Applied Membranes W-G2162EM Instruction Manual

Industry Leader in RO Expertise and Membrane Applications since 1983™
Systems Membranes & Chemicals Filters
2325 Cousteau Ct. Vista, CA 92081 • [phone] • FAX: [phone]
Internet: www.appliedmembranes.com • E-mail: [email protected] Document ID# OMC21-24EM
Revision: 06-26-2013
Manual for
Operation & Maintenance
Of
Carbon Filter with
Metered Valve
for Models:
W-G2162EM & W-G2472EM

Installation and Service Manual – Metered Carbon Filter
Page 2
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
Panel Operation Quick Reference Guide
User Display When in normal operation, one of five displays may be shown. Pressing NEXT will alternate between the displays.
User Screen 1: Typical user display. Shows volume remaining (in gallons)
until next regeneration.
User Screen 2: Displays number of days to next regeneration.
User Screen 3: Displays flow rate in gallons per minute.
User Screen 4: Displays total flow in gallons since last reset.
(Press and hold ▼for 3 seconds to reset to 0.)
User Screen 5: Shows current time.
User screens 1, 3 and 4 will not be shown if 7 or 28 day options are selected in configuration settings.
Regeneration Screens
During Regeneration: The display shows the time remaining in the current cycle.
Pressing “REGEN” will advance to the next cycle.
Set Time of Day
In the event of a prolonged power
outage, time of day flashes,
indicating that it needs to be reset.
All other information will be stored in
memory no matter how long the
power outage. Please complete the
steps as shown to the right.
(Time of day will only need to be set when a
power outage lasts more than 8 hours, or
when daylight savings time begins or ends.)
Press NEXT until the time of day screen is
displayed.
Press and hold ▲or ▼until the SET indicator is
displayed and the hour flashes.
Press ▲or ▼until the correct hour is displayed.
Press NEXT, the minutes will flash.
Press ▲or ▼until the correct minute is
displayed.
Press NEXT to return to the display screen.
Button Operation and Function
Scrolls to the Next Display
Press once and release to schedule a regeneration at the preset delayed regeneration
time. (Press and release again to cancel the regeneration.)
Press and Hold for 3 seconds to initiate an immediate regeneration.
While Regeneration is in Process: Press to advance to the next cycle.
While in Programming Screens: Press to go backwards to the previous screen.
Changes variable being displayed.
Key sequence to lock and unlock program settings.
Press and Hold for 3 seconds to initiate a control reset. The software version is displayed
and the piston returns to the home/service position, resynchronizing the valve.
Error Message
If the word “ERROR” and a number are flashing on the display, check the trouble shooting section of
this manual to identify the error. Clear error by disconnecting the power supply at the PC board and
reconnecting, or press the NEXT & REGEN buttons simultaneously for 3 seconds.
Manual Regeneration
Delayed Regeneration: Press and Release the “REGEN” button.
“◄” will flash towards REGEN. Regeneration will be performed “tonight” at the preset time
of day. (Cancel request by pressing the “REGEN” button again.)
Immediate Regeneration: Press and Hold the “REGEN” button for approximately 3
seconds. Regeneration will begin immediately. Request cannot be cancelled.

