IBC Water AFM20-180 User guide

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COMMERCIAL
WATER FILTER
INSTALLATION
&
OPERATING
INSTRUCTIONS
Model : AFM20-180
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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General
OurAFSeriesFiltersarefullyautomaticincorporating Backwash, Rinse-Pause, Fast Rinse
and ServiceCycles, controlled bycamswitchesinthe timer. Frequency of Backwashing can
be altered fromthat suggested inthe Commissioning Section, if actualsiteconditions
dictatealterations.
Waterentersthe unit through the multi-port valveand passesthrough the media,
underdraingraveland the distributorleaving through the multi-port valve.
Multi-MediaFilters
Removefilterableturbidityat high flowratesseveraltimesthe flowrateof conventional
filters, producing clearfiltered waterdownto10 micron through the stratified bed without
chemicalflocculation. Noadditionalpumping isnecessaryforBackwashing, asthe
Backwashwaterrequired isnormallyonly80-90%of the serviceflowrate. MultiMediaFilter
capacityismanytimesthat of conventionalfiltration due toutilisation of the entirestratified
bed, resulting inlowoperating costs.
Thisunitisnotdesignedtoremovecolloidal matter, aplantcapableofcoagulationis
requiredinsuchcases.
OperatingParameters
WaterTemperature 5ºC-48ºC
WaterpH 5.5-9.0
WaterPressure 205 -690 kPa
Oil Free of Hydrocarbons
AFSERIES FILTERS
Table2
OPERATINGPRINCIPLE
TYPE MODEL CONTINUOS
FLOWRATE
L.P.M
PEAK FLOW
RATEL.P.M BACKWASH FLOWRATE
L.P.M
VALVE APPROX.
WEIGHT
KG
OPERATING
PROCEDURES
Multi-
Media AFM 20-180 120 160 114 180 320 WaterTemp: 5ºC-48ºC
WaterpH: 5.5-9.0
SuspendedSolids:
Max100 mg/l
(Referfactory)
Iron: NoEffect
Oil: Free of
Hydrocarbons
NOTE:Notrecommended
forColloidal Sediment
removal
Valve 180
Inlet
(mm) 40
Outlet
(mm) 40
Drain
(mm)
40
Operating Pressure: 205 -690 kPa
Temperature: 5ºC-48ºCElectrical: 240V50Hz3wattsmaximum
Warning: Apressurereduction valveshouldbe installed ifwaterpressureisgreaterthan 600kPa.
Warning: Apressurereduction valveshouldbe installed ifwaterhammerprevails.
Tableat left showsrecommended MINIMUMplumbing sizes.
FAILURETO OBSERVE WARNING WILL VOIDWARRANTY

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Check the equipmentupon arrivalfordamage orshortagesand reportsametoourOfficeorAgent
beforecommencing installation.
Locatethe unit on aclean, firm, levelfoundation, preferablyconcrete, withsufficient spacefor
operation and maintenance. Levelwithshimsifnecessary. Position the tankinthe correct position
beforeloading the Media. The filtershouldbe fitted withinlet and outlet pressuregaugestomonitor
the pressureloss through the filter. It isrecommended that the filterbe backwashed when the
pressuredifferentialincreasesby35 kPa.
The controlsystemissometimesshipped asasub-assemblytoavoiddamage intransit. The water
filtershouldbe assembled, piped and wired according tothe following recommendations. The
following instructionsareprovided asageneralguide. The filterrequiresa10amp240 volt GPO.
The filterinstallation must be protected fromthe elements
FIG.4-INSTALLATION-- SINGLETANK SOFTENERINSTALLATION
* PipeworkLayout -suggestiveonly
* Unit onlysupplied
* Pipe, Valves, Solenoids, WaterMeter
supplied byothers
All pipeworkconnectionstobe 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 toterminals2and 5inside valvecover.
FlowController
supplied separate
must be fitted before
Connecting Drain
Line
INSTALLATION
External
Backwash

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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. 40kg.
b)Levelout the underbed gravelusing abroomhandle/PVCpipe. The underbed
gravelshouldcoverthe bottomdistributorbyabout 25mm.
CAUTION:
Donotraise thedistributorpipe. Ifgravel isallowedtogetunderthe
distributor, emptyandstartagain.
c)Afterloading and levelling the No. 6Gravelunderbed, placethe mediainthe
tankinthe correctorderwhichisD1, D2, 7MSand, and D3.
¬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 tankthread ‘O’ring and the internalRiserPipe "O"ring
sealsareinplace. Using alittlesilicone “O”ring lubricant, lubricatethe outerseal
surfacesonly.
Step8: Fit the adaptortothe tank, carefully, toallowthe distributorpipe tolocate
centrally. Screwdownfirmlybyhand. Donot overtighten. Placethe gasket on
the tankadaptor, fit the valvebodywithcap screwsprovided. Tighten cap screws
evenly.
MEDIAINSTALLATION

