Commercial
Manufacturing Tanks Since 1969
Taylex Technical and Operational
Specifications Manual for a
C.A.B.S
5,000Litres Per Day
Commercial Advanced
Blower System
A purpose designed, commercial treatment plant using a monolithic constructed tank,
therefore it is one piece of concrete with no silicone, mortar or internal joins.
Built to Last!
2750mm
Version 4 - 25-03-2013
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Page 1
INDEX
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Taylex Commercial Treatment Solutions Brochure
3
Specifications / General Descriptions / Description of Process Train
17
General Component List
21
System Drawings
47
Installation/Excavation Details
55
Lifting Requirements
57
Lifting Certification from Reid Construction Systems
57
Owner’s Manual
61
Spare Parts List
73
Electrical Specifications and Diagrams
75
Commissioning Checklist
97
Trouble Shooting
98
Optional Extras
100
Servicing Procedures
161
Field Service Report
163
Monitoring Forms
164
Taylex
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Page 2
Commercial Sewage
Treatment Solutions
A purpose designed, commercial treatment plant using a monolithic constructed tank that
is made out of one piece of concrete with no silicone, mortar or internal joins.
Built to Last!
Taylex Industries Pty Ltd 56 Prairie Rd Ormeau Q 4208 Phone: (07) 3441 5200
Fax: (07) 3287 4199 Email: alistair@taylex.com.au
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Page 3
About Taylex - The biggest producer of Treatmant Plants in Australia
Taylex was founded in 1969 and we were the first company to manufacture domestic
Aerobic Wastewater Treatment Systems (AWTS) in Australia. Taylex continues to
lead the field in both precast concrete, rotational moulding manufacturing, design &
installation of Rainwater Tanks, Home and Commercial Sewage Treatment Plants.
Taylex has a National Distribution Network which is supported by factory trained
licensed distributors. Our Distributors can supply, install, service and maintain our
range of both concrete and plastic products from Tasmania to Darwin, Perth to
Brisbane. We manufacture all our own concrete and plastic products.
Taylex’s Queensland
Head Office
Taylex is an ISO 9001 Quality Assured Company. Our range of products carries all
relevant State Government Approvals throughout Australia.
Project Management for Your Installation & Commissioning
Your Taylex consultant will project manage your installation with your builder or
project manager. They will advise on, and discuss matters with you that may affect
the final outcome for you (eg sub-surface irrigation and positioning of tanks;
possible excavation problems like rock and high water tables etc.). This ensures a
trouble-free install with maximum aesthetic value and minimal environmental impact.
Taylex’s Design Philosophy when building a Commercial Sewage
Treatment System
It’s simple… we used our 40+ years of knowledge and manufactured a range of purpose
built tanks for the commercial sewage market.
We designed these systems so that they are:
• Cost effective.
• Simple to maintain
• Able to grow with your future requirements.
• Able to cope with high flows that commercial environments can generate.
• Able to treat effluent over a full 24 hour period, this gives you the best possible output from a commercial system.
• Built with large buffer zones to handle the continued influent flow despite a breakdown; almost a full day’s capacity.
• Modular. No matter how it is configured, all our breakdown staff will be able to troubleshoot every system.
• Designed with all parts being 240 volt standard 3 pin plug, including the CABS controller. No electrician required for
parts exchange if required.
• Fitted with a self-diagnostic controller which will indicate the nature of the fault that has occured.
The system is that easy!
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About the CABS (Commercial Advanced Blower System)
The Taylex CABS System is a purpose built ‘off the shelf’ Commercial Sewage Teatment Plant. It is not a series of
Domestic Treatment Plants to make up a commercial system. It is essentially a 5,000 litre per day off-the-shelf modular
system that can be used to treat commercial sewage from 5,000, 10,000, 15,000 or 20,000 litres per day. Larger systems
such as 50,000 or 60,000 litres per day can also be created.
To our knowledge the 5,000 litres per day “CABS” tank is the only off-the-shelf module aerobic commercial treatment
system in Australia. There are tremendous benefits with the CABS design which we will cover later in this brochure.
CABS
The system Taylex has created, is called a CABS (Commercial Advanced Blower System)
How did we do it?
Taylex is the largest producer of Domestic Treatment Systems in Australia. We sell over 2,000 systems a year and we
have been in the business of sewage treatment for over 40 years. In fact, we now have our 3rd generation of family
working in our business. It took us nearly 3 years from design implementation to a completed CABS on the ground.
We have built a dedicated Commercial Tank that rectifies many of these problems that all commercial systems face.
The Taylex Difference
We build our range of commercial systems to last the test of time. They are easy to maintain and operate and they are
very price competitive.
Commercial treatment systems are expensive to buy, so don’t just pick one on price alone. The system you are about to
buy has to last many years and work constantly, 24 hours a day 7 days a week, year in year out. One of the common
reasons for future problems is that the system has not been designed correctly.
A Taylex system is scalable to your future effluent processing needs!
- Because, you can add to it at a later date
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The Design Flow Process
The 5 Stage Process
Step 1 & 2: All waste from the facility enters the primary pre-treatment chamber of the Taylex System with
liquid then flowing into the secondary/buffer chamber. The time that waste spends in both these anaerobic
chambers allows bacterial action to condition it before it is then control pumped evenly over a 24 hour period
into the aeration chamber.
Step 3: The CABS system uses an air blower to introduce oxygen into the aeration chamber. The aerobic
bacteria multiplies rapidly in this oxygen enriched environment and are thoroughly mixed with the pre-treated
liquid to ensure complete digestion of organic material. The blower is set to turn on and off as needed to
accommodate the flow of each individual treatment system.
Step 4: The liquid then flows into the clarification chamber for settlement where the remaining organics are
then pumped back to the Primary Chamber. The remaining liquid then flows through to the Irrigation
Chamber.
Step 5: Pre-treated, aerated and settled, the liquid then passes through Taylex outlet filters prior to
disinfection. The filtered liquid passes through a chlorinator, ozone unit, chlorine dioxide unit or U.V. light
which ensures the disinfection of the reclaimed effluent. Then your reclaimed effluent is returned to the
environment via spray or underground irrigation by a silent pump.
The Five Stages to a Taylex
Commercial Treatment System
1 Primary Anaerobic
All waste from the
facitity enters the
system
Digestion and
Sedimentation
Chamber
1
2 Secondary Anaerobic
Digestion and
Sedimentation
Chamber/Buffer
Zone
3
5
2
5
3
4
4
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How Does a 5000 Litres Per Day CABS (Commercial Advanced Blower System) Work?
Aeration
Primary
Effluent
The CABS is a specifically designed, monolithic, 5
chamber tank that can treat 5,000 litres of effluent
per day. The influent is treated over a full 24 hour
period using a timed buffering system.
The secret to treating commercial effluent
correctly is to treat it slowly.
Clarifier
The CABS system allows us to hold the effluent in
the secondary/buffer chamber so that it can be
treated over an extended 24 hour period. Every
hour we pump a controlled flow through the
system. The CABS will treat 208 litres every hour.
That’s 5,000 litres over a 24 hour period!
Buffer Zones
Description of a CABS Process Train
Another great feature of the CABS System is
the extremely large buffer zones.
The Buffer Volumes are as follows:
Primary =
1604 litres
Secondary = 1020 litres
Aeration =
Clarifier =
Irrigation =
1153 litres
633 litres
392 litres
Total buffer in case of emergencies (excluding the pump
station) is 4802 litres. Or nearly one day’s buffer. So, if
something goes wrong, we have a day before it becomes a
problem.
Proven Track Record:
The CABS System is a giant version of our domestic
treatment plant which we designed in the early 1990’s.
We have a proven track record with literally 10’s of
thousands of these systems being installed all over
Australia.
Irrigation Areas:
Each CABS will come with its own irrigation pump so we
can irrigate to different irrigation areas if required.
Flow Meters:
All CABS tanks are fitted with a flow meter in the irrigation
chamber that records the hydraulic volume used by each
system. This meter over time, gives us accurate records
of the volume of effluent that your CABS system
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both in quiet and busy periods.
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The 5,000 litre per day CABS system is a 5
chambered monolithic tank that uses an
extended aeration process that can be turned
on and off to adjust nitrogen levels.
The effluent enters the primary chamber and
then flows into the secondary/buffer chamber
which then pumps the desired amount of
conditioned effluent to the aeration chamber via
the CABS controller unit.
This effluent is pumped from the secondary
buffer tank to the aeration chamber once per
hour and the amount of effluent pumped across
can be varied depending on the amount of
effluent that enters the system on a daily basis
i.e 100 litres per hour 150, 208 litres per hour.
The aerated (aerobic) chamber has large areas
of submerged fixed film growth media to
promote stable biomass which acts as a
biological filter through which all effluent passes
many times before entering the clarifier.
From this the aeration chamber effluent flows
into a coned clarifier where any solid particles
remaining sink to the bottom of this cone and
are pumped via a Davey D25 Vortex pump that
operates 4 times a day for 10 seconds to the
primary chamber.
The remaining liquid then gravity feeds through
2 Taylex TFG filters which are located in the
clarifier to stop any solid particles from flowing
to the irrigation chamber.
From this clarification chamber the treated,
cleaned effluent is then gravity fed into the
irrigation disinfection chamber, the disinfected,
cleaned effluent is then pumped to the irrigation
management area.
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Increasing the System’s Capacity at a Later Stage
The CABS system was designed so that at a later stage, you can cost effectively add another CABS System as
your needs grow.
In most cases to add one CABS tank is a one day job.
Steps to putting an extra CABS tank in:
1) Dig the new CABS tank into the ground.
2) Run power to the new CABS.
3) Run a line to the irrigation field.
4) Run an extra 32mm line from the pump station to the new CABS tank.
It’s that easy!
We can make a
CABS Bigger
This is a simple process.
10,000 LITRE PER DAY SYSTEM
2 x CABS plus 1 x 10,000Lt Up-Front Pump Station
15,000 LITRE PER DAY SYSTEM
PUMP STATIONS
One pump station can supply to 2 to
4 CABS Tanks.
3 x CABS plus 1 x 10,000Lt Up-Front Pump Station
20,000 LITRE PER DAY SYSTEM
4 x CABS plus 1 x 22,000Lt Up-Front Pump Station
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Design Parameters of the CABS Tank
Water Volume
Primary
Secondary
Secondary Air Gap Buffer
Aeration
Clarifier
Total Working Capacity
Tank Construction – All Concrete
Height
2835mm
Inlet Invert (from Base)
2165mm
Tank Diameter
3450mm
5,420
1,342
2,068
3,927
1,726
Tank Dry Weight
Lid Dry Weight
14,483 Litres
Plus Irrigation
Plus Irrigation Air Gap Buffer
Total Working Capacity
Total Tank Weight
392
897
1,289
Maximum Hydraulic Loading
Operating Capacity
Total Tank Capacity
Air Volume
Primary
Secondary Air Gap
Aeration
Clarifier
Irrigation Air Gap
from Working
Volume
from Working
Volume
Total Air Volume
11.5 tonnes
2 tonnes
1,604
1,020
1,153
633
534
13.5 tonnes
5,000 Litres/day
14,483 Litres
20,716 Litres
4,944 Litres
B
65 AT 300mm FROM TOP
585
The CABS Tank
2165
2835
A Purpose Built
Commercial
Treatment System
Total Weight
13.5 Tonnes
125
95
150
A
3450
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Commercial Advanced Blower System (CABS)
Features
Benefits
A Purpose Built Commercial System
Not a Converted Domestic Treatment System
Large Purpose Built Tank
Designed to handle Commercial Effluent
Walls that go all the way to the roof
Minimising Cross Contamination Issues
Tank & Chambers poured all at the same time
No Leaking Internal Walls - Extremely Strong Tank
Purpose Built Simple Diagnostic Controller.
The System tells you exactly what’s wrong with it.
Simple to read and understand.
Timed Dose Pump in Secondary Chamber
The Effluent is treated evenly over a full 24 hour period
Every electrical item is fitted with its own Earth
Leakage Safety Switch
If there is a fault with any electrical component the
system will shut off that electrical component and not the
entire treatment plant. The alarm will then sound so
the fault can be fixed.
Timed Controlled Aeration
The Aeration motor can be turned off and on to suit the
system’s needs where possible, saving power.
Systems can be added to at a later stage
A very cost effective way to add to the systems as your
needs grow
All eletrical components are 3 pin, plug-in, plug-out
No electrician required to change components
Taylex Manufacture The Most Reliable Vessel for a Commercial Sewage Treatment Plant in Australia
Design Parameters for Effluent
The Taylex CABS Commercial System will acheive the below effluent discharge provided the incoming influent is not
greater than the table below, and/or the system is not overloaded by adverse chemicals.
Unit
Influent
Effluent
Biological Oxygen Demand (BOD5)
mg/L
400
<10
Total Suspended Solids (TSS)
mg/L
350
<10
Oil & Grease
mg/L
75
<5
Parameter
(In)
(Out)
6.5 - 8.2
pH
Faecal Coliforms, FC
cfu/100mL
<10/100
Phosphorus Removal:
Sometime in 2013, most of the major manufacturers of detergents in Australia will cease using phosphates in their
manufacturing processes as they did in America some years ago. This being the case, phosphate should not be an issue in
treatment plants but if for some reason you have a treatment plant that needs phosphate reduction, Taylex has a phosphorus
reduction system that can be fitted.
Nitrogen Reduction:
This is a very complex issue in treatment plants and there is no easy fix to nitrogen reduction. There are many ways to reduce
nitrogen in treatment systems and we have found that each site is unique and comes with its own set of challenges depending
X
on Tthe Egrade
of influent that each commercial site produces. Nitrogen reduction has to be treated on a site by site basis and we
Taylex
& Rainwater
Specialists
will not know the actual
levels thatWastewater
can be acheived
until the treatment
plant is fully functional.
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The Working Parts to a CABS (Commercial Advanced Blower System)
CABS Control Panel
Each CABS tank has only five working parts which are off the
shelf and very reasonably priced.
Taylex TFS (Taylex Filter Septic)
Taylex has a range of filters that we build. In the CABS System we use
two TFS filters which reduce solid carry over from the clarification
chamber to the irrigation chamber. These filters greatly reduce solid
Davey D25
Submersible pump to
transfer effluent from the
Secondary Chamber
matter from entering the irrigation field and assist greatly with the final
effluent results. The Taylex TFS filters are extremely robust and are
cleaned during regular routine maintenance programs.
Picture of CABS
Dual Fliter setup
Nitto Air Blower
Davey D25
Submersible
pump to transfer
effluent from
the Clarifyer to
the Primary
Chamber
Taylex TFG Filter
Toro Irrigation
Flow Meter
Submersible pump
from the Irrigation
Chamber.
The size of this
pump may vary
depending on
the irrigation
requirements
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Filter
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Self Diagnostic Commercial Controller
The CABS Controller tells us exactly what the system is doing and indicates if there is a fault.
The Taylex CABS controller has a built in visual flashing light
350.00 mm
Taylex CABS 5,000 Litres Per Day Controller
and an audible alarm if a fault occurs. The controller has a
mute button that will silence the alarm when pressed. The
alarm will automatically re-activate after 24 hours if the fault is
not rectified. The controller is also fitted with a battery backup.
Secondary Chamber
Flow Overload
FAULT
FAULT
Alarm
Mute
Alarm Mute
The buffer pump operates
once per hour x 24 hours
Maximum Setting 75 Seconds
Minimum Setting 30 Seconds
Set in 5 Second Increments
Please note the Taylex CABS Controller has
been designed to use only Davey D25 Vortex
pumps in the Clarifier, and Secondary
Chambers. The Control Panel will not work
correctly using other pumps as it measures
amperage draw.
Davey D25 VA Pumps
3.3 Litres per second
Table Indicates Litres Pumped Per Day
From Secondary Buffer Chamber to
Aeration Chamber
30 Secs = 99 Litres x 24 hours
= 2376 Litres
35 Secs = 115.5 Litres x 24 hours = 2772 Litres
40 Secs = 132 Litres x 24 Hours
= 3168 Litres
45 Secs = 148.5 Litres x 24 Hours = 3564 Litres
50 Secs = 165 Litres x 24 Hours
= 3960 Litres
55 Secs = 181.5 Litres x 24 Hours = 4356 Litres
547.00 mm
60 Secs = 198 Litres x 24 Hours
= 4752 Litres
65 Secs = 214.5 Litres x 24 Hours = 5148 Litres
70 Secs = 231 Litres x 24 Hours
= 5544 Litres
75 Secs = 247 Litres x 24 Hours
= 5940 Litres
In case of power failure the alarm will activate.
Master Fault Diagnostic Codes
Code 0 = No Fault - Normal Operation
Breaker Alarms
Code 1 = Reset Spare 1 Breaker
Code 2 = Reset Spare 2 Breaker
Code 3 = Reset Ozone Generator Breaker
Code 4 = Reset Chlorine Dioxide Generator Breaker
Code 9 = Reset Clarifier Pump Breaker
Code 10 = Reset Buffer Pump Breaker
Code 20 = Reset Air Blower Breaker
Code 30 = Reset Irrigation Pump 1 Breaker
Code 31 = Reset Irrigation Pump 2 Breaker
Float Alarms
Code 40 = Master High Water Alarm located in Buffer tank
Code 41 = High Water Alarm in Irrigation Chamber
Code 42 = High Water Alarm in Wet Weather Storage Tank
Other Alarms
Code 50 = Buffer Tank Pump Impeller Jammed
Code 60 = Air Blower - No Air Flow
Code 70 = Replace Battery
Pressing Alarm Mute will only Silence Audible
alarm for 24 hours. Fault must still be rectified.
Code
4
Code
3
Chlorine Dioxide
Generator
Ozone Generator
Code
20
If Connected
Code
10
Code
9
Buffer Pump
Clarifier Pump
Code
30
Code
31
(1)
(2)
If Connected
If Connected
TAYLEX CABS 5,000 Litres Per Day System
Spare 1
Spare 2
Earth Leakage
Circuit Breaker
Earth Leakage
Circuit Breaker
Code
1
Code
2
Switch Off Main Isolator Located
Outside Control Box
Before Opening Door.
N1597
Having a large modular system like the CABS has some great advantages...
The CABS is a very simple system to maintain and operate due to its simple design. Each CABS comes with a simple
self diagnostic controller that will give you a fault code which will indicate the nature of a fault.
Breakdowns: Due to our large buffer system, if a CABS breakdown occurs due to power loss etc, and it can’t be fixed
immediately, you can by-pass the affected CABS unit and allow the other units to take the extra load for a short period of
time. Each CABS system has nearly one day’s buffer of extra capacity before the sewerage causes a problem.
Electrical Components: All electrical components are 240 volt standard 3 pin plug, including the CABS controller so no
electrician is required for failed parts exchange! Every electrical part in the system is protected by an individual circuit
breaker allowing the continued operation of the system in the event of a single component failure. Fault-finding is then a
quick and easy process.
For remote sites: Because of the CABS’ simple nature, Taylex will supply our customers, if required, with the four
replaceable spare parts in a CABS system that your staff can fit when required.
The system is that easy!
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Why the Tank is such a good design
To our knowledge, Taylex is the only company in Australia that has
specifically built a concrete tank to make a commercial system. It is not
a rainwater tank, or a domestic treatment system that has been
converted to make a commercial treatment plant.
PRIMARY
TANK
THE TANK
Pictured to the right is a photo of why the CABS is such a good
AERATION
TANK
IRRIGATION
TANK
SECONDARY
TANK
CLARYFIER
TANK
system. Taylex has specifically designed a commercial tank that has all
the boxes ticked.
A large monolithic, five chambered tank that is made out of
one piece of concrete.
The chambers go all the way to the roof to stop cross contamination
between chambers.
The tank is unbelievably strong due to its simple but effective design.
There are no silicones, mortar or epoxy used that generally fail after
several years of sitting in sewerage.
Large buffer zone built into the tank for unforseen breakdowns due to
power loss or equipment failure. (Nealy one full day’s buffer)
And probably the most important part about the tank. Taylex has been
making this tank for domestic use for more than 15 years and we have
A CABS tank being
de-moulded
never had a structural tank failure in the field. All we have done is scale
it for commercial use.
OUR TANK DESIGN IS THAT GOOD!
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2 x CABS Tanks installed at the Lake Moogerah SkiPage
Club13
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The Taylex
Yatala
Factory
TAYLEX WARRANTY
CABS (Commercial
Advanced Blower System)
15 year manufacturer’s warranty.
There is a 15 year warranty on the precast
concrete tank including baffles and a 12
month warranty on all electrical and
mechanical components, including the
irrigation pumps and blower, control panel
and a 12 month extended warranty is
available.
Please refer to your Taylex distributor for more
information.
Darwin
Cairns
Townsville
Bowen
Mackay
Rockhampton
Biloela
Bundaberg
Roma
Nanango
Toowoomba
Hervey Bay
Sunshine Coast
Laidley
Warwick
Tamworth
Mildura
Perth
Orange
Deniliquin
Kyabram
Adelaide
1300 660 225 Australia Wide
Bendigo
Melbourne
Canberra
Albury
Shepparton
Seymour
Gold Coast
Tweed Heads
Ballina
Coffs Harbour
Port Macquarrie
Port Stevens
MacMasters Beach
Sydney
Mossy Point
Bega
Stratford
Gippsland
Hobart
se
cy
cl e
www.taylex.com.au
Re U
Taylex Industries Pty Ltd 56 Prairie Rd Ormeau Q 4208 Phone: (07) 3441 5200
Fax: (07) 3287 4199 Email: alistair@taylex.com.au
eclaim
R
Re
14-11-2012
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Page 14
PRIMARY
TANK
IRRIGATION
TANK
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AERATION
TANK
SECONDARY
TANK
CLARYFIER
TANK
Wastewater & Rainwater Specialists
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La
akeMoog
gerahSkkiClub
Mo
ountSam
msonStatteSchooll
Mullum
mbimbySSchool
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SPECIFICATIONS
Taylex Commercial Advanced Blower System (CABS)
General Description
The Taylex CABS aerated Wastewater Treatment System (AWTS) is
designed to treat the wastewater from a commercial site with a hydraulic
influent loading up to 5,000 litres per day.
The Taylex CABS AWTS is contained in one ver cal axis type concrete
collec on well with a design capacity of 20,716 litres and an opera onal
capacity of 15,772 litres.
The opera onal water level in the primary, secondary, aera on and
clarifier chambers is 1985mm from the base.
The Taylex CABS unit consists of:
1.
2.
1 x primary pre- treatment chamber with a capacity of 5,420 litres.
1 x secondary pre-treatment flow balance chamber with a working
capacity of 3,410 litres
1 x aera on chamber with a capacity of 3,927 litres containing Bio-Blok®
media panels with a surface area of 800m²
1 x sedimenta on / clarifier chamber with a capacity of 1,726 litres
1 x irriga on pump chamber with a capacity of 1,289 litres
3.
4.
5.
Water Volume
Primary
Secondary
Secondary Air Gap Buffer
Aeration
Clarifier
Total Working Capacity
5,420
1,342
2,068
3,927
1,726
14,483 Litres
Plus Irrigation
Plus Irrigation Air Gap Buffer
Total Working Capacity
392
897
1,289
Air Volume
Primary
Secondary Air Gap
Aeration
Clarifier
Irrigation Air Gap
Total Air Volume
from Working
Volume
from Working
Volume
1,604
1,020
1,153
633
534
4,944 Litres
A chlorine disinfec on unit is installed on the outlet pipe of the clarifier (standard) and can be removed if chlorine
disinfec on is not required.
Description of a CABS Process Train
The 5,000 litre per day CABS system is a 5 chambered monolithic tank that uses a submerged, fixed media, extended
aera on process. The aera on in the Taylex CABS unit can be turned on and off as required to adjust nitrogen reducon levels.
Primary Chamber
Raw effluent from the site enters the primary chamber of the CABS unit. Inside the primary tank, anaerobic breakdown occurs. The primary tank is sized to allow sufficient residence me to ensure sufficient BOD reduc on has
occurred in this process. The effluent then flows via a submerged out let into the secondary Buffer chamber. The
submerged outlet ensures that large floatable material and heave sludge is held back in the primary chamber.
