Ebbco CLS-141-24K H.E.-SWS User manual

INDUSTRIAL FILTRATION SYSTEMS
CUSTOMER:
MODEL #: CLS-141-24K H.E.-SWS
OPERATION AND MAINTENANCE MANUAL
EBBCO INC.51536 Industrial Drive, New Baltimore, Michigan, 48047
Phone: [phone] www.ahbinc.com
EMPLOYEES

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
CUSTOMER: AHB/ ALCOA
MANUFACTURER: 51536 INDUSTRIAL DRIVE,
NEW BALTIMORE, MICHIGAN,
48047, USA
TEL: [phone]
MODEL #: CLS-141-24K-H.E.-SWS
OPERATION AND
MAINTENANCE
MANUAL
IMPORTANT!
Failure to install Ebbco Inc. brand Filter
Cartridges in any Ebbco Inc. Filtration
System, housings and or units requiring
Filter Cartridges for necessary operation,
will cause Ebbco Inc.’s standard
warranty to be null and void.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Table of Contents:
Section 1 Introduction
1.1 Introduction
1.2 Sequence of Operation
Section 2 System Specifications
2.1 System Utilities Requirements
2.2 System Components
Section 3 Installation and Start-Up Procedures
3.1 Site Requirements
3.2 Installation Procedure
3.3 Heat Exchanger Installation Procedure
3.4 Chiller Installation Procedure
3.5 Start-Up Procedure
Section 4 System Maintenance
4.1 CLS Daily Check List
4.2 Pump Maintenance
4.3 Pre-Filter Bag Maintenance
4.4 Bag Vessel Maintenance
4.5 Hurricane Vessel Maintenance
4.6 D.I. Vessel Maintenance
4.7 Final Filter Vessel Maintenance
4.8 Service Beacon Maintenance
4.9 Ozone Generator Maintenance
4.10 Reservoir Maintenance
4.11 Settling Weir Maintenance
4.12 Chiller Maintenance
Section 5 System Troubleshooting
5.1 System Troubleshooting
5.2 Ozone Troubleshooting
5.3 System Pump Troubleshooting
5.4 Feed Pump Troubleshooting
5.5 Chiller Troubleshooting
Section 6 Spare Parts List
6.1 Replacement Spares Parts
6.2 Recommended Spare Parts
6.3 Consumables
Section 7 General Policy & Warranty
Section 8 Product Literature & System Drawings
8.1 Bag Vessel
8.2 Hurricane Vessel
8.3 D.I. Vessel
8.4 Final Filter Vessel
8.5 TDS Meter
8.6 Flow Schematic
8.7 Electrical Schematic
8.8 Acceptance Forms

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 1: Introduction
1.1 Introduction
This manual provides technical instruction on the installation, and operation of the Closed Loop
Filtration System manufactured by Ebbco Inc. With regular maintenance and proper operation, the Closed
Loop Filtration System will reuse the overflow water from the work tank, and process it so that it meets the
high-pressure pump specifications. The Closed Loop Filtration System will require some on-site
assembly, which includes connecting the Closed Loop Filtration System to the water-jet cutting machines
work tank overflow, connecting the make-up water line, and connecting hoses from the Closed Loop
Filtration to the high-pressure pump. The Closed Loop Filtration System is manufactured using quality
materials by a highly experienced production staff. The Closed Loop Filtration System is tested by Ebbco
Inc. to ensure that it meets all of the specifications required by each customer. The Closed Loop Filtration
System is inspected, and all test data documented prior to shipment.
1.2 Sequence of Operation
The Ebbco Inc. Closed Loop Filtration System (CLS) is designed to allow the user to shut off the
drain and capture overflow water for reuse by polishing it with specialized equipment. The system
operates by using the overflow water from the customer’s waterjet catch tank.
Water from the customer’s waterjet catch tank will overflow into a Settling Weir, preventing any
large solids from entering the Closed Loop System. The Settling Weir will then overflow through the CLS
1.5” system inlet. The water flows through a Pre-Filter Bag on the inside of the CLS 1.5” inlet. This pre-
filter bag will prevent any debris (150 microns and above) from settling into the dirty portion of the system
tank. The dirty tank water level should be consistently around 10 –14”. The float level assembly inside of
the dirty tank will open a valve and supply make-up water if the catch tank overflow supply is insufficient.
From the dirty tank water is pumped, via the system pump, through the bag vessel (vessel # 1).
