Galcon AMC-6DC User manual

AMCFlushing Controller
User Guide
Revision 1.0 - August 2016

Revision History
Revision Date Description
1.0 August 2016 First release of the document.
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Copyright © 2016 Galcon LTD. All rights reserved.
Information in this documentation is subject to change without notice and does not represent a
commitment on part of Galcon LTD. The software described in this document is subject to the license
agreement that is included with the product, which specifies the permitted and prohibited uses of the
product.
Any unauthorized duplication or use of this documentation, in whole or in part, in print, or in any other
storage or retrieval system is prohibited. No part of this publication may be reproduced, transmitted,
transcribed, stored in a retrieval system, or translated into any language in any form by any means for
any purpose other than the purchaser’s personal use without the permission of Galcon LTD.

Contents
Safety Instructions 4
General Safety Instructions 4
Electricity Instructions 4
Introduction 6
System Overview 7
Technical Data 8
Installation 10
Terminal Strips Drawings 11
Installing and Replacing Batteries (DC Models) 17
Connecting to Main Power (AC Models) 20
Setup and Operation 22
Operational Workflow 23
Overview of the Interface 26
Configuring the Controller 29
Using the Pre-defined Flushing Programs 38
Manual Operations 39
Chaining Controllers 40
Monitoring the Controller 41
Handling Faults 44
Model Specifications 45
AMCFlushing Controller User Guide 3

Safety Instructions
General Safety Instructions
lUse the controller only for its intended use as designed by the manufacturer, any misuse of the
controller may lead to undesired damage and may affect your warranty coverage. Consult with the
manufacturer prior to any non-regular use of this equipment.
lThe terminals enclosure lid of the unit must remain closed at all times.
lOnly a qualified technician may remove this lid and only when the controller is properly disconnected
from its power source.
lServicing the unit can be done only by qualified technician.
lMake sure that the filters controlled by the controller are disconnected from the water system whenever
servicing the controller.
lIn case the controller is connected to an external AC power supply unit, make sure that the power
supply connection is done only by a licensed electrician and the connection complies with your local
standards for High Voltage out-doors connection.
lPlease note: The filter enters into a flushing mode automatically, without early warning.
lNo change or modification to the equipment is permitted without a written notification given in advance
by the manufacturer or by its representative, on the manufacturer’s behalf.
lAlways observe standard safety instructions and good engineering practices whilst working in the filter’s
vicinity.
Electricity Instructions
lElectric wiring should be performed by an authorized electrician only, using standardized and approved
components.
lInstall a lockable main power cut-off switch close to the control panel.
lIf due to site constraints, the control panel is installed without a clear line-of sight of the filter, an addi-
tional lockable power disconnect cut-off switch should be installed near each filter unit.
lUse only the built-in transformer.
lIn case the controller is supplied with a power supply cable connected to it, the controller is for indoor
installations only!
lIn order to use the controller for outdoor installation, a licensed electrician must disconnect the power
supply cable, and connect the controller according to the instructions given in the installation chapter of
this document and in compliance with all the safety instructions and the local standards for High Voltage
out-door connection.
lIf the plug does not comply with your local regulation, it must be replaced with suitable plug by licensed
electrician only.
lHazardous Live voltages connected to the following output terminals :
lFilter Motor Control terminal (230VAC/115)
l24VAC for solenoid control and for 24VAC auxiliary (24VAC IS CONSIDERED HAZARDOUS LIVE IN WET
LOCATIONS!).
4 AMCFlushing Controller User Guide
Contents

lBe careful while doing installation and maintenance of the filter flushing system Make sure that the
protective earth is well connected to the input terminal and to the motor body
lIt is necessary to connect a two-pole switch between the power supply and the controller, 115VAC or
230VAC depends on the actual controller model.
lThe supply point 115VAC or 230VAC (depends on the actual controller model), the circuit and connection
to the transformer must be performed according to “Field Electrical Regulations” by a licensed electrician
who is accredited with a license according to the Electrical Bill and security requirements.
lWhen using an internal transformer, minimal wire diameter must be 0.7mm. Check with standard
measuring equipment that there is no voltage in the electric circuit.
lNever cut, connect, or disconnect any wire at the controller’s vicinity.
lMake sure that the controller is not exposed to water splashes.
lKeep the keyboard cover closed at all times when not using the keyboard.
AMCFlushing Controller User Guide 5
Contents

Introduction
The AMC Flushing controllers are electronic devices capable of controlling the back-flush process of
various automatic filter models installed in various configurations.
Galcon provides the AMCFlushing controller in the following configurations:
lDC controller
l115 VAC/230 VAC controller
Each controller has two solenoid configurations: 6 and 12 solenoids.
This document describes the configuration and operation procedures of the controller.
1