Secondary Chamber/ Buffer Chamber
Within the secondary chamber further anaerobic breakdown of the wastewater is achieved. This chamber also acts
as a buffer chamber.
The buffer chamber stores peak flows and allows 24 hour emergency storage. A Davey D25 Vortex pump is fi ed
within the chamber. This pump is operated by a state of the art Taylex CABS electronic control panel, and programmed to pump the required volume of condi oned effluent into the aera on chamber. It is factory set to pump
once every hour, the volume pumped can be varied depending on the volume of the influent entering the system on
a daily basis.
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The secondary chamber is fi ed with two mercury float switches. One is a high water level alarm and
the other is a counter float. This counter float will count the amount of mes the High Water Level alarm
has been triggered. Using this informa on the service person can if required, re-adjust the volume that is
pumped to the aera on chamber to suit the volume of the influent into the system.
Aera on Chamber
Aera on chambers contain sufficient submerged fixed film growth media to ensure there is a large surface
area per unit volume for micro-organisms to grow on to promote stable biomass. This becomes a biological filter through which the effluent passes many me before leaving the chamber. Fine bubble diffusers
are installed at the base of the chambers to ensure efficient oxygen distribu on and thus providing a high
rate of biomass produc on on the filter media. The placement of the diffusers is cri cal to the designed to
ensure uniform aera on.
Clarifier Chamber
From aera on chamber effluent is gravity fed into a coned clarifier where it is further polished. Solid parcles se le to the bo om of the cone as ac vated sludge. This ac vated sludge is then pumped via a Davey
D25 Vortex pump back to the oxygen starved anaerobic primary tank this pump operates 4 mes a day for
10 seconds. The remaining now polished liquid is then gravity feed through two Taylex TFG filters which are
located in the clarifier and through to the irriga on chamber.
Irriga on Chamber
Depending on the design of the en re system the inlet to the irriga on chamber is typically fi ed with
Chlorine dispensers to disinfect the effluent. This can be removed and other systems used such as Chlorine
Dioxide, Ozone and Ultra Violet systems.
Most systems will require wet weather storage tanks prior to irriga on. In these systems the effluent will be
disinfected prior to store in the wet weather chamber, Ozone can also be fi ed within this chamber. There
are many different op ons available and will be site specifically designed.
Once the wastewater is full treated the effluent is then pumped to the effluent irriga on management
area. This area is aging designed base on the area and requirements of the local regulatory authority.
1 Primary Anaerobic
All waste from the
facitity enters the
system
Digestion and
Sedimentation
Chamber
1
2 Secondary Anaerobic
Digestion and
Sedimentation
Chamber/Buffer
Zone
3
5
2
5
3
4
4
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 18
Effluent Compliance Criteria
1. Biological oxygen demand (BOD5) ≤ 10mg/L
2. Suspended solids (ss) ≤ 10 mg/L
3. Thermotolerant coliforms (TC) ≤ 10 organisms per 100ml
** Note
The above effluent criteria is based on data provided by Sci Qual Interna onal from results taken from
tes ng on our domes c ABS (Advanced Blower System).
As Taylex has no control over effluent entering the system we cannot guarantee the final effluent
results.
Control
The system is controlled via a mer which has been parameterized on site to specific requirements.
Faults are signalled visually via the mer display as well as acous cally via an alarm mounted within
the control panel.
The control system is equipped with a mains independent power failure monitor func on.
The control panel can also be connected to a modem if required.
Power Saving mode
The control system can be set to the requirements of each site by calcula ng the daily flow and adjusting the pump mer in the flow balance chamber to suit.
Sludge Removal
Sludge deposit removal will be required as determined necessary by a licensed Taylex technician or the
client.
Servicing
Rou ne maintenance servicing of the Taylex CABS is to be scheduled a minimum of 4 mes per year or
as per the site specific approval.
Refer to the field service report sheet for tes ng requirements.
Tank
Material
Height
Diameter
Invert
Working volume
Total volume
Weight
EX
T
TM
Tanks
Taylex
Tanks
Concrete
2,835mm
3,450mm
2,165mm
15,772 litres
20,716 litres
14 tonnes
Wastewater & Rainwater Specialists
Page 19
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 20
GENERAL COMPONENTS LIST
1. Inlet Baffle
2. 100mm Sweep Tees
3. Air Diffuser
4. Bio Blok®
5. 316 Stainless Steel Pump Plate
6. DAVEY D 25 VA Flow Balance Pump
7. DAVEY D25 VA Sludge Return Pump
8. DAVEY D42 Irrigation Pump
9. Flow Meter
10. TFG Filter
11. Chlorine Tube
12. Flow Balance Float
13. High Water Flow Balance Chamber Float
14. Sludge Return Float
15. High Water Irrigation Float
16. NITTO 200Lt Blower
17. 316 Stainless Steel Blower Box Cover
18. Taylex CABS 5,000LPD Controller
19. BNR Mine Spec 316 Stainless Steel Control Box
20. 12V Trickle Charger plus Backup Battery
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 21
1. CABS Inlet Baffle
Material:
Size:
Supplier:
ABS
410mm x 110mm x 160mm
Maxwell Downs
2. 100mm Sweep Tee
Placement
within
system:
Material:
PVC
Size:
Length:
Width:
Depth:
EX
T
TM
Tanks
Taylex
Tanks
770mm
110mm
200mm
Wastewater & Rainwater Specialists
Watermark AS/NZS 1260
Lic No. 2157
SAI Global
Manufacturer:
Pipe King or Equivalent
Page 22
3. Air Diffuser/Board Membrane Micropore Aerator
Top View
Placement within system:
Centre of Aeration Chamber Under BioBlok
Size:
Length:
Width:
Model:
Rubber Membrane Material:
Rubber Membrane Thickness:
Aeration Suface Area:
Hole Number of Single Membrane:
Bubble Diameter:
Membrane Service Life:
Standard Aeration Rate:
Resistance Loss:
Standard Oxygen Transfer Efficiency:
Standard Oxygenation Capacity:
Theroretical Dynamic Efficiency:
Working Area:
Manufacturer:
Bottom View
660mm
160mm
UD660
USA Dupont EPDM
1.8-2.0mm
0.1000m2
12,994pcs
0.8-1.9mm
>5years
8.0m3/hr
2.0-4.3kPa
>40% (6m water depth)
>.099kg O2/h
>9.2kgo2/kw.h
0.5~2.5m2/pcs
U&D Environmental
Equipment Technology
Co., Ltd
Air Diffuser with 316 Stainless Steel Bracket
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 23
4. BioBlok 200 Fitted into a 316 Stainless Steel Frame
Placement within
system:
Within Tank - Centre
Aeration Chamber
BioBlok with Stainless Steel Frame
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Manufacturer:
Dimensions:
Width:
Depth:
Height:
Expo-Net
1100mm
550mm
1100mm
Page 24
Biological Wastewat
W
ter Treatment witth BIO-B
BLOK®
BIO-BLOK®
filter media
As a resu
ult of many
y years of R
R&D, a structured filte
er
media ha
as been de
eveloped. T
The media has prove
ed
extremely
y efficient in
n biologicall treatment of domesttic
sewage, industrial wastewateer and pro
ocess wate
er
within the
e aquaculture field. Thhe media is
s made from
m
the enviro
onmentally friendly maaterial polye
ethylene an
nd
consists of net tube
es, which aare welded
d together to
t
form a sq
quare block
k. The uniqque surface structure of
o
the many net tubes provides
p
a l arge accessible surfacce
area for enhanced
e
biiological groowth on the
e filter media
a.
The filter m
media is ca
alled BIO-BLOK® and tthe surface
e acts as a substrate ffor specialis
sed bacterial
strains, wh
hich are able
e to treat an
nd degrade a wide range of waste
ewater qualiities.
The treatm
ment capacity of a biological filterr depends on the qua
antity of baccteria that the
t
filter ca
an
sustain. Th
he larger a specific
s
surrface area iss, the largerr the bacterrial populatioon.
Future con
nstruction, refurbishme
r
ent or upgra
ading of bio
ological was
stewater treeatment plan
nts is merely
a matter of creating optimal
o
‘livin
ng condition
ns’ for the bacteria.
b
BIO
O-BLOK® hhas excellent propertie
es
in this resp
pect, and the result is an
a increase in treatmen
nt capacity.
Table 1: Technical speccifications Bio
o-Blok®
1
100
BIO-B
BLOK®
150 HD
BIIO-BLOK®
200 HD
BIO-BLOK®®
D
300 HD
BIO-BLOK®
S
Surface (m2/m
m3)
1
100
150
200
300
F
Flow area
70
0%
64%
60%
51%
V
Void percenta
age
90
0%
88%
82%
65%
Type of BIO-BLOK®
T
Tube diamete
er
D
Dimensions, standard module
70
0mm
55mm
55mm
36mm
54x54
4x55 cm
55x
x55x55 cm
55x55x55 cm
m
55x25x55cm
A biologica
al wastewatter treatmen
nt plant in w
which BIO-B
BLOK® filter media has been installed has thu
us
unique flexxibility and, if necessary, the abil ity to increa
ase its capa
acity to hanndle flow va
ariations an
nd
load chang
ges, which inevitably oc
ccur in the inlet to all waste
w
water treatment pplants.
Table 2: Sp
pecific biologiically active surface
s
area
a for BIO-BLO
OK® filter me
edia
EX
T
TM
Tanks
Filter type
t
Dry condition
BIO-BLO
OK® 100
BIO-BLO
OK® 150
BIO-BLO
OK® 200
BIO-BLO
OK® 300
100
1 m2/m3
150
1 m2/m3
200
2 m2/m3
300
3 m2/m3
Taylex
Tanks
1mm
Thickness of bio-film
2mm
3mm
165 m2/m3
268 m2/m3
312 m2/m3
312 m2/m3
233 m2/m3
387 m2/m3
426 m2/m3
426 m2/m3
Wastewater & Rainwater Specialists
4mm
299 m2/m3
507 m2/m3
366 m2/m3
560 m /m
2
3
Page 25
Cross secction of for BIO-BLOK®
A “tthin” bio-film
m results in a
rela
atively low specific
s
biologically active surface
e area
Bio-film growth
g
increeases the
specific biologically aactive surfac
ce
area signiificantly
equirementts for biolo
ogical filterr media in order
o
to ac
chieve optim
mal treatment results
s:
General re
1. The
e filter mediia should ha
ave a relativvely rough surface
s
in order
o
to enhhance rapid
establishment of a biologically active
e surface (bio-film)
2. The
e filter mediia must hav
ve a structurre that mak
kes back wa
ash and cleaaning opera
ations on sitte
posssible. Cana
als have to be vertical and through
h the entire media coluumn.
3. The
e filter mediia must hav
ve a structurre that ensu
ures optimal oxygen traansfer to the
e bio-film i.e
e.
it m
must have sufficiently high porosityy.
4. The
e media mu
ust never clo
og and it mu
ust have se
elf-cleaning properties. The structu
ure must
allo
ow shed bio
o-film fragme
ents to passs unhindere
ed througho
out the filterr.
5. The
e filter mediia modules should be cconstructed
d with circula
ar or oval thhreads. Bac
cterial growtth
on a circular or
o oval surfa
ace increase
es the diam
meter, thus in
ncreasing thhe specific biologically
active surface area. (Plea
ase note! Th
his is in opp
position to media
m
with leevel surface
es on which
h
the
e specific bio
ologically ac
ctive surfacce area is co
onstant).
6. The
e filter mediia has to be
e biologicallyy and chem
mically non-d
degradable .
7. The
e filter mediia must be self-support
s
tive and me
echanically strong. It m
must be able
e to carry
ove
erlying mate
erial and personnel sho
ould be able
e to walk fre
eely and peerform servic
ce tasks
with
hout deform
mation of the
e media.
8. The
e filter mediia must be UV
U stable a
and it must tolerate
t
poe
etical variatiion in tempe
erature.
9. The
e filter mediia should be
e made from
m an enviro
onmentally compatible
c
m
material (i.e
e. no PVC
com
mpounds orr glue).
10. The
e filter mediia must be modular
m
an d easy to handle. This will ease innstallation and
a potentia
al
tem
mporary rem
moval in order to perforrm service tasks below the filter.
11. Th
he filter med
dia must be
e easy to fit into any typ
pe of tank or
o bio-reactoor without any waste off
spa
ace and ma
aterial.
BIO-BLOK® filter media ccomply with
w all of the
t above
e criteria!
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 26
Product:
pe BIO-BLO
OK® 200 (200 m2/m3)..
Typ
by:
Produced b
EX
XPO-NET Da
anmark A/S
S.
Raw materrial:
Polyethylene that is a 100% recy
yclable mate
erial.
Filter form::
Constructed o
of 10 x 10
0 net tube
es that aree subseque
ently welde
ed
tog
gether in the
e tube ends so that the filter becom
mes a cubic
cal block.
Standard d
dimensions::
App
prox. 55 x 5
55 x 55 cm.
The
e BIO-BLO K® units arre available
e in heightss (length of block tubess)
from
m 45 to 75ccm.
urface:
Specific su
200
0 m2/m3 in dry conditio
on. Depend
ding on the thickness of
o the biofilm
m,
the
e accessible
e biologicall surface varies from 200 m2/m3 to approxx.
426
6 m2/m3.
Horizontal free flow arrea:
App
prox. 64 %
Vertical fre
ee flow area
a:
App
prox. 15 %
Void perce
entage:
App
prox. 82 %
Net weightt:
App
prox. 60 kg//m3
Uplift presssure withou
ut
biofilm coa
ating:
g/m3
App
prox. 120 kg
Density:
App
prox. 0.55 g
gr./cm3
Maximum vvertical
evenly disttributed load
d:
App
prox. 5,000
0 kg/m2 (ple
ease ask our technical departmentt).
Working w
weight:
Depends on the workin
ng form of the wasteewater trea
atment plan
nt.
ganic decom
mposition or nitrification.
Org
Maximum ttemperature
e:
80°° C.
Average diiameter of
the vertical passages is:
Inside approx.. Ø 45 mm
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 27
5. 316 Stainless Steel Pump Plate
Placement within system:
Flow Balance Chamber and Irrigation Chamber
Manufacturer:
Material:
Dimensions:
Width:
Depth:
Height:
EX
T
TM
Tanks
Taylex
Tanks
Lyndael
316 Stainless Steel
250mm
250mm
120mm
Wastewater & Rainwater Specialists
Page 28
6/7. Davey D25VA
Placement within system:
Flow Balance Chamber and Clarifyer Chamber
Manufacturer:
Dimensions:
Width:
Height:
Depth:
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Davey
205mm
395mm
130mm
Page 29
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 30
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 31
8. Davey D42A
Placement within system:
Irrigation Chamber
Manufacturer:
Dimensions:
Width:
Height:
Depth:
EX
T
TM
Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
Davey
195mm
475mm
235mm
Page 32
SUBMERSIBLE DRAINAGE PUMPS
Model Numbers:
D42A, D42M,
D42A/B, D53A/B
SUMP PUMPS
PRODUCT
DESCRIPTION
Submersible sump pump with two and
three impeller designs for higher
pressure, up to 45m head
A P P L I C AT I O N S
•
•
•
•
•
D42A/B, D53A/B
F E AT U R E S & B E N E F I T S
Double mechanical seal, one in oil
bath on motor and extra mechanical
seal on pump
• Superior reliability
• Long service life
Corrosion resistant 304 stainless steel
shaft, motor shell and fasteners
• Long service life
D42A/B & D53A/B have cast 316
stainless steel motor caps and super
tough engineered thermo plastic
pump casing
• Outstanding corrosion resistance
• Long life
Centrifugal multistage 2 & 3 impeller
designs
• Higher pressures & increased
efficiency
Closed vane impellers with long
engagement “D” drives
• Positive operation
• Long service life
T
D42A & D42M have labyrinth
impeller neck rings
• Maintain pump performance
E
• XLess susceptible to wear
TM
Tanks
Taylex
Tanks
D42A/B & D53A/B have patented
independently floating neck rings
• Outstanding pump performance
• Long pump life
Corrosion resistant hard wearing
polycarbonate impellers
• Long service life
Corrosion resistant stainless steel fine
mesh suction strainer with large
surface area
• Prevents blockages of the pump
by solids
In-built automatic thermal overload
• Protects the motor in the event of
blockage or voltage supply
problems
HO7RNF oil resistant leads, 10 metres
long with 3 pin power plug
• Easy to connect to power supply
• Longer life in dirty water
Wastewater & Rainwater Specialists
“A” suffix models equipped with present
length automatic float switch fitted for
automatic operation.
O P E R AT I N G L I M I T S
Capacities to
D42A,M
D42A/B, D53A/B
110 lpm
130 lpm
26m
32m, 45m
Max. total head
Max. submergence
12m
Max. pumped
water temperature
40oC
Max. soft solids
1.9mm O.D.
Outlet size (BSP)
1” F
Suitable Fluids
Clean water of neutral pH containing up
to 1% small solids. Some wear should be
expected while pumping hard solids in
suspension.
H/O & MFG SCORESBY
D42A, D42M
Lawn & garden irrigation
Sump emptying to higher heads
Treated effluent disposal
Water transfer from wells
A/B models are specially designed for
non potable rainwater applications
Page 33
T E C H N I C A L S P E C I F I C AT I O N S
M AT E R I A L S O F C O N S T R U C T I O N
PA R T
HYDRAULIC PERFORMANCE
50
M AT E R I A L
45
(D42A/B), (D53A/B)
Diffuser and blanking ring
Mechanical seal - pump
Mechanical seal - motor
Shaft seal elastomer
Pump shaft
Orings
Motor shell
Bottom bearing housing
Glass filled noryl
Carbon/ceramic
Silicon carbide/ceramic in
oil bath
Nitrile rubber
304 stainless steel
Nitrile rubber
304 stainless steel
Cast iron - FC200 (D42A&M)
Cast 316 stainless steel
40
35
Total Head ( m )
Glass filled polycarbonate
304 stainless steel
Cast iron - FC200 (D42A&M)
Glass filled polycarbonate
Impeller
Lock nut
Pump casing
D53 A/B
30
20
D42A & M
15
10
5
0
(D42A/B), (D53A/B)
0
Cast iron - FC200 (D42A&M)
Cast 316 stainless steel
Upper motor cover
D42A/B
25
20
40
60
80
Flow ( l/min )
100
120
140
(D42A/B), (D53A/B)
Handle
Fasteners
Float & power supply leads
304 stainless steel
304 stainless steel
HO7RN-F oil resistant
E L E C T R I C A L D ATA
Supply voltage
Supply frequency
Speed
Full load current
Locked rotor current
Input power (P1)
Output power (P2)
IP rating
Insulation class
Starting
Lead
DIMENSIONS
D42, D42A/B
D53A/B
220-240V
50Hz single phase
2 pole, 2850rpm
4.0A
5.7A
14A
0.94kW
1.31kW
0.60kW
0.84kW
X8
Class F
P.S.C.
10m long
I N S TA L L AT I O N & P R I M I N G
Use a rope to position and retrieve the pump. Do not lower or retrieve the pump
using the power lead as this may damage the cable entry seals, causing water leaks
and unsafe operation.
Don’t use this product for recirculating or filtering swimming pools, spas, etc.
While these pumps are built to high safety standards, they are not approved for
installations where people will be in the water while they are operating.
Don’t pump abrasive materials. Sand and grit in the water being pumped will
accelerate wear, causing shortened pump life.
Keep your pump clean, particularly in situations where lint, hair or fibrous materials
may get bound around the pump shaft. Regular inspection and cleaning will
extend pump life.
Make room for the float switch to operate. Automatic models have a float switch
to turn them on when the water level rises and turn them off again when it has
been pumped down to the safe operating level of the pump. If the float switch is
not free to rise and fall, correct pump operation may not be possible.
Don’t run your pump dry. Non-automatic models must be switched off manually
or by way of an external float/level switch when the water level is reduced to the
top of the pump housing.
Model
D42A
D42M
D42A/B
D53A/B
A
B
C
D
E
F
475
475
475
535
130
130
130
170
370
370
370
430
235
235
235
235
195
195
195
195
330
330
330
330
Outlet
Net
B.S.P. Weight (kg)
1”F
1”F
1”F
1”F
20
19.5
18.5
19.5
All dimensions in mm unless otherwise stated.
This literature is not a complete guide to product usage. Further information is available from your Davey dealer, Davey Customer Service Centre and
from the relevant product Installation and Operating Instructions. This data sheet must be read in conjunction with the relevant product Installation
and Operating Instructions and all applicable statutory requirements. Product specifications may change without notice.
® Davey is a registered trademark of Davey Products Pty Ltd. © Davey Products Pty Ltd 2001.
Davey Water Products Pty Ltd
Member of the GUD Group
EX
T
TM
Tanks
Taylex
Tanks
ABN 18 066 327 517
Head Office and Manufacturing
6 Lakeview Drive,
Scoresby, Australia 3179
Ph:
+61 3 9730 9222
Fax:
+61 3 9753 4100
Website: davey.com.au
Customer Service Centre
Ph:
1300 367 866
Fax:
1300 369 119
E-mail: sales@davey.com.au
Interstate Offices
Sydney • Brisbane • Adelaide
Perth • Townsville
Wastewater & Rainwater Specialists
International
6 Lakeview Drive,
Scoresby, Australia 3179
Ph:
+61 3 9730 9121
Fax:
+61 3 9753 4248
E-mail: export@davey.com.au
Germany
Kantstrasse 53,
04275 Leipzig
Ph:
+49 341 301 0412
Fax:
+49 341 301 0413
E-mail: akrenz@daveyeurope.com
USA
Ph:
+1 630 898 6976
Website: daveyusa.com
E-mail: sales@daveyusa.com
Davey Water Products
– New Zealand
7 Rockridge Avenue,
Penrose, Auckland 1061
Ph:
+64 9 570 9135
Fax:
+64 9 527 7654
Website: daveynz.co.nz
E-mail: sales@daveynz.co.nz
Davey Spa – New Zealand
2 Rothwell Avenue,
North Harbour, Auckland 0632
Ph:
+64 9 415 8622
Fax:
+64 9 415 8621
Website: spa-quip.co.nz
E-mail: service@spa-quip.co.nz
Page 34
DPM128-4/5K/1108/IPM supersedes DPM128-3a/0806/WEB
9. Flow Meter
Placement within system:
Irrigation Chamber
Toro A
Austrralia
Supplier:
Toro Australia
Sin
ngle Je
et Watter Me
eter
(BSP Threaded Irrigation Meter 15-25mm)
Features of the thrreaded Irrig
gation Metter
x High Reliability
y
x Lon
ng term meter accuracyy
x Com
mpletely sea
aled dial – S
Stops moistture entering
x The
e body is ma
ade of high quality bras
ss with anti--corrosion ssurface trea
atment
x Minimal moving
g parts
king pressu re: 16 Bar (1600kPa)
(
x Maxximum work
x Maxximum work
king temperrature: 50°C
C
x Hot water availlable on req
quest – Max
ximum work
king Tempeerature 90 °C
C
x Pulsse output sttandard
x Com
mpatible witth Data Log
gging Units
x Com
mes comple
ete with cou
uplings-threa
aded BSP
x 12 Months
M
Rep
placement W
Warranty
SPECIFICATIONS
Size (MM
M
Maximum
m Flow m³/h (Qmax)
Optimum
m Flow m³/h
h (Qn)
Transitio
onal Flow lk
k/h +/-2% (Q
Qt)
Minimum
m Flow l/h+//-5% (Q min
n)
Litres / Pulse
P
Length (L)
( (mm)
Width (B
B) (mm)
Height (H
H) (mm)
EX
T
TM
Tanks
Taylex
Tanks
15
2
1.5
120
30
10
110
81
86
20
5
2.5
200
50
10
130
81
86
Wastewater & Rainwater Specialists
25
7
3.5
0
280
70
10
160
0
81
93
Page 35
10. Taylex TFG Filter
2 Filters in every 5,000 Litres Per Day System
Placement within system:
Clarifier Chamber
Manufacturer:
Dimensions:
Width:
Height:
EX
T
TM
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Taylex
Tanks
Wastewater & Rainwater Specialists
Maxwell Downs
330mm
405mm
Page 36
11. Solid Chlorine Dispenser Tube
Placement within system:
Irrigation Chamber
Manufacturer:
Dimensions:
Width:
Height:
EX
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Tanks
Taylex
Tanks
Maxwell Downs
90mm
340mm
Wastewater & Rainwater Specialists
Page 37
12/13/14/15.
