amiad SAF-4500 Manual

AMIAD Automatic Filters
"SAF-4500" FILTER
cat. no. 2-84
Installation, Operation
and Maintenance
Instructions
Ref. 92-9450-5
06.98
amiad filtration systems
Serial Number: ____________________
Order Number: ____________________
Catalogue Number: ________________
Filtration Degree: __________________
Tested By: _______________________

2amiad filtrationsystems
TABLE OF CONTENTS
Technical Specifications....................................................................... 3
Safety instructions ............................................................................... 4
Dimensional and recommended installation Drawing.......................... 5
Description and Filter Operation .......................................................... 6
Installation............................................................................................. 7
Maintenance ......................................................................................... 8
Disassembling and Reassembling................................................9 -10
Parts Schedule ................................................................................... 11
Parts Drawing -Section 1................................................................... 12
Parts Drawing -Section 2................................................................... 13
Control system, PLC Type "D" ....................................................14 -19
Control system, Relay Type "C"..................................................20 -24
With any inquiry please quote Filter Serial Number, located on the filter housing.

3amiad filtrationsystems
TECHNICAL SPECIFICATIONS
General
Maximum flow rate
250 m3/h
1100 USgpm
Consult manufacturer for optimum
flow depending on filtration degree
& water quality.
Min. working pressure 1.5 bar 21 psi or lower if pressure is increased
. for flushing
Max. working pressure 10 bar 150 psi 16 bar = 240 psi upon request
Filter area 4,500 cm
2
700 in
2
Inlet/Outlet diameter 100,150, 200 mm 4", 6", 8" Flange standards as per request.
Filter housing 250 mm 10" Epoxy-coated steel, or other on
request.
Max. working temperature 80
0
C176
0
F
Weight 100 mm = 150 Kg 4"= 330 lb.
150 mm = 156 Kg 6" = 344 lb.
200 mm = 165 Kg 8"= 364 lb.
Flushing Data
Exhaust valve
50 mm
2"
Flushing cycle time 20 seconds 20 seconds
Wasted water per cycle 83 liter 22 gallon at 2 bar = 30 psi
Minimum flow for flushing 15 m
3
/h 66 USgpm at 2 bar = 30 psi
Control and Electricity
Control voltage
24V AC
(12V or 24V DC upon request)
Electric motor 1/3 HP 50 / 60 Hz, 35 / 42 Gear output R.P.M.
Rated operation Voltage 3 phase 220 / 380 / 440 V, 50 / 60 Hz
Single phase 110 / 220 V, 50 / 60 Hz
DC 12V or 24V (upon request)
Current consumption 0.8 Amp. (with 3 phase 380 / 440 V)
Construction Materials
Filter Housing and Lid
Epoxy-coated carbon steel 37-2 (Stainless Steel 316 available on request).
Screens Stainless Steel 316
Cleaning mechanism Stainless Steel 316, POM
Exhaust valve Epoxy-coated cast iron, Natural Rubber
Seals Synthetic Rubber, Teflon
Control Aluminum, Brass, Stainless Steel, PVC
Standard Filtration Degrees
Stainless Steel Weavewire Screen
micron 500 300 200 130 100 80 50 25 10
mm 0.5 0.3 0.2 0.13 0.1 0.08 0.05 0.02 0.01
Mesh 30 50 75 120 155 200 300 450 600

