Sterling Water System SGM 250A User Manual

Water Management Systems  
Filtration and Separation Systems  
SGM-250A Sand and Gravel Filter  
CSM Centri Separator  
BFS Bag Filter  
SWF Full Flow Strainers  
Product Manual  
Sterling, Inc.  
2900 S. 160th Street  
New Berlin, WI 53151  
Tel [262] 641-8610  
Fax [262] 641-8653  
Part Number A0568850  
Revision C  
Bulletin No. SC7-600.4  
 
Safety Considerations  
Sterling/Sterlco water management systems products are designed  
to provide safe and reliable operation when installed and operated  
within design specifications, following national and local safety  
codes.  
To avoid possible personnel injury or equipment damage when  
installing, operating, or maintaining this equipment, use good  
judgment and follow these safe practices:  
; Follow all SAFETY CODES.  
; Wear SAFETY GLASSES and WORK GLOVES.  
; Disconnect and/or lock out power before servicing or  
maintaining the system.  
; Use care when LOADING, UNLOADING, RIGGING, or  
MOVING this equipment.  
; Operate this equipment within design specifications.  
; OPEN, TAG, and LOCK ALL DISCONNECTS before  
working on equipment. You should remove the fuses and carry  
them with you.  
; Make sure that system equipment and components are properly  
GROUNDED before you switch on power.  
; Do not jump or bypass any electrical safety control.  
; Do not restore power until you remove all tools, test  
equipment, etc., and the system and related equipment are fully  
reassembled.  
; Only PROPERLY TRAINED personnel familiar with the  
information in this manual should work on this equipment.  
Water Management Systems and Products  
Page 3  
 
Table of Contents  
1 Introduction...............................................................5  
1-1  
1-2  
1-3  
1-4  
1-5  
General Description  
Sand and Gravel Automatic Backwash Filters  
Centri-Separator Filter Systems  
BFS Series Bag Filters  
SWF Series Full Flow Stainless Steel Filters  
2 Shipping Information ...............................................8  
2-1  
2-2  
2-3  
2-4  
2-5  
Unpacking and Inspection  
In the Event of Shipping Damages  
If the Shipment is Not Complete  
If the Shipment is Not Correct  
Returns  
3 Installation...............................................................10  
3-1  
3-2  
3-3  
3-4  
Installing the Sand and Gravel Filter  
Installing the Centri-Separator System  
Installing the BFS Series Bag Filter  
Installing the SWF Series Full Flow Stainless Steel Filter  
4 Specifications .........................................................13  
5 Operation.................................................................14  
5-1  
5-2  
5-3  
5-4  
Sand and Gravel Automatic Backwash Filter  
Centri-Separator System  
BFS Series Bag Filters  
SWF Series Full Flow Stainless Steel Filters  
Page 4  
Water Management Systems and Products  
 
1
Introduction  
1-1 General Description  
Filtration is used on cooling tower systems or chilled water  
systems requiring removal of large, heavy-duty suspended solids.  
Four filtration systems are available; sand and gravel filters,  
centrifugal separators, bag filters, and strainers.  
Sand and gravel filters use two layers of gravel and one layer of  
sand for filtration. It is piped in a by-pass configuration. A timer  
can be preset at any interval to automatically back wash the sand  
and gravel. The SGM-250A sand and gravel filter is designed to  
handle up to 250 ton tower systems and 500 ton chiller systems.  
The Centri-Separator System uses centrifugal force by directing  
the water in a circular motion allowing suspended solids to drop  
out and be purged from the system. It is piped in a by-pass  
configuration and is supplied with an integral pump, electrically  
operated ball valve, and controls. A timer can be preset at any  
interval to automatically purge the separator. The CSM Centri  
Separator is available for cooling tower systems up to 400 tons and  
chiller systems up to 800 tons.  
BFS bag filters use a 25-micron bag to filter suspended solids in  
either a by-pass or full flow piping configuration. A differential  
pressure alarm is available to warn when bag is full. BFS bag  
filters are available for tower systems up to 150 tons and chiller  
systems up to 200 tons.  
SWF Series full flow filters use a strainer basket to filter the water.  
An 80-mesh strainer screen is standard. Other mesh sizes are  
available upon request. The filter housing, strainer basket, and  
flanges are made from 304 stainless steel. A differential pressure  
alarm and automatic purge valve are available as an option. SWF  
Series full flow filters are available for tower systems up to 650  
tons and chiller systems up to 850 tons.  
Water Management Systems and Products  
Page 5  
 
