RAINFRESH CGFE GREENSAND FILTERS FOR REMOVAL OF IRON, MANGANESE & HYDROGEN SULFIDE Installation & operation instructions Thank you for purchasing one of our ENVIROGARD / Rainfresh Greensand Filter Systems. We are committed to ensuring that you are totally satisfied. If you have any problems, don t go back to the store please contact us! Most issues can be resolved over the phone. Help Line : 1-800-667-8072 Monday to Friday 8:30 AM to 5:00 PM EAST Website : www.rainfresh.ca TABLE OF CONTENTS System Specifications... 1 How The CGFE System Works... 2 Cautions Before Installation... 2 Installation... 3 a) Unpacking the unit.... 3 b) Plumbing the Filter unit.. 4 c) Start-up and Programming... 5 Winterizing the System... 8 Troubleshooting... 8 Parts List... 9 Warranty... 9 SYSTEM SPECIFICATIONS: Model No. Rated Service Flow US GPM (LPM) Max Flow Rate US GPM (LPM) Backwash Flow Rate US GPM (LPM) Inlet / Outlet CGFE 948 2.2 (8.3) 5 (19) 5 (19) 3/4" MNPT Drain Connection 1/2" Hose Electrical Requirement Pressure Drop 110V AC < 15 psig Operating Pressure 30 100 psig Shipping Weight 140 lbs (63.5 Kg) Approx Potassium Permanganate (Pot-Perm) used per regeneration : 0.125 lbs (56 g) Water Temp 4-38 C (39-100 F) Water ph Range 6.5 to 8.5* Max Raw Water Turbidity 5 NTU *- higher the ph, better the performance Max Raw Water Iron+Manganese 15 PPM Max Raw Water Hydrogen Sulphide 5 PPM Oil in Water Nil
HOW THE CGFE SYSTEM WORKS Your Rainfresh CGFE filter utilizes oxidation and filtration technology to remove dissolved Iron, Manganese and Hydrogen Sulphide from water. Rainfresh Greensand Filter is based on the technology of oxidation and filtration. It incorporates a special high-oxidant media called Manganese Greensand. When water flows through the Greensand filter system, dissolved Iron and Manganese are oxidized to insoluble precipitates by contact with Greensand Filter CGFE948 Chemical Tank the greensand media, and simultaneously filtered out. Hydrogen Sulphide is reduced to an insoluble sulphur precipitate, which is also filtered in the bed. Water coming out of the greensand filter is virtually free of Iron, Manganese and Hydrogen Sulphide. When the oxidizing capacity of the greensand bed is exhausted, the system automatically backwashes to rid it of the trapped Iron, Manganese & Hydrogen Sulphide and regenerates using Potassium Permanganate which is stored in a separate small container. CAUTIONS BEFORE INSTALLATION Follow all plumbing codes for installation. To operate properly, the well pump flow rate must exceed the backwash flow rate (5 US GPM (19 LPM)). If your well pump does not deliver this flow rate, do not install the unit as it will not work properly. You may need to either change the well pump or call Rainfresh for a custom size unit that will operate within your pump specifications. The automatic control valve works on 110V AC. We recommend a GFI (ground fault interrupter) 120 volt outlet within 5 feet of the filter. Extension cords are not recommended. If water pipes are used to ground electrical system, you will need to install a jumper wire (#4 gauge solid copper wire) across the filter unit. CGFE systems do not kill or remove bacteria or any other pathogenic microorganisms. To continuously disinfect all the water in your house, we recommend that you install a Rainfresh UV system. Call Rainfresh for details. Protect your unit from freezing - drain the unit if freezing temperatures exist. NOTE: If solder type fittings are used DO NOT USE torch near inlet/outlet connections. All solder joints should be made before joining pipe to filter head. DO NOT over-tighten metal fittings on to unit connections. The unit should only be moved by 2 or more people due to heavy weight. Failure to do so can result in back or other injury. 2
INSTALLATION Grounding jumper wire Optional Bypass outside taps Cold water to house Optional Rainfresh sediment filter & UV Disinfection System Hot water to house Pressure Tank Drain Optional Rainfresh Water Softener Well Pump Rainfresh CGFE Filter Water Heater Figure 1. Piping Schematic a) Unpacking the unit The Rainfresh CGFE filter system includes: 1) The main media tank with automatic electronic control valve 2) 110V AC power adapter for control valve 3) Chemical tank (for storing potassium permanganate) & connecting tubing (3/8 ) 4) By-pass valve & Allen key with 2 metal clips and 2 screws 5) Two ¾ Male NPT elbow inlet/outlet fittings 6) Drain Fitting (for 1/2 Hose Hose not included) Unpack the unit and place it at the location where you intend to install the unit. Stand back and look at the main media tank and make sure it is standing straight up and not tilted to one side. Sometimes during shipment, the bottom of the tank will get knocked out of alignment and you will need to straighten it out before starting installation. If your tank is a bit tilted, simply pick the tank up 2 3 inches off the floor and drop it gently but firmly down, favoring the side that needs to be adjusted to make the filter stand straight up again. Make sure your chosen location is fairly level, dry, and protected from possible freezing conditions. The plastic base of the filter