Installation and Service Manual – Metered Carbon Filter
Page 3
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
TableofContents
Design Basis & Specifications.............................................................................................................................................4
General Information and Safety...........................................................................................................................................4
Installation .............................................................................................................................................................................4
Location...............................................................................................................................................................................4
Loading the Media...............................................................................................................................................................5
MediaQuantity per Model ....................................................................................................................................................5
Plumbing..............................................................................................................................................................................6
Operating Do’s and Don’ts...................................................................................................................................................7
Initial Start-Up........................................................................................................................................................................8
System Monitoring and Record Keeping............................................................................................................................8
Operating Conditions ...........................................................................................................................................................8
Control Valve Operation & Service .....................................................................................................................................9
Control Valve Specifications................................................................................................................................................9
User Display ......................................................................................................................................................................10
Regeneration Screens.......................................................................................................................................................10
Set Time of Day.................................................................................................................................................................10
Button Operation and Function .........................................................................................................................................10
Error Message...................................................................................................................................................................10
Manual Regeneration........................................................................................................................................................10
General Warnings & Site Requirements ...........................................................................................................................11
Control Valve General Features and Information..............................................................................................................11
Configuring and Programming Control Valve Options...................................................................................................11
Metered Backwash Filter Recommended Programming Overview...................................................................................12
Configuration Settings (Pre-Programmed to Factory Defaults).......................................................................................13
Regeneration Cycle Time Settings (Pre-Programmed to Factory Defaults)..................................................................14
Installer Displays and Settings for Control Valve Options.................................................................................................15
Diagnostics........................................................................................................................................................................17
Control Valve Drawings and Components.......................................................................................................................18
CV1.5 Overview Drawings.................................................................................................................................................18
CV1.5 Drive Cap Assembly, Downflow Piston, Regenerate Piston & Spacer Stack Assembly ......................................19
CV1.5 Injector Valve Body, Refill Flow Control and Injector Plug.....................................................................................20
CV1.5 Drain Line Flow Controls........................................................................................................................................21
Meter Assembly.................................................................................................................................................................22
CV1.5 Flow Diagram, Service ...........................................................................................................................................23
CV1.5 Flow Diagram, Backwash.......................................................................................................................................23
CV1.5 Flow Diagram, Rinse..............................................................................................................................................24
Service Spanner Wrench...................................................................................................................................................24
Control Valve Service Instructions ...................................................................................................................................25
Drive Assembly..................................................................................................................................................................25
Drive Cap Assembly..........................................................................................................................................................26
Main Piston........................................................................................................................................................................26
Spacer Stack Assembly.....................................................................................................................................................27
Injector Cap, Screen, and Injector Plug.............................................................................................................................27
Refill Port Plug...................................................................................................................................................................27
Drain Line Flow Control.....................................................................................................................................................27
Meter Assembly Service Instructions ................................................................................................................................27
Maintenance – Removal & Replacement of Carbon Media.............................................................................................28
Troubleshooting..................................................................................................................................................................29
Product Warranty................................................................................................................................................................32

Installation and Service Manual – Metered Carbon Filter
Page 4
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
DesignBasis&Specifications
Table 1 – Design Basis
Model No.* Flow Rate** (gpm) Backwash
Flow** (gpm) Volume of Media
(cu.ft.) Resin Tank
(Dia”×H”) Valve & In/Out
Conn.
5gpm/ft
2
15gpm/ft
2
Carbon (only) Total (Incl.
Underbed)
W-G2162EM 13 36 25 6 7 21 × 62 1.5”
W-G2472EM 15 47 35 8 10 24 × 72 1.5”
*
Filters are available with USA or European style plugs and voltages.
W-G2162EM-US & W-G2472EM-US = 120V AC/60Hz with USA cord
W-G2162EM-EU & W-G2472EM-EU = European 220V AC (EU plug is removable to convert into universal 220v cord)
**
Backwash flow rate based on 25 psi pressure drop.
Operating Limits: Vessel rated at 150 psi max. operating pressure, 120°F max. operating temp.
GeneralInformationandSafety
DISCLAIMER:
The information contained in this document is subject to change
without notice. Applied Membranes, Inc. shall not be liable for
technical or editorial omissions made herein; nor for incidental or
consequential damages resulting from the furnishing,
performance, or use of this material.
READ THIS MANUAL:
Prior to operating or servicing this unit, this manual must be read
and understood. If anything is not clear, call for assistance before
proceeding. Keep this and other associated manuals for future
reference and for new operators or qualified service personnel.
USE PROPER POWER CONNECTIONS:
Use proper wiring and connection methods to satisfy local
electrical codes. SHOCK HAZARD: Connect this unit to a
properly grounded connection in accordance with the National
Electrical Code. DO NOT, under any circumstances, remove the
ground wire or ground prong from any power plug. Do not use
extension cords or an adapter without proper consideration.
SERVICE WARNING:
To prevent electrical shock, disconnect power to the system
prior to servicing.
WARNING:
Do not make any alteration or modification in the wiring or
plumbing of the system. This can result in damage to the
system and cause injury to operators or users.
WARNING:
Flush the system for at least 30 minutes before use to
remove all chemicals present.
CAUTION:
Never let the filter freeze. Freezing can damage the resin
tank.
Installation
Unpack the filter. Inspect assemblies for damage (cracked couplings, broken or split pipes, loose straps, etc.).
Location
Select a location for the filter with adequate clearance from walls and other equipment to allow access on all sides of the
tank. The unit must be located near a drain able to accommodate the backwash flow rate of your unit (see the table on
page 4). This is in addition to any other equipment sharing the drain.
Select a location for the brine tank that is accessible for easy refilling. Ensure floor beneath the brine tank is clean and
level.
A grounded power supply of the appropriate voltage and a local disconnect switch is required.
Caution: The unit must not be located near any corrosive chemicals, or in an area where the
temperature may exceed 113°F (45°C). Do not install any water conditioner with less than 10 feet of piping
between its outlet and the inlet of a water heater.
Warning: The power supply must be properly grounded to avoid injury from electrical shock.