1-2 Sand and Gravel Automatic Backwash Filters  
Sterling/Sterlco sand and gravel filters are shipped complete with:  
Tank  
Valve manifold  
Gauges  
Initial charge of sand and gravel  
The system switches valves automatically. Two backwash control  
mechanisms are available. Backwash cycles can be based on a time  
cycle (SGM-250A) or pressure differential across the unit (SGM-  
250P).  
SGM-250A sand and gravel automatic backwash filters are  
available in a 250-ton (756,000 Kcal/hr) model for cooling towers  
and a maximum-capacity 500-ton (1,512,000 Kcal/hr) chiller  
model. The SGM250A model is equipped with automatic valves  
operated from a timing device so that the backwash cycle  
automatically activates on a periodic basis.  
Filters must be installed in a bypass line so that plugging of the  
filter or temporary shutdown required for back washing does not  
hinder process operation.  
1-3 Centri-Separator Filter Systems  
Sterling/Sterlco centrifugal separation systems are used on cooling  
tower or chilled water systems requiring large capacity, heavy-duty  
suspended solids removal.  
The Centri-Separator System (CSM-150) is designed to handle up  
to 150-ton (567,000 Kcal/hr) cooling tower systems and up to 300-  
ton (907,200 Kcal/hr) chiller systems. The CSM-150 includes a  
centrifugal separator, 1/3 hp (0.25 kW) pump, 1/2” PVC electrically-  
activated ball valve, and a 115 volt single-phase 60 hertz control  
station. The CSM-150 can be mounted on a pump tank or piped in  
a bypass line. The system performs all operations, including  
separator purging, automatically.  
The CSM-400 is designed for larger tower water system  
applications; up to 400-ton (1,512,000 Kcal/hr) cooling tower  
systems and up to 800-ton (2,419,200 Kcal/hr) chiller systems.  
Page 6  
Water Management Systems and Products  
 
Note: Centrifugal separation systems must not be used for closed-  
loop or chilled water systems; back flushing eliminates  
chemicals added to the system.  
1-4 BFS Series Bag Filters  
BFS Series bag filters can be used for full flow or bypass  
applications. BFS Series filters feature single cell 25-micron  
polyester filter bags, and include pressure gauges. BFS bag filters  
are available for tower systems up to 150 tons and chiller systems  
up to 200 tons.  
1-5 SWF Series Full Flow Stainless Steel Filters  
SWF Series full flow stainless steel filters feature 304 stainless  
steel construction of filter housings, strainer baskets, and flanges.  
Maximum working pressure is 100 psi (689.5 kPa/6.9 bars); 150  
psi (1,034.5 kPa/10.3 bars) is available. Maximum operating  
temperature is 110ºF (43ºC); consult the factory for higher  
operating temperatures. 80-mesh screen size is standard for the  
stainless steel strainer basket; 40 mesh can be used for cooling  
tower water applications. Options include ΔP pressure alarm and  
automatic purge valve with timer.  
Note: Valving and bypass are not included with SWF Series  
filters.  
BFS Series and SWF Series full flow filters must be installed with  
bypass piping so that plugging of the filter or temporary shutdown  
required for back-washing does not hinder process operation.  
Water Management Systems and Products  
Page 7  
 
2
Shipping Information  
2-1 Unpacking and Inspection  
You should inspect your Sterling/Sterlco water management  
systems and products for possible shipping damage.  
Thoroughly check the equipment for any damage that might have  
occurred in transit, such as broken or loose wiring and  
components, loose hardware and mounting screws, etc. In case of  
breakage, damage, shortage, or incorrect shipment, refer to the  
following sections.  
2-2 In the Event of Shipping Damages  
Important!  
According to the contract terms and conditions of the Carrier,  
the responsibility of the Shipper ends at the time and place of shipment.  
The Carrier then assumes full responsibility of the shipment.  
; Notify the transportation company’s local agent if you discover  
damage.  
; Hold the damaged goods and packing material for the  
examining agent’s inspection. Do not return any goods to  
Sterling/Sterlco before the transportation company inspection  
and authorization.  
; File a claim against the Transportation Company. Substantiate  
the claim by referring to the agent’s report. A certified copy of  
our invoice is available upon request. The original Bill of  
Lading is attached to our original invoice. If the shipment was  
prepaid, write us for a receipted transportation bill.  
; Advise Sterling/Sterlco. regarding your wish for replacement  
and to obtain an RMA (return material authorization) number.  
Page 8  
Water Management Systems and Products  
 
