Sand Media Filter Installation Manual
Contents
1. Revision 11 10 20 Sand Media Manual Revision 11 10 21 Sand Media Manual2. OUTLET pa Revision 11 10 4 Sand Media Manual 1 1 1 2 1 3 1 4 1 5 1 6 INSTALLATION Position the tanks on a concrete pad with two legs facing front one towards the rear Position tanks on centers of tank diameter 4 Once the filter tanks have been placed and aligned the outlet manifold should now be connected Locate the corresponding grooved coupling that matches the outlet spud size and remove the gasket Lubricate the coupling gasket with soapy water and slide the gasket onto the outlet connection on the filters Lift the outlet manifold into position so that the tank and manifold connections are touching Using floor jack or blocks will help to hold the manifold in place Slide the gasket down until it is in the center of the two grooves Install the grooved coupling and bolts and tighten enough to keep the manifold in place Using the above procedure install the remaining couplings and re tighten all of the bolts on the lower manifold Install the backwash valve on each tank using corresponding grooved coupling Remove the gasket from the coupling apply soapy water and slide gasket onto the tank inlet connection Locate backwash valve on top connection and slide the gasket into the middle of the 2 grooves Install the grooved coupling and bolts and tighten partially The automatic actuator or manual operator should face the front of the filter Install the upper inlet manifold to the backwash valves using the corre
3. manifold On systems operating at pressures above 100 PSI refer to the assembly drawing on Page 13 for a description of the high pressure water stack assembly On the discharge manifold lower install the 1 2 x 1 4 galvanized bushing and 1 4 poly elbow into the 1 2 port in the outlet manifold Connect the poly tubing to the poly connector on the outlet manifold Connect the other end of the poly tubing to the poly tee 5A on the 1 4 three way valve 8 on the water stack assembly The high pressure port of the differential pressure switch is factory assembled Install the solenoid valves to the valve actuators The solenoid port marked 1 is connected to the 1 4 port on the valve actuator with a 1 4 close nipple Depending on the number of backwash valves install either a 1 4 poly elbow or a 1 4 poly tee to the solenoid port marked 2 Refer to the diagram on Page 12 The flow arrow on the bottom of the base of the solenoid valve should point toward the valve actuator Semi automatic systems utilize 3 way ball valves in lieu of solenoid valves Refer to the diagram on Page 21 Connect the poly tubing to the poly tee on the water stack 5 and connect the other end to the poly fitting installed to the solenoid port marked 2 on filter 1 in Step 3 4 above Filter 42 should be connected in the same manner In the case of larger filter systems three filters or more it will be necessary to use either poly elbows or poly tees t
4. the sand bed may be required Revision 11 10 11 Sand Media Manual FIGURE E Hydraulic Actuator and Water Stack for the Automatic Valve Standard Pressure Systems 100 psi and lower Revision 11 10 12 Sand Media Manual FIGURE F Hydraulic Actuator and Water Stack for the Automatic Valve High Pressure Systems above 100 psi Revision 11 10 13 Sand Media Manual WINTERIZATION Winterization of the Rain Bird Sand Media Assembly 1 After the last irrigation cycle of the season run a back flush cycle two 2 times 2 Drain the system completely ensure all 1 4 and 3 8 poly lines are completely drained Use compressed air to remove remaining water from poly lines and components Once it has been verified that all remaining water has been removed reconnect lines 3 Loosen the fasteners on the 3 Way Solenoid Hydraulic Actuator flanges to allow water to exit the valve Remove via quick connect fitting 14 poly tubes from solenoids and blow remaining water out of the solenoid replace poly tubes when complete Use compressed air to ensure any remaining water is removed NOTE Any remaining water that can freeze in a contained area will cause damage Complete removal of water is critical to avoid damage Loosen these fasteners Hydraulic Actuator and remove water Valve in diaphragm Revision 11 10 14 Sand Media Manual MEDIA FILTER PREVENTIVE MAINTENANCE SCHEDULE The following is a