Installation and Service Manual – Metered Carbon Filter
Page 5
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
LoadingtheMedia
1. Place tank on a level, solid surface in the correct position for installation. Lift the riser tube
from the tank, keeping the attached hub within the opening of the tank. Within the tank,
assemble the laterals onto the hub, twisting each lateral into the hub to lock securely.
Gently lower the assembly to the bottom of the tank. The top of the riser tube should be
about level with the top of the tank.
2. The “riser tube” inside the media/resin tank delivers treated water to your control valve. It
will need to be temporarily covered with tape on the top end to prevent anything from falling
down inside the tube during loading.
3. Step back and look at the tank to make sure it is standing straight, and not tilted. The black
base on the bottom of the tank should also be straightened before filling the tank. If your
tank is tilted, simply pick up the tank 2-3 inches off the floor and drop it gently (but firmly)
down, favoring the side of the base that needs to be adjusted.
4. Before loading the media, fill the tank with 2-3 feet of water (or 1/3 full, depending on the
tank size), to soften the fall of the rocks and prevent damage to the distributor. To load the
media, use a funnel in the top of the media tank with the riser tube still inside. Make sure
the riser tube is covered with tape to keep media out.
5. Scoop the media into the funnel, slowly letting it fall down inside the media tank around the
riser tube. Fill the tank with the media provided, pouring the media in the following order
(1stwill end up on the bottom of the tank, last will end up at the top of the tank, etc.). Note:
The tank will be approximately ½ - ⅔full after loading is complete. Refer to Table 2 for the
proper quantities of each media.
I. Gravel – YMGRVL11618 – 1 CF (100 lbs.) per bag
II. Gravel ¼” × ⅛” – YMGRVL1418 – 0.5 CF (50 lbs) per bag (not used in W-G2162EM)
III. YMC1240RCOAL – 1 CF (27.5 lbs.) per bag
6. Remove the funnel from the top of the tank, and the tape from the end of the riser tube.
Brush any loose media or resin off the top opening of the tank.
7. The bottom of the control valve has an opening with O-rings inside; lubricate the O-ring with a non-petroleum based
lubricant. Position the valve over the top of the media tank, making sure the top of the riser tube inserts inside the
opening in the bottom of the valve.
8. Screw the valve down into the media tank. Another person should hold the tank as the valve is being snugly tightened
onto the tank. Do not over-tighten. Tighten until snug, tighten a bit more, then STOP. The large o-ring will seal itself.
MediaQuantityperModel
Table 2 –Media Quantities
Model No.*
(-US or –EU) Gravel 1
/ 16 ×⅛
I Gravel ¼ × ⅛ II Carbon III
W-G2162EM 1 CF (100 lbs) N/A (0) 6 CF (165 lbs)
W-G2472EM 1 CF (100 lbs) 1 CF (100 lbs) 8 CF( 220 lbs)