The water is polished by an ultra-fine bag filter (installed inside of vessel #1) polishing the fluid to 1
micron. Water is then sent through the Hurricane Filter Vessel (vessel #2), where the hurricane filter
cartridge removes particles above 0.35-microns. Water leaves the hurricane vessel as clean fluid and is
deposited into the clean portion of the system tank. The clean tank is constantly monitored by a TDS
(Total Dissolved Solids) Meter to maintain a safe level of D.I. controlled water. Water is directed from the
outlet of the Hurricane Filter Vessel (vessel # 2) into the D.I. Vessel (vessel #3) when the TDS level goes
above the preset high point of the system holding tank. The D.I. vessel is filled with a waterjet resin bag,
which will remove dissolved solids from the water. Water will be reintroduced into the clean tank after
running through the D.I vessel. The High-Pressure Feed Pump delivers the clean, cooled TDS-controlled
water from the clean tank back to the High-Pressure Waterjet Pump. Water will continuously overflow
back into the CLS, continuing the filtration sequence.
The clean tank should always be continuously overflowing into the dirty tank to ensure that there
is always a positive level of clean water for the CLS High-Pressure Feed Pump. This will ensure that there
is always a positive level of clean water for the feed pump to draw from, which will prevent potential
catastrophic feed pump damage or failure. The water that overflows into the dirty tank is again drawn up
and filtered through the aforementioned process.
The CLS is fitted with an Ozone Generator, which will continuously introduce a mixture of ozone
and air into the clean portion of the system tank. This action will help eliminate biological fouling agents in
the entire system. Clean water is routed through a heat exchanger and a closed loop chiller, cooling the
water and removing heat generated by the High-Pressure Cutting Pump, and heat generated by the
cutting process itself.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 1: Introduction
Hurricane
Vessel # 2
Bag Filter
Vessel # 1
System
Tank
D.I. Vessel
# 3
Emergency
Overflow
Work Tank
Overflow
(System Inlet)
Feed
Pump
TDS
Meter
Ozone
Generator
Final Filter
Vessel #4
(x2_
System
Pump
City Water
Make-Up
Connection
Figure 1.1
Filtration System Assembly
Pressure
Switch
Figure 1.3
Rear System Tank Connections
essel #1 Outlet/ Vessel #
2 Inlet Pressure Gauge
System 0.5”
Outlet
Heat
Exchanger
Figure 1.2
Settling Weir
Settling Weir
Drain
Settling Weir
Outlet (Inlet on
opposite side)
Settling Weir
Bag Filter

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 2: System Specifications
2.1 System Utilities Requirements
Electrical:
460vac/3ph/60Hz
Closed Loop System Full Load Amps:
Overall Full Load Amps for GRS and CLS:
5.0 Amps
19.0 Amps
Make-Up Water connection:
2 GPM @ 20 PSI min
Inlet connection:
1.5” BHF connection
Outlet connection:
0.5” hose barb connection
Heat Exchanger inlet/outlet connection:
0.75” hose barb connection
2.2 System Components
Tank
General Dimension: 66" l x 36" w x 62" h
Tank Dimension: 30" l x 36" w x 30" h
Clean Tank Capacity: 50 US GAL
Dirty Tank Capacity: 100 US GALLONS
Max Tank Capacity: 150 US GALLONS
Bag Vessel (Vessel #1) –SLBV-0833-BC
Construction: 304 Passivated Stainless Steel
Bag Requirement: This unit accepts one (1) Filter Bag, extra fine extended
area Pre-Filter
Rim Gasket: Buna-nitrile
Media Requirement: CLS-1-G2PS-EA
Hurricane Vessel (Vessel #2) –HRF-LP
Construction: 316 Passivated Stainless Steel
Recommended Flow Rate: 30 GPM
Service Height Clearance: 62”
Filter Cartridge: This unit accepts one (1) 0.35 micron-rated Pleated
Polyester-PlusFilter Cartridge
Rim Gasket: E.P.D.M.
Media Requirement: HR-930-Q.35
D.I. Vessel (Vessel #3) –DI-1
Construction: 316 Passivated Stainless Steel
Capacity: One cubic foot of Water-jet Resin in a Poly Sateen Bag
(recyclable)
Rim Gasket: Buna-nitrile
Media Requirement: CLSR-100-PKG
Final Filter Vessel (Vessel #4 x2) –(HSL-10-0.50-WCP)
Quantity: 2 Separate Cartridges
Construction: Polypropylene
Flow Rate: 10 GPM
Filter Cartridge: This unit accepts one (1) 0.35 micron-rated Pleated
Filter Cartridge
Rim Gasket: E.P.D.M.
