Lakos STS Series Setup guide

FRESNO, CALIFORNIA, USA
LS-644E(Rev. 12/20)
Installation and Operators Manual
Model: Tower SystemMedia Filters STS

STS SERIES MEDIA FILTERS
Installation, Operation, & Maintenance
Manual
I. INTRODUCTION
The LAKOS STS Series Media Filters are specifically designed for use in full-
stream, side-stream, and basin sweeping (SWP) applications. For side-stream, we
recommend the industry standard filtration rate range of 10%-20% based on the full-
stream flow of the system. The standard STS Series Sand Filters can be filled with
media for either 10 micron filtration @ 95% removal efficiency (standard), or 5
micron filtration @ 90% removal efficiency (optional). Please refer to section X for
“How it Works” STS systemdiagram.
The LAKOS STS Series Media Filters can be installed for either full-stream
operation or side-stream operation (most common). Side-stream installations
should be applied by tapping into a mainstream line after the pump (see drawing
STS-0001), or by tapping directly to a basin or remote sump to achieve a given
turnover rate. Please note that all standard STS system pumps require flooded
suction for proper operation! Please contact the factory if you have a installation
that will require the pump tolift water!
LAKOS does not recommend using the standard STS Series Media Filters for
basin/remote sump sweeping applications. The proper use of this technique
requires a specific sweeping design using Hydroboosters and the proper
flow/pressure to ensure maximum performance. LAKOS does offer a special
system (SWP) for sweeping applications. These systems come with higher head
pumps to meet the specific pressure requirements needed for basin sweeping.
Please contact the factory to see if the STS/SWP Media Filter can be used for your
application.
The maximum operating pressures for the LAKOS STS Series Sand Filters are as
follows;
-STS-15-025 thru STS-36-165 models: 100 psi (6.9 bar)
-STS-48-310 models: 80 psi (5.5 bar)
2

II. WARRANTY
All products manufactured and marketed by this corporation are warranted to be
free of defects in material and workmanship for a period of at least one-year from
the date of delivery. Extended warranty or no coverage applies as follows:
**All LAKOS separators---five year warranty
**Pump seals are not covered under warranty
All other components and coatings: 12 months from the date of installation; if
installed 6 month or more after ship date, warranty shall be a maximum of 18
months from ship date.
If a fault develops, notify us or your local representative, giving a complete
description of the alleged malfunction. Include the model numbers(s), date of
delivery and operating conditions of subject products(s). We will subsequently
review this information and, at our option, supply you with either servicing data or
shipping instructions with returned materials authorization number. Upon prepaid
receipt of subject product(s) at the instructed destination, we will perform such
necessary product repairs or replace such product(s) at our expense.
This limited warranty does not cover any products, damages or injuries resulting
from misuse, misapplication, neglect, normal expected wear, chemically-caused
corrosion, improper installation or operation contrary to factory recommendation.
Nor does it cover equipment that has been modified, tampered with or altered
without authorization.
No other extended liabilities are stated or implied and this warranty in no event
covers incidental or consequential damages, injuries or cost resulting from any such
defective products(s).
This warranty supersedes any and all previous warranties provided by LAKOS
Filtration Solutions.
III. DELIVERY INSPECTION OF STS SERIES MEDIA FILTERS
1. Immediately inspect the system upon arrival for any damage that may have
occurred during shipping. Look for crate damage, pierced or torn boxes or
any other signs of handling, which may suggest damage to the system.
2. LAKOS STS Series Media Filters are shipped with all major components
assembled onto the skid. Selected small items, such as the pressure
gauges, may be removed and inserted into the control box for shipping.
3