System Overview
The AMCFlushing Controller is pre-configured according to the filtration system’s types to be
controlled. This provides easy setup and operation and ensures reliable long-term operation. The
AMCFlushing Controller controllers are housed inside ABS enclosures and are designed for outdoor use
(IP 65).
The AMCFlushing Controller can control either 6 or 12 solenoids allowing them to operate six default
flushing programs covering a wide range of filters.
The operation method of each program is similar, however the timings of the various operation stages
vary according to the program.
The controller supports the following flushing processes:
lDifferential Pressure (DP) signal
lTime Interval parameter
lManual Start command
The controller is also capable of controlling the following additional functions:
lMain/Downstream Valve - (replaces one of the 6 filter units outputs) one of the controller's
outputs operates as a main or downstream valve. Downstream Valve is usually installed at the
outlet port of the filtration system. It is energized during the back-flush process to ensure sufficient
water pressure during flushing. A Main Valve enables the operation of a valve or a pump (through a
dry contact latch relay) for increasing the pressure or supplying additional water source during the
flushing process.
Note:
If a pump is connected to the Main Valve output, it is important to make sure that the relay
operating the pump control loop draws no more than 0.5 Ampere from the Main valve
output.
lDelay Valve (replaces one of the 6 or 12 maximum filter units outputs) - one of controller's out-
put operates as a Delay Valve together with the flushing filter. For example, delay Valve can be used
for sampling the flushing water or for controlling an air-pressure operated back-flush system.
lAlarm output - a special dry contact output (up to 0.2 Ampere) that is switched on in case of a sys-
tem fault.
lEnd of cycle chaining output - a special dry contact output (up to 0.2 Ampere) that is switched on
for 5 seconds at the end of each flushing cycle. This output can be chained to the DP input of
another controller to start a flush cycle sequentially after the first controller.
7 AMCFlushing Controller User Guide
System Overview

Technical Data
DCModels
Outputs
lOut 1 - Out 6 - These are the terminals for the Two Wire 12V DC Latching Solenoids.
If a main valve or a delay valve has been designated during the controller’s configuration process,
it's solenoid's output will always assigned to output number 6 If a main valve and a delay valve are
configured the main valve will be assigned to output number 5 and the delay valve to output
number 6.
lAlarm - This output is a Dry Contact Relay (a free potential contact); it provides a command pulse to
an external alarm device. The alarm is activated in two cases:
lWhen selected number of consecutive flushing cycles have taken place due to continuous dif-
ferential pressure input signal, which usually occurs when the filters are clogged.
lWhen the battery voltage is lower than 4.7 VDC.
lEnd of Cycle - This output is a Dry Contact Relay (a free potential contact); it provides a command
pulse for 5 seconds and can be used to chain controllers. See "Chaining Controllers" on page40.
Inputs
See "Terminal Strips Drawings" on page11.
D.P.
This is the connection to the differential pressure switch.
Power Supply
6-12 VDC - The connection terminal of the DC models is used to connect, when available, a 7.2-12 VDC
1000 milliamp external power supply unit to the controller.
When an external power supply is connected, the internal batteries of the controller are used only for a
back up and not for the actual operation of the controller.
ACModels
Outputs
lOut 1 - Out 6- These are the terminals for the Two Wire 24VAC Solenoids.
If a main valve or a delay valve has been designated during the controller’s configuration process,
it's solenoid's output will always assigned to output number 6.
If a main valve and a delay valve are configured the main valve will be assigned to output number 5
and the delay valve to output number 6.
lAlarm - This output is a Dry Contact Relay (a free potential contact); it provides a command pulse to
an external alarm device. The alarm is activated in two cases:
lWhen a selected number of consecutive flushing cycles have taken place due to continuous dif-
ferential pressure input signal, which usually occurs when the filters are clogged.
lEnd of Cycle - This output is a Dry Contact Relay (a free potential contact); it provides a command
pulse for 5 seconds and can be used to chain controllers. See "Chaining Controllers" on page40.
Inputs
See "Terminal Strips Drawings" on page11.
D.P.
This is the connection to the differential pressure switch.
8 AMCFlushing Controller User Guide
Introduction

TAFMotor Control - The AC models feature an ability to control the operation of TAF filters motor
S7I15GX-TCE SPG.
9 AMCFlushing Controller User Guide
Technical Data

Installation
2

Terminal Strips Drawings
Flushing Controller Model AMC-6DC
11 AMCFlushing Controller User Guide
Terminal Strips Drawings