Media Requirement: CLS-801-Q.35 / CLS-801-0.2

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 2: System Specifications
System Pump –B82418
Closed-coupled, end suction, single-stage Centrifugal Pump.
Pumps water from Filtration System’s dirty tank through system vessels.
Motor: 460vac/3φ/60Hz
Horsepower: 1 HP
Speed: 3450 R.P.M.
Enclosure: T.E.F.C.
Full Load Amp @ 460vac: 2.0 Amps
Temperature: 212ºf maximum operating temp
Impeller: 5”diameter AISI 316 Stainless Steel
High-Pressure Feed Pump –TC40S340
Direct-coupled, self-priming, multi-stage Centrifugal Pump.
Delivers water from the Filtration System’s clean holding tank to customer’s machine tool.
Motor: 460vac/3φ/60Hz
Horsepower: 1.15 HP
Speed: 3300 R.P.M.
Enclosure: T.E.F.C.
Full Load Amp: 2.5 Amps
Impeller: multistage
Electrical Panel
Custom enclosure that controls both the Garnet Removal System and the closed loop system.
System Pump starter module: PKZMO Thermal Overload
Thermal overload set point @ 460vac: 2.0 (FLA of motor)
Feed Pump starter module: PKZMO Thermal Overload
Thermal overload set point @ 460vac: 2.5 (FLA of motor)
Total Dissolved Solids Meter –CIC-152-4
Digital monitor/controller.
Dual set point is internal to discourage unauthorized adjustments. If the conductivity signal becomes
greater than the conductivity set point at the solenoid valve will open allowing water to pass through
the D.I. Vessel. The conductivity probe is located inside the clean tank.
Range: 0-500 PPM
Conductivity Set Point A: 40 PPM
Change Resin-Flashing Beacon: 100 PPM
Contact Rating: SPDT 10 Amp @ 250vac, 30vdc.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 2: System Specifications
Ozone Generator –ZO-200-CD
Lamp: Corona Discharge
Operating Temperature: 35º F to 100º F
Ozone Output: 5.0 SCFH @ 2 PSI
Cabinet: Metal Construction
Check Valve : 1/4" Plastic Internal
Pressure Switch –MCS4FORMCDN
Material: conforms to IEC 947, en 60-947, VDE
0660, csac2 2-2
Temperature: -10ºf min - to 150ºf max
Max Pressure: 65 PSI (4.4 bar)
Reading: Service Filter
Set Point: 10 PSI
Reading Pickup: Inlet Header of Hurricane Vessel
Service Beacon –Dry contact
Bulb: 5w
Enclosure: IP54 /UL Type 12
Triggered by: TDS meter
Set Point: see TDS settings/ Descending Pressure Switch
Location: Dry Contact signal
Pressure Gauge –WJF-GA-0-60
Range: 0-60 PSI
Face Diameter: 2 1/2"
Inlet Size: 1/4" NPT
Case Material: Stainless Steel
Wetted Parts: Brass
Settling Weir
Dimension: 36” l x 24” h x24” w
Inlet: 1.5” BHF connection
Outlet: 1.5” BHF connection
Material of Construction: Carbon Steel
Thickness: 10 gauge
Media Requirement (if equipped): WJF-SWB
Heat Exchanger –36,000 BTU
Capacity 36,000 BTU/HR
Inlet connection size: 1.0” NPT [x2]
Outlet connection size: 1.0” NPT [x2]

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 3: System Installation and Operation Procedures
Carefully check each component against the enclosed packing list upon shipment arrival to
ensure that everything has been received. A claim must be filed with the carrier immediately if any
damages are found. Remove the filtration system from the wooden skidding it was shipped in using
suitable materials and proper handling equipment.
3.1 Site Requirements
The Closed Loop Filtration System requires a level space as close to the customer’s waterjet
catch tank as possible. The system occupies an area of 66” l x 36” w, with a service clearance height of
62”. It is recommended that at least three feet of additional space be allocated around the perimeter of
the filtration system for operator service access, inspection, and routine system maintenance.
Electrical: 460vac/3ph/60Hz
3.2 Closed Loop Installation Procedure
1) Un-package the Ebbco Inc. Closed Loop Filtration System (CLS) and inspect for any damage that
may have occurred in transit.
