IBC Water AFB16-180 Manual

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COMMERCIAL
WATER FILTER
INSTALLATION
&
OPERATING
INSTRUCTIONS
Model : AFB16-180
Serial No: ………………………..
Telephone:[phone] Facsimile:[phone]
Email: [e-mail] Website: www.ibcwater.com.au
FILTRATION &WATERTREATMENTPRODUCTS
forcommercial, industrial andresidential application
Manufacturerand Supplierof

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IronRemoval -Birm
Iron isremoved bycatalyticoxidation and filtration inthe mediabed, bothsolubleand
Insolubleiron isremoved inone operation undermost conditions.
The unit normallyonlyrequiresBackwashing periodicallytorestorethe filterbed. Chemical
regeneration isnot normallyrequired
OperatingParameters
WaterTemperature 5ºC-50ºC
WaterpH 6.8-8.5
WaterPressure 280 -690 kPa
Oil &Hydrogen Sulphide Tobe absent
ColloidalIron Tobe absent
Suspended Solids 5 mg/l
Alkalinity 4mg/lforeach1mg/lof Iron and/ormanganese
15%dissolved oxygen of iron level
Max. 4-5mg/lorganicmatterasindicated bydissolved oxygen consumed value.
15%dissolved oxygen of iron level
NOTE: If fitted withamicronizertoinduceoxygen intothe waterpriortothe filter-
install the micronizeron avalved by-pass asindicated infigure4.
AFSERIES FILTERS
Table2
OPERATINGPRINCIPLE
TYPE MODEL CONTINUOS
FLOWRATE
L.P.M
PEAK FLOW
RATEL.P.M BACKWASH FLOWRATE
L.P.M
VALVE APPROX.
WEIGHTKG
Multi-Media AFB
16-180 25 40 49 180 152
Valve 180
Inlet
(mm) 40
Outlet
(mm) 40
Drain
(mm) 40
Operating Pressure: 280 -690 kPa
Temperature: 5ºC-50ºCElectrical: 240V50Hz3wattsmaximum
Warning: Apressurereduction valveshouldbe installed ifwaterhammerprevails.
Tableat left showsrecommended MINIMUMplumbing sizes.
FAILURETO OBSERVE WARNING WILL VOIDWARRANTY

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Check the equipment upon arrivalfordamage orshortagesand report sametoourOfficeorAgent before
commencing installation.
Locatethe unit on aclean, firm, levelfoundation, preferablyconcrete, withsufficient spaceforoperation and
maintenance. Levelwithshimsifnecessary. Position the tankinthe correct position beforeloading the Media.
The filtershouldbe fitted withinlet and outlet pressuregaugestomonitorthe pressureloss through the filter. It
isrecommended that the filterbe backwashed when the pressuredifferentialincreasesby35 kPa.
The controlsystemissometimesshipped asasub-assemblytoavoiddamage intransit. The waterfilter
shouldbe assembled, piped and wired according tothe following recommendations. The following instructions
areprovided asageneralguide. The filterrequiresa10amp240 volt GPO. The filterinstallation must be
protected fromthe elements
FIG.4-INSTALLATION-- SINGLETANK BIRMIRONREMOVAL FILTERINSTALLATION
* Pipework Layout -suggestiveonly
* Unit onlysupplied
* Pipe, Valves, Solenoids, WaterMeter
supplied byothers
All pipework connectionstobe flanged
orbarrelunion, foreaseofremovaland
maintenance.
* USE PIPEWORKSIZES SHOWNIN
PERFORMANCEDATATABLE2
A= Inlet Isolating Valve-- Manual
B= Outlet Isolating Valve-- Manual
C= Bypass Valve-- Manual-optional
D= WaterMeter-optional, fit onlywheremetering ofsupplyisrequired
E= SolenoidValve-optional, fit onlywhererawwatertoserviceisnot required during REGENERATION.
Valvemust be 240V. 50Hzoperation normallyopen and equaltopipeline size-connect toterminals2
and 5inside valvecover(ReferFig.17)
F =Inlet AirRegulating Valve-- Manual
G =Inlet / Outlet PressureGauges
FIG.5-INSTALLATION-- MULTIPLEUNITS
INSTALLATION
To Drain
To Drain
ExternalBackwash
FlowController
supplied separatemust
be fitted before
Connecting DrainLine
To Drain
Micronizer
(Note:-arrowflowdirection
25&bypass line
withisolating valves