/13/14/15. High Level Mercury Float Switch
Placement within system:
Flow Balance Chamber
Clarifyer Chamber
Irrigation Chamber
Supplier:
EX
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TM
Tanks
Taylex
Tanks
2 of
1 of
1 of
Recycled Water Solutions
Wastewater & Rainwater Specialists
Page 38
16. NITTO 200lt Blower
Placement within system:
Under Stainless Steel Blower Box Cover on Lid
EX
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Tanks
Taylex
Tanks
Supplier:
Nitto
Demensions:
Length:
Width:
Height:
410mm
212mm
268mm
Wastewater & Rainwater Specialists
Page 39
LA BLOWER
Blower
MOTOR MAGNET
PISTON SYSTEM
200
LAM-
Airflow Characteristics
Specifications
300
8.83
50Hz
200
7.06
60Hz
5.30
100
3.53
0.015
0.15
2.13
Rated Frequency
50 Hz, 60Hz
Rated Pressure
0.020 MPa {0.20 kgf/!}, 0.20 bar or 2.84 psig
Rated Airflow
150
0.01
0.1
1.42
120 V, 220 V, 230 V, 240 V AC
Power Supply
10.59
250
Airflow
LAM-200
(cfm)
( L/min)
LAM-200
0.02
0.2
2.84
0.025
0.25
3.56
Power Consumption
200 L/min {7.06 cfm}
215 W / 50 Hz
215 W / 60 Hz
0.03 (MPa)
0.3 (bar)
4.27 (psig)
Weight
12.3 kg {27.1 lbs}
Discharge pressure
Application Examples
Liquid Mixer Bubbling
Home Aerobic Sewage
Treatment System
Sketch Drawing and Mounting Dimensions Diagram (mm)
418
383
53
ø 26
268
212
242
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Tanks
Wastewater & Rainwater Specialists
126
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Tanks
Wastewater & Rainwater Specialists
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Taylex
Tanks
Wastewater & Rainwater Specialists
Page 42
17. 316 Stainless Steel Blower Box Cover
Placement within system:
On Lid
EX
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Tanks
Taylex
Tanks
Supplier:
Taylex
Dimensions:
Length:
Width:
Height:
800mm
630mm
430mm
Wastewater & Rainwater Specialists
Page 43
18. Taylex CABS 5,000 Litres Per Day Controller
350.00 mm
Taylex CABS 5,000 Litres Per Day Controller
Secondary Chamber
Flow Overload
FAULT
FAULT
Alarm
Mute
Alarm Mute
The buffer pump operates
once per hour x 24 hours
Maximum Setting 75 Seconds
Minimum Setting 30 Seconds
Set in 5 Second Increments
Please note the Taylex CABS Controller has
been designed to use only Davey D25 Vortex
pumps in the Clarifier, and Secondary
Chambers. The Control Panel will not work
correctly using other pumps as it measures
amperage draw.
Davey D25 VA Pumps
3.3 Litres per second
Table Indicates Litres Pumped Per Day
From Secondary Buffer Chamber to
Aeration Chamber
30 Secs = 99 Litres x 24 hours
= 2376 Litres
35 Secs = 115.5 Litres x 24 hours = 2772 Litres
40 Secs = 132 Litres x 24 Hours
= 3168 Litres
45 Secs = 148.5 Litres x 24 Hours = 3564 Litres
50 Secs = 165 Litres x 24 Hours
= 3960 Litres
55 Secs = 181.5 Litres x 24 Hours = 4356 Litres
547.00 mm
60 Secs = 198 Litres x 24 Hours
= 4752 Litres
65 Secs = 214.5 Litres x 24 Hours = 5148 Litres
70 Secs = 231 Litres x 24 Hours
= 5544 Litres
75 Secs = 247 Litres x 24 Hours
= 5940 Litres
Master Fault Diagnostic Codes
Code 0 = No Fault - Normal Operation
Breaker Alarms
Code 1 = Reset Spare 1 Breaker
Code 2 = Reset Spare 2 Breaker
Code 3 = Reset Ozone Generator Breaker
Code 4 = Reset Chlorine Dioxide Generator Breaker
Code 9 = Reset Clarifier Pump Breaker
Code 10 = Reset Buffer Pump Breaker
Code 20 = Reset Air Blower Breaker
Code 30 = Reset Irrigation Pump 1 Breaker
Code 31 = Reset Irrigation Pump 2 Breaker
Float Alarms
Code 40 = Master High Water Alarm located in Buffer tank
Code 41 = High Water Alarm in Irrigation Chamber
Code 42 = High Water Alarm in Wet Weather Storage Tank
Other Alarms
Code 50 = Buffer Tank Pump Impeller Jammed
Code 60 = Air Blower - No Air Flow
Code 70 = Replace Battery
Pressing Alarm Mute will only Silence Audible
alarm for 24 hours. Fault must still be rectified.
Control Panel fitted into a
316 Stainless Steel, Mine
Spec Control Box
Code
4
Code
3
Chlorine Dioxide
Generator
Ozone Generator
Code
20
If Connected
Code
10
Code
9
Buffer Pump
Clarifier Pump
Code
30
Code
31
(1)
(2)
If Connected
If Connected
TAYLEX CABS 5,000 Litres Per Day System
Spare 1
Spare 2
Earth Leakage
Circuit Breaker
Earth Leakage
Circuit Breaker
Code
1
Code
2
Switch Off Main Isolator Located
Outside Control Box
Before Opening Door.
Supplier:
Demensions:
Width:
Height:
EX
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Tanks
Taylex
Tanks
Wastewater & Rainwater Specialists
N1597
Inventco
350mm
550mm
Page 44
19. Stainless Steel B&R Mine Spec Control Box
Placement within system:
Top of Enclosure Stand on Lid
Supplier:
Demensions:
Width:
Height:
Depth
B&R
400mm
600mm
255mm
19a. Trickle Charge Battery Backup
EX
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Taylex
Tanks
Wastewater & Rainwater Specialists
Page 45
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Tanks
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TITLE
T
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Tanks
TM
Taylex
Tanks
AERATION
1
3
5
4
6
Wastewater & Rainwater Specialists
8
5
7
2
IRRIGATION
2
SECONDARY
2
TAYLEX COMMERCIAL A.B.S. SYSTEM (CABS)
Wastewater Treatment System
with Ultraviolet Disinfection
PRIMARY
2
2
10
2
Page 47
9
9
TAYLEX INDUSTRIES
56 PRAIRIE RD
ORMEAU 4221
10
11
CLARIFICATION
DRAWN BY
DARYL WILLSHER
DATE 12/08/2012
1. Inlet Baffle
2. 100mm Transfer Tees
3. Air Diffuser
4. BioBlok 200
5. Pump Plate
6. Flow Balance Pump & Sludge Return
7. Irrigation Pump
8. Flow Meter
9. TFG Filters
10. Chlorine Tubes
11. Sludge Return Pump
Top View
COMPONENT LIST
T
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TM
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 48
TITLE
2
11
SECONDARY
2
5
6
2
TAYLEX COMMERCIAL A.B.S. SYSTEM (CABS)
Wastewater Treatment System
with Ultraviolet Disinfection
PRIMARY
1
12
2
17
AERATION
16
3
4
2
14
6
9
10
IRRIGATION
12
TAYLEX INDUSTRIES
56 PRAIRIE RD
ORMEAU 4221
CLARIFICATION
2 13
15
7
5
8
DRAWN BY
DARYL WILLSHER
DATE 12/08/2012
1. Inlet Baffle
2. 100mm Transfer Tees
3. Air Diffuser
4. BioBlok 200
5. Pump Plate
6. Flow Balance Pump & Sludge Return
7. Irrigation Pump
8. Flow Meter
9. TFG Filters
10. Chlorine Tubes
11. Counter Float
12. High Level Alarm
13. Sludge Pump Float
14. Nitto 200Lt Blower
15. Stainless Steel Blower Box
16. Control Panel
17. B&R Box
Side View
COMPONENT LIST
T
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Page 49
TITLE
1
TAYLEX COMMERCIAL A.B.S. SYSTEM (CABS)
Wastewater Treatment System
with Ultraviolet Disinfection
2
9
1
3
4
TAYLEX INDUSTRIES
56 PRAIRIE RD
ORMEAU 4221
DRAWN BY
DARYL WILLSHER
DATE 12/08/2012
1. 32mm PVC Pressure Pipe from Flow Balance Pump
2. 25mm PVC Pressure Pipe from Blower to Difuser
3. 32mm PVC Pressure Pipe from Sludge Return Pump
4. 32mm PVC Pressure Pipe from Irrigation Pump
Placement of Pipework
Within System
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TITLE
TAYLEX COMMERCIAL A.B.S. SYSTEM (CABS)
Wastewater Treatment System
with Ultraviolet Disinfection
4
1
1
2
3
1
TAYLEX INDUSTRIES
56 PRAIRIE RD
ORMEAU 4221
1
1
DRAWN BY
DARYL WILLSHER
DATE 12/08/2012
1. Havestock 600mm Round Class B LA60B S/W
2. Stainless Steel Blower Box 800mm x 430mm x 430mm
3. Mine Spec B&R Control Panel and Stand
4. 150mm Brass Cleanout 1.0s
Top View Lid
PLACEMENT OF
ACCESS PORTS
EX
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Taylex
Tanks
Wastewater & Rainwater Specialists
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Tanks
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Tanks
Wastewater & Rainwater Specialists
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INSTALLATION MANUAL
• Overall Heigh 2,835 mm
• Hole Size 4,000mm square by 3,000mm high
• Bedding Material 5-7 gravel
• Height to 100mm inlet 2,165mm
(measured from tank bottom to bottom inlet pipe)
• Evenly fill the tank with approximately 15,000L of water to prevent movement through
the ground water pressure.
• Backfill – Use sand or excavation material/spoil with maximum particle size of 50mm.
Ensure that sand or excavated material does not fall on the lid of the Tank, as this will
fall into the system through the manholes and clog the system and irrigation pump.
Ensure that the backfill material is kept at least 70mm below the surface of the tank lid.
• Organise electrical and drainage contractor to connect to the CABS System
• The electrical contractor must follow the electrical specification supplied with the
CABS alarm panel at the time of delivery
• The drainage connection is a standard 100mm sewer inlet
• Commission – The CABS is ready to commission once the electrical power is provided to the system
IMPORTANT: THE SYSTEM CANNOT BE COMMISSIONED
UNLESS POWER IS AVAILABLE AT THE UNIT
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TITLE
4000mm
TAYLEX COMMERCIAL A.B.S. SYSTEM (CABS)
Wastewater Treatment System
with Ultraviolet Disinfection
100mm
5-7mm
drainage
gravel
2165mm
675mm
DARYL WILLSHER
DRAWN BY
DATE 12/08/2012
NOTE:
TAYLEX TAKES NO RESPONSIBILITY FOR
FLOATING TANKS
TAYLEX INDUSTRIES
56 PRAIRIE RD
ORMEAU 4221
2850mm
1. Dig hole 4000mm square
2. Hole Depth - 2850mm
3. Cover base of hole with 100mm of
5-7mm Drainage Gravel ensuring base
is finished perfectly level. Do not leave
exposed rocks in the base as this will
Void Warranty. Do NOT use sand.
4. Backfill with sand/soil - NOT ROCKS
5. To prevent floatation, fill tank to at least
70% (15,000Lt). Failure to fill tank may cause
the tank to float
EXCAVATION INSTRUCTIONS
T
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TM
Taylex
Tanks
Wastewater & Rainwater Specialists
Page 57
TITLE
TAYLEX COMMERCIAL A.B.S. SYSTEM (CABS)
Wastewater Treatment System
with Ultraviolet Disinfection
WARNING:
DO NOT ATTEMPT TO LIFT
WITHOUT SPREADER BAR
TAYLEX INDUSTRIES
56 PRAIRIE RD
ORMEAU 4221
WARNING:
DO NOT ATTEMPT TO LIFT
WITHOUT SPREADER BAR
DRAWN BY
DARYL WILLSHER
DATE 12/08/2012
1. USE ONLY CERTIFIED SPREADER
2. TANK WEIGHT 14 TONNES
1. USE ONLY CERTIFIED SPREADER
3. 4 x 5 TONNE SWIFT LIFTS ARE REQUIRED
2. TANK WEIGHT 14 TONNES
3. 4 x 5 TONNE SWIFT LIFTS ARE REQUIRED
LIFTING REQUIREMENTS
LIFTING REQUIREMENTS
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TAYLEXCABSKtEZ^MANUAL
Taylex™CommercialAdvancedBlowerSystem
(CABS)
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TABLEOFCONTENTS
1. AboutTaylex
2. WhatisaCommercialAdvancedBlowerSystem?
3. HowdoesaCABSwork?
4. WhatdoesaCABSneed?
5. Whatupsetsthebalance?
6. HowtolookafteryourCABS
7. ServicingyourTaylexCABS
8. Warranty
9. OperatingInstructionsforyourCABSController
10. AlarmCodes
11. Whotocontactforhelp
ϭϮ͘ ĂǀĞLJ<ŝŶĞƚŝĐŽ^ĂŶĚ&ŝůƚĞƌ
ϭϯ͘WƌŽĐĞƐƐŽŶƚƌŽůŚůŽƌŝŶĞŝŽdžŝĚĞhŶŝƚ
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Tanks
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Page 62
1. ABOUTTAYLEX™
TaylexisanAustralianCompanywhichcommencedbusinessin1969manufacturingthefirstpurposedesigned
HomeSewageTreatmentPlantinAustralia
TaylexhasanationalgroupofAuthorisedDistributorswhomarket,installandservicetherangeofTaylextanks
throughoutAustralia.Theyareallprivatelyownedandoperatedsmallbusinessenterprisesinyourlocalarea.
TheyareissuedwithCertificatesofCompetencybyTaylexverifyingtheirsuccessfultrainingintheinstallation
andmaintenanceofTaylexequipment.
Taylex has an ongoing commitment to the industry͘It has ISO:9000 Certification and its products are
approvedbyallStateAuthoritiesandcomplywithallrelevantAustralianStandards.
Taylex also has a commitment to continually developing the best products by way of its Research &
Developmentactivities.TheTaylexCABSisaproductofthisresearch.
Most importantly, Taylex has a continuing commitment to its clients, the end user of its products. This is
honoured by only appointing the best tradespeople as its Authorised Distributors, generously honouring any
validWarrantyclaimthataDistributorpresentsonanowner’sbehalf,providingsparepartsbackͲup,inͲservice
trainingatourmanufacturingworksandassistance,whennecessary,inthefield.
Taylexisnowoperatedbythesecondgenerationofthefoundingfamiliesandwearedeterminedtobeherefor
atleastthenext40years.
Pleaserefertoourwebsiteforadditionalinformation
www.taylex.com.au
2. WHATISACOMMERCIALADVANCEDBLOWERSYSTEM;^Ϳ?
AlsoknownasĂŶĞĂƌƚĞĚtĂƐƚĞtaterTreatmentSystem(AWTS).
A^ƵŶƚŝƐĂƐLJƐƚĞŵthatcontainsandtreatsallofthewastewatergeneratedfromasite.
Thismeansyoucanhavealltheadvantagesofmainssewerage,evenwhenthereĂƌĞfullflushtoilets,washing
machine͕dishwasher,multipleshowers,handbasinsĂŶĚbathroomƐ.
Itisyourownsewagetreatmentplant.
3. HOWDOESACABSWORK?
Thewastewaterfrom commercialsites containnumeroustypes oflivingbacteria.Someofthesebacteriause
ourwasteproductsasafoodsourcewhileothersusethesewasteeatingbacteriaastheirfoodsource.
Thisprocessisnaturalandisjusthownatureintendedittobe.WhenthewastewaterissuppliedwithĂŶ
oxygenƌŝĐŚĞŶǀŝƌŽŶŵĞŶƚ,thesenaturalůLJŽĐĐƵƌŝŶŐbacteriadoubletheirnumberseveryĞŝŐŚƚhoursuntilthereare
literallybillionsofthemlivinginthetank,automaticallyreducingthewastestoanonͲpollutingliquid.
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Design Parameters of the CABS Tank
Water Volume
Primary
Secondary
Secondary Air Gap Buffer
Aeration
Clarifier
Total Working Capacity
Tank Construction – All Concrete
Height
2835mm
Inlet Invert (from Base)
2165mm
Tank Diameter
3450mm
5,420
1,342
2,068
3,927
1,726
Tank Dry Weight
Lid Dry Weight
14,483 Litres
Plus Irrigation
Plus Irrigation Air Gap Buffer
Total Working Capacity
Total Tank Weight
392
897
1,289
Maximum Hydraulic Loading
Operating Capacity
Total Tank Capacity
Air Volume
Primary
Secondary Air Gap
Aeration
Clarifier
Irrigation Air Gap
from Working
Volume
from Working
Volume
Total Air Volume
11.5 tonnes
2 tonnes
1,604
1,020
1,153
633
534
13.5 tonnes
5,000 Litres/day
14,483 Litres
20,716 Litres
4,944 Litres
B
65 AT 300mm FROM TOP
585
The CABS Tank
2165
2835
A Purpose Built
Commercial
Treatment System
Total Weight
13.5 Tonnes
125
95
150
A
3450
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The Design Flow Process
The 5 Stage Process
Step 1 & 2: All waste from the facility enters the primary pre-treatment chamber of the Taylex System with
liquid then flowing into the secondary/buffer chamber. The time that waste spends in both these anaerobic
chambers allows bacterial action to condition it before it is then control pumped evenly over a 24 hour period
into the aeration chamber.
Step 3: The CABS system uses an air blower to introduce oxygen into the aeration chamber. The aerobic
bacteria multiplies rapidly in this oxygen enriched environment and are thoroughly mixed with the pre-treated
liquid to ensure complete digestion of organic material. The blower is set to turn on and off as needed to
accommodate the flow of each individual treatment system.
Step 4: The liquid then flows into the clarification chamber for settlement where the remaining organics are
then pumped back to the Primary Chamber. The remaining liquid then flows through to the Irrigation
Chamber.
Step 5: Pre-treated, aerated and settled, the liquid then passes through Taylex outlet filters prior to
disinfection. The filtered liquid passes through a chlorinator, ozone unit, chlorine dioxide unit or U.V. light
which ensures the disinfection of the reclaimed effluent. Then your reclaimed effluent is returned to the
environment via spray or underground irrigation by a silent pump.
The Five Stages to a Taylex
Commercial Treatment System
1 Primary Anaerobic
All waste from the
facitity enters the
system
Digestion and
Sedimentation
Chamber
1
2 Secondary Anaerobic
Digestion and
Sedimentation
Chamber/Buffer
Zone
3
5
2
5
3
4
4
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4. WHATDOESACABSNEED?
a) FOOD
b) AIR
c) AGOODENVIRONMENT
FOOD
Thisissuppliedinthewaterwedischargeintothetank.Itcomesfromthetoilets,handbasins,sink,showers,
washingmachine,infactanythingthatweputdownthesinkorflushdownthetoilet.
AIR
TheTaylextankisfittedwithanairblowerthattakesfreshairandintroducesittothewaterthroughanaerator
ĚŝĨĨƵƐĞƌ.Someofthegaseousoxygenintheairdissolvesinthewaterasitbubblesuptothetopandthisgives
thewaterahigherthannormaldissolvedoxygencontent.Thisishowthebacteriabreathe,liveandmultiply:
theycanaccessthedissolvedoxygen.
AGOODENVIRONMENT
Thisiswhereyouhaveamajorinfluence.
ͲToomuchFOODwillkillthebacteria.
ͲToolittleAIRwillkillthebacteria.
ͲHeavyPollutantswilldegradeAGOODENVIRONMENTandkillthebacteria.
5.WHATUPSETSTHEBALANCE
Thegreatestcauseofproblemswithtreatmentsystemsarecleaningproducts,greaseandfats.
CLEANINGPRODUCTS
Unfortunatelywhatwecallcleaningproducts,thetreatmentplantsmayclassaspoisons.
Likehumans,somepoisonskilluswhileotherswilljustmakeussickandthesamewillhappentothebacteriain
theCABS.Youmustuseenvironmentallyfriendlyproducts,nochlorine,bleaches,nappysanetc.
The treatment system relies on bacteria for your system to work effectively. Any product used that kills
bacteriaisharmfultothesystem. If you wish to use some of the harsher cleaning products,it is suggested
that you use a bucket and discard the contents inthegarden. Thisalsoappliestodisinfectant,surfacesprays
andwipes.
Whenworkingproperly,yourCABSwillworkefficientlywithnoodoursorproblems.
Itneedsahappybalance.
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6. HOWTOLOOKAFTERYOURTAYLEXCABS
• NeverturntheelectricitysupplytotheplantOFF*.TurningthesupplyOFFwill:
1. Stoptheairsupplyandkillthebacteria.
2. Floodthesystem
3. Disablethealarmsystem
4. CausebackͲupinyoursewerlinefromthepremises.
Theplantwillsmell,theequipmentmaybedamagedandyouwillbeincontraventionofyour
“PermittoUse”
• Neverpourdownthesinkorflushdownthetoiletanyofthefollowing:
1. Anythingfromyourhomebrewkit
2. Sourmilkoryogurt
3. Cookingoils
4. Excessfoodscraps(particularlyfromagarbagegrinder)
Allofthesewillprovidetoomuchfoodmaterialforthebacteriatouse.Theymustbedisposedofinproper
containersinyourgarbagecollection.
• Neverdisposeofanyofthefollowingitemsintothesystem
1. Automotiveoil͕ĐŽŽŬŝŶŐŽŝů͕ĨĂƚƐĂŶĚŐƌĞĂƐĞƐ
2. Bleaches,disinfectants,whiteners
3. Nappyliners,condoms,sanitarynapkins
Automotive oil͕ ĨĂƚƐ ĂŶĚ ŐƌĞĂƐĞƐ ĂƌĞ not treatable by the bacteria; the disinfectants will take away all the
bacteria’soxygen;thesanitaryitemsareimpregnatedwithantiͲbacterialmatter,sotheywillneverbreakdown.
Theresultswillbe Ͳ thebacteriawilldie.Thetankwillalmostcertainlyneedtobepumpedouttoremovethe
grosspollutantsandthetankrefilledandreͲstarted.
Whatever the product, always ensure that it is marked as BioͲdegradable and Safe for Use in septic/onsite
systems.RefertotheLANFAXLABORATORIESINDEPENDENTLAUNDRYPRODUCTRESEARCHwebsiteformore
unbiasedinformation.www.lanfaxlabs.com.au
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7. SERVICINGYOURTAYLEXCABS
All Commercial Treatment Systems are required by State laws to be serviced on a regular basis. Your local
municipality enforces these laws. Systems may only be serviced by appropriately trained and licensed
WastewaterServicepersonnel.
TherearebetterreasonsforservicingyourTaylexCABSthanjustcomplyingwiththelaw.
Yourservicepersonistrainedtomonitoryoursystem;theycandetectproblemsoftenbeforetheybecomea
hazard.Moreimportantly,aproperlyoperatedandmaintainedsystemisyourcontributiontotheenvironment,
rightinyourownbackyard.
Correctlyoperatingsystemsdonotsmell,theyguaranteeahealthyphysicalenvironmentandtheysavewater.
• HOWCANYOUASSISTINSERVICINGYOURTAYLEXCABS?
1. Donotcoverthetopofthetankwithearth,gravel,tanbark,concrete,pavers,pot
plants,barbecue,swingset,seatetc.
2. Provideclearaccesstotheplantandtheinspectionopenings.
3. Ifyouhavealockedyard,provideyourservicepersonwithakey.
4. Makesuresurfacewaterdoesnotpoolandcanneverentertheplant,evenduringtorrentialrain
events.