2) Place the CLS on a level surface within 15 ft. of the customer’s waterjet catch tank.
3) Have a qualified industrial electrician connect the dedicated electrical power supply to the CLS
electrical panel per the enclosed electrical drawing E-2214-071-001.
4) If a settling weir is equipped, use the provided hose to connect from the customer’s waterjet catch
tank overflow discharge to the 1.5” inlet port on the settling weir. Connect the provided plumbing from
the settling weir 1.5” outlet port to the 1.5” catch tank overflow inlet on the CLS.
5) Connect the float ball to the float valve assembly inside of the dirty tank (if this step has not already
been done prior to shipment). The float assembly has been preset at the factory to the correct height
and does not require adjustment.
Note: The float valve assembly on the City Water Make-Up port should be set to maintain a water
depth of 10 –14" and no higher. This is used to make-up water lost from evaporation and
insufficient overflow from the waterjet catch tank.
6) Connect the make-up water source to the 0.75” water make-up connection on the CLS.
7) Connect the hose from the outlet of the High-Pressure Feed Pump to the Final Filter Vessel inlet
(vessel #4 2 pcs) if this was not done prior to shipment.
8) Plumb into the customer’s machine tool inlet from the final filter vessel 0.5” hose barb outlet.
9) Run hose from the emergency overflow on the CLS to either a drain or into a catch bucket.
10) Ensure all unions are tight and all drains are closed
Note:
The float valve assembly on the city water make-up inlet must be
set to maintain a water depth of 10 –14"

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 3: System Installation and Operation Procedures
3.3 Heat Exchanger Installation Procedure
To connect pre-existing cooling unit to heat exchanger:
1) Remove the white caps protecting the threads on the 1.0” inlet and
outlet threads.
2) Connect pluming from the customer’s preexisting cooling device
discharge to the 1.0”fluid inlet on the heat exchanger (red circle).
3) Connect plumbing from the heat exchanger 1.0” fluid outlet (blue
circle) to the customer’s preexisting cooling device inlet.
3.4 Chiller Installation Procedure
To install a 90K in-line chiller unit:
1) Remove the ¾” hose from the chiller inlet and outlet hose barbs on the CLS (see right and below right
images).
2) There are two lengths of provided hose to connect the chiller to the CLS. Connect the CLS to the in-
line chiller as follows:
a. Attach one length of hose to the 0.75” hose barb inlet located on the CLS tank (see Figure 3.1).
Connect the opposite end of that hose to the 0.75” hose barb on the in-line chiller marked fluid
outlet from chiller.
b. Attach the second length of hose to the 0.75” hose barb outlet on the CLS base (see Figure 3.2).
Connect the opposite end of that hose to the 0.75” hose barb on the in-line chiller marked fluid
inlet to chiller.
Figure 3.2
Chiller Outlet (to chiller) Connection
Figure 3.1
Chiller Inlet (from chiller) Connection

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 3: System Installation and Operation Procedures
3.5 Start-Up Procedure
1) Fill the clean side of the system tank (smaller side) with filtered water (min 20 micron) with a TDS
level no greater than 150 PPM. Fill the clean tank so it completely fills and spills over the dividing
baffle into the dirty tank (larger side). Keep filling the clean tank until the water level inside of the dirty
tank is just below the city water make-up port.
2) Prime the system pump by loosening the prime nut on the top of the pump housing and letting the air
bleed out. Tighten the nut once water is flowing out of the port.
Note: While clockwise may typically be the normal factory set rotation, some motors do rotate
counter-clockwise. Every pump leaves our facility with an arrow affixed to the motor correctly
identifying the motor rotation direction. Advise said arrow for proper motor rotation direction.
3) The motor(s) have been synchronized at the factory, but if they are running in reverse have a
qualified industrial electrician swap over one of the incoming power lines at the electrical panel.
4) Carefully open the bleeder valve on top of vessel # 2 to bleed out the trapped air. Close the bleeder
valve once all the air is purged and fluid start to escape the valve.
Note: The inlet pressure gauge (on vessel # 1) should read approximately 38 PSI.
5) Water should be flowing from the clean tank over the dividing baffle into the dirty tank. The fluid may
appear cloudy and/or have a foam layer on top after initial startup or with installation of a new filter.
This is normal and should clear itself up within due time.
6) Ensure the ozone generator is on once the water quality clears up; bubbles should be coming out of
the dispersion stone (located inside the clean tank) and rising towards the surface.