3. LAKOS sand media is shipped separately in 50 lb. bags and gravel shipped
in 80 lb. bags. The exact number of bags is determined by the actual
system size (see chart below). Do not introduce media sand or gravel into
the STS system until the system is placed in its final operating position.
MEDIA SAND CHART
MODEL MEDIA SAND REQ’D MEDIA GRAVEL REQ’D
(LBS)
(KG)
(LBS)
(KG)
STS-18-045
200
91
80
36
STS-24-075
400
181
120
54
STS-30-110
500
227
160
73
STS-36-165
800
363
240
109
STS-48-310
1300
590
560
254
IV. INSTALLATION OF STS SERIES MEDIA FILTERS
1. A suitable foundation or pad must be provided to support the full operating
weight of the STS system, including liquid (see media sand chart above).
Use caution when moving the STS system into position. Move the system
only by lifting the entire skid (forklift or crane/hoist). Never try and lift the
equipment with hooks or straps attached to system piping or manifold, as
damage could occur to the system. Anchor the unit to the foundation to
prevent vibration and/or movement.
2. All STS systems required flooded pump suction for proper operation.
Please make sure that all inlet piping to the system is located to ensure
that the pump is flooded with water at all times. If you system is equipped
with a self priming pump this will not apply.
3. The control panel must be wired for the proper voltage and rotation of
the pump (see wiring diagram in control box door). All wiring should be
done by a licensed electrician in accordance with local codes. Motor
nameplates should be referenced for voltage, amperage draw, cycles,
phase, speed and other motor information.
4. Piping connections to and from the STS system should be of at least the
same pipe size as the STS inlet and outlet connections. Do not install
smaller diameter pipe anywhere on the inlet, outlet, or backwash lines.
Check local codes to determine if appropriate backflow prevention is
necessary at the inlet.
4

5. It is recommended that service valves be installed on the STS system inlet
and outlet so that the unit can be isolated for any maintenance or repairs
when necessary.
6. All LAKOS STS systems are configured for either Source (S) or City (C)
backwash. If your system is designed for City (C) backwash, city (or other
external) water supply piping will need to be plumbed to the system
backwash inlet connection (see drawing STS-0002). The pressure fromthis
external source must not exceed 30 PSI and may require that a pressure
regulator be installed (supplied by others).
7. Backwash connection piping is not supplied by LAKOS and must be
provided on-site. Do not reduce the line size any smaller than the backwash
outlet pipe size. A backwash throttling valve (by others) should always be
installed in the piping to control backwash flow. Check local codes to
determine if appropriate backflow prevention is necessary on the backwash
line.
8. Determine if the drain for the backwash can handle the necessary backwash
flow (see backwash flow chart below). All LAKOS STS Media Filters are
factory set to backwash for 3 minutes**. If the drain can not handle the total
backwash flow, LAKOS does offer backwash holding tanks that will allow the
backwash water to be siphoned off at a slower rate so as not to overwhelm
the drain. Please contact you local LAKOS representative for details.
BACKWASH FLOW CHART
MODEL MINIMUM BACKWASH FLOW
(US GPM) (M3/HR)
STS-15-025
18
4
STS-18-045
27
6
STS-24-075
47
11
STS-30-110
74
17
STS-36-165
106
24
STS-48-310
188
43
**NOTE: Flow values should be multiplied times “3” minutes to get the total backwash
gallons of water that will be purge during a standard factory recommended backwash cycle
9. Check the STS system pump pre-strainer and remove any foreign matter.
Close and secure the strainercover.
5

10. Once all pipe connections are installed and properly secure, open the STS
Media filter’s top access port. Inspect the PVC underdrain to be sure all parts
(laterals) and connections are secure and nothing is broken. Fill the STS
about one-third to half full with water. Then, SLOWLY add the appropriate
amount of sand (refer to media sand chart above). It is important that the
sand be added slowly so that no damage occurs to the laterals on the
underdrain assembly. Spread the sand level within the tank, then close and
secure the access port.
11. Remove pressure gauges from packaging and install at the street tee
connections on the inlet manifold elbow and tank outlet elbow.
12. Double check the controller settings. Factory settings should be as follows:
- Pressure differential switch – 10 psi (0.7 bar)
- One Shot Relay (white timer) – D005S (see detail below)
- Omron timer – 3 minute backwash ever 24 hours (see detail below)
ONE-SHOT RELAY OMRON BW TIMER
6

STS - HOW IT WORKSSCHEMATIC
The Basic Steps of Media Filtration
1. Unfiltered system water enters the pump suction INLET.
2. Water is pumped to top and is uniformly dispersed over the media bed.
3. Water passes thru the media bed leaving debris behind.
4. Filtered water exits the OUTLET.
5. The media bed is cleaned through a backwash cycle at specified intervals or differential
pressure. The backwash cycle runs for a 3 minute period.
6. System returns to normal operating mode.
7