8. WARRANTY
EveryTaylexCABSiscoveredbyafullmanufacturerswarranty.Thereisa15yearwarrantyonthepreͲcast
concretetankanda12monthwarrantyonallelectricalandmechanicalcomponentsincludingtheirrigation
pump,anda12monthextendedwarrantyisavailable.PleaserefertoyourTaylexdistributorformore
information.
Thisguaranteedoesnotcoverdamagecausedbymisuse,neglect,failuretokeeptheunitcleanandfunctional,
accident,useofincorrectpowersupply,orrepairorattemptstorepairbyunauthorisedpersonnel.Thebenefits
conferredbythiswarrantyareinadditiontoallotherrightsandremediesinrespectoftheproductwhichthe
consumerhasundertheTradePracticesActandotherlegislations.
TOENSUREYOURWARRANTYISVALID,THEFOLLOWINGSHOULDBEOBSERVED:
• DONOTusesystemorallowwastewatertoentertanksbeforepowerservicesareavailabletotheSystemand
aTaylexAuthorisedDistributorhasbeennotifiedofpendingoccupancyofthepropertyandhassubsequently
commissioned(activated)thesystem.
• DONOTcoverlidswithsoil
• DONOTpositionconcretepathsordrivewaysoverSystem
• DONOTallowsurfacewatertoentersystembyincorrectfallsandlandscapingaroundSystem.
• NEVERturnthepoweroff.
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9. OPERATINGINSTRUCTIONSFORACABSCONTROLLER
Thesystemconsistsofaconcretetankwithseveralchambers:
PrimaryTank Effluentisstoredhereandisgravityfedtothesecondarytankandisthenpumpedintotheaerationtankunder
normalloadingconditions.Duringabnormalloadseffluentcanentertheaerationtankdirectlyfromthe
secondarytank.Therearenodevicesintheprimarytank.
SecondaryTank
IsaholdingtankwhereeffluentispumpedviaaDaveyD25VAtotheaerationtank.
Operation
Thispumprunseveryhourandistimedonthehourfromϭϱsecondstoϯ0secondsin5secondblocks.
Acurrenttransducerindicatesifthepumpcurrentisoutofrangebyanalarmcode.
Thiscouldbeablockageoratrippedcircuitbreaker.
IfacircuitbreakeristrippedaCode2alarmisgenerated.
TherearetwofloatswitcheƐonthistank
1. Amasteralarmforhighwaterlevelforthesystem.ThisgeneratesamasterhighlevelalarmCodeϰϬ.
2. TransferFloatcountsthenumberoftimesthefloatisactivatedandstoresinmemoryuntilreset.The
countgivesthenumberoftimeswaterhasoverflowedratherthanbeingpumpedintotheaeration
tank.dŚŝƐĚŝƐƉůĂLJǁŝůůďĞĐůĞĂƌĞĚďLJƚŚĞƐĞƌǀŝĐĞƉĞƌƐŽŶŶĞů͘
AcurrenttransducermonitorsŝfthereareanyobjectsthatjamtheimpellerandraiseanalarmCodeϱϬ.
Whenthisalarmisraisedthepumpisdisabledfromfurtheroperationuntiltheimpellerhasbeenchecked
andcleared.Thiswillpreventdamagetothepump.
Ifthecurrentalarmclearsitselfwithin20secondsthisalarmwillautocancel.Thisisthemaximumperiodthe
circuitcanrununderhigherthannormalcurrentconditions.After20secondsthecircuitwillassumethe
impellercannotselfͲclearandwillisolatethecircuitwithanalarm.
ClarifierTank
ADaveyD25VApumpoperatesevery6hoursfor1Ϭseconds.The6hoursistimedfromthestartofpowerup
andcontinuesevery6hoursǁŝƚŚnoadjustment.Itiscontrolledwiththefloatswitchsignaltoensurethatit
onlyoperateswhenwaterlevelsareaboveapresetlevel.Thispumpswatertotheprimarytank.Analarm
operatesifthepumpcircuitbreakerhasbeentripped.
ThegreenLEDisonsteadyduringoperation,aredLED(andalsothemasteralarm)indicatesafaultCodeϵ.
AerationTank
A120–200litreBlowerisprogrammableĂŶĚǁŝůůƌƵŶŝŶbetween20minutesto60minutesperhour
(defaultis60minutes).AgreenLEDindicatestheblowerisrunning,aredLEDindicatesafaultofnoair
CodeϲϬ.AnalarmoperatesifthepumpcircuitbreakerhastrippedCodeϭϬ.
IrrigationTank
Thistankstorescleareffluent,readyforpumpingout,whenthecorrectlevelhasbeenreachedviaafloat.
HighwaterintheirrigationtankisindicatedbyaredLEDandalarmCodeϰϭ.
Thepumpismonitoredbyacircuitbreaker.IntheeventofthecircuitbreakertrippingaCodeϯϬŽƌϯϭ
alarmisgeneratedonthemasteralarmdisplay.
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Irrigationtankpump
Ͳ10ACircuitbreakerDINmountRCBO.
GreenandredLEDforoperation/fault.
Floatswitchesforlevelthatindicatesfloatup(blueLED)andaredescribedonthefrontpanel.
Sharedmasterfaultoutputs
BlowerͲ
120–200litreNittoblower
10ACircuitbreakerDINmountRCBO.Adjustabletimeshownfrom20minutesto60minuteswhenactive.
Dualdigitdisplayshowsprogrammedtime
Airswitchesmonitoring
GreenandredLEDforoperation/fault(circuitbreaker,airetc)shownalsoonmasterfaultdiagnostics.
SecondaryChamber
GreenandredLEDforoperation/fault(circuitbreaker).Programmablefor30secondsto70secondsperhour
in5secondblocks.Shownondualdigitdisplayprogramandtestbuttons.
10ACircuitbreakerDINmountRCBO.
2xfloatswitchedwithLEDmonitoringforstatus(bluemeansfloatlevelisHIGH)
GreenandredLEDforoperation/fault(circuitbreaker)
Afloatmeasuresmasterhighwaterlevel.
Another float counts the number of overloads (activations) and stores the value in a Secondary chamber
overloadcounter.Toresetholdprogrambuttonandmutealarmfor5seconds+
2digitdisplayshowsrunningnumberofchamberoverloads.
ClarifierTank
10AcircuitBreakerDINmountECBO
CurrentTransducer
Floatswitchallowsoperationifhigh.Operates15secondsevery6hours
Testbutton,overridesfloatindicator
Green/RedLEDforoperatingorfault(circuitbreaker)
IfimpellerisblockedMasteralarmsignalfault(sensedbycurrent)
MasterAlarmStatus
SingledigitREDLEDdisplaytoindicatefaultsacrosscontrolsystem
Mutealarmbuttonfor24hoursthenreactivates
ExternalLEDoutputboth+12Vanddrycontacts
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MasterCircuitBreaker
Supplies3GPO’soneofwhichisusedtoconnectagelcellbatterycharger.
Masteron/offandsuppliespowertoallotherbreakersandelectronics.Ifthemasterswitchisturnedtotheoff
positiontheinnercabinetdoorcanbeopenedforserviceaccess.Intheeventofamasterbreakertripafault
Code1willbedisplayed.
BackupBattery
AsealedrechargeableLeadacidbatterywillbeprovided.Adynamicbatterytestwillbeperformedonthisona
regularbasis.Ifthebatteryfailsafaultcodewillindicatereplacement.
FlashingLEDLight
IntheeventofanyalarmaflashingLEDlightwillactivateandkeeprunninguntilthefaultiscleared.TheAudible
alarmmaybesilencedbythemutebuttonbutwillreactivateafter24hoursifthefaulthasnotbeencleared.
1Ϭ. SUMMARYOFALARMCODES
Solid0=NofaultNormaloperation
CircuitBreakers
Code1=Reset^ƉĂƌĞϭƌĞĂŬĞƌ
Code2=Reset^ƉĂƌĞϮƌĞĂŬĞƌ
Code3=ResetKnjŽŶĞBreaker
Code4=ResetŚůŽƌŝŶĞŝŽdžŝĚĞBreaker
Codeϵ=ResetůĂƌŝĨŝĞƌBreaker
ŽĚĞϭϬсZĞƐĞƚ^ĞĐŽŶĚWƵŵƉƌĞĂŬĞƌ
ŽĚĞϮϬсZĞƐĞƚůŽǁĞƌƌĞĂŬĞƌ
ŽĚĞϯϬсZĞƐĞƚ/ƌƌŝŐĂƚŝŽŶϭƌĞĂŬĞƌ
ŽĚĞϯϭсZĞƐĞƚ/ƌƌŝŐĂƚŝŽŶϮƌĞĂŬĞƌ
FloatAlarms
CodeϰϬ=MasterHighLevelŝŶSecondaryTank
Codeϰϭ=IrrigationChamberHighWaterůĂƌŵAlarm
ŽĚĞϰϮс,ŝŐŚtĂƚĞƌtĞƚtĞĂƚŚĞƌ^ƚŽƌĂŐĞdĂŶŬ
OtherAlarms
CodeϱϬ=^ĞĐŽŶĚĂƌLJTankPumpImpellerJammĞĚ
CodeϲϬ=BlowerͲNoAirFlow
CodeϳϬ=Replace>ŽǁBĂƚƚĞƌLJ
Displays
Thereare3xdualdigitdisplayswhichindicateoperationalstatusandoverusestatusandoneMasteralarm
display.DuringnormaloperationonlytheMasterAlarmdisplayshowsafigurezerotoindicatecorrect
operationofthesystem.
Allotherdisplaysaredimmedtosavepower.Pressinganykeywillactivatealldisplaysuntil10secondsafterthe
lastkeypress,thentheygooutagainexcepttheMasterAlarmDisplay0
TheFloatstatusbarshowsthepositionofeachfloatasonwhenaBLUELEDisonanddowntheLEDisOFF.This
aidsdiagnosticsbyindicatiŶŐeachfloatposition.
AMasterOn/Offswitchdisablesthepowertoallcircuitanddisconnectspowerfromthecontroller.
Italsoenablesthedoortobeopenedtoaccessthecontrollerforservice.
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11. WHOTOCONTACTFORHELP
Beforeyoucallforhelpandtoavoidunnecessarycalloutfees,checktheseitemsbeforeyoucallfor
assistance:
1. IsthepowerturnedONattheplant?
2. AretherelightsONinthepanelface?
3. HasaSafetySwitch,notrelatedtotheplant,trippedinyourswitchboard?
4. Hastheoutlethosebecomekinked,preventingtheplantpumpingout?
5. Ifyouhaveremovable“TurfKeys”onyoursprinklers,makesuretheyareengagedproperly,PUSHDOWN
HARD.
6. Istheoutletdripperfilterblocked?
Ifyouhaveanissue,youcantrytoresetyoursystemwiththefollowingsequence:
a. TurnthesystemOFFusingthecontrolpanelON/OFFswitchonthefrontofthepanel.Thiswill
resettheprogram.
b. Turnthesystem“ON”usingtheON/OFFswitch.
c. Ifthesystemstartsandoperatescorrectly,observethesystemoverthenextfewdaysfor
anotherALARMeventanddiscussitwithyourServiceAgent.
d. IfthesystemgoesbackintotheALARMmode,callyourServiceAgent.Limityourwaterusage
untilthefaultisrectified.
YoucanfindyourclosestDistributoronourwebsite
www.taylex.com.au
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SPARE PARTS
TAYLEX IDUSTRIES recommends the following Parts be kept on site as part of the
ongoing Maintenance programme of the CABS Wastewater Treatment System.
Part No.
1.
2.
3.
4.
5.
Davey D25VA Sludge Pump
Davey D42A Irrigation Pump
Nittro 120Lt or 200Lt Blower
Nittro 120Lt or 200Lt Blower Filter
Mercury Float Switch
P16
P2
B2 / B3
B5 / B6
P15
Davey D25VA Sludge Pump
Davey 42A Irrigation Pump
Mercury Float Switch
Blower Filters
Nittro 200Lt Blower
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Electrical Specifications and Power Requirements
1. Equipment Shed
Power requirement
Fluorescent Light
6 x Single Power point
2. CABS Controller
Power Supply
3. Davey D25 Pump
Motor Power
Power Supply
Start amps
Run amps
4. Davey D42 Pump
Supply Voltage
Supply Frequency
Full Load Current
Locked rotor Current
Input Power (P1)
Output Power (P2)
Starting
5. Davey D53A
Supply Voltage
Supply Frequency
Full Load Current
Locked rotor Current
Input Power (P1)
Output Power (P2)
Starting
6. Blower LAM200
Power Supply
Rated Frequency
Power Consumption
7. UV Tube NF150
Power Supply
Power Consumption
8. Chlorine Dioxide Generator
Power Supply
Rated Frequency
9. Ozone
Power Supply
Rated Frequency
10. Toro Filter
Power Supply
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20A Separate Circuit Feed
20A Separate Circuit Feed
250watts
230v / 50Hz AC
12.0 amps
2.2 amps
220-240watts
50Hz singe phase
4.0A
14A
0.94kW
0.06kW
P.S.C
220-240watts
50Hz singe phase
5.7A
14A
1.31kW
0.84kW
P.S.C
240 V
50Hz
215 W
240V
150 W
230V
50/60Hz
240V
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PowerTestingAssessmentReport
Insert Sci-Qual International Pty Ltd
Power Assessment Report once completed
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Commissioning Check List
For the owner/operator please ensure the following is completed prior to contacting Taylex
or your Taylex Agent prior WRcommissioning.
1.
2.
3.
4.
Irrigation area is completed
Irrigation line is available at the tank
Electrical power is connected and is live.
Drains from the dwelling etc. are connected to the Inlet of the Primary tank
Commissioning Procedure
Drains from the dwelling etc. are connected to the Inlet of the Primary tank
Check Irrigation area is installed and completed
Check Irrigation Pump Line is connected to Irrigation pump
Check each Chamber and make sure water level is adequate to cover media, pumps
and filters.
. Check each Chamber and ensure that all floats are clear of walls and pipework and
are free to move
. Check all pumps and blower leads are plugged in and are in the correct outlet at the
controller
. Ensure all Float leads are connected in the control panel to the correct connection
. Close Control Panel door, turn main power on. (The system will count down from 9 to
0 then it will test the Blower then the Secondary and Clarifier pumps. This will take
approximately one minutH. If the water levels are correct you will see the test
activating)
. Lift float on Irrigation pump to engage the pump, check for leaks in the irrigation area.
1. Set timing for the secondary pump as per the design flow of the system (Litres Per
day it will be treating) Calculations for this are on the cover.
1. Set Blower timer (40 minutes on 20 minutes off) (Evaluate this at the next service
and adjust as required)
1. Note down Meter reading so the flow rate of the system can be calculated at the next
service ( The Flow record Sheet is in the back of the Technical Manual)
.
.
.
.
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Trouble Shooting
For help call Taylex Commercial
Phone 07 3441 5200 any time
Code Fault
No Fault Normal
0
Operation
Spare 1 Breaker
1
2
3
4
9
10
20
30
31
40
41
42
50
Reset Breaker switch Lf it continues call an electrician
Reset Ozone
Breaker
Reset Chlorine
Dioxide Breaker
Reset Clarifier
Breaker
Reset Second
Chamber Pump
Breaker
Reset Blower
Breaker
Reset Irrigation 1
Breaker
Reset Irrigation
Breaker 2
Master High Level
in Secondary Tank
Irrigation Chamber
High Water Alarm
High Water Wet
Weather Storage
Tank
Secondary Tank
Pump Impeller
Jammed
Blower - No Air
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Reset Breaker switch Lf it continues call an electrician
Spare 2 Breaker
60
70
Solution
Replace Low
Battery
Taylex
Tanks
Reset Breaker switch Lf it continues call an electrician
Reset Breaker switch Lf it continues call an electrician
Reset Breaker switch Lf it continues to trip check pump.
Reset Breaker switch Lf it continues to trip check pump.
Reset Breaker switch Lf it continues to trip check blower.
Reset Breaker switch Lf it continues to trip check
irrigation pump.
Reset Breaker switch Lf it continues to trip check
irrigation pump.
Reset Breaker switch Lf it continues to trip check pump.
Check Irrigation Pump
Check Irrigation Pump
Check Irrigation Pump, clean and clear Impeller
Check the clear tube from the blower back to the panel is
connected and not damaged, Check Blower, check blower is
plugged in and turned on, check air switch, Fheck all air lines.
Check connection to battery, if alarm continues disconnect
from terminals, if it still alarms call Taylex. Charger may need
to be replaced if it is not charging battery.
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Optional Extra Systems
1.
2.
3.
4.
5.
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Davey Automatic Backwash Media Filter
Toro Filter system
Chlorine Dioxide Generator
Nature Flow Ultra Violet Treatment System
Ozone disinfection
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DAVEY BACKWASHING MEDIA FILTER
Model Number:
Mach 2060F OD
WATER FILTERS
PRODUCT
DESCRIPTION
High performance non-electric
backwashing media filter
A P P L I C AT I O N S
Davey Kinetico media filters are ideal for
reducing sediment and ferric iron from
water.
F E AT U R E S & B E N E F I T S
O P E R AT I N G L I M I T S
Inlet Water Quality
Pressure Range
Non Electric
Only Davey Kinetico uses the kinetic
energy of moving water to power its
system instead of electricity – thanks
to the patented hydraulic valve. So
you’ll never have to worry about costly
repairs or higher electricity bills.
Filtered Water Rinse
Uses only filtered water to clean the
media, which extends the life of the
system.
1.0-8.6 Bar
2 - 49ºC
5 – 10 SU
Operating Specs
Flow Range (1.0 – 2.1 Bar)
30 - 45 lpm
Flow Rate (service)
26.5 lpm
Flow Configuration
Overdrive
Dimensions
(w x d x h)
432 x 203 x 1,168mm
Weight (Operating / Shipping) 91 / 64kg
H/O & MFG SCORESBY
24/7
Our twin tank design allows our
system to backwash without ever
going offline for round the clock
operation. You’ll never be interrupted
or inconvenienced by backwashing.
Metered Backwashing
Measures water use to accurately
determine when it’s time to backwash
with clock like precision. Your filter
automatically adjusts to your water use
patterns.
Temperature Range
pH Range
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T E C H N I C A L S P E C I F I C AT I O N S
SYSTEM COMPONENTS
Media Vessel (qty) Size
Media Vessel Construction
(2) 203 x 1,016mm
Fiberglass Wrapped
Polyethylene
Empty Bed Volume (empty / media)
29.4 / 11.3 litres
Media Type
Macrolite
Media Volume
11.3 litres
Riser Tube
25mm ABS
Distributor Upper
None
Lower
0.18mm Slots, Noryl Basket
Under bedding
6mm x 0.13mm Garnet
Backwash Control
Non-electric Use Meter
Service
Down Flow
Meter Type
1.1-94.6 lpm Polypropylene Turbine
CONNECTIONS
DIMENSIONS
Inlet / Outlet Connections
32mm Custom Adapter
and E-clip
Drain Connection
13mm Tube
Auxiliary Drain Line Connection
13mm Tube
Power
None
63.5
B A C K WA S H S P E C I F I C AT I O N S
Backwash Volume
Backwash Time
Backwash Flow Control
322 Litres
20 minutes
15.1 lpm
1168
210
432
All dimensions in mm unless otherwise stated.
BACKWASH DISC SELECTION – Disc 4 Fitted
Meter Disc
1
2
3
4
5
6
7
8
Litres / backwash
8,327
4,163
2,774
2,082
1,665
1,385
1,188
1,041
This literature is not a complete guide to product usage. Further information is available from your Davey dealer, Davey Customer Service Centre and
from the relevant product Installation and Operating Instructions. This data sheet must be read in conjunction with the relevant product Installation
and Operating Instructions and all applicable statutory requirements. Product specifications may change without notice.
® Davey is a registered trademark of Davey Water Products Pty Ltd. © Davey Water Products Pty Ltd 2008.
Davey Water Products Pty Ltd
Member of the GUD Group
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ABN 18 066 327 517
Head Office and Manufacturing
6 Lakeview Drive,
Scoresby, Australia 3179
Ph:
+61 3 9730 9222
Fax:
+61 3 9753 4100
Website: davey.com.au
Customer Service Centre
Ph:
1300 367 866
Fax:
1300 369 119
E-mail: sales@davey.com.au
Interstate Offices
3YDNEYs"RISBANEs!DELAIDE
0ERTHs4OWNSVILLE
Wastewater & Rainwater Specialists
International
6 Lakeview Drive,
Scoresby, Australia 3179
Ph:
+61 3 9730 9121
Fax:
+61 3 9753 4248
E-mail: export@davey.com.au
Germany
Kantstrasse 53, 04275 Leipzig
Ph:
+49 341 301 0412
Fax:
+49 341 301 0413
E-mail: akrenz@daveyeurope.com
USA - Davey Pumps Inc.
Ph:
+1 630 898 6976
Fax:
+1 630 851 7744
Website: daveyusa.com
E-mail: sales@daveyusa.com
Davey Water Products
– New Zealand
7 Rockridge Avenue,
Penrose, Auckland 1061
Ph:
+64 9 570 9135
Fax:
+64 9 527 7654
Website: daveynz.co.nz
E-mail: sales@daveynz.co.nz
Davey Spa – New Zealand
2 Rothwell Avenue,
North Harbour, Auckland 0632
Ph:
+64 9 415 8622
Fax:
+64 9 415 8621
Website: spa-quip.co.nz
E-mail: service@spa-quip.co.nz
Page 102
DPM268/2K/1008/IPM
Owner’s Manual • Guide d'utilisation • Manual del usuario
Para-Flo™ Backwashing Filter
Filtre de lavage à contre-courant Kinetico Para-FloMD
Filtro Para-Flo™ Backwashing Kinetico
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Kinetico Para-Flo™
Backwashing Filter
Owner’s Manual
Congratulations for choosing Kinetico to improve the quality of your water.
You will immediately begin to notice the numerous benefits of having
quality water throughout your home and the benefits of having a Kinetico
Quality Water System.
Since 1970, Kinetico Incorporated has designed and manufactured products
to improve the quality of your water. Kinetico offers a complete line of quality
water systems to solve your water problems. Pioneers in non-electric,
demand operated water treatment, Kinetico continually sets the direction for
the entire water quality industry.
“Kinetico,” the Kinetico Logo and the water drop design are registered trademarks
of Kinetico Incorporated, Newbury, Ohio. MADE IN U.S.A.
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The Kinetico Para-Flo Backwashing Filter
About The Kinetico Para-Flo Backwashing Filter
Now that your Kinetico Para-Flo
Backwashing Filter is installed, you
can start enjoying the benefits
of problem-free water.
Offensive Taste and Odors – Algae,
chlorine and other elements that
could be in your water can
cause a foul smell and taste
and make using and
drinking your water
unpleasant.
Kinetico offers a variety
of backwashing filters
to handle problem
water which may
Acid – Acidic water
have iron or be
can cause blue-green
dirty, cloudy, smelly
stains on sinks, tubs,
or acidic. All these
toilets and fixtures. It
water problems cause
can also cause corrohavoc in the home.Your
sion of plumbing and
water can stain and ruin
water-using appliances.
clothing, plumbing, fix- Para-Flo 100
tures and water-using appliances Turbidity – Cloudy or dirty water
as well as be just plain difficult to
can be caused by sediment, silt, dirt
live with.
or other suspended matter. Turbid
water can create problems with
Water Problems Solved With
plumbing and water-using appliKinetico Para-Flo Backwashing
ances as well as make drinking,
Filters
cleaning and cooking with water
unpleasant.
Iron – Iron in water can cause rust
colored stains on clothing, plumbing, Your water conditions determine
fixtures and water-using appliances.It
what is necessary to solve your water
can also give water a metallic taste.
problems. In many cases, several
Iron Stains
3
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pieces of equipment may be needed
to do the job. Your authorized
Kinetico dealer has analyzed your
water and has recommended
the most appropriate
system(s) to solve your
specific water problems.
