AFIM20-180 - IBC Water
Contents
1. 16 G Spool Seat Page 11 COMMISSIONING A period of 4 hours soaking should elapse after filling with water and potassium permanganate before commissioning so as to precondition the media Step 1 Check plug is dry first then connect lead into power outlet switch on Step 2 Remove clear cover from timer face by pulling the two black lock pins outward Depress the red knob Fig 14 and rotate anti clockwise to backwash position release red knob wait for valve drive to index to backwash position if not already in this position spindle fully out Fig 1 1 Step 3 Just open inlet isolating valve approximately 1 1 2 turns Allow unit to fill slowly water will issue to drain continue to run until the unit automatically indexes to Pause position which may take up to 20 minutes All air must be removed Step 4 Depress the red knob and turn anti clockwise until the microswitch trips into the fast rinse position Allow the valve to move fully into this position ie Fig 13 The filter should then purge any remaining potassium permanganate to waste Further rotate the red knob anti clockwise so that the arrow tip is pointing at about a seven o clock position Then allow the red knob to advance electrically around to the Service position This may take up to 10 minutes Step 5 Depress the red knob and turn anti clockwise to start release the unit will now go through each cycle Backwash purge and back to service automatica2. coagulation is required in such cases Operating Parameters Water Temperature 5 C 50 C Water pH 6 8 8 8 Water Pressure 205 690 kPa Oil Free of Hydrocarbons Maximum practical iron limit 15 mg l of iron and manganese Maximum practical limit hydrogen sulphide 5 mg l Minimum of 4 mg l alkalinity for each mg l of iron or iron manganese present NOTE If Filter will be in an area accessible to small children and pets it is strongly recommended that the Potassium tank be placed out of reach to avoid accidents The following label is attached to every Potassium Permanganate container Please take note of caution label This unit is not designed to remove colloidal iron matter a plant capable of coagulation is required in such cases Page 2 AF SERIES FILTERS Table 2 CONTINUOS PEAK BACKWASH TYPE MODEL FLOWRATE FLOW FLOW RATE VALVE WEICHE PROCEDURES L P M RATE L P M L P M Water Temp 5 c 50 M AFIM20 39 62 82 180 300 Water pH 6 8 8 8 n Suspended Solids g 50 mg l a Refer factory Iron amp Manganese S 15 mg l Free of amp hydrocarbons Alkalinity 4 mg l for G each 1 mg l of iron and r or manganese Note Due to the n complexities of iron S manganese and a hydrogen sulphide it is d recommended that product selection be referred to IBC Water Valve 180 Operating Pressure 205 690 kPa Inlet Temperature 5 C 50 C Electri
3. fill the tank with water to approximately 300mm from the tank top 7 Clean top of neck and threads of all traces of media Remove the plastic cap fitted in Step 3 taking care not to raise the distributor pipe 8 Unpack the valve remove the cap screws and separate the adaptor Store gasket safely Check that the tank seal is in place Fig 1 Remove the rubber sleeve and using a little O ring lubricant lubricate the inside surface only Place rubber sleeve into tank adaptor Fig 1 9 Fit the adaptor to the tank carefully to allow the distributor pipe to enter the rubber sleeve and locate centrally Screw down firmly by hand Do not over tighten Place the gasket on tank adaptor fit the valve body with the cap screws provided Fig 1 Tighten cap screws evenly 10 Plumb the unit referring to figures 4 amp 5 for pipework installation to suit the specific unit noting the following a Use only pipe sizes recommended for this unit in the performance data Table 1 inside front cover of these instructions Fit pipe unions or flanges to inlet outlet and drain lines for ease of access for maintenance or cleaning c Install inlet and outlet isolating valves and A Manual Bypass Valve Refer Fig 4 Item C 7 b 7 Page 4 d Connect pipework and valves MUST be support to prevent loading on the valve and filter Before connecting pipework flush or lines close inlet outlet and bypass valves e The drain line must d
