the
dirt collector tube through the lower bearing. When the filter goes into a rinse, the rinse
valves open and pressure is also released on the piston’s head. This allows the piston
to relax and the natural action of the dirt collector pushes the fluid out of the piston
cylinder. The rate at which this fluid drains out of the piston, out its tubing and through
the two-stage manifold to drain through the open solenoid valve, determines how fast
the dirt collector travels to sweep the surface of the fine screen. By observing the travel
of the piston’s pin, one can determine if the travel is too fast or too slow. Ideally, the pin
should reach the end of its travel (about ¼’’ from the end) just as the solenoid valve is
de-energized. Sooner than that, and the screen’s clean pattern may be like a helix,
where the nozzles are stationary at the end of the stroke for several seconds. If the pin
does not reach the end, then only portions of the screen are cleaned.

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ORIVAL, INC. • 213 S. Van Brunt St. • Englewood, NJ 07631 • [phone]

If the pin does not reach the end of its stroke in time, just increase the rinse time setting
in the controller.

If the pin reaches the end of its stroke too soon and the rinse time has been properly set
to the recommended interval, then this stroke must be slowed down. This can be
accomplished with the addition of a flow control needle valve in the piston’s hydraulic
tubing line. ORIVAL can supply this valve. The valve is a bi-directional check valve that
can have its flow adjusted in one direction. When used and properly adjusted, it will
slow the flow out of the piston to provide a gradual movement of the dirt collector to
allow a thorough cleaning of the screen.

The installation of this flow control needle valve is easy. See drawing on page 45.

1. Disconnect the piston’s hydraulic tubing line at the two-stage manifold.

2. Remove the vacated elbow fitting at the two-stage manifold.

3. Thread a short ¼’’ nipple in the open port.

4. Thread the flow control needle valve onto the nipple noting to use the low­pressure port of the valve.

5. Thread the elbow fitting removed in step 2 into the valve’s other port.

6. Reconnect the piston’s tubing to the elbow fitting.

7. Perform several manual rinse cycles while observing the piston’s pin and making
adjustments to the flow control needle valve. The ideal adjustment is reached
when the pin reaches the end of its stroke just as the rinse solenoid is de­energized. This allows a brief period before the rinse valves close while the dirt
collector is at the end of its stroke.

It is also important to remember that the efficiency of the cleaning and rinsing is
dependent on the dirt collector nozzles’ ability to always remove the particles. Having
the proper pressures and a slow, deliberate dirt collector travel provides the best
conditions for the nozzles to do an efficient cleaning job. However, filter and nozzle
maintenance must also be performed. The PVC nozzles wear with time as particle are
sucked across its tips and into the openings. With wear, the tips get shorted and the
distance to the dirt increases. This reduces the suction effect. Inspection of nozzle tips
for wear should be part of routine filter preventive maintenance.

Also, the dirt collector is suspended on the center axis of the screen. With time, the dirt
collector shaft and upper bearing may wear and cause a dirt collector mis-alignment.
And a similar mis-alignment can occur at the dirt collector’s rear support of the lower
bearing and piston bushing assembly. These low cost parts should be inspected and
replaced if any signs of wear are observed or when filter performance has decreased.

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