Flushing Controller Model AMC-6AC 230V
12 AMCFlushing Controller User Guide
Installation

Flushing Controller Model AMC-6AC 115V
13 AMCFlushing Controller User Guide
Terminal Strips Drawings

Flushing Controller Model AMC-12DC
16 AMCFlushing Controller User Guide
Installation

Flushing Controller Model AMC-12AC 230V
15 AMCFlushing Controller User Guide
Terminal Strips Drawings

Flushing Controller Model AMC-12AC 115V
16 AMCFlushing Controller User Guide
Installation

Installing and Replacing Batteries (DC Models)
Replacing the batteries procedure in the DC-6 and the DC-12 controllers is the same. The following
pictures display replacing batteries in the DC-6 model.
The controller is powered by four 1.5V D type batteries. The unit starts to operate automatically when
inserting the batteries. Alternatively, an external 7.2-12V DC supply can be connected to the power
connection terminal; (Labeled as 7.2-12DC-In on the terminal board circuit board).
If an external power supply is connected while a set of batteries is installed, the batteries are served as a
backup and are not in use as long as the external power supply is connected.
To install or replace the batteries:
1. Open the Controller’s lid.
2. Unscrew the and open the keyboard cover.
3. Unscrew the two bolts and remove the batteries compartment lid.
17 AMCFlushing Controller User Guide
Installing and Replacing Batteries (DC Models)

4. Pull out the batteries holder and insert (or replace) four D type 1.5VDC batteries according to the (+)
and (–) marks on the compartment.
5. Insert the battery holder back to the battery compartment. Make sure that the red and black wires
are not jammed.
18 AMCFlushing Controller User Guide
Installation

6. Reassemble the battery compartment lid and the keyboard lid in reverse order.
19 AMCFlushing Controller User Guide
Installing and Replacing Batteries (DC Models)

Connecting to Main Power (AC Models)
Before you Begin
lAMC AC controllers are intended to be supplied in Europe by AC power with a 16A rated over cur-
rent protective device and 2 poles disconnecting device (circuit breaker) or with 20A over current
protective device and 2 poles disconnecting device (UL 489 circuit breaker) in the US and North
America. This device is to be suitably located and easily reached and marked as the disconnecting
device for the equipment. The circuit breaker shall meet the requirements of IEC 60947-1 and IEC
60947-3 and be suitable for the application.
lUse only the built-in transformer.
lIn case the controller is supplied with a power supply cable connected to it, the controller is for
indoor installations only!
lPower supply cable should be Outdoor rated, suitable for the installation site, and should comply
with IEC 60227 or IEC 60245 for Europe or ANSI/UL 817 and CSA C22.2 No. 21 for USA and Canada.
lPower supply cable rating: 250VAC, 1A: -30°C ~ +120°C or 115VAC, 1A: -30°C ~ +120°C depends on
the controller’s actual model.
lPower supply cord cables yellow and green are for ground connection only.
lIf the supply cord is damaged, it must be replaced by the manufacturer or service agent or a sim-
ilarly qualified person in order to avoid hazard.
lIn order to use the controller for outdoor installation, a licensed electrician must disconnect the
power supply cable, and connect the controller according to the instructions given in the install-
ation chapter of this document and in compliance with all the safety instructions and the local
standards for High Voltage out-door connection.
lIn order to use the controller for outdoor installation, a licensed electrician must disconnect the
power supply cable, and connect the controller according to the instructions given in the install-
ation chapter of this document and in compliance with all the safety instructions and the local
standards for High Voltage out-door connection.
lIf the plug doesn’t comply with your local regulation it must be replaced with suitable plug by
licensed electrician only. Please note that opening additional cable holes in the controller’s housing
bottom plate should be done by drilling only and not by hammering the knock-outs!
lIt is necessary to connect a two-pole switch between the power supply and the controller 115VAC
or 230VAC (depends on the actual controller model).
lThe supply point 115VAC or 230VAC (depends on the actual controller model), the circuit and con-
nection to the transformer must be performed according to “Field Electrical Regulations” by a
licensed electrician who is accredited with a license according to the Electrical Bill and security
requirements.
lWhen using an internal transformer, minimal wire diameter must be 0.7mm. Check with standard
measuring equipment that there is no voltage in the electric circuit.
Connecting to Power
1. Route an AC power cable through the cable gland at the bottom side of the cabinet.
The cable range should be Ø4-Ø7 mm.
2. Connect the wires to the transformer wires located inside the cabinet. The Controller units are
supplied with a built in terminal strip.
See "Terminal Strips Drawings" on page11 for wiring diagrams.
20 AMCFlushing Controller User Guide
Installation