4. on any numbered day having the regeneration pin pressed inward and will skip days having the pins pulled fully outward Normal factory setting of the regeneration time is 2 30am Plug must be in outlet having a constant 240 volt AC power supply The filter will regenerate automatically according to the preset schedule If an extra regeneration is desired because of heavy water usage between regular regenerations press RED knob to start automatic cycle A period of 14 minutes will elapse before the cycle actually begins This will not change the normal schedule 5 Press the RED knob to initiate regeneration When regeneration is complete the unit will be ready for service Page 10 POTASSIUM TANK FLOAT VALVE ADJUSTMENT OF VALVE 1 Lift float rod to full up position 2 Set float to distance shown Measure from top of crown nut to the bottom of 464 13 the float MODEL FLOAT DISTANCE X AFIM20 180mm NOTE Float height should be such the water is approximately 15 20mm above shelf in regenerating tank PARTS LIST Part No Description 464 1 Body 464 2 Plug 464 3 O Ring 464 4 Check Ball 464 6 Quad Ring 464 9 Float Rod 464 10 Float Grommet 2 Req 464 11 Float 464 12 Float Rod Guide 464 13 Float Rod Guide Lock 464 15 Washer 464 16 A Crown Nut 464 16 B 464 16 C Air Check Ball 464 16 0 Quad Cup Seat 464 16 Ball Cage Bottom 464 16 Stem 464
5. ALVE MOTOR MICRO SWITCH BURNED OUT replace micro switch H VALVE MOTOR MICRO SWITCH NOT OPENING OR CLOSING replace micro switch TIMER MOTOR SWITCH BURNED OUT replace micro switch 2 Unfiltered Water to Service A RUBBER SLEEVE MISALIGNED OR MISSING AT TOP OF DISTRIBUTOR PIPE remove valve head and replace rubber sleeve B UNIT INSTALLED BACKWARD check arrow markings on top of valve head for correct inlet outlet plumbing C REFER SECTION 1 FOR FURTHER INFORMATION D BYPASS VALVE NOT CLOSED check operation E INSUFFICIENT DOSING OF POTASSIUM PERMANGANATE Page 21 check sample prior to filter pink F INSUFFICIENT BACKWASH FREQUENCY increase backwash frequency 3 Leak to Drain A CHECK PLUNGER POSITIONING refer Fig 12 B CHECK DRAIN SHUT OFF O RING located in upper cap refer Part No 35G 4 Insufficient Service Flow Rate A VALVE NO OPENING Units equipped with optional service isolation valve the valve must open fully when in service dirt rust scale etc May prevent the valve from opening disassemble and clean B UNIT MAY BE FOULED WITH SUSPENDED SOLIDS backwash and check again C SERVICE INLET OR OUTLET VALVE NOT FULLY OPENED ensure they are opened D PISTON OUT OF POSITION reposition refer Fig 10 E INSU
6. ERATION Step 1 START UP OR INSPECTION REGENERATION a Pushin RED KNOB and turn counterclockwise past START to BACKWASH Disconnect electrical power and leave in position for desired time Reconnect electrical power b Pushin RED KNOB and repeat for all desired cycles Step 2 MANUAL INITIATION OF REGENERATION a Reconnect electrical power Page 14 b Push in RED KNOB and turn counterclockwise to the START position Release Unit will then go through a complete regeneration as programmed BACKWASH CYCLE TIME INSTRUCTIONS PIN TIME CHART TYPICAL FILTER APPLICATION CYCLE BACKWASH OR PAUSE FAST RINSE Backwash 20 min 5 pins outward NO OF TIME NO OF TIME Pause 1 5 min 2 pins inward PINS PINS IN Fast Rinse 11 min 2 pins outward OUT 1 8min 2 1 5 min 2 11 min 3 4 5 min Rotatior 3 14 min 4 7 5 min 4 17 min 5 10 5 5 20 6 13 5 min 6 23 min 7 16 5 min 7 26 min 8 19 5 min 8 29 min 9 22 5 min 9 32 min 10 25 5 min 10 35 min 11 28 5 min 11 38 min 12 31 5 min 12 41 min 13 34 5 min 13 44 min 14 37 5 min 14 47 min 15 40 5 min Outward 15 50 min 16 43 5 min Pins Inward Each additional pin either pulled out or pushed equals 3 minutes TIMER REAR VIEW SET BACKWASH TIMING Pull pins as shown for backwash time de
7. FFICIENT WATER PRESSURE check 5 Mineral to Service Page 22 RUBBER SLEEVE MISALIGNED OR MISSING AT OF DISTRIBUTOR PIPE remove valve head and replace rubber sleeve UNIT INSTALLED BACKWARD check arrow markings on top of valve head for correct inlet outlet plumbing BACKWASH FLOW RATE EXCESSIVE check flow control RISER PIPE OR BOTTOM STRAINER BROKEN remove media and replace riser tube assembly Page 23