Installation and Service Manual – Metered Carbon Filter
Page 6
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
Plumbing
Note: All plumbing is to be done in accordance with state and local codes.
Caution: Before placing wall anchors to support piping ensure that no electrical conduit or wiring is located
behind the intended mounting location.
Note: The control valve, fittings and/or bypass are designed to accommodate minor plumbing misalignments
but are not designed to support the weight of a system or the plumbing.
Note: Connect to a supply line downstream of outdoor spigots. Install an inlet shutoff valve and plumb them
to the unit’s inlet. Installation of a bypass valve is recommended. If using plastic fittings, ground the water
conditioner per local electrical codes. If a water meter is used, install the water meter on the outlet side of the
control valve. The turbine assembly may be oriented in any direction, but is usually oriented pointing up to reduce
drainage out of the pipe during service.
Note: Do not use pipe dope or other sealant on threads. Use teflon tape on threaded inlet, outlet and drain
fittings.
1. Install connecting piping between raw
water source and input pipe on control
valve.
2. Install drain line from control valve to
a free flowing drain.
A 1.25” Male NPT × 1.5” Female NPT SS
drain flow control is installed on the valve.
Solder joints near the drain must be done
prior to connecting the drain line flow
control fitting. Leave at least 6”
(152.4mm) between the drain line flow
control itting and the solder joints to
prevent heat from damaging the flow
control. Avoid elevating the drain line
above the control valve where possible.
Discharge the drain line through an air
gap to a receptacle in accordance with
local plumbing codes.
Important: Never insert a drain line directly into a drain, sewer line or trap. Always allow an air gap between
the drain line and the receptacle to prevent back siphonage.
3. Install the water meter on the outlet side of the control valve.
The meter may be threaded directly into the valve or may be
plumbed separately downstream of the unit*. Ensure the arrow on
the meter body is going the same direction as the water flow. The
turbine assembly may be oriented in any direction, but is usually
oriented pointing up to reduce drainage out of the pipe during
service. Meter can be installed horizontally or vertically.
*A longer cable (Part #V3221) is required for distances longer than 3” from
the valve body.

Installation and Service Manual – Metered Carbon Filter
Page 7
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
4. Connect the meter cable: Remove the valve cover
and strain relief cover on rear of valve. Bring meter
cable through the knockout hole in the back of the
valve and connect to the three-pin connection labeled
“METER” on the PC board. Weave the meter cable
through the strain relief and replace the cover and
fastening screw.
Ensure meter cable is connected to the meter
assembly. See “Meter Service Instructions” in the
“Control Valve Service Instructions” section of this
manual for detailed meter disassembly and
reassembly instructions.
5. Install piping between meter output and point of use.
OperatingDo’sandDon’ts
DO:
Monitor system and keep a log.
Maintain proper water pressure for backwashing.
DON’T:
Permit oils or fats in feed water.
Shut down system for extended periods.
Exceed operating pressures or temperatures.
Backwash filter with insufficient water flow.

Installation and Service Manual – Metered Carbon Filter
Page 8
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
InitialStart-Up
1. Check all piping connections and make sure feed valves are open. Inspect plumbing for leaks.
2. Check that control valve is connected to electrical source.
3. Open Raw Water source valve.
Note: Check for leaks throughout system as pressure is applied.
4. Fully open a cold water faucet downstream of the system. Allow water to run until clear. Close the cold water
faucet.
5. Turn off the supply water.
6. Initiate manual backwash of the control valve: Press and hold the REGEN button for three seconds until the drive
motor starts. Press the REGEN button to advance the unit into the backwash cycle. Wait until the motor stops
and the backwash time begins to count down.
7. Open the inlet water supply valve very slowly, allowing the water to fill the tank in order to expel air.
Caution: If water flows too rapidly, there will be a loss of media out the drain.
8. When water is flowing steadily to the drain without the presence of air, fully open the water supply inlet valve.
Press the REGEN button again to advance to the rinse position and allow the water to run to drain for 2-3 minutes
or until the drain runs clear.
9. Press the REGEN button to advance to the service position.
10. Review the control valve operations section of this manual and ensure settings are properly programmed before
placing the carbon filter in service.
System Monitoring and Record Keeping
Monitor filter and record all pertinent data. This data is needed to determine operating efficiency and for performing
system maintenance. The latter includes changing of the media, pressure drop across the mineral tank and control valve.
Note: Warranty Claims cannot be processed without adequate operating data and filter history.
OperatingConditions
For optimum filter performance, observe the following:
Maintain a minimum of 25 psi during backwash cycle.
Water pressure should not exceed 120 psi across mineral tank.
Water temperature should not exceed 110 °F.
CAUTION: Hydrocarbons such as kerosene, benzene, gasoline, etc., may damage products that
contain o-rings or plastic components. Exposure to such hydrocarbons may cause the products to leak. Do
not use the product(s) contained in this document on water supplies that contain hydrocarbons such as
kerosene, benzene, gasoline, etc.