2-3 If the Shipment is Not Complete  
Check the packing list. The apparent shortage may be intentional.  
Back-ordered items are noted on the packing list. You should have:  
; Sterling/Sterlco water management system equipment or  
chemical treatment products  
; Bill of lading  
; Packing list  
; Operating and Installation packet  
; Electrical schematic and panel layout drawings  
; Component instruction manuals  
Re-inspect the container and packing material to see if you missed  
any smaller items during unpacking. Determine that the item was  
not inadvertently taken from the area before you checked in the  
shipment. Notify Sterling/Sterlco immediately of the shortage.  
2-4 If the Shipment is Not Correct  
If the shipment is not what you ordered, contact the parts and  
service department immediately at [262] 641-8610. Have the  
order number and item number available. Hold the items until you  
receive shipping instructions.  
2-5 Returns  
Important!  
Do not return any damaged or incorrect items  
until you receive shipping instructions from Sterling/Sterlco.  
Water Management Systems and Products  
Page 9  
 
3
Installation  
3-1 Installing the Sand and Gravel Backwash Filter  
Selecting an Installation Site  
Place the unit on a suitable and level foundation, preferably a  
concrete floor or pad and near the pump for best operation. The  
location you select must also have an open drain to a sewer for  
backwash, a hookup to city water, and a 110-volt electrical source.  
Use a fork lift truck when moving the unit to avoid damage.  
Installing the Unit  
Be sure that piping to the unit has a bypass circuit. The bypass  
circuit allows for removal of the unit for servicing without  
interrupting water service. Always run piping full size at 1½” NPT  
(approx. 38 mm). Connect the entering water connection of the  
filter unit to the process supply and the leaving connection to the  
tank. Use 2” NPT (approx. 51 mm) to hook up city water or  
process water to the backwash connector piping, as well as to  
connect back-flush connections to the city waste or sewer.  
Figure 1  
Typical Sand and Gravel Filter  
Page 10  
Water Management Systems and Products  
 
Filling the Unit  
Fill the water tank with water by opening valves e and f. Valves  
c, d, g, and h are automatically controlled by a timer. After you  
open valves e and f, water flows and is filtered in the normal  
direction.  
Take a moment now, while the filter is clean, to record pressure  
gauge readings at the inlet and outlet of the filter. You’ll use these  
readings later to determine the cleanliness of the filter media.  
Complete the installation of the sand and gravel filter by plugging  
the unit into a 110-volt source of electricity. The sand and gravel  
filter is now ready to use.  
3-2 Installing the Centri-Separator System  
Selecting an Installation Site  
Place the unit on a suitable and level foundation, preferably a  
concrete floor or pad and near the pump for best operation. The  
location you select must also have an open drain to a sewer for  
purging and a 110-volt electrical source.  
Use a fork lift truck when moving the unit to avoid damage.  
Installing Piping  
Be sure that piping to the unit has a bypass circuit. The bypass  
circuit allows for removal of the unit for servicing without  
interrupting water service. Part of your Centri-Separator system  
includes a three foot (about 1 m) suction leg, including a priming  
valve/connection for startup. Connect the pump suction leg to the  
pump suction connection. Sterling/Sterlco recommends that you  
use a hose at least 1½” (about 38 mm) in diameter for clean water  
flow to the pump tank. Your system includes a threaded barbed  
fitting and clamps to install the hose.  
Priming the Pump and Preparing for Operation  
Be sure that the pump on your Centri-Separator system is primed  
before you start up the system. To do this, connect a city water line  
to the priming valve. Allow enough time for the suction leg to fill  
with water, then close the priming valve.  
Water Management Systems and Products  
Page 11  
 
