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«Owner’s Operation and Maintenance Manual 800 Orange Avenue, Daytona Beach Fl 32114 Phone: 386/248-0500 - Fax: 386/248-3033 - Toll Free: 800/881- ...»

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____________________________________________________________________________________________

Owner’s Operation

and

Maintenance

Manual

800 Orange Avenue, Daytona Beach Fl 32114

Phone: 386/248-0500 - Fax: 386/248-3033 - Toll Free: 800/881- 0320

www.millerleaman.com

___________________________________________________________________________________________

Turbo Disc Operations & Maintenance

____________________________________________________________________________________________

The Turbo-Disc Filtration System is protected by the following patent:

#6,419,826

OTHER PATENTS MAY BE PENDING.

COPYRIGHT © 2008 by Miller-Leaman, Inc.

All Rights Reserved Miller-Leaman, Inc.

• 800 Orange Avenue • Daytona Beach, FL 32114 •

• Toll Free: 800 881-0320 • Phone: 386 248-0500 • Fax: 386 248-3033 •

• E-mail: sales@millerleaman.com • Web Site: www.millerleaman.com • First Edition Copyright © 2006, 2013 by Miller-Leaman, Inc. - 800 Orange Avenue, Daytona Beach, FL 32114 Printed in the United States of America. All rights reserved. This manual or parts thereof may not be reproduced in any form, mechanical, electronic, Internet, or in any form without the written permmission of Miller-Leaman, Inc.

Toll Free: 800 881-0320 • Phone: 386 248-0500 • Fax: 386 248-3033 E-mail: sales@millerleaman.com • Web Site: www.millerleaman.com ___________________________________________________________________________________________

2 Turbo Disc Operations & Maintenance ____________________________________________________________________________________________

CONTENTS

Use of this Manual ……………………………………………………………….. 6 Preface …………………………………………………………………………….. 7 About the Company …………………………….…………………………………. 8 Safety & Operational WARNINGS ………………………………………………. 9 Safety & Operational CAUTIONS ……………………………………………….. 10 Wearing Personal Protective Equipment (PPE) …………………………………… 12 General Equipment Lockout Procedures …………………………………………... 13 Section 1 - Introduction to Automatic Filtration ……………………………….. 15

1.1 Definitions of Abbreviations …………………………………………………... 16

1.2 Definitions of Terms ……………………….…………………………………... 17

1.3 Filtration Applications ………..……………………………………………… 18

1.4 TURBO-DISC Basic Technical data ………………..………..……………….. 19 Section 2 - Turbo Disc Product Identification …………………………………... 21

2.1 Product Identification Label …………………………………………………... 21

2.2 Turbo Disc System Component Identification ………………………………... 24

2.3 System Descriptions Based on Backflush Method ……………………………. 27 System Supplied Pressure ……………………………………………………….. 28 Booster System ………………………………………………………………….. 29 Air Assist System ………………………………………………………………. 30 Pressure Sustaining System ……………………………………………………... 31 Section 3 - Installation and Operating Instructions …………………………….. 33

3.1 Overview……………….……………………………………………………… 33

3.2 Initial Installation and Set Up ………….……………………………………… 34

3.3 Initial System Start Up ……………………………..………………………….. 35

3.4 Normal System Operation …………………………………………………….. 37

3.5 Cold Weather System Operation ……….……………………………………… 38

–  –  –

CONTENTS - Continued Section 4 - Regular Maintenance Procedures …………………………………… 39

4.1 Maintenance Schedule ………….……………………………………………. 40

4.2 Maintenance Check List …………….………………………………………… 41 Section 5 - Maintenance and Inspection of Filter System Components ………. 43

5.1 Exploded View of Filter Housing and Filter …………………………………... 44

5.2 Parts List of the Filter Housing and Filter ……………………………………... 45

5.3 Housing and Cartridge Maintenance & Cleaning Instructions ………………... 46

5.4 Filter O-Rings ………………………………………………………………….. 50

5.5 Filter Piston Actuator ………………………………………………………….. 51

5.6 Solenoids and Air Valves ……………………………………………………… 54

5.7 Air line Override Check Valves ……………………………………………….. 55





5.8 Sustaining Valves ……………………………………………………………… 55

5.9 Main Process Pump ……………………………………………………………. 57

5.10 Main Pump & Booster Pump Troubleshooting Chart ……………………….. 59

5.11 Checking Pump Direction of Rotation ……………………………………….. 60

5.12 Booster Pump - Inspection and Maintenance ………………………………… 61

5.13 The 3-way Flow Control valves - Inspection & Maintenance ……………….. 63

5.14 MAXIM Filter Controller - Setup and Troubleshooting …………………….. 65

5.15 Cleaning and General Maintenance …………………………………………… 73 Section 6 - Troubleshooting Troubleshooting Tree - Back Flush Cycle Not Complete …………………………. 74 Troubleshooting Tree - Water in the Drainage Manifold ………………………… 75 Troubleshooting Tree - Too Frequent Back Flush Cycles, System Alarm ………… 76 Section 7 - Appendix Turbo Disc Maintenance Work Log …………………...…………………………... 78 Turbo Disc Maintenance Schedule - Spring - Summer ……………………………. 79 Turbo Disc Maintenance Schedule - Fall - Winter …………………………………. 80 Section 8 - Replacement Parts List ……………………………………………….82 Section 9 - Engineering Drawings ………………………………………………. 84 Section 10 - Bill of Material ………………………………………………………. 86 Limited Warranty ……………….………………………………………………….. 88 Important Contacts (Back Cover) ………………………………………………….. 89 ___________________________________________________________________________________________

4 Turbo Disc Operations & Maintenance ____________________________________________________________________________________________

Miller-Leaman knows the Industrial Markets with thousands of installations and many unique applications. Our experience along with our Thompson Strainer line of filtration products, Helix HD & HS Series Filters, and our innovative Turbo-Disc Filter gives you a selection of filtration equipment that will solve your most challenging problems.