Installation and Service Manual – Metered Carbon Filter
Page 9
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
Control Valve Operation & Service
CV1.5 Control Valve
Control Valve Specifications
Minimum/Maximum Operating Pressures: 20 psi (138 kPa, 1.4 bar) to 125 psi (862 kPa, 8.6 bar)
Minimum/Maximum Operating Temperatures: 40°F (4°C) to 110°F (43°C)
No user serviceable parts are on the PC board, the motor, or the power adapter. The means of disconnection from the
main power supply is by unplugging the power adapter from the wall.

Installation and Service Manual – Metered Carbon Filter
Page 10
Copyright © 2012 Applied Membranes, Inc. All Rights Reserved.
User Display
When in normal operation, one of five displays may be shown. Pressing NEXT will alternate between the displays.
User Screen 1: Typical user display. Shows volume remaining (in gallons)
until next regeneration.
User Screen 2: Displays number of days to next regeneration.
User Screen 3: Displays flow rate in gallons per minute.
User Screen 4: Displays total flow in gallons since last reset.
(Press and hold ▼for 3 seconds to reset to 0.)
User Screen 5: Shows current time.
User screens 1, 3 and 4 will not be shown if 7 or 28 day options are selected in configuration
settings.
Regeneration Screens
During Regeneration: The display shows the time remaining in the current cycle.
Pressing “REGEN” will advance to the next cycle.
Set Time of Day
In the event of a prolonged power
outage, time of day flashes,
indicating that it needs to be reset.
All other information will be stored
in memory no matter how long the
power outage. Please complete
the steps as shown to the right.
(Time of day will only need to be set when a
power outage lasts more than 8 hours, or
when daylight savings time begins or ends.)
Press NEXT until the time of day screen is
displayed.
Press and hold ▲or ▼until the SET indicator is
displayed and the hour flashes.
Press ▲or ▼until the correct hour is displayed.
Press NEXT, the minutes will flash.
Press ▲or ▼until the correct minute is
displayed.
Press NEXT to return to the display screen.
Button Operation and Function
Scrolls to the Next Display
Press once and release to schedule a regeneration at the preset delayed regeneration
time. (Press and release again to cancel the regeneration.)
Press and Hold for 3 seconds to initiate an immediate regeneration.
While Regeneration is in Process: Press to advance to the next cycle.
While in Programming Screens: Press to go backwards to the previous screen.
Changes variable being displayed.
Key sequence to lock and unlock program settings.
Press and Hold for 3 seconds to initiate a control reset. The software version is displayed
and the piston returns to the home/service position, resynchronizing the valve.
Error Message
If the word “ERROR” and a number are flashing on the display, check the trouble shooting section of
this manual to identify the error. Clear error by disconnecting the power supply at the PC board and
reconnecting, or press the NEXT & REGEN buttons simultaneously for 3 seconds.
Manual Regeneration
Delayed Regeneration: Press and Release the “REGEN” button.
“◄” will flash towards REGEN. Regeneration will be performed “tonight” at the preset time of
day. (Cancel request by pressing the “REGEN” button again.)
Immediate Regeneration: Press and Hold the “REGEN” button for approximately 3
seconds. Regeneration will begin immediately. Request cannot be cancelled.