Complete the installation of your Centri-Separator system by  
plugging the unit into a 110-volt source of electricity. The Centri-  
Separator system is now ready to use.  
3-3 Installing the BFS Series Bag Filter  
Selecting an Installation Site  
Place the unit on a suitable and level foundation, preferably a  
concrete floor or pad and near the pump for best operation.  
Use a fork lift truck when moving the larger units to avoid damage.  
Installing Piping  
Be sure that piping to the unit has a bypass circuit. The bypass  
circuit allows replacement of bag filter without interruption of  
service. Connect to the inlet and outlet as labeled on filter housing.  
Solids will collect inside the bag filter preventing spill over when  
the bag is removed. Always run piping full size. Filter housing  
maximum operating pressure is 150 psi.  
3-4 Installing the SWF Series Full Flow Stainless  
Steel Filter  
Selecting an Installation Site  
Place the unit on a suitable and level foundation, preferably a  
concrete floor or pad and near the pump for best operation.  
Use a fork lift truck when moving the larger units to avoid damage.  
Installing Piping  
Be sure that piping to the unit has a bypass circuit. The bypass  
circuit allows for removal of the unit for servicing without  
interrupting water service. Connect to the inlet and outlet as  
labeled on the housing. Solids will collect in the bottom of the  
housing where it will be purged out of the system. Always run  
piping full size. Filter housing maximum operating pressure is 100  
psi.  
Page 12  
Water Management Systems and Products  
 
4
Specifications  
Sand and Gravel Automatic Backwash Filters  
Model SGM-250A is equipped with automatic valves operated from a time device so that backwash is accomplished  
periodically on an automatic basis.  
Dimensions in. (cm)  
Shipping  
weight  
lbs.  
Pressure  
differential  
backwash c  
Model  
L
W
H
number  
in.  
cm  
in.  
cm  
in.  
cm  
Kg  
SGM-250A  
40  
101  
48  
122  
39  
99  
1,800  
818  
SG-250P  
c Model SGM-250P. Automatic valves are operated from pressure switch. Pressure switch monitors the pressure drop in the filter  
media and activates backwash cycle at preset pressure drop.  
Centri-Separator Systems  
Note: Not to be used for closed-loop or chilled water systems; back flushing eliminates chemicals added to the system.  
Dimensions  
in. (cm)  
W
Shipping  
weight  
Model  
L
H
number  
Description  
in.  
29  
29  
cm in. cm  
74 19½ 50  
74 19½ 50  
in.  
26  
26  
cm  
66  
66  
lbs.  
130  
130  
Kg  
60  
60  
150-ton (453,600 Kcal/hr) tower maximum  
300-ton (907,200 Kcal/hr) chiller maximum  
400-ton (1,209,600 Kcal/hr) tower maximum  
CSM-150  
CSM-400  
26  
26  
66 20  
51  
51  
41  
41  
104  
104  
150  
150  
69  
69  
66 20  
800-ton (2,419,200 Kcal/hr) chiller maximum  
BFS Series Bag Filters  
Note: Can be used for full flow or bypass.  
Max. flow  
No. filter bags  
Pipe size  
Model c  
BFS-30  
BFS-65  
BFS-90  
gpm  
lpm  
113  
246  
340  
required  
supplied  
inches  
mm  
30  
65  
90  
1
1
1
3
3
3
1½” NPT  
2½” NPT  
2½” NPT  
38 mm  
63 mm  
63 mm  
BFS-200  
BFS-300  
BFS-450  
200  
300  
450  
757  
1,135  
1,703  
1
2
3
3
6
12  
3” (flanged)  
4” (flanged)  
5” (flanged)  
76 mm (flanged)  
102 mm (flanged)  
127 mm (flanged)  
c Single cell filters include bypass, pressure gauges and 25 micron filter bags. Multi-cell filters include pressure gauges and 25 micron  
filter bags.  
SWF Series Full Flow Stainless Steel Filters  
Maximum working pressure is 100 psi (689.5 kPa/6.895 bars); 150 psi (1,034.25 kPa/10.343 bars) is available.  
Maximum operating temperature is 110ºF (43ºC). Consult factory for higher temperatures.  
Maximum flow  
Connection size/flange  
inches  
Model cd  
SWF-100  
SWF-200  
SWF-350  
gpm  
100  
200  
350  
lpm  
378  
757  
mm  
2” flange  
3” flange  
4” flange  
51 mm flange  
76 mm flange  
102 mm flange  
1,325  
SWF-750  
SWF-1300  
SWF-2000  
750  
1,300  
2,000  
2,839  
4,920  
7,570  
6” flange  
8” flange  
10” flange  
152 mm flange  
203 mm flange  
254 mm flange  
c
d
80 mesh screen size is standard for stainless steel strainer basket. 40 mesh can be used for tower water. Specify mesh size.  
Valving and bypass are not included with SWF Series stainless steel filters.  
Water Management Systems and Products  
Page 13  
 