V. START-UP AND OPERATION
CAUTION !!!!!!!!!!!!
Please be aware that when the main power disconnect is turned to the “ON”
position the STS system valves and linkage will automatically rotate into a
backwash configuration and will stay in the backwash cycle for 3 minutes.
The valves and linkage should then rotate back into the filter operation
mode.
NOTE:
Make sure that all suction valves (from the source of water to the pump
intake) are fully opened when the pump is running. Operating the system
with a partially closed suction valve can damage the pump and/or affect
the system’s performance. Each model requires a minimum liquid
submergence level (above the pump intake) to meet the pump’s Net
Positive Suction Head Required (NPSHR) to avoid air intrusion or
cavitation (vortexing at point of source). See appropriate pump curve
included with this manual. This is also very important when LAKOS
Hydroboosters are in use
1. Make sure that there is water in the main inlet line to provide flooded suction
to the STS system pump. DO NOT DRY RUN THE PUMP! All pumps
require a wet/primed suction before starting, using water as a lubricant for
their seals. John Crane-type seals (e.g., Silicon Carbide Seals) can wear out
in 20 seconds of dry operation. It only takes a small amount of water to
lubricate the seal, and it vaporizes during pump operation.
2. Turn the main disconnect switch to the “ON” position. The valves and linkage
should move and rotate in the backwash mode. After 3 minutes the valves
should rotate back into the filtermode.
3. Turn the HOA switch to “HAND” and “bump” the pump motor to check fan
rotation to make sure pump is rotating in the correct direction. Turn the HOA
switch back to “HAND” and check the system for any leaks. If leaks start to
develop turn the HOA and main disconnect off immediately and fix the
problems.
4. Once the STS system is running any air in the system should be vented
automatically out of the air relief valve located at the top of the STS system
piping.
8

5. Check STS system inlet and outlet pressure gauges. Proper operating
parameters will result in an inlet pressure from approximately 17-20 psi (1.2-
1.4 bar) above the system flow pressure to the STS system and an outlet
pressure of 16-19 psi (1.1-1.3 bar) above the system pressure flow pressure
to the STS system. If your system is a STS/SWP model that is being
used in conjunction with sweeper piping please see addition
information below.
6. STS/SWP systems use a high head pump to provide higher pressure for
sweeper piping. These pumps range from 90’-100’ TDH. If your system is
equipped with one of these pumps, the proper operating parameters will
change from listed in Item 5 above. Your inlet pressure should be
approximately 35-38 psi (2.4-2.6 bar) and an outlet pressure of 33-36 psi
(2.2-2.5 bar) at the discharge connection. Although the hydroboosters do
provide backpressure for the system, it is highly recommended that avalve
(ball or butterfly type) be installed on the outlet of the system to give
additional flow control when using an STS/SWP system.
7. BACKWASHING
Differential pressure across the filter media progressively increases as
trapped particulate accumulate in the filter media bed. On filter equipped with
automatic backwash, the backwash cycle is initiated upon reaching a 10
psig pressure differential. Since units with automatic controls perform this
function as necessary, a detailed backwash procedure is only provided for
manual units. However, automatic units can be manually backwashed by
pressing the manual push-button switch located on the control panel. The
backwash cycle is field adjustable on most units and is factory set at three
minutes. To prevent unfiltered water from “short circuiting” through the media
and to extend media life, the filter should be backwashed regularly; at least
once every 24-48 hours.
8. FOR NEGATIVE SUCTION (LIFT)
If the water level of the sump is lower than the centerline of the pump inlet, the
use of a self-priming pump might be necessary. Follow priming procedures
every time the pump is started. Consult the factory for systems requiring
suction lift.
9. WINTERIZING
In areas subject to freezing winter temperatures, protect the pump when
not in use by removing both drain plugs (from the pump volute and from
9

the suction strainer). Use a compressed air hose to remove any water
trapped in the pump casing or flush the system with antifreeze. Do not
replace the plugs. Store them in the strainer basket for the winter.
Alternatively, remove the pump and motor from the plumbing entirely.
Store them indoors in a warm and dry place.
The STS tank and the purge line should also be drained of liquid to
prevent damage from freezing. To remove trapped water from the
separator, use a compressed air hose, directed into the acceptance
chamber. Alternatively, flush system with antifreeze.
Heat tracing or pipe insulation may be used. Please contact your local
supplier of these products to ensure proper usage.
10