4amiad filtrationsystems
SAFETY INSTRUCTIONS
General
1. Prior to installation or any treatment given to the
filter, read carefully the installation and operation
instructions.
2. While treating the filter all conventional safety
instructions should be observed in order to avoid
danger to the workers, the public or to property
in the vicinity.
3. Please note, the filters enters into a flushing
mode automatically, without prior warning.
4. No changes or modification to the equipment are
permitted without a written notification given by
the manufacturer or by its representative, on the
manufacturer behalf.
Installation
1. Install the filter according to the installation
instructions detailed in this manual.
2. Make sure to leave enough clearance so as to
enable easy access for future treatments and
safe maintenance operations.
3. Electric wiring should be performed by an
authorized electrician only, using standardized
and approved components.
4. Install main power disconnect cut-off switch
close to the control panel.
5. If the control panel is installed far away and
there is no eye contact with the filter, a power
disconnect cut-off switch should be installed
near each filter unit.
6. Installation of the filter should be performed so
as to avoid direct water splashing on the
electrical components or on the control panel.
7. Extra safety devices should be installed on hot
water applications to avoid skin burn danger.
Operation, Control and Maintenance
1. Disconnect the filter from power supply before
maintenance or treatment.
2. Loosening or unscrewing bolts should be done
only after the pressure in the filter had been
released.
3. Avoid splashing and water leaking so as to
minimize slipping electrifying danger or damage to
the equipment caused by moisture.
4. Always open and close valves slowly and
gradually.
5. Remove grease and fat material residues in order
to avoid slipping.
6. After treatment has been completed, re-assemble
the protection covers of the drive mechanism.
7. Manual cleaning of filter element using high water
pressure or steam, should be performed in
accordance with the cleaning system instructions
and without endangering the operator or his
vicinity.
8. Manual cleaning of filter element using acid or
other chemical agents, should be performed in
accordance with the relevant material safety
instructions and without endangering the operator
or his vicinity.
Use of Lifting Equipment
1. While using lifting equipment, make sure that the
filter or the lifted part is chained securely and in a
safe manner.
2. Do not leave lifted equipment if there is no
necessity. Avoid working below lifted equipment.
3. Ware a safety helmet while using lifting equipment

5amiad filtrationsystems
DIMENSIONAL DRAWING AND RECOMMENDED INSTALLATION
Key:
Dimensions in mm (inches)
1. 6" SAF-C 4500
2. 6"inlet butterfly valve
3. 6" by-pass valve (option)
4. 6" downstream valve (recommended)
5. 6"non-return check valve (option)
•Minimum distance required for maintenance.

6amiad filtrationsystems
DESCRIPTION OF FILTER OPERATION
Filtering process:
The SAF-4500 is a sophisticated yet easy-to-operate automatic filter, with a self-cleaning mechanism driven by
an electric motor. The SAF-4500 is designed to work with various types of screens in filtration degrees from 500
to 10 micron, and is available in 4", 6" and 8"inlet/outlet diameter.
The water enters through the inlet pipe into the coarse screen from outside in, and through the fine screen from
inside out. The "filtration cake" accumulates on the fine screen surface and causes head loss to develop.
The coarse screen is designed to protect the cleaning mechanism from large dirt particles. It should not
accumulate large quantities of suspended solids and is not cleaned automatically.
Self-cleaning process:
The SAF-4500 will start the self-cleaning process when the pressure differential across the screen reaches a
pre-set value or a predetermined lapse of time.
Cleaning of the filter element is carried out by the suction scanner which rotates in a spiral movement while
removing the filtration cake from the screen and expels it out through the exhaust valve.
The rotation of the scanner is operated by a 2-way (fwd/rev) drive unit that is attached to the scanner by a
threaded shaft which provides the linear movement.
The exhaust valve is activated for the duration of the cleaning cycle by a 3-way solenoid. During the self-
cleaning process, which takes approximately 20 seconds, filtered water continues to flow downstream.
Different modes of filtration:
The filtration system may be found in one of the following modes:
1. Filtering mode: This is the normal function condition. Flushing is not occurring and the power light on the
control board is lit.
2. Flushing mode: A mode in which the flushing process is in progress. The motor and exhaust valve are
operating according to the program.
3. Continuous flushing mode: It is possible to activate the self-cleaning mechanism continuously by changing
the switch near the timer in the control board to "CONT." position.
4. Malfunction mode: During malfunction mode the self-cleaning operation is stopped, the malfunction light on
the control board is turned on and an external output is activated with 24V AC.
The filtration system may enter a malfunction mode in the following cases:
1st. When there is a continuous signal from the pressure differential switch for a duration of more than the pre-set time.
This means that the self-cleaning process is not successful.
2nd. When the motor protector was activated, either manually or due to over load.
3rd. As a result of a malfunction in the limit switches.
Initiation of self-cleaning:
The filter will enter the self-cleaning process as a result of any of the following causes:
1. A signal from the Pressure Differential Switch (PDS) -The PDS which is situated on the filter body, sends an electric
signal when the pressure differential across the screen reaches the pre-set value (usually 0.5 bar =7 psi). The control
board registers the signal and operates the flushing process according to its program.
2. Manually pressing the "TEST" push button at the control board.
3. The TIMER installed in the control board allows operation of self-cleaning process at time intervals that can be set up,
independent from the head loss factor. The timer resets after every flushing cycle.
4. A signal from Continual flushing switch -This switch in the control board allows operation in continuous flushing mode;
meaning, the filter is flushing itself all the time regardless of flow rate or water quality.
Control system:
Two types of control boards are available: PLC Type and Relay Type. See Appendix A or B for details.