5
Operation  
5-1 Sand and Gravel Automatic Backwash Filter  
Adjusting Timer  
Adjust the time control of the SGM-250A if desired. The factory  
set timer is set to backwash four minutes every 24 hours.  
Frequency and duration may be reset as required. See diagram  
below to adjust timer.  
M ANUAL  
For manual regeneration, move  
lever in direction of arrow as far  
as it will go - then release.  
REGENERATION  
Red  
Dial  
1. Set skipper wheel so that  
"TO-DAY" or number one is  
opposite arrow.  
White  
Dial  
Lift tabs on skipper wheel  
corresponding to days  
regeneration as desired.  
Yellow  
Dial  
Skipper wheel.  
DAY  
2. Set time of day at which unit  
is to regenerate by loosening  
this screw, and turning this dial  
in either direction so that arrow  
points to desired regeneration  
time in the window of the black  
dial.  
Then tighten screw.  
F
3. Set time of day by lifting up  
yellow dial and turning it in  
either direction until actual time  
is opposite arrow.  
To change the length of backwash time, rotate the complete dial  
assembly until the red arrow is at 11:00. Loosen the center screw  
and lift the black, yellow, and white dials together pointing to the  
desired time to on the red scaled dial. Lift the black knob and the  
red dial pointer to 6 on the white-scaled dial. Then lift the black  
knob pointer to 6 on the yellow-scaled dial. Tighten screw. Rotate  
the complete assembly until the red arrow is pointing to the rib on  
the pressure box (6:00 position). The timer will now back wash for  
six minutes.  
Important!  
Make sure gears are engaged before tightening screw  
Page 14  
Water Management Systems and Products  
 
The Model SGM-250P backwashes based upon pressure  
differential across the filter media. Additionally, an adjustable  
timer allows back washing for up to five minutes. The factory  
setting is four minutes.  
The pressure differential switch is adjustable for pressure drop and  
dead band. Backwash will start when the pressure differential  
reaches set point plus the dead band. For example, if the pressure  
differential is set for 6 psi, the dead band for 4 psi, and the  
backwash timer for 4 minutes, then the backwash cycle will start at  
10 psi for a duration of four minutes.  
Replacing Sand and Gravel  
Replace the sand and gravel every two years, when contaminated,  
or when sand has carried over from excessive water flow.  
There are three layers of filter media. First, starting from the  
bottom, place 200 lbs. of ½” x ¼” round gravel. Second, place 300  
lbs. of ¼” x 1/8” round gravel and third, the top final layer, place  
700 pounds of #20 filter sand.  
Anode Replacement  
On top of the filter housing is a sacrificial anode made of  
magnesium. Inspect and replace when it has depleted.  
5-2 Centri-Separator System  
The CSM-150 and CSM-400 require a 120/1/60-power source and  
are provided with a standard plug. The separators are designed to  
operate to a prescribed flow range for maximum solid removal.  
The CSM-150 operates at a flow rate of 10 to 20 gpm and the  
CSM-400 operates at 45 to 70 gpm. Liquid enters the upper portion  
of the separator housing tangentially and the solids are drawn  
through internal slots to the bottom chamber. An electrically  
operated ball valve automatically back flushes the solids from the  
separator. Periodically inspect and ensure that the purge line is  
clear to flow freely.  
Water Management Systems and Products  
Page 15  
 