Filter Ag – used to remove larger
particles from water such as iron, sediment, dirt, silt and suspended matter
How Your Kinetico
Para-Flo Backwashing
Filter Works
Kinetico Para-Flo BackProblem water usually
washing Filters are
has something in it that
customized and contain
needs to be removed.
filter media most approRunning your water
priate for your application.
through a backwashing filter
Macrolite
Please refer to the Mainthat contains the appropriate
tenance Record section of
media is basically how it’s
this manual to identify the
done. The filtering media
media used in your system or contraps the matter that needs to be filtact your authorized Kinetico dealer.
tered from your water and allows the
virtually particle-free water to leave
Media Options for Kinetico
the system and be used throughout
Para-Flo Backwashing Filters
your home.
Once the media bed is loaded
with the trapped particles, it
must be cleansed. This is
done through a process
Activated Carbon –
called
backwashing.
used to remove objecDuring backwash, water
tionable taste, odors
is forced through the
and color from water
media bed in the opposite
flow direction of the sysCalcite –used to neutralize
tem to clean the particles off
water by raising its pH
level
Activated Carbon the media and flush them to
drain. Once the process is
complete, the media is again ready to
Macrolite® Ceramic Media – used
filter your water.
to remove extremely fine particles
from water such as iron, sediment,
dirt, silt and suspended matter
Birm – used to remove iron and
manganese from water
Syntrex™ – used to remove particles
from water such as iron, sediment,
dirt, silt and suspended matter
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The Kinetico Para-Flo Backwashing Filter
What Makes Your Kinetico Para-Flo Backwashing
Filter Different Is What Makes It Better
Para-Flo Service
Kinetico Backwashing Filters feature
Para-Flo Service – both tanks of the
twin tank system are filtering your
water simultaneously.This is the best
and most thorough way to filter
your water since it allows your
water to have longer contact with
the filter media and is less taxing on
the system.
Non-Electric Operation
Kinetico Para-Flo Backwashing
Filters are powered by the energy of
moving water, not electricity. So
there’s nothing to plug in, no buttons to push, timers to set and reset,
Tank In
Service
Tank In
Service
or adjustments to make. You really
don’t need to do anything special to
operate your Kinetico system – it
runs itself, not you.
Demand Operation
Your Kinetico Para-Flo Backwashing
Filter has a built-in water meter
which means it operates “on
demand” based on your actual water
usage. So a simple flush of the toilet
or run of the faucet can send your
Kinetico Para-Flo Backwashing
Filter into backwash. Depending on
your water usage, your Kinetico
Filter could backwash more
frequently (if you have a house full
Tank In
Regeneration
Tank In
Service
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of guests, for instance) or
not at all for several days
(if you’re on vacation).
Demand
operation
means the system backwashes when necessary (when the media
tank’s capacity is reached),
not based on an estimated
time interval. So demand operation
ensures maximum efficiency and
less waste from unnecessary backwashes while providing you with a
continuous supply of filtered
water, even as your water usage
changes.
Countercurrent Backwash
A process known as countercurrent
backwashing forces water through
the media bed in the opposite water
flow direction. Particles trapped in
the media bed are loosened and
flushed to drain. Kinetico is able to
effectively use countercurrent
backwashing, recognized as the
optimum process for backwashing,
since our filters have twin tanks and
can backwash with filtered water. If
filtered water isn’t used,
countercurrent backwash
is less effective.
Twin Tank Design
The twin tank design of
a Kinetico Para-Flo Backwashing Filter allows the
unit to provide parallel service
– both tanks are in service simultaneously.Twin tanks also provide you
with a continuous supply of filtered
water 24 hours a day, even through
the backwashing process. When a
backwash is necessary, one tank
backwashes while the other tank
remains in service. When the backwash process is complete, the tank
that was backwashed goes back into
service. Once again, both tanks are in
service simultaneously. When the
second tank needs to be backwashed, the first tank remains in
service while the second backwashes.
Parallel service is resumed again after
the backwash process.Thanks to the
twin tank design, you can do a
week’s worth of laundry in one day.
Your Kinetico Filter can handle it.
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The Kinetico Para-Flo Backwashing Filter
Your Kinetico Para-Flo Backwashing
Filter is engineered to provide you
with quality water without requiring extensive maintenance. Should
you have any questions or
need any assistance, contact
your
local,
authorized Kinetico
dealer.
Note:
Leaky
faucets, toilets or
pipes should be
repaired to ensure
proper product performance.
Maintaining Your Para-Flo
Backwashing Filter
The media used in your Kinetico
Para-Flo Backwashing Filter will
provide you with years of service,
but certain media may eventually
require replenishment or replacement. How long the filtering media
lasts depends on your specific water
conditions. If the problem your
system was installed to correct
returns, it could mean your water
conditions have changed and your
system may only require a slight
adjustment by your local, authorized
Kinetico dealer.Your Kinetico water
professional will determine if the system needs adjustments or if the
media bed needs to be replenished.
Manual Backwash
If your water problem reappears,
manually backwash your system to
see if the change in your water
conditions is temporary.
To manually backwash your system,
depressurize the system by turning the
by-pass valve to the
“OFF” position (see
By-pass section) and
opening a faucet somewhere in your home until
the pressure is relieved. The
procedure will make it easier to
manually backwash your filter.
Using a Phillips screwdriver, push
down firmly on the filter valve
screw located on top of the control
valve and slowly turn clockwise
(ONLY) (fig. 1) until the actuator
has advanced the indicator dot
(fig. 2 ) to the “BACKWASH” position . You should hear at least five
“clicks” while turning the screw
before the indicator dot reaches the
“BACKWASH” position. Return
the by-pass valve to the service
position. At this point you should
hear water begin to run through
the system. If you do not hear
water running through the system,
the indicator dot has not been
advanced far enough and you must
repeat the previous procedure.After
one tank backwashes, repeat the
procedure for manual regeneration
after the water flow stops to be sure
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both media tanks are backwashed.
Protection Against
Cold Temperatures
NOTE: Never turn the filter valve
screw counterclockwise.
By-pass
Set the by-pass to the “OFF” position when you need to shut off the
water supply to your entire house.
No water will flow through the
house. To restart the water, set the
by-pass valve to the “SERVICE”
position.You may by-pass the filter
at any time, if necessary, by putting
the by-pass valve into the “BYPASS” position. You will still get
water throughout the house; however, all of the water will be unfiltered.To return the filter to service,
set the by-pass valve to the “SERVICE” position.
If your Kinetico Para-Flo Backwashing Filter is installed outside or
in an area that is not heated, you
may want to take precautionary
measures to prevent damage to your
unit from freezing.
NOTE: Kinetico’s warranty doesn’t
include damage to your system due
to freezing.
If you have questions about your
Kinetico system, or if you suspect
that it isn’t working properly, contact your local, authorized Kinetico
dealer.
NOTE: By-pass styles vary and yours
may not be as described. Contact
your Kinetico dealer for further
assistance.
fig. 1
fig. 2
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0DFKI2'0DFUROLWH
6\VWHP&RPSRQHQWV
Media Vessel (qty) Size .......................................................... (2) 8 x 40”
Media Vessel Construction ................................ Wrapped Polyethylene
3
Empty Bed Volume ...................................................................... 1.04 ft
Media ................................................................. 40 x 60 Mesh Macrolite
3
Media Volume .............................................................................. 0.40 ft
Under bedding (each tank)................................................. ǩ x ¼ Gravel
3
Under bedding Volume (each tank) .............................. 0.06 ft (6.0 lbs.)
Riser Tube.................................................................................... 1” ABS
Distributor
Upper ........................................................................None
Lower ................. 0.007” Slots, Engineered Plastic Basket
Regeneration Control ..........................................Non-electric Use Meter
Service ....................................................................................Down-flow
Backwash.................................................................................... Up-flow
Meter Type ............................. .0.30 - 25.00 gpm Polypropylene Turbine
´
,QOHW:DWHU4XDOLW\
Pressure Range .................................... 15 – 125 psi Dynamic Pressure
o
Temperature Range ............................................................. 35 – 120 F
pH Range ................................................................................ 5 – 10 SU
46”
2SHUDWLQJ6SHFV
Service Flow Rate (15 – 30 psig) .................................... 8.0 – 12.0 gpm
Optimal Media Flow Rate (service) ............................................ 7.0 gpm
Flow Configuration ............................................................... Overdrive™
Dimensions (width x depth x height) .....................................17 x 8 x 46”
Weight (Operating / Shipping)............................................300 / 120 lbs.
&RQQHFWLRQV
Inlet / Outlet Connections.............................Custom Adapter and E-Clip
Drain Connection ....................................................................... ½” Tube
Secondary Drain Connection .................................................... .Ǫ” Tube
Power ..............................................................................................None
6\VWHP3DUW1XPEHUV
Mach 2060f Overdrive, Macrolite Filter ......................................... 11211
Mach 2060f Overdrive, No Media ................................................. 11206
$FFHVVRU\
Lock-out Kit (for installation with a softener) ................................... 8070
17”
8”
5HJHQHUDWLRQ6SHFLILFDWLRQV
Backwash Volume................................................................... 85 gallons
Backwash Time......................................................................20 minutes
Backwash Flow Control............................................................ 4.00 gpm
'LVF6HOHFWLRQ
Usable Gallons between Backwash
2,168
1,084
723
542
434
366
310
271
2SHUDWLQJ3URILOH
The filter shall remove suspended solids to a nominal rating of 5 micron. Ceramic based non-consumable media shall be used
for the filtration process. The system shall provide continuous filtered water through the use of a duplex (two tank) configuration.
System backwashes shall be initiated by a water meter. The water meter shall measure the processed volume and be
adjustable.
%DFNZDVK&RQWURO9DOYH
The backwash control valve shall be top mounted (top of media tank), and manufactured from non-corrosive materials. Control
valve shall not weight more than four pounds. Control valve shall provide service and backwash control for two media tanks.
Inlet and outlet ports shall accept a quick connect, double o-ring sealed adapter. Interconnection between tanks shall be made
through the control valve with a quick connect adapter. Control valve shall operate using a minimum inlet pressure of 15 psi.
Pressure shall be used to drive all valve functions. No electric hook-up shall be required. Control valve shall incorporate three
operational cycles including; service, backwash and service flow rinse. The control valve will prevent the bypass of unfiltered
water to service during the backwash cycle.
0HGLD7DQNV
The tanks shall be designed for a maximum working pressure of 125 psi (8.8 kg/cm2) and hydrostatically tested at 300 psi.
Tanks shall be made of fiberglass-reinforced polypropylene with a 2.5" threaded top opening. Each tank shall be NSF approved.
Upper and lower distribution system shall be of a slot design. They will provide even distribution of regeneration water and the
collection of processed water.
)LOWUDWLRQ0HGLD
Each system shall use ceramic based filter media capability of operating in an average service flow of 10 gpm per square foot of
media. The media shall be solid, of a proper particle size, 40-70 mesh. A minimum 24” bed depth shall be used with the
system. Backwash shall produce a minimum of 50% bed expansion at a flow rate of 8 gpm per square foot of media.
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&OHDU)ORŒ
(SR[\&RDWHG
0HGLD)LOWHUV
2SHUDWLRQDQG0DLQWHQDQFH0DQXDO
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7DEOHRI&RQWHQWV
General Principals of Operation .............................................................................................. 3
How the Backwash Works .................................................................................................. 4
System Components – Epoxy Coated tanks with vertical inlets ( tanks F640, F650, F660) .. 7
Components – Epoxy Coated tanks with vertical inlets ...................................................... 8
System Components – Epoxy Coated tanks with horizontal inlets (Tanks F610, F620, F635)
................................................................................................................................................. 9
Components – Epoxy Coated tanks with horizontal inlets .................................................. 9
Components – Epoxy Coated tanks with horizontal inlets ................................................ 10
Accessories ............................................................................................................................ 11
Site Location .......................................................................................................................... 14
Concrete Pad Requirements .................................................................................................. 14
Installation Procedure ............................................................................................................ 15
Install Outlet Manifold ...................................................................................................... 15
Install Backwash Valves .................................................................................................... 15
Installing 1014416 Backwash Valves................................................................................ 16
Install Inlet Manifold ......................................................................................................... 16
Install Backwash Manifold Assembly ............................................................................... 16
Groove Coupling Assembly .............................................................................................. 17
Install Controller Assembly ............................................................................................... 17
Install Hydraulic Charging Assembly ............................................................................... 18
Install Tubing..................................................................................................................... 19
Install High Pressure Supply Line ..................................................................................... 19
Install Solenoid Valves ...................................................................................................... 22
Install Low Pressure Line .................................................................................................. 22
Install Pressure Differential Gauge/Switch ....................................................................... 23
Install Pressure Differential Gauge/Switch ....................................................................... 24
Media Loading Instructions ................................................................................................... 25
Pre-Start-Up Checklist........................................................................................................... 26
Start-Up Procedure ................................................................................................................ 27
Initial Cleaning of Tanks ................................................................................................... 27
Final Adjustments .............................................................................................................. 27
Backwash Throttle Valve Adjustment............................................................................... 27
Pressure Gauge Assembly ................................................................................................. 27
Pressure Differential Adjustments ..................................................................................... 28
Scheduling Backwash Cycles ............................................................................................ 28
Backwash Flush Time ....................................................................................................... 28
Dwell Time ........................................................................................................................ 28
Periodic Start Function ...................................................................................................... 29
Recommended Maintenance Schedule .................................................................................. 30
Season Start-Up ................................................................................................................. 30
At Every Irrigation............................................................................................................. 30
The First Week of Every Month ........................................................................................ 30
Mid Season ........................................................................................................................ 30
Post-Season Shutdown ...................................................................................................... 31
Other Maintenance Considerations ....................................................................................... 31
Trouble Shooting ................................................................................................................... 33
Foreword: - The following manual is intended for use for both stainless steel and epoxy
coated media tanks.
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General Principals of Operation
The principal of sand media filtration is quite straightforward. The irrigation source water is
pressurized and introduced into the top of the media tanks. A diffusion plate in the top
throat of the tank serves to reduce water velocity and distribute the water evenly across the
top of the media bed. The media bed is a layer of size-graded crushed silica sand about
400mm in depth. The contaminates in the water are captured in the media bed and filtered
water passes into the discharge manifold at the bottom of the tanks.
Figure 1
Filtration Mode
Sand media filters are effective at filtering both organic and inorganic contaminants. The
large tank size and three-dimensional nature of a media bed provides more contact area and
has greater holding capacity than many other types of filters. Determining filter capacity
and understanding the backwash function (cleaning) of your system are among the most
important aspects of successful filtration. These operations and more will be covered in the
following pages.
The key to superior media filtration is
the effective removal of the captured
contaminates from the media bed,
commonly referred to as
"backwashing". Located in the bottom
of every media filter tank is a highly
engineered underdrain system that is
designed to perform two functions.
First it must not allow any media sand
to pass through the filters and into the
irrigation system.
Figure 2 – Typical “mushroom”
Second, during the backwash operation it must
strainers in base of tank
allow the flush-water to be evenly distributed
throughout the entire media bed, with no pockets or dead spots. This insures that the media
is lifted and uniformly rinsed free of contaminants in an efficient manner.
The epoxy coated tanks have a false floor with a series of plastic “mushroom” like strainers
installed into the floor.
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Covering these elements is a layer of gravel. The purpose of the gravel is to deflect the
high-velocity backwash water and create a very uniform flow, capable of gently lifting the
media in the most efficient manner possible. Efficient backwashing results in cleaner media
sand and shorter backwash cycles.
How the Backwash Works
The backwash operation is accomplished by
sequentially flushing each tank in a series of
two or more filters. To backwash a tank, the
small 3-way control valve on the backwash
valve is either manually or automatically
turned to the ON position. This allows
pressurized water from the hydraulic
command system to fill the actuator
diaphragm and push the piston into the
backwash valve. Connected to this piston is
a two-sided valve plunger. In the nonactuated position, the spring-loaded valve is
Figure 3
seated between the tank inlet and the backwash
discharge manifold. This prevents water from escaping into the backwash system during the
filtration mode. When actuated, the piston and valve seal move across the inlet port of the
tank and seat against the intake manifold, (where unfiltered water enters the tank). This
single motion prevents unfiltered water from entering the tank and allows pressurized
filtered water in the irrigation system to escape backwards through the tank and out the
backwash manifold. Because the backwash flow is dependent upon a source of filtered
water from the irrigation system, all media filter systems require at least two tanks, one to
supply filtered water for the other tank that is flushing. It is important to keep in mind that
only one tank should be flushed at a time.
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The Backwash throttle valve is placed on the
backwash discharge manifold to control the volume
of water that can escape during back-wash.
Obtaining the proper flow rate of the backwash
water is critical for effective flushing. Too high a
flow rate will flush all of the media out of the tank.
Too low a flow rate will not allow the media to
gently lift, fluidize and flush the contamination
from the sand. The proper flow rate is dependent
upon tank diameter, as shown in the accompanying
table. The most common way to adjust the
backwash throttle valve is to manually set one filter
to backwash with the throttle valve fully closed.
Slowly open the throttle valve until small amounts
Figure 4
of media are evident in the backwash discharge. It is
most desirable to place a nylon stocking or fine mesh screen over the discharge pipe to
check for the presence of media. If this is not possible, a sight tube can be used as an
alternative. It is desirable to have a slight amount of media discharged during the backwash.
You should expect to loose 50 to 80mm of sand per season (50-90 kg. per 1200mm tank).
Although the media bed is about 400mm deep, it makes the most sense to try to keep the
contamination in the top 50 to 100mm. This allows you to quickly rinse the sand during a
backwash sequence. If the lower depths of media become contaminated, it will take much
longer to rinse the sand and you run the risk contaminating the underdrain. In order to
prevent contamination from reaching the lower depths of the media bed, proper backwash
frequency and duration must be determined.
The backwash frequency is dependent upon the characteristics of the contaminants present
in the source water. Although Toro’s automated backwash controller is equipped with a
logic circuit to initiate a back-wash when the pressure differential across the filters reaches a
given level, (typically 30-40 kPa higher than when the tanks are clean), it is sometimes
more desirable to initiate a backwash sooner than this. Very fine silts, for example, are able
to migrate deeply into the media bed before an appreciable pressure differential is reached,
and they become difficult to remove. Algae and other organic matter tend to harden and
cake with time, cementing the media together if not flushed on a regular basis. Therefore, it
is a good idea to set the controller or manually flush the filters once daily, as a minimum.
For heavier loads of contaminants, perhaps every two to four hours. In many installations
the water quality changes during the season, and the irrigator is wise to adjust the backwash
frequency to the current conditions.
The backwash duration is dependent upon the characteristics of the contaminants and the
backwash frequency. A 90-second flush duration should be adequate if the captured
contaminants are large particles such as flakes of rust, weed seeds and leaves, which will be
laid out upon the surface of the media bed. If the contaminates are fine silts that migrate
into the media bed, the backwash duration becomes more a factor of how deep they have
migrated, which is directly related to how often the filters are flushed. This is why it is
important for the irrigator to periodically observe a backwash sequence and confirm that the
duration is of sufficient length to remove all of the contaminants. The backwash water
should run clear for 15-20 seconds before the valve is signalled to close.
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The operational speed of the backwash valves is a critical factor in determining the
backwash duration. When the valve is signalled to open and the actuator diaphragm is
filling and pushing the valve piston back, unfiltered water is able to pass underneath the
valve seals and escape into the backwash manifold. To the untrained irrigator it appears that
the filter is flushing, although it is not. Backwashing does not begin until the piston and
valve are fully seated against the intake port, closing off that high-pressure unfiltered water.
Only then can the lower-pressure filtered water from the bottom of the filter escape through
the backwash manifold, carrying with it the filter contaminants.
A new backwash valve operating with good system pressure (250-500 kPa) will fully open
in 10-15 seconds. Older valves operating in corrosive or dirty environments can take longer
to open because of wear and tear on the piston, bushing and R-rings. The filter for the
hydraulic control system needs to be cleaned periodically to insure that the valve pistons are
receiving clean high-pressure water to operate the valves. It is not uncommon to find one or
two filters in a multi-tank system that have slow-acting backwash valves and these tanks are
never properly flushed. Occasional careful observation of an entire backwash sequence and
periodic inspection of the media will alert the irrigation team to these potential problems.
The dwell time setting on the automatic controller allows you to select the amount of time
the controller waits for one valve to close before signalling the next valve to open. This
enables you to adjust for slow-acting valves or allows the irrigation system to rebuild its
pressure between flushes. If the system pressure drops to a point where it is affecting the
filtration backwash capacity, it may be necessary to place a pressure-sustaining valve on the
discharge side of the filter station. This valve will automatically partially close off the flow
to the field, allowing the pressure of the filter tanks to be sustained at a pre-set level.
It is important to periodically inspect the media. Begin by draining the filters and
opening the inspection ports. The sand should be level and up to the fill line (sticker placed
on outside of tank). Dig down through the sand, looking for clay lenses or mud balls that
indicate improper backwashing dynamics. If there is any evidence of contaminates reaching
the bottom of the media bed, it may be necessary to adjust the backwash frequency or
duration. In cases of severe contamination, it may be necessary to remove all of the gravel
and media from the filter and replace it with new material. (Periodic inspection will catch
most situations before they become this severe.) With new systems, it is advisable to check
the media monthly during the first season, and thereafter once or twice per season. Before
replacing the inspection covers remember to top off the tanks with your selected media.
We hope this summary has increased your understanding of the principals of operation of
your new Clear-Flo filtration system. The pages that follow will guide you through
installation, maintenance and trouble shooting.
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System Components – Epoxy Coated tanks with vertical
inlets ( tanks F640, F650, F660)
System components are divided into two categories: Components; items included with
your filter purchase and Accessories; recommended items that are not included with your
filter. The diagram below identifies Components. See tables below for item descriptions.
Figure 5
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Components – Epoxy Coated tanks with vertical inlets
Item Label
A
B
C
D
E
F
G
H
I
J
K
L
M
N
Description
Filter tank
Inlet Manifold
Victaulic Coupling
Inlet Manifold Support
Outlet Manifold Support
Backwash Valve – no coil
Hydraulic Charging Head
Flanged Inline Strainer
50mm Poly Plug
20mm Poly Plug
M16 x 50mm GI Nut, Bolt and Washer
Table D Insertion Gasket
Hydraulic Tube Kit – suits up to 3 tanks
PTFE Tape – one roll per tank
The Hydraulic Tube Kit includes the following:Item
Plastic Elbow 1/8”MBSP x 8mm
Plastic Tee 1/8”MBSP x 8mm
Plastic Adaptor ¼” MBSP x 1/8” FBSP
Plastic female connector 1/8” FBSP x 8mm
Plastic Union Elbow – 8mm
Plastic Union Tee – 8mm
Brass Nipple – 1/8” MBSP
Plastic Director 1/8” MBSP x 8mm
¾” x ¼” Screwed Bush
3M 316IR Cable Connector
12mm x 10m PTFE Tape
8mm Tube x 10m
1mm2 x 2 core Cable x 50m
Hex plug ¼”
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1
1
1
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System Components – Epoxy Coated tanks with
horizontal inlets (Tanks F610, F620, F635)
System components are divided into two categories: Components; items included with
your filter purchase and Accessories; recommended items that are not included with your
filter. The diagram below identifies Components. See tables below for item descriptions.
Figure 6
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Components – Epoxy Coated tanks with horizontal inlets
Item Label
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Description
Filter tank
Inlet / Outlet Manifold
Hex Nipple
Bush
Victaulic Adaptor
Victaulic Adapator
Victaulic Clamp
Support Manifold - long
Support Manifold - short
2” x 2” Backwash Valve with 24VAC coil
Hydraulic Charging Head
Manual Screen Filter
50mm Poly Plug
20mm Poly Plug
Gasket
GI Bolt/Nut/Washer
The Hydraulic Tube Kit includes the following:Item
Plastic Elbow 1/8”MBSP x 8mm
Plastic Tee 1/8”MBSP x 8mm
Plastic Adaptor ¼” MBSP x 1/8” FBSP
Plastic female connector 1/8” FBSP x 8mm
Plastic Union Elbow – 8mm
Plastic Union Tee – 8mm
Brass Nipple – 1/8” MBSP
Plastic Director 1/8” MBSP x 8mm
¾” x ¼” Screwed Bush
3M 316IR Cable Connector
12mm x 10m PTFE Tape
8mm Tube x 10m
1mm2 x 2 core Cable x 50m
Hex Plug ¼”
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Accessories
(Extras required to complete the system. These items are not included in the system
componentry because they are site specific)
1. Solenoid and Base:
These are supplied as accessories because the available voltage will vary from site to site.