7) Let system run until the TDS meter on the electrical panel reads within the preset TDS level (40 –100
PPM).
8) After the previous steps have been accomplished, start sending water to the customer’s water-jet by
turning feed pump on via the control switches on the electrical panel.
Note:
The Float Valve Assembly on the water make-up in the dirty side of the
Closed Loop should be set to maintain a water depth of 10 - 12"

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
Warning:
Always disconnect power and relieve pressure from the system before performing
any maintenance on this Filtration System
Caution:
Always follow correct lock out procedures when working on this Filtration System
The system will require the following items to be maintained on a scheduled basis:
4.1 Closed Loop System Daily Check List
1) Lift the lid on the system’s clean tank and observe the water quality (the clean tank must be 100%
clean at all times).
2) Start the system pump by rotating the system pump control switch on the electrical panel.
3) Check the pressure differential on bag vessel inlet and outlet pressure gauges (vessel #1).
Note: The red service beacon on top of electrical panel will flash when the outlet pressure reaches
10 PSI, signaling that the bag filter inside of vessel #1 needs to be serviced. Allow 5 –10 minutes
to elapse prior to changing the bag filter. Once the allotted time has passed perform the
maintenance to the bag filter, as described in section 4.4. Observing the pressure gauge at startup
will give you a good indication of how close you are to servicing the bag filter.
4) The hurricane filter cartridge typically will not get a large pressure differential. This filter should be
changed on a routine maintenance schedule. Ebbco Inc. recommends changing the cartridge on the
1st of each month, or *200 hours of operation (see maintenance section in manual for cleaning
procedure).
*Note: The material being cut and the abrasive being used may affect filter life.
5) Check the TDS meter on the front of the electrical panel. The TDS Meter is preset at the pump
manufacturer recommended settings. Your preset TDS level is 40.
Note:
TDS levels may spike during filter service or when make-up water is added.
This is normal, however the desired TDS level should return within a few
minutes (see maintenance section in this manual for Resin Bag information).
6) Open the lid to clean/dirty tank. First, the water should be overflowing from the clean tank into the
dirty tank. Second, the water in the clean tank must be clean at all times. Sending dirty water to High-
Pressure Feed Pump could result in catastrophic maintenance/damage.
7) Observe the water make-up float assembly. The water level in the dirty tank should maintain the
present float height with city water barely trickling in or shut off.
8) Start the High-Pressure Feed Pump. Your feed pump should be running at ~80 –90 PSI.
Note: Pressure reading is before the High-Pressure Feed Pump is turned on; the pressure will
drop a couple of PSI after feed pump is turned on.
Please call the Ebbco Waterjet service department if you have any questions or
comments at [phone]

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
Warning:
Always disconnect power and relieve pressure from the system before performing
any maintenance on this Filtration System
Caution:
Always follow correct lock out procedures when working on this Filtration System
4.2 Pump Maintenance
Inspect pump once a year: Replace any worn parts, mechanical pump seal, impeller, impeller
housing, and wear plates if necessary. Ebbco Inc. recommends keeping spare system pump and feed
pump seal kits in stock at all times.
4.3 Dirty Tank Pre Filter Maintenance (Filter #5)
Remove the tank lids and check the condition of the dirty tank inlet pre-filter bag. Remove and
clean as necessary; replace if worn or damaged.
4.4 Bag Vessel Maintenance (vessel #1)
Change the bag filter when the outlet pressure gauge reads 10 PSI (or less).
Bag Filter change out procedure:
1) Shut down the filtration system by turning both the system
control switch and the rotary disconnect to the off position.
2) Carefully relieve vessel pressure by opening the bleeder valve,
located on top of the vessel lid.
3) Open the drain valve located near the bottom of the vessel (red
valve). Wait until the pressure gauge reads 0 PSI prior to
removing the lid.
Note: Do not forget to close the drain valve prior to restoring
power to the CLS!
4) Open the vessel by loosening the band clamp; remove the
band-clamp from the vessel followed by removing the lid.
5) Remove the bag filter from the inner basket using the plastic
pull tabs on the top seal.
6) Push the replacement bag filter into the vessel inner basket.
Ensure that the plastic ring sits flush in the sealing area.
7) Visually inspect the lid O-ring gasket. Ensure that it is free of
debris and sits flush inside of the O-ring groove. Replace the
O-ring gasket if it has become worn or damaged. It is
recommended that sufficient O-ring seal kits be kept in stock at
all times.