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Step 1:Removevalvecoverbypartlyunscrewing the three coversecuring screwsand
lifting the coverforward. Removethe clearplasticwindowinthe coverby
removing twoscrewsand loosening the othertwoscrewsand sliding the window
out. Replacethe coveron the valve. Connect the powerlead tothe powerpoint
and turnon the electricpower. Depress the redknob (Fig. 7) and rotate anti-
clockwise to backwash position, release redknob. Notethat the timerface
design can varybetween valvemodelsfromthat illustrated and that the
regeneration positionsareindicated pictorially withBackwashbeing Flow
shownina Upwarddirection and the otherregeneration positionsshownwith
theircorresponding flowpath. Wait forvalvedrivetoindextobackwashposition,
(if not alreadyinthisposition)that isthe spindleisfullyextended.
Step 2:Just partlyopen inlet isolating valve. Allowunit tofill slowly(waterwill issueto
drain)continue torun until the unit automaticallyindexes tothe second position
whichisa Pause toallowmediatosettle. Thismaytakeup to15 minutesand
allowsall the entrained airtobe removed.
Step 3:Depress the red knob againand rotateanti-clockwisetothe fast rinseposition
and release. Verifythat the spindlehasmoved toitscorrect position asindicated
inthe following illustrations.
Step 4: Allow theredknob toelectricallyreturntotheservice position. It is
recommended togivethe filteracompletebackwashcyclesoastoremoveany
dirt/colourand tofurtherlevelout the media. Depress the red knob and turnanti-
clockwisetothe startposition orthe first arrowposition just anticlockwise from
the service position then releasethe red knob. The unit will nowgo through each
cycle-Backwash, pause, purge and back toserviceautomatically, the full cycle
will takeapproximately30 minutes, depending on pinsettings.
NOTE:Asmall amount of mediamaypass todrainduring the initialbackwash, thisis
considered normal.
Step 5:Check withsitesupervisorthat unit can go on line. If so-slowlyopen outlet
isolating valvefully, check that manualbypass valveisfullyclosed. Thisunit is
nowon line.
Step 6:Check forand report anyleaks. Gotothe nearest tap, nowon filtered water, open
and allowtoflowforafewminutesasit maytakeseveralminutesforthe treated
watertodisplacethe waterinthe pipe systemtothe tap. Check forthe clarityof
the treated waterand if unclean waterpersistsrefertothe TroubleShooting in
theseinstructions.
COMMISSIONING

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Step7: It isnownecessarytoset up the TimerControltobackwashthe filter
automaticallyon specificdays of the week. Thisisachieved bydepressing pins
on the SkipperWheelrelating tothe days selected forthe backwashing. Toset
theskipperwheel upas required, pull all skipperwheel pinsout.
Turnthedial tothecorrectdayoftheweek (notedialsmaybeindicated
as theactual dayofweek oras numbereddaysoftheweek)onwhichyou
aresettingthedial. Now depress thepinsforthedesiredday/sfor
backwashing. Initiallyatcommissioningsetthefiltertobackwashevery
secondday.
Notewhen you aresetting the backwashing frequency you shouldtakeinto
account the working days, forinstanceif the installation will onlyworkweekdays,
backwashing on the weekend wouldbe aneedless wasteof water. Always set in
accordancewiththe dutyconditionsformaximumeconomy.
NOTE: Thisisonlyaguide forinitialsetting and shouldbe altered tosuit eachindividual
installation inaccordancewithload conditionsof the rawwater.
Step 8:Set timeof daypull timerknob and set arrowtothe timeof day(timeof your
watch)notetimeof daymaybe as12 houror24 hourclock, release, makesure
that the knob hasre-engaged gear, ie. knob right in. The filterwill backwash
around 2.30 AM. If it isdesired tobackwashat adifferent timeit will be necessary
tooffset the actualtimeof daysetting bythe corresponding timedifference
desired forthe newbackwashtime.
Step 9:Afterthe filterhasdone the first backwashand the backwashsequenceand time
of dayhasbeen set, turnoff the electricpowerand removethe valvecover.
Replacethe clearplasticwindowinthe coverand then replacethe valvecoveron
tothe valveand reconnect the electricpower. Thisunit isnowon line.
Step 10:Dofinalcheck forleaks etc. Ensureinstruction bookiskept withrelevant
personnel