5. EAK Probable Cause Solution 1 Obstruction in valve seat 1 Remove obstruction 2 Polyurethane sealing disk is worn 2 Replace valve seal or damaged 3 Diaphragm damaged leaking 3 Replace diaphragm from port of diaphragm chamber at rear of valve 4 Pinched or worn O Ring 4 Replace O Ring and or lubricate shaft PROBLEM WATER HAMMER Probable Cause Solution 1 Air in tanks 1 Bleed off trapped air See start up instructions Also check for leaks in the pump suction line An air bleed at the filter inlet may also help 2 Long backwash line causing 2 Install a vacuum breaker on vacuum induced slamming of the backwash line valves Revision 11 10 17 Sand Media Manual PROBLEM INCREASING FREQUENCY OF BACKWASH CYCLE Probable Cause Solution 1 Backwash flow or duration is 1 Readjust backwash flow not adequate to flush filter and or increase duration tanks of all contaminants of backwash cycle 2 Insufficient media depth 2 Add media sand to achieve proper depth 3 Increased concentration of 3 Add extra filter tank s contaminants in water supply to system or reduce flow rate Note May only be a seasonal problem PROBLEM AUTOMATIC BACKWASH FAILS TO CYCLE Probable Cause Solution 1 Controller power off blown 1 Turn power on Be sure wiring is fuse or circuit breaker connected Reset circuit breaker or tripped install new fuse 2 Improper setting on 2 Inspect seal for signs of different
6. RAINY BIRD Sand Media Filter Installation Manual Revision 11 10 1 Sand Media Manual Table of Contents Quick Statt e sk 5 nc cd cani sad se aes inci Page 3 General IO NOM adn Page 4 Tank Installation Instructions aussi cds Page 5 Media Installation eii Page 6 Control Installati n si cr Page 7 SUN EE E N A E O e ee Page 8 Backwash Restrictor Adjustment oooooccoccccccnccccncncnccncnccnnnnnnancnnns Page 9 Notes on Backwash na patio se UT cece els ees ones Page 11 Water Stack Assembly Diagram Low Pressure ooocccoccccoccccccncos Page 12 Water Stack Assembly Diagram High Pressure oooooccccccccccccocnco so Page 13 WITS Za Ora lia e aa aE Page 14 Preventive Maintenance Schedule ceceeeeeeeeeeeeee teens Page 15 Troubleshooting Guide sra eso Page 16 Filter Underdrain Blockage occooccccococccccccccococononcncnncnnancnnns Page 19 Solenoid Valve Wiring Diagram 0oococccccccccccccnncncnccnnnnnnnncnccnnnos Page 20 Revision 11 10 2 Sand Media Manual Rain Bird Corporation QUICK START INSTRUCTIONS Sand Media Filter Installation and Start up Overview Concise general directions for the experienced installer complete with detail references for the less experienced 1 Place filters in desired arrangement two legs face front one towards rear Tanks should be on centers of tank diameter 4 Install outlet manifold Ref Page 3 Install backwash valves actuator faces front Ref Page 4 Install inlet mani
7. ared to the amount of water filtered it is discharged at a high rate for a short period of time Provisions should be made to drain away store or otherwise dispose of the dirty backwash water The backwash line should not be connected to a pressure line and should be discharged to atmosphere When returning backwash water to a reservoir the discharge point should be as far away as possible from the pump intake The backwash water flow should discharge to atmosphere above the water not underwater This will allow for proper backwash flow adjustment 3 FILTER COUPLINGS Grooved type couplings are supplied as standard on all piping supplied with the filters These couplings mechanically lock the filters together while allowing some line flexibility The backwash discharge ports have grooved type couplings with slip PVC adapters to facilitate PVC backwash manifold installation The backwash discharge line should be the same size pipe as the PVC adapter supplied on the unit If the backwash discharge line is excessively long or runs on a downhill slope a vacuum breaker should be installed on the backwash line after the backwash flow restrictor valve NOTE The backwash manifold and backwash flow control valve should be supplied by the installer or dealer See Fig A FIGURE A BACKWASH MANIFOLD AND FLOW CONTROL VALVE GROOVE FOR COUPLING BACKWASH FLOW CONTROL VALVE BACKWASH i a OUTLET ee GROOVE FOR f i COUPLING Sea Seay Ne
8. ective backwash requires that back pressure be maintained on the system during backwash A pressure maintenance valve may be required Backwashing should be more frequent on low pressure lt 40PSI applications with an allowable increase in pressure differential over clean of 5 PSI The backwashing function of the sand media filtration system is the most important aspect of the filter system operation Without proper backwashing the entrapped dirt is not expelled from the system Filters should be flushed when the pressure loss increases by 8 PSI over the clean filter pressure loss Each filter should be flushed for a minimum of 90 seconds per tank If backwash water is not visually clear after 90 seconds time extend the flush duration Filters should be flushed for a minimum of 90 seconds each at least once every 24 hours even if an 8 PSI pressure drop is not attained The dwell setting is properly set when there is a slight overlap of two filters flushing Measure the time required for a valve to return to the filter position from the backwash position Set the dwell setting to the next shortest setting The quality of product water produced by your sand media filters is directly affected by the quality and frequency of the backwashing operation In filters utilizing the wedgewire underdrain some contamination build up may occur where heavy silt loading is present Under these circumstances a periodic longer backwash cycle or mechanical agitation of