The correct coil and base must be
a) Normally Closed,
b) orifice size must be 1.8mm or greater,
c) 3 way,
d) the same voltage as that of the controller output.
Options supplied by Toro for backwash valves are:•
•
•
•
S390-3DB24VAC – 24 VAC, normally closed, 3 way coil and base
F011-SOOA - 24VAC, normally closed, 3 way coil and base
S-985 - 12to40VDC Latching, 3 wire, 3 way coil and base, NO/NC
982-3B - 12 to 40 VDC Latching, two wire, 3 way coil and base, NO/NC
F011-SOOA
S390-3DB24VAC
S-985 and 982-3B
Figure 7
2. Filter Flush Controller – 8 station (Code: 101FFC8)
As with the solenoids, the controller can be determined once the power on-site is known.
Toro’s 8 station filter flush controller will operate on various voltages (user selectable)
•
•
•
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240VAC
24VAC
12VDC
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Please note, some irrigation controllers, such as the MicroMaster 4500 controller have a
filter flush program that can be used WR control the filter flushing. In instances like this, a
dedicated filter flush controller may not be required.
3. Filter Flush Controller Plate. (Code : 101FFCP)
All the filter inlet manifolds have a 25mm FBSP half socket (blind) welded at one end. The
filter flush controller plate has an opposite MBSP thread so that the plate can be screwed
onto the inlet manifold. The plate also has a hole cut to locate a Murphy pressure gauge and
four pre-drilled holes to suit mounting of the 101FFC8 filter flush controller.(Note, screws
not supplied)
4. PD Switch
The switch measures the difference in pressure from the inlet manifold to the outlet
manifold. When connected to the PD terminals of the filter flush controller, it will trigger
the filter flush program on the controller. Toro has two PD gauges to select from, depending
on the pressure differential range required. Each gauge comes with two 8mm tube x 1/8”
FBSP female connectors.
Code
A20DPK15-K
A20DPK30-K
Differential Range
(kPa)
0 - 100
0 - 200
5. Backwash manifold (Normally not supplied)
The pipework taking the backwash water away from the filter station is generally uPVC,
ABS or MDPE. Care should be taken to properly support the pipework according to
manufacturer’s specifications.
6. Backwash Throttle Valve (Normally not supplied)
To assure correct backwash flow from the media tanks, it is necessary to install a gate valve
to throttle flow on the backwash manifold outlet.
7. View Tube .(Item not supplied by Toro Ag.)
Enables visual inspection of the backwash water. A view tube is a handy tool where the
backwash water is directed back into a dam, and access to view the quality of the backwash
water is restricted.
8. Backwash Manifold Air Vent (Normally not supplied)
Facilitates draining and prevents vacuum from developing in the backwash piping.
9. Pressure Relief Valve (Normally not Supplied)
Installed in the supply system pipe within 1 metre of the inlet manifold connection to
protect the filters from over-pressurization.
10. High Pressure Shut-off Switch .(Item not supplied by Toro Ag.)
Preset to shut down system in case of over pressurization.
11. Continuous Acting Air Release valve (Normally not supplied)
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Evacuates air during initial system charging and during operation. This should be installed
on the pipework connecting to the inlet manifold flange.
12. Pressure Sustaining Valve (Normally not supplied)
Installed on the discharge outlet of the back-up filter for two (2) reasons. First, the valve
facilitates backwash of the media upon initial start-up. Second, it permits throttling of the
outlet flow to increase backwash and allow occasional deep cleaning cycles.
13. Flow Meter .(Item not supplied by Toro Ag.)
A flow meter is helpful in determining the quantity of irrigation water applied and in
monitoring pump performance. A flow meter may also be used to more precisely determine
the proper duration of the backwash cycle.
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Site Location
Select a site which is readily accessible for installation and servicing of the filter. Other
factors to consider are: location of power source for automation control, provision for
backwash water disposal, and safety and security of equipment and operators.
Concrete Pad Requirements
The concrete pad supporting the filter unit must be level and relatively smooth. The pad
should be flat within 3mm from end to end. Allow sufficient curing time before installing
the tanks and pipework. Minimum pad dimensions are shown on the assembly drawing on
the tank system. Dimensions allow for a minimum 600mm clearance from filter components
to the edge of the concrete. Dimensions can be reduced if the filter system is not going to be
enclosed.
Epoxy Coated Steel Tanks
Filter Assembly Code
No. of Tanks Length (mm)
101FSP0216
2x400
2838
101FSP0316
3x400
3683
101FSP0416
4x400
4233
101FSP0220
2x500
3234
101FSP0320
3x500
3884
101FSP0420
4x500
4692
101FSP0225
2x635
3384
101FSP0325
3x635
4291
101FSP0425
4x635
5041
101FSP0230
2x760
3782
101FSP0330
3x760
5007
101FSP0430
4x760
5917
101FSP0236
2x900
4036
101FSP0336
3x900
5400
101FSP0436
4x900
6450
101FSP0348
3x1200
5639
101FSP0448
4x1200
7009
101FSP0548
5x1200
8457
101FSP0648
6x1200
9827
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Width (mm)
2076
2153
2153
2204
2204
2239
2297
2325
2325
2369
2369
2369
2424
2454
2454
3180
3156
3156
3156
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Installation Procedure
Install Outlet Manifold
Couple outlet manifold to tank bottom ports (see item B Figure 5 or item B Figure 6). Do
not fully tighten VICTAULIC groove couplings (see Victaulic Groove Coupling Assembly
instructions below). Install manifold support(s) for the outlet manifold (see item E Figure 5,
item I Figure 6). Please note that the support is a universal outlet support and may need to
be cut to length on-site to suit the actual manifold height.
Install Backwash Valves
Couple backwash valves to media tanks. Do not install backwash valve upside-down. Ports
may be the same size on some models (see diagram below for details).
Figure 8
1014416
BFLV32/
BFLV43
Tank
Inlet
Backwash
Inlet
Manifold
Arrow points
Towards tank
Valves for Epoxy Coated Tanks
Tank
Size
(mm)
400
500
635
760
900
1200
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Flush Valve
1014416LS
1014416LS
1014416LS
BFLV32
BFLV32
BFLV43
Taylex
Tanks
Inlet Port Tank
(mm)
Port
(mm)
50
50
50
50
50
50
80
80
80
80
100
100
Flush
Port
(mm)
50 FBSP
50 FBSP
50 FBSP
50 FBSP
50 FBSP
80 FBSP
Wastewater & Rainwater Specialists
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Installing 1014416 Backwash Valves
These valves are used only on tanks F610, F620, F635.
The valves come from the factory with a victaulic x threaded fitting screwed into each port.
Before installing the valve, unscrew the three victaulic adaptors from each valve.
Figure 9
Install Inlet Manifold
Couple the inlet manifold to the backwash valve inlet ports. Install manifold support(s) for
the inlet manifold (see item D Figure 5 or item H Figure 6). Please note that the support is a
universal inlet support and may need to be cut to length on-site to suit the actual manifold
height.
Install Backwash Manifold Assembly
The backwash manifold assembly is normally constructed on-site using either uPVC or
medium density poly pipe and fittings. Neither pipe nor fittings for the backwash manifold
are normally provided with the filter. It is necessary to install a throttle valve (C) for proper
backwash flow regulation. The optional view tube will facilitate proper adjustment of the
throttle valve and aid in adjusting the length of the backwash cycle, especially where the
backwash line is fed back into a dam and inspection of the backwash water is restricted.
Always install an air-vacuum relief valve on the backwash manifold. Tighten all groove
couplings when above steps are completed.
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Groove Coupling Assembly
Check gasket for defects. Apply a thin coat of
lubricant to the gasket lips and outside of gasket.
Place gasket over pipe end, being sure it doesn't
overhang the pipe lip. Align and bring the two pipe
ends together and slide the gasket into position
centred between the grooves on each pipe. No
portion of the gasket should extend into the
grooves. Place clamp over the gasket, being sure it
engages the grooves. Insert bolts and tighten nuts
alternately and equally until housing bolt pads are
firmly together metal to metal. Excessive nut
tightening is not necessary. Caution: Uneven
tightening may cause gasket to pinch.
Figure 10
Install Controller Assembly
Locate the controller on the opposite end of the charging assembly. Screw the controller
mounting bracket (code 101FFCP) onto the blind 25mm threaded off-take on the inlet
manifold. The bracket has a hole in the top left hand side for mounting a Pressure
differential gauge/switch (code A20DPK30-K or A20DPK15-K). Drill holes as required in
bracket and secure controller to the bracket.
Refer to the controller manual for connection of power supply, solenoid cables and PD
switch. The controller manual is packaged with the controller.
Connecting the 2 wire 982-3b solenoid to the 8 station filter flush controller (101FFC8)
1. Firstly program the controller
to let it know that it will be
operating 12 VDC latching
coils. To do this, go into the
Commissioning mode,
stepping through until the
solenoid coil is displayed.
Change this to 12 VDC.
2. Next, step to the solenoid
type and change this to 2
wire latching. (Please be
aware that the manual
supplied by the manufacturer
shows that a 3 wire latch
Figure 11
option is available on this
controller. This is not the
case. The only options are Standard or 2 wire latch.
3. Final step is to connect the solenoid leads to the controller terminals. Connect the
BLACK lead to an active terminal (1 to 8) and the RED lead to one of the two terminals
marked COM. See photo, Figure 11.
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Connecting the 3 wire S-985 solenoid to the 8 station filter flush controller (101FFC8)
1. Firstly program the controller to let it know that it will be operating 12 VDC
latching coils. To do this, go into the Commissioning mode, stepping through until
the solenoid coil is displayed. Change this to 12 VDC.
2. Next, step to the solenoid type and change this to 2 wire latching. (Please be aware
that the manual supplied by the manufacturer shows that a 3 wire latch option is
available on this controller. This is not the case. The only options are Standard or 2
wire latch.
3. Final step is to connect the solenoid leads to the controller terminals. Connect the
RED lead to an active terminal (1 to 8) and the WHITE lead to one of the two
terminals marked COM. Note, the BLACK lead is not used. See photo Figure 12.
1
2
3
5
4
6
7
8
Figure 12
Install Hydraulic Charging
Assembly
Thread the hydraulic charging
assembly onto the 20mm tapping on
the inlet manifold.
Use only PTFE tape as a thread
sealant.
Figure 13
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Install Tubing
Cut tube squarely and remove any burrs. Loosen nut on fitting until three (3) threads are
visible. Moisten end of tube with water. Push tube straight into fitting until it meets the
fitting's shoulder. Tighten nut by hand, additional tightening should not be necessary. Do
not over tighten.
Note:
Water will be exhausted through the exhaust port of each solenoid every time each tank is
flushed. To avoid having water discharged onto the floor around the filter, install a length of
tubing, attached to the exhaust port of each solenoid valve to direct exhaust water from the
actuator to outside the filter unit area.
Install High Pressure Supply Line
Use PTFE tape thread sealant on all threads .
Install hydraulic tube from the elbow upstream of the pressure gauge on the Hydraulic
charging head to the “pressure” port of each solenoid base and then onto the PD switch.
Schematics depending on the type of valve and coil being used are shown in Figures 14 and
15.
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Figure 14 – Typical Schematic for BFLV32, BFLV43, 1014416 Valve with S-985 or 9823B Coil and Base
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Figure 15 - Typical Schematic for BFLV32, BFLV43, 1014416 Valve with S3903DB24VAC Coil and Base.
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Install Solenoid Valves
Use only PTFE tape as a thread sealant. Solenoid ports are stamped for identification.
Bermad S390-3DB24VAC, S-982, S-985 Solenoids and Bases
Check that the base has a green coloured manual over-ride handle. This signifies that the
coil and base is configured correctly as a normally closed coil and base.
The Port stamped “1” is the high pressure port and connects to the pressure line from the
high pressure line from the hydraulic charging assembly. The port marked “2” or “C” is the
common port and connects to the bonnet of the backwash valve, via a screwed bush and
nipple or hydraulic tube.
The port stamped "3” is the Exhaust Port and is vented to the atmosphere. See Figures 14
and 15 for plumbing schematics.
Install Low Pressure Line
Use PTFE tape thread sealant on all threads .
Install hydraulic tube from the offtake on the discharge manifold to the Hydraulic charging
head and then onto the PD switch.
At the Hydraulic Charging Head connect to the port on the 3 way brass tap marked
“OPEN”.
Figure 16 – Typical connection Low pressure line to Discharge Manifold
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Figure 17 – Typical Low pressure Hydraulic plumbing Schematic
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Install Pressure Differential Gauge/Switch
Push the gauge through the hole in the controller
mounting bracket. Using the mounting U shaped
bracket supplied with the gauge, secure the gauge to
the controller bracket.
Connect the hydraulic tube from the low pressure
off-take to the port on the back of the gauge marked
“L”. Be careful not to use a spanner or wrench on
the port as it will possibly cause damage to the
gauge. Connect the high pressure tube from the
hydraulic charging assembly to the port marked
“H”.
Determine whether the filter flush controller
Rear View of PD Switch
requires a normally open or closed PD sensor. The
MicroMaster® and the 8 station filter flush
controller both require a normally open sensor. Install wires from the terminals on the back
of the gauge that correspond with the type of sensor required (eg for normally open use the
terminals marked NO and C. Please note that the terminal screws are provided with the
gauge in their own plastic sealed bag. Connect the two wires into the appropriate terminals
of the controller. (Refer controller manual).
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Media Loading Instructions
Remove tank access covers and inspect the inside of the tanks for debris. Check element
covers in the base of each tank to be sure all are secure.
Load media in accordance with media requirements (see tables below). Gravel should be
installed first, ensuring an even layer over the tank floor.
After media has been loaded, secure access covers.
On the 600mm Stainless steel tanks you will notice a raised tab on each of the brackets that
holds the nuts that secure the lid to the tank. These tabs are stops for the lid to set against.
Correct torque on the bolts is reached when, with the gasket in place, the bolts are tightened
enough to bring the lid in contact with the tabs. Do not over tighten!
Having loaded the media, the filter system is ready for the pre-start check list.
Epoxy Coated Steel Tanks
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No. of Tanks
Gravel (25kg bags)
Sand (25kg bags)
2x400
3x400
4x400
2x500
3x500
4x500
2x635
3x635
4x635
2x760
3x760
4x760
2x900
3x900
4x900
3x1200
4x1200
5x1200
6x1200
2
3
4
3
4
6
5
7
9
7
10
14
9
13
18
30
40
50
60
6
9
12
9
14
18
15
23
31
21
32
42
31
47
62
66
88
110
132
Wastewater & Rainwater Specialists
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Pre-Start-Up Checklist
1. Check power to the controller. Be sure voltage corresponds to that required by the filter
flush controller.
2. All grooved couplers should be fully tightened.
3. Check access covers, ensure gaskets are in place and lids are properly tightened.
4. Power to the controller should be in the OFF position.
5. Open the on/off valve to allow passage of water from filters to field.
6. Close the backwash manifold throttle valve.
7. Place one backwash valve in manual backwash mode (manual override screw/lever in the
on position.
When the arrow on the manual override screw is pointing to the Off position the valve will
be in normal operating mode.
To place a backwash valve into the backwash mode, rotate the arrow to the On position.
The backwash valve will be open and remain open until the override screw is turned back to
the Off position. Be sure the controller is in the Off position when manually operating
solenoid valves.
WARNING! Over-pressurization can cause serious damage to any hydraulic system. Check
the maximum pressure capacity of the pump or system supplying water to the filtration unit.
Several conditions during start-up and operation can stop water flow, producing a full head
of static pressure within the filter unit. Protect against damage by installing a pressure relief
valve with capacity sufficient to adequately discharge over- pressurization. In systems
where the supply to the filters is elevated, "water hammer" can cause rapid pressure spikes
significantly higher than the systems normal operating pressure. Consult the manufacturer
for all installations where supply elevations exceed the filter elevation. Over-pressurization
can severely damage filter tanks.
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Start-Up Procedure
Initial Cleaning of Tanks
Start pump or open valve supplying pressurized water to the filters. The backwash valve
previously set in the manual backwash mode will open and begin a backwash cycle. Open
the back-wash valve until a small amount of media is visible in the view tube.
Initial flow through the filters may be sluggish for several cycles. To speed up the initial
cleaning of the tank, close the outlet valve until a healthy backwash flow appears in the
view tube. Wait approximately two minutes then rotate to a second tank by closing the
override screw/lever on the first solenoid and opening the second. Repeat this procedure
until all filter tanks have been backwashed a minimum of three times. BACKWASH ONLY
ONE TANK AT A TIME!
All tanks contain contaminants and fines prior to initial backwash. Flow through the media
system will be sluggish until some cleaning occurs. If, after three backwash rotations, the
tanks are not yet clean, continue with additional cycles until cleaning occurs.
The backwash valves operate hydraulically and take 10 to 15 seconds to fully open. While
the valve is opening, flow through the backwash manifold will be higher than normal. When
the valve is fully open the flow will decrease and the backwash water will become dirty in
appearance. Do not attempt to adjust the system until the valve is fully open. Early
differential readings are not accurate until the system is fully operational. After the initial
cleaning of the media filter, set regulators and repair any leaks. When the system is
operating properly, proceed with final adjustments.
Final Adjustments
Backwash Throttle Valve Adjustment
Pre-set the controller for a 90 second backwash and a 30 second dwell time. Turn on
controller power and initiate a flush cycle (see controller instructions). Adjust the backwash
throttle valve as follows: During the flush cycle, check the backwash water through the
view tube, or catch a backwash sample using a fine sieve. Adjust the back- wash throttle
valve downward until only a trace of media is being lost and the backwash valve is fully
open. Use the field throttle valve to direct additional flow for backwash. Adjust backwash
flow until a minute loss media occurs. (In systems where backwash flow is inadequate, the
throttle valve must be adjusted in this manner each time a backwash cycle is initiated.)
WARNING! Failure to follow the above procedure may cause differential pressure to build
gradually and the frequency of required backwash cycles to increase.
Pressure Gauge Assembly
Because pressure gauges vary in accuracy, a single gauge is utilized to measure both
incoming and outgoing pressure. A 3-way ball valve directs distribution of pressure to the
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gauge from the top (inlet) manifold or the bottom (outlet) manifold. Rotate the lever to read
either inlet or outlet pressure.
Pressure Differential Adjustments
The pressure differential (P.D.) switch, located on the controller mounting plate, measures
the differential pressure between inlet and outlet pressure. When the difference between the
two, increases to a preset level, the switch signals the controller to begin a backwash cycle.
The P.D. setting can be changed by adjusting the knob on the face of the P.D. switch. Take
note of what the differential is across the inlet and outlet after the tanks have been
thoroughly cleaned. This is the inherent “clean water” loss across the filter. Adjust the PD
trigger point to approximately 30-40 kPa above this inherent loss. This is done by turning
the red dial on the gauge face.
Scheduling Backwash Cycles
The quality of the source water will dictate the frequency required. A backwash cycle
should begin when the P.D. increases 30-40 kPa. above the "optimum system differential"
(the differential when all tanks are clean).
Backwash Flush Time
Backwash flush time is adjusted on the filter flush controller. Start with a 90 second setting.
Observe the water quality at the beginning and end of a backwash cycle through the view
tube or at the outlet of the backwash manifold. If the backwash water is still dirty near the
end of the cycle, increase the flush time. If the water appears clean several seconds before
the end of the cycle, decrease the flush time. In addition to the water quality, check the
pressure differential after backwash. If the P.D. has returned to the optimum level, the flush
duration is adequate. If not, increase the backwash duration until optimum differential is
achieved.
Note: As the backwash valve open and closes, water from the back-wash manifold is mixed
with incoming water from the inlet manifold. The first and last 15-20 seconds of flow will
be diluted in this manner and is not representative.
Dwell Time
The dwell between tanks enables the irrigation system pressure to recover before the next
tank flushes. This delay provides the system with a full head of pressure with which to
initiate flushing of the next tank. To adjust the dwell time, observe the backwash cycle of
the last tank in the battery. Calculate the length of time from the end of the cycle until
maximum system pressure is regained. This is the approximate time that should be set as
dwell time.
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Periodic Start Function
The periodic start function is used to set the interval between time initiated flush cycles.
This is useful when the period between PD initiated flushes can be a long period, ensuring
that the filters get a regular flush, or to act as a back-up to the PD switch should it fail.
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Recommended Maintenance Schedule
The following maintenance schedule is based upon field observations of typical Clear-Flo
installations. It should be thought of as a starting point for a systematic maintenance
program, not as a hard and fast set of tasks that must be completed to be successful.
Season Start-Up
Note: This assumes that the Post-Season Shutdown procedures were performed. If this
assumption is incorrect, please review the Post-Season Shutdown section.
1. Inspect all access holes, drains, air vents, pressure relief valves, control filters and
hydraulic tubing, ball valves, flow meters and backwash manifolds to Hnsure they are
ready for start-up.
2. Start the system and initiate a backwash sequence with very low pressure on the tanks, if
possible (20-25 psi). Because the tanks were drained, there is a good likelihood that they
contain trapped air. This air has the potential of disrupting the media bed when a backwash
is sequenced under high pressures.
At Every Irrigation
1. Check the filter pressure differential.
2. Check the flow meter.
3. Check the water treatment injection systems.
The First Week of Every Month
1. Check the hydraulic command.
2. Remove and clean the charging manifold screen at the end of the outlet manifold.
3. Observe a filter backwash sequence and confirm that there is sufficient time to flush the
media in all of the tanks.
4. Check pressure gauge during operation. Be sure gauge returns to “0” when at rest.
5. Check P.D. reading after backwash and adjust flush time if needed.
6. Check manual backwash throttle valve for proper setting. If it has been tampered with,
readjust the valve.
7. Check the reservoirs (if applicable) to confirm that the algae control program is
appropriate.
8. To keep tanks looking good in corrosive atmospheres, wash with soap and water, dry and
coat with WD40.
Mid Season
1. Open all of the sand media tanks and inspect the media down to the under-drains to
determine if the backwash controllers are appropriately adjusted.
2. Check sand level in tank.
3. Top-off the sand levels as needed.
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Post-Season Shutdown
1. Initiate a normal backwash cycle. Do not add cleaners or additives of any kind to the
water system. Time the sequencing of the backwash valves' opening and closing speeds
with a stopwatch and make note of the time.
2. Disconnect power to the controller.
3. Rinse and drain all filters, manifolds, control filters, ball valves, backwash valve
actuators, backwash lines, chemigation valves, booster pump volutes and all above ground
components.
4. Inspect and lubricate all of the filter backwash valves. Replace any leaking access hole
gaskets or troublesome bolts & nuts.
5. Brush any rusted spots on the cast iron filter components with a wire brush down to clean
metal and apply a minimum of two coats of paint.
Other Maintenance Considerations
Some of the other maintenance considerations of your Clear-Flo Filters involve the pressure
gauges, backwash valves and view tube, rubber gaskets and seals. The pressure gauge is
subject to frequent pressure shocks and in time may loose its sensitivity or not return to "0"
when the system is de-pressurized. Because the gauge is an important diagnostic tool for the
entire irrigation system, it should be frequently checked and replaced if it appears to be
giving erroneous readings.
The backwash valves have a stainless steel operating stem that slides through a PVC guide
bushing and a set of o-rings. This is lubricated with lithium-based grease. Placing a yearly
shot of grease on the stem through the drain hole on the bottom of the valve actuator body
should keep it in good shape. The backwash valves also contain a rolling diaphragm that is
subject to wear and may leak after a number of years. Water leaking through the drain hole
during backwash is an indication of hydraulic command water passing through the
diaphragm.