8) Reapply the lid on top of the vessel. Replace the band clamp and properly tighten.
9) Verify that the drain and bleeder valves are closed before restoring power to the CLS.
10) Restore power to the CLS. Place a rag over the bleeder valve and slightly open the valve to release
any trapped air inside of the vessel; close the bleeder valve once all the air is purged and fluid starts
to flow out of the valve.
Warning:
Do not open the lid until the pressure gauge reads 0 PSI!
Figure 4.1
Bag Vessel (exploded view)

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
4.5 Hurricane Vessel Maintenance (vessel #2)
Ebbco Inc. recommends changing the filter cartridge on the 1st of each month or every 200 hours
of runtime; whichever comes first.
Filter Cartridge change out procedure:
1) Shut down the filtration system by turning both the system control switch and the rotary disconnect to
the off position.
2) Open the drain valve and completely drain the vessel of water.
3) Open the bleeder valve on top of the lid to purge any trapped air from the vessel.
Caution:
Failure to drain the hurricane vessel when performing a filter change out can
result in a charge of unfiltered water being sent to the High-Pressure Pump
4) Open unit by removing wing nuts followed by the lid.
5) Lift out the filter cartridge assembly and place it inside a 5-
gallon bucket.
6) Unscrew the cartridge retainer nut from the assembly.
7) Remove the filter cartridge from the top disk and wipe both
components with a rag to remove some of the debris.
8) Apply wax (part # WJF-STW) to the top and bottom seals of
the replacement filter cartridge, on the cartridge retaining nut
threads, and on both sides of the top disc that come into
contact with cartridge and the retaining nut.
9) Place the top disc on the replacement filter cartridge while
the assembly is still outside of the vessel. Reapply the
retainer nut and properly tighten so the top disc does not
rotate or spin freely.
Note: Do not change the filter while it is inside of the vessel
as the top disc WILL NOT seal properly and cause
performance issues.
10) Visually inspect the lid O-ring gasket. Ensure that it is free of
debris and sits flush inside of the O-ring groove. Replace the
O-ring gasket if it has become worn or damaged. It is
recommended that sufficient O-ring seal kits be kept in stock
at all times.
11) Replace the assembly into the hurricane vessel.
12) Replace the lid and lightly tighten each of the wing nuts.
Fasten down all of the wing nuts in a star-shaped pattern to
evenly disperse pressure across the lid. Over-tightening can
cause damage to the O-ring gasket, which may lead to an
uneven leaking seal.
13) Restore power to the CLS. Place a rag over the bleeder valve
and slightly open the valve to release any trapped air inside of
the vessel; close the bleeder valve once all the air is purged
and fluid starts to flow out of the valve.
Note: The operator must apply wax lubricant (part # WJF-STW) to the top and bottom seals of the
filter cartridge and on the top and bottom of the top disc surface that come into contact with the
cartridge and retainer nut. This must be done prior to filter cartridge installation back into vessel #
2. Ensure that top disc does not rotate or spin freely once reinstalled.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
4.6 D.I. Resin Vessel Maintenance (vessel #3)
Replace the waterjet resin bag and pre-filter disc when the PPM reading on the TDS Meter
reading does not return to its proper range (between 40 –100 PPM).
Resin Bag change out procedure:
1) Close the fluid inlet valve and open the bleeder valve on top of the lid to release the trapped air inside
the vessel.
2) Open the drain valve to drain out any water still in the vessel. While this is not necessary in order to
change the resin bag, it does make the resin bag easier to remove.
3) Remove the wing nuts from the lid and remove the lid.
4) Lift out the pre-filter disc and properly dispose of.
5) Remove the waterjet resin bag and properly dispose of.
6) Install a waterjet resin bag and a new pre-filter disc back into the top rim.
7) Visually inspect the O-ring gasket. Ensure all dirt particles are removed from the O-ring gasket, and
that it is not worn or damaged. Replace the O-ring gasket if it is worn or damaged.
8) Replace the lid and properly tighten all wing nuts.
9) Close the drain valve and bleeder valve prior to restoring flow to the vessel.
10) Open the fluid inlet valve. Place a rag over the bleeder valve and slightly open the valve to release
any trapped air inside of the vessel; close the bleeder valve once all the air is purged and fluid starts
to flow out of the valve. Fluid should now flow through the D.I. vessel whenever the solenoid opens.
