Magnaflux S500 User manual

Operating Manual
S500 filtration plant
Part numbers 009Z001, 009Z002

CONTENTS
1 Activated carbon filtration 1
2 Typical system to waste 2
3 Installation 2
3.1 Electrical controls 3
4 Operation 3
5 Servicing 4
6 Recommended spare parts 4
1
1. ACTIVATED CARBON FILTRATION
The purpose of the filter is the removal of water washable ZYGLO penetrant and a
mixture of ZYGLO penetrant and remover from the rinse water. The filter may also
be used in conjunction with a coalescing filter to remove post emulsified ZYGLO
penetrant from rinse water.
The unit comprises a vertical cylindrical fibreglass pressure vessel fitted with the
necessary inlet and outlet control valves. The filter media is activated carbon.
Contaminated water enters the top of the vessel and passes downwards through
the filter bed, during which time the contaminates are removed. Filtered water then
passes to service.
The bed area has a direct relationship to flow rate. Bed depth and flow rate control
the contact time. Trials have proved that a contact time of 20 minutes gives the
best results.
As the contaminated water passes through the bed, the filter material becomes
progressively blocked, with contaminates being removed, evidenced by an in-
crease in back pressure, gauge 1.
At this stage it is necessary to backwash the unit by passing a counter current flow
of water through the media to wash out the contaminate.
Exhausted carbon may be pumped from the vessel in the form of a slurry.
The amount of contaminates absorbed by the media depends on several factors
but can be generally be assumed to be a quarter of a litre per kilogram of carbon.
It is good practice to occasionally dose the rinse tank with Sodium Hypochlorite
(Bleach), to control odours and suppress growth of micro-organisms. 20 to 30m1 of
Bleach per 1001tr should be adequate to most situations.
MAGNAFLUX WARRANTY AGREEMENT
Your new Magnaflux product, when properly used, maintained and
serviced should give years of excellent service.
Magnaflux guarantees that its products will be free from defects in
materials and workmanship for a period of 12 months from the date
of invoice. This Magnaflux warranty covers only those defects which
arise as a result of normal use of the product and not apply if the
item has had :-
a) Improper or inadequate maintenance.
b) Misuse or unauthorised modification.
c) Operation outside the products design capabilities.
This guarantee is in addition to and does not reduce your minimum
statutory rights.

2
2. TYPICAL SYSTEM TO WASTE
Contaminated water is drawn from the wash tank by pump.
The pump is controlled by high and low level float switches fitted to the wash tank.
Water is fed into the inlet pipe through valve one. The water passes through the
filter bed and is discharged from the outlet pipe through valve six, which should be
piped to a suitable drainage system.
The normal operation, valves one, two, three and six are open, four, five and seven
are closed.
FOR UNITS WITH COALESCER
The dierence is that a filtration plant with coalescer is for filtering pre-rinse water and
as such passes the rinse water through the coalescer to remove the globules of oil
before the water enters the carbon tower.
3. INSTALLATION
When selecting a suitable position for the carbon filter unit take into consideration
the following points:-
• Drainage for decontaminated water.
• Source of contaminated water.
• Mains water supply for back washing purposes.
• Access to control valves on a regular basis.
• Access for container when discharging spent carbon.
• Access to and height of carbon discharge valve.
• Access to top of carbon tower for filling with carbon.
Set the unit on a firm and level foundation considering the points above and make
a permanent electrical connection to the electrical cabinet via a suitable fused
isolator. Supply 240 volts, single phase, 50 hertz and earth, fused at 6 amps.
Make appropriate pipe connections between the 5500 inlet pipe and the wash
tank outlet, and between the S500 waste water drain pipe and a suitable drainage
system.
If using UPVC fittings ensure the solvent cement is to BS 305 and BS 306. Use 11/4
I/D hose for the carbon discharge and backwash connections.
Mount the high and low level float switches into the wash tank. Locate the lower
one as near to the base of the tank as possible with the high level one a minimum
distance of 75mm above the low one. Ensure a grille is fitted above the high float
switch so the component(s) are not sitting in the contaminated rinse water. (The
fitting of float switches and grille are not necessary if the S500 is purchased at the
same time as a MAGNAFLUX Penetrant Tank System).
Fill the carbon tower with the supplied activated carbon from the top of the vessel,
firstly disconnect the union joints then unscrew the top cover.
Fill the vessel with water to a depth of 400 mm approximately. Pour the activated
carbon taking care not to damage the bottom distributor system, adding water as
required to keep the carbon covered. The vessel should not exceed 2/3 full which
is approximately 0.25 m3of carbon volume (125 kg). Continue adding water until
the vessel is full.
Replace the top cover and reconnect the pipe work.
Allow the carbon to soak for 24 hours and then backwash (Section 4.2) to remove
fine particles of carbon before the unit is put into service.
Fill the wash tank with water, above the high float switch level. Set the S 500 for
normal filtration (section 4.1), then set the flow rate to 8 — 8.5 litres per minute as
shown on the flow meter (item 43) using valve 1.
Fill the wash tank with water, above the high float switch level. Add some Zyglo
penetrant. Set the S 500 for normal filtration (Section 4.1 ) and allow unit to run,
check the waste water output for contaminates.

3
3.1 ELECTRICAL CONTROLS
SWITCHES
ISO 1 Isolator
Function Switches mains power to the unit
S1 Selector switch Label: MAN - BACK FLUSH - AUTO
Function Selects between the following operations:
MAN - Manual operation of the pump. Press the "START" button
(PB2) to energise the pump; release PB2 and the pump will stop.
BACKFLUSH - with the valves in the correct position, press the
"START" button (PB2) to pump clean water into the vessel, in the
reverse direction to normal filtration.
AUTO - the unit will run automatically, with the pump being con-
trolled via the float switches in the wash tank for normal filtration
PUSH BUTTONS
PB1 Push button - RED, latching Label: STOP
Function When pressed, PB1 will disable the pump control circuit
PB2 Push button - GREEN Label: START
Function When pressed, PB2 will start the pump running when the S1 switch
is in the Manual and Backflush positions.
LAMPS
LP1 Lamp - CLEAR Label: MAINS ON
Function When lit, LP1 signifies that the mains power is on.
LP2 Lamp - RED Label: HIGH PRESSURE
Function When lit, LP2 signifies that the pressure within the vessel or pipe-
work is too high.
4. OPERATION
The S500 is fitted with safety pressure switches (PS1, 2 & 3) which will stop the
pump running and illuminate a lamp LP2 "High Pressure" if any blockages occur
during the normal filtration and backwash cycles. Pressure setting is 5 bar (70 psi).
4.1 NORMAL FILTRATION
For normal filtration, firstly check the valves are in the correct position:
Valve 1 - Open
Valve 2 - Open
Valve 3 - Open
Valve 4 - Closed
Valve 5 - Closed
Valve 6 - Open
Valve 7 - Closed
Switch on the isolator the "Mains On" lamp will be illuminated and set the selector
switch Si to the "Auto" position. Reset the "Stop" button PB1.
When the wash tank is used and enough contaminated water collected to activate
the high float switch the pump motor will switch on and pump the contaminated
water through the system.
4.2 BACKWASH
A pressure reading of 10 psi on gauge 1 dictates the necessity to backwash. Alter
the position of the following valves:
Valve 3 - Closed
Valve 4 - Open
Valve 5 - Open
Valve 6 - Closed
Arrange for a drum to collect the slurry that will escape from the backwash outlet
during this operation. Backwashing should last for 5 minutes.
NOTE: DO NOT ALLOW THE WATER LEVEL IN THE WASHTANK TO FALL BELOW
THE LOW LEVEL FLOATSWITCH. DO NOT ALLOW THE PUMP TO RUN DRY
To discharge exhausted carbon, determined when pressure gauge 2 reads 10 psi
and after a backwash has been done. Close valves 4, 5 and 6 and open valve 7.
Start the unit running, clean water from the wash tank will be pumped into the car-
bon filter. The exhausted carbon will discharge from valve 7 in a form of a slurry.
Collect the carbon slurry in a perforated container allowing the water to drain away
leaving the contaminated carbon for safe disposal.

4
6. RECOMMENDED SPARE PARTS
Part number Description Quantity
001R029 Relay 1
015F004 Replacement cartridge (for coalescer unit only) 1
015S126 Floatswitch 2
017P023 Pump service kit 1
079C002 Activated carbon x 25 Kg 5
015S212 Pressure Gauge 0 - 200 psi 1
Ball Valve 11/4" 1
Flow meter 1
5. SERVICING
It is important to carry out the following to allow the filter to do its job properly.
Failing to carry out these procedures will result in contaminated water leaving the
filter, damage to pump motor and early charge of carbon.
DAILY
• Drain the coalescer's collected oil. The drain cock is at the top of the coalescer
body (if fitted).
• Backwash (see section 4.2) to redistribute the carbon to prevent compacting
and loss of eciency. Allow carbon 15 minutes to settle after backwashing
before resuming normal operation.
NOTE: Backwashing water supply can be obtained by leaving the wash gun run-
ning in the wash tank.
WEEKLY
Check system for any leaks
6-MONTHLY
Check all electrical connections, contactors, relays and pressure switches for good
condition, tightness and operation.
Electrical Circuit: 23659 A3
General Assembly: 20880 Al With Coalescer
20835 Al Without Coalescer
Layout Drawing: P2690.A3

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Faraday Road, South Dorcan Industrial Estate, Swindon, SN3 5HE, UK
Telephone: + 44 (0)1793 524566 Fax: [phone]
Email: sales.eu@magnaflux.com Web: eu.magnaflux.com