If water drains continually through the drain hole, not just during backwash, it is an
indication that the o-ring seals on the piston guide bushing have failed, and unfiltered water
is leaking through from the "wet side" of the valve. Another sign of wear in the backwash
valves is water continually weeping into the backwash discharge manifold, visible through
the sight tube. This is an indication that the plunger seal is not fully seated against the valve.
This is usually caused by either a defective plunger seal or chipped epoxy on the valve seat.
Removing the valve by taking off the three grooved couplers will allow visual inspection.
Removing a backwash valve is quite simple and requires very little time to maintain.
The rubber gaskets and grooved coupler seals may harden with age. If they begin to leak,
replace them. Gaskets that continually weep will soon become a worker safety issue as
algae growth will make the concrete pad dangerously slick. Because the irrigators will be
opening the tank ports to inspect the sand, it is a good idea to have a couple spare port
gaskets on hand. Applying anti-seize compound to the bolt threads will also keep the
inspections a simple task.
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The cast iron components of the filters (painted blue) will corrode if the epoxy paint is
chipped. It is a good idea to annually inspect the valves, covers and coupler clamps for signs
of corrosion. Clean the rust with a stiff wire brush and apply two coats of touch-up paint.
The stainless steel components will remain shiny in corrosive atmospheres if they are
periodically washed with soap and water and given an application of light oil, such as WD40.
Chemigation and Fertigation (the injection of chemicals and fertilizers into an irrigation
system) are very common practices. Careful consideration should be given to the
compatibility of the material being injected with the natural salts present in the source water
as well as the potential corrosiveness to stainless steel. The injection of various fertilizers
can result in the formation of precipitates that have the potential of plugging the irrigation
filter and emission devices. In general, it is advisable to place the injection point
downstream of the main irrigation system filters.
(CAUTION: This requires placing a suitable filter on the injection line.) By injecting
downstream of the filters, there is no threat of plugging the main irrigation filters or of
discharging chemicals or fertilizers with the backwash water.
In certain types of source water it may be necessary to pre-treat the source water to prevent
natural precipitation, such as lime scale (calcium carbonate) or iron hydroxide. It may be
advantageous to inject these water pre-treatments ahead of the media tanks. The
compatibility of these compounds with the filters and their ultimate fate in the backwash
discharge are important concerns.
Note: As with all chemical use, a clear understanding is required. It is recommended
that you contact your dealer for assistance.
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Trouble Shooting
The filters will not backwash automatically.
Check the following.
• Controller switch is ON.
• Controller switch is in the RUN mode.
• Controller circuit breaker is engaged.
• Controller is are properly programmed.
• Backwash time is not set to 0 MIN and 0 SEC.
• There is power to the Controller.
• The Hydraulic Charging Valve is open and the Filter is clean.
• Manual Override Screw on all of the Solenoid Valves is in the OFF position.
• The Backwash Throttle Valve (on the Backwash Discharge Manifold) is at least
partially open and the Backwash Discharge is clear of obstructions.
Once you have checked all of the above:
Initiate a backwash sequence by pressing the MANUAL START button.
Does the Controller respond by indicating that Station One is active?
• If not, the Controller circuit board appears to be faulty.
As the Controller sequences the various Stations, listen for a corresponding "Click" at each
solenoid valve.
Check to ensure that the hydraulic charging line is not connected to the outlet (low pressure)
side of the filter.
Check that the correct solenoids are used and are connected correctly to the controller
output terminal.
•
If not, the wiring to the Solenoid Valves is probably faulty, or the manual override
knob is in the ON position.
• If not, the controller is faulty.
If only one tank will backwash automatically.
Recheck the controller Dip Switches on the backside of the controller for proper setting.
While the Solenoid Valves are energized, high-pressure water from the Hydraulic Charging
system should be filling the Backwash Valve Actuator and causing the Backwash Valve to
open.
Does it sound like the Backwash Valve is trying to open?
• It may also be that everything up to this point is functioning properly, but there is
insufficient pressure to actuate the Backwash Valves. It may be a blockage of the
Hydraulic Charging tubing or the pressure of the irrigation system is too low.
Confirm that the hydraulic system is well charged. If you suspect insufficient system
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pressure, partially close the mainline valve to the field (downstream of the filters) to
increase the pressure in the filters. If this is successful in causing the Backwash
Valves to open it appears that you need to increase pressure during the backwash
either by irrigating fewer acres per set or by installing a pressure sustaining valve
downstream of the filters that is actuated by the Controller during a backwash
sequence.
If not, it may be that even though the solenoid coils of the Solenoid Valves are energizing,
the "wet side" of the Solenoid Valves are not allowing water to fill the Actuator on the
Backwash Valve. The hydraulic ports of the Solenoid Valves may be blocked or stuck.
Attempt to initiate a backwash in one filter (with the Controller OFF) by rotating the
Manual Override Screw to the ON position. If this is unsuccessful in initiating a backwash,
it appears that the mechanical portion of the Solenoid Valve is faulty and it should be
cleaned or replaced.
•
It may also be that the Backwash Valves are seized and cannot open. (It is unlikely
that all the Backwash Valves would be seized.)
The filters appear to be backwashing all the time, even when the Controller is OFF.
Manual Override Screw on all of the Solenoid Valves is in the ON position.
Listen to determine which Backwash Valve is allowing water to escape into the Backwash
Manifold.
• Confirm that the Solenoid Valve is not stuck in the energized position. (You can
close the Hydraulic Charging Valve and disconnect the hydraulic tube to the
Solenoid Valve. If high pressure water squirts out and the Backwash Valve closes,
the Solenoid Valve is stuck in the “energized" position, and should be cleaned or
replaced.)
• When using latching solenoids check wiring to verify that all positive leads are
connected to the common terminal of the controller.
• If no water escapes and the Backwash Valve remains backwashing, the Backwash
Valve itself is stuck open or faulty and should be re-built.
The media level is low in the tanks.
The sand should be up to the top weld line of the filter, or 25mm below the inlet baffle.
It is normal to lose 50 to 80mm of media per tank per year.
•
If you feel that you are losing too much media, adjust the Backwash Throttle Valve,
as described in the Backwash Throttle Valve section on page 3.
The media remains dirty after backwashing.
Confirm that the backwash sequences are appropriate for your type of source water.
• Review the sections on Backwash Frequency and Duration, pages 3-4, and make the
necessary adjustments.
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The differential pressure remains high after a backwash.
Inspect and determine if the media bed is clean.
• If not, review the sections on Backwash Frequency and Duration, pages 3-4, and
make the necessary adjustments.
• If the media is clean, it would appear that the underdrain is partially blocked with
precipitates or organic material. Dig down through the media bed and uncover one
or more of the Underdrain Elements and carefully remove it for close visual
inspection. If the Element is plugged, it is necessary to clean all of the elements.
This may or may not require removing the media and gravel, depending on the
nature of the contamination. Contact your dealer for assistance.
Water is escaping through the drain hole on the bottom of the actuator housing.
Check rolling diaphragm for holes. Replace if needed. • If not, replace o-rings.
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E-CDG52 Chlorine Dioxide Generator
For Taylex
B
A
D
H
G
C
K
E
L
F
N
M
I
Q
J
R
Q
P
O
1. System Description for Model E-CDG52-8x8x-V1
A
Zydox Pump – HC897
J
Non Return Valve – Spring Loaded
B
Acid Pump – HC897
K
Vent Valve for Calibration Cylinder
C
Controller
L
Calibration Cylinder
D
Back Pressure Valve, Adjustable
M
Drain Valve for Calibration Cylinder
E
Reaction Chamber
N
Water Supply Solenoid Valve
F
2x Injection Nozzles with Non-Return Valve
O
Water Supply Connection
G
Discharge Isolation Valve
P
Discharge Connection
H
Calibration Cylinder Isolation Valve
Q
System Isolation Valve
I
Flow Switch
R
Drain Valve for Water Line
Safety Notes:
1. The generation of chlorine dioxide solution can result in chlorine dioxide gas becoming present.
When mixed with air chlorine dioxide gas can become hazardous with a risk for explosion. Ensure
chlorine dioxide gas cannot accumulate to a hazardous level by keeping the area well ventilated or
implementing a shutdown facility based on gas detection.
2. Corrosive chemicals are used in this equipment. Ensure the equipment is handled only by
qualified technicians.
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1. System Description - Continued
The Controller (C) operates the system based on the status of the Flow Switch (I). An On/Off/Auto
manual switch is on the front of the controller. The interface with the field instruments is made via
terminals inside the controller enclosure. The chemical dosing pumps (A & B) are driven via the
controller to dispense Zydox and Acid into the Reaction Chamber (E) to generate Chlorine Dioxide.
The reaction is carried out under pressure and the pressure is generated by the Back Pressure
Valve (D). Two Injection Nozzles (F) with integral non-return valves connect the pumps to the
reaction chamber.
The Water Supply Solenoid Valve (N) is driven by the user via terminals in the controller and allows
dilution water to flow into the system to mix with the Chlorine Dioxide solution and the diluted
solution flows to the users tank via the Discharge Connection (P). A Non-Return valve (J) is installed
to prevent flow of chemical into the flow switch (M) and Solenoid Valve which are not resistant to the
corrosive chemicals.
The Flow Switch (I) reports to the Controller that water is flowing. The use of the calibration cylinder
requires the discharge to be closed via the Discharge Isolation Valve (G).
A Calibration Cylinder (L) is included to check the flow rates of the pumps to enable accurate
dispensing of the raw chemicals. The function of the calibration cylinder requires venting via the
Vent Valve (K) and draining via the Drain Valve (M). The Calibration Cylinder Isolation Valve (H)
isolates the cylinder while not in use.
2. Functional Description
On power up of the Water Solenoid Valve flow will be detected by the flow switch and power is
applied to the two dosing pumps. The dosing pumps are interlocked with the water flow switch and
low level switches in the raw chemical tanks. The dosing pumps will only operate when water flow is
verified by the flow switch and the chemical tank level switches verify there is chemical present.
When the generator is activated, the dosing pumps dispense raw chemicals into the reaction
chamber which operates under pressure to combine the chemicals and form the chlorine dioxide
solution. The chlorine dioxide solution from the reactor combines with the dilution water to produce a
diluted solution of chlorine dioxide which flows into the water line and is diluted.
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3. Set Up Procedure
The system requires the dosing pumps to be set up to dispense chemical at the ratio recommended
by the supplier of the chemical.
The dose rate of the pumps is set by an adjustment knob on the top of the pump and is adjustable
from 0% to 100%. If operation below 20% of full capacity is required, the pump can be put into low
flow rate mode by turning the adjustment knob from fully anticlockwise to fully clockwise and back
again (see pump manual for more information). When the pump is in low flow rate mode, the pump
will dispense at 20% of full capacity when the adjustment knob is in the maximum position. The
dose rate of each pump can be determined using the integral calibration cylinder and the stroke rate
can then be adjusted to achieve the individual required flow rate for each pump.
To determine the flow rate of a pump; close the System Isolation Valves, open the Calibration
Cylinder Isolation Valve, open the Calibration Cylinder Drain Valve, open the Water Line Drain
Valve, open the Calibration Cylinder Vent Valve and close the Discharge Isolation Valve. Switch off
the pump that is not to be tested (using the On/Off switch on the underside of the pump) and switch
the controller selection switch to ON.
Any liquid that was present in the calibration cylinder should have drained away and the pump to be
tested should be operating at it’s set stroke rate. Chemical should be flowing into the calibration
cylinder. When the flow appears stable, close the Calibration Cylinder Drain Valve and watch for the
rising liquid level in the calibration cylinder. When the level rises to the “0” scale mark, note the time
and wait for one minute. At one minute, note the scale value that corresponds to the liquid level.
This value is in l/hr and represents the flow rate of the pump. Adjust the stroke rate of the pump
proportionally to achieve the desired flow rate. The instructions for adjusting the pump are in the
separate manual provided for the pumps.
To test the second pump, open the calibration cylinder drain valve, switch off the pump not to be
tested and switch on the pump to be tested. When stable flow is observed repeat the steps
described above to determine the flow rate of the pump. Adjust the stroke rate of the pump
proportionally to achieve the desired flow rate.
4. Maintenance
The dosing pumps are a electromechanical device and have parts that wear from use. Separate
instructions are provide for the pumps and these instructions include information about the
maintenance of the pumps.
The discharge tubing from the pumps suffers frequent impact and in time the material can weaken.
The discharge tubing will need occasional replacement and the life of the tube will be dependent on
the duty and environment of the installation.
Corrosive chemicals are used in this equipment. Ensure the equipment is handled only by qualified
technicians.
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Nature Flow® Systems
Self Cleaning
Ultra Violet
Water Treatment
Systems
Efficient
Effective
Chemical free
Australian Made & Owned.
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Germicidal Ultra Violet
Ultra Violet water treatment is a unique and rapid method of water disinfection without the use of heat or
chemicals. Through the years ultra violet technology has become well established as a method of choice for
effective and economical water disinfection.
Nature Flow® Ultra Violet Water Treatment Systems utilise germicidal ultra violet lamps that produce shortwave energy which is effective against greater than 99% of waterborne bacteria and viruses (subject to
source water quality).
Nature Flow® Ultra Violet Water Treatment Systems are the ideal solution for an ever growing range of users
choosing their water treatment needs.
Advantages of the Nature Flow® System
9 EFFECTIVE – virtually all micro-organisms are susceptible to Nature Flow® Disinfection.
9 ECONOMICAL – Hundreds of litres can be purified for each cent of operating cost.
“Why buy bottled water when you can own the factory?”TM
9
9
9
9
9
SAFE – No danger of overdosing, no addition of dangerous chemicals.
FAST – Water is ready for use as soon as it leaves the system – no further contact time required.
AUTOMATIC – continuous or intermittent disinfection without special attention or measurement.
NO CHEMICALS – No chlorine taste or corrosion problems. Environmentally responsible.
VERSATILE – UV water disinfection has a wide range of applications.
The Nature Flow® Turbine
Nature Flow® incorporates into all of its models their patented self-cleaning UV technology – the Turbine Cleaner.
What Does It Do?
The Turbine eliminates the need to clean
the Quartz Sleeve which can be come dirty
with use. It also eliminates the need for
manual or motor driven wipers.
Does The Turbine Require
Maintenance?
Simply replace the Turbine felts when the
Ultra Violet lamp is replaced (minimum once
per year). The Turbine is made of Acetyl
and will last for years.
What Happens In Other
Purifiers?
Quartz Sleeves & Thimbles
The build-up of deposits on the glassware
must be cleaned manually and/or with
chemicals on a regular basis.
How Does It Work?
Teflon (AFP) Tube Units
Teflon tubes will have deposits reducing the
penetration of Ultra Violet light through the
tube. The unit must be dismantled to clean
the Teflon Tubes and the manifolds – a very
time consuming process. Alternatively high
pressure cleaning must be used.
The exclusive Turbine gently spins upwards
when water flow commences. Its twin felt
cleaners clean the Quartz Thimble as it
rotates to the top of the Chamber where it
stays whilst flow continues. When the water
flow ceases, the Turbine returns to the
bottom of the Chamber, cleaning as it
descends. The cleaning cycle is repeated
when water flow recommences.
How Often Does It Happen?
Every time the water flow commences and
ceases, the Turbine spins and cleans the
Thimble. If you have continuous flow,
simply turn off on a monthly cycle to utilise
the Turbine.
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Why Is It Exclusive?
No other manufacturer has the Turbine.
The inventor has patent, design and
trademark protection on this innovative
technology.
Wastewater & Rainwater Specialists
Can It Be Retrofitted Into
Existing Units?
No. If you have an existing Quartz or Teflon
Water Purifier and you want to upgrade to
cutting edge 21st century technology and
not waste money on manual cleaning, call
for a quotation to replace your existing unit
with a Nature Flow® Self Cleaning Turbine
Unit.
Page 151
Specifications for Standard Models
INLET
OUTLET
SIZE
POWER
CONS
WATTS
LAMP
FAILURE
ALARMS
UNIT DIMENSIONS
IN
MILLIMETRES
Chamber
Control Box
H
W
Diam
L
W
D
NF 20
900
½” BSP
20
400
160
60
270
100
70
NF 30
1680
¾” BSP
30
670
160
60
270
100
70
NF 40
2220
1” BSP
40
1060
160
60
270
100
70
NF 58
2460
1” BSP
58
670
160
60
270
100
70
NF 75
4500
1” BSP
75
1060
160
60
270
100
70
NF 150
7800
32 mm
150
1300
300
260
Custom Built
Visual
LITRES
HOUR*
Audible
MODEL
9
9
9
9
9
9
9
9
9
9
9
9
Note: NF150 is no longer available. Recommended replacement is dual NF75 treatment unit.
MAX
PRESS
KPA
TEMP
RANGE
ŃC
TURBINE
600
2-50
600
2-50
600
2-50
600
2-50
9
9
9
9
9
9
600
2-50
600
2-50
All units are designed to give 40 000 microwatt seconds per square centimeter of 254nm
Ultra Violet at the end of lamp life.*
*Assuming: Source Water quality complies with maximum concentration table below and 95% transmission.
For larger flow rates or variances in source water quality contact Nature Flow Systems.
Maximum Concentration
Levels Before Ultra Violet
Options
9
9
9
9
9
Flow Control Valve
Solenoid Valve
UV Monitor
Time Delay Mechanism
Hour Run Meter
Use of these options is required to comply with
ANSI/NSF Standard 55-1996 & AS/NZS 3497-1998.
Turbidity
Suspended Solids
Colour
Iron
Manganese
pH
Hardness
5 NTU
10mg/litre
NONE
0.3mg/litre
0.05mg/litre
6.5-9.5
6 gpg
Models:
NF 40/75
NF 30/58
NF 20
All Nature Flow®
chambers include earth
point as standard.
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COMMERCIAL & INDUSTRIAL SYSTEMS
APPLICATIONS
Aquaculture
Effluent Treatment
Ingredient water
Wash Down Water
Spa Water
Breweries
Storm Water Recycling
Warm Water Lines
Grey Water Recycling
Aquariums
Fish Hatcheries
Laboratories
Rain Water
Bore Water
Hydroponics
Soft Drink Manufacturing
Pharmaceutical
R.O Water
Bottle washing
Houseboats
Chicken Hatcheries
Spring Water
Swimming Pool
Cooling Towers
Processing Waters
Drinking Water
Ice Making
PRODUCT FEATURES
Nature Flow® Water Purifiers are designed to provide maximum Ultra Violet output and use
high quality components to ensure long life.
9
9
9
9
9
9
9
9
9
Waterproof (IP68) control boxes on all Nature Flow® models.
Exclusive patented self-cleaning Turbine Quartz Cleaner.
316L polished stainless steel chamber – Marine Grade – AUSTRALIAN MADE.
High quality Quartz Thimbles for optimum operating temperature and Ultra Violet transmission.
High quality Hard Glass Ultra Violet lamps for maximum germicidal efficiency and long life.
Removeable bottom sealing nut for ease of cleaning.
Audible and visual lamp fail alarms activated via light sensor standard on all models.
MADE IN AUSTRALIA – Your dollars come back to you.
All units are designed to give 40 000 microwatt seconds per square centimeter of 254nm Ultra Violet at
the end of lamp life.*
SERVICE REQUIREMENTS
WARRANTY
For maximum germicidal efficiency, the
following replacement cycle must be conducted:
Nature Flow® Water Purifiers carry the
following warranty2 against faulty parts and
workmanship:
Ultra Violet Lamp
Quartz Thimble
Service Kit1
Chamber
Ultra Violet Lamp
Quartz Thimble
Other components
Electrical
1 year
2 years
1 year
1
1 x set turbine felts, 3 x o’rings. NB 09 models forward
will also require 1 x light sensor - additional to standard kit.
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2
1
1
2
1
years
year
year
years pro rata
year
For full details refer to warranty statement.
Wastewater & Rainwater Specialists
Page 153
UV Model Only. Check UV unit operation. Check 2 minute delay from UV lamp on to pump operation.
Refer to manufacturer’s instructions (owner’s manual – UV unit). Replace cleaning felts and o’rings (if
applicable). Check lamp fail alarm (sensor operation). Replace UV lamps as required (intermittent
operation). Replace UV thimble as required. Refer detailed procedure in this manual.
NOTES
UV Disinfection Units are to be maintained as per manufacturer’s recommendations. UV units may
vary between installations and geographic areas. The TYPICAL unit is a proprietary Nature Flow® UV
Disinfection Unit – unit size/style to suit individual application. It is anticipated that the standard size
be a 40 watt unit with the standard style being tank mounted. UV units from alternative manufacturers
may be used subject to adherence to that manufacturer’s servicing and operation maintenance. All
alternative units require approval from Nature Flow Systems Pty Ltd prior to their inclusion in any
Nature Flow Mk II STP. Procedures detailed below are directly applicable to the typical unit however
will have some commonality with similar alternative UV units. Where alternative UV units are utilised
servicing must be done in conjunction with the applicable manufacturer’s recommendations/manual.
Maintenance – UV Unit
Maintenance for the UV unit only is detailed below. Additional maintenance may be required for those
systems including pre-filtration and/or other options. Refer to your supplier/installer.
ALWAYS ENSURE THAT ALL POWER TO THE TREATMENT PLANT IS SWITCHED OFF PRIOR
TO SERVCING THE UV UNIT. UNPLUG AT POWERPOINTS AND TAG.
1. UV lamp is to be replaced after 9 000 hours of continuous use (one year) or after 2 years of
intermittent use whichever is the sooner. After this time the lamp will photo chemically change
and no longer allow sufficient 254-nm shortwave UV, the germicidal ray of the lamp, through
the glass to effectively disinfect. (Mercury vapour lamps rarely burn out completely but suffer
from lumen depreciation. The lamp produces less light over time, to the point of becoming
ineffective while still drawing the same amount of power it drew when it was new. This comes
about because the emitter is deposited as a film darkening the arc tube wall and reducing
light output.) IE: Even if the lamp is still “ON” it may not still be emitting light at 254nm and as
such may not be providing germicidal effect –change lamp at recommended intervals
regardless.
2. The turbine cleaner (if applicable) requires annual servicing at which time, the cleaning felts
and o’rings shall be replaced.
3. The UV thimble should be replaced as required. Intermittent operations should be checked for
cracks, crazing and general degradation on annual inspection and replaced as required.
Where a sleeve cleaning device is not utilised the quartz sleeve should be checked regularly
(approx every three months subject to water quality) and cleaned should evidence of
substance build-up be evident. Use a piece of cloth soaked in vinegar or citric to gently wipe
the sleeve clean. Avoid touching the glassware with your bare fingers as this will leave marks
on the sleeve/lamp and reduce its effectiveness.
4. O’Rings are to be replaced on annual service. When installing glassware (whether a
replacement or reinstall) ensure the O’Rings are greased with food grade lubricant.
5. We recommend light sensors are replaced as required. At the time of replacement older units
with the hardwired light sensor must be upgraded to the new “push-in” plug type light sensor
(upgrade kits available – a licensed electrician is required for this). The “push in” type sensors
do not require a licensed electrician and may be replaced by suitable competent person.
WARNINGS & PRECAUTIONS – UV UNIT FAILURE TO FOLLOW THESE PRECAUTIONS CAN
CAUSE SERIOUS PERSONAL INJURY OR DAMAGE TO THE SYSTEM.
1. The lamp(s) in this system emit ultraviolet light. Exposure to ultraviolet light can cause serious
burns to unprotected eyes and skin. Never view ultraviolet directly with the naked eye. Always
view ultraviolet light through a properly rated viewing port or through properly rated protective
eyewear. Always wear protective clothing when exposed to ultraviolet light. Ensure all lamps
are properly secured within the chamber before turning the system on. Turn the system off
before servicing.
2. To prevent electrical shock, turn the system off before removing any of the covers on the
chamber or opening the control panel.
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3. Ultraviolet lamps become hot during operation. Hot lamps can cause serious burns. Allow the
lamps to cool before servicing.
4. The ultraviolet lamps, and the sleeves/thimbles they are housed in, are constructed of quartz
tubing. Quartz tubing is very fragile and easily fractured. Do not strike, bend or apply pressure
to this material or it will break. Broken lamps or sleeves can cause serious cuts.