4.7 Final Filter Vessel Maintenance (vessel #4)
Change the filter cartridges inside of the two filter vessels # 4 when there is a 30 PSI pressure
differential between the surrounding inlet and outlet pressure gauges.
Final Filter change out procedure:
1) Shut off the High-Pressure Feed Pump via the feed pump control switch on the electrical panel.
2) Open the unit by unscrewing the vessel housing from the mounting manifold.
3) Remove the fluid still inside of the vessel by discarding it into a drain or back into the CLS dirty tank.
NEVER discard the fluid into the clean tank.
4) Remove the spent filter cartridge and properly dispose of.
5) Ensure that all dirt is removed from the vessel threads and the threads on the vessel mount.
6) Visually inspect the O-ring seal for dirt or particles. If the seal is worn or damaged, replace with a new
lid seal. It is recommended that spare O-ring seal kits are kept in stock at all times.
7) Place the new filter cartridge inside of the vessel housing.
8) Screw the vessel housing back onto the manifold and properly tighten.
9) Return the vessel to service by turning the high-pressure feed pump back on.
10) Using a rag, relieve any trapped air from the vessel by pushing the bleeder valve down until fluid
starts to come out. Release the bleed valve once all the trapped air is purged.
11) Repeat steps for second filter cartridges.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
4.8 Service Beacon Maintenance
Service Beacon light bulb replacement:
1) Shut down the filtration system (isolate electrical power) turning both the system control switch and
the rotary disconnect to the off position.
2) Turn the service beacon housing counter-clockwise to gain access to light bulb.
3) Remove the light bulb by turning counter-clockwise and pulling up.
4) Insert the new light bulb and turn clockwise to lock into place.
5) Replace the service beacon housing by lining up the arrows and turning clockwise.
6) Restore power to the filtration system.
4.9 Ozone Generator Maintenance
Checking the dispersion stone is releasing ozone: Check the dispersion regularly to be sure ozonized
air is being pushed into system tank. This is done by opening the lid above the cleaning tank and looking
towards the bottom of the tank. The operator should notice bubbles exiting the stone and rising towards
the surface. After prolonged use, the dispersion stone may require cleaning.
Cleaning the dispersion stone: The dispersion stone may clog up with mineral deposits after prolonged
use. This will reduce the amount of ozone flow through the stone. The stone will start to appear a darker
color as it begins to clog. To clean the dispersion stone, remove it from the clean tank. Soak it in lemon
juice or vinegar for up to 24 hours until the discoloration is gone. The dispersion stone should return to a
uniform color. Rinse the dispersion stone thoroughly with fresh water. Reinstall the dispersion stone back
onto the ozone line within the clean tank.
Note: Sometimes the stain will be permanent; if ozone bubbles still flow from the dispersion
stone, the stain will not affect operation.
4.10 Reservoir Maintenance
Check the systems reservoir on a daily scheduled maintenance. The reservoir tank will require
cleaning at regular intervals to maintain proper operating conditions. Remove the lids check for any
garnet build up in the dirty tank; visually check that the Ozone Stone is bubbling and that there is a
positive water overflow from the clean tank to the dirty tank. Replace the lids on the reservoir.
Note: Do not add ANY chemicals, chlorine, oils, mop water, or any other liquids to any of the water
components (i.e. worktable, Closed Loop System, Settling Weir, etc.). Doing so will greatly reduce
filter life and may cause catastrophic system failure. Warranty will also be null and void if any of
the previously stated fluids are detected in the system’s components.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 4: System Maintenance
4.11 Settling Weir Maintenance
The settling weir bag should be serviced when solids have built up to approximately two to three
inches below the inlet and outlet 90° PVC pipes.
Settling Weir Bag change out procedure:
1) Disconnect plumbing to and from the settling weir.
2) Remove both 90° PVC inlet and outlet pipes.
3) Remove the metal bar running across the top of the settling weir frame by removing the set-screw on
each side of the weir.
4) Remove the drain plug to discharge all of the water inside of the weir to drain out. It is recommended
this is done by a drain or into a catch tank/bucket.
5) Using a forklift, guide all four straps onto the forklift forks. Once secured, lift the settling weir bag out.
6) Install the replacement settling weir bag. Replace both 90° PVC inlet and outlet pipes. The inlet 90°
PVC pipe should be facing downwards, and the outlet 90° PVC pipe should be facing upwards.
Note: When installing a new settling weir bag, the side that has the black inlet lettering printed on
it should be installed on the inlet side of the weir. Installing the bag backwards will affect
performance.