8. IRON amp MANGANESE REMOVAL FILTER INSTALLATION amp OPERATING INSTRUCTIONS Model AFIM20 180 Serial No Manufacturer and Supplier of FILTRATION amp WATER TREATMENT PRODUCTS gt Water for commercial industrial and residential application Quality DUM Telephone 07 3219 2233 Facsimile 07 3219 2266 Email sales ibcwater com au Website www ibcwater com au Page 1 OPERATING PRINCIPLE CONTINUOUS REGENERATION General Our AF Series Filters are fully automatic incorporating Backwash Rinse Pause Fast Rinse and Service Cycles controlled by cam switches in the timer Frequency of Backwashing can be altered from that suggested in the commissioning section if conditions dictate alterations Water enters the unit through the multi port valve and passes through the media underdrain gravel and the distributor leaving through the multi port valve Iron Manganese and Hydrogen sulphide are removed using media through oxidation and filtration Regeneration is required with Potassium Permanganate The oxidised precipitate is filtered out in the top layer of filter coal and the bottom layer of manganese greensand media mainly acts as a barrier to remove any unprecipitated iron manganese The regeneration is automatically drawn from the regenerate tank and passed through the media thus effecting regeneration This unit is not designed to remove colloidal iron matter a plant capable of
9. cal 240V 50Hz 3 watts maximum 40 mm om Warning A pressure reduction valve should be installed if water hammer prevails 40 com Table at left shows recommended MINIMUM plumbing sizes form 40 FAILURE TO OBSERVE WARNING WILL VOID WARRANTY The above flow rates are only suitable for an Iron Manganese total content of 1 mg l Refer to the factory for suitability of flow rates at a higher total metal content Page 3 INSTALLATION Check the equipment upon arrival for damage or shortages and report same to our Office or Agent before commencing installation Locate the unit on a clean firm level foundation preferably concrete with sufficient space for operation and maintenance Level with shims if necessary Position the tank in the correct position before loading the Media Make due allowances for space for maintenance purposes 1 Make sure the filter tank is empty and clean 2 Install the distributor pipe in the filter tank check the height in relation to top of filter tank The pipe must be level or 3mm below the top of the tank The distributor consists of a length of pipe with a bottom strainer and top disc 3 Place a clean rag or a plastic bag over the end of the distributor pipe no gravel or media must enter distributor pipe 4 Pour in the underbed gravel 5 Level out the underbed gravel 40kg No 6 Gravel 6 After loading and levelling the gravel underbed add the bags of manganese greensand and level Then
10. er Meter optional fit only where metering of supply is required Solenoid Valve optional fit only where raw water to service is not required during REGENERATION Valve must be 240V 50Hz operation normally open and equal to pipeline size connect to terminals 2 and 5 inside valve cover Refer Fig 17 How m m n FIG 5 INSTALLATION MULTIPLE UNITS quum om pm uus cec nate 6 AFIM20 180 MANGANESE GREENSAND FILTER 25mm BSPF BACKWASH FLOW CONTROLLER Ne 40mmBSPF z fi OUTLET e 40mmBSPF NLET RUBBER SEAL SIDE VIEW TANK ADAPTER ON TANK C L REAR VIEW 180 TOP MOUNT VALVE 240 VOLT 50 Hz FIG 1 Page 7 MEDIA PLACEMENT MANGANESE FILTER Table 1 Sequence in Tank AFIM20 15 40kg 6 gravel in bottom of tank 2 x 20kg ond 200kg Manganese Greensand 5 x 40kg Page 8 INSTALLATION OF POTASSIUM PERMANGANATE TANK Pour 2kg of Potassium Permanganate into the tank A further 1kg container of Potassium Permanganate should be added when the colour of the solution in the Potassium Permanganate tank lightens in colour If your hands or arms are stained the stain can be removed by washing with a softener mineral cleaner containing sodium hydrosulphide 1kg Potassium Permanganate is sufficient for two 2 regenerations Place the Potassium Permanganate tank as near as possible to the mineral tank a If filter will be i