VI. MAINTENANCE
1. A STS System START-UP FORM is included in this manual Record all
readings (inlet andoutlet pressures, motor amperage draw and
liquid flow rate) during start-up as reference point (see note 3). Please
complete the required information and return this form to your local
representative as soon as possible. You may want to keep a copy for your
records.
2. Record and compare these readings whenever periodic check-up and
maintenance is required. These records would be helpful in troubleshooting
the system when a problem occurs during the operational life of the system.
A. SUCTION STRAINER BASKET:
The suction strainer basket is sized to allow a maximum pressure
drop of 2 psi at the specified flow rate. It will protect the pump,
separator, flow control valves and other equipment from becoming
plugged by dirt and debris 1/4” in size and greater. The strainer
basket is easy to clean. Isolate the strainer by closing the isolation
valves installed before the pump and after the separator outlet. These
are not provided as a standard option by Lakos, but are available if a
valve kit is ordered. Loosen the nuts or threaded stud and remove the
lid. Remove the basket and clean. Inspect the ‘O’ ring or gasket and,
if damaged, replace. Replace the lid and tighten the nuts.
B. PUMP AND MOTOR
Make sure that there are no leaks in the pump housing. If leaks occur
at the back of the volute casing, you may have a damaged the seal
(pump seals are not covered under warranty) and/or loose bolts.
Replace and/or tighten as necessary.
Whenever maintenance or repair is needed for the pump, SHUT-OFF
and LOCK-OUT power into the panel feeding the pump; close the
suction and discharge valves, open drain plug/valve, making sure no
air or hydraulic pressure is in the system before unhooking the pump.
Refer to Pump Manual.
Outside air is very important to cool the motor. The TEFC motor has a
fan in the back. Ensure that the fan is rotating when motor is
energized. Zerk fittings were installed in the front and back of the
pump shaft/bearing housing. A small amount of grease might be
needed periodically to replenish the old grease in the housing.
Whenever new grease is injected, the old grease will ooze out on the
11

opposite side. Wipe it clean. Whenever motor is required to be
unhooked/ repaired, follow shut-off lock-out procedure and refer to the
pump/motor manufacturers I&O manual as required.
C. CONTROL PANEL/PUMP STARTER:
A blown-out fuse and/or consistently kicked-back circuit breaker is
indicative of a motor overloading/overheating. The built-in
thermostat in the motor is experiencing an excessive rise in
temperature, which might be caused by sudden voltage
increase/drop, phase imbalance or over-torqued shaft. Verify
motor bearings, terminal connections for looseness and
correctness. Verify pump is rotating freely. Mechanical
interference inside the pump might be causing this problem.
Under-rated circuit breakers, contactors, relays and/or heaters will
also cause this situation. Use appropriately sized components.
Also, undersized wires/cables might cause shorting and
overheating. An excessively hot environment might also cause
premature failure of motor and electrical components. Avoid
installing system in direct sunlight or near heated objects or
equipment. Vibrating equipment may cause loosening of terminal
bolts and screws; make sure vibration is dissipated whenever the
STS System is required to be installed in such a location.
D. PRESSURE GAUGES:
Stuck needles/pegged gauges might indicate false readings. Verify
their operation by opening and closing petcock valve installed
before the gauges. Replace gauges, if necessary.
12

STS Operation and Maintenance Schedule
Type of
Service
Start Up Monthly Semi-
annually
Shutdown Annually
General Condition
of Unit
X X
Drain Condensate
from air line to
pneumatic
actuator (if
applicable)
As
Required
As Required As Required As Required As Required
Clean pre-strainer
basket
As
Required
As Required As Required As Required As Required
Inspect gaskets
X
X
X
Check pump shaft
for free rotation
X X
Check operation
of valves
X X X
Check, lubricate
clamp on filter
tank access port
X X
Inspect over-drain
assembly &
media pack
X X X
Check pump
motor for proper
rotation
X
Check motor
voltage & current
X X X
Prime Pump
X
Check pressure
gauge reading
(top of filter)
X X
Check unit for
unusual noise or
vibration
X X
Check unit for
leaks
X X
13

VII. TROUBLE SHOOTING PROCEDURES
PROBLEM
POSSIBLE CAUSES
SOLUTIONS
Poor Filtration

Excessive flow through filters,
causing “coning” of media sand
and/or forcing contaminants
through filter outlet.

Air in tank(s) may cause
disruption of the media sand
bed.

Incorrect media sand.

Excessively high pressure
differential before backwashing,
which forces contaminants
through filter bed.
 Insufficient volume of media in
filter, which allows
contaminants to pass through
the system.
1. Install throttling valve to control flow.
2. Bleed off trapped air in system.
3. Replace with proper media sand.
ConsultyourLAKOS representative.
4. Backwash more often at lower
differential pressure.
5. Add proper sand media to tank(s) to
specified level.
Consistently
High
Pressure
Differential

Excessive contaminant load
restricts flow through the filters
and prevents sufficient flow for
backwashing.