Typical Applications Include:

 Spray Nozzle Protection  Cooling Tower Water  Chilled Water  Process Cooling Water (injection molding, extrusion, etc.)  HVAC Systems (protection of heat exchanger, etc.)  Makeup Water  Pre-Filtration for R.O. and Other Filters  Well Water  Surface Water (lakes, rivers, canals, etc.)  Intake Water / City Water Intake  Municipal Water  Reclaimed Water  Wastewater  Scrubbers  White Water  Gland Seal Protection  Vacuum Pump Protection  Golf Course / Turf Irrigation  Landscape / Irrigation  Agricultural Irrigation

Automatic Turbo-Disc Filter Features:

 Extremely Low Amount of Backwash Water Volume  Automatic, Self-Cleaning System Triggered By Differential Pressure, Elapsed Time, or Manual Override  Centrifugal Separator Action Built Into Design, Therefore Keeping Disc Media Clean Longer Before Back Flush Cycle  Polypropylene Disc Media, Designed for a Long Service Life  Interchangeable Color-Coded Disc Cartridge Options for Different Micron Levels of Filtration  Modular Design with Small Footprint  Continuous Supply of Downstream Flow, Even During Backflush Cycle  Booster Pump Option Available for Low Pressure Applications  No Tools Necessary to Service Disc Cartridge

–  –  –

Use of this Manual Congratulations on your purchase of a Turbo-Disc Filtration System.

This Operations and Maintenance (O&M) Manual provides instructions on how to operate the system and carry out routine maintenance.

The objective of this manual is to provide simple, clear and complete instructions. It is backed by Miller-Leaman, Inc.’s commitment to offer superior customer support. Every effort has been made to ensure the accuracy and completeness of information in this manual.

General Information If any of the information or procedure explanations in this manual are unclear, please contact a Miller-Leaman Service Provider for assistance.

ONLY service personnel trained in electrical and mechanical safety should undertake operation, repairs or servicing of this equipment.

If there is any concern regarding the level of training, skill or comprehension of the manual’s instructions, please have the work done by a qualified operator or a Miller-Leaman representative.

Failure to do so could result in injury or damage to the equipment. Common sense and good judgment are crucial to the safe and successful operation and maintenance of the Turbo-Disc Filtration System.

1. Read the Warnings and Safety Precautions and General Equipment Lockout Procedure in this section before operating or performing any maintenance on this equipment.

2. Read the Safety Procedures thoroughly before starting.

3. Review all warnings and cautions that accompany any procedure and review the Warnings and Precautions section each time you prepare to perform maintenance in the Turbo-Disc Filtration System.

___________________________________________________________________________________________

6 Turbo Disc Operations & Maintenance ____________________________________________________________________________________________

Preface

The Evolution of Automatic Filtration:

The Automatic Turbo-Disc Filter sets the standard for reliable, high-efficiency filtration. Utilizing a stack of injection-molded polypropylene disc media, the Automatic Turbo-Disc Filter is exceptionally durable and engineered for longevity. Automatic Turbo-Disc Filter systems are designed with a modular approach, where multiple filter housings (pods) are manifolded together with stainless steel inlet/outlet manifolds. The sizing of the system is a function of the flow rate and the solids’ loading in the application. The back flush cycle is rapid and precise, using a fraction of the flush water used by traditional automatic sand media filters on the market.

Quality of Disc Filtration:

Although the three-dimensional disc media is the heart of the filter, there are other principles at work. As water enters the filter housing, it passes through the Helix Element at the base of the disc cartridge. The Helix Element spins the water at a high velocity, causing heavier particles (i.e. sediment) to centrifugally spin outward, away from the disc media.

The dirty water passes through the depth of the discs, from the outside to the inside. The discs contain grooves that run radially across the surface of the discs. These grooves are precisely molded in the surface of the discs, slightly tapered from the outside to the inside. On the opposite side of the disc surface, the grooves are running in the opposite direction, therefore creating a cross-hatching of grooves across the depth of the discs.

The combination of the Helix Turbo-Element, the grooves molded in the surface of the discs, and the caking effect achieved by the depth of the media, extremely fine particulate removal is achieved.

The discs have tapered grooves that the water passes through. The discs are stacked tightly onto a cartridge frame. The entire disc cartridge fits inside an injection-molded polyamide housing (pod).

Each groove alternates direction, causing a torturous path for the water. As the water passes through the grooves, extremely fine particles are trapped in the media. During backflush, the discs uniformly separate and release the contaminants from the surface of the discs.

–  –  –

About the Company Miller-Leaman, Inc. was founded in 1991 by Bill Miller, Marty Shuster and Robert Leaman.

Miller-Leaman manufactures three unique filtration products: a patented line of stainless steel liquid filters/strainers commonly known as the Thompson Filter/Strainer, the Helix Screen/Disc Series and the automatic Turbo-Disc filter. Many new custom Filtration and Ultra-Filtration systems are being added to meet the needs of our customers.

Manufacturing operations and management personnel are located in Daytona Beach, Florida in a newly renovated, state-of-the-art 52,000 square foot facility. If your ever in the area we encourage you to visit our facility for plant tour.



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