9. ent and to supply filtered water to the field you can increase the backwash flow by installing a valve in the filtered water output line and closing off or partially restricting the flow through this line during backwash If this method is used the flow must be restricted exactly the same amount each flush or variable backwash performance will occur 5 THE BACKWASH FUNCTION Backwashing the filters is the process by which clean water flows upward through the underdrain lifting and expanding the media bed allowing it to release the collected contaminate The contaminant is then carried away with the backwash water Excessive backwash flow rates will expand the media to the point that the media itself is expelled out of the tank Insufficient backwash flow will not expand the media enough to purge all the entrapped contaminant This Revision 11 10 10 Sand Media Manual could result in a residual pressure loss through the bed even after backwash To achieve maximum filter performance the backwash flow must be properly adjusted IMPORTANT NOTES 1 If at a later time you make any significant changes in pressure or flow the above adjustments should be re checked 2 Backwashing at 8 PSI above clean filter pressure differential is recommended 3 The minimum stated system operating pressure is 20 PSI When operating at pressures lower than 40 PSI pay especially close attention to the backwash function to ensure adequate cleaning An eff
10. ficient pressure will not allow the valve to open fully Tighten the locking nut once the pressure regulator is set properly The automatic filter controller should be set so that the frequency of filter backwashing corresponds with the build up of pressure drop to the established dirty filter pressure differential set point Establishing the time frequency of flush may require several days of monitoring to determine the proper setting Example If it takes 6 hours of operation to reach the dirty filter pressure switch setting of 13 PSI the backwash frequency setting on the controller should be set at 6 hours Revision 11 10 8 Sand Media Manual 4 8 4 8 a 4 8 b 4 8 c 4 8 d 4 8 e 4 8 f 4 8 9 The backwash restrictor valve adjustment The most critical factor to proper sand filter operation Open the backwash restrictor control valve approximately 25 Be sure that all air is purged from each tank by partially opening and closing each tank flush valve Before proceeding with backwash adjustments the pump must be run long enough to fill the entire irrigation system at the designed pressure and flow Manually initiate a backwash on one tank by turning the manual override screw to the ON position With semi auto systems turn the 3 way ball valve on backwash valve to introduce water into the valve actuator By the use of hand sampling use of a clear jar or a screen sampling device monitor the contents of
11. fold Ref Page 4 Wash gravel then install gravel and media to levels indicated on tanks Ref Page 4 Install the water stack assembly on the inlet manifold Ref Page 6 Poly tube discharge manifold to low pressure port on 3 way valve on water stack Ref Page 6 Install solenoid valves on automatic valve actuator 1 port to valve arrow on bottom of solenoid valve should point toward backwash valve Ref Page 6 Semi automatic systems refer to diagram on Page 21 then proceed to step 11 below Poly tube solenoid valve 2 ports to water stack poly tube remaining ports to drain Ref Page 6 Install the backwash discharge manifold and backwash throttling valve These are installer supplied items Ref Page 3 10 Install Control Box Stand and mount controller Ref Page 7 11 Wire solenoids and pressure differential switch Refer to controller manual Set pressure differential switch to 13 PSI Ref Page 7 12 Gradually introduce water to the system and purge air from the system Ref Page 7 13 Adjust the backwash throttling valve to about 25 open Ref Page 8 14 Manually backwash the system open backwash throttle valve until a slight amount of media is identified in the backwash stream Adjust the valve slightly closed until only trace amounts of media are detectable Ref Page 8 15 Set the delay time on the controller by timing the time it takes a valve to go from the backwash position back to the filter positio