7amiad filtrationsystems
INSTALLATION
Design recommendations
1. If flow increases and pressure drops dramatically for a long period of time during network filling-up, it is recommended
that a pressure sustaining valve is installed downstream. The pressure sustaining valve will ensure a controlled filling-up
of the line.
2. If continual water flow is essential even during maintenance period, it is recommended that a manual or automatic by-
pass is installed, and the isolating valves will be used to isolate each filter unit.
3. In places where there is an expected temporary worsening of water quality, it is possible to operate an emergency
flushing program. In order to do so, a hydraulic controlled valve has to be installed downstream. For details, please
consult the manufacturer.
Installation instructions
1.Install the filter horizontally in such way that allowsconvenient approach and enough space to dismantle the filter for
maintenance purposes.
2. Ensure the direction of flow according to the arrows marked on the filter housing.
3. It is recommended to install a mechanical non-return valve downstream of the filter.
4. Connect a minimum of 2"pipe to the exhaust valve. The exhaust pipe should be designed so that it creates minimal
resistance to flow of 15 m3/h (66 USgpm).
5. If the system is designed to operate with working pressure higher than 6 bar (85 psi), it is recommended that a manual
valve is installed on the exhaust pipe, in order to enable regulation of the flushing flow rate.
6. The user should arrange suitable lighting at the area of the filter to enable good visibility and safe maintenance.
7. The user should arrange suitable platforms and safety barriers to enable easy access to the filter without climbing on
pipes and other equipment.
IMPORTANT !!
•• Prevent static back pressure or reverse flow through the filter.
•• Install a manual or a hydraulic valve downstream of the filter.
Electric wiring
1. Install the control board in a dry and protected place (It is possible to order a special control board for out-door
installation).
2. Power connection to the control board:
a.Connect a three-phase voltage source through a semi-automatic switch, or 16 Amp. fuse to the L1 L2 L3 inlet
at the terminal strip in the control board.
b.b. Earth the control board.
3. Power connection to the motor:
Connect the drive unit to the control panel by means of a 4 x 2.5 mm (12 or 14 AWG) wire in flex-conduct. Use a long
enough cable to allow removal of the drive unit and placing it near the filter for maintenance, without having to disconnect
it from the cable. (It is recommended that this installation meets or exceeds local or national electrical codes, this is a
"high" voltage connection).
4. Control wiring:
Connect between the control junction box and the control board by means of 6 x 1.5 mm 2 (16 AWG) wire in flex-
conduct. The numbers on the terminals in the board and in the junction box are identical.
Start-up and first operation
1. Make sure all the electric wiring is correct, according to the enclosed drawings.
2. Switch the control & 24V circuit breakers and the motor protector to ON. The motor will start operating*.
The suction scanner shaft should turn clockwise and move towards the filter housing until it reaches limit switch "A". If
the motor rotates in the opposite direction, disconnect the electricity immediately and change the direction of the motor
rotation by changing between two phases.
The motor must stop when the magnetic disc reaches limit switch "A" and causes it to operate.
3. Operate a "dry" flushing cycle by pressing on the "TEST" push button. Make sure all flushing stages occur as described
in the filter description chapter of this manual.
4. Open the inlet valve to the filter, while the outlet valve remains closed or with an open by-pass valve (This will keep the
flow in the filter at a minimum), and operate a flushing cycle.
Make sure the exhaust valve opens and all stages of the flushing cycle are carried out. Attend to leakages, if any.
Close the 1/4" valve at the low pressure point of the pressure differential switch for 5 seconds. The PDS hand will move
to the red area and the filter will start the flushing process. Open the 1/4" valve.
5. Gradually open the outlet valve and/or close the by-pass valve. Operate the filter at the designed hydraulic conditions.
6. Set the timer for 6-8 hours.
7. Check and re-tight all bolts after the first week of operation.
•When using Control board type "C" (Relay type) it is necessary to press the "Test" push button in order to start the motor
operation for the first time.