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SETTIMER
Determine aregeneration scheduleforthe
conditionerand adjust the automatictimerasfollows
(ReferenceFigures7and 8):
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 tripperarm
pointstocorrect timeofdayon faceplate.
5.Timerwill automaticallyinitiateregeneration on
preset daysat 2:30AM. Toaltertime, simply
reset TIMERKNOBtoan earlierorlatertime,
whichwill change the timeofregeneration by
the samenumberofhours. (Timeindicated as
BLACKARROWwill no longerbe correct).
Eachadditionalpineitherpulled out orpushed in
equals3minutes
SETBACKWASHTIMING
Pull pinsasshownfordesired backwashtime.
-See chart.
SETPAUSE TIME
Depress pinsasshownfordesired time.
-See chart. (Minimumoftwopinsdown)
SETFASTRINSE TIME
Pull pinsasshownfordesired fast rinsetime.
-See chart
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
Figure7
Figure8

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TYPICAL FILTERAPPLICATIONCYCLE
Backwash………………….. 20 min. -5pinsoutward
Pause………………………. 1.5min. -2pinsinward
Fast Rinse…………………. 11 min. -2pinsoutward
ValvePosition
MANUALOPERATION
PushinREDKNOBand turnCOUNTERCLOCKWISE
tothe START position. Release. Unit will then go
through acompleteregeneration asprogrammed.
VALVE AND CYCLE PINPOSITIONING
4. SERVICEPOSITION
1. BACKWASHPOSITION
2. BRINEAND SLOWRINSE POSITION
3. FAST RINSE POSITION

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ELECTRICALDIAGRAMS
Wiring Diagram-
450 ImpulseTimer
Wiring Diagram-
440 Six-Dayor
Seven-DayTimer

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FLOWSCHEMATIC

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REPLACEMENTPARTS

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VALVE ASSEMBLYPARTS LIST
Ref# PartNo. Description Ref# PartNo. Description
1ValveBody: 21 1077710 Wireguide bushing, .875
1034502 NPT 22 1035085 Drivelinkassembly
1034506 BSPP 23 1035041 Gasket (valvemotorplate)
2InjectorAssy. 24 1077699 Nut, keps, 6-32, plated steel
1034936 "A"(Yellow) (4required)
1034931 "B"(Orange) 25 1078196 Screw, HexHd., 10-32 x3/8
1034934 "C"(Gold) (3required)
1034170 Blank(undrilled) 26 SCS-0070 Screw, 6-32 x3/8round head
1034173 Injectorscreen (4required)
1010301 Injectoro-ring 27 1005585 Screw, HexHd., ¼-20 x3/8
31003062 Injectorplug, ½inNPT (10 required)
4 1006285 Cap screw, 5/16-18 x2¾ 28 1077798 962-180 turbine metercable
(5required) 29 1035042 Gasket (valvetoadapter
5 1035018 Gasket, UpperCap 30 1034851 Adapterkit, top mount
6BackwashAssembly:
1034704 4 gpm, NPT 31 ORE-347 O-ring
1034705 4 gpm, BSPT 32 ORE-225 O-ring
1034706 5 gpm, NPT 33 1077721 Cover
1034707 5 gpm, BSPT 34 1034524 Side Mount Adapter
1034708 6 gpm, NPT
1034709 6 gpm, BSPT 962 ElectronicControl Parts(Sub-Assy. P/N:1077719)
35 107713 Wireharness assembly
1034710 10 gpm, NPT
1034711 10 gpm, BSPT 36 1076297 PWAassembly962
1034712 15 gpm, NPT 37 ZHDW4152 Markerstrip, 11-20
1034713 15 gpm, BSPT 38 650022 10 Terminalblock
1034714 25 gpm, NPT 39 SCS-0064 Screw, 4-40 x5/8round head
1034715 25 gpm, BSPT (2required)
1034700 Open, NPT 40 SCS-0054 Screw, 2-56 x¼ph/pnhd
1034701 Open, BSPT (2required)
71006266 Cap Screw, 5/16-18 x¾ 41 1075767 Battery Clip, 962
(4required) 42 1075721 Wireharness, 10 cond., 962
81035159 DrainShut-off
91010130 O-ring 43 1075768 Battery, NiMH, 9V, 962 (optional)
10 1035069 Piston Assembly 44 1075764 Wireharness, battery, 9V
11 1005222 CotterPin 45 1070488 Keypad, membrane, 962
46 1075766 Screw, 8-32 x¼ph/flhd
12 1010144 O-ring (4required)
13 1010136 O-ring 47 1077706 PWAMounting bracket 962
14 1035022 Cap 48 1070491 Relay, SPDT, 12VAC, 962
49 1077915 Screw, 4-40 x¼ph/pnhd, Stl,
15 1034940 24VACDriveMotorAssembly SEMS
1034961 120VACDriveMotorAssembly (4required)
1034962 230VACDriveMotorAssembly
16 1005580 Screw, HexHd., 8-32 x¾ 440 or450 Timer Parts
17 1033889 CamAssembly 50 1035047 TimerMounting Bracket
18 1008332 Switch(3required) 51 TimerAssembly
Included withitem15 52 Screw, 8-32 x¼(4required)
19 1005850 Screw, HexHd., 10-24 x½ 53 1035479 WireHarness Assembly
(6required0 54 1077751 Window
20 1035156 Bracket, Switch 55 1035431 TimerLock