12. ge any remaining air When 100 of system pressure is reached or after 15 minutes of operation repeat the flush cycle allowing 3 minutes flush per tank With all of the solenoid manual override knobs in the OFF position turn the flush controller on Set the flush time to 90 seconds and the delay time to 30 seconds Push the manual start button and the system should go through a flush cycle Set the Pressure Differential P D switch pointer contact at 8 PSI over the clean filter pressure differential Example Clean filter pressure differential of 5 PSI 8 PSI 13 PSI switch setting NOTE On high pressure systems those operating at 100 PSI or more it will be necessary to adjust the pressure regulator that is supplied on the high pressure water stack assembly to permit the backwash valves to open As soon as the system operating pressure has been reached loosen the lock nut on the regulator handle and turn the adjustment handle counter clockwise This will reduce the pressure on the backwash valve actuator Then put one valve into backwash using the manual override on the solenoid valve Slowly turn the adjustment handle on the regulator clockwise which increases the pressure on the backwash valve Slowly continue increasing the pressure until the backwash valve opens smoothly and completely Excessive pressure on the valve actuator could result in the backwash valve opening too fast creating water hammer and possible valve damage Insuf
13. ial pressure switch tampering 3 Solenoid s malfunctioning 3 Check connections Clean ports Check filter screen on water pickup assembly for damaged screen and clean or replace if necessary 4 Loss of sufficient system 4 Check system for pressure leaks Also pressure to actuate valve s inspect filter screen on water pickup assembly for damaged screen Clean or re place if necessary Revision 11 10 18 Sand Media Manual FILTER UNDERDRAIN OBSTRUCTION OR BLOCKAGE Infrequent flushing the lack of chemical treatment an improperly set backwash restrictor valve or operating the filters outside of the recommended flow range are the four most common causes of media filter underdrain blockage All four of these situations either singularly or in combination will result in contaminants reaching and possibly fouling the filter underdrain Evidence of underdrain blockage can be seen by monitoring the pressure gauges If the pressure differential does not return to 2 6 PSI after a flush cycle there is a possibility of underdrain contamination First the cause of the blockage must be determined and rectified i e reset the backwash restrictor valve increase the frequency of flushing adjust the flow rate to comply with the manufacturer s recommendation or install chlorine injection equipment If the cause of the blockage has been identified and corrected and the pressure differential does not return to 2 6 PSI after backflushing more se
14. n Set the delay time to the next time setting shorter than the valve travel time Ref Page 10 16 Set the backwash frequency by monitoring the time it takes the system to build a pressure differential 8 PSI greater than the clean system pressure differential Set the periodic flush time to this time or the next shorter time The time function should be the primary backwash control function Ref Page 10 17 Set the backwash duration after the initial clean up Set the duration for the time it takes clear water to discharge from the backwash line This should be a minimum of 90 seconds Ref Page 10 NOOR ON go System set up is now complete Refer to the following complete manual for more detailed instructions and troubleshooting guide SERVICE NOTE PRESSURE IS REQUIRED TO BE RELEASED FROM THE FILTER BEFORE PERFORMING ANY SERIVCE OR MAINTENANCE OPERATION ON THE FILTER WORKING ON A PRESSURIZED VESSEL CAN CAUSE INJURY AND SHOULD NEVER BE ATTEMPTED FOR ANY REASON SERVICE FEE BASED SERVICE BY RAIN BIRD AUTHORIZED SERVICE PROVIDERS IS AVAILABLE IN MOST AREAS Revision 11 10 3 Sand Media Manual GENERAL INFORMATION 1 ON SITE HANDLING A filter tank should only be lifted from under the tank or by strapping around the legs where they join the tank and lifting vertically NEVER LIFT A FILTER TANK BY THE VALVE 2 PROVISIONS FOR BACKWASH WATER DISCHARGE Although the amount of water required to backwash the filter bed is small comp