Insufficient backwash flow.
 Inadequate media sandvolume,
which may minimize coverage of
backwash flow across filter bed,
creating dead spots of
accumulated contaminants.
1. Drain tank and remove manway
access ports. Carefully skim away any
excess or caked contaminants from
the media sand bed’s surface. Return
tank to normal service and backwash
system.
2. Check backwash valve linkage for
proper operation.
3. Add sand media as necessary.
14

VII. TROUBLE SHOOTING PROCEDURES (con’t)
PROBLEM
POSSIBLE CAUSES
SOLUTIONS
Automatic
Backwash Fails to
Cycle

Controller power may
be off or circuit fuses
tripped.

Improper setting of
differential switch.

Actuator
malfunctioning.
1. Be sure wiring is connectedcorrectly.
Replace circuit fuses. Turn on power.
Controller may be faulty and need
replacement.
2. Adjust as necessary.
3. Check connections
Media Sand

Incorrect media sand
(i.e. too fine and too
1. Replace media with proper sizedmedia.
Appears
Downstream
small)

Broken, damaged, or
missing lateral.
2. Repair or replace laterals of the underdrain.

Obstruction in the
valve seat.

Rubber seatingis
worn or damaged.
 Actuator Diaphragm
damaged.
 Linkage outof
adjustment
1. Remove the obstruction.
Backwash Valve
Leaks
2. Replace Valve.
3. Replace diaphragm.
4. Adjust linkage
Water Hammer

Air in tanks.

Long backwashline
causing vacuum.
1. Bleed off trapped air in system. Air vent on
system may be required.
2. Install vacuum breaker on backwash line.
15

VII. TROUBLE SHOOTING PROCEDURES (con’t)
PROBLEM
POSSIBLE
CAUSES
SOLUTIONS
Pump will not prime
(standard, not self-
priming)

Suction line is not
flooded with water.

Debris in basket
strainer.

Air leaks.

Pump rotating wrong
direction.
1. Check and clean out pump suction pre-
strainer as required.
2. Check and clean pump pre-strainer as
required.
3. Check and tighten all connectionsas
required.
4. Check pump rotation against motor
rotation arrow and rewire if necessary
for proper rotation.
Pump motor runs hot

Motor located in
direct sunlight.

Poor ventilation.

Low voltage
1. Cover motor with some type of sun
shade if possible.
2. All motors require air movement for
cooling. Make sure that motor has a
fresh source of air for cooling.
3. Check voltage with meter.
System “Trips” out when
running and shuts down

Overload setting is
too low.

Supply voltageis
incorrect.
 System flow is too
high.
 Loose Wire.
1. Check overload setting in control panel.
Overload setting should be just above
full load amp value on motor nameplate.
2. Check incoming supply voltage with
STS system power requirements
located on control panel door (outside
and inside).
3. Install valve on system discharge
to control flow.
4. Check all wires for loose connections.
Unit stays in backwash
or valves do not operate
correctly

Incorrecttimer
settings.

Wire may be loose or
wired incorrectly.
1. Refer to Section IV Paragraph 12 for
factory settings.
2. Contact factory while onsite if possible
for further troubleshooting review.
16

1365 North Clovis Avenue ~ Fresno, California 93727 USA
[phone] • Fax:[phone] •[e-mail]
STS MEDIA FILTER SYSTEMS
START-UP FORM
DATE OF START-UP:
COMPANY NAME:
ADDRESS:
PROJECT NAME/DESCRIPTION:
CONTACT PERSON(S):
(Please include titles)
DESCRIPTION OF LIQUID & SOLIDS (type, size, etc.):
COOLING TOWER MODEL:
DOES SYSTEM USE HYDROBOOSTERS IN THE TOWER BASIN:.
Yes No HOW MANY PER CELL:
Upon start-up, please record this data:
MOTOR AMPS: MOTOR VOLTAGE:
PRESSURE TO INLET OF SAND FILTER:
PRESSURE AT OUTLET OF SAND FILTER:
BACKWASH DURATION:
ADDITIONAL OBSERVATIONS/REMARKS:
Please complete this form and send a copy to LAKOS; keep a copy for your records.
1365 North Clovis Avenue ~ Fresno, California 93727 USA
[phone] • Fax:[phone] •[e-mail]