11. ischarge into open drain or pipe with a maximum of 100mm diameter and an air gap to conform to sanitary codes and permit observation not more than 7 6 metres from the unit f Power supply is required not more than 1 5 metres from the unit and should be a 3 pin 10A 240V 50Hz G P O preferably earth leakage protected Total power draw is 13 watts maximum g Fit external backwash flow controller using cap screws provided Fig 1 h Maximum operation pressure 450 kPa 65 p s i Maximum operating pressure 690 kPa valve this must be a non fluctuating supply The control system is sometimes shipped as a sub assembly to avoid damage in transit The water filter should be assembled piped and wired according to the following recommendations The following instructions are provided as a general guide The filter requires a 10amp 240 volt GPO The filter installation must be protected from the elements FIG 4 INSTALLATION SINGLE TANK BIRM IRON REMOVAL FILTER INSTALLATION Pipework Layout suggestive only Unit only supplied Pipe Valves Solenoids Water Meter supplied by others External Backwash Flow Controller supplied separate must be fitted before Connecting Drain Line All pipework connections to be flanged or barrel union for ease of removal and maintenance USE PIPEWORK SIZES SHOWN IN PERFORMANCE DATA TABLE 2 Inlet Isolating Valve Manual Outlet Isolating Valve Manual Bypass Valve Manual optional Wat
12. lly NOTE Asmall amount of media may pass to drain during the initial backwash this is considered normal Step 6 Check with site supervisor that unit can go on line If so slowly open outlet isolating valve fully check that manual bypass valve is fully closed This unit is now on line Step 7 Check for and report any leaks Step 8 Set the backwash frequency to Tuesday Thursday and Saturday if frequency of backwash has not already been calculated To set PUSH the skipper pins IN on the skipper wheel on days Backwashing is required Note This is only a guide for initial setting and should be altered to suit each individual installation in accordance with load conditions If more than one backwash per day is required the 440 Timer Knob will have to be replaced with a special unit Please consult the factory Page 12 Step 9 Step 10 Step 11 Step 12 Step 13 Set time of day pull timer knob Fig 14 and set arrow to the time of day time of your watch release make sure that the knob has re engaged gear knob right in Backwash will take place at approximately 2 a m If this time is not convenient it will be necessary to offset the time of day setting to make allowances for the desired time of backwashing Eg If 4 a m is desired it will be necessary to set the time of day two hours earlier than actual time Replace the timer cover depress the lock pins wipe over unit Do final check for leaks etc Ens
13. n an area accessible to the general public and or animals it is strongly recommended that this Potassium Permanganate Tank be placed out of their reach to avoid accidents b The backwash waste water from the unit should not be pumped to an open drain or any area accessible to the general public and or animals NOT TO BE TAKEN KEEP OUT OF REACH OF CHILDREN POTASSIUM PERMANGANATE If external by pass valve is used be certain it is left in the SERVICE position after installation is completed The timer may be set for a regeneration frequency of from once in seven 7 days to once each day Determine a regeneration schedule and adjust the timer To calculate regeneration frequency it is assumed each person used 0 25 kl day and the capacity of the unit is For Iron Removal only 91 0 grams For Iron and Manganese Removal 53 0 grams Page 9 The following are examples of how to calculate regeneration periods Number of people P Iron content A mg L as Fe Manganese B mg L as Mn Number of regenerations per 7 days 0 25 7 91 N for Iron amp Manganese removal P x 0 25 x A B x 7 53 Always increase N to the next highest whole number Example Let P 4 people 10mg L Fe iron 0 2mg L Mn manganese Then N 4x0 25x10 2x7 1 35 2 53 In this case the number of pins to press IN will be two Note The unit uses 500 grams of permanganate every regeneration The filter will regenerate