15. o connect the poly tubing from one solenoid valve to the next Install poly elbows on the remaining solenoid ports drain ports and connect a length of poly tubing long enough to be inserted inside of a leg of tank During the course of normal filter operation a small amount of water will drain from this tubing to the ground Mount the controller to controller stand that is provided Refer to the separate manual provided with the automatic backwash controller for wiring and operational instruction Revision 11 10 7 Sand Media Manual 4 1 4 2 4 3 4 4 4 5 4 6 4 7 SYSTEM START UP NOTE First time start up should be done with caution All air must be purged out of all lines and filters prior to start up Valves and pumps must be opened slowly to prevent damage to filters and the irrigation system due to entrapped air Start the system in the manual mode with the controller in the OFF position with the backwash restriction valve in the 1 4 open position Introduce water into filter system filling lines and tanks slowly The 1 2 ball valve on the water stack should be in the open position When approximately 10 PSI pressure is reached turn the manual override knob on the solenoid on tank 1 to the ON position for 1 to 2 minutes to purge entrapped air from the system Turn tank 1 OFF and repeat this process on tanks 2 3 4 etc When 50 of the system operating pressure is reached repeat the flush cycle manually to pur
16. ock must cover the wedge wire underdrain by 2 to 3 inches TABLE A MEDIA FILL LEVELS 2 3 Remove the access cover and pour in the recommended gravel pack and media The gravel pack goes in first with the filtration media loading in on top of the gravel pack Prior to filling with media inspect inside of the filters for any foreign material Filters should be filled with media to approximately the level given in chart above Do not allow any of the packaging material to get mixed in with the media Revision 11 10 6 Sand Media Manual 2 4 Clean the access cover and replace Tighten bolts alternately at 180 locations See the diagram on the cover Bolts should not be tightened over 25 foot pounds as over tightening will cut the gasket material DO NOT OVER TIGHTEN BOLTS INSTALLATION OF BACKWASH CONTROLS FOR RAIN BIRD SAND MEDIA FILTERS On filter systems that are supplied with automatic backwash controls the procedure listed below should be followed to assure correct installation of the automatic backwash controls Similar instructions should be followed for systems provided with semi automatic controls with exceptions noted below 3 1 3 2 3 3 3 4 3 5 3 6 3 7 The water stack is shipped pre assembled An assembly diagram for future reference can be found on Page 12 The water stack is connected to the inlet manifold upper screwing the 1 2 male ball valve into the 1 2 port on the inlet
17. simple schedule for start up and operational preventative maintenance The format is a simple one that can be adapted to all forms of filtration and even to other agricultural equipment The chart should be located in an accessible but protected location on the filter pad The responsible individual should be instructed to date and sign the respective block after each task is performed Seasonal start up Seasonal shut down Daily Weekly Bi Monthly Monthly Quarterly Winterization X Check media depth X Clean water pickup assembly filter Inspect all poly line connections Inspect elec con amp control box seals Lubricate backwash valve gt lt gt lt gt lt gt X lt Inspect inner valve components seals diaphram amp shaft Check coupling gaskets for leaks Check system pressure diff Xx Adjust backwash flow rate proper flow rate x gt lt gt lt gt x lt X Check flowmeter to assure X Monitor duration of flush cycle Xx Evaluate seasonal water quality fluctuations Service down stream strainer Chlorine shock treatment Revision 11 10 15 Sand Media Manual TROUBLE SHOOTING MEDIA FILTERS PROBLEM POOR FILTRATION Probable Cause Solution 1 Excessive flow through the filters 1 Reduce the flow rate or add causing coning of media and or filter unit s See manufact
18. sponding grooved coupling Using the soapy water slide the gaskets onto the inlet manifold spuds and connect manifold to the backwash valves with the grooved couplings Tighten the couplings partially then check alignment of manifolds and valves and re tighten the bolts on all couplings Connect the incoming water supply to the top inlet manifold Connect the bottom outlet manifold to the field side of the irrigation system Install PVC grooved adapters to the backwash ports on the backwash valves using the corresponding size grooved coupling Complete the assembly of the backwash manifold installer dealer provided A backwash restrictor valve must be installed within 5 feet of the last backwash valve for proper system operation NOTE The flush restrictor valve is essential for the correct operation of a sand media filter Any gate globe or butterfly valve is satisfactory if after adjustment the valve stem can be locked in place to protect against accidental or inadvertent adjustment Revision 11 10 5 Sand Media Manual 2 MEDIA INSTALLATION FOR RAIN BIRD SAND MEDIA FILTERS 2 1 The Rain Bird Sand Media Filters require the use of a gravel pack for optimum performance 2 2 The amount of 1 2 to 3 4 crushed rock and filtration media required to properly fill each filter can be found in Table A on page 6 Crushed rock must be thoroughly washed to remove dirt and other foreign material that could plug the filter underdrain The crushed r