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Step 1:Removethe tankand risertube assemblyfromthe carton and makesurethe
softenertankisemptyand clean.
Step 2:Coverthe distributorpipe withaclean rag orplasticsothat NO gravelormedia
entersthe distributorpipe.
Step 3:Load the media-ReferMediaPlacement instructions.
a)Pourinthe underbed gravel(No.6). ReferTable1. 25kg.
b)Levelout the underbed gravelusing abroomhandle/PVCpipe. The underbed
gravelshouldcoverthe bottomdistributorbyabout 25mm.
CAUTION:
Donot raisethe distributorpipe. If gravelisallowed toget underthe
distributor, emptyand start again.
b)Afterloading and levelling the No. 6Gravelunderbed, half fill the tankwith
waterand add the Birm(ReferTable1. 54kg.)
¬Slowlyfill thetank.
Step 4:Toobtainoptimumperformancefromyourunit, exerciseparticularcarein
ensuring that eachgrade of mediaislevelled evenlyoverthe previouslayer.
Step 5:Fill the tankwithwaterto50mm fromthe top.
Step 6:Clean top of tank(neck &threads)of all tracesof media. Removethe rag or
plasticfitted inStep 2, taking carenot toraisethe riserpipe.
Step 7:Unpack the valve, removethe cap screwsand separatethe adaptor. Storegasket
safely. Check that the tank‘O’ring sealisinplace. Removethe rubbersleeve
and, using alittlesilicone “O”ring lubricant, lubricatethe inside surfaceonly.
Place rubbersleeveintotank adaptor. ReferFig. 1.
Step 8:Fit the adaptortothe tank, carefully, toallowthe riserpipe tolocatecentrally.
Screwdownfirmlybyhand. Donot overtighten. Placethe gasket on the tank
adaptor, fit the valvebodywithcap screwsprovided. Tighten cap screwsevenly.
RefervalveassemblyPage 6.
MEDIAINSTALLATION

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Step 1:Check plug isdryfirst, then connect lead intopoweroutlet, switchon.
Step 2:Removeclearcoverfromtimerfacebypulling the twoblack lock pinsoutward.
Depress the red knob (Fig.14) and rotateanti-clockwisetobackwashposition,
releasered knob,waitforvalvedrivetoindextobackwashposition,(ifnot
alreadyinthisposition)spindlefullyout. (Fig.11).
Step 3:Justopen inletisolating valveapproximately1.1/2turns.Allowunittofill slowly
(waterwill issue todrain)continue torun until the unitautomaticallyindexesto
Pauseposition whichmaytakeup to20 minutes. All airmust be removed.
Step 4:Depress the red knob and turnanti-clockwiseuntil the microswitchtripsintothe
fastrinseposition.Allowthe valvetomovefullyintothisposition ie.Fig.13.
Furtherrotatethe red knob anti-clockwisesothatthe arrowtipispointing at
aboutaseven o'clock position.Then allowthe red knob toadvanceelectrically
around tothe Serviceposition. Thismaytakeup to10 minutes.
Step 5:Depress the red knob and turnanti-clockwisetostart, release,the unitwill now
go through eachcycle-Backwash, purge and back toserviceautomatically.
NOTE:Asmall amountofmediamaypass todrainduring the initialbackwash,
thisisconsidered normal.
Step 6:Check withsitesupervisorthatunitcan go on line.If so-slowlyopen outlet
isolating valvefully,check thatmanualbypass valveisfullyclosed.Thisunitis
nowon line.
Step 7:Check forand report anyleaks.
Step 8:Setthe backwashfrequency toTuesday,and SaturdayforCarbon Filterif
frequency ofbackwashhasnotalreadybeen calculated.Toset, PUSHthe
skipperpinsINon the skipperwheelon days Backwashing isrequired.
Note:Thisisonlyaguide forinitialsetting and shouldbe altered tosuiteach
individualinstallation inaccordancewithload conditions.
Turnthe dialtothe correct dayof the weekon whichyou aresetting the dial.Now
depress the pinsforthe desired day/sforbackwashrequired.
COMMISSIONING