14. nt of each function This is done at the factory and rotation checked at this time However resetting may be necessary from time to time should the unit fail to draw brine Setting is simple index position to service position fully in switch off power loosen screw A adjust cam to position shown above Switch on power MICRO SWITCH STACK P d SCREW A 1 Wess CAM 5 a jx SCREW nh SHAKEPROOF WASHER FIG 19 Page 19 TROUBLE SHOOTING GUIDE AFIM20 180 Iron amp Manganese Removal Filter PROBLEM REF PAGE UNIT WILL NOT BACKWASH AUTOMATICALLY Page Twenty UNFILTERED WATER TO SERVICE Page Twenty LEAK TO DRAIN Page Twenty One INSUFFICIENT SERVICE FLOW RATE Page Twenty One MINERAL TO SERVICE Page Twenty Two Page 20 1 Unit will not Backwash Automatically A IS THERE POWER TO THE UNIT B IS THE POWER CORD PLUGGED IN C IS THERE A REMOTE SWITCH IN THE LINE ISOLATED check these possibilities and correct if necessary D IS THE TIMER MOTOR RUNNING if the timer motor is running the small driven gear on the timer motor will be turning If not replace the timer motor E BACKWASH DRIVE GEAR NOT ENGAGED check gear behind push button on timer for proper alignment and time of day lever is down and fully engaged F VALVE MOTOR MICRO SWITCH NOT OPENING OR CLOSING adjust micro switch stack Fig 19 V
15. over Window Cover 43G Lock Washer 1 66G Fasteners 1 44G Nut 1 67G Top Mount Adaptor O Ring 1 45G Screw 2 68G Side Mount Adaptor NPT 1 46G Switch Bracket 1 69G Side Mount Adaptor BSPP 1 47G Terminal Strip 1 70G Distributor Seal 1 48G Marker Strip 1 71G ORing 1 Page 17 SEVEN DAY 440 TIMER LIST OF PARTS Item Description No Item Description No Required Required 14A Cam Screw 1 89F Day Dial Washer 1 16A Timer Mounting Screw 3 99F4 7 Day Tripper Assy 1 Limit Switch 2 1G Timer Bracket 1 14F7 Skipper Wheel 7 Day 1 2G Adjustable Cam 1 15F Friction Washer 1 3G Timing Pin 36 18F Motor Mounting Screw 2 4G O Ring 1 19F Wire Nut 2 5G Retaining Washer 1 84F Cover Plate 1 Switch Insulator 2 85F Screw 4 7G Switch Spacer 2 87F Compression Spring 1 8G Switch Mounting Screw 2 88F Gear Retainer 1 9G Wiring Harness 1 oo Seven Day 440 Timer zl D la is aa ae eee WIRING DIAGRAM 440 t i 7 sj 2 25 SIX DAY SEVEN DAY TIMER be FIG 17 1 NEUTE Page 18 ERSTSTS T a 4 B 2 D MODEL 180 VALVE CAM POSITION GENERAL MAINTENANCE For correct operation the cam should be set to stop the position at the poi
16. sired see chart SET PAUSE TIMING Depress pins as shown for desired brine rinse time see chart Minimum of two pins down SET FAST RINSE TIMING Pull pins as shown for desired fast rinse time see chart Adjustable Cycle Pin e Switca Service Switch i Bottom Regenesation Cycle Cam Page 15 0 E oc lt LLI lt 1 A LLI oc BE ATBWASSY HAMIL A quiassy JAPA Page 16 VALVE ASSEMBLY PARTS LIST Item Description No Item Description No Required Required 12G Valve Body NPT 1 49G Screw 2 13G Valve Body BSPP 1 50G Nut 2 14G Injector Assy small 1 51G Limit Switch 3 15G Injector Assy Med 1 52G Machine Screw 2 16G Injector Assy Large 1 53G Cam Screw 1 17G 1 2 Brass Pipe Plug 1 54G Cam 1 18G Cap Screw 5 55G Lock Washer 2 32G Backwash Assy BSPP 1 56G Drive Motor 100v 1 33G O Ring 1 120v 50Hz 60Hz 34G Cap Screw 4 57G Drive Motor 240v 50Hz 1 Drive Motor 240v 35G Piston Assy 1 58G 50Hz 60Hz 1 36G Lower Cap Assy 1 596 Motor Screws 4 37G Cotter Pin 1 60G Wiring Harness 1 38G Manifold Gasket 1 61G Drive Link Assy 1 39G Timer Lock 1 62G Drain Shut off Valve 1 40G Motor Plate Assy 1 63G O Ring 1 41G Hex Head Screw 10 64G Cover 1 42G Ground Screw 1 65G Window Cover w Fasteners 1 C
17. ure instruction book is kept with relevant personnel Use Manganese Greensand only Adjust the regenerate float as follows 220 mm DRAW DOWN RATE 11 mm minute Connect regenerant throttle valve at the rear of main valve and connect regenerant throttle valve approximately 1 1 2 turns The regenerant tank will fill add 3kg of potassium permanganate stir for 1 minute or until all crystals are dissolved open or close regenerant throttle valve until 11 mm minute draw down rate is attained Page 13 DRIVE PISTON POSITIONING Fi IZH Zo wn far mM 2 1 SERVICE POSITION 2 7 e 2 jen gu a 2 BACKWASH POSITION 4 FAST RINSE POSITION SKIPPER SKIPPER SET TIMER WHEEL PINS Determine a regeneration schedule for the conditioner and adjust the automatic timer as follows 1 Pull all SKIPPER PINS out away from control 2 Rotate SKIPPER WHEEL until DAY ARROW points to day of week or number 1 3 Depress SKIPPER PIN S for day s regeneration is required 4 Pull TIMER KNOB out away from timer face and rotate until BLACK ARROW on tripper arm points to correct time of day on Face Plate 5 Timer will automatically initiate regeneration on preset days at 2 30AM To alter time simply reset TIMER KNOB to an earlier or later time which will change the time of regeneration by the same number of hours Time indicated as BLACK ARROW will no longer be correct MANUAL OP
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