19. the backwash discharge water Gradually open the backwash restrictor valve until a small amount of media from the backwash water appears in the discharge flow When media begins to show up in the backwash water close the backwash flow control valve until the water is essentially clear of media A small trace of media is acceptable since it is desirable that the lighter granules fines in the bed be allowed to wash out After completing the above adjustments all tanks should be backwashed extensively 3 to 5 minutes each to remove contaminants and fine material usually found in newly installed media Revision 11 10 9 Sand Media Manual RECOMMENDED BACKWASH FLOW RATES BY TYPE OF MEDIA The following table shows the approximate backwash flow rates that are required to provide for proper filter backwash All factors are per single tank Actual backwash flow should be determined as described in Section 5 Use of a flow meter for setting of backwash restrictor valve is not recommended Media Type Mean Eff Uniformity Approximate Backwash Flow Rate Media Size Coefficient GPM By Filter Size 18 24 30 36 48 S 47 20 Silica 47 mm 1 42 25 50 80 110 200 G 78 11 Granite 78 mm 1 54 25 50 80 110 200 During backwash the tanks not being backwashed supply clean water for backwashing and also supply the filtered water for the field If the volume of your source water is not adequate for both the backwash requirem
20. urer forcing contaminants through or recommended flow range the filter to outlet 2 Air in filter s causing disruption 2 Install auto or manual coning of the media bed air bleed device 3 Incorrect media in the filtration 3 Replace with proper system media See manufacturer for recommended media 4 Insufficient depth of media 5 Add media to achieve which allows contaminants to proper depth Typically pass through system 13 14 inches 5 Excessively high pressure 4 See section below differential forcing contaminants through the filters PROBLEM CONSISTENTLY HIGH PRESSURE DIFFERENTIAL Probable Cause Solution 1 Filter sealed over with con 1 Open tanks and skim away any excess taminates restricting backwash or caked contaminants from the media flow Sand beds surface Return tanks to normal service Backwash each filter tank until backwash flow runs clean 2 Insufficient backwash flow rate 2 Readjust the backwash restrictor valve and or partially close the field valve to create system backpressure oo 3 Filter media level low causing Addition of media to correct inadequate backwash level Revision 11 10 16 Sand Media Manual PROBLEM MEDIA SAND APPEARS DOWNSTREAM Probable Cause Solution 1 Incorrect filter media sand 1 Replace with the proper media i e too fine sand See manufacturers recommendations 2 Broken or damaged underdrain 2 Repair or replace PROBLEM BACKWASH VALVE S L
21. vere steps will have to be taken to clear the underdrain If organic contaminants are suspected a chlorine shock treatment may be necessary CHLORINE SHOCK TREATMENT FOR SAND MEDIA FILTERS Step 1 Remove filter manway lids and fill each tank with water up to the top weld seam It is not necessary to remove the sand Make sure that the field valve is closed so water will be held in the filter tanks Step 2 Add 10 to 20 ounces of 12 pool chlorine per square foot of filtration area to each vessel If unavailable double the amount of chlorine bleach is an acceptable alternative Step 3 Allow to stand for 12 hours BEWARE OF CHLORINE FUMES Step 4 Secure manway lids open the field valve and initiate a backflush cycle Flush each vessel for approximately 3 minutes and repeat the full sequence several times NOTE One or two shock treatments will usually be enough to unplug an underdrain that is contaminated with organics Consult the manufacturer if a high pressure differential persists SAFETY NOTE Always wear eye protection gloves and protective clothing whenever handling any chemicals A safety water rinse station should also be available to rinse off any chemicals which may come into contact with filter personnel Do not mix with other chemicals in this procedure and always induce chemicals into a water filled filter tank Revision 11 10 19 Sand Media Manual
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