8amiad filtrationsystems
MAINTENANCE
General inspection
In order to check the proper operation of the filter, close the low pressure 1/4"valve to the pressure differential
switch for a period of 5 seconds. This will initiate the self-cleaning cycle: Check that the exhaust valve opens,
that the scanner moves forwards, and when it reaches limit switch "B"-verify that the exhaust valve closes.
Weekly maintenance
1. Check that the filter operates properly, following a general inspection.
2. Clean the 3/4" filter (close the 3/4" valve and operate a flushing cycle in order to release pressure and then
open the bowl).
3. Check that there is grease on the drive shaft, and drive bushing. Add grease if necessary.
4. Take care of any leakage from the scanner shaft. If necessary, replace the Sealing Nut Internal O-Ring (6.9)
Changing the sealing nut internal O-ring:
1. Close the inlet valve to the filter and release the pressure.
2. If the Suction Scanner is in the outer position, operate a flushing cycle and bring it to the inner position.
3. Remove the Split pin (8.4) and pull out the connecting pin (8.3).
4. Operate a flushing cycle.
5. Stop the motor operation when the drive shaft reaches half way of its movement. The drive shaft is now
separated from the Suction Scanner.
6. Unscrew the sealing nut (6.8).
7. Remove the used internal o-ring and clean the o-ring seat.
8. Insert a new o-ring (6.9)
9. Apply some grease on the external o-ring and on the shaft.
10. Tighten the sealing nut (6.8).
11.Re-connect the drive shaft to the suction scanner shaft.
12. Operate the control board and open the filter inlet valve.
Maintenance prior to long term cessation of filter operation
The following must be done if the filter will not operate for more than a month.
1. Operate flushing cycle (If possible, with a closed downstream valve).
2. Disconnect the control board from the power.
3. Release pressure from the filter.
4. Grease the drive shaft and the drive bushing.
5. Clean the 3/4" control filter.
6. Clean the coarse screen through the service port.
Maintenance prior to re-operation
1. Connect the control board to the mains.
2. Check proper operation of the filter.
3. Grease the drive shaft and the drive bushing.
4. If necessary change the Sealing Nut Internal O-Ring.
IMPORTANT !!
THE DRIVE SHAFT MUST BE LUBRICATED WITH HEAVY-DUTY, WATER RESISTANT GREASE, THAT
WILL NOT OXIDIZE. (SHELL, DARINA EP-2 OR SIMILAR).
Cleaning the coarse screen:
1. Close the filter inlet valve.
2. Release pressure from the filter by operating a flushing cycle.
3. Remove the service lid (5) by disconnecting the bolts (5.2) from the nuts (5.4)
4. Clean the coarse screen:
-To remove large particles insert your hand into the coarse screen area.
-To remove fine particles and organic matter rinse the screen. Afterwards, partially open the inlet valve and
let water flow out.