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SPECIFICATIONS
Hydrostatictest pressure……………………………………………………………………………………………. 250 psi(17.2
bar)
Working pressure……………………………………………………………………………………….. 20 -100 psi(1.38 -6.89
bar)
Standardelectricalrating …………………………………………………………………………………………………….
120V/60Hz
Optionalstandardelectricalrating (Timers)………… 24V/50Hz, 24V/60Hz, 120V/50Hz, 100V/60Hz, 100V/50Hz,
230V/50HzOptionalstandardelectricalrating (962 Controller) …………………………………………………………………...
230V50/60Hz
Electricalcord(when furnished, withstandardrating ………………………………………………………….. 6ft, 3wirewith
plug
ElectricalConnection …………………………………………………………………………………………………….. Terminal
strip
Standardplumbing connection ………………………………………………… 1-1/2inNPT inlet, outlet top and bottomof
tank 1/2inNPT brine; 3/4in
NPTdrain
Rubberparts………………………………………………………………………………………... Compound forcoldwater
service
Valvebody…………………………………………………………………………………………………………………………..
Brass
Injector………………………………………………………………………………….. 3sizesavailable: A, B, C(Refertopage
20)

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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. 20

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MEDIAPLACEMENT
MULTI-MEDIASEDIMENTFILTER
Sequence inTank AFM20
1st
(inbottomof tank) 30kg#6 gravel(1 Bag +)
2nd 44kgD1(2 Bags)
3rd 44kgD2(2 Bags)
4th 80kg7MSand (4 Bags)
5th 50kgD3(2 Bags)
Table1

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PROBLEM REF. PAGE
UNITWILL NOTBACKWASHAUTOMATICALLY Page Eighteen
UNFILTEREDWATERTO SERVICE Page Eighteen
LEAK TO DRAIN Page Nineteen
INSUFFICIENTSERVICEFLOWRATE Page Nineteen
TROUBLESHOOTING
GUIDE
AFM20-180
MULTI MEDIAFILTER

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. 20)
G) VALVE MOTORMICRO SWITCH BURNEDOUT
replacemicroswitch
H) VALVE MOTORMICRO SWITCH NOTOPENING ORCLOSING
replacemicroswitch
I) TIMERMOTORSWITCH BURNEDOUT
replacemicroswitch
A) RISERTUBE"O"RING MISALIGNEDORMISSING ATTOPOFDISTRIBUTORPIPE
INVALVE ADAPTOR
removevalvehead and replacerubber"O"ring
B) UNITINSTALLEDBACKWARD
check arrowmarkingson top of valvehead forcorrect inlet/outlet plumbing
C) REFERSECTION1FORFURTHERINFORMATION
1. Unitwill notBackwashAutomatically
2. UnfilteredWatertoService

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A) CHECK PLUNGERPOSITIONING
refervalvepositions
B) CHECK DRAINSHUT-OFF 'O' RING
located at drainand of plunger
A) UNITMAYBEFOULEDWITHSUSPENDEDSOLIDS
backwashand check again
B) SERVICEINLETOROUTLETVALVE NOTFULLYOPENED
ensuretheyareopened
C) PISTONOUTOFPOSITION
reposition (refervalveposition diagram)
3. Leak toDrain
4. InsufficientService FlowRate

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