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Step 9:Settimeofday,pull timerknob (Fig.14)and setarrowtothe timeofday(timeof
yourwatch)release,makesurethatthe knob hasre-engaged gear,knob rightin.
Backwashwill takeplaceatapproximately2am.If thistimeisnotconvenientit
will be necessarytooffsetthe timeofdaysetting tomakeallowanceforthe
desired timeofbackwashing.eg.if4amisdesired,itwill be necessarytosetthe
timeof daytwohoursearlierthan actualtime.
Step 10:Replacethe timercover, depress the lock pins, and wipe overunit.
Step 11:Check that the micronizerisinjecting oxygen intothe feed stream-check thatthe
side valvegateisscrewed all the wayinand thatthe vacuumisoccurring atthe
barbed fitting.Todo thisplaceafingeroverthe open end ofthe fitting and check
forvacuumeffect. If avacuumcan notbe feltitwill be necessarytorestrictthe
maininlet valvetothe filtersoastoforcemoreflowthrough the micronizer.Make
surethe micronizerbypass loop valveisfullyopen.
Step 12:Dofinalcheck forleaks etc.Ensureinstruction bookiskeptwithrelevant
personnel. Run the unit and check the waterqualityproduced.

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SETTIMER
Determine aregeneration scheduleforthe conditioner
and adjust the automatictimerasfollows:
1.Pull all SKIPPERPINSout (awayfromcontrol).
2.RotateSKIPPERWHEELuntil DAY ARROW
pointstodayofweekornumber1.
3.Depress SKIPPERPIN(S) forday(s)regeneration
isrequired.
4.Pull TIMERKNOBout (awayfromtimerface)and
rotateuntil BLACKARROWon tripperarmpoints
tocorrect timeofdayon FacePlate.
5.Timerwill automaticallyinitiateregeneration on
preset daysat 2:30AM. Toaltertime, simplyreset
TIMERKNOBtoan earlierorlatertime, which
will change the timeofregeneration bythe same
numberofhours. (Timeindicated asBLACK
ARROWwill no longerbe correct).
MANUALOPERATION
Step 1.START-UPORINSPECTION
REGENERATION
a)PushinREDKNOBand turncounterclockwise
past START toBACKWASH. Disconnect
electricalpowerand leaveinposition fordesired
time. Reconnect electricalpower.
b)PushinREDKNOBand repeat forall desired
cycles
Step 2.MANUALINITIATIONOF REGENERATION
a)Reconnect electricalpower.
DRIVE PISTONPOSITIONING
(1)SERVICEPOSITION
(2)BACKWASHPOSITION
(3)BRINEAND SLOWRINSE POSITION
(4)FASTRINSE POSITION
FIG. 14

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b)PushinREDKNOBand turncounterclockwiseto
the START position. Release. Unit will then go
through acompleteregeneration asprogrammed.
Eachadditionalpineitherpulled out orpushed in
equals3minutes
SETBACKWASHTIMING
Pull pinsasshownforbackwashtimedesired
-see chart.
SETPAUSE TIMING
Depress pinsasshownfordesired brine/rinsetime
-see chart. (Minimumoftwopinsdown)
SETFASTRINSE TIMING
Pull pinsasshownfordesired fast rinsetime
-see chart
TYPICAL FILTERAPPLICATIONCYCLE
Backwash………………….. 20 min. -5pinsoutward
Pause………………………. 1.5min. -2pinsinward
Fast Rinse…………………. 11 min. -2pinsoutward
BACKWASHCYCLE TIME INSTRUCTIONS
BACKWASHOR
FAST RINSE PAUSE
NO. OF
PINS
OUT
TIME NO. OF
PINSIN TIME
18min. 2 1.5min.
2 11 min. 3 4.5min.
3 14 min. 4 7.5min.
4 17 min. 5 10.5min.
5 20 min. 6 13.5min.
6 23 min. 7 16.5min.
7 26 min. 8 19.5min.
8 29 min. 9 22.5min.
9 32 min. 10 25.5min.
10 35 min. 11 28.5min.
11 38 min. 12 31.5min.
12 41 min. 13 34.5min.
13 44 min. 14 37.5min.
14 47 min. 15 40.5min.
15 50 min. 16 43.5min.
PINTIMECHART
TIMER(REARVIEW)