9amiad filtrationsystems
DISMANTLING AND ASSEMBLING THE FILTER COMPONENTS
Prior to opening the filter it is recommended to operate a flushing cycle by pressing the "TEST" push button.
Fine screen
Dismantling:
1. Close the filter inlet and outlet valves and release the pressure.
2. Release the lid bolts (1.5) from their nuts and remove the lid (1).
3. Pull the screen (3) out of the filter housing.
4. Remove the screen seals (3.1, 3.2) from the screen.
Assembly:
1. Put the screen seals (3.1, 3.2) on the screen edges (3).
2. Insert the screen into the filter housing (4) while the support legs point upwards. After pushing the screen all the way in,
rotate the screen so the legs will support it and lead it to itsposition.
3. Clean and apply some grease on the suction scanner pipe and on the o-ring of the lower bearing (1.3).
4. Assemble the lid on the filter housing. Make sure the screen and seal are correctly positioned in the lid seat.
5. Tighten the bolts (1.5) in a controlled and balanced method. The bolts seats of the lid should touch the bolts seats of the
filter housing.
6. Open the filter inlet and outlet valves and operate the control board.
7. Check proper operation of the filter.
Suction scanner
Dismantling:
1. Begin the dismantling procedure as per 1-4 in the chapter "dismantling the fine screen".
2. Remove the cover from the drive shaft housing (7.9) by unscrewing the wing nuts (7.11).
3. Remove the Split pin (8.4) and pull out the connecting pin (8.3).
4. Pull the suction scanner (2) in a spiral movement out of the filter housing.
5. Unscrew the sealing nut (6.8).
Assembly:
1. Apply some grease on the smooth side of the suction scanner (2) and insert it into the screen (3). Make sure the scanner
(2) passes through the flushing chamber (6). When the suction scanner shaft appears from its port, apply some grease
on it and tighten the sealing nut (6.8).
2. Insert the suction scanner shaft (2.2) into the drive shaft (8). Make sure the holes in the above shafts are parallel.
3. Insert the connecting pin (8.3) to the parallel hole of the suction scanner shaft (2.2) and the drive shaft (8) and lock it with
the split pin (8.4).
4. Continue to assemble the parts as per 1-7 in the chapter "Assembling the fine screen".

10 amiad filtrationsystems
Drive shaft housing and coarse screen
Dismantling:
1.Close the inlet and outlet valves of the filter and release pressure.
2.Disconnect power supply from the control board.
3.Dismantle the suction scanner and fine screen as described previously.
4.Pull out the plug from the solenoid coil (16).
5.Remove the limit switch sling (10) from the drive shaft housing by unscrewing the bolts (10.1). Carefully
put the limit switch sling near the filter to avoid any damage to the electrical wires.
6.Disconnect the tube (16.3) from the solenoid valve (16) and from connector (19.3).
7.Disconnect the drain pipe from the exhaust valve.
8.Remove the drive shaft cover by unscrewing wing nuts (14.3)
9.Remove the drive unit (12+12.1) from the drive shaft housing (7) by unscrewing the nuts (12.5) from the
bolts (12.2). By doing so the drive shaft key (13) will be pulled out.
10.Dismantle the drive shaft housing (7) from the flushing chamber flange (6) by unscrewing the bolts (7.1).
11.Remove the rest of the flange bolts and pull out the flushing chamber assembly which includes: flushing
camber (6), coarse screen (6.4), screens adapter (6.5) and screens adapter seal (6.6).
Assembly:
1.Place the coarse screen (6.4) in its seat in the flushing chamber.
2.Place the screens adapter (6.5) on the flushing chamber and the coarse screen.
3.Attach the screens adapter seal (6.6) to its place with its flat side, using some grease (as adhesive
material).
4.Attach the flushing chamber o-ring (4.1) to its place using some grease (as adhesive material).
5.Apply some grease on the o-ring of the upper bearing (6.2).
6.Insert the flushing chamber assembly into its place. Use the centering pin (4.2) to locate the flange in its
position.
7.Tighten the flange to the filter housing with the side bolts only (6.10).
8.Apply some grease on the o-rings (6.7 & 6.9) of the shaft sealing nut (6.8) and tighten to its place.
9.Install the drive shaft housing, using the rest of the flange bolts (7.1).
10.Insert the suction scanner (2) and the fine screen (3) as described previously.
11.Connect the drive shaft (8) to the scanner shaft using the connecting pin (8.3) and split pin (8.4).
12.Make sure the drive shaft key (13) is fitted properly in the gear box. Thread the drive shaft through the
drive unit and make sure that the drive shaft groove is adjusted in accordance with the drive shaft key.
13.Connect the drive unit (12+12.1) to the drive shaft housing (7) with the bolts (12.2) and tighten them.
14.Connect the pilot tube between the solenoid valve (16) and the control filter connector (19.3).
15.Assemble the limit switch sling (10) in its place and push in the plug of the solenoid coil.
16.Connect the drain pipe to the exhaust valve (15).
17.Operate the control board and make sure the filter is operating properly.
18.Open the inlet and outlet valves and recheck filter operation.