SMF2-FG Series Media Filter
Operating & Maintenance Manual
Process Efficiency Products filtration equipment has been designed to give long, troublefree service when properly installed, operated and maintained. This manual is a guide to establishing installation procedures and a maintenance program. IT IS IMPORTANT THAT MAINTENANCE PERSONNEL REVIEW THIS MANUAL CAREFULLY - INCLUDING THE SAFETY PRECAUTIONS AND WARNINGS LOCATED ON PAGE 11 PRIOR TO PERFORMING ANY REPAIRS OR MAINTENANCE ON THE INDUSTRIAL WATER FILTER.
Included in this manual are the recommended procedures for installation, start-up, operation and shutdown for the PEP Industrial Water Filters. Note that the recommendations on frequency of service are minimums, and where operating conditions are severe, the service should be performed more often. For each required service, follow the procedures outlined under the Maintenance Procedures section of this manual. The PEP Industrial Water Filter construction details are shown on the cover with the major points of inspection and service identified. If you need further information that is not covered in this manual, please contact your local PEP Representative or the PEP factory.
TABLE OF CONTENTS |
PAGE |
|
Operation |
7 |
Filter Illustration |
Cover |
|
Cold Weather Operation |
7/8 |
General Description |
2 |
|
Seasonal Shutdown |
8 |
Filter Operation |
2 |
|
Maintenance Procedures |
|
Installation |
|
|
Pump Pre-Strainer |
8 |
Rigging |
2/3 |
|
Pump |
9 |
Piping |
3 |
|
Backwashing |
9 |
Electric Actuator Requirement 4 |
|
Filter Tank |
10 |
|
Loading the Media |
4 |
|
Water Treatment |
10 |
Wiring |
4/5 |
|
Factory Authorized Parts |
10/11 |
Operation and Maintenance |
|
SAFETY PRECAUTIONS |
11 |
|
Initial and Seasonal Start-Up |
6 |
|
Miscellaneous |
12/15 |
After 1st Hour of Operation |
7 |
|
Drawings |
|
PEP Filters • 322 Rolling Hill Road • |
Mooresville, NC 28117 • |
800-243-4583 • www.pepfilters.com |
704-662-3133 (Outside USA) |
Page 1 of 16 |
Fax 704-662-3155 |
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rev. 01/02 |
SMF2-FG Series Media Filter
Operating & Maintenance Manual
GENERAL DESCRIPTION
The PEP SMF-FG Series Industrial Water Filters are permanent media type units specifically designed to clean industrial and process water. The PEP SMF-FG filters are designed for side-stream or in-line applications on non-pressurized systems. The SMF-FG filter vessel is constructed of fiberglass reinforced thermoplastic and has a pressure rating of 50 psig (350 kPa).
FILTER OPERATION
Water from the system is pumped through the over-drain assembly at the top of the filter tank and distributed evenly over the media. Suspended particles are trapped in the filter media. The filtered water then passes from the vessel through the under-drain assembly at the bottom of the filter and returns to the system.
When the trapped particles cause the pressure differential across the media bed to reach a pre-determined pressure of approximately 10 PSIG (69 kPa) over starting gauge pressure, the valves are automatically or manually repositioned and the media is backwashed. The media is backwashed with a rigorous scouring action and the trapped particles are released. The dirty water passes from the filter tank through the over-drain assembly at the top of the vessel and is flushed to the drain. When the media is cleaned after a preset time (2 minutes standard), the valves are again repositioned and the filtration cycle is continued.
INSTALLATION
UNPACKING
When the PEP Industrial Water Filter is delivered to the jobsite, it should be checked thoroughly to ensure that all required items have been received and the filter equipment is free of any shipping damage prior to signing the bill of lading.
The model number of the filter will appear on a nameplate located on the unit and should be checked against the invoice/packing list. Table 1 shows the parts that should be inspected when the unit is unpacked.
RIGGING
1. PEP SMF-FG units should be lifted with a forklift or overhead crane. If these units are lifted with an overhead crane, lifting straps must be located below the filter skid and should not come in contact with the filter components.
PEP Filters • 322 Rolling Hill Road • |
Mooresville, NC 28117 • |
800-243-4583 • www.pepfilters.com |
704-662-3133 (Outside USA) |
Page 2 of 16 |
Fax 704-662-3155 |
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|
rev. 01/02 |
SMF2-FG Series Media Filter
Operating & Maintenance Manual
2.All PEP Industrial Water Filters should be rigidly anchored to the floor or support steel by means of anchor bolts. The SMF-FG has holes suitable for 1/2" (13mm) anchor bolts.
3.After the unit is installed at a permanent location, the pressure gauge and air relief valves should be installed on the top of the filter tank (some units will have vents already installed). The sand media should be loaded into the filter at this time. Refer to loading media section on the following page and Table 6.
PIPING
Piping to and from the PEP SMF-FG filter should be installed in accordance with the drawing that was specifically furnished with the unit. In the event of a conflict between subject drawing and labels on the filter piping, the drawing dictates and takes precedence over the labels.
1.Connect the feed water line from the system sump or piping to the pump inlet. If the inlet connection is located above the operating water level of the system sump, install a foot/check valve to prevent loss of suction on the pump.
2.Connect the filtered water return line from the filter outlet to the system sump or piping.
3.A service valve should be installed on the inlet, outlet, and city water line (if city water is used) to allow servicing of the filter. For units using a backwash source other than the system sump, refer to Table 3 to determine required backwash flow. Connect this line to the "City Water" connection as shown in the drawing. The maximum city water backwash supply pressure on the SMF filters should never exceed the pressure rating of the filter vessel. If public or municipal water is used for backwash, a backflow prevention or check valve is required in the line on all units (check standard local codes).