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REPLACEMENTPARTS

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VALVE ASSEMBLYPARTS LIST
Item Description No.
Required Item Description No. Required
12G ValveBodyNPT 1 49G Screw 2
13G ValveBodyBSPP 1 50G Nut 2
14G InjectorAssy. small 1 51G Limit Switch 3
15G InjectorAssy. Med 1 52G Machine Screw 2
16G InjectorAssy. Large 1 53G CamScrew 1
17G 1/2"Brass Pipe Plug 1 54G Cam 1
18G Cap Screw 5 55G Lock Washer 2
32G BackwashAssy. BSPP 1
33G O Ring 1 56G DriveMotor, 100v-
120v, 50Hz/60Hz 1
34G Cap Screw 4 57G DriveMotor, 240v50Hz 1
35G Piston Assy. 1 58G DriveMotor, 240v
50Hz/60Hz 1
36G LowerCap Assy. 1 59G MotorScrews 4
37G CotterPin 1 60G Wiring Harness 1
38G ManifoldGasket 1 61G DriveLinkAssy. 1
39G TimerLock 1 62G DrainShut-off Valve 1
40G MotorPlateAssy. 1 63G O Ring 1
41G HexHead Screw 10 64G Cover 1
42G Ground Screw 1 65G WindowCoverw/-Fasteners 1
43G Lock Washer 1 66G CoverWindowCover
w/-Fasteners 1
44G Nut 1 67G Top Mount Adaptor-O Ring 1
45G Screw 2 68G Side Mount Adaptor(NPT) 1
46G SwitchBracket 1 69G Side Mount Adaptor(BSPP) 1
47G Terminal Strip 1 70G DistributorSeal 1
48G
MarkerStrip
1
71G
ORing
1

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SEVENDAY440 TIMERLISTOFPARTS
Item Description No.
Required Item Description No. Required
14A CamScrew 1 89F DayDialWasher 1
16A TimerMounting Screw 3 99F4 7DayTripperAssy. 1
3E Limit Switch 2 1G TimerBracket 1
14F7 SkipperWheel-7Day 1 2G AdjustableCam 1
15F Friction Washer 1 3G Timing Pin 36
18F MotorMounting Screw 2 4G O Ring 1
19F WireNut 2 5G Retaining Washer 1
84F CoverPlate 1 6G SwitchInsulator 2
85F Screw 4 7G SwitchSpacer 2
87F Compression Spring 1 8G SwitchMounting Screw 2
88F GearRetainer 1 9G Wiring Harness 1
WIRING DIAGRAM -440
SIX-DAY ORSEVEN-DAY TIMER
FIG. 17

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Forcorrect operation the camshouldbe set tostop, the position at the point of eachfunction.
Thisisdone at the factoryand rotation checked at thistime. However, resetting maybe
necessaryfromtimetotimeshouldthe unit fail todrawbrine. Setting issimple, indexposition
toserviceposition, (fullyin), switchoff power, loosen screw"A", adjust camtoposition shown
above. Switchon power.
MODEL180 VALVE CAMPOSITION
GENERALMAINTENANCE
FIG. 19