5-3 BFS Series Bag Filters  
Bags are easily removed from the top of the filter housing. Before  
removing the bag filter be sure that pressure has been relieved and  
that the filter housing has been isolated to prevent spill over.  
! CAUTION  
SEVERE INJURY WILL RESULT IF HOUSING COVER IS REMOVED UNDER  
PRESSURE. RELIEVE PRESSURE AND ISOLATE HOUSING BEFORE  
REMOVING COVER.  
Loosen and unlatch the V-clamps or swing type bolts that fasten  
down the top of the filter housing. The top is hinged on one end  
and will swing open. Reach down and lift the bag handle and  
remove the filter bag. Unfold and install the new bag. Close the  
cover and tighten down the swing bolts.  
5-4 SWF Series Full Flow Stainless Steel Filters  
Periodically, solids that settle to the bottom of the filter housing  
will need to be purged out. The drainage port valve, which is piped  
to an open drain, will need to be opened to purge the debris from  
the reservoir. Over time, one should be able to accurately  
determine how often the valve should be opened. Do not allow the  
debris to collect beyond the capacity of the reservoir.  
An optional automatic purge valve is available to open based upon  
an adjustable time cycle. Periodically inspect and ensure that the  
purge line is clear to flow freely.  
! CAUTION  
SEVERE INJURY WILL RESULT IF HOUSING COVER IS REMOVED UNDER  
PRESSURE. RELIEVE PRESSURE AND ISOLATE HOUSING BEFORE  
REMOVING COVER.  
The cover of the SWF full flow filter is removable if the strainer is  
clogged with debris. A pressure drop of 10 psi, after purging debris  
from the reservoir, would indicate that the strainer requires  
cleaning. Do not remove the cover under pressure. Relieve the  
pressure and isolate the filter from the system first. Lift the strainer  
element out of the filter housing and scrub it carefully with a rigid  
nylon brush and water until clean. Wash it off with clean water,  
Page 16  
Water Management Systems and Products  
 
preferably a garden hose if possible. Return it to the filter housing  
ensuring that the U-shaped gasket fits securely to the bottom of the  
strainer. Make sure that the strainer head gasket is secure.  
Reposition the strainer cover on top of the filter housing.  
On those models with a band clamp, replace the band clamp  
around the strainer cover and housing latching the T-bolt. Then  
push the latch handle towards the filter housing. The T-bolt latch  
does not need adjustment when installed. It is set at the factory for  
proper clamp compression.  
Bolted cover models require a torque sequence as follows: 12:00 to  
6:00, 3:00 to 9:00, 11:00 to 5:00, and 2:00 to 7:00. Bolt torque  
requirements are: 3/8” bolts (15 to 25 ft.lbs.), ½” bolts (45 to 55  
ft.lbs.), and 5/8” bolts (80 to 100 ft.lbs.).  
Service Notes  
Water Management Systems and Products  
Page 17  
 
Parts Department  
[
]
[262]  
Call toll-free 7am–5pm CST 800 423-3183 or call 641-8610 or fax [262] 641-8653  
The ACS Customer Service Group will provide your company with genuine OEM quality parts manufactured to  
engineering design specifications, which will maximize your equipment’s performance and efficiency. To assist in  
expediting your phone or fax order, please have the model and serial number of your unit when you contact us. ACS  
welcomes inquiries on all your parts needs an is dedicated to providing excellent customer service.  
Service Department  
[
]
[262]  
Call toll-free 8am–5pm CST 800 423-3183 or call 641-8610  
[847]  
Emergencies after 5pm CST, call  
439-5655  
We have a qualified service department ready to help. Service contracts are available for most of our products.  
Sales Department  
[262]  
Call  
641-8610 Monday–Friday, 8am–5pm CST  
Our products are sold by a world-wide network of independent sales representatives. Contact our Sales Department  
for the name of the sales representative nearest you.  
Contracting Department  
Call [262] 641-8610 Monday—Friday, 8am—5pm CST  
Let us install your system. The Contracting Department offers any or all of these services: project planning; system  
packages including drawings; equipment, labor, and construction materials; and union or non-union installations.  
Sterling/Sterlco  
2900 S. 160th Street  
New Berlin, WI 53151  
[262]  
[262]  
641-8653  
641-8600 Fax  
Page 18  
Water Management Systems and Products  
 

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