5. Lamp connections and end plate surfaces can become hot during normal operation. Do not
touch while the unit is operating.
6. Acids used to clean the lamps and sleeves can cause burns. Wear protective clothing and
eyewear when handling these materials. Rinse the components thoroughly in distilled water
after cleaning. Always follow the safety precautions provided by the manufacturer of the
cleaning solution.
7. This system uses ultraviolet light to reduce the concentration of pathogens to non-infectious
levels. Failure to follow the maintenance instructions or respond to alarms will reduce the
effectiveness of the system.
8. This system has been designed to be effective under operating conditions described by the
customer. Any changes in these conditions can reduce the effectiveness of the system to
disinfect. Some of the factors affecting operation include source water quality, flow rate and
temperature.
9. This system is meant to treat liquids water only.
10. Intermittent operation of the system requires a minimum flow to be circulated through the
system in order to remove heat from the lamps. Never operate the unit empty or without flow
for extended periods of time.
11. Do not operate the system unless the chamber is completely filled with flowing water.
12. If your piping system is subject to impulse pressure (i.e. water hammer), a surge tank or other
means of removing this condition must be provided.
13. The ultraviolet output of these lamps decreases with time. The ultraviolet lamps in this system
must be replaced every 12 months of continuous use or every 24 months of intermittent use
to ensure proper operation.
14. Periodic evaluation of the system performance through standard methods is recommended.
Sampling before system and immediately after system should be taken and reduction
calculated.
15. Installation and maintenance to be performed by qualified persons only.
16. All repairs to be performed by Nature Flow Systems Pty Ltd service technicians or qualified
personnel.
17. As an ultraviolet treatment unit does not introduce any chemical residue within the water it is
strongly recommended that a periodic chlorine flush of the pipework and fittings downstream
of the UV unit is undertaken.
Refer to Figure 1 and pictorial depiction of components servicing by service agent is
recommended.
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Pictorial Des
scription of Componentts
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HOW TO REPLACE UV LAMP
1. Switch off power and unplug from power point.
2. Lift top cap.
3. Disconnect 4-pin fitting from UV lamp. Care should be taken when handling UV lamp, hold by
white ceramic ends only.
4. Gently pull UV lamp upwards and remove from thimble.
5. Carefully lower replacement UV lamp GENTLY into the thimble with pins at the top - hold by
white ceramic ends only. Do not touch the clear parts of the UV lamp as it will become
contaminated. Remove any marks from the UV lamp with a cloth soaked in methylated spirit.
Any deposit on the UV lamp, such as fingerprints can affect the output and rated life of the UV
lamp. DO NOT DROP UV LAMP INTO UNIT AS THIS WILL RESULT IN DAMAGE. Make
sure the 4-pin plug is attached to the lamp before completely lowering the UV lamp into the
unit. As the lamp is lowered into the unit ensure that the UV sensor is also inserted into
thimble just below ceramic end of lamp with metal circuit facing towards the lamp.
6. Replace o’ring at top of thimble holder, ensuring it is lubricated prior to placement. Push top
cap back into place on thimble holder.
7. Plug leads back into power point and switch on.
8. For a new lamp allow 5-10 minutes for the UV lamp to establish germicidal output. Note that
system utilises a 2 minute time delay. Dispersal pump will not activate until 2 minutes after UV
lamp operation.
HOW TO TEST LIGHT SENSOR AND ALARMS
1. Follow steps 1-4 above.
2. Replace top cap on cylinder pressing down firmly. (This will ensure that the 4-pin plug and
light sensor is lowered into the cylinder without the UV lamp attached).
3. Connect 3-pin supply plug to power point.
4. Turn unit on.
5. Listen for audible buzzer and watch for blue strobe. If light sensor is operating correctly both
alarms should activate.
6. Turn off unit. Disconnect from power supply and follow steps 5-8 above to reinstall lamp.
7. Once lamp has been installed and the system is again operational there should be no active
alarms.
8. If alarms are active then disconnect power and check lamp connection and placement of light
sensor (light sensor should be facing lamp). If lamp and sensor installation is confirmed
correct then assume light sensor requires replacement.
HOW TO REPLACE LIGHT SENSOR
1 Follow steps 1-4 in “How to replace UV Lamp”.
2 Identify type of lamp sensor – hardwired Type A or plug-in Type B. Type A will require installation by
a licensed electrician. Type B may be replaced by a suitably competent person. We recommend that
those installations with Type A sensors be upgraded at time of replacement with the new Type B
sensors. These are available in kit form from Nature Flow Systems.
Type A Sensor
A. Cut old sensor wires from lamp loom leaving as much length as possible.
B. Place 5mm heat shrink over both sensor wires.
C. Place 3mm heat shrink over individual sensor wires.
D. Solder new sensor leads to sensor wires (Core 5 & 6).
E. Shrink 3mm heat shrink in place over soldered joints and 5 mm heat shrink over both joints to
provide further protection.
Type B Sensor
A. Unplug old sensor from lamp lead. Take care not to force connection.
B. Press release latch on plug to facilitate disconnection.
C. Connect new sensor ensuring plug and socket mate firmly together.
D. If plug and socket do not go together easily check orientation of plug and socket.
E. Follow steps 5-8 in “How to replace UV Lamp”.
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HOW TO REPLACE QUARTZ THIMBLE
1. Switch off power and disconnect from GPO.
2. Remove top cap.
3. Disconnect UV lamp from 4-pin fitting. Place UV lamp carefully to one side on a clean
surface.
4. Loosen hexagon nut at bottom of cylinder to allow water to drain. Do not remove nut entirely.
5. Unscrew black thimble holder.
6. Gently lift thimble holder up. Thimble should remain attached to holder.
7. Grasp thimble and support as thimble holder is raised to allow for removal.
8. Remove the thimble holder from the thimble.
9. Completely remove hexagon nut and thimble seat from bottom of cylinder. Clean thimble
seat, replace o’ring (lubricate first) and reinstall thimble seat and hexagon nut.
10. Place replacement thimble (6) gently into the top of the stainless steel cylinder ensuring to
locate centre of turbine and thimble seat.
11. Next lubricate the O’Ring in the Thimble Holder using a food grade grease eg Vineleo WT90,
then screw the thimble holder (2) onto the cylinder firmly. DO NOT OVERTIGHTEN!
12. Switch on power at GPO.
13. Perform leak checks on the system.
14. Once leak checks have been performed, switch off power and disconnect from GPO.
15. Replace Ultraviolet lamp (follow steps 5-8 in “How to replace UV Lamp”). NOTE: When
withdrawing thimble take care not to let the end drop into the stainless steel cylinder as it
could break.
HOW TO CLEAN THE QUARTZ SLEEVE/THIMBLE
1. Remove the quartz sleeve(s) as directed above.
2. Using a non-abrasive cloth soaked in an appropriate cleaning solution and wiped along the
length of the quartz sleeve.
3. After cleaning, rinse the acid solution thoroughly from the sleeves with distilled water. Inspect
the interior of the sleeve before installation to make sure they are clean and dry. Clean the
interior of the sleeves with alcohol if they have been exposed to water or acid solutions.
4. Reinstall the quartz sleeve(s) as per above.
Sleeve Cleaning Solutions
The following sleeve cleaning solutions are recommended for removal of scale build-up and
coatings from the quartz sleeves. Mild acid solutions are recommended. Acid solutions can
be bought commercially or diluted form industrial strength acids. (Cleaners such as “Lima-AWay” and “CLR” may be used.)
• 15% Phosphoric Acid
• 5% Nitric Avid
• 10% Citric Acid*
*Citric acid solutions cannot be reused. All other types can be stored indefinitely and reused until they
no longer have the strength to effectively clean the sleeves. Refer to MSDS from manufacturer of
cleaning solution for further information on storage and handling.
HOW TO SERVICE TURBINE CLEANER
1.
2.
3.
4.
5.
Switch off power and disconnect from GPO.
Loosen hexagon nut at bottom of UV cylinder to allow water to drain.
When drained completely remove hexagonal nut at bottom of UV cylinder.
Thimble seat will drop from cylinder. Move to one side until reassembly required.
Turbine cleaner will also drop down from UV cylinder. If turbine cleaner does not drop out see
instructions for dislodging.
6. Remove used felts (2).
7. Snap out locking ring by laying turbine on its side, pulling spacer away from locking ring,
place screwdriver through centre hole of turbine and tap gently to remove locking ring.
8. Remove spacer.
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9. Wet new feltts. Insert firstt felt. Replacce spacer. Insert second felt.
10. Replace lockking ring.
11. Remove and
d replace thimble seat o
o’ring. This is
s located in recess at boottom of cyliinder (on
cylinder end
d). Lubricate o’ring with va
alve lubrican
nt prior to placement.
12. Re -insert cleaning turbin
ne into UV cyylinder with locking
l
ring to
t the top.
13. Clean thimble seat and re-insert
r
- ho
old in place.
14. Screw hexag
gonal nut back into place
e at bottom of
o UV cylinder.
15. Plug leads in
nto powerpoint and turn ssystem on.
16. Check pipew
work for leaks.
17. If leaking check
c
where
e leak is co
oming from – check o’rring seal annd check ten
nsion on
hexagonal nut.
n
IF TURB
BINE CLEAN
NER BECOM
MES LODGE
ED IN UV CY
YLINDER AN
ND WILL NO
OT DROP OU
UT
1. Switch off po
ower and dis
sconnect from
m GPO.
2. Loosen hexa
agon nut at bottom
b
of cyl inder to allow
w water to drrain. Do not rremove nut entirely.
e
3. Remove top
p cap.
4. Disconnect UV lamp from 4-pin fittting. Place UV lamp ca
arefully to oone side on a clean
surface.
5. Unscrew bla
ack thimble holder.
h
6. Gently lift thimble holderr up. Thimble
e should remain attached to holder.
7. Grasp thimb
ble and support as thimblle holder is raised
r
to allow for removaal. Place thim
mble and
holder to one side.
8. Continue as per Steps 2-14 of “How to service th
he turbine cle
eaner”.
9. After comple
eting all step
ps in “How to
o service the turbine cleaner”, carefullly and gently
y replace
thimble and screw on bla
ack thimble h
holder.
10. Perform leakk checks on the system.
11. Once leak checks have been
b
perform
med, switch off
o power and disconnectt from GPO.
12. Replace Ultrraviolet lamp
p (see instrucctions steps 5-8).
5
FIGURE 1 SCHEMAT
TIC OF UV CYLINDER ASSEMBLY
Top cap
4 pin end
UV lamp
STANDARD REPLACEMENT PARTS UV UNIT
UV lamp size may vary between individual
installations. Please check with your
supplier/installer to confirm the size lamp in your
system.
Ultra Violet Lamp 20 watt
Ultra Violet Lamp 30 watt
Ultra Violet Lamp 40 watt
Ultra Violet Lamp 58 watt
Ultra Violet Lamp 75 watt
Quartz Thimble 20 watt
Quartz Thimble 30/58 watt
Quartz Thimble 40/75 watt
Food Grade Lubricant 20mL tube
Service kit (o’rings & cleaning felts only)
Light Sensor Type A (hardwire type upgrade kit)
Light Sensor Type B (plug-in type)
Thimble Holder
S/S UV Cylinder
Quartz Crystal Thimble/Sleeve
Locking Ring
Felt 1
Spacer
Felt 2
Turbine Cleaner
Hexagonal Nut
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SERVICEMAN PROCEDURE NOTES
TAYLEX CABS
BEFORE STARING: NOTIFY RELEVANT PERSON OF YOUR INTENTIONS TO SERVICE THE SYSTEM
1. Approach the system and note any unusual noises or foul odours.
2. Remove access lid over Primary Chamber, check inlet for blockages.
3. Remove access lid over Secondary Chamber, undo pump at barrel union, pull up and ensure pump base
is clear and not blocked. Clean and place back in chamber and ensure floats and pump are clear from
the wall and pump line. Do up barrel union firmly.
4. Test float in Secondary Chamber. Check bottom float for overload counter and top float for master high
water alarm, audible and visual.
5. Remove access lid over Aeration Chamber and check that the diffusers are working. Check there is even
flow of air around media. Adjust vales if required.
6. Lower Probe into Aeration chamber and measure dissolved oxygen in parts per million and record. Also
take water temperature in degrees Celsius.
7. Remove access lid over Clarification Chamber undo pump at barrel union, pull up and ensure pump
base is clear and not blocked. Clean and place back in chamber and ensure floats and pump are clear
from the wall and pump line. Do up barrel union firmly.
8. Remove the two Taylex TFG filters, hose off over and into the Primary Chamber. When clean, replace
filters into Clarification Chamber.
9. Remove access lid from Pump chamber. Before touching anything within the chamber take a grab
sample of the water within the chamber and check Chlorine Levels, record findings on Service Report in
Test Results section. Remove Chlorine dispensers and clean tube, remove Chlorine tablets, clean base
of dispenser by hosing off base into the pump chamber. Recharge dispenser with whole remaining
tablets first then top up with new tablets. Adjust dispenser to ensure correct minimum/maximum residual
chlorine is available.
10. Test high level float in Pump chamber, Visual and Audible.
11. Remove pump from Pump chamber. Undo pump at barrel union, pull up and ensure pump base is clear
and not blocked. Clean and place back in chamber and ensure floats and pump are clear from the wall
and pump line. Do up barrel union firmly.
12. Check Pump chamber pump and pump line for leaks. To do this starts the pump by raising the float, if it
is stopped. Then look at the walls of the chamber and below the pump, any turbulence noticed while
pumping would indicate a leak in the PVC pipe or damage to the pump. If required place sludge pump in
the bottom of the chamber and hose and pump out any sludge.
13. Check and record the reading from the flow meter in the pump chamber. Record findings in the Test
Results section of the field Service Report.
14. Manually back wash the Sand Filter, (see Kinetico manual for instruction on how to manually back wash
on page 109 of the manual.
15. Check, Clean and backwash Taylex DRP Filter. Ensure all pumps are turned off. Open the 25mm drain
valve at the base of the filter. Undo the 12 Stainless Steel Allen key screws and remove the top cover,
remove the top stainless steel screens and Matala filters. Take them out onto a grassed area and hose
them clean. (Do Not hose them into any chambers in the system). Replace the Screens and the Matal
filters. Once the unit is drained close the drain valve, fill the unit with clean water from a hose. Once it is
full reopen the drain valve at the bottom and allow the unit to backwash as it drains out. Once it is empty
close the valve, and screw the lid back on.
16. Check Chlorine dioxide unit. While the pump is going check the unit is working. Check the Chlorine and
Hydrochloric acid containers. Top up or replace as required.
17. Check Ozone is working.
18. Check UV Tube. Look through viewing port to see that the light is on. For cleaning procedure see page
154 of the manual. Warning Never look directly at a lighted UV lamp, Ultraviolet ray can be damaging to
eyes. Always where gloves when handling the UV Lamp and The Quartz Tube.
19. Remove blower box cover, remove blower filter cover and replace filter. Wash the old filter in water and
place it in the blower box cover for future use. In areas of high dust this filter should be replaced every
service. Clean and vacuum the inside of the blower box ensuring all sand, dust, ants, spiders and other
insects are removed. If insects are a problem spray the base and sides of the blower box with an Insect
surface spray.
20. Disconnect the airline from the blower to the control panel and test the visual and audible arm.
Reconnect the airline.
21. Open stainless steel panel door, turn power off on isolator switch next to panel. This will test the battery
backup and should alarm both audibly and visually.
22. Turn switch on panel to off position and open door slightly. Turn main isolation switch back on, close the
panel door and turn the switch to the on position. This will allow the panel to count down from nine, it will
then test the blower, secondary and clarifier pumps if levels allow. This should take around a minute.
23. Check the reset times for the blower and secondary pump are set to match the flow rates for the system.
Refer to the flow meter readings.
24. Reset overload counter if necessary by holding the mute button and the reset button at the same time.
25. Check all float leads, pump leads, air hoses and electrical cables for ware.
26. Clean all access grates, replace all lids on system, bolt down blower cover, close Panel door.
27. Complete Field Service Report and leave at the premises clean and tidy.
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STANDARD TESTS TO BE UNDERTAKEN AT ANNUAL SERVICE
Clarity
To measure turbidity/clarity, using a suitable dipper, immediately scoop a little more than a litre of effluent
from pump well 2/test point and pour it into the Imhoff Cone and set the cone and sample aside for approx
20-30 minutes. Observe and record Suspended Solids (SS) reading from Imhoff Cone sample. Observe
colour of settled sludge and clarity of top of sample. On completion, pour sample back into primary chamber
and replace lid. Obtain effluent sample for clarity test from pump well 2/test point, pour into clarity
measurement vessel, raise and lower centre tube focussing on cross on bottom of cylinder, read and record.
(Or can also use marked dip stick with marked disc at end, noting depth till disk cannot be seen.)
Dissolved Oxygen
This test is performed by testing a sample of the effluent with a dissolved oxygen test kit. The results are
expressed as parts per million of dissolved oxygen. A normal operating plant should have a dissolved
oxygen content of at least 1.0 PPM in the final effluent. To measure the Dissolved Oxygen level take sample
of effluent from pump well 2 or sprinkler. Place the Dissolved Oxygen probe into the sample and measure
the DO in Parts per Million and record.
Temperature
Leave the DO probe in place, read the temperature of the effluent, using the temperature function on the
Dissolved Oxygen meter and record. Remove probe.
pH
Basically, the pH test is one which measures the acidity or alkalinity (causticity) of the liquid in the aeration
chamber. The pH range is from one to fourteen; a pH of one indicating completely acidic conditions and a
pH of fourteen indicating completely alkaline conditions. The pH is measured by using a colour comparator
with 7 indicating a neutral condition. A normally operating domestic sewage treatment plant should have a
pH of between 6.5 and 8.0. The bacteria responsible for the digestion of sewage cannot normally live and
grow if the pH is not in this range. A pH reading outside this range indicates either (1) that the plant is septic;
this can be corrected by the methods listed in the first section of the manual or (2) acidic or caustic wastes
are being emptied into the plant; these must be stopped before they enter the plant. To determine pH of
system take sample of effluent from pump well 2 or sprinkler. Place pH meter into effluent sample and read
the pH level and record.
Residual Chlorine
The principal reason for chlorination of sewage effluent is for disinfection. Sewage treatment may not
completely remove the pathogenic (disease-causing) bacteria which can be present. The chlorine residual is
measured by using a colour comparator, generally part of the same instrument used to measure pH. When
effluents are discharged to bodies of water which are, or may be used as a source of public water supply, or
for recreational purposes, chlorination to kill harmful bacteria will require a chlorine residual of greater than
0.5 PPM. This residual must be the minimum maintained in the effluent. If the test results show less than
this, increase the rate of chlorine feed. A dose of 8ppm free chlorine should produce a chlorine residual of
0.5 PPM or more in a normally operating plant. To determine free chlorine in final effluent, take sample of
effluent from pump well 2 or sprinkler, using chlorine comparator indicator kit. Drip indicator chemicals into
sample and observe and record result.
Sludge Level in Primary Chambers
To measure the accumulated sludge level in the primary tank use “sludge judge”. Clear a hole in sludge,
place sludge judge in the primary at the wall. If over 750mm tank needs a pump-out. Advise client to have
primary chamber pumped out. System should be filled back to operating level with clear water to prevent
any damage to chambers.
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TAYLEX COMMERCIAL
Field Service Report
Name (Owner /Occupier)
Site Address
Municipality Or Shire
System Type
(For Instructions on how to carry out Action Refer to Taylex CABS Service Procedure Notes on page161)
Actions
Note Yes
Check Odour on approach of System
1
Check Primary Tank Inlet for Blockages
2
3
Remove Secondary Chamber Pump Check Base for Blockage
Test Bottom Float in Secondary Chamber for Overload Counter (Audible & Visual)
4
Test Top Float in Secondary Chamber for Master High Water Alarm (Audible & Visual)
Check Diffusers are working in Aeration Chamber
5
7
Remove Pump from Clarification Chamber, Check for blockages
8
Remove and Clean 2 x Taylex TFG Filters in Clarification Chambers
Remove and Clean Chlorine Dispenser in Pump Chamber, Top Up with Chlorine Dispenser
9
Adjust Chlorine Dispenser to ensure Minimum/maximum Residual Chlorine is available.
Test Pump Chamber High Level Float alarm (Audible & Visual)
10
11
Remove Irrigation from Pump Chamber, Check for blockages
Check Pump Chamber Pump Line for Leakage
12
Backwash Sand Filter
14
Check DRP Filter
15
Check Chlorine Dioxide
16
Check Ozone
17
Check UV Filter and Tube and Lamp replace Lamp if required
18
19
Replace Blower Filter, Wash Old Filter in Water and place in Blower Box
Disconnect Airline from Blower to Control Panel and Test Alarm (Audible & Visual)
20
Test Battery Back Up
21
Run Panel Auto Test
22
Check the Pre-set times for Blower and secondary are set to match Flow rate for system
23
Reset Overload Counter if necessary
24
Check all Leads for ware
25
Clean all Access Grates, Replace all Lids on System, bolt Down Blower Cover, Close Panel Door
26
Complete Field Service Report and leave at the Premises.
27
Effluent Management Area:
Check High Water Alarm in Irrigation/Wet Weather Storage Chamber (Audible & Visual)
Check Irrigation Timer
Irrigation Lines & Sprinklers
Clean Sub Surface Irrigation Filter
Check For Ponding
Root Inhibitor added
Flush All Irrigation Lines
YES
No
N/A
NO
Test Results
Test
Note
Aeration Chamber - Dissolved Oxygen
Aeration Chamber - Water Temperature
Pump Chamber - Check Chlorine Levels
Check and Record Flow Meter in Irrigation Chamber
pH Test Results from Aeration Chamber
Primary Sludge
Secondary Sludge
Aeration Sludge
Clarity of Clarifier (Black Disk Test)
6
9
13
Secondary Tank Buffer
Pump
PPM
°C
mg/litre
mm
mm
mm
mm
Control Panel Settings
Aeration Chamber Air
Blower
Result
Service Person
Secondary Tank
Overload Counter
Signature
Licence Number
Date
Comments
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IncidentRegister
Date
Incident
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DailyFlowMonitoring
ForTheYearͺͺͺͺͺͺͺ
Date
January
February
March
April
May
June
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Comments:
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DailyFlowMonitoring
ForTheYearͺͺͺͺͺͺͺ
Date
July
August
September
October
November
December
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Comments:
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Weekly Monitoring Results
Date
pH
Free Chlorine
Date
pH
Free Chlorine
Comments:
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mg/L
mg/L
mg/L
cfu/100 ml
mg/L
Total Nitrogen
Total Phosphorus
Total suspended Solids
E.coli
Dissolved Oxygen
mg/L
mg/L
mg/L
mg/L
cfu/100 ml
mg/L
Total Chlorine
Total Nitrogen
Total Phosphorus
Total suspended Solids
E.coli
Dissolved Oxygen
Comment:
mg/L
BOD5 mg/l
Units
mg/L
Total Chlorine
Quality Characteristics
mg/L
Units
BOD5
Quality Characteristics
2
15
10
5
10
10
Minimum Maximum
Required Allowable
2
15
10
5
10
10
Minimum Maximum
Required Allowable
July
January
August
February
For The Year BBBBBBBB
Monthly Monitoring Results
September
March
October
April
November
May
December
June
Soil Impact Monitoring
Date
Quality Characteristics
pH
Units
ph Scale
Electrical Conductivity (1:5)
μS/cm
Cation Exchange capacity
meg/100g
Exchangeable sodium percentage
Soil Depth
Result
%
Total Organic Caron
mg/L
Total Nitrogen
mg/L
Oxidised Nitrogen
mg/L
Total Phosphorus
mg/L
Phosphate Sorption Capacity
Chloride
mg/L
mg/L
Soil Type
Soil Moisture
Site Map Showing Sample Sites
Comments:
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Comments:
Date
Disciption
QTY
Waste Origin
Name of Waste Remover
Waste Management Report
Destination Of Waste