4.Connect a backwash waste line to the waste connection as shown in the drawing. This line carries the backwash wastewater to the drain.
IMPORTANT: Do not put a valve in the waste line!
Refer to Table 3 for the minimum and maximum backwash flow rates. Note: If the drain is not large enough to handle the volume of water during backwash, it may be necessary to use a storage tank to collect the wastewater. A valve can be used to regulate the flow from tank at a suitable rate to the drain. NEVER REDUCE THE SIZE OF WASTE WATER LINE.
5. All interconnecting piping, fittings, valves, or other accessories connected to the filter system (whether supplied by PEP or others) must be independently supported to eliminate
PEP Filters • 322 Rolling Hill Road • |
Mooresville, NC 28117 • |
800-243-4583 • www.pepfilters.com |
704-662-3133 (Outside USA) |
Page 3 of 16 |
Fax 704-662-3155 |
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rev. 01/02 |
SMF2-FG Series Media Filter
Operating & Maintenance Manual
stress on piping.
Check with local, county, or other government authorities to ensure compliance with applicable government industry requirement codes.
NOTE: The filter vessel drain plug is located on the tank bottom for 20”, 24” and 30” units, and on the side near the tank bottom for 36”, 42” and 48” units.
ACTUATOR REQUIREMENTS
PEP SMF-FG filters utilize electric actuators to control the valve action between the filtration and backwash modes. The electric actuator is designed for 110 VAC control.
LOADING THE FILTER MEDIA
The special spherical silica sand media used in all PEP Industrial Water Filters is designed to remove over 95% (by volume/weight) of all suspended solids. The media will ship to the jobsite in 0.5 ft3 (14,160 cu. cm.) drums @ 50 lb./drum or in 1 ft3 (28,320 cu. cm.) bags @ 100 lbs./bag for easy handling during the media loading process.
1. NEVER LOAD MEDIA INTO A DRY FILTER TANK, fill tank one-third to one half full with water before loading. Always check filter internals before loading media. This procedure is the same for Unigran 55 and 85. Refer to Table 6 for appropriate media quantities for a specific filter size.
WIRING
PEP Industrial Water Filters supplied with a pump and automatic backwash controls are provided with the following as standard: UL Type 4X control cabinet containing an on/off disconnect switch, motor overload protection, transformer to provide 110v control voltage, backwash timer, 24 hour time clock, pressure differential switch to initiate backwash, valve actuator to reposition valves for backwash, and push button for manual backwash initiation. Units are provided with the customer requested voltage/phase (460 volt, three phase standard). Check the current draw upon initial start-up and make sure that it is equal to or less than the prescribed value shown in Table 4.
Units supplied with city or other source backwash are provided with a magnetic motor starter. Units supplied as manual are provided with no motor control of any kind.
THE FOLLOWING RECOMMENDATIONS CONFORM TO THE 1993 NATIONAL ELECTRIC
PEP Filters • 322 Rolling Hill Road • |
Mooresville, NC 28117 • |
800-243-4583 • www.pepfilters.com |
704-662-3133 (Outside USA) |
Page 4 of 16 |
Fax 704-662-3155 |
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|
rev. 01/02 |
SMF2-FG Series Media Filter
Operating & Maintenance Manual
CODE. CHECK WITH LOCAL, COUNTY, OR OTHER GOVERNMENT AUTHORITIES FOR PRESCRIBED REQUIREMENTS.
NOTE: CHECK FILTER PUMP NAMEPLATE FOR HORSEPOWER AND AMP DRAW
Single Phase Manual Units
1.Install a separate power supply line with circuit breaker protection between the closest branch distribution panel and the pump motor. The full load current for standard models is listed in Table 4.
2.Install an externally operated switch with fuse protection and door interlock in plain sight of the filter and not more than 50 feet (15m) away. The thermal overload protection, if required, must be sized for full load amp draw listed on the pump motor name plate.
Three Phase Manual Units
1.Install a separate power supply line with circuit breaker protection between the closest branch distribution panel and the pump motor. The full load current for standard models is listed in Table 5.
2.Install a service disconnect switch in plain sight of the filter and not more than 50ft/15m away.
3.Install an externally operated manual or magnetic starter with thermal overload and fuse protection. If the unit is to be controlled remotely with a time clock, switch, or other device, a magnetic starter must be used. The thermal overload protection, if required, must be sized for the full load amp draw listed on the pump motor nameplate.
Single and Three Phase Automatic Units
1. Install a separate power supply line with circuit breaker protection between the closest branch distribution panel and the control box. The full load current for standard single and three phase units is listed in Tables 4 & 5. The control box contents are pre-wired and include a service disconnect switch, thermal overload, a transformer to convert the power supply to single phase 110v for controls. Wire the power supply lines to the disconnect switch. ALL INCOMING POWER SUPPLY LINES MUST CONNECT TO DOOR INTERLOCK DISCONNECT.
24 HOUR/7-DAY TIME CLOCK
The 24-hour time clock (standard, unless equipped with a PLC) is used to initiate the 2 minute backwash timer relay at any specified time in the day. The 24 hour backwash clock
PEP Filters • 322 Rolling Hill Road • |
Mooresville, NC 28117 • |
800-243-4583 • www.pepfilters.com |
704-662-3133 (Outside USA) |
Page 5 of 16 |
Fax 704-662-3155 |
|
|
rev. 01/02 |
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