7) Reinstall metal bar across top of the weir frame followed by tightening the set-screws.
8) Reconnect the pluming to the inlet and outlet of the weir.
4.12 Chiller Maintenance
We supply our chiller units with air filters. It is imperative for the customer to establish a
preventative maintenance program in order to keep the air filters clean.
oAs a minimum, air filters should be visually
checked once per week. Filter screens should
also be removed from the chiller and cleaned
at least once every three months.
oEffective rinsing of the filter screen can be
accomplished with a normal garden hose
connected to city water supply.
oThe filter screen should be placed on a clean
flat surface and sprayed from a distance of
60”.
oCheck the filter screen thoroughly for any
damage and replace if there any visible signs
of ripped or torn media or broken frames.
Figure 4.4
Chiller Air Filter

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 5: System Troubleshooting Guide
Warning:
Always disconnect power and relieve pressure from the system before performing any
maintenance on this Filtration System
Caution:
Always follow correct lock out procedures when working on this Filtration System
5.1 System Troubleshooting
Low flow and low pressure gauge readings:
1) Check the water level in the dirty tank. The pump suction screen must be completely submerged.
2) Check that the suction screen inside the dirty tank is not plugged. The screen should be free of debris
for best performance.
3) Check the electrical hookup for proper direction and power requirements. In most cases, the pump
motor(s) should run clockwise looking down from the top.
4) Check the fuses in the step-down transformer. Replace as necessary.
5) Check the pump for any foreign objects.
6) Pressure gauges should read approx. 40 PSI at the inlet to the Bag Filter Vessel (vessel #1) if the
reading is 10 –15PSI less than this check pump for correct rotation (clockwise as viewed from the
rear of the motor) by bumping the start/stop button on the electrical panel. All of the motors have
been synchronized at the factory, if the pump motor is running in reverse have a qualified electrician
swap over one of the in-coming power wires within the electrical panel.

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 5: Troubleshooting Guide
Warning:
Always disconnect power and relieve pressure from the system before performing
any maintenance on this Filtration System
Caution:
Always follow correct lock out procedures when working on this Filtration System
5.2 Ozone Troubleshooting
There are five areas to check to determine the location of any problem:
1) Ensure all cords between ozone generator and dispersion stone are kink free.
2) Ensure all cords are undamaged.
3) Ensure ozone generator is turned on.
4) Ensure electrical connection is functioning properly.
5) Ensure there is a presence of ozone bubbles inside of the clean tank.
5.3 System Pump Troubleshooting
Problem
Cause
Remedy
Failure to Pump
Pump not properly primed
Make sure pump casing and
suction line are full of water
Reduced capacity
and/or head
Air pockets or leaks in suction line
Check suction piping
Clogged impeller
Remove and clean
Pump loses prime
Air leaks in suction line
Check suction piping
Excessive suction lift and operating
too near shut-off point
Move pump nearer to water level
Water level drops while pumping,
uncovering suction piping
Check water supply and add
length of pipe to suction to keep
submerged end under water
Mechanical
troubles and
noises
Bent shaft and/or damaged bearing
Take motor to authorized motor
repair shop
Suctions and/or discharge piping not
properly supported and anchored
See that all piping is supported to
relieve strain on pump assembly

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This document is proprietary. No disclosure, reproduction or use of any part thereof may be made without the expressed
written permission of Ebbco Inc. or its subsidiaries.
Section 5: Troubleshooting Guide
Warning:
Always disconnect power and relieve pressure from the system before performing
any maintenance on this Filtration System
Caution:
Always follow correct lock out procedures when working on this Filtration System
5.4 Feed Pump Troubleshooting
Problem
Cause
Remedy
Motor does not
start/no motor noise
At least two of the power supply
leads have failed
Check fuses, terminals, and
supply leads
Motor does not
start/humming noise
One of the supply leads has failed
See above
Impellers faulty
Replace impeller
Motor bearing faulty
Replace bearing
Pump does not pump
Liquid level too low
Fill up liquid
Pump mechanism faulty
Replace pump mechanism
Pipe blocked
Clean pipe
Insufficient flow and
pressure
Wrong direction of rotation of
impeller
Switch two power supply
leads
Pump mechanism silted up
Clean pump mechanism
Worn pump mechanism
Replace pump mechanism
Power consumption is
too high
Lime or other deposits
See above
Mechanical friction.
Repair pump