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HOWTO INSTALL REPLACEMENTPARTS:
The Wateritemicronizerconsistsofhigh impact ABS plasticbodycontaining twowaterpassages. The
waterpassagesclosest tothe check valve(M-005)containbuilt-inconvergent and divergent cones
forming aventuri. The venturicausesairtobe drawnintothe waterstreamwhen waterisflowing. The
second waterpassage actsasaby-pass. The percentage ofwaterflowallowed through the by-pass is
regulated bythe valvegate(M-003)/ gateretainer(M-002)assembly. Thisinturnregulatesthe amount
ofairdrawnintothe waterstreamthrough the venturi. Turning the valvegatescrewclockwiseintothe
by-pass servestorestrict waterflowinthe by-pass and at the sametimeforcemorewaterthrough the
venturipassage. Thisinturncausesmoreairtobe drawnintothe waterstream.
Inthe event that partsmust be replaced, thiscan be accomplished byfollowing afewsimple
instructions:
1. Toreplacethe rubbercheck valve(M-005), wet the check valvewithwaterorsilicone oil and install
it inthe mainbody. Thread the cap downsnuglybyhand. Donot overtighten. Failuretolubricate
the rubberproperlywill causethe valvetotwist inside the cap and will result inleakage ofwater
through the valve. Ifthisshouldoccur, removethe valve, re-lubricate, and re-install it.
2. Toreplacethe "O"ring orvalvegate/gateretainerassembly, start bywetting the rubber"O"ring
withwaterorasilicone oil. Carefullyinsert the "O"ring intoitsseat inthe bottomofthe holeinthe
mainbody. Thread the valvegatefullyintothe gateretainer. Thread the gateretainerintothe main
bodybyhand toasnug fit. Withuseofasuitabletool(wrenchorpliers), turnthe gateretainer
another1/4turnintothe mainbody. Donot overtighten.
NOTE: Toprevent leakage through the 1"NPTthreads, useteflon tape during assembly. Care
shouldbe taken when wrapping the tape overthe threadstoensurethat no tape entersthe
micronizerand clogsthe venturi.
WATERITE MICRONIZER

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Table1
MEDIAPLEACEMENT
BIRMFILTER
Sequence inTank AFB16
1st
(inbottomof tank) 25kg#6 gravel (5kg&1x20kg)
2nd *54kgBirm
(3 x18kg)

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PROBLEM REF. PAGE
UNITWILL NOTBACKWASHAUTOMATICALLY Page Seventeen
UNFILTEREDWATERTO SERVICE Page Seventeen
LEAK TO DRAIN Page Eighteen
INSUFFICIENTSERVICEFLOWRATE Page Eighteen
TROUBLESHOOTING
GUIDE
AFB16-180
Birm Filter

Page18
A) ISTHEREPOWERTO THEUNIT?
B) ISTHEPOWERCORD PLUGGEDIN?
C) ISTHEREAREMOTESWITCH INTHELINEISOLATED?
check thesepossibilities, and correct if necessary
D) ISTHETIMERMOTORRUNNING
if the timermotorisrunning, the small driven gearon the timermotorwill be
turning. If not, replacethe timermotor.
E) BACKWASHDRIVE GEARNOTENGAGED
check gearbehind pushbutton on timerforproperalignment, and timeof day
leverisdownand fullyengaged.
F) VALVE MOTORMICRO SWITCH NOTOPENING ORCLOSING
adjust microswitchstack (Fig. 19)
G) VALVE MOTORMICRO SWITCH BURNEDOUT
replacemicroswitch
H) VALVE MOTORMICRO SWITCH NOTOPENING ORCLOSING
replacemicroswitch
I) TIMERMOTORSWITCH BURNEDOUT
replacemicroswitch
A) RUBBERSLEEVE MISALIGNEDORMISSING ATTOPOFDISTRIBUTORPIPE
removevalvehead and replacerubbersleeve
B) UNITINSTALLEDBACKWARD
check arrowmarkingson top of valvehead forcorrect inlet/outlet plumbing
C) REFERSECTION1FORFURTHERINFORMATION
1. Unitwill notBackwashAutomatically
2. UnfilteredWatertoService
3. Leak toDrain

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A) CHECK PLUNGERPOSITIONING
referFig. 12
B) CHECK DRAINSHUT-OFF 'O' RING
located inuppercap (referPart No. 35G)
A) UNITMAYBEFOULEDWITHSUSPENDEDSOLIDS
backwashand check again
B) SERVICEINLETOROUTLETVALVE NOTFULLYOPENED
ensuretheyareopened
C) PISTONOUTOFPOSITION
reposition (referFig.12)
4. InsufficientService FlowRate