is slightly adjustable to non-even floors. If shimming is needed, you can make shims from small, flattened pieces of copper pipe, or some other non-corrosive material but do not use wood. The filter can sit directly on the floor, it will not corrode. DO NOT set the tanks onto make shift platforms as this may cause the filter to topple. The following materials can be used for installing your new system, but it is recommended that you check your local plumbing codes. Copper and PVC, CPVC, and PEX are the most popular. You may choose not to treat the water spigots that go outside used for irrigation or sprinkler systems. You will have to plan the job so that you cut in to feed the CGFE filter AFTER these spigots. Installing the CGFE filter after the pressure tank on a well water system is the preferred location. If you intend to install a water softener for soft water or a UV system for disinfecting the water, these should be installed after the CGFE filter (see Fig 1) 3
b) Plumbing in your CGFE Greensand Filter Turn the power off to the well pump then shut off the main water shut off valve which should be located after the pressure tank. If your hot water tank is electric, turn off the power to it to avoid damage to the element in the tank. Open a faucet closest to the pressure tank, but after the main shut-off valve to de-pressurize the lines. Position the filter in the desired location, which is after the pressure tank. Attach the bypass valve to the control valve by pushing it in and secure it with the metal clips and screws (Fig 2). Fully push the inlet/outlet elbow fittings into the open end of the bypass valve and lock them in by inserting the red locking clips into the slots (Fig 3) For ease of installation, orient the inlet/outlet fittings in the direction of the inlet & outlet pipes by simply rotating them (Fig 4) Plumb in the inlet and outlet of the CGFE filter. Plumb in a ½ flexible plastic drain line running from the filter (white elbow hose fitting) (Fig 5). Fig 2 Fig 3 o This can be ran up overhead or down along the floor. If running drain line more than 30 feet overhead, increasing the line size to 3/4" will be required. Please follow your local health dept. Codes for where to run filter discharge water. NEVER MAKE A DIRECT CONNECTION INTO A WASTE WATER DRAIN. A PHYSICAL AIR GAP OF AT LEAST 3" SHOULD BE USED TO AVOID BACTERIA AND WASTEWATER TRAVELLING BACK THROUGH THE DRAIN LINE INTO THE GREENSAND FILTER (Fig 5A). o There will be a fair amount of pressure on this flexible plastic drain line when the filter is in the regeneration mode, so secure it to the drain fitting by a hose clamp. Also secure the drain tube to the wall or ceiling. Bypass valve Closed. Close both inlet & outlet valve Drain Fig 5 Fig 4 Fig 5A Remove the locking clip on the brine fitting & insert one end of the 3/8" tubing (included) into this fitting all the way until the tube can go in no further. Replace the locking clip (Fig 6). Remove the top lid of the chemical tank. The other end of the tubing goes through the small hole near the top of the chemical tank (Fig 7). Bring the end of the 3/8" tubing into the brine well and make the connection with the compression fitting on the safety float. The barbed elbow near the middle of the chemical tank (Fig 8) is for a "gravity" overflow line in case of a malfunction resulting in a tank overflow. This must be run to drain. It uses the same size tubing as the drain line. DO NOT TEE THESE TWO TOGETHER. Fig 6 Fig 7 Fig 8 4
With a bucket or hose, pour approximately 1 gallon of water into the chemical tank. The exact level is not critical, but be careful not to overflow the tank. Pour the entire 5 lb jug of potassium permanganate (POT PERM for short) into the chemical tank. Typically, five pounds of potassium permanganate should last three to four months or more before refilling with new potassium permanganate powder is required. Turn on the switch for the well pump. If you had emptied the pressure tank, allow it to fill up until the well pump shuts off. Insert the Allen key into the inlet side of the bypass valve (Fig 9) and turn it on only slightly and watch for leaks. Make sure a faucet is on somewhere and that any aerator is removed Fig 9 to avoid clogging from loosened scale in the pipes. Leave the bypass valve in the same position and slowly turn the main shutoff valve on all the way. If you have no leaks, proceed to the next steps. Connect the control valve to the AC power source. Manually put the CGFE filter into the regeneration cycle by pressing the regeneration button. Turn the bypass valve slightly more into the service position to allow water to run into the unit. You want water to initially fill the tank slowly. Once the tank is full of water, you can open valve fully. This prevents filter media from being pushed up into the control head by the initial surge of water going in. Once the tank is full of water you should start to see water flowing from the drain line. It may look somewhat discoloured at first. This is normal. Once the water runs clear and free from air pockets, turn the bypass valve further and further into the "service position". You should have a full flow to the drain at this point. Your water may be discoloured for a day to two after initial installation or may have small air bubbles. This is normal. Also, it will take a few days to get all the untreated water out of your hot water tank and you may choose to empty your hot water tank at the time of installation and clean it before letting water in from the filter. The system is now ready for use. Check the chemical level in the chemical tank about once a month and top up if required. STARTUP & PROGRAMMING The control valve is pre-programmed at factory. You can however change the default settings or to change regeneration frequency. We recommend setting backwash at least every 3 days with a minimum 10 minute backwash, 60 minute brine draw, 10 minute rinse & 10 minute refill time. If you have questions about programming, please call Rainfresh at 1800-667-8072. When power is first supplied, the valve electronics may take up to two minutes to initialize. During this time the screen will show INTIALIZING WAIT PLEASE. Do not touch any buttons at this time. When the valve reaches the service position, it will display the following information in sequence: Fig 8 1. Date & Time 2. Regeneration Days/Capacity 3. Remaining Days 4. Regeneration Time The control valve has a display screen and 4 buttons 5. Last Regeneration Date 6. Current Flow Rate (GPM) 7. Peak Flow Rate (GPM) 1 3 & 4 2 5
1) MENU BUTTON : The function of this key is to enter the level one programming mode where the valve settings can be adjusted. 2) SET / REGEN BUTTON : This button has two functions. The first is to initiate a manual regeneration by holding the button for 3 or more seconds. The second function is while in programming mode, pressing this key allows the user to change the value of each setting. 3 & 4) UP / DOWN : These buttons are used to increase or decrease the value of the settings while in the programming mode. VALVE PROGRAMMING The valve has 2 levels of programming Level 1 and Level 2 You will need to only go through Level 1 programming to start up your unit. Level 2 programming is factory set and can be changed only if desired. Level 1 programming allows you to set - Current time, Current date, Vacation mode LEVEL 1 USER PROGRAMMING STEP 1 : Setting Current Time Press MENU for 3 seconds to unlock screen. Press MENU again and the hour value becomes highlighted once again and the highlighted value flashes. Now press or UP OR DOWN arrows to change the hour values. again to accept the hour value and advance to change the minute value Press SET / REGEN again to accept the AM/PM value. Highlight stops flashing. Continue to Step 2 Press or UP OR DOWN to change the AM/PM value again to accept the minute values and advance to adjust the AM/PM values Press or UP OR DOWN arrows to change the minute value STEP 2 : Setting Current Date & Exit Level 1 Programming From Step 1 Press DOWN arrow to advance to CURRENT DATE once and the MONTH value flashes Now press or arrows to change the month to current month again to accept the month and advance to change the DATE Press SET / REGEN again to accept the YEAR. Highlight moves back to MONTH and stops flashing. Press or to change the YEAR again to accept the DATE and advance to set current YEAR Press or arrows to change the DATE. Press DOWN arrow to advance to VACATION MODE Press DOWN arrow to exit programming mode 6
LEVEL 2 USER PROGRAMMING Press and hold UP AND DOWN together for three seconds to enter Level Two Master Programming. The following chart indicates choices and default settings. Note: Default settings are indicated in bold letters NOTE : Use same programming method as you used in level 1 to advance and/or change values. Parameter Option 1 Option 2 Option 3 Option 4 Comments 1 System Language English Spanish French Set to French if desired. Spanish not enabled 2 Valve Operation Softener Filter Iron Leave at default setting Filter 3 Regeneration Mode Meter Delayed Meter Override Calendar Clock Meter Immediate Leave at default setting 4 Regeneration Time 2:00 AM The unit is factory set to backwash at 2:00 AM on the day of backwash. You can change to another time if desired. Capacity Manual Automatic Leave at default setting Calculation 5 Regeneration Days 3 Days Leave at default setting. Before changing this value, contact Rainfresh 6 Backwash 10 Leave at default setting 7 Brine/Rinse 60 Leave at default setting 8 Rapid Rinse 10 Leave at default setting 9 Refill 10 Leave at default setting 10 Restore Default NO Leave at default. Change only if you want to re-start programming from start Manual Regeneration If screen is locked, press MENU for 3 seconds to unlock. To start an immediate backwash, Press the SET/REGEN button for 3 seconds, an option for Delayed or Immediate regeneration will appear. Press the SET/REGEN button again and Delayed will begin flashing. Now press the or buttons and Immediate will flash. Press the SET/REGEN button once and then press the MENU button once. Valve will immediately start manual regeneration. OTHER FEATURES Control Operation during a Power Failure In the event of a power failure, the valve will keep track of the time and day for 48 hours. The programmed settings are stored in a non-volatile memory and will not be lost during a power failure. If power fails while the unit is in regeneration, the valve will finish backwash after power is restored. If the valve misses a scheduled backwash due to a power failure, it will queue backwash at the next backwash time once power is restored. New Sounds You may notice new sounds as your water softener operates. The regeneration cycle lasts approximately 2 hours. During this time, you may hear water running intermittently to the drain. Care of Your Iron Filter To retain the attractive appearance of your new Greensand Filter, clean occasionally with mild soap solution. Do not use abrasive cleaners, ammonia or solvents. Check the chemical level once a month and make sure the level of chemical is decreasing with time 7
A) How to calculate Regeneration Frequency : a) Calculate KMnO 4 (Potassium Permanganate) demand Multiply Manganese concentration by 3 and Hydrogen Sulphide (H 2 S) concentration by 5 and add these to the Iron concentration. For example if Iron level is 2 PPM, Manganese is 0.5 PPM and H 2 S is 1 PPM, then KMnO 4 demand = 2 + (3 x 0.5) + (5 x 1) = 2 + 1.5 + 5 = 8.5 PPM b) Calculate Unit Capacity Unit capacity in US Gallons is then given by: 37,850 = 37,850 = 1,176.4 US Gal KMnO 4 demand x 3.785 8.5 x 3.785 c) Estimate water usage in the home Multiply the number of people in the house by 60 to get estimated water consumption per day. For example for 4 people in the house, total water consumed = 4 x 60 = 240 Gal. d) Calculate Regeneration frequency (days between regenerations) Therefore system should be set to regenerate = 1176/240 = 4.9 days = once every 4 days. WINTERIZING THE SYSTEM If the unit is to be winterized, the best way is to close the by-pass valve and unscrew the 2 screws adjacent to the by-pass valves that hold the unit and the by-pass valve together, and carry the unit to a place where it will not be subject to freezing temperatures. TROUBLESHOOTING PROBLEM POTENTIAL CAUSE SOLUTION Filter fails to backwash Filter does not seem to remove iron, manganese or hydrogen sulphide. Loss of water pressure. Drain flows continuously. 1. Electricity interrupted to system 2. Control head malfunction 1. Bypass valve is in the bypass position. 2. System may not be regenerating soon enough 3. Chemical tank is empty 1. Iron/Manganese buildup in filter. 2. Not enough water flow available for backwash. 3. Inlet of control plugged. 1. Internal control leak. 2. Control valve jammed in backwash position. 1. Assure continuous power supply to system. 2. Check control head manual for solution. 1. Move bypass valve to service position. 2. Reduce backwash/regeneration interval. 3. Add Potassium Permanganate to chemical tank 1. Increase backwash/regeneration frequency. 2. Check flow rate of pump and make sure it delivers at least 5 US GPM 3. Remove piston and clean control of foreign material. 1. Replace seals, spacers or pistons. 8
PARTS LIST 2 3 4 1 5 6 7 9 10 8 11 DESCRIPTION 1 CGFE Control Valve complete 2 Inlet/Outlet Fitting - elbow (90 ) ¾ 3 Locking clip for inlet/outlet 4 Locking clip for bypass valve 5 Bypass valve assembly 6 Bypass valve metal clips and screw set 7 Drain fitting (Elbow) 8 Brine elbow fitting 3/8 stem x 3/8 QC 9 AC power adapter 110V AC 10 Chemical Tank 11 Mineral tank 9 x 48 WARRANTY This System is warranted to the original Consumer purchaser for a period of one (1) year, from the date of purchase, against defects in materials or workmanship. The electronic controls and mineral tank are warranted for 5 and 10 years respectively against defects in materials or workmanship. The company's obligation under this warranty shall consist of repair or replacement, at its option, of any part found by company inspection to be defective, provided that the product has not been misused, abuse, altered or damaged by Consumer with respect to the original installation, as determined by the company. This warranty will not apply if feed water does not meet specifications of this system. This limited Warranty applies only to a unit when returned to the Warrantor at the owner s expense and in accordance with shipping instructions received from the Warrantor. This warranty does NOT cover, and is intended to exclude, any liability on the part of Envirogard for any incidental damages, consequential damages, labour charges or any other costs incurred in connection with the purchase, installation, use, maintenance or repair of the system whether under this warranty or any other warranty implied by law. Some provinces/states do not allow the exclusion of incidental or consequential damages, so the above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and you may also have other rights, which vary from province/state to province/state. This warranty applies only to water filter/systems purchased in Canada or the U.S.A. Jan 2013 Envirogard Products Limited 446 Major Mackenzie Drive East, Richmond Hill, ON L4C 1J2, CANADA Toll Free: 1800 667 8072 Tel: (905) 884 9388 Fax: (905) 884 3532 E-Mail: info@rainfresh.ca